Hollow composite body having an axis of symmetry

• US 4,847,063 A
• Filed: 12/02/1987
• Issued: 07/11/1989
• Est. Priority Date: 12/02/1987
• Status: Expired due to Fees

• Current Assignee: Fiber Materials Incorporated Biddeford Maine
• Original Assignee: Fiber Materials, Incorporated (Spirit Aerosystems Holdings Incorporated)
• Inventors: Smith, Jack B.
• Primary Examiner(s): Doll, John
• Assistant Examiner(s): Kunemund, Robert M.
• Application Number:
  US07/127,390
• Time in Patent Office: 587 Days
• Field of Search: 423/445, 423/448, 423/449, 423/461, 252/510, 252/511, 87/1, 87/7, 87/9, 87/34
• US Class Current: 423/445.00R
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: D04C 1/06 Braid or lace serving particular purposes
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs

Abstract

Method of forming a hollow, carbon/carbon composite article around an axis of symmetry, in which method a heat refractory mandrel is shaped to provide a desired inner surface configuration and tolerances of the article, and one or more plies of thermally stable carbon filaments are braided over the surface of the mandrel. The filaments have a diameter of substantially not greater than about 6 microns and a modulus of elasticity of substantially not less than about 45×10⁶ psi. The plies are then impregnated with a carbonizable liquid impregnant, and the assembly of impregnated plies and mandrel is heat treated so as to carbonize the impregnant. The resulting composite article has a high translation of the original strength of the filaments and has an inner surface defined by the outer surface of the mandrel.

Claims

1. A method of forming a hollow carbon/carbon composite article around an axis of symmetry, said method comprising the steps of:

shaping a surface of a heat refractory mandrel to the desired inner surface configuration and tolerances of said article;

covering said surface of said mandrel with one or more plies of thermally stable carbon filaments having diameters of substantially not greater than about 6 microns and a modulus of elasticity of substantially not less than about 45×

10⁶ psi;

impregnating said plies with a carbonizable impregnant while on said mandrel; and

heat treating the assembly of said impregnated plies so as to carbonize said impregnant. said surface and said assembly being releasable intact from one another.

2. A method as defined in claim 1 including the steps of reimpregnating said assembly with additional impregnant and carbonizing said reimpregnated assembly cyclically until a desired density of carbon/carbon is reached.

3. A method as defined in claim 1 wherein said step of covering is effected by triaxially braiding said filaments.

4. A method as defined in claim 1 wherein said step of covering is effected by biaxially braiding said filaments.

5. A method as defined in claim 1 wherein said impregnant is a mixture of aldehyde and phenol.

6. A method as defined in claim 1 wherein the step of impregnating includes saturating said plies with impregnant.

7. A method as defined in claim 1 wherein said mandrel is formed of metal, ceramic or graphite.

8. A method as defined in claim 7 including the step of treating the surface of said mandrel with a release agent prior to braiding said plies on said mandrel.

9. A method as defined in claim 1 wherein said surface of said mandrel is formed in part of metal and in part of graphite, and including the step of treating only the metallic portions of said surface with a release agent prior to braiding said plies on said mandrel.

10. A method as defined in claim 1 wherein said mandrel is formed of polytetrafluorethylene.

11. A method as defined in claim 1 wherein said mandrel is formed of graphite and the step of heat treating said assembly is carried out at a temperature at which said impregnant will graphitize.

12. A method as defined in claim 3 including the step of angularly shifting, during braiding, the position of axial filaments in each said ply with respect to the corresponding axial filaments in each immediately adjacent ply.

13. A hollow, composite carbon/carbon article having an axis of symmetry, said article comprising:

a plurality of successive plies of carbon filaments embedded in a carbonized matrix, said filaments being heat stabilized, having a diameter of less than about 6 microns and having a modulus of elasticity of substantially not less than 45×

10⁶ psi;

the inner surface of said article being established by the surface of a mandrel on which said plies were originally placed.

14. A hollow, composite article as defined in claim 13 having a density of not less than 1.35 gm/cc.

15. A hollow, composite article as defined in claim 13 including elements of carbon/carbon material bonded to the interior surface of said article by the material of said matrix, said elements having a higher density than the density of said plies and matrix.

16. A hollow, composite article as defined in claim 13 and having a wall thickness of as small as 20 mil inches.

17. A hollow, composite article as defined in claim 13 and having a substantially conical form.

18. A hollow, composite article as defined in claim 13 wherein said carbon filaments are braided together.