Systems and methods for producing a carbon composite material

Patent metadata

Field	Value
Publication number	US-10689305-B2
Application number	US-201514752551-A
Country	US
Kind code	B2
Filing date	Jun 26, 2015
Priority date	Jun 26, 2015
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

A carbon/carbon brake disk is provided. The carbon/carbon brake disk may comprise a carbon fiber, wherein the carbon fiber is formed into a fibrous network, wherein the fibrous network comprises carbon deposited therein. The carbon fiber may undergo a FHT process, wherein micro-cracks are disposed in the carbon fiber. In various embodiments, the micro-cracks may be at least partially filled with un-heat-treated carbon via a final CVD process, wherein the final CVD process is performed at a temperature in the range of up to about 1,000° C. (1,832° F.) for a duration in the range from about 20 hours to about 100 hours. In various embodiments, the un-heat-treated carbon may be configured to prevent oxygen, moisture, and/or oxidation protection systems (OPS) chemicals from penetrating the carbon/carbon brake disk. In various embodiments, the final CVI/CVD process may be configured to increase the wear life of the carbon/carbon brake disk.

First claim

What is claimed is:

1. A method of manufacturing a carbon/carbon brake disk comprising:
forming a fibrous network from an oxidized carbon fiber precursor; subsequently
carbonizing the oxidized carbon fiber precursor in a furnace by heating the oxidized carbon fiber precursor at a first temperature in a first range of about 1,400° C. to 2,800° C. to form a carbon fiber preform; subsequently
infiltrating the carbon fiber preform with carbon using chemical vapor infiltration or deposition (CVI/CVD) processing, by flowing at least one hydrocarbon gas into the furnace and by decreasing the first temperature in the furnace to a second temperature in a second range of about 900° C. to 1,100° C., to increase a density of the carbon fiber preform to form a carbon/carbon (C/C) part having a first portion with a first coefficient of friction; subsequently
stopping the flow of the at least one hydrocarbon gas into the furnace; subsequently
heat treating the C/C part, by increasing the second temperature in the furnace to a third temperature in a third range of about 1,200° C. to 2,600° C. to form a microscopic crack in the C/C part; and subsequently
performing a final chemical vapor deposition (CVD) process after the heat treating the C/C part, by reducing the third temperature in the furnace to the second temperature in the second range of about 900° C. to 1,100° C. to at least partially fill in the microscopic crack in the C/C part with carbon having a second coefficient of friction different from the first coefficient of friction,
wherein the C/C part includes the first portion comprising the first coefficient of friction and a second portion comprising the second coefficient of friction within the microscopic crack, and
wherein the first portion comprises a first carbon that is heated between 900 to 1,100° C. and 1,200 to 2,600° C. and the second portion comprises a second carbon heated between 900 to 1,100° C. only.

2. The method of manufacturing the carbon/carbon brake disk of claim 1 , wherein at least one of the infiltrating, heating, and performing are performed under a vacuum.

3. The method of manufacturing the carbon/carbon brake disk of claim 1 , wherein the performing the subsequent final CVD process prevents at least one of oxygen, moisture, and oxidation protection systems chemicals from penetrating the C/C part.

4. The method of manufacturing the carbon/carbon brake disk of claim 1 , wherein the performing the subsequent final CVD process is configured to increase wear life of the C/C part.

5. A carbon/carbon brake disk made by a method, comprising:
forming a fibrous network from an oxidized carbon fiber precursor; subsequently
carbonizing the oxidized carbon fiber precursor in a furnace by heating the oxidized carbon fiber precursor at a first temperature in a first range of about 1,400 to 2,800° C. to form a carbon fiber preform; subsequently
infiltrating the carbon fiber preform with carbon using chemical vapor infiltration or deposition (CVI/CVD) processing, by flowing at least one hydrocarbon gas into the furnace and by decreasing the first temperature in the furnace to a second temperature in a second range of about 900° C. to 1,100° C., to increase a density of the carbon fiber preform to form a carbon/carbon (C/C) part having a first portion comprising a first coefficient of friction; subsequently;
stopping the flow of the at least one hydrocarbon gas into the furnace; subsequently
heat treating the C/C part, by increasing the second temperature in the furnace to a third temperature in a third range of about 1,200 to 2,600° C. to form a microscopic crack in the C/C part; and subsequently
performing a subsequent final chemical vapor deposition (CVD) process after the heat treating the C/C part, by reducing the third temperature in the furnace to the second temperature in the second range about 900 to 1,100° C. to at least partially fill in the microscopic crack in the C/C part with carbon having a second coefficient of friction different than the first coefficient of friction,
wherein the C/C part includes the first portion comprising the first coefficient of friction and a second portion comprising the second coefficient of friction within the microscopic crack, and
wherein the first portion comprises a first carbon that is heated between 900 to 1,100° C. and 1,200 to 2,600° C. and the second portion comprises a second carbon heated between 900 to 1,100° C. only.

6. The carbon/carbon brake disk of claim 5 , wherein at least one of the infiltrating, heating, and performing are performed under a vacuum.

7. The carbon/carbon brake disk of claim 5 , wherein the performing the subsequent final CVD process prevents at least one of oxygen, moisture, and oxidation protection systems chemicals from penetrating the C/C part.

8. The carbon/carbon brake disk of claim 5 , wherein the performing the subsequent final CVD process is configured to increase wear life of the C/C part.

9. The method of manufacturing the carbon/carbon brake disk of claim 1 , wherein the second coefficient of friction is lower than the first coefficient of friction.

10. The carbon/carbon brake disk of claim 5 , wherein the second coefficient of friction is lower than the first coefficient of friction.

Assignees

• Goodrich Corp

Inventors

• Rudolph James Warren
• Linck John

Classifications

• C04B35/83 Primary

  Carbon fibres in a carbon matrix · CPC title

• C23C16/26

  Deposition of carbon only · CPC title

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title

• F16D2065/13

  Parts or details of discs or drums · CPC title

• C04B2235/614

  Gas infiltration of green bodies or pre-forms · CPC title