Fiber reinforced composite and method of making

Patent metadata

Field	Value
Publication number	US-12351530-B2
Application number	US-202017070069-A
Country	US
Kind code	B2
Filing date	Oct 14, 2020
Priority date	Oct 18, 2019
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

A method of making a fiber reinforced composite includes: infiltrating a preform having a perimeter with an electrophoretic gel; adding nanoparticles to wells located in the electrophoretic gel outside the preform perimeter; introducing the nanoparticles to the preform using gel electrophoresis; removing the electrophoretic gel to result in a preform having embedded nanoparticles; and infiltrating the preform having embedded nanoparticles with a matrix material or a matrix material precursor.

First claim

What is claimed is:

1. A method of making a fiber reinforced composite comprising:
infiltrating a preform with an electrophoretic gel, the preform having a perimeter and comprising a fiber structure, the preform in a tank of the electrophoretic gel;
adding particles to wells located in the tank outside the preform perimeter; wherein the particles comprise nanoparticles having a size that is less than the diameter of the fibers used to make a tow; and wherein an initial coating of a matrix material is disposed onto the preform prior to infiltrating the preform with the electrophoretic gel and preforming electrophoresis;
introducing the particles to the preform using gel electrophoresis, wherein a voltage is applied from multiple sides of the preform during the gel electrophoresis and the voltage is applied simultaneously or sequentially;
removing the electrophoretic gel to result in a preform having embedded particles; and
infiltrating the preform having embedded particles with the matrix material or a matrix material precursor, wherein
1) The preform comprises carbon fiber, SiC fiber, Al 2 O 3 —SiO 2 fiber, silicon dioxide (SiO 2 ) fiber, aluminum silicate fiber, aluminum oxide (Al 2 O 3 ) fiber, titanium oxide (TiO 2 ) fiber, zirconium silicate fiber, silicon nitride fiber, boron nitride (BN) fiber, and combinations thereof,
2) The particles comprise carbon (C), silicon oxide (SiO 2 ), boron nitride (BN), boron carbide (B 4 C), aluminum oxide (Al 2 O 3 ), zirconium oxide (ZrO 2 ), zirconium boride (ZrB 2 ), zinc oxide (ZnO 2 ), molybdenum disulfide (MoS 2 ), silicon nitride (Si 3 N 4 ), and combinations thereof, and/or
3) The matrix material comprises carbon (C), silicon carbide (SiC), silicon oxide (SiO 2 ), boron nitride (BN), boron carbide (B 4 C), aluminum oxide (Al 2 O 3 ), zirconium oxide (ZrO 2 ), zirconium boride (ZrB 2 ), zinc oxide (ZnO 2 ), molybdenum disulfide (MoS 2 ), silicon nitride (Si 3 N 4 ), and combinations thereof.

2. The method of claim 1 , wherein introducing the particles to the preform using gel electrophoresis results in the particles being introduced and deposited in a controlled size gradient.

3. The method of claim 1 , wherein the preform comprises uniaxial fiber layup, a 2D woven fabric layup, 3D weave or a combination thereof.

4. The method of claim 1 , wherein the preform comprises carbon fiber, Al 2 O 3 —SiO 2 fiber, SiC fiber, silicon dioxide (SiO 2 ) fiber, aluminum silicate fiber, aluminum oxide (Al 2 O 3 ) fiber, titanium oxide (TiO 2 ) fiber, zirconium silicate fiber, silicon nitride fiber, boron nitride (BN) fiber, and combinations thereof.

5. The method of claim 1 , wherein the particles comprise carbon (C), silicon carbide (SiC), silicon oxide (SiO 2 ), boron nitride (BN), boron carbide (B 4 C), aluminum oxide (Al 2 O 3 ), zirconium oxide (ZrO 2 ), zirconium boride (ZrB 2 ), zinc oxide (ZnO 2 ), molybdenum disulfide (MoS 2 ), silicon nitride (Si 3 N 4 ), and combinations thereof.

6. The method of claim 1 , wherein the electrophoretic gel comprises agarose, polyacrylamide, starch or a combination thereof.

7. The method of claim 1 , wherein the matrix material comprises carbon (C), silicon carbide (SiC), silicon oxide (SiO 2 ), boron nitride (BN), boron carbide (B 4 C), aluminum oxide (Al 2 O 3 ), zirconium oxide (ZrO 2 ), zirconium boride (ZrB 2 ), zinc oxide (ZnO 2 ), molybdenum disulfide (MoS 2 ), Silicon nitride (Si 3 N 4 ), and combinations thereof.

8. The method of claim 1 , wherein the particles further have sizes of 0.1 to 100 micrometers (μm).

9. The method of claim 1 , wherein the particles are present in an amount of 1 to 20 wt % based on the weight of the preform.

10. The method of claim 1 , further comprising densifying the preform having an infiltrated matrix material and embedded particles to form a fiber reinforced composite having a porosity less than 15%.

11. The method of claim 1 , wherein the particles have functional groups grafted onto a surface or are coated in a surfactant to provide functional groups.

12. The method of claim 2 , wherein the controlled size gradient has a particle size gradient ranging from smallest on a first size of the fiber reinforced composite to largest on a second side of the fiber reinforced composite.

Assignees

• Rtx Corp

Inventors

• Lenz Brendan M

Classifications

• C04B2235/614

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

• C04B2235/5445

  submicron sized, i.e. from 0,1 to 1 micron · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• C04B2235/5256

  Two-dimensional, e.g. woven structures · CPC title

• C04B2235/5248

  Carbon, e.g. graphite · CPC title