Reinforced composites, methods of manufacture, and articles therefrom

Patent metadata

Field	Value
Publication number	US-2016136923-A1
Application number	US-201414540177-A
Country	US
Kind code	A1
Filing date	Nov 13, 2014
Priority date	Nov 13, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

A reinforced composite comprises: a reinforcement material comprising one or more of the following: a carbon fiber based reinforcing material; a fiberglass based reinforcing material; a metal based reinforcing material; or a ceramic based reinforcing material; and a carbon composite; wherein the carbon composite comprises carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and wherein the metal is one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

First claim

What is claimed is:

1 . A reinforced composite comprising:
a reinforcing material comprising one or more of the following: a carbon fiber based reinforcing material; a fiberglass based reinforcing material; a metal based reinforcing material; or a ceramic based reinforcing material; and a carbon composite; wherein the carbon composite comprises carbon and a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and wherein the metal is one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

2 . The reinforced composite of claim 1 , wherein the carbon fiber based material comprises one or more of the following: a carbon fiber filament; a carbon fiber roving; a carbon fiber yarn; a carbon fiber tow; a carbon fiber tape; a carbon fiber ribbon; a carbon fiber mesh; a carbon fiber tube; a carbon fiber film; a carbon fiber braid; a woven carbon fiber; a non-woven carbon fiber; or a carbon fiber mat.

3 . The reinforced composite of claim 1 , wherein the carbon fiber comprises a woven carbon fiber having a mesh size of about 10 to about 400.

4 . The reinforced composite of claim 1 , wherein the metal based reinforcing material comprises one or more of the following: a metal fiber; a metal fiber yarn; a metal fiber mesh; or a metal fiber fabric; the fiberglass based reinforcing material comprises a fiberglass fabric; and the ceramic based reinforcing material comprises one or more of the following: a ceramic textile; ceramic fiber wool; or refractory ceramic fiber.

5 . The reinforced composite of claim 1 , wherein the carbon in the carbon composite comprises one or more of the following: expanded graphite; expandable graphite; natural graphite; or synthetic graphite.

6 . The reinforced composite of claim 1 , wherein the carbon composite comprises carbon microstructures having interstitial spaces among the carbon microstructures; wherein the binder is disposed in at least some of the interstitial spaces; and wherein the carbon microstructures comprise filled voids within the carbon microstructures.

7 . The reinforced composite of claim 1 , wherein the carbon composite comprises at least two carbon microstructures and a binding phase disposed between the at least two carbon microstructures; and wherein the binding phase comprises the binder.

8 . The reinforced composite of claim 6 , wherein the binding phase comprises a binder layer and an interface layer bonding one of the at least two carbon microstructures to the binder layer; and wherein the interface layer comprises one or more of the following: a C-metal bond; a C—B bond; a C—Si bond; a C—O—Si bond; a C—O-metal bond; or a metal carbon solution.

9 . The reinforced composite of claim 1 , comprising a first layer and a second layer; wherein the first layer comprises the reinforcing material and the second layer comprises the carbon composite.

10 . The reinforced composite of claim 8 , wherein the first layer further comprises a binder containing one or more of the following: SiO 2 ; Si; B; B 2 O 3 ; a metal; or an alloy of the metal; and wherein the metal is one or more of the following: aluminum; copper; titanium; nickel; tungsten; chromium; iron; manganese; zirconium; hafnium; vanadium; niobium; molybdenum; tin; bismuth; antimony; lead; cadmium; or selenium.

11 . The reinforced composite of claim 8 , wherein the thickness of the first layer relative to the thickness of the second layer is about 1:10 to about 10:1.

12 . The reinforced composite of claim 8 , wherein the reinforced composite comprises alternating first and second layers.

13 . The reinforced composite of claim 1 , wherein the reinforcing material is disposed in a matrix of the carbon composite.

14 . The reinforced composite of claim 12 , wherein the weight of the carbon composite matrix relative to the weight of the reinforcing material is about 50:1 to about 1:50.

15 . The carbon composite of claim 1 , wherein the composite is in the form of a bar, block, sheet, tubular, cylindrical billet, toroid, powder, or pellets.

16 . An article comprising the reinforced composite of claim 1 .

17 . The article of claim 15 , wherein the article is a load-bearing element.

18 . The article of claim 16 , wherein the article is a bearing; a bearing seat; a bushing; a piston; or a backup ring.

19 . A method of manufacturing the reinforced composite of claim 1 , the method comprising:
alternately disposing a reinforcing material and a composition comprising a carbon and a binder in a mold to provide a reinforced composition; and compressing the reinforced composition at a temperature of about 350° C. to about 1400° C. and a pressure of about 500 psi to about 30,000 psi to form the reinforced composite.

20 . A method of manufacturing the reinforced composite of claim 1 , the method comprising:
laminating a reinforcement layer on a carbon composite layer to provide a reinforced composition; and compressing the reinforced composition at a temperature of about 350° C. to about 1400° C. and a pressure of about 500 psi to about 30,000 psi to form the reinforced composite.

21 . A method of manufacturing the reinforced composite of claim 1 , the method comprising:
compressing a reinforced composition comprising a carbon composite and a reinforcing material at a temperature of about 350° C. to about 1400° C. and a pressure of about 500 psi to about 30,000 psi to form the reinforced composite.

22 . The method of claim 21 , wherein the carbon composite is present in the form of a powder.

Assignees

• Zhao Lei
• Xu Zhiyue
• Baker Hughes Inc

Inventors

• Zhao Lei
• Xu Zhiyue

Classifications

• C04B35/6262

  of calcined, sintered clinker or ceramics · CPC title

• B32B2313/04

  Carbon · CPC title

• C04B35/6303

  Inorganic additives · CPC title

• C22C49/14

  characterised by the fibres or filaments · CPC title

• C04B35/76

  Fibres, filaments, whiskers, platelets, or the like · CPC title