Carbon-matrix composites, compositions and methods related thereto
AssigneeBallard Material Products Inc.
InventorsJohn J. Gaffney, Raymond C. Loszewski
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Abstract
The present invention relates to carbon-matrix composites, such as carbon—carbon composites, and a method for forming them by forming a fabric of fusible and infusible fibers which can be processed and carbonized to form a composite. The methods disclosed herein permit preparation of composites which are particularly thin, uniform, and highly pure. The invention also relates to preprocessed fabrics and precarbonized composites, such as those comprising carbon or oxidized polyacrylonitrile fibers and fusible polyacrylonitrile fibers.
Claims50
A composite comprising thermoplastic fibers and stabilized carbon precursor reinforcing fibers, wherein the thermoplastic fibers are fused to the reinforcing fibers and wherein the thermoplastic fibers and the reinforcing fibers are carbonized to yield the composite.
A composite prepared by a method comprising
- combining thermoplastic fibers and stabilized carbon precursor reinforcing fibers,
- fusing the thermoplastic fibers to the reinforcing fibers, and
- carbonizing the thermoplastic and reinforcing fibers to produce a composite.
A composite prepared by a method comprising
- forming a precursor substrate comprising polyacrylonitrile fibers and oxidized polyacrylonitrile reinforcing fibers,
- fusing the polyacrylonitrile fibers to the oxidized polyacrylonitrile reinforcing fibers, and
- carbonizing the polyacrylonitrile fibers and the oxidized polyacrylonitrile reinforcing fibers to produce a composite.
A method for forming a composite, comprising
- combining thermoplastic fibers and stabilized carbon precursor reinforcing fibers,
- fusing the thermoplastic fibers to the reinforcing fibers, and
- carbonizing the thermoplastic and reinforcing fibers to produce a composite.
A conductive catalyst support for a proton exchange membrane fuel cell, the catalyst support comprising
- thermoplastic fibers and stabilized carbon precursor reinforcing fibers, wherein the thermoplastic fibers are fused to the reinforcing fibers and wherein the thermoplastic fibers are carbonized to yield the composite.
A frictional member comprising
- thermoplastic fibers and stabilized carbon precursor reinforcing fibers, wherein the thermoplastic fibers are fused to the reinforcing fibers and wherein the thermoplastic fibers are carbonized to yield the composite.
A method of forming a composite comprising:
- stabilizing a plurality of carbon precursor fibers,
- combining the stabilized carbon precursor fibers with a plurality of thermoplastic fibers,
- fusing the thermoplastic fibers to the carbon precursor fibers, and
- carbonizing the thermoplastic and reinforcing fibers to produce a composite.
Dependencies are inferred from the claim text.