# US 10,480,119 B2 · Method of applying oxidation protection coating to carbon fibers

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- Number: US 10,480,119 B2
- Document ID: US10480119B2
- Status: Granted
- Kind: B2
- Application number: 15/352,030
- Filed: 2016-11-15
- Published: 2018-05-17
- Granted: 2019-11-19
- Earliest claimed: 2016-11-15
- Assignees: Goodrich Corporation
- Applicants: Goodrich Corporation
- Inventors: Steven A. Poteet; Gavin Charles Richards
- Web page: https://patentgrep.com/patent/US10480119B2

## CPC

- D06M 11/83: with metals; with metal-generating compounds, e.g. metal carbonyls; Reduction of metal compounds on textiles
- B05D 1/02: performed by spraying
- B05D 1/18: performed by dipping
- B05D 1/28: performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
- B05D 5/00: Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- C04B 35/628: Coating the powders {or the macroscopic reinforcing agents}
- C04B 35/62847: {with oxide ceramics}
- C04B 35/62849: {Silica or silicates}
- C04B 35/62852: {Alumina or aluminates}
- C04B 35/62855: {Refractory metal oxides}
- C04B 35/62886: {by wet chemical techniques}
- C04B 35/632: Organic additives
- C04B 35/83: Carbon fibres in a carbon matrix
- F16D 69/023: {Composite materials containing carbon and carbon fibres or fibres made of carbonizable material}
- C04B 2235/3208: Calcium oxide or oxide-forming salts thereof, e.g. lime
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- C04B 2235/3244: Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/441: Alkoxides, e.g. methoxide, tert-butoxide
- C04B 2235/443: Nitrates or nitrites
- C04B 2235/5248: Carbon, e.g. graphite
- D10B 2101/12: Carbon; Pitch
- D10B 2505/12: Vehicles (D10B2505/08 takes precedence)
- F16D 2200/0052: Carbon
- D06M: TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES

## Abstract

A method for coating a carbon fiber for a composite structure may comprise applying a slurry onto a surface of the carbon fiber, wherein the slurry is a sol gel comprising a metal precursor and a carrier fluid, and heating the carbon fiber to a temperature sufficient to form a sol gel-derived layer on the carbon fiber. The slurry may comprise a metal precursor such as a metal salt or a metal alkoxide. The sol gel-derived layer may help prevent the carbon fiber from oxidizing.

## Claims

### Claim 1

A method for coating a fiber for a composite structure, comprising:
applying a slurry comprising tetraethylorthosilicate (TEOS) onto the fiber;
forming an oxidized polyacrylonitrile fiber (OPF) preform from the fiber;
carbonizing the OPF preform and the slurry;
heating the slurry to a temperature sufficient to form a protective layer on the fiber; and
condensing the slurry into a silicon oxide.

### Claim 2 (depends on 1)

The method of claim 1, wherein the protective layer is configured to aid in preventing oxidation of the carbon fiber.

### Claim 3 (depends on 2)

The method of claim 2, wherein the applying the slurry is completed by at least one of submerging the fiber into a slurry bath, spraying the slurry onto the fiber, or brushing the slurry onto the fiber.

### Claim 4 (depends on 3)

The method of claim 3, wherein the temperature is between 100° C. (212° F.) to about 1100° C. (2012° F.).

### Claim 5 (depends on 1)

The method of claim 1, wherein the protective layer encases the fiber.

### Claim 6

A method for manufacturing a composite structure, comprising:
forming an oxidized polyacrylonitrile fiber (OPF) preform from a fiber;
carbonizing the OPF preform;
applying a slurry to the carbonized OPF preform;
heating the carbonized OPF preform and the slurry to a temperature sufficient to form a protective layer on the fiber; and
densifying the carbonized OPF preform to form the composite structure.

### Claim 7 (depends on 6)

The method of claim 6, wherein the applying the slurry is completed by at least one of submerging the fiber into a slurry bath, spraying the slurry onto a surface of the fiber, or brushing the slurry onto the surface of the fiber.

### Claim 8 (depends on 7)

The method of claim 7, wherein the protective layer is configured to help prevent oxidation of the fiber.

### Claim 9 (depends on 8)

The method of claim 8, wherein the slurry comprises at least one of aluminum nitrate, calcium nitrate, aluminum sec butoxide, aluminum tri-sec butoxide, aluminum isopropoxide, aluminum oxide, and tetraethylorthosilicate (TEOS).

### Claim 10 (depends on 6)

The method of claim 6, further comprising applying a second protective layer to an outer surface of the composite structure.

### Claim 11

A method for manufacturing a composite structure, comprising:
forming an oxidized polyacrylonitrile fiber (OPF) preform from a fiber;
coating the OPF preform with a slurry;
carbonizing the coated OPF preform;
heating the carbonized OPF preform and the slurry to a temperature sufficient to form a protective layer on the carbonized OPF preform; and
densifying the carbonized OPF preform to form the composite structure.