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

Patent metadata

Field	Value
Publication number	US-11976178-B2
Application number	US-201715792349-A
Country	US
Kind code	B2
Filing date	Oct 24, 2017
Priority date	Oct 24, 2017
Publication date	May 7, 2024
Grant date	May 7, 2024

Abstract

The present disclosure provides compositions including a carbon fiber material comprising one or more of an acyclic olefin group or a thiol 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 carbon-containing zinc-titanium or a thiol 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 metal substrate comprising a composition disposed thereon, the composition comprising:
a carbon fiber composite comprising:
one or more carbon fibers having one or more acyclic olefin groups bonded thereto, the acyclic olefin being represented by the structure:

wherein R is hydrogen or a linear or branched C 1 -C 40 alkane and the unsaturation shown in the structure is bonded directly to the carbon fiber; and
a polymer comprising a bismaleimide,

wherein the metal substrate is a component of an aircraft and the composition is disposed directly on the metal substrate at a thickness of about 1 micron to about 10 microns.

2. The metal substrate of claim 1 , wherein the carbon fiber composite has a composite structure selected from a mat, a tow, a layered structure, a ply, a braid, or a filament.

3. The metal substrate of claim 2 , wherein the carbon fiber composite comprises graphite.

4. The metal substrate of claim 2 , wherein the composition comprises the polymer from about 30 wt % to about 60 wt % based on the total weight of the composition.

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

6. The metal substrate of claim 2 , wherein the carbon fiber has orientations comprised of about 0°, about +/−45°, and about 90°.

7. The metal substrate of claim 2 , wherein the composition comprises the polymer from about 40 wt % to about 50 wt % based on total weight of the composition.

8. The metal substrate of claim 2 , wherein the composition comprises the carbon fiber composite from about 50 wt % to about 70 wt % based on total weight of the composition.

9. The metal substrate of claim 2 , wherein the composition comprises the carbon fiber composite from about 60 wt % to about 65 wt % based on total weight of the composition.

10. The metal substrate of claim 9 , wherein the composition comprises the polymer from about 30 wt % to about 60 wt % based on total weight of the composition.

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

12. The metal substrate of claim 1 , wherein the metal substrate is a component of an aircraft selected from the group consisting of 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, and a wing rib-to-skin joint.

13. The metal substrate of claim 1 , wherein R of the one or more acyclic olefin groups is the linear or branched C 1 -C 20 alkane.

14. A method, comprising:
introducing a carbon fiber composite to a dihaloalkane, zinc, titanium tetrachloride, and a lead dichloride catalyst to form a coated carbon fiber comprising one or more acyclic olefin groups represented by the structure:

wherein R is hydrogen or a linear or branched C 1 -C 40 alkane and the unsaturation shown in the structure is bonded directly to the carbon fiber;

mixing the coated carbon fiber composite with a bismaleimide polymer to form a composition;
depositing the composition onto a metal substrate; and
curing the composition at a temperature of about 20° C. to about 300° C. to form a cured carbon fiber composite having a thickness of about 1 micron to about 10 microns disposed directly on the metal substrate, wherein the metal substrate is a component of an aircraft.

15. The method of claim 14 , wherein the metal substrate is steel, aluminum, titanium, magnesium, tantalum, copper, or an alloy thereof.

16. The method of claim 14 , wherein the carbon fiber composite comprises graphite, and the method further comprises:
introducing a fiber into a furnace;
introducing an inert gas into the furnace; and
heating the furnace to a temperature of about 2,000° C. to about 2,700° C. to form the graphite.

17. The method of claim 14 , wherein the carbon fiber composite has a composite structure selected from a mat, a tow, a layered structure, a ply, a braid, or a filament.

18. The method of claim 14 , wherein mixing the coated carbon fiber composite with the bismaleimide polymer is performed by resin-transfer molding or resin-film infusion to form the composition.

19. The method of claim 14 , wherein depositing the composition onto the metal substrate is performed by a lay-up process or a collation process.

20. The method of claim 14 , wherein R of the one or more acyclic olefin groups is the linear or branched C 1 -C 20 alkane.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick J

Classifications

• C08K7/06 Primary

  Elements · CPC title

• C01B32/174

  Derivatisation; Solubilisation; Dispersion in solvents · CPC title

• C01B32/194

  After-treatment · CPC title

• C01B32/21

  After-treatment · CPC title

• C08J5/06

  using pretreated fibrous materials · CPC title