Compositions with coated carbon fibers and methods for manufacturing compositions with coated carbon fibers

Patent metadata

Field	Value
Publication number	US-11472944-B2
Application number	US-201715792125-A
Country	US
Kind code	B2
Filing date	Oct 24, 2017
Priority date	Oct 24, 2017
Publication date	Oct 18, 2022
Grant date	Oct 18, 2022

Abstract

The present disclosure provides compositions including a carbon fiber material comprising one or more of dibromocyclopropyl or polysilazane disposed thereon; and a thermosetting polymer or a thermoplastic polymer. The present disclosure further provides metal substrates including a composition of the present disclosure disposed thereon. The present disclosure further provides vehicle components including a metal substrate of the present disclosure. The present disclosure further provides methods for manufacturing a vehicle component, including contacting a carbon fiber material with a polysilazane or a dibromocarbene to form a coated carbon fiber material; and mixing the coated carbon fiber material with a thermosetting polymer or a thermoplastic polymer to form a composition. Methods can further include depositing a composition of the present disclosure onto a metal substrate.

First claim

What is claimed is:

1. A component comprising:
a metal substrate; and
a composition disposed on the metal substrate, the composition comprising:
a carbon fiber material functionalized with dibromocyclopropyl groups on the carbon fiber material to form a covalently bonded coating on the surface, wherein the carbon fiber material consists of graphite; and
a polymer selected from a group consisting of a thermosetting polymer, a thermoplastic polymer, and combinations thereof.

2. The component of claim 1 , wherein the carbon fiber material has a composite structure selected from a group consisting of a mat, a tow, a layered structure, a ply, a braid, a filament, and combinations thereof.

3. The component of claim 1 , wherein the polymer is a bismaleimide or polyaryletherketone.

4. The component of claim 3 , wherein the composition comprises the polymer from about 30 wt % to about 60 wt % based on the total weight of the composition.

5. The component of claim 4 , wherein the composition comprises the carbon fiber material from about 50 wt % to about 70 wt % based on the total weight of the composition.

6. The component of claim 1 , wherein the metal substrate is steel, aluminum, titanium, magnesium, tantalum, copper, or an alloy thereof.

7. The component of claim 1 , wherein the composition is disposed on the substrate at a thickness of about 1 micron to about 100 microns.

8. The component of claim 1 , wherein the component is a vehicle component.

9. The component of claim 8 , wherein the vehicle component is a rotor blade, a landing gear, an auxiliary power unit, a nose of an aircraft, a fuel tank, a tail cone, a panel, a coated lap joint between two or more panels, a wing-to-fuselage assembly, a structural aircraft composite, a fuselage body-joint, or a wing rib-to-skin joint.

10. The component of claim 1 , wherein:
the carbon fiber material has a composite structure selected from the group consisting of a mat, a tow, a layered structure, a ply, a braid, a filament, and combinations thereof, and
the polymer is a bismaleimide or polyaryletherketone.

11. The component of claim 1 , wherein the dibromocyclopropyl reduces galvanic corrosion of the component.

12. The component of claim 11 , wherein the dibromocyclopropyl reduces galvanic corrosion of the component by inhibiting oxygen reduction reaction by the composition.

13. The component of claim 1 , wherein the composition is disposed directly on the metal substrate.

14. The component of claim 7 , wherein the composition is disposed on the substrate at a thickness of about 1 micron to about 10 microns.

15. The component of claim 1 , wherein the substrate is a surface of a wind turbine.

16. The component of claim 1 , wherein the carbon fiber material has a filament diameter of about 1 micron to about 20 microns.

17. The component of claim 16 , wherein the carbon fiber material has a thickness of about 1 micron to about 10 microns.

18. The component of claim 8 , wherein:
the vehicle component is a rotor blade, a landing gear, an auxiliary power unit, a nose of an aircraft, a fuel tank, a tail cone, a panel, a coated lap joint between two or more panels, a wing-to-fuselage assembly, a structural aircraft composite, a fuselage body-joint, or a wing rib-to-skin joint;
the carbon fiber material has a composite structure selected from the group consisting of a mat, a tow, a layered structure, a ply, a braid, a filament, and combinations thereof, and
the polymer is a bismaleimide or polyaryletherketone.

19. The component of claim 8 , wherein the carbon fiber material has a density of about 0.5 g/cm 3 to about 1 g/cm 3 .

20. The component of claim 1 , wherein the composition is substantially free of graphene.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick J

Classifications

• B32B2307/708

  Isotropic · CPC title

• C08K9/08 Primary

  Ingredients agglomerated by treatment with a binding agent · CPC title

• D06M2101/40

  Fibres of carbon · CPC title

• C08J2371/10

  from phenols · CPC title

• B32B38/0036

  Heat treatment (for heating or cooling of layers during lamination B32B37/06, B32B37/08) · CPC title