# US 11,993,031 B2 · Carbonization shape forming of oxidized PAN fiber preform > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,993,031 B2 - Document ID: US11993031B2 - Status: Granted - Kind: B2 - Application number: 17/832,426 - Filed: 2022-06-03 - Published: 2022-12-22 - Granted: 2024-05-28 - Earliest claimed: 2021-06-18 - Assignees: Goodrich Corporation - Applicants: Goodrich Corporation - Inventors: John S. Linck; Katherine E. Waugh - Web page: https://patentgrep.com/patent/US11993031B2 ## CPC - B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding - C04B 35/83: Carbon fibres in a carbon matrix - B29B 11/12: Compression moulding - B29B 11/14: characterised by structure or composition - B29B 13/02: by heating (B29B13/06, B29B13/08 take precedence) - B29C 43/3642: {Bags, bleeder sheets or cauls for isostatic pressing} - B29C 43/52: Heating or cooling - B29C 49/071: {Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties} - B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs - B29C 70/541: {Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30)} - B29C 70/544: {Details of vacuum bags, e.g. materials or shape} - B29C 43/10: Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies - B29C 2043/3644: {Vacuum bags; Details thereof, e.g. fixing or clamping} - B29K 2033/20: PAN, i.e. polyacrylonitrile - C04B 2235/602: Making the green bodies or pre-forms by moulding - C04B 2235/614: Gas infiltration of green bodies or pre-forms - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - 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 - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract A single stage OPF-to-carbon preform shape forming method includes positioning an oxidized PAN fiber preform with a female forming tool, positioning a vacuum bag over the oxidized PAN fiber preform, and vacuum forming the oxidized PAN fiber preform into a shaped body. The vacuum formed shaped body (while still in the shape forming fixture) may be loaded into a carbonization furnace and carbonized. The vacuum bag may be burned away in the carbonization furnace during carbonization. ## Claims ### Claim 1 A method for manufacturing a C/C part, the method comprising: positioning an oxidized PAN fiber preform with a female forming tool, the female forming tool comprising a die recess; positioning a vacuum bag over the oxidized PAN fiber preform; forming the oxidized PAN fiber preform into a shaped body; loading the female forming tool and the shaped body into a carbonization furnace; and carbonizing the shaped body with the carbonization furnace, and the vacuum bag is burned away in the carbonization furnace during the carbonizing; wherein the forming step comprises: evacuating air from between the vacuum bag and the female forming tool to press the oxidized PAN fiber preform against the die recess of the female forming tool with the vacuum bag. ### Claim 2 (depends on 1) The method of claim 1, wherein the forming further comprises: moving a first plug at least partially into the die recess and over the vacuum bag, the oxidized PAN fiber preform disposed between the first plug and the female forming tool; moving a second plug at least partially into the die recess and over the vacuum bag, the oxidized PAN fiber preform disposed between the second plug and the female forming tool; moving a wedge between and against the first plug and the second plug along a first axis; in response to the wedge pressing between and against the first plug and the second plug, moving the first plug and the second plug along a second axis substantially perpendicular to the first axis; and in response to the moving the first plug and the second plug along the second axis, compressing the oxidized PAN fiber preform and the vacuum bag between the first plug and the female forming tool and between the second plug and the female forming tool. ### Claim 3 (depends on 2) The method of claim 2, wherein the movement of the wedge along the first axis further causes the first plug and the second plug to move parallel to the first axis. ### Claim 4 (depends on 1) The method of claim 1, further comprising: positioning a dowel at least partially into a dowel recess disposed in the oxidized PAN fiber preform; positioning the dowel at least partially into a slot disposed in the female forming tool to secure at least a portion of the oxidized PAN fiber preform with respect to the female forming tool. ### Claim 5 (depends on 1) The method of claim 1, further comprising compressing a lateral end of the oxidized PAN fiber preform between an external load and a top side of the female forming tool. ### Claim 6 (depends on 1) The method of claim 1, further comprising applying water to the oxidized PAN fiber preform. ### Claim 7 (depends on 1) The method of claim 1, wherein the carbonizing the shaped body with the carbonization furnace comprises heating the oxidized PAN fiber preform in the carbonization furnace to a carbonization temperature of between 1,200° C. and 2,400° C. (2,732° F. to 4,352° F.). ### Claim 8 A method for manufacturing a C/C part, the method comprising: positioning an oxidized PAN fiber preform with a female forming tool, the female forming tool comprising a die recess; positioning a vacuum bag over the oxidized PAN fiber preform; forming the oxidized PAN fiber preform into a shaped body by evacuating air from between the vacuum bag and the female forming tool to press the oxidized PAN fiber preform against the female forming tool with the vacuum bag; moving a first plug at least partially into the die recess and over the vacuum bag, the oxidized PAN fiber preform disposed between the first plug and the female forming tool; moving a second plug at least partially into the die recess and over the vacuum bag, the oxidized PAN fiber preform disposed between the second plug and the female forming tool; moving a wedge between and against the first plug and the second plug along a first axis; loading the female forming tool and the shaped body into a carbonization furnace; placing an external load on top of the wedge, the external load biasing the wedge toward the female forming tool; and carbonizing the shaped body with the carbonization furnace, and the vacuum bag is burned away in the carbonization furnace during the carbonizing. ### Claim 9 (depends on 8) The method of claim 8, wherein the vacuum bag completely encapsulates the female forming tool.