Z-direction reinforced composites and methods of forming z-direction reinforced composites

Patent metadata

Field	Value
Publication number	US-12565452-B2
Application number	US-202217718925-A
Country	US
Kind code	B2
Filing date	Apr 12, 2022
Priority date	Apr 12, 2022
Publication date	Mar 3, 2026
Grant date	Mar 3, 2026

Abstract

A fiber reinforced composite component may include interleaved fiber layers and ceramic particle layers coated with matrix material. The fiber reinforced composite component may be fabricated by forming a fibrous preform, needling the fibrous preform to form a plurality of z-direction fibers, and densifying the fibrous preform. The fibrous preform may be fabricated by forming a first ceramic particle layer over a first fiber layer, disposing a second fiber layer over the first ceramic particle layer, forming a second ceramic particle layer over the second fiber layer, and disposing a third fiber layer over the second ceramic particle layer.

First claim

What is claimed is:

1 . A method of fabricating a composite component, comprising:
forming a fibrous preform by:
disposing a first fiber layer on a first plate;
locating a first shim around an outer perimeter of the first fiber layer;
depositing a first ceramic particle layer over the first fiber layer, the first ceramic particle layer including a first group of boron carbide particles having a first average particle size and a second group of boron carbide particles having a second average particle size, the second average particle size being less than the first average particle size;
locating a second fiber layer over the first ceramic particle layer;
locating a second shim around an outer perimeter of the second fiber layer;
depositing a second ceramic particle layer over the second fiber layer;
locating a third fiber layer over the second ceramic particle layer;
needling the fibrous preform to form a plurality of z-direction fibers;
disposing a second plate over the third fiber layer, wherein at least one of the first plate or the second plate includes at least one of a groove or an orifice; and
densifying the fibrous preform while applying a compressive load to the third fiber layer.

2 . The method of claim 1 , wherein the first group of ceramic particles forms a greater weight percentage of the first ceramic particle layer as compared to the second group of ceramic particles.

3 . The method of claim 1 , further comprising performing a silicon melt infiltration after densifying the fibrous preform.

4 . The method of claim 3 , further comprising:
forming the fibrous preform in a mold; and curing the fibrous preform prior to densification.

5 . The method claim 4 , wherein each of the first ceramic particle layer and the second ceramic particle layer includes a phenolic resin powder.

6 . The method of claim 1 , further comprising locating a carbon/carbon member through the fibrous preform.

7 . The method of claim 6 , further comprising forming an opening through the carbon/carbon member.

8 . The method of claim 7 , wherein a diameter of the opening is between 25% and 75% of a diameter of the carbon/carbon member.

9 . A method of forming a fibrous preform for fabricating a composite component, comprising:
locating a first fiber layer in a mold; forming a first layer of ceramic particles and phenolic resin powder over the first fiber layer, the first layer of ceramic particles and phenolic resin powder including a first group of boron carbide particles having a first average particle size and a second group of boron carbide particles having a second average particle size, the second average particle size being less than the first average particle size; locating a second fiber layer in the mold and over the first layer of ceramic particles and phenolic resin powder; forming a second layer of ceramic particles and phenolic resin powder over the second fiber layer; locating a third fiber layer over the second layer of ceramic particles and phenolic resin powder; and curing the fibrous preform.

10 . The method of claim 9 , further comprising locating a plurality of carbon/carbon members in the mold, wherein the plurality of carbon/carbon members is located through each of the first fiber layer, the second fiber layer, the third fiber layer.

11 . The method of claim 10 , wherein the first group of ceramic particles forms a greater weight percentage of the first layer of ceramic particles and phenolic resin powder as compared to the second group of ceramic particles.

12 . The method of claim 9 , further comprising needling through the first fiber layer, the second fiber layer, and the third fiber layer to form a plurality of z-direction fibers extending between the first fiber layer and the third fiber layer.

13 . The method of claim 12 , wherein the first fiber layer, the second fiber layer, and the third fiber layer each have an open weave comprised of between 25% and 75% open area.

14 . A method of fabricating a composite component, comprising:
forming a fibrous preform in a mold by: depositing a first ceramic particle layer over a first fiber layer, the first ceramic particle layer including a phenolic resin powder, a first group of boron carbide particles having a first average particle size, and a second group of boron carbide particles having a second average particle size, the second average particle size being less than the first average particle size; locating a second fiber layer over the first ceramic particle layer; depositing a second ceramic particle layer over the second fiber layer, the second ceramic particle layer including the phenolic resin powder; locating a third fiber layer over the second ceramic particle layer; needling the fibrous preform to form a plurality of z-direction fibers; curing the fibrous preform; and densifying the fibrous preform.

15 . The method of claim 14 , wherein the first group of ceramic particles forms a greater weight percentage of the first ceramic particle layer as compared to the second group of ceramic particles.

16 . The method of claim 14 , further comprising performing a silicon melt infiltration after densifying the fibrous preform.

17 . The method of claim 14 , further comprising locating a carbon/carbon member through the fibrous preform.

18 . The method of claim 17 , further comprising forming an opening through the carbon/carbon member.

19 . The method of claim 18 , wherein a diameter of the opening is between 25% and 75% of a diameter of the carbon/carbon member.

20 . The method of claim 14 , further comprising:
disposing the first fiber layer on a first plate; locating a first shim around an outer perimeter of the first fiber layer; locating a second shim around an outer perimeter of the second fiber layer; disposing a second plate over the third fiber layer, wherein at least one of the first plate or the second plate includes at least one of a groove or an orifice; and applying a compressive load to the third fiber layer.

Assignees

• Goodrich Corp

Inventors

• Kirkpatrick Christopher T

Classifications

• C04B2235/616

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

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title

• C04B2235/5256

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

• C04B2235/5248

  Carbon, e.g. graphite · CPC title

• C04B2235/48

  Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins · CPC title