Composites and methods of forming composites having tailored hardness profile

Patent metadata

Field	Value
Publication number	US-12427748-B2
Application number	US-202217864288-A
Country	US
Kind code	B2
Filing date	Jul 13, 2022
Priority date	Dec 6, 2021
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

An aerospace component may comprise a fiber reinforced composite material. The fiber reinforced composite material includes a plurality of fiber layers and a carbon matrix surrounding the plurality of fiber layers. A plurality of ceramic particles is dispersed in the carbon matrix. A first fiber layer of the plurality of fiber layers may include a carbon fiber, and a second fiber layer of the plurality of fiber layers may include a non-carbon fiber. A hardness of the non-carbon fiber is greater than a hardness of carbon fiber.

First claim

What is claimed:

1. An aerospace component, comprising:
a fiber reinforced composite material including:
a plurality of fiber layers; and
a carbon matrix surrounding the plurality of fiber layers, wherein a plurality of ceramic particles is dispersed in the carbon matrix;

wherein a first fiber layer of the plurality of fiber layers includes only carbon fiber tows devoid of non-carbon fibers and
wherein a second fiber layer of the plurality of fiber layers includes only non-carbon fiber tows, the non-carbon fiber tows including elements other than carbon, a hardness of the non-carbon fiber tows being greater than a hardness of carbon fiber tows.

2. The aerospace component of claim 1 , wherein the plurality of ceramic particles includes at least one of silicon carbide particles, silicon nitride particles, or zirconium oxide particles.

3. The aerospace component of claim 2 , wherein the non-carbon fibers includes at least one of a silicon carbide fiber, a silicon nitride fiber, or a zirconium oxide fiber.

4. The aerospace component of claim 1 , wherein the plurality of fiber layers includes a plurality of carbon fiber layers interleaved with a plurality of non-carbon fiber layers, the plurality of carbon fiber layers including the first fiber layer, and the plurality of non-carbon fiber layers including the second fiber layer.

5. The aerospace component of claim 1 , wherein a first portion of the fiber reinforced composite material comprises a first hardness, and wherein a second portion of the fiber reinforced composite material comprises a second hardness greater than the first hardness.

6. The aerospace component of claim 5 , wherein at least one of a volume of the plurality of ceramic particles or a density of the plurality of ceramic particles in the second portion of the fiber reinforced composite material is greater than at least one of the volume of the plurality of ceramic particles or the density of the plurality of ceramic particles in the first portion of the fiber reinforced composite material.

7. The aerospace component of claim 5 , wherein at least one of a ratio of non-carbon fiber tows to carbon fiber tows, a density of non-carbon fiber tows, or a volume of non-carbon fiber tows in the second portion of the fiber reinforced composite material is greater than at least one of the ratio of the non-carbon fiber tows to the carbon fiber tows, the density of the non-carbon fiber tows, or the volume of the non-carbon fiber tows in the first portion of the fiber reinforced composite material.

Assignees

• Rohr Inc

Inventors

• Kukuchek Paul E
• Pujar Vijay V

Classifications

• B32B2605/18

  Aircraft · CPC title

• B32B2313/04

  Carbon · CPC title

• B32B2307/536

  Hardness · CPC title

• B32B2305/188

  Woven fabrics · CPC title

• B32B2305/076

  Prepregs · CPC title