Methods of making high temperature elastic composites

Patent metadata

Field	Value
Publication number	US-10759092-B2
Application number	US-201514945488-A
Country	US
Kind code	B2
Filing date	Nov 19, 2015
Priority date	Nov 19, 2015
Publication date	Sep 1, 2020
Grant date	Sep 1, 2020

Abstract

A method of manufacturing an elastic composite includes forming a preform from a filler filled one-dimensional elastic structure that contains a filler and a matrix material forming a pattern that provides elasticity to the one-dimensional elastic structure; and forming the elastic composite from the preform via one or more of the following: sintering; compression molding; or hot isostatic pressing.

First claim

What is claimed is:

1. A method of manufacturing an elastic composite, the method comprising:
forming a preform from a filler filled one-dimensional elastic structure that comprises a filler and a wire comprising a matrix material, the wire forming a pattern that provides elasticity to the one-dimensional elastic structure, the matrix material comprising one or more of the following: a metal; a metal alloy; or a ceramic material, and the filler comprising a carbon composite and optionally one or more of the following: a polymer; a metal; graphite; cotton; asbestos; or glass fiber, the carbon composite comprising carbon microstructures having an aspect ratio of about 10 to about 500, and a binder disposed in interstitial spaces among the carbon microstructures; and
forming the elastic composite from the preform via one or more of the following: sintering; compression molding; or hot isostatic pressing,
wherein the filler filled one-dimensional elastic structure has an elastic deformation of greater than about 50%.

2. The method of claim 1 , wherein the filler is coated on the wire.

3. The method of claim 1 , wherein the pattern is a spring.

4. The method of claim 1 , wherein the filler is in the form of one or more of the following: rods; tubes; powders; or pellets.

5. The method of claim 1 , wherein forming the preform comprises forming a filled sheet from the one-dimensional elastic structure; and forming the preform from the filled sheet.

6. The method of claim 5 , wherein forming the preform from the filled sheet comprises one or more of the following: bending, folding, or rolling the filled sheet, or stacking multiple filled sheets.

7. The method of claim 1 , wherein forming the elastic composite from the preform comprises
molding the preform at a pressure of about 500 psi to about 50,000 psi and a molding temperature of about 20° C. to about 30° C. to provide a molded product; and
sintering the molded product at a sintering temperature of greater than about 150° C. and less than the melting points of both the filler and the matrix material to form the elastic composite.

8. The method of claim 7 , further comprising heating the elastic composite at a temperature of about 20° C. to about 500° C. lower than the sintering temperature and an atmospheric pressure to release residual stress.

9. The method of claim 1 , wherein the filler comprises the carbon composite and the polymer, and the polymer comprises one or more of the following: a acrylonitrile butadiene rubber; hydrogenated nitrile butadiene; acrylonitrile butadiene carboxy monomer; ethylene propylene diene monomer; fluorocarbon rubber; perfluorocarbon rubber; tetrafluoro ethylene/propylene rubber; silicone rubber; polyurethane; nylon; polyethylene; polytetrafluoroethylene; perfluoroalkoxy alkane; polyphenylene sulfide; polyether ether ketone; polyphenylsulfone; polyimide, polyethylene tetraphthalate; or polycarbonate.

10. The method of claim 1 , wherein the matrix material comprises one or more of the following: the metal; or the metal alloy.

11. The method of claim 1 , wherein the binder in the carbon microstructure comprises one or more of the following: a nonmetal, a metal, an alloy of the metal, the non-metal is one or more of the following: SiO 2 ; Si; B; or B 2 O 3 and the metal is at least one of aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

Assignees

• Yu Chengjiao
• Xu Zhiyue
• Wang Xiao
• Shyu Goang Ding
• Baker Hughes A Ge Co Llc

Inventors

• Yu Chengjiao
• Xu Zhiyue
• Wang Xiao
• Shyu Goang-Ding

Classifications

• B29B11/16 Primary

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• B29C70/88 Primary

  characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced · CPC title

• B29C70/16

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title

• F16F3/02

  with springs made of steel or of other material having low internal friction · CPC title

• B29C70/205

  the structure being shaped to form a three-dimensional configuration · CPC title