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

Patent metadata

Field	Value
Publication number	US-12180352-B2
Application number	US-202217967306-A
Country	US
Kind code	B2
Filing date	Oct 17, 2022
Priority date	Oct 24, 2017
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

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 composition comprising:
a carbon fiber material comprising a polysilazane covalently bonded to the carbon fiber material; and
a polymer selected from a thermosetting polymer or a thermoplastic polymer.

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

3. The composition of claim 2 , wherein the carbon fiber material is graphite.

4. The composition of claim 1 , wherein the polymer is an epoxy, a bismaleimide, a polyimide, or polyaryletherketone.

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

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

7. A metal substrate comprising a composition disposed thereon, wherein the composition comprises:
a carbon fiber material comprising a polysilazane covalently bonded to the carbon fiber material; and
a polymer selected from a thermosetting polymer or a thermoplastic polymer.

8. The metal substrate of claim 7 , wherein the metal is steel, aluminum, titanium, magnesium, tantalum, copper, or an alloy thereof.

9. The metal substrate of claim 8 , wherein the composition is disposed on the substrate at a thickness from about 1 micron to about 100 microns.

10. A vehicle component comprising the metal substrate of claim 9 .

11. The vehicle component of claim 10 , 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.

12. A method for manufacturing a component, comprising:
contacting a carbon fiber material with a polysilazane to form a coated carbon fiber material, wherein the coated carbon fiber material comprises the polysilazane is covalently bonded to the carbon fiber material; and
mixing the coated carbon fiber material with a polymer selected from a thermosetting polymer or a thermoplastic polymer to form a composition.

13. The method of claim 12 , further comprising depositing the composition onto a metal substrate.

14. The method of claim 12 , wherein the carbon fiber material 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 from about 2,000° C. to about 2,700° C. to form the graphite.

15. The method of claim 12 , wherein contacting further comprises contacting the carbon fiber material with an acid.

16. The method of claim 15 , wherein contacting the carbon fiber material with the acid comprises immersing the carbon fiber material in a solution comprising the acid for from about 0.5 seconds to about 1 minute and removing the carbon fiber material from the solution comprising the acid at a rate of about 0.3 m/min.

17. The method of claim 15 , wherein contacting the carbon fiber material with the polysilazane comprises:
dissolving the polysilazane in a solvent; and
applying an amount of the polysilazane to the carbon fiber material from about from about 0.003 mg polysilazane/mm 2 of carbon fiber material to about 0.007 mg polysilazane/mm 2 of carbon fiber material.

18. The method of claim 17 , further comprising thermally treating the carbon fiber material at a temperature from about 500° C. to about 700° C. after applying the polysilazane to the carbon fiber material.

19. The method of claim 15 , wherein the polysilazane is represented by formula (I):
—(SiR 1 R 2 —NR 3 ) n —  (I)

wherein:
R 1 , R 2 and R 3 are independently selected from hydrogen, alkyl, aryl, vinyl, or (trialkoxysilyl)alkyl;
n is a positive integer, and the polysilazane has a number-average molecular weight of from about 150 g/mol to about 150,000 g/mol.

20. The method of claim 15 , wherein contacting the carbon fiber material with the polysilazane comprises:
dissolving the polysilazane in a solvent; and
applying an amount of the polysilazane to the carbon fiber material from about from about 0.003 mg polysilazane/mm 2 of carbon fiber material to about 0.007 mg polysilazane/mm 2 of carbon fiber material, wherein the polysilazane is represented by formula (I):
—(SiR 1 R 2 —NR 3 ) n —  (I)

wherein:
R 1 , R 2 and R 3 are independently selected from hydrogen, alkyl, aryl, vinyl, or (trialkoxysilyl)alkyl;
n is a positive integer, and the polysilazane has a number-average molecular weight of from about 150 g/mol to about 150,000 g/mol.

Assignees

• Boeing Co

Inventors

• Kinlen Patrick J

Classifications

• C08J5/06

  using pretreated fibrous materials · CPC title

• D06M15/6436

  containing amino groups · CPC title

• D06M13/08

  with halogenated hydrocarbons · CPC title

• D06M2101/40

  Fibres of carbon · CPC title

• B32B38/0036

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