Apparatus and methods for bonding carbon-carbon composites through a reactant layer

#This application is related to U.S. patent application Ser. No. 11/391,255 filed Mar. 29, 2006, the contents of which are incorporated herein by reference in their entirety.

#This disclosure relates generally to the manufacturing of carbon-carbon composites, such as carbon brake discs and, more particularly, to an apparatus and methods for bonding carbon-carbon composites through a reactant layer.

#Carbon-carbon brake discs are widely used on commercial and military aircraft. Wide-bodied commercial jets required improved brake materials because traditional steel brake systems simply could not absorb all of the thermal energy created during stops associated with landings. Carbon-based composites were developed which provide heat capacity, thermal conductivity, and thermal strength able to meet the demanding conditions involved in landing large commercial jets. On the military side, the lower weights as well as the thermal and strength properties of the carbon composites has helped to ensure their acceptance in brake applications.

#FIG. 1 is a front perspective view of an example apparatus for bonding carbon-based composites through a reactant layer.

#FIG. 2 is a front elevational view of the example apparatus of FIG. 1.

#FIG. 3 is a plan view of the example apparatus of FIG. 1.

#The following description of the disclosed embodiment is not intended to limit the scope of the invention to the precise form or forms detailed herein. Instead the following description is intended to be illustrative of the principles of the invention so that others may follow its teachings.

#Referring now to the drawings, FIG. 1 is an illustration of an example apparatus, such as a press 10, for bonding two carbon-based composites. The exemplary press 10 includes a housing 12, which in this embodiment generally includes a support frame 13, a press die assembly 14, a clamping device 16, and a protective guard 24. Additionally, the press 10 may include a controller 20, and a power supply 22. While the structure of the press 10 will be described, for ease of understanding, in conjunction with a plurality of separate components, it will be understood by one of ordinary skill in the art that the components may be combined or separated in various combinations.

#In this example, a lower portion 26 of the support frame 13 may include a plurality of heavy square tube frame segments 30 forming a generally rectangular support structure. The support frame 13 may be mounted on or otherwise coupled to a suitable transportation device such as, for example, a plurality of lockable casters 32 which may have step-on pads (not shown) to selectively hold the casters 32 stationary as desired. An upper portion 36 of the support structure 13 may include a top plate 40, which in this example is horizontally supported by the lower portion 26 of the support frame 13. Coupled to the top plate 40 is support structure, such as, for example, a plurality of vertically extending heavy square tube frame segments 42. In this example, the frame segments 42 support a plurality of transverse support beams 46, to form a top crown weldment 43 adapted to support the press die assembly 14, one example of which is disclosed in further detail below. Optionally, the support frame 13 may be at least partially surrounded by the protective guard 24, which in this embodiment surrounds the upper portion 36 of the support structure 13 and is constructed of a durable material, such as, for example a plurality of shatter resistant MAKROLON® (polyacrylic) panels.