公开(公告)号：US20100000070A1

公开(公告)日：2010-01-07

申请号：US11028719

申请日：2005-01-04

申请人： Mark L. La Forest ,  Slawomir T. Fryska ,  Christopher S. Wahlers ,  Darrell L. Johnson ,  Allen H. Simpson

发明人： Mark L. La Forest ,  Slawomir T. Fryska ,  Christopher S. Wahlers ,  Darrell L. Johnson ,  Allen H. Simpson

IPC分类号： B21J15/00 ,  B32B37/02

CPC分类号： C04B35/83 ,  C04B2235/614 ,  C04B2235/616 ,  C04B2235/75 ,  C04B2235/77 ,  F16D65/12 ,  F16D69/023 ,  F16D69/04 ,  F16D2069/002 ,  F16D2069/005 ,  F16D2069/0491 ,  Y10T29/49956 ,  Y10T156/10

摘要： 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.

摘要翻译： 制造碳 - 碳复合制动盘的方法，其包括密集的可重复使用的芯。 优选地，可重复使用的芯的密度为1.8-2.05g / cc。 该方法包括：形成致密的碳 - 碳复合芯; 将致密核心定位在碳 - 碳复合制动盘内的位置; 并将致密的碳 - 碳复合材料芯固定在碳 - 碳复合制动盘内的位置。 在将其定位在制动盘中之前，从磨损的制动盘回收致密的核心在经济上是有利的。 另外，由含有15-75重量％含碳纤维和25-85重量％树脂粘合剂的摩擦表面和一个含有40-75重量％的含碳纤维的密集碳 - 碳复合材料芯构成的环形碳 - 碳复合制动盘， ％含碳纤维和25-60重量％树脂粘合剂。

公开(公告)号：US07763192B2

公开(公告)日：2010-07-27

申请号：US11389022

申请日：2006-03-27

申请人： Allen H. Simpson ,  Mark L. La Forest ,  Slawomir T. Fryska

发明人： Allen H. Simpson ,  Mark L. La Forest ,  Slawomir T. Fryska

IPC分类号： B29C45/14 ,  C01B31/02 ,  B64C25/00

CPC分类号： C04B35/83 ,  C04B2235/48 ,  C04B2235/5212

摘要： 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.

摘要翻译： 通过以下方式制造复合轮束梁钥匙的方法：完全由碳纤维前体或碳纤维前体和陶瓷材料形成具有所需轮梁钥匙形状的纤维预制坯料，其中预制坯坯的纤维体积分数至少为50 ％; 碳化碳纤维前体; 通过使碳化预成型坯坯进行CVD的至少一个循环来硬化; 研磨预制坯坯的表面以在其表面上开孔; 并对开孔预成型件坯料进行间距处理。 此外，通过该方法制造的碳 - 碳复合材料或碳 - 陶瓷复合材料轮束密钥的密度为1.5g / cc至2.1g / cc，最大内部孔隙率为10％以下。

公开(公告)号：US07700014B2

公开(公告)日：2010-04-20

申请号：US11402791

申请日：2006-04-13

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Barry P. Soos

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Barry P. Soos

IPC分类号： C01B31/00

CPC分类号： F16D69/023 ,  B29C70/48 ,  C04B35/83 ,  C04B2235/608 ,  C04B2235/614 ,  C04B2235/616 ,  C04B2235/77

摘要： Method of manufacturing dense carbon-carbon composite material by: infiltrating a fibrous preform with pitch to form pitch-infiltrated preform; carbonizing the pitch-infiltrated preform; injecting resin or pitch into the preform in a mold; oxygen stabilizing the filled preform and carbonizing and heat-treating the oxygen-stabilized impregnated preform; and subjecting the preform to a single final cycle of chemical vapor deposition. This process reduces densification time as compared to comparable conventional carbon-carbon composite manufacturing procedures.

摘要翻译： 通过以下步骤制造致密碳 - 碳复合材料的方法：用沥青渗透纤维预制件以形成沥青渗透的预制件; 沥青渗透预制件碳化; 在模具中将树脂或沥青注入预成型件; 氧稳定填充的预制件并碳化和热处理氧稳定的浸渍的预制件; 并对预制件进行化学气相沉积的单个最后循环。 与可比较的常规碳 - 碳复合材料制造方法相比，该方法降低致密化时间。

公开(公告)号：US07632435B2

公开(公告)日：2009-12-15

申请号：US11435734

申请日：2006-05-18

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Barry P. Soos

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Barry P. Soos

IPC分类号： C01B31/00

CPC分类号： F16D69/023 ,  C04B35/83 ,  F27B17/0016

摘要： Method of carbonizing pitch-infiltrated fibrous annular preform by: infiltrating the preform with pitch; placing the pitch-infiltrated preform in a constraint fixture having an ejector base plate, an inner wall, an outer wall, and a top press plate; selecting the relative sizes of the preform and the constraint fixture so that a layer of inert friable material may be situated between the preform and walls of the constraint fixture; placing inert friable material (e.g., activated carbon) between the preform and the top, bottom, and walls of the constraint fixture; and subjecting the pitch-infiltrated fibrous preform to carbonization in the constraint fixture. The activated carbon or other inert friable material adsorbs pitch molecules that escape the preform during carbonization, which reduces problems with foaming. The layer of activated carbon or other friable material between the fibrous preform and the constraint fixture also provides an easily crushable region that facilitates removal of the preform from the constraint fixture after carbonization.

摘要翻译： 沥青渗透纤维环状预成型体通过以下方式浸渗预成型体的方法： 将沥青渗透的预成型件放置在具有顶出板底板，内壁，外壁和顶部压板的约束夹具中; 选择预成型件和约束夹具的相对尺寸，使得惰性脆性材料层可以位于约束夹具的预成型件和壁之间; 将惰性脆性材料（例如，活性炭）放置在预成型件与约束夹具的顶部，底部和壁之间; 并且在沥青渗透的纤维预型体中在约束夹具中进行碳化。 活性炭或其他惰性易碎材料在碳化过程中吸附脱离预成型体的沥青分子，这减少了起泡问题。 在纤维预制件和约束夹具之间的活性炭层或其它易碎材料层还提供了易于压碎的区域，其有助于在碳化之后从约束夹具上移除预型件。

公开(公告)号：US20090236763A1

公开(公告)日：2009-09-24

申请号：US11389022

申请日：2006-03-27

申请人： Allen H. Simpson ,  Mark L. La Forest ,  Slawomir T. Fryska

发明人： Allen H. Simpson ,  Mark L. La Forest ,  Slawomir T. Fryska

IPC分类号： B29C45/02 ,  C01B31/02

CPC分类号： C04B35/83 ,  C04B2235/48 ,  C04B2235/5212

摘要： 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.

摘要翻译： 通过以下方式制造复合轮束梁钥匙的方法：完全由碳纤维前体或碳纤维前体和陶瓷材料形成所需轮梁钥匙形状的纤维预制坯料，其中预制坯坯的纤维体积分数至少为50 ％; 碳化碳纤维前体; 通过使碳化预成型坯坯进行CVD的至少一个循环来硬化; 研磨预制坯坯的表面以在其表面上开孔; 并对开孔预成型件坯料进行间距处理。 此外，通过该方法制造的碳 - 碳复合材料或碳 - 陶瓷复合材料轮束密钥的密度为1.5g / cc至2.1g / cc，最大内部孔隙率为10％以下。

公开(公告)号：US08858846B2

公开(公告)日：2014-10-14

申请号：US12410903

申请日：2009-03-25

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Nabil Abu Gharbieh

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Nabil Abu Gharbieh

IPC分类号： C01B31/00 ,  C04B35/80 ,  B82Y30/00 ,  C04B35/56 ,  F16D69/02

CPC分类号： F16D69/023 ,  B82Y30/00 ,  C04B35/5611 ,  C04B35/806 ,  C04B35/83 ,  C04B2235/48 ,  C04B2235/5248 ,  C04B2235/5445 ,  C04B2235/5454 ,  C04B2235/96 ,  Y10T428/213

摘要： 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.

摘要翻译： 通过将尺寸范围为0.01至10微米直径的碳化钛颗粒，树脂粘合剂和模具中的碳纤维或碳纤维前体组合制备碳 - 碳复合预制件，特别适用于飞机着陆系统中的制动盘的方法， 并随后使组合的组分进行加压和加热以通过方法使树脂粘合剂碳化，由此提供碳 - 碳复合预成型体，其中颗粒状碳化钛均匀地分布在其整个质量中。 在该方法中将碳化钛与粘合剂与纤维结合之前，可将颗粒碳化钛与液体粘合剂混合，然后使所得到的TiC /粘合剂混合物固化，并将所得固体TiC /粘合剂混合物研磨成 精细粉末用于该过程。 另外，用于制备碳 - 碳复合材料摩擦材料的组合物，以及改善碳 - 碳复合制动盘中的磨损和动态稳定性的方法。

公开(公告)号：US20100078839A1

公开(公告)日：2010-04-01

申请号：US11471602

申请日：2006-06-21

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest

IPC分类号： C01B31/00

CPC分类号： F16D69/023 ,  C04B35/83 ,  C04B2235/614 ,  C04B2235/616 ,  C04B2235/77

摘要： 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.

摘要翻译： 沥青密实化方法，广泛应用于碳纤维预成型体和稳定沥青纤维预制件的致密化。 该方法包括：（a）将液体沥青引​​入纤维状碳预制件中; （b）通过在不存在氧化剂的情况下加热沥青浸渍的预成型体来碳化沥青浸渍的预成型体; 并随后（c。）进一步致密化碳化沥青浸渍的预制件。 用于致密化的沥青可以是煤焦油沥青，石油沥青或合成沥青。 根据赋予成品的性质，沥青的软化点通常在100℃至340℃的范围内。

公开(公告)号：US07632436B2

公开(公告)日：2009-12-15

申请号：US11455743

申请日：2006-06-20

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest

IPC分类号： C01B31/00

CPC分类号： C04B35/83 ,  B29K2707/04 ,  B29L2031/7482 ,  C04B2235/48 ,  C04B2235/5248 ,  C04B2235/6562 ,  C04B2235/6565 ,  F16D69/023

摘要： 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.

摘要翻译： 通过以下步骤制造碳 - 碳复合预制件的方法：（i）在渗透容器中排列一批碳纤维预制件; （ii）在大气压下在惰性气氛中具有热液相沥青的溢流容器; （iii）将渗透容器中的压力提高到升高压力，然后缓慢降低压力; 和（iv）重复步骤（iii）。 可以使用的装置是能够在高于100psi的压力下操作的加热的渗透容器，可能配备有在容器内循环加热沥青的装置，以便促进被沥青渗透的碳纤维预制件的热传递。 消除了对真空泵的需要，并且大大减少了加热预制件所花费的时间。 代替真空，采用循环高压渗透具有沥青的碳纤维预成型件。 使用预热的沥青作为传热剂避免了在渗透之前将热量缓慢地传递到预制件中。

公开(公告)号：US07438839B2

公开(公告)日：2008-10-21

申请号：US10956582

申请日：2004-10-01

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Barry P. Soos

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Barry P. Soos

IPC分类号： B29C43/02

CPC分类号： C04B35/83 ,  C04B35/63496 ,  C04B2235/602 ,  C04B2235/604 ,  C04B2235/614 ,  C04B2235/656 ,  C04B2235/6567 ,  C04B2235/6586 ,  C04B2235/77 ,  F16D65/12 ,  F16D69/023 ,  F16D2200/0052 ,  Y10T428/30

摘要： Method for manufacturing a carbonized carbon-carbon composite preform, by: mixing (a) chopped carbon fiber, chopped stabilized pitch fiber, or chopped oxidized polyacrylonitrile (PAN) fiber, (b) thermoplastic pitch binder powder, and (c) activated carbon powder to form a mixture of 15-60 parts by weight of chopped carbon fiber or chopped stabilized pitch fiber or chopped oxidized PAN, 28-83 parts by weight of thermoplastic pitch binder powder, and 1-12 parts by weight of activated carbon powder; depositing this mixture into a mold; pressing/heating the materials in the mold to form a preform by compaction; removing the compacted preform from the mold; and carbonizing the compacted preform. The preform is preferably configured in the form of an aircraft landing system brake disc.

摘要翻译： 通过以下方法制备碳化碳 - 碳复合预型体：（a）将短切碳纤维，短切稳定沥青纤维或短切的氧化聚丙烯腈（PAN）纤维，（b）热塑性沥青粘合剂粉末和（c）活性炭粉末 形成15-60重量份短切碳纤维或短切稳定沥青纤维或短切氧化PAN，28-83重量份热塑性沥青粘合剂粉末和1-12重量份活性炭粉末的混合物; 将该混合物沉积到模具中; 压制/加热模具中的材料以通过压实形成预制件; 从模具中移除压实的预成型件; 并将压实的预制件碳化。 预成型件优选地以飞机着陆系统制动盘的形式配置。

公开(公告)号：US08448685B2

公开(公告)日：2013-05-28

申请号：US13038953

申请日：2011-03-02

申请人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Roger L. Klinedinst ,  Alexander Mukasyan ,  Charles D. D'Amico

发明人： Allen H. Simpson ,  Slawomir T. Fryska ,  Mark L. La Forest ,  Roger L. Klinedinst ,  Alexander Mukasyan ,  Charles D. D'Amico

IPC分类号： B29C65/32 ,  B32B37/06 ,  B32B41/00 ,  B32B43/00 ,  B30B15/34

CPC分类号： F16D69/023 ,  B32B2315/02 ,  C04B37/005 ,  C04B37/006 ,  C04B2235/404 ,  C04B2235/422 ,  C04B2237/083 ,  C04B2237/122 ,  C04B2237/385

摘要： 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.

摘要翻译： 用于通过反应物层将第一碳复合材料结合到第二碳复合材料的装置包括壳体和与壳体电隔离的一对导电压板。 压板适于将两个待粘合的部件与其间的反应物层定位。 压板受到电势和夹紧力，足以启动产生熔融陶瓷以将碳 - 碳复合材料粘合在一起的燃烧反应。