In situ carbonization of a resin to form a carbon-carbon composite

• US 10,022,890 B2
• Filed: 09/15/2015
• Issued: 07/17/2018
• Est. Priority Date: 09/15/2015
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: La Forest, Mark L., Fryska, Slawomir T., Flask, David, Troester, Jeffrey
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US14/854,993
• Publication Number:
  US 20170072587A1
• Time in Patent Office: 1,036 Days
• Field of Search: 264 291, 264 295, 264113, 264129, 264134, 264135, 264136, 264137, 264308, 264482, 264483, 264486
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/30 Process control
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29C 2035/0811 using induction
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/295 Heating elements
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/58 Cuttability
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/744 : Non-slip, anti-slip
• CPC Class Codes: B32B 2605/18 : Aircraft
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 9/007 : comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: B32B 9/04 : comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/045 : of synthetic resin
• CPC Class Codes: B32B 9/047 : made of fibres or filaments
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: C01B 32/00 : Carbon; Compounds thereof C01B21/00, C01B23/00 take precedence; percarbonates C01B15/10; carbon black C09C1/48
• CPC Class Codes: C01B 32/05 : Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
• CPC Class Codes: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 2235/665 : Local sintering, e.g. laser sintering
• CPC Class Codes: C04B 35/622 : Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• CPC Class Codes: C04B 35/83 : Carbon fibres in a carbon matrix
• CPC Class Codes: F16D 2069/008 : Layers of fibrous materials
• CPC Class Codes: F16D 2200/0052 : Carbon
• CPC Class Codes: F16D 2200/0086 : Moulding materials together by application of heat and pressure
• CPC Class Codes: F16D 2250/00 : Manufacturing; Assembly
• CPC Class Codes: F16D 69/023 : Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
• CPC Class Codes: G03G 15/224 : Machines for forming tactile or three dimensional images by electrographic means, e.g. braille, 3d printing

Abstract

In some examples, the disclosure describes a method including depositing a first layer including a resin and at least one of a carbon fiber or a carbon fiber precursor material on a work surface of a three-dimensional printing system, carbonizing at least the resin of the first layer using a carbonizer attached to the three-dimensional printer to form a first layer of carbon-carbon composite including carbon fibers and carbonized matrix material, depositing an additional layer including a resin and at least one of a carbon fiber or a carbon fiber precursor material of material on the first layer of carbon-carbon composite, and carbonizing at least the resin of the additional layer using the carbonizer to form an additional layer of carbon-carbon composite on the first layer of carbon-carbon composite.

Claims

1. A method comprising:

depositing a first layer of material on a work surface of a three-dimensional printing system, wherein the first layer of material comprises a resin and at least one of a carbon fiber or a carbon fiber precursor material, and wherein depositing the first layer of material comprises depositing the resin on the work surface via at least one print head of the three-dimensional printing system;

carbonizing the resin of the first layer of material to form a first layer of carbon-carbon composite comprising carbon fibers and a carbonized matrix material, wherein carbonizing the resin comprises carbonizing localized sections of the resin of the first layer of material using a carbonizer of the three-dimensional printer system to convert the resin to the carbonized matrix material;

depositing an additional layer of material on the first layer of carbon-carbon composite, the additional layer of material comprising the resin and at least one of the carbon fiber or the carbon fiber precursor material, and wherein depositing the additional layer of material comprises depositing the resin on the first layer of carbon-carbon composite via the at least one print head of the three-dimensional printing system; and

carbonizing localized sections of the resin of the additional layer of material using the carbonizer to convert the resin of the additional layer of material to the carbonized matrix material.

2. The method of claim 1, wherein depositing the first layer of material comprises:

depositing a fiber layer of the at least one of the carbon fiber or the carbon fiber precursor material; and

depositing the resin on the fiber layer via the at least one print head of the three-dimensional printing system.

3. The method of claim 2, wherein depositing the fiber layer of the at least one of the carbon fiber or the carbon fiber precursor material comprises depositing the fiber layer via the at least one print head of the three-dimensional printing system.

4. The method of claim 1, wherein depositing the first layer of material comprises:

coating a carbon filament with the resin to form a coated carbon filament, wherein the carbon filament comprises the at least one of the carbon fiber or the carbon fiber precursor material; and

depositing the coated carbon filament on the work surface of a three-dimensional printing system via the at least one print head of the three-dimensional printing system to form the first layer of material.

5. The method of claim 1, wherein carbonizing localized sections of the resin of the first layer of material using the carbonizer comprises carbonizing localized sections that define an area of about 0.1 mm to about 10 mm in diameter.

6. The method of claim 1, wherein the carbonizer comprises at least one of a focused plasma torch, a concentrated laser, or an induction heat source.

7. The method of claim 6, wherein carbonizing localized sections of the resin comprises, heating a localized area of the resin via the carbonizer to a temperature above about 450 degrees centigrade to convert the resin of the localized area of the resin to the carbonized matrix material.

8. The method of claim 1, wherein depositing the additional layer of material and carbonizing localized sections of the resin of the additional layer of material comprises repeatedly depositing the additional layer of material and carbonizing localized sections of the resin of the additional layer of material to form at least about 15 layers of carbon-carbon composite.