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Abstract

A fiber-reinforced composite material and articles of manufacture formed thereof are formed by the method comprising: forming a compound material comprising a mixture of curable matrix-forming binder, heat resistant reinforcing fibers, and at least one particulate material, wherein the curable matrix-forming binder is 5 to 50% by volume of the compound material; curing the curable binder under simultaneous application of externally applied pressure and ultrasonic energy. Articles according to the invention are useful in a multitude of applications, particularly in applications where the article must retain its shape and properties when subjected to temperatures above the melting point of usual thermoplastic materials, e.g. above 1000.degree. C. The method provides dense, thermally stable, coherent composite materials having a desired high density. Forming and curing times are typically 10 times shorter than conventional methods, e.g. for brake pads in about 3-5 seconds.

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First Claim