Multilayered carbon-carbon composite

• US 10,131,113 B2
• Filed: 05/13/2015
• Issued: 11/20/2018
• Est. Priority Date: 05/13/2015
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Troester, Jeffrey, Fryska, Slawomir T., Flask, David
• Primary Examiner(s): Turocy, David P
• Application Number:
  US14/711,590
• Publication Number:
  US 20160332416A1
• Time in Patent Office: 1,287 Days
• CPC Class Codes: B29C 64/159 using only gaseous substances, e.g. vapour deposition
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/00 Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2475/00 Frictional elements
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• 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 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 9/00 Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
• 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: 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 50/02 for controlling or regulating additive manufacturing processes
• 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 2235/48 : 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 35/83 : Carbon fibres in a carbon matrix
• CPC Class Codes: C23C 16/045 : Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
• CPC Class Codes: C23C 16/26 : Deposition of carbon only
• CPC Class Codes: C23C 16/52 : Controlling or regulating the coating process C23C16/45557, C23C16/279 take precedence
• CPC Class Codes: F16D 2121/04 : acting on a piston-type actuator, e.g. for liquid pressure
• 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 65/12 : Discs; Drums for disc brakes
• 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, the disclosure describes a method including densifying a layer of carbon fibers by at least one of depositing a resin on the layer of carbon fibers via a print head of a three-dimensional printing system or applying CVD on the layer of carbon fibers via the print head; and forming at least one additional layer of densified carbon fibers on the densified layer of carbon fibers, wherein forming the at least one additional layer of densified carbon fibers comprises, for each respective layer of the at least one additional layer, adding an additional layer of carbon fibers on the densified layer of carbon fibers, and densifying the additional layer of carbon fibers by at least one of depositing the resin on the additional layer of carbon fibers or applying CVD on the additional layer of carbon fibers. In some examples, the example method may be used to form a densified carbon-carbon composite component, such as, e.g., a densified carbon-carbon composite brake disc.

Claims

1. A method comprising:

densifying a layer of carbon fibers using a print head of a three-dimensional printing system to apply a carbonaceous gas using chemical vapor deposition (CVD) on the layer of carbon fibers, wherein the print head is maneuvered in three-dimensional space relative to the layer of carbon fibers to apply the carbonaceous gas to the layer of carbon fibers; and

forming at least one additional layer of densified carbon fibers on the densified layer of carbon fibers, wherein forming the at least one additional layer of densified carbon fibers comprises, for each respective layer of the at least one additional layer;

adding an additional layer of carbon fibers on the densified layer of carbon fibers, and

densifying the additional layer of carbon fibers by at least one of depositing a molten resin on the additional layer of carbon fibers or applying the carbonaceous gas using CVD on the additional layer of carbon fibers.

2. The method of claim 1, wherein the carbonaceous gas comprises at least one of natural gas, methane, ethane, propane, butane, propylene, or acetylene.

3. The method of claim 1, wherein adding the additional layer of the carbon fibers on the densified layer of carbon fibers comprises depositing a pre-fabricated fabric layer of carbon fibers on the densified layer of carbon fibers.

4. The method of claim 1, wherein densifying the additional layer of carbon fibers comprises depositing the molten resin on the additional layer of carbon fibers, the method further comprising, carbonizing the molten resin after depositing the molten resin on the additional layer of carbon fibers and before forming at least one of the additional layer of densified carbon fibers.

5. The method of claim 1, wherein densifying the additional layer of carbon fibers comprises densifying the additional layer of the carbon fibers by depositing the molten resin on the additional layer of carbon fibers and applying the carbonaceous gas using CVD on the additional layer of carbon fibers.

6. The method of claim 1, wherein after densifying the layer of carbon fibers using the print head to apply the carbonaceous gas, the layer of carbon fibers exhibits a density greater than approximately 1.7 grams per cubic centimeter.

7. The method of claim 1, wherein the step of forming at least one additional layer of densified carbon fibers is repeated until at least approximately 15 layers of densified carbon fibers are formed.

8. The method claim 1, wherein the layer of carbon fibers forms a rippled or a corrugated layer of carbon fibers.

9. A method comprising:

densifying a layer of carbon fibers by depositing a first molten resin on the layer of carbon fibers using a print head of a three-dimensional printing system, wherein the print head is maneuvered in three-dimensional space relative to the layer of carbon fibers to apply the first molten resin;

carbonizing the first molten resin after depositing the first molten resin on the layer of carbon fibers to form a carbonized layer;

after carbonizing the first molten resin, using a second print head of the three-dimensional printing system to apply a carbonaceous gas using chemical vapor deposition (CVD) on the carbonized layer, wherein the second print head is maneuvered in three-dimensional space relative to the carbonized layer to apply the carbonaceous gas; and

after applying the carbonaceous gas on the carbonized layer, forming at least one additional layer of densified carbon fibers on the carbonized layer, wherein forming the at least one additional layer of densified carbon fibers comprises, for each respective layer of the at least one additional layer;

adding an additional layer of carbon fibers on the carbonized layer, and

densifying the additional layer of carbon fibers by at least one of depositing a second molten resin on the additional layer of carbon fibers or applying the carbonaceous gas using CVD on the additional layer of carbon fibers.

10. The method of claim 9, wherein the carbonaceous gas comprises at least one of natural gas, methane, ethane, propane, butane, propylene, or acetylene.

11. The method of claim 9, wherein adding the additional layer of the carbon fibers on the carbonized layer comprises depositing a pre-fabricated fabric layer of carbon fibers on the carbonized layer.

12. The method claim 9, wherein the carbonized layer forms a rippled or a corrugated layer, and wherein adding the additional layer of carbon fibers on the carbonized layer comprises depositing the additional layer of carbon fibers on the rippled or corrugated layer.

13. The method of claim 9, wherein densifying the additional layer of carbon fibers comprises depositing the second molten resin on the additional layer of carbon fibers, the method further comprising, carbonizing the second molten resin after depositing the second molten resin on the additional layer of carbon fibers and before forming at least one of the additional layer of densified carbon fibers.

14. The method of claim 9, wherein carbonizing the first molten resin comprises using laser coupled to three-dimensional printing system, wherein the laser is maneuvered by the three-dimensional printing system in three-dimensional space relative to the layer of carbon fibers to carbonize the first molten resin.

15. The method of claim 9, wherein densifying the additional layer of carbon fibers comprises densifying the additional layer of the carbon fibers by depositing the second molten resin on the carbonized layer and applying the carbonaceous gas using CVD on the additional layer of carbon fibers.

16. The method of claim 9, wherein the step of forming at least one additional layer of densified carbon fibers is repeated until at least approximately 15 layers of densified carbon fibers are formed.