Multilayered carbon-carbon composite

Patent metadata

Field	Value
Publication number	US-2016332416-A1
Application number	US-201514711590-A
Country	US
Kind code	A1
Filing date	May 13, 2015
Priority date	May 13, 2015
Publication date	Nov 17, 2016
Grant date	—

Abstract

In some examples, the disclosure describes a method including densifying a layer of carbon fibers by at least one of depositing a resin on the layer of carbon fibers via a print head of a three-dimensional printing system or applying CVD on the layer of carbon fibers via the print head; and forming at least one additional layer of densified carbon fibers on the densified layer of carbon fibers, wherein forming the at least one additional layer of densified carbon fibers comprises, for each respective layer of the at least one additional layer, adding an additional layer of carbon fibers on the densified layer of carbon fibers, and densifying the additional layer of carbon fibers by at least one of depositing the resin on the additional layer of carbon fibers or applying CVD on the additional layer of carbon fibers. In some examples, the example method may be used to form a densified carbon-carbon composite component, such as, e.g., a densified carbon-carbon composite brake disc.

First claim

1 : A method comprising:
densifying a layer of carbon fibers by at least one of depositing a resin on the layer of carbon fibers via a print head of a three-dimensional printing system or applying CVD on the layer of carbon fibers via the print head; and forming at least one additional layer of densified carbon fibers on the densified layer of carbon fibers, wherein forming the at least one additional layer of densified carbon fibers comprises, for each respective layer of the at least one additional layer,
adding an additional layer of carbon fibers on the densified layer of carbon fibers, and
densifying the additional layer of carbon fibers by at least one of depositing the resin on the additional layer of carbon fibers or applying CVD on the additional layer of carbon fibers.

2 : The method of claim 1 , wherein depositing the resin on the layer of carbon fibers comprises melting the resin and depositing the melted resin on the layer of carbon fibers.

3 : The method of claim 1 , wherein applying CVD on the additional layer of carbon fibers comprises depositing a carbonaceous gas on the additional layer of carbon fibers via the print head.

4 : The method of claim 3 , wherein the carbonaceous gas comprises at least one of natural gas, methane, ethane, propane, butane, propylene, or acetylene.

5 : The method of claim 1 , wherein adding the additional layer of the carbon fibers on the densified layer of carbon fibers comprises depositing a pre-fabricated fabric layer of carbon fibers on the densified layer of carbon fibers.

6 : The method of claim 1 , further comprising, carbonizing the resin at least one of after depositing the resin on the additional layer of carbon fibers and before forming at least one of the additional layer of densified carbon fibers, or after depositing the resin on the additional layer of the carbon fibers and after adding at least one of the additional layer of carbon fibers.

7 : The method of claim 1 , wherein densifying the additional layer of carbon fibers comprises densifying the additional layer of the carbon fibers by depositing the resin on the additional layer of carbon fibers and applying CVD on the additional layer of carbon fibers.

8 : The method of claim 1 , wherein the first layer and at least one additional layer of densified carbon fibers exhibit a density greater than approximately 1.7 grams per cubic centimeter.

9 : The method of claim 1 , wherein the step of forming at least one additional layer of densified carbon fibers is repeated until at least approximately 15 layers of densified carbon fibers are formed.

10 : A carbon-carbon composite material comprising a plurality of densified carbon fiber layers, the plurality of densified carbon fiber layers including a first layer of densified carbon fibers densified by at least one of depositing a resin on a first layer of carbon fibers via a print head of a three-dimensional printing system or applying CVD on a first layer of carbon fibers via the print head, and a second layer of densified carbon fibers deposited on the first layer of densified carbon fibers and subsequently densified on first layer of densified carbon fibers by at least one of depositing a resin on a second layer of carbon fibers via the print head or applying CVD on a second layer of carbon fibers via the print head.

11 : The carbon-carbon composite material of claim 10 , wherein the first layer of densified carbon fibers is densified by depositing the resin on the first layer of carbon fibers, and wherein the second layer of densified carbon fibers is densified by applying CVD on the second layer of carbon fibers.

12 : The carbon-carbon composite material of claim 11 , wherein the resin of the first layer of densified carbon fibers is carbonized and the resin of the second layer of densified carbon fibers is not carbonized.

13 : The carbon-carbon composite material of claim 11 , wherein the densified carbon-carbon composite component exhibits a density greater than approximately 1.7 grams per cubic centimeter.

14 : The carbon-carbon composite material of claim 11 , wherein the carbon-carbon composite material exhibits an overall thickness of about 0.75 inches to about 1.25 inches.

15 : The carbon-carbon composite material of claim 11 , wherein the plurality of densified carbon fiber layers comprises at least approximately 15 layers.

16 : A system comprising:
a print head configured to at least one of deposit a CVD gas or deposit a resin relative a work surface; and a controller configured to control the at least one of depositing the CVD gas or depositing the resin relative the work surface to form a plurality of densified carbon fibers layers, wherein each layer of the plurality of densified carbon fiber layers is formed by the at least one of depositing the resin via the print head on to a layer of carbon fibers or depositing the CVD gas via the print head on to the layer of carbon fibers.

17 : The system of claim 16 , further comprising a resin feed module configured to melt the resin prior to depositing the resin via the first printer head.

16 . (canceled)

18 : The system of claim 16 , wherein the print head comprises a first print head configured to deposit the resin relative a work surface, the system further comprising a second print head configured to deposit a CVD gas relative the work surface.

19 : The system of claim 16 , wherein, for a respective layer of the plurality of densified carbon fiber layers, the controller is configured to control the print head to deposit resin on a layer of carbon fibers and deposit the CVD gas on to the layer of carbon fibers to densify the respective layer.

20 : The system of claim 16 , wherein the controller is configured control the print head to deposit the resin on a first layer of carbon fibers to form a first densified layer of the plurality of densified carbon fiber layers, and control the print head to deposit the CVD gas on a second layer of carbon fibers on the first densified layer to form a second densified layer of the plurality of densified carbon fiber layers.

Assignees

• Honeywell Int Inc

Inventors

• Troester Jeffrey
• Fryska Slawomir T
• Flask David

Classifications

• B29C64/159

  using only gaseous substances, e.g. vapour deposition · CPC title

• B32B18/00

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• B32B2307/56

  Damping, energy absorption · CPC title

• B32B2605/18

  Aircraft · CPC title

• B32B2307/75

  Printability · CPC title