Manufacture of functionally graded carbon-carbon composites

US7063870B2 · kind B2 · utility

Assignee

• HONEYWELL INTERNATIONAL INC. · US

Inventors

• Mark L. La Forest · Granger, US
• Charles A. Parker · Saylorsburg, US
• Frank Dillon · Granger, US
• Thomas Siegmund · West Lafayette, US
• Raymond J. Cipra · West Lafayette, US
• Alan Fatz · Centerville, US
• Peter Franz Braunisch · Rochester, US
• Tobey Cordell · Dayton, US

Key dates

• Filing date: May 25, 2004
• Grant date: Jun 20, 2006
• Expiry date: Jun 22, 2024

Classification

• Technology area (CPC Y): Emerging Cross-Sectional Technologies
• CPC primary: Y10T428/249924
• WIPO field: Materials, metallurgy
• WIPO sector: Chemistry

Abstract

Annular brake disc preform (15), wherein 40 to 80 layers of reinforcement fibers of at least two different lengths (11, 19) ranging from 10–60 mm are distributed in a planar gradient throughout the body of the preform, with the reinforcement fibers located near the exterior planes of the disc being predominately shorter fibers (11) and with the reinforcement fibers located in the central planes of the disc being predominately longer fibers (19). Also, process of making carbon-carbon composite preforms by: providing chopped pitch or PAN fibers (11, 19) of at least two different lengths; directing a robotic spraying apparatus to spray the chopped fibers into an annular mold (5) in 40 to 80 concentric iterations of chopped fiber deposition to provide a matrix of fibers in the mold; depositing a curable binder into the mold to intermix the binder with the fiber matrix; compressing the fiber matrix and curable binder within the mold; curing the binder to form a preform matrix; filling the preform matrix with pitch to form a pitch matrix; and subjecting the pitch matrix to chemical vapor deposition to form a carbon-carbon composite preform (15).