Carbon fiber preforms

• US 9,944,526 B2
• Filed: 05/13/2015
• Issued: 04/17/2018
• 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.
• Primary Examiner(s): Handville, Brian
• Application Number:
  US14/711,426
• Publication Number:
  US 20160332881A1
• Time in Patent Office: 1,070 Days
• CPC Class Codes: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for 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: C04B 2235/5268 Orientation of the fibers
• 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 2235/77 Density
• CPC Class Codes: C04B 2237/385 Carbon or carbon composite
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• 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 for forming a carbon fiber preform includes depositing, via a print head of a three-dimensional printing system, a first plurality of carbon fibers to form a first layer of carbon fibers in approximately an x-y plane, wherein the first plurality of carbon fibers are deposited around an array of carbon fiber filaments extending in approximately a z-axis direction relative to the x-y plane.

Claims

1. A method for forming a carbon fiber preform, the method comprising:

forming an array of carbon fiber filaments by extending a plurality of carbon fiber filaments between a bottom plate and a top plate, wherein each carbon fiber filament of the array of carbon fiber filaments extend in approximately a z-axis direction relative to an x-y plane;

depositing, via a print head of a three-dimensional printing system, a first plurality of carbon fibers on the bottom plate to form a first layer of carbon fibers in approximately the x-y plane, wherein the first plurality of carbon fibers are deposited around and between carbon fiber filaments of the array of carbon fiber filaments; and

depositing, via a print head of a three-dimensional printing system, a second plurality of carbon fibers on the first layer of carbon fibers to form a second layer of carbon fibers in approximately the x-y plane, wherein the second plurality of carbon fibers are deposited around and between carbon fiber filaments of the array of carbon fiber filaments extending in approximately the z-axis direction relative to the x-y plane, wherein each carbon fiber filament of the array of carbon fiber filaments extends completely through both the first and second layers of carbon fibers.

2. The method of claim 1, further comprising:

at least one of translating the array of carbon fiber filaments relative to the first layer of carbon fibers or rotating the array of carbon fiber filaments about an axis substantially parallel to the z-axis direction and relative to the first layer of carbon fibers following the formation of the first layer of carbon fibers, wherein the depositing the second layer of carbon fibers occurs following the at least one of translation or rotation of the array of carbon fiber filaments.

3. The method of claim 2, wherein rotating the array of carbon fiber filaments about the axis substantially parallel to the z-axis direction comprises rotating the top plate relative to the bottom plate between approximately one degrees and approximately ten degrees about the axis to cause the array of carbon fiber filaments to rotate relative to the first layer of carbon fibers.

4. The method of claim 2, wherein the carbon fiber preform includes between approximately 15 to approximately 30 total layers each formed by depositing a plurality of carbon fibers to form a respective layer of carbon fibers followed by the at least one of translating or rotating the array of carbon fiber filaments following the formation of the respective layer of carbon fibers, wherein the array of carbon fiber filaments extends through each of the approximately 15 to approximately 30 total layers.

5. The method of claim 1, wherein the first plurality of carbon fibers comprises a plurality of at least one of polyacrylonitrile (PAN) fibers, pitch fibers, oxidized PAN fibers, carbon fibers derived from PAN, carbon fibers derived from pitch, or rayon fibers.

6. The method of claim 1, wherein depositing, via the print head of the three-dimensional printing device, the first plurality of carbon fibers to form the first layer of carbon fibers comprises depositing, via the print head of the three-dimensional printing device, the first plurality of carbon fibers along with a resin binder to form a first layer of carbon fibers and resin binder.

7. The method of claim 6, wherein the resin binder comprises at least one of a synthetic resin, coal tar resin, petroleum isotropic and mesophase pitch, phenolic resin, or epoxy resin.

8. The method of claim 6, wherein preform includes between approximately 45 weight percent to approximately 85 weight percent of the plurality of carbon fibers, and between approximately 15 weight percent and approximately 55 weight percent of the resin binder.

9. The method of claim 1, further comprising:

carbonizing the carbon fiber preform; and

densifying the carbonized carbon fiber preform to form a densified carbon-carbon composite material.

10. The method of claim 9, wherein the densified carbon-carbon composite material exhibits a density greater than or equal to approximately 1.7 grams per cubic centimeter.

11. The method of claim 1, wherein the array of carbon fiber filaments comprises carbon fiber tows comprising the plurality of carbon fiber filaments, the carbon fiber tows extending from the bottom plate to the top plate.

12. A carbon fiber preform comprising:

a first layer of carbon fibers formed by depositing, via a print head of a three-dimensional printing system, a first plurality of carbon fibers and a first resin binder in approximately an x-y plane, the first resin binder configured to bind the first plurality of carbon fibers to form the first layer of carbon fibers;

a second layer of carbon fibers formed by depositing, via a print head of a three-dimensional printing system, a second plurality of carbon fibers and a second resin binder in approximately an x-y plane on the first layer, the second resin binder configured to bind the second plurality of carbon fibers to form the second layer of carbon fibers; and

an array of carbon fiber filaments extending in approximately a z-axis direction relative to the x-y plane, wherein the first plurality of carbon fibers and the second plurality of carbon fibers are both deposited around and between carbon fiber filaments of the array of carbon fiber filaments, wherein each carbon fiber filament of the array of carbon fiber filaments extends completely through both the first and second layers of carbon fibers.

13. The preform of claim 12, wherein the second plurality of carbon fibers and a second resin binder are deposited around and between the carbon fiber filaments of the array of carbon fiber filaments following at least one of translation of the array of carbon fiber filaments relative the first layer of carbon fibers or rotation of the array of carbon fiber filaments about an axis substantially parallel to the z-axis direction and relative to the first layer of carbon fibers.

14. The preform of claim 13, wherein the carbon fiber preform includes between approximately 15 to approximately 30 total layers each formed by depositing a plurality of carbon fibers to form a respective layer of carbon fibers followed by the at least one of translation or rotation of the array of carbon fiber filaments following the formation of the respective layer of carbon fibers, wherein each carbon fiber filament of the array of carbon fiber filaments extends through each of the approximately 15 to approximately 30 total layers.

15. The preform of claim 12, wherein the first plurality of carbon fibers comprises a plurality of at least one of polyacrylonitrile (PAN) fibers, pitch fibers, oxidized PAN fibers, carbon fibers derived from PAN, carbon fibers derived from pitch, or rayon fibers.

16. The preform of claim 12, wherein the first or second resin binder comprises at least one of a synthetic resin, coal tar resin, petroleum isotropic and mesophase pitch, phenolic resin, or epoxy resin.

17. The preform of claim 12, wherein the first and second layers of carbon fibers each include between approximately 45 weight percent to approximately 85 weight percent of the plurality of carbon fibers, and between approximately 15 weight percent and approximately 55 weight percent of the resin binder.

18. The preform of claim 12, wherein the array of carbon fiber filaments comprises carbon fiber tows comprising the plurality of carbon fiber filaments, the carbon fiber tows being substantially continuous through the first layer of carbon fibers and the second layer of carbon fibers.