Z-direction reinforced composites and methods of forming z-direction reinforced composites
AssigneeGoodrich Corporation
InventorChristopher T. Kirkpatrick
Life of this patent
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Abstract
A fiber reinforced composite component may include interleaved fiber layers and ceramic particle layers coated with matrix material. The fiber reinforced composite component may be fabricated by forming a fibrous preform, needling the fibrous preform to form a plurality of z-direction fibers, and densifying the fibrous preform. The fibrous preform may be fabricated by forming a first ceramic particle layer over a first fiber layer, disposing a second fiber layer over the first ceramic particle layer, forming a second ceramic particle layer over the second fiber layer, and disposing a third fiber layer over the second ceramic particle layer.
Claims20
A method of fabricating a composite component, comprising:
- forming a fibrous preform by:
- disposing a first fiber layer on a first plate;
- locating a first shim around an outer perimeter of the first fiber layer;
- depositing a first ceramic particle layer over the first fiber layer, the first ceramic particle layer including a first group of boron carbide particles having a first average particle size and a second group of boron carbide particles having a second average particle size, the second average particle size being less than the first average particle size;
- locating a second fiber layer over the first ceramic particle layer;
- locating a second shim around an outer perimeter of the second fiber layer;
- depositing a second ceramic particle layer over the second fiber layer;
- locating a third fiber layer over the second ceramic particle layer;
- needling the fibrous preform to form a plurality of z-direction fibers;
- disposing a second plate over the third fiber layer, wherein at least one of the first plate or the second plate includes at least one of a groove or an orifice;
- and
- densifying the fibrous preform while applying a compressive load to the third fiber layer.
A method of forming a fibrous preform for fabricating a composite component, comprising:
- locating a first fiber layer in a mold;
- forming a first layer of ceramic particles and phenolic resin powder over the first fiber layer, the first layer of ceramic particles and phenolic resin powder including a first group of boron carbide particles having a first average particle size and a second group of boron carbide particles having a second average particle size, the second average particle size being less than the first average particle size;
- locating a second fiber layer in the mold and over the first layer of ceramic particles and phenolic resin powder;
- forming a second layer of ceramic particles and phenolic resin powder over the second fiber layer;
- locating a third fiber layer over the second layer of ceramic particles and phenolic resin powder;
- and
- curing the fibrous preform.
A method of fabricating a composite component, comprising:
- forming a fibrous preform in a mold by:
- depositing a first ceramic particle layer over a first fiber layer, the first ceramic particle layer including a phenolic resin powder, a first group of boron carbide particles having a first average particle size, and a second group of boron carbide particles having a second average particle size, the second average particle size being less than the first average particle size;
- locating a second fiber layer over the first ceramic particle layer;
- depositing a second ceramic particle layer over the second fiber layer, the second ceramic particle layer including the phenolic resin powder;
- locating a third fiber layer over the second ceramic particle layer;
- needling the fibrous preform to form a plurality of z-direction fibers;
- curing the fibrous preform;
- and
- densifying the fibrous preform.
Dependencies are inferred from the claim text.