Method for making a carbon-carbon cylinder block
AssigneeThe United States of America as represented by the Administrator of the National Aeronautics and Space Administration
InventorPhilip O. Ransone
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Abstract
A method for making a lightweight cylinder block composed of carbon--carbon is disclosed. The use of carbon--carbon over conventional materials, such as cast iron or aluminum, reduces the weight of the cylinder block and improves thermal efficiency of the internal combustion reciprocating engine. Due to the negligible coefficient of thermal expansion and unique strength at elevated temperatures of carbon--carbon, the piston-to-cylinder wall clearance can be small, especially when the carbon--carbon cylinder block is used in conjunction with a carbon--carbon piston. Use of the carbon--carbon cylinder block has the effect of reducing the weight of other reciprocating engine components allowing the piston to run at higher speeds and improving specific engine performance.
Claims21
The method of making a carbon--carbon cylinder block comprising the steps of:
- weaving fiber tows having carbon fibers into two-dimensional fabrics;
- heat treating the two-dimensional fabrics at a desired temperature;
- prepregging the two-dimensional fabrics with a carbonaceous resin;
- stacking the two-dimensional fabrics to form a block;
- molding the block;
- pyrolizing the block in an inert atmosphere;
- densifying the block;
- heat treating the block at a desired temperature to produce a desired thermal conductivity;
- and
- machining at least one cylinder bore in the block.
The method of making a carbon--carbon cylinder block comprising the steps of:
- weaving fiber tows having carbon fibers into a three-dimensional preform;
- heat treating the three-dimensional preform at a desired temperature;
- prepregging the three-dimensional preform with a carbonaceous resin;
- molding the three-dimensional preform to form a block;
- pyrolizing the block in an inert atmosphere;
- densifying the block;
- heat treating the block at a desired temperature to produce a desired thermal conductivity;
- and
- machining at least one cylinder bore in the block.
A process for making a cylinder block having at least one cylinder bore with a cylinder axis along each cylinder bore, said process comprising the steps of:
- prepregging two-dimensional fabric plies of carbon fibers with a carbonaceous resin;
- stacking the two-dimensional fabric plies into a stack;
- molding a block from the stack of two-dimensional fabric plies;
- curing the carbonaceous resin in the block;
- pyrolizing the carbonaceous resin in the block;
- densifying the block;
- and
- finish-machining each cylinder bore such that the cylinder axis of each cylinder bore is substantially perpendicular to the two-dimensional fabric plies.
A process for making a cylinder block having at least one cylinder bore with a cylinder axis along each cylinder bore, said process comprising the steps of:
- weaving fiber tows of carbon fibers into a three-dimensional preform such that a substantial majority of the carbon fibers lie substantially in parallel planes of carbon fibers;
- prepregging the three-dimensional preform with a carbonaceous resin;
- molding the three-dimensional preform to form a block;
- curing the carbonaceous resin in the block;
- pyrolizing the carbonaceous resin in the block;
- densifying the block;
- and
- finish-machining each cylinder bore such that the cylinder axis of each cylinder bore is substantially perpendicular to the parallel planes of carbon fibers.
Dependencies are inferred from the claim text.