PROCEDURE FOR MAKING PRE-IMPREGNATED REINFORCED COMPOSITE, AS WELL AS FIBER REINFORCED COMPOSITE, AND THEIR APPLICATION

• US 20110171452A1
• Filed: 01/24/2011
• Published: 07/14/2011
• Est. Priority Date: 07/23/2008
• Status: Abandoned Application

• Current Assignee: Sgl Carbon Se
• Original Assignee: Sgl Carbon Se
• Inventors: Kuster, Tobias, Gojny, Florian, Öttinger, Oswin
• Application Number:
  US13/012,372
• Publication Number:
  US 20110171452A1
• Time in Patent Office: Days
• US Class Current: 428/221
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/226 the structure comprising mainly parallel filaments interconnected by a small number of cross threads
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D04H 3/002 Inorganic yarns or filaments
• CPC Class Codes: D04H 3/04 in rectilinear paths, e.g. crossing at right angles
• CPC Class Codes: D04H 3/115 by applying or inserting filamentary binding elements
• CPC Class Codes: D04H 3/12 with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component

Abstract

The present invention relates to a method for producing a fiber-clutch reinforced composite material comprising: preparing a fiber clutch, comprising preparing an arrangement of two or more layers of fiber that are partially or completely disposed one on top of the other, wherein one or more fiber layers comprise at least 50 wt.-% of the fibers selected from the group consisting of carbon fibers, precursor fibers of carbon fibers, ceramic fibers and mixtures thereof, affixing at least one fiber layer onto one or more other fiber layers using an affixing binder thread, wherein the affixing binder thread comprises one or more fibers selected from the group consisting of carbon fibers, precursor fibers of carbon fibers, ceramic fibers and mixtures thereof; high temperature treating the fiber clutch at a temperature of at least 400° C. under an inert atmosphere for a high temperature treatment period, impregnating the fiber clutch with at least one binder; curing the impregnated fiber clutch and optionally pressing at least one surface section of at least one surface of the impregnated fiber clutch before beginning and/or at least during a portion of the curing period, wherein a fiber clutch reinforced composite material is formed. The present invention also relates to the use of high temperature treated fiber clutch and to fiber clutch reinforced composite materials.

Claims

1. A method for producing a fiber-clutch reinforced composite material, said method comprising the steps of:

a) preparing a fiber clutch, including;

preparing an arrangement of at least two fiber layers that are one of partially and completely disposed one on top of another, at least one of said fiber layers including at least 50 wt. % of a plurality of fibers selected from the group consisting of carbon fibers, carbon fiber precursor fibers, ceramic fibers, and a plurality of mixtures thereof; and

affixing at least one said fiber layer onto at least one other said fiber layer using an affixing binder thread, said affixing involving passing said affixing binder thread through at least one said fiber layer and through at least one other said fiber layer, said affixing binder thread including at least one fiber selected from the group consisting of said carbon fibers, said carbon fiber precursor fibers, said ceramic fibers, and a plurality of mixtures thereof;

b) treating with a high temperature said fiber clutch at a temperature of at least 400°

C. under an inert atmosphere for a high temperature treatment period;

c) impregnating said fiber clutch treated with said high temperature with at least one binder; and

d) curing an impregnated said fiber clutch during a curing period at a curing temperature of at least 40°

C., the fiber-clutch reinforced composite material being formed.

2. The method according to claim 1, further including pressing at least one surface section of at least one surface of said impregnated fiber clutch at least one of before beginning and at least during a portion of said curing period, the fiber-clutch reinforced composite material being formed, the method further including obtaining one of the fiber-clutch reinforced composite material and a fiber-clutch reinforced composite material product after said steps of curing and pressing.

3. The method according to claim 1, further including treating thermally one of the fiber-clutch reinforced composite material and a fiber-clutch reinforced composite material product, and obtaining a thermally treated said one of the fiber-clutch reinforced composite material and said fiber-clutch reinforced composite material product after said step of treating thermally.

4. The method according to claim 3, further including at least one of densifying, siliconizing, and gas phase coating of one of said thermally treated fiber-clutch reinforced composite material and said thermally treated fiber-clutch reinforced composite material product, and obtaining at least one of a densified, siliconized, and gas phase coated said one of the fiber-clutch reinforced composite material and said fiber-clutch reinforced composite material product after said step of at least one of densifying, siliconizing, and gas phase coating.

5. The method according to claim 1, wherein said affixing involves sewing.

6. The method according to claim 1, wherein at least one said fiber layer includes one of more than 70 wt. %, more than 85 wt. %, more than 92 wt. %, and more than 98 wt. % of said plurality of fibers selected from the group including said carbon fibers, said carbon fiber precursor fibers, said ceramic fibers, and said plurality of mixtures thereof, related to a total weight of a respective said fiber layer.

7. The method according to claim 1, wherein said affixing binder thread is used with a sum of contents of elements C, Si, B, N, Al, Zr, Ti, W being one of more than 50 wt. %, more than 83 wt. %, more than 85 wt. %, and more than 95 wt. % of a total weight of said affixing binder thread, wherein a content of at least one of said elements C, Si, B, N, Al, Zr, Ti, W is 0 wt. %.

8. The method according to claim 1, wherein said affixing binder thread is one of partially and completely enveloped by an affixing liquid before said step of affixing.

9. The method according to claim 8, wherein said affixing liquid includes at least one compound selected from the group including water, silicone oils, polyurethanes, epoxide resin compounds, epoxy esters, polyvinyl alcohols, waxes, fatty acid esters, polyurethane esters, polyurethane ethers, and a plurality of mixtures hereof.

10. The method according to claim 1, wherein said step of affixing includes a mounting-fixation thread entering a first said fiber layer at a first entry point, being fed through said first fiber layer and at least a next said fiber layer, and leaving at a first emersion point in at least said next fiber layer.

11. The method according to claim 10, wherein said mounting-fixation thread enters through a second entry point in at least said next fiber layer, is fed through at least another next said fiber layer and said first fiber layer, and leaves at a second emersion point on said first fiber layer.

12. The method according to claim 1, wherein at least one of said carbon fiber precursor fibers of said affixing binder thread is selected from the group including pre-oxidized textile fibers, pre-oxidized viscose fibers, pre-oxidized polyacrylnitrile fibers, phenolic resin fibers, pitch-based precursor fibers, and a plurality of mixtures thereof.

13. The method according to claim 1, wherein at least one of said ceramic fibers of said affixing binder thread is selected from the first group including basalt fibers, Si-, C-, B-, N-, Al-based fibers or compounds thereof, glass fibers, aluminum oxide-based fibers, zircon oxide-based fibers, TiC-based fibers, WC-based fibers, and a plurality of mixtures thereof.

14. The method according to claim 13, wherein at least one of said ceramic fibers is selected from the second group including basalt fibers, fibers including SiNC, SiBNC, SiC, B₄C, BN, Si₃N₄, aluminum oxide, zircon oxide, TiC, WC, a plurality of mixtures thereof, and a plurality of mixtures of said first group and said second group.

15. The method according to claim 1, wherein at least one said fiber layer has a surface-specific weight one of in a range of 50 g/m² to 500 g/m², in a range of 150 g/m² to 350 g/m², and in a range of at least 305 g/m² to 500 g/m².

16. The method according to claim 1, wherein a number of filaments in at least one said fiber layer is one of in a range of 500 filaments to 500,000 filaments, in a range of 1,000 filaments to 400,000 filaments, and in a range of 12,000 filaments to 60,000 filaments.

17. The method according to claim 1, wherein said affixing binder thread includes at least one of at least one resin and at least one inorganic impregnating agent, wherein at least one of (a) said at least one resin is selected from the group including phenolic resins, epoxide resins, benzoxazine resins, cyanate ester resins, polyester/vinyl ester resins, polyimide resins, furan resins, polyacrylate resins, and a plurality of mixtures thereof, and (b) said at least one inorganic impregnating agent is selected from the group including silicone, SiC-precursor polymers, SiC-precursor oligomers, and a plurality of mixtures thereof.

18. The method according to claim 1, wherein at least one of at least one and all said fiber layers are in a same direction.

19. The method according to claim 1 wherein said affixing binder thread has one of a linear density of not more than 1 Tex, a linear density in a range of 0.04 to 1 Tex, and a linear density in a range of 0.04 to 0.75 Tex, determined in accordance with DIN 60905.

20. One of a fiber-clutch reinforced composite material and a fiber-clutch reinforced composite material product, comprising:

said one of the fiber-clutch reinforced composite material and the fiber-clutch reinforced composite material product being obtained according to the following method;

a) preparing a fiber clutch, including;

preparing an arrangement of at least two fiber layers that are one of partially and completely disposed one on top of another, at least one of said fiber layers including at least 50 wt. % of a plurality of fibers selected from the group consisting of carbon fibers, carbon fiber precursor fibers, ceramic fibers, and a plurality of mixtures thereof; and

affixing at least one said fiber layer onto at least one other said fiber layer using an affixing binder thread, said affixing involving passing said affixing binder thread through at least one said fiber layer and through at least one other said fiber layer, said affixing binder thread including at least one fiber selected from the group consisting of said carbon fibers, said carbon fiber precursor fibers, said ceramic fibers, and a plurality of mixtures thereof;

b) treating with a high temperature said fiber clutch at a temperature of at least 400°

C. under an inert atmosphere for a high temperature treatment period;

c) impregnating said fiber clutch treated with said high temperature with at least one binder; and

d) curing an impregnated said fiber clutch during a curing period at a curing temperature of at least 40°

C., the fiber-clutch reinforced composite material being formed.

21. The one of the fiber clutch reinforced composite material and the fiber-clutch reinforced composite material product according to claim 20, wherein the method further includes treating thermally the one of the fiber-clutch reinforced composite material and the fiber-clutch reinforced composite material product, and obtaining a thermally treated one of the fiber-clutch reinforced composite material and the fiber-clutch reinforced composite material product after said step of treating thermally.

22. The one of the fiber clutch reinforced composite material and the fiber-clutch reinforced composite material product according to claim 21, wherein the method further includes at least one of densifying, siliconizing, and gas phase coating of one of said thermally treated fiber-clutch reinforced composite material and said thermally treated fiber-clutch reinforced composite material product, and obtaining at least one of a densified, siliconized, and gas phase coated said one of the fiber-clutch reinforced composite material and said fiber-clutch reinforced composite material product after said step of at least one of densifying, siliconizing, and gas phase coating.

23. A fiber clutch, comprising:

the fiber clutch being obtained according to the following method;

a) preparing a fiber clutch, including;

preparing an arrangement of at least two fiber layers that are one of partially and completely disposed one on top of another, wherein at least one of said fiber layers corresponding to a total weight of a respective said fiber layer includes at least 50 wt. % of a plurality of fibers selected from the group consisting of carbon fibers, carbon fiber precursor fibers, ceramic fibers, and a plurality of mixtures thereof; and

affixing at least one said fiber layer onto at least one other said fiber layer using an affixing binder thread, said affixing involving passing said affixing binder thread through at least one said fiber layer and through at least one other said fiber layer, said affixing binder thread including at least one fiber selected from the group consisting of said carbon fibers, said carbon fiber precursor fibers, said ceramic fibers, and a plurality of mixtures thereof;

b) treating with a high temperature said fiber clutch at a temperature of at least 400°

C. under an inert atmosphere for a high temperature treatment period.

24. A method of using one of a composite material and a composite material product, said method comprising the steps of:

providing that said one of the composite material and the composite material product is respectively one of a fiber-clutch reinforced composite material and a fiber-clutch reinforced composite material product;

obtaining said one of said fiber-clutch reinforced composite material and said fiber-clutch reinforced composite material product according to the following method;

a) preparing a fiber clutch, including;

preparing an arrangement of at least two fiber layers that are one of partially and completely disposed one on top of another, at least one of said fiber layers including at least 50 wt. % of a plurality of fibers selected from the group consisting of carbon fibers, carbon fiber precursor fibers, ceramic fibers, and a plurality of mixtures thereof; and

affixing at least one said fiber layer onto at least one other said fiber layer using an affixing binder thread, said affixing involving passing said affixing binder thread through at least one said fiber layer and through at least one other said fiber layer, said affixing binder thread including at least one fiber selected from the group consisting of said carbon fibers, said carbon fiber precursor fibers, said ceramic fibers, and a plurality of mixtures thereof;

b) treating with a high temperature said fiber clutch at a temperature of at least 400°

C. under an inert atmosphere for a high temperature treatment period;

c) impregnating said fiber clutch treated with said high temperature with at least one binder; and

d) curing an impregnated said fiber clutch during a curing period at a curing temperature of at least 40°

C., the fiber-clutch reinforced composite material being formed; and

using said one of said fiber-clutch reinforced composite material and said fiber-clutch reinforced composite material product for at least one of manufacturing furnaces, manufacturing lining for heating areas of furnaces, heating elements, chemical reaction devices or elements thereof, and hot press molds.

25. One of an element and a device, comprising:

one of a composite material and a composite material product, said one of said composite material and said composite material product being respectively one of a fiber-clutch reinforced composite material and a fiber-clutch reinforced composite material product, said one of said fiber-clutch reinforced composite material and said fiber-clutch reinforced composite material product being obtained according to the following method;

a) preparing a fiber clutch, including;

preparing an arrangement of at least two fiber layers that are one of partially and completely disposed one on top of another, at least one of said fiber layers including at least 50 wt. % of a plurality of fibers selected from the group consisting of carbon fibers, carbon fiber precursor fibers, ceramic fibers, and a plurality of mixtures thereof; and

affixing at least one said fiber layer onto at least one other said fiber layer using an affixing binder thread, said affixing involving passing said affixing binder thread through at least one said fiber layer and through at least one other said fiber layer, said affixing binder thread including at least one fiber selected from the group consisting of said carbon fibers, said carbon fiber precursor fibers, said ceramic fibers, and a plurality of mixtures thereof;

b) treating with a high temperature said fiber clutch at a temperature of at least 400°

C. under an inert atmosphere for a high temperature treatment period;

c) impregnating said fiber clutch treated with said high temperature with at least one binder; and

d) curing an impregnated said fiber clutch during a curing period at a curing temperature of at least 40°

C., the fiber-clutch reinforced composite material being formed,

wherein said one of the element and the device is selected from the group including furnaces, an inner lining of furnaces, a heating area lining of furnaces, heating elements, chemical reaction devices or components thereof, and hot press molds.