US 12,497,335 B2 · High temperature composites and methods for preparing high temperature composites

Abstract

A method for making a carbon carbon, carbon ceramic matrix, or carbon silica composite, comprising melt processing a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive to make a precursor part, pyrolyzing the precursor part to make a pyrolyzed part, infusing a liquid second resin into the pyrolyzed part to make an infused part, and pyrolyzing the infused part. Other methods comprise processing aligned reinforcing additives and a resin comprising a PAEK to make an aligned reinforcing additives PAEK, aligned 1-2 dimensional flake material, or aligned 1-2 dimensional platelet material, to create a fabric, prepreg or tape comprising the aligned reinforcing additives and impregnated PAEK. Other methods comprise impregnating continuous fiber tape or fabric with a resin comprising PAEK and at least one reinforcing additive or co-weaving a continuous fiber or fabric with a PAEK fiber comprising PAEK and at least one reinforcing additive.

Claims18

Dependent claims

A method for making a high temperature composite, which is a carbon carbon composite, a carbon ceramic matrix composite, or a carbon silica composite, comprising:

a. making a precursor part from a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive;
b. pyrolyzing the precursor part to a pyrolyzed part, wherein during the pyrolyzing of the precursor part, a temperature within a chamber increases to a peak temperature of about 1000° C. or more, wherein said temperature within the chamber increases one or more times at a rate from 1° C./h to about 17° C./h during said pyrolyzing of the precursor part, and wherein optionally said pyrolyzing of the precursor part is maintained for a period of time at one or more temperatures;
c. infusing a liquid second resin into the pyrolyzed part to make an infused part;
and
d. pyrolyzing the infused part to make the carbon carbon composite, the carbon ceramic matrix composite, or the carbon silica composite,
e. optionally repeating steps c. through d. one or more times.

3 more elements

A method for making a high temperature composite, which is a carbon carbon composite, a carbon ceramic matrix composite, or a carbon silica composite, comprising:

a) making a precursor part from a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive;
b) initially pyrolyzing the precursor part to a pyrolyzed part, wherein during the pyrolyzing of the precursor part, a temperature within a chamber increases to a peak temperature of about 1000° C. or more, wherein said temperature within the chamber increases one or more times at a rate from 1° C./h to about 20° C./h during said pyrolyzing of the precursor part, and wherein optionally said pyrolyzing of the precursor part is maintained for a period of time at one or more temperatures.

Dependencies are inferred from the claim text.

High temperature composites and methods for preparing high temperature composites

Life of this patent

High temperature composites and methods for preparing high temperature composites

Life of this patent

Abstract

Claims18