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US 9,546,438 B2Granted
Low z high performance carbon composite materials
AssigneeGoodrich Corporation
InventorRobert Fiala
Life of this patent
Estimating the term…
Abstract
A carbon/carbon part and processes for making carbon/carbon parts are provided. The process involves forming steps, carbonization steps and densification steps. The forming steps may include needling fibrous layers to form fibers that extend in three directions. Pressure may be applied to a fibrous preform at an elevated temperature to increase the fiber volume ratio of the fibrous preform. The densification steps may include filling the voids or pores of the fibrous preform with a carbon matrix.
Claims15
A method for forming a fibrous preform comprising:
- superposing a first fibrous layer aligned in a machine direction with an additional fibrous layer aligned in an acute angle to the machine direction;
- needling the first fibrous layer and the additional fibrous layer together at a needle density of between approximately 60 and 65 needle punches per square centimeter to form a first combined fibrous mat;
- superposing an additional combined fibrous mat with the first combined fibrous mat;
- needling the first combined fibrous mat and the additional combined fibrous mat at a needle density of between approximately 45 and 55 needle punches per square centimeter to form the fibrous preform comprising oxidized polyacrylonitrile (OPF) fibers extending in multiple directions and having pores extending therethrough,
- wherein a fiber volume ratio of the fibrous preform is between about 30% fiber volume and about 35% fiber volume;
- compressing the fibrous preform;
- and
- carbonizing the fibrous preform by heating the fibrous preform to convert fibers of the fibrous preform into carbon fibers, wherein the fiber volume ratio of the fibrous preform after the carbonizing is between about 20% to 24% fiber volume.
5 more elements
A method for forming a fibrous preform comprising:
- needling a first fibrous layer and an additional fibrous layer together at a needle density of between approximately 60 and 65 needle punches per square centimeter to form a first combined fibrous mat;
- needling the first combined fibrous mat and an additional fibrous mat at a needle density of between approximately 45 and 55 needle punches per square centimeter to form the fibrous preform;
- applying mechanical pressure to the fibrous preform prior to a carbonization step to compress a thickness of the fibrous preform and thereby increase a fiber volume ratio of the fibrous preform;
- and
- carbonizing the fibrous preform by heating the fibrous preform in a furnace to convert the fibers into substantially carbon fibers, wherein the fiber volume ratio of the fibrous preform after the carbonizing is between about 20% and 24% fiber volume.
2 more elements
Dependencies are inferred from the claim text.