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US 5,609,707 AGranted
Carbon fiber reinforced carbon/carbon composite and method of its manufacture
AssigneeThe B. F. Goodrich Company
InventorsAfshin Bazshushtari, Edward L. Morris, Jr.
Life of this patent
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Abstract
Fibrous substrates for the production of carbon and/or ceramic (including mixtures of these) fiber reinforced carbon and/or ceramic (including mixtures of these) matrix composites, particularly friction discs, and to methods of manufacture of same. Offcut waste fibrous sheet material may be recycled and reformed into a web useful in the manufacture of such composites.
Claims27
A method of making a sheet of fibrous material comprising
- a) opening fibrous material having a fiber volume of from about 29 to about 58 percent having a plurality of layers of fibrous material made from PAN fibers including OPF, carbon fibers, graphite fibers, ceramic fibers, precursors of carbon fibers and precursor of ceramic fibers, and mixtures of these that are mechanically united by needlepunching, to provide discrete staple fibers having a mean length of between about 10 and about 25 millimeters (0.4 and 1.0 inches) when tested according to ASTM D 1440;
- and
- b) airlaying said opened fibers into a web having substantially uniform randomness in direction.
A method of making a sheet of fibrous material comprising
- a) opening offcut fibrous material having a density of 0.4 to 0.8 g/cc made from a plurality of layers of PAN fibers that are mechanically united by needlepunching;
- b) processing said opened fibrous material to provide discrete staple fibers having a mean length of between about 10 and about 25 millimeters (0.4 and 1.0 inches) when tested according to ASTM D 1440;
- and
- c) airlaying said discrete staple fibers into a web having substantially uniform randomness in direction.
1 more element
A method of making a sheet of fibrous material comprising
- a) providing discrete staple fibers selected from the group consisting of PAN fibers including OPF, carbon fibers, graphite fibers, ceramic fibers, precursors of carbon fibers and precursor of ceramic fibers, and mixtures of these, the discrete staple fibers having a mean length of between about 10 and about 25 millimeters (0.4 and 1.0 inches) when tested according to ASTM D 1440;
- b) airlaying said fibers into a web having substantially uniform randomness in direction;
- c) superposing a plurality of said webs and needlepunching said superposed webs together to produce cross-linking of the superposed webs by filaments displaced out of the webs and extending in a direction generally perpendicular to the faces of the webs to form a non-woven substrate;
- and
- d) further comprising placing the first of said plurality of web layers on a cotton cloth layer prior to further needlepunching.
2 more elements
Dependencies are inferred from the claim text.