Patent application number | Description | Published |
20080233286 | Method and apparatus for removing carbonized pitch from the surface of a pitch infiltrated disk - A device for removing carbonized pitch from first and second parallel surfaces ( | 09-25-2008 |
20080251959 | Method of manufacturing a carbon-carbon brake disc - A method of manufacturing a carbon-carbon brake disc uses a restraint fixture ( | 10-16-2008 |
20080277824 | Pitch infiltration of carbon fiber preforms under high pressure - Process of manufacturing carbon-carbon composite preform by: (i.) arranging batch of carbon fiber preforms in infiltration vessel; (ii.) flooding vessel with hot liquid phase pitch at atmospheric pressure in inert atmosphere; (iii.) raising pressure in infiltration vessel to elevated pressure, and then slowly lowering pressure; and (iv.) repeating step (iii.). An apparatus that may be used is a heated infiltration vessel capable of operating at pressures above 100 psi, possible equipped with means to circulate heated pitch inside the vessel, in order to facilitate heat transfer into the carbon fiber preforms being infiltrated by the pitch. The need for a vacuum pump is eliminated, and the time spent heating the preform is substantially reduced. Instead of vacuum, cycled high pressure is employed to infiltrate carbon fiber preforms with pitch. The use of preheated pitch as a heat transfer agent avoids the slow transfer of heat into the preform prior to infiltration. | 11-13-2008 |
20080283174 | Bonding of carbon fibers to metal inserts for use in composites - Resin-impregnated carbon fiber composites containing metal inserts. Carbon fibers or a carbon fiber preform are bonded to a metal structural member. Once the carbon fiber-metal bond is established, the fiber-metal assembly or hybrid preform is impregnated with resin, to form an article in which bonding between the metal structural member and the composite remainder of the article is greatly enhanced. In a process embodiment, a metal insert, e.g. a steel insert, is provided in contact with particulate carbide-forming metal, e.g. titanium, and with carbon fiber segments. Then an electric current is passed through the carbide-forming metal particles and carbon fibers to heat them to a temperature above the melting point of the carbide-forming metal. This initiates an exothermic reaction, which forms liquid phase metal carbide. Subsequently the liquid phase metal carbide is cooled and solidified, thereby bonding the carbon fiber segments to the metal insert. | 11-20-2008 |
20090139807 | Brake assembly having multi-piece core and replaceable friction surfaces - A brake disk ( | 06-04-2009 |
20090148699 | CARBON FIBER CONTAINING CERAMIC PARTICLES - Small ceramic particles (e.g., of TiC) are incorporated into fibers. The ceramic particles enhance the friction and/or wear properties of a carbon-carbon composite article made with the impregnated or coated fibers. The impregnated fibers can be, e.g., polyacrylonitrile (PAN) fibers, pitch fibers, and other such fibers as are commonly employed in the manufacture of C—C friction materials. The impregnated fibers can be used to make woven, nonwoven, or random fiber preforms or in other known preform types. Preferred products are brake discs and other components of braking systems. The particles may be included in the fibers by mixing them with the resin employed to make the fibers and/or by applying them to the surfaces of the fibers in a binder. | 06-11-2009 |
20090194895 | CVD DENSIFIED PREFORM FOLLOWED BY VPI AND RTM - Method for producing carbon-carbon composite brake discs by: (a) providing annular nonwoven carbon fiber brake disc preforms; (b) carbonizing the brake disc preforms; (c) densifying the carbonized preforms by CVD/CVI (chemical vapor deposition/chemical vapor infiltration); (d) densifying the products of step (c) with isotropic or mesophase pitch by VPI (vacuum pitch infiltration) or RTM (resin transfer molding) processing; (e) carbonizing the preforms to remove non-carbon volatiles from the pitch and to open porosity in the pitch-infused preforms; (f) densifying the products of step (e) with isotropic or mesophase pitch by VPI or RTM processing; (g) carbonizing the preforms to remove non-carbon volatiles from pitch and to open porosity in the pitch-infused preforms; and (h) heat-treating the resulting pitch-densified carbon-carbon composite brake disc preforms. This manufacturing approach reduces lot-to-lot variability in friction performance of the resulting carbon-carbon composite brake discs. | 08-06-2009 |
20090214781 | CVI FOLLOWED BY COAL TAR PITCH DENSIFICATION BY VPI - Method for manufacturing pitch-densified carbon-carbon composite brake discs from carbon fiber preforms, by the following sequential steps: (a) providing a carbon-carbon composite brake disc preform; (b) heat treating the preform; (c) subjecting the heat-treated preform to Chemical Vapor Deposition/Chemical Vapor Infiltration processing; (d) infiltrating the preform with an isotropic low to medium char-yield pitch by Vacuum Pitch Infiltration processing or Resin Transfer Molding processing; (e) carbonizing the pitch-infiltrated preform; (f) machining the surfaces of the resulting carbonized preform; and (g) repeating steps (d) through (f) until the density of the carbon-carbon composite preform is at least 1.70 g/cc. The use of VPI equipment with isotropic, low to medium char-yield pitches for all densification steps following an initial CVD densification reduces capital and pitch materials cost. However, one or more RTM processing steps employing low to medium char-yield pitches may also be used to obtain improved economics. | 08-27-2009 |
20090230582 | DENSIFICATION OF CARBON FIBER PREFORMS WITH PITCHES FOR AIRCRAFT BRAKES - Low cost isotropic and/or mesophase pitch is used to densify carbon fiber preforms by VPI and/or RTM equipment in place of CVI/CVD processing, for reduced manufacturing cycle times and costs and reduced need for expensive densification equipment. The process includes: heat treating a carbon fiber preform; infiltrating the preform with a pitch feedstock by VPI and/or RTM; carbonizing the pitch-infiltrated carbon fiber preform at 1200-2450° C. with a hold time of 4 hrs to ensure the entire furnace reaches the max temperature; repetition of the pitch infiltration and carbonization steps until the density of the preform is about 1.7 g/cc or higher; and a final heat-treatment of the densified composite. Brake discs manufactured in this way have higher densities and better thermal characteristics, which result in improved mechanical properties and friction and wear performance as compared with conventional CVI/CVD-densified brake discs. | 09-17-2009 |
20090236763 | Resin transfer molding to toughen composite beam keys - Method of manufacturing composite wheel beam key by: forming entirely from carbon fiber precursors or from carbon fiber precursors and ceramic materials a fibrous preform blank in a shape of a desired wheel beam key, wherein the fiber volume fraction of the preform blank is at least 50%; carbonizing the carbon fiber precursors; rigidifying the carbonized preform blank by subjecting it to at least one cycle of CVD; grinding the surface of the preform blank to open pores on its surface; and subjecting the open-pored preform blank to RTM processing with pitch. Also, carbon-carbon composite or carbon-ceramic composite wheel beam key produced by this process, having a density of from 1.5 g/cc to 2.1 g/cc and a maximum internal porosity of 10% or less. | 09-24-2009 |
20090238966 | DENSIFICATION OF C-C COMPOSITES WITH PITCHES FOLLOWED BY CVI/CVD - Method of manufacturing pitch-based carbon-carbon composite useful as a brake disc, by: (a) providing annular carbon fiber brake disc preform; (b) heat-treating the carbon fiber preform; (c) infiltrating the carbon fiber preform with pitch feedstock by VPI or RTM processing; (d) carbonizing the pitch-infiltrated carbon fiber preform; (e) repeating steps (c) and (d) to achieve a density in the carbon fiber preform of approximately 1.5 g/cc to below 1.7 g/cc; and (f) densifying the preform by CVI/CVD processing to a density higher than 1.7 g/cc. Employing lower cost VPI and/or RTM processing in early pitch densification cycles and using more expensive CVI/CVD processing only in the last densification cycle provides C-C composites in which the pitch-based components resist pullout, resulting in a longer wearing composite. | 09-24-2009 |
20100000070 | Reusable core carbon-carbon composite brake disc - Method of manufacturing carbon-carbon composite brake disc comprising a dense reusable core. Preferably, the reusable core has a density of 1.8-2.05 g/cc. The method includes: forming a dense carbon-carbon composite core; positioning the dense core in a location within a carbon-carbon composite brake disc; and fixing the dense carbon-carbon composite core in place in its location within the carbon-carbon composite brake disc. It is economically advantageous to recover the dense core from a worn brake disc prior to positioning it in the brake disc. Also, an annular carbon-carbon composite brake disc made up of a friction surface containing 15-75 weight-% carbon-containing fibers and 25-85 weight-% resin binder and a dense carbon-carbon composite core comprising 40-75 weight-% carbon-containing fibers and 25-60 weight-% resin binder. | 01-07-2010 |
20100001130 | Hybrid aircraft wheel having metal and composite portions - An aircraft wheel ( | 01-07-2010 |
20100006698 | Hybrid strut having metal and composite portions | 01-14-2010 |
20100044170 | REACTIVE SINTERING TO ELIMINATE METAL INSERTS IN CARBON-CARBON BRAKE DISCS - A brake disc rotor or stator is manufactured with slots in the interior face of the disc. A paste comprised of a fine powder of a carbide-forming metal along with fine carbon powder, suspended in an organic binder, is applied to the force-bearing areas in the rotor slot faces or the stator slot faces. The disc is then placed into a furnace in a nitrogen atmosphere and heated to the ignition temperature. When the furnace reaches the ignition temperature, a combustion reaction begins that creates a molten liquid ceramic material on the slot face. Upon cooling, the resulting brake disc has a tough, hard, abrasion-resistant ceramic surface on the portion of the brake disc slot that bears pressure. | 02-25-2010 |
20100078839 | Pitch densification of carbon fiber preforms - A pitch densification process which is widely applicable in the densification of carbon fiber preforms and stabilized pitch fiber preforms. The process includes: (a.) introducing liquid pitch into a fibrous carbon preform; (b.) carbonizing the pitch-impregnated preform by heating it in the absence of oxidizing agents; and subsequently (c.) further densifying the carbonized pitch-impregnated preform. The pitch used for densification may be coal tar pitch, petroleum pitch, or synthetic pitch. The softening point of the pitch will normally range from 100° C. to 340° C., depending upon the properties to be imparted to the finished product. | 04-01-2010 |
20100084075 | Strength enhancement of carbon-carbon composite brake pads using fiber pre-stressing - This invention relates to an improved carbon-carbon composite material and method of preparation. The carbon-carbon composite material comprises a plurality of carbon fiber substrates that have been joined or consolidated. In the present invention, the carbon fibers are stressed during the preparation of the composite material. The invention comprises adding a low-melting point pitch to the carbon fiber substrates and heat treating the carbon fiber substrates. The fibers tend to shrink more than the pitch during heat-treatment which produces stress in the fibers. This invention enhances the strength of the composite material and improves reliability. | 04-08-2010 |
20100104465 | COMBUSTION SYNTHESIS TO BOND METAL INSERTS TO C-C COMPOSITE SURFACES - Method of joining a carbon-carbon composite piece | 04-29-2010 |
20100104886 | FUNCTIONALLY GRADED HIGH TEMPERATURE BONDING OF FIBERGLASS FIBERS TO STEEL - Method for chemical bonding of fiberglass fibers to steel surfaces to prepare the steel for bonding with carbon composite material. This fiber-bonding step greatly increases the strength of the subsequent metal-composite bond. The fiberglass fibers which are chemically bonded to the steel provide a high surface area interface to entangle with carbon fibers in the composite component, and thereby inhibit crack formation on the boundary surface between the steel and composite components when they are bonded together. | 04-29-2010 |
20100129551 | PREVENTING CARBON AO MIGRATION BY LIMITING SURFACE POROSITY - In the manufacture of carbon-carbon composite brake discs, migration of anti-oxidant substances into the friction surfaces is prevented by limiting or eliminating surface porosity in the carbon-carbon composite brake materials. The method includes infusing a suitable resin into pores in surface layers of the carbon-carbon composite disc and then charring the resin-infused disc to convert the resin in the pores to pyrolytic carbon. The resin may be infused into the carbon disc by submerging the disc in a molten resin. Prior to submerging the disc in the molten resin, the disc may subjected to a vacuum to remove air from the pores. While the disc is submerged in the molten resin, the pressure in the pressurizable vessel may increased to force the molten resin into the open porosity of the disc. | 05-27-2010 |
20100304038 | TITANIUM CARBIDE OR TUNGSTEN CARBIDE WITH COMBUSTION SYNTHESIS TO BLOCK POROSITY IN C-C BRAKE DISCS FOR ANTIOXIDATION PROTECTION - A metal powder is applied to the surface of the area of a carbon-carbon composite brake disc to be protected against migration of antioxidant. The metal powder may be titanium powder or tungsten powder. A chemical reaction between the metal powder and carbon is then initiated by heating the powder-coated brake to the ignition temperature via application of electric current (Joule preheating) or by heating it in a furnace. Upon combustion, the metal particles react with carbon in the composite, forming liquid carbide that flows into pores of the composite brake disc to be protected. | 12-02-2010 |
20110155323 | BONDING CARBON-CARBON COMPOSITES THROUGH A REACTANT LAYER - An apparatus for bonding a first carbon composite to a second carbon composite through a reactant layer includes a housing, and a pair of conductive press plates electrically isolated from the housing. The press plates are adapted to position the two parts to be bonded with a reactant layer therebetween. The press plates are subjected to an electrical potential and a clamping force, sufficient to initiate a combustion reaction that creates a molten ceramic to bond together the carbon-carbon composites. | 06-30-2011 |
20110156297 | DENSIFICATION OF C-C COMPOSITES WITH PITCHES FOLLOWED BY CVI/CVD - A method of manufacturing pitch-based carbon-carbon composite useful as a brake disc, includes (a) providing annular carbon fiber brake disc preform; (b) heat-treating the carbon fiber preform; (c) infiltrating the carbon fiber preform with pitch feedstock by VPI or RTM processing; (d) carbonizing the pitch-infiltrated carbon fiber preform; (e) repeating steps (c) and (d) to achieve a density in the carbon fiber preform of approximately 1.5 g/cc to below 1.7 g/cc; and (f) densifying the preform by CVI/CVD processing to a density higher than 1.7 g/cc. Employing lower cost VPI and/or RTM processing in early pitch densification cycles and using more expensive CVI/CVD processing only in the last densification cycle provides C-C composites in which the pitch-based components resist pullout, resulting in a longer wearing composite. | 06-30-2011 |
20110180946 | TITANIUM CARBIDE AS A FRICTION AND WEAR MODIFIER IN FRICTION MATERIALS - Methods of making a carbon-carbon composite preforms, particularly suitable as brake discs in aircraft landing systems, by combining titanium carbide particles ranging in size from 0.01 to 10 microns in diameter, resinous binder, and carbon fibers or carbon fiber precursors in a mold, and subsequently subjecting the combined components to pressure and heat to carbonize the resinous binder by methods, thereby providing the carbon-carbon composite preform having particulate titanium carbide uniformly distributed throughout its mass. Prior to combining the titanium carbide and the binder with the fibers in this process, the particulate titanium carbide may be mixed with liquid binder, the resulting TiC/binder mixture may then solidified, and the resulting solid TiC/binder mixture may be ground into a fine powder for use in the process. Also, compositions for preparing a carbon-carbon composite friction materials, and methods of improving wear and dynamic stability in a carbon-carbon composite brake discs. | 07-28-2011 |
20110195182 | CVI FOLLOWED BY COAL TAR PITCH DENSIFICATION BY VPI - A method for the manufacture of carbon-carbon composite brake discs comprises (a) heat treating a carbon-carbon composite preform in the shape of a brake disc at 1600-2540° C., (b) directly following heat treating, subjecting the heat-treated preform to Chemical Vapor Deposition/Chemical Vapor Infiltration processing, (c) infiltrating the preform with an isotropic low to medium char-yield pitch derived from coal tar, employing Vacuum Pitch Infiltration processing or Resin Transfer Molding Processing, (d) stabilizing and carbonizing the pitch-infiltrated preform (e) machining the surfaces of the resulting carbonized preform, and (f) repeating steps (c) through (e) at least two additional times to raise the density of the carbon-carbon composite preform to at least approximately 1.75 g/cc. | 08-11-2011 |
20110254182 | METHOD FOR REDUCING VARIABILITY IN CARBON-CARBON COMPOSITES - Method for producing carbon-carbon composite brake discs by: (a) providing annular nonwoven carbon fiber brake disc preforms; (b) carbonizing the brake disc preforms; (c) densifying the carbonized preforms by CVD/CVI (chemical vapor deposition/chemical vapor infiltration); (d) densifying the products of step (c) with isotropic or mesophase pitch by VPI (vacuum pitch infiltration) or RTM (resin transfer molding) processing; (e) carbonizing the preforms to remove non-carbon volatiles from the pitch and to open porosity in the pitch-infused preforms; (f) densifying the products of step (e) with isotropic or mesophase pitch by VPI or RTM processing; (g) carbonizing the preforms to remove non-carbon volatiles from pitch and to open porosity in the pitch-infused preforms; and (h) heat-treating the resulting pitch-densified carbon-carbon composite brake disc preforms. This manufacturing approach reduces lot-to-lot variability in friction performance of the resulting carbon-carbon composite brake discs. | 10-20-2011 |
20130243953 | REACTIVE SINTERING TO ELIMINATE METAL INSERTS IN CARBON-CARBON BRAKE DISCS - A brake disc rotor or stator is manufactured with slots in the interior face of the disc. A paste comprised of a fine powder of a carbide-forming metal along with fine carbon powder, suspended in an organic binder, is applied to the force-bearing areas in the rotor slot faces or the stator slot faces. The disc is then placed into a furnace in a nitrogen atmosphere and heated to the ignition temperature. When the furnace reaches the ignition temperature, a combustion reaction begins that creates a molten liquid ceramic material on the slot face. Upon cooling, the resulting brake disc has a tough, hard, abrasion-resistant ceramic surface on the portion of the brake disc slot that bears pressure. | 09-19-2013 |
20150034432 | PREVENTING CARBON AO MIGRATION BY LIMITING SURFACE POROSITY - In the manufacture of carbon-carbon composite brake discs, migration of anti-oxidant substances into the friction surfaces is prevented by limiting or eliminating surface porosity in the carbon-carbon composite brake materials. The method includes infusing a suitable resin into pores in surface layers of the carbon-carbon composite disc and then charring the resin-infused disc to convert the resin in the pores to pyrolytic carbon. The resin may be infused into the carbon disc by submerging the disc in a molten resin. Prior to submerging the disc in the molten resin, the disc may subjected to a vacuum to remove air from the pores. While the disc is submerged in the molten resin, the pressure in the pressurizable vessel may increased to force the molten resin into the open porosity of the disc. | 02-05-2015 |