Reinforced composites, methods of manufacture, and articles therefrom

Patent metadata

Field	Value
Publication number	US-9962903-B2
Application number	US-201414540177-A
Country	US
Kind code	B2
Filing date	Nov 13, 2014
Priority date	Nov 13, 2014
Publication date	May 8, 2018
Grant date	May 8, 2018

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 reinforcing material is disposed in a matrix of the carbon composite;
the carbon composite comprising carbon microstructures having interstitial spaces among the carbon microstructures, 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, and
wherein the carbon microstructures comprise graphite basal planes stacked together; the binder is disposed in at least some of the interstitial spaces; and the carbon microstructures comprise voids within the carbon microstructures that are at least partially filled with the binder.

2. The reinforced composite of claim 1 , wherein the carbon fiber based reinforcing 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 based reinforcing material 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 microstructures in the carbon composite comprise microstructures of one or more of the following: expanded graphite; expandable graphite; natural graphite; or synthetic graphite.

6. The reinforced composite of claim 1 , wherein the binder disposed in at least some of the interstitial spaces forms a binding phase.

7. The reinforced composite of claim 6 , wherein the binding phase comprises a binder layer and an interface layer bonding the 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.

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

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

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

11. The article of claim 10 , wherein the article is a load-bearing element.

12. The article of claim 11 , wherein the article is a bearing; a bearing seat; a bushing; a piston; or a backup ring.

13. A method of manufacturing the reinforced composite of claim 1 , the method comprising:
compressing a reinforced composition comprising a carbon composite powder 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.

14. The reinforced composite of claim 1 , wherein the reinforced composite comprises about 50 wt. % to about 99 wt. % of the carbon composite, based on the total weight of the reinforced composite.

15. The reinforced composite of claim 1 , wherein the reinforced composite comprises about 92 wt. % to about 99 wt. % of the carbon composite, based on the total weight of the reinforced composite.

16. The reinforced composite of claim 1 , wherein the voids within the carbon microstructures have a size of about 20 nanometers to about 1 micron.

Assignees

• Zhao Lei
• Xu Zhiyue
• Baker Hughes A Ge Co Llc

Inventors

• Zhao Lei
• Xu Zhiyue

Classifications

• B32B2457/00

  Electrical equipment · CPC title

• B32B2250/02

  2 layers · CPC title

• C04B35/76

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

• B32B5/16

  characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)} · CPC title

• B32B2262/101

  Glass fibres · CPC title