Method of making carbon fiber preforms

• US 10,035,305 B2
• Filed: 06/30/2015
• Issued: 07/31/2018
• Est. Priority Date: 06/30/2015
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: La Forest, Mark L., Fryska, Slawomir T.
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US14/788,217
• Publication Number:
  US 20170001373A1
• Time in Patent Office: 1,127 Days
• Field of Search: 264113, 264131, 264255, 264279, 2642791, 264 291, 264257, 264258, 4234471, 4234474
• 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: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• 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 70/021 Combinations of fibrous reinforcement and non-fibrous material
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29K 2309/02 Ceramics
• CPC Class Codes: B29K 2507/04 Carbon
• CPC Class Codes: B29K 2509/04 Carbides; Nitrides
• CPC Class Codes: B29K 2995/0072 Roughness, e.g. anti-slip
• CPC Class Codes: B29L 2031/16 Frictional elements, e.g. brake or clutch linings
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/107 Ceramic
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2475/00 Frictional elements
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 38/08 Impregnating
• 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 9/047 : 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 70/10 : Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: C04B 2111/00362 : Friction materials, e.g. used as brake linings, anti-skid materials
• CPC Class Codes: C04B 2235/3826 : Silicon carbides
• CPC Class Codes: C04B 2235/3843 : Titanium carbides
• CPC Class Codes: C04B 2235/3847 : Tungsten carbides
• CPC Class Codes: C04B 2235/424 : Carbon black
• CPC Class Codes: C04B 2235/425 : Graphite
• CPC Class Codes: C04B 2235/48 : Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 2235/5248 : Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 2235/614 : Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 : Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2237/385 : Carbon or carbon composite
• CPC Class Codes: C04B 2237/582 : by joining layers or articles of the same composition but having different additives
• CPC Class Codes: C04B 2237/62 : Forming laminates or joined articles comprising holes, channels or other types of openings
• CPC Class Codes: C04B 35/83 : Carbon fibres in a carbon matrix
• CPC Class Codes: C04B 38/0032 : one of the precursor materials being a monolithic element having approximately the same dimensions as the final article, e.g. a paper sheet which after carbonisation will react with silicon to form a porous silicon carbide porous body
• CPC Class Codes: F16D 2200/0047 : Ceramic composite, e.g. C/C composite infiltrated with Si or B, or ceramic matrix infiltrated with metal
• CPC Class Codes: F16D 2200/0091 : Impregnating a mat of fibres with a binder
• CPC Class Codes: F16D 65/126 : the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor
• CPC Class Codes: F16D 69/023 : Composite materials containing carbon and carbon fibres or fibres made of carbonizable material

Abstract

In some examples, a method includes depositing a mixture including a resin and an additive powder via a print head of a three-dimensional printing system to form a carbon fiber preform including a plurality of individual carbon fiber layers, wherein each individual layer of the plurality of individual carbon fiber layers includes a plurality of carbon fibers and the mixture of the resin and the additive powder.

Claims

1. A method comprising:

forming a carbon fiber preform comprising a plurality of individual carbon fiber layers, wherein forming each individual carbon fiber layer of the plurality of individual carbon fiber layers comprises;

forming a fibrous layer comprising a plurality of carbon fibers, and

depositing a mixture including a resin and an additive powder via a print head of a three-dimensional printing system on the fibrous layer; and

pyrolyzing the carbon fiber preform to form a carbon-carbon composite.

2. The method of claim 1, wherein the additive powder is configured to at least one of prevent oxidation, modify a friction property, increase a density, or increase a strength of a densified carbon-carbon composite material formed from the carbon fiber preform.

3. The method of claim 1, wherein the additive powder comprises a ceramic powder.

4. The method of claim 3, wherein the ceramic powder is configured to at least one of prevent oxidation or increase a density of a densified carbon-carbon composite material formed from the carbon fiber preform.

5. The method of claim 3, wherein the ceramic powder comprises at least one of silicon carbide powder, titanium carbide powder, or tungsten carbide.

6. The method of claim 1, wherein the additive powder comprises a carbon powder.

7. The method of claim 6, wherein the carbon powder is configured to at least one of modify a friction property or increase strength of a densified carbon-carbon composite material formed from the carbon fiber preform.

8. The method of claim 6, wherein the carbon powder comprises at least one of activated carbon powder, graphite powder, or carbon black powder.

9. The method of claim 1, wherein the mixture includes approximately 0.1 weight percent to approximately 50 weight percent of the additive powder, and approximately 50 weight percent and approximately 99.99 weight percent of the resin.

10. The method of claim 1, wherein the plurality of individual carbon fiber layers includes a first carbon fiber layer and a second carbon fiber layer, wherein a concentration of the additive powder in the first carbon fiber layer is less than a concentration of the additive powder in the second carbon fiber layer.

11. The method of claim 1, wherein the mixture includes the plurality of carbon fibers.

12. The method of claim 1, wherein forming the fibrous layer comprises forming a woven layer comprising the plurality of carbon fibers.

13. The method of claim 1,

wherein the plurality of individual carbon fiber layers includes a first carbon fiber layer comprising a first additive powder, a second carbon fiber layer comprising a second additive powder, and a third carbon fiber layer comprising a third additive powder, the second carbon fiber layer positioned between the first and third carbon fiber layers,

wherein a concentration of the second additive powder is different than the first and third additive powders.

14. The method of claim 13, wherein the first and third additive powders comprise a higher concentration of at least one of a ceramic powder or a carbon powder than the second additive powder.

15. The method of claim 13, wherein the second additive powder comprises a higher concentration of a ceramic powder than the first and third additive powders.