Rigidized fiber array

Patent metadata

Field	Value
Publication number	US-10105915-B2
Application number	US-201414917413-A
Country	US
Kind code	B2
Filing date	Aug 20, 2014
Priority date	Sep 11, 2013
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A composite component includes a fiber array, a plurality of platelets bridging between fiber filaments of the fiber array and rigidizing the fiber array, and a resin-based phase disposed within voids of the fiber array. A method of making a composite component is also disclosed.

First claim

What is claimed is:

1. A composite component, comprising:
a fiber array,
a plurality of platelets bridging between fiber filaments of the fiber array and rigidizing the fiber array;
a matrix phase disposed within voids of the fiber array; and
a reaction product formed from a reaction between a constituent of the platelets and carbon of the matrix phase.

2. The component of claim 1 , wherein the platelets include at least one of silicon, boron, hafnium, zirconium, yttrium and ytterbium, alumina, ceria, silica, tin oxide, titania, zinc oxide, zirconia, hafnia, ytterbia and yttria.

3. The component of claim 1 , wherein the constituent of the platelet is a metal.

4. The component of claim 1 , wherein the platelets have an orientation relative to the fiber filaments, and wherein the orientation is perpendicular to the fiber filaments.

5. The component of claim 1 , wherein the platelets contribute to at least one of a wear resistance, heat resistance, oxidation resistance, and impact resistance of the component.

6. The component of claim 1 , wherein the platelets increase the glass transition temperature of the component relative to an unrigidized component.

7. The component of claim 1 , wherein the platelets bridge between the fiber filaments such that the voids are formed to receive the matrix.

8. A method of making a composite component, comprising:
applying a colloidal suspension to a fiber array;
precipitating the colloidal suspension to rigidize the fiber array; and
impregnating the rigidized fiber array with a resin to form a component; and
reacting the colloidal suspension with the resin.

9. The method of claim 8 , wherein the impregnating step includes placing the rigidized fiber array into a mold and applying the resin to the mold.

10. The method of claim 9 , further including changing the viscosity of the resin prior to applying the resin to the mold.

11. The method of claim 8 , further including curing the component subsequent to the impregnating step.

12. The method of claim 11 , wherein curing includes at least one of pyrolysis and thermal treatment.

13. The method of claim 8 , wherein the precipitating step includes cooling the colloidal suspension.

14. The method of claim 13 , further comprising heating the fiber array subsequent to the precipitating step.

15. The method of claim 8 , wherein the precipitating step provides voids between fibers filaments of fiber filament bundles of the fiber arrays.

16. The method of claim 15 , wherein the voids receive the resin during the impregnating step.

17. The method of claim 16 , wherein the reacting comprises reacting the colloidal suspension with carbon in the resin.

18. The method of claim 8 , wherein the precipitating step restricts fiber filaments of the fiber array from moving relative to one another within the array during the impregnating step.

Assignees

• United Technologies Corp

Inventors

• Jarmon David C
• Schmidt Wayde R

Classifications

• B29K2505/00

  Use of metals, their alloys or their compounds, as filler · CPC title

• B29C70/025

  with particular filler · CPC title

• B29K2509/02

  Ceramics · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• B29C70/467

  and impregnating the reinforcements during mould closing (B29C70/465 takes precedence) · CPC title