WO2006127002A1 - Fabrication de composites preformes epais au moyen de couches de mats fibreux preformes multiples - Google Patents

Fabrication de composites preformes epais au moyen de couches de mats fibreux preformes multiples Download PDF

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Publication number
WO2006127002A1
WO2006127002A1 PCT/US2005/018353 US2005018353W WO2006127002A1 WO 2006127002 A1 WO2006127002 A1 WO 2006127002A1 US 2005018353 W US2005018353 W US 2005018353W WO 2006127002 A1 WO2006127002 A1 WO 2006127002A1
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WIPO (PCT)
Prior art keywords
preform
carbon
binder
fibrous
fiber
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Ceased
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PCT/US2005/018353
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English (en)
Inventor
Mark L. La Forest
Nabil Abu Gharbieh
Alan E. Fatz
Raymond J. Cipra
Thomas H. Siegmund
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Honeywell International Inc
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Honeywell International Inc
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Publication of WO2006127002A1 publication Critical patent/WO2006127002A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C04B35/83—Carbon fibres in a carbon matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/305—Spray-up of reinforcing fibres with or without matrix to form a non-coherent mat in or on a mould
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02—Composition of linings ; Methods of manufacturing
    • F16D69/023—Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/18—Polymers of nitriles
    • B29K2033/20—PAN, i.e. polyacrylonitrile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/128—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2633/00—Use of polymers of unsaturated acids or derivatives thereof for preformed parts, e.g. for inserts
    • B29K2633/18—Polymers of nitriles
    • B29K2633/20—PAN, i.e. polyacrylonitrile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/748—Machines or parts thereof not otherwise provided for
    • B29L2031/7482—Brakes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/02—Ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5268—Orientation of the fibers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/38—Fiber or whisker reinforced
    • C04B2237/385—Carbon or carbon composite
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D2069/005—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces having a layered structure
    • F16D2069/008—Layers of fibrous materials

Definitions

  • the present invention relates to a method of producing preform parts by layering fibrous objects.
  • the fibrous objects that are layered in this invention are nonwoven fiber mats produced, by a spray deposition process.
  • the present invention is particularly well adapted for the use of near-net shape fiber mats, that is, mats whose relevant
  • Composite materials are materials of choice in many industrial applications, including the application of carbon-carbon composites to brake components. In these carbon-carbon composite
  • microstructural design that can be varied include fiber length (short to continuous), reinforcement type (e.g., pitch or PAN, etc.), reinforcement architecture (woven or nonwoven), reinforcement configuration (planar or three-dimensional), and
  • the Programmable Powder Preform Process is a fully automated process for chopping and spraying fibers to produce a fiber mat. With appropriate automated control of the fiber deposition, the P4 process enables the creation of fiber mats with complex shapes of both defined outer contour and three-dimensional shape.
  • the P4 process consists of two major steps. A computer controlled chopper head with rotation knives, generally mounted on a six-axis robot, is used to cut continuous fiber tow into segments of defined length. Fiber tow segments are then sprayed or dropped onto a planar or spatially contoured surface. The surface may be, for instance, a screen of perforated sheet metal.
  • the screen is generally connected to a vacuum system, and the vacuum holds the fiber tow segments temporarily in place on the screen.
  • a small amount of polymeric powder is applied to the fibers as binder.
  • the next step is the consolidation of the mat by melting of the binder, such that the fibers are held in position and the mat can be manipulated. Once the mat is treated in this manner, it can be removed from the screen and is capable of holding its shape for further handling and processing.
  • Current commercial P4 systems have the major disadvantage that they can be used only to manufacture thin-walled or shell-type composite structures - they cannot be used to make preform for thick composite parts. . Jhis disadvantage of current P4 processing is overcome by the present invention.
  • Laminated Object Manufacturing is used to fabricate parts by stacking material layers upon one another.
  • Materials conventionally used in LOM are sheets of paper, green ceramic tape, or composite fabrics (prepregs).
  • prepregs the required outline of the individual layers of the material being processed is cut (for example by a laser) from a continuous feed or from rectangular plates of the material.
  • the cutting tool e.g. the laser
  • the crosshatched part ultimately allows for removal of the final structure as the process is completed.
  • An individual layer is adhered to the previously deposited layer by an adhesive on the backside of the layer.
  • LOM processes have major disadvantages for fabricating composite structures.
  • the cutting process is an essential step in the process. This cutting process is inefficient in its use of material, and a large quantity of scrap material is produced. This scrap rate becomes unacceptable if material costs are to be reduced. Building structures with internal cavities is limited, as additional cutting and lift-up processes have to be included in such cases.
  • the incorporation of gradients in material properties within the LOM is limited to a layering approach. That is, gradients can be achieved only across the stacking direction.
  • the planar build technique does not allow for interconnection between the individual layers beyond the adhesive used to bond the individual layers.
  • the LOM process is limited to the assembly of initially flat sheets of material.
  • Curved layer object manufacturing as it exists today produces parts in which the curved layers are stacked onto a shaped mandrel. As a consequence all layers in the final product will then be in parallel to each other.
  • the planar build technique does not allow for interconnection between the individual layers beyond the adhesive use to bond the individual layers. Such disadvantages of current LOM processes are overcome by the present invention.
  • US 4,867,086 teaches stitching a continuous tow of structural yarn to a substrate in the preparation of multi-layer fiber/resin composites.
  • US 5,184,387 relates to needle punching in the production of multi-layer composites.
  • US 5,217,770 teaches structures that may include a plurality of helically wound braided tapes in the production of composites.
  • US 5,439,627 discloses a method of manufacturing composites which includes chopping a green tape or ribbon, mixing it with binder, and forming moldings from the mixture.
  • US 6,013,371 relates to the production of near net shape carbon pistons and other artifacts by sintering petroleum pitch powders, preferably with pitch-base carbon fibers.
  • US 6,365,257 teaches the fabrication of thick, three-dimensional preforms comprising fibers disposed as chords of a circle.
  • US 6,478,926 relates to the formation of structural preforms from electromagnetic energy-activated binder and reinforcing material.
  • US 5,654,059 and 5,705,008 disclose the fabrication of thick, three-dimensional structures comprising discontinuous themoset pitch fiber.
  • Claim 4 of the '008 patent recites "A method for producing a fibrous preform comprising the steps of: providing shaping means for holding fiber; placing discontinuous thermoset pitch fiber having a length greater than about 0.5 inch into said shaping means and forming a mat having a thickness in a range of from about Vk inchto about 4 inches and a density of from about 0.3 to about 0.6 g/cc; needle punching said mat at a needle density of from about 100 to about 10,000 per square inch to form filaments bundles and re-orient a portion of said filament bundles in the needled direction, thereby providing a three-dimensional filamentary structure; and carbonizing said filamentary structure by heating in an inert atmosphere to a temperature greater than about 1000 0 C to provide a porous carbon preform". All of these patents contain disclosure that is illustrative of the state of the relevant art and the knowledge available to those skilled in the art, and the disclosure of each of the above patents is hereby expressly incorporated by reference.
  • VARIABILITY IN COMPOSITE ARCHITECTURE The present invention provides the ability to fabricate parts with a predefined internal composite architecture. Each individual layer used to build the composite preform should allow for an internal structure optimized for desired properties. This internal microstructure can be based on variations in fiber volume fraction, fiber type, fiber length, and orientation. This invention allows one to introduce such variations is material characteristics in targeted areas within the final three-dimensional product. With this invention, it is even possible to embed objects (dense material components of differing composition and properties) into the preform, if such is desired to provide enhanced properties.
  • NEAR-NET SHAPE The process of the present invention, with its ability to assemble individual fibrous mats into a unitary preform having a desired shape, reduces or even eliminates cutting processes that are conventionally required to finish a preform. This significantly reduces material waste, as well as simplifying overall processing. Moreover, the lack of necessity for extensive cutting facilitates the manufacture of preforms for composite parts having internal cavities.
  • the present invention can advantageously be applied to the manufacture of carbon-carbon composite brakes, where preforms made of carbon fibers in a pitch matrix represent an intermediate step in the production of the final product.
  • pitch and polyacrylonitrile (PAN) fibers can be mixed, and fiber orientation can be adjusted to preferred load transfer conditions, especially in the lug areas and heat transfer directions.
  • PAN polyacrylonitrile
  • the out-of-plane direction introduced in this manner will also aid in heat transfer away from the friction surface. Locations near the friction surface can be optimized for wear and friction, while the remainder of the part can be optimized for heat storage and strength.
  • the system of this invention comprises an automated process for chopping and spraying fiber tow segments onto a perforated screen through which a vacuum is drawn.
  • the deposition of the fiber tow segments may be controlled by a computer. Cutting of continuous fiber tows may be accomplished within a computer-controlled chopper head with rotation knives mounted, for instance, on a six-axis robot.
  • the chopping and spraying device may be connected to a device that allows for the orientation of fiber tows in desired directions. Those skilled in the art are familiar with such computer-controlled fiber deposition.
  • chopped fiber tow segments are sprayed onto a screen through which a vacuum is being drawn.
  • an optionally reconfigurable tool is positioned that produces the desired outer (and inner if desired) outline of the fiber mat.
  • a computer program controls the motion of the spray within the area within the form, such that a desired fiber coverage as well as fiber tow orientation is obtained.
  • Fiber tow orientation is accomplished by the use of a fiber tow orientation device attached to the chopping device, or by a programmed interaction of the fiber tow spray with the walls defining the outer (and inner if any) mat contour.
  • a polymeric binder is also applied, preferably together with the fiber tow spray.
  • the fiber mat is consolidation by curing or melting the binder, for instance by heating or by subjecting the binder-containing mat to ultraviolet light. Next, the form or tool providing the outer (and possibly inner) contours of the fiber mat is removed. Once the mat is such consolidated, it is removed from the screen. At this point, the fibrous mat is capable of holding its shape for further handling and processing.
  • additional binder generally phenolic resin
  • phenolic resin binder can be applied by spraying on the binder as a liquid, by adding the binder as a powder deposition, or by the use of sheets (e.g., in a technique known as Resin Film Infusion).
  • a Resin Transfer Molding process can be applied together with a constraint fixture which holds the fiber mats in place during infiltration.
  • the stack is then placed into a mold and heated. Subsequently, a press is used to compact the preform and to achieve the desired density.
  • the composite preform will then be subjected to processes leading to carbonization and finally to densification.
  • FIG 1 illustrates features of an apparatus that may be used to practice certain aspects of the present invention.
  • Figure 2 is a plan view of a fiber-filled tool in accordance with the present invention.
  • Figure 3 is a plan view of another fiber-filled tool in accordance with this invention.
  • Figure 4 is a block diagram illustrating aspects of a process of the present invention.
  • Figure 5 is a perspective view of a thick multi-layer composite article of the invention.
  • Figures 6A and 6B are photographs showing fiber detail.
  • This invention provides a process for the manufacture of preforms for thick structural composite parts.
  • individual layers of fiber mats with defined microstructure are produced by means of a fiber spray system.
  • the individual fiber mats are subsequently stacked to make a multi-layer composite preform.
  • the individual fiber mats are interlinked, for example by needling of the three- dimensional preform or by the use of tabs and lugs built into the individual fiber mats or by virtue of three-dimensionality in the individual fiber mats themselves.
  • the fiber preform is densified by resin infiltration.
  • the novel manufacturing apparatus comprising one or more fiber spray-up and layer assembly stations, also constitutes an aspect of this invention.
  • the present inventive system for the fabrication of preforms for thick, three-dimensional composite parts includes various components.
  • One component of this invention is a robotic process for chopping continuous fiber tows and spraying the chopped fiber tows, with control over fiber type (that is, different types of fiber can be mixed to make the fiber mats of this invention), fiber tow segment length and orientation, and fiber output rates.
  • the chopped fiber tow segments are sprayed onto a screen to which is operatively connected to a vacuum.
  • An apparatus for accomplishing this aspect of the invention is illustrated in Figure 1.
  • the vacuum settles the fiber tow segments as they are sprayed into a form and holds them against the screen.
  • the screen will define the three-dimensional contour of a fiber mat.
  • FIG. 1 Another aspect of this invention is the use of reconfigurable forms (or tools) to provide the side contours of the desired fiber mats.
  • a form is used to provide the outer shape (and that of internal cavities) of each fiber mat.
  • Figure 2 shows a tool having a wall 22 which defines the outer shape of a disc comprising fibers 1 1. In Figure 2, the fibers have not yet been sprayed into outer interior area 29 of the tool.
  • the mat is configured as a ring or to include inner cavities
  • forms are used to provide both the outer and inner shapes of each fiber mat.
  • Figure 3 in which the tool has an outer wall 32 and an inner wall 33 to define the shape created by fibers 1 1.
  • the forms may advantageously be made to be reconfigurable, so that differently shaped preforms can be made using the apparatus shown in Figure 1.
  • tools that possess contours producing fiber mats with slots as well as corresponding tabs for interlocking of individual layers.
  • a computer may be used to direct the spray system such that the fiber spray follows a sequence of desired paths in the area between the outer contour (and any inner contour) of a form or reconfigurable tools defining the shape of the fiber mat.
  • This invention also contemplates a system to dispense binder into the chopped fiber tows and a system to melt or cure the binder, for instance by heat or ultraviolet light, thereby providing a fiber mat that can be handled.
  • this invention includes the use of a form (or reconfigurable tool) to sequentially assemble the fiber mats and any resin layers joining them together into stacks, and a press for compacting the fiber mat stack into a preform that is ready for densification and final machining into a useful article such as a friction brake component.
  • the present invention provides a system designed for the fabrication of preforms of thick, three-dimensional composite parts, such as preforms for carbon-carbon brake discs. While preforms made in accordance with this invention will often range in thickness from about 0.25 through about 7.5 inches, thicker (and thinner) preforms can be made in accordance with this invention. Individual layers of fiber mats of carbon fibers (pitch or PAN or combinations thereof) with defined reinforcement microstructures and defined overall shape are produced using a fiber spray system in combination with a powder binder application. Individual fiber mats are subsequently stacked such that a multi-layer composite preform is assembled.
  • the individual fiber mats may be joined together by application of additional binder (preferably, phenolic resin binder) between the layers, lnterlayer connectivity may be enhance by stitching layers together by needling, or the process can make use of built-in slots and tabs to provide for locking between individual layers of fibrous mats.
  • Figure 6A is a close up of a fiber mat before needling.
  • Figure 6B shows a fiber mat after needling.
  • the composite preform may comprise three-dimensionally shaped mats that are tacked and assembled in more than one direction to provide interconnections conforming to stress paths, thus providing a desired three-dimensional preform architecture. If desired, additional filler and additive materials may be embedded within the composite preforms.
  • Implementation of this invention may make use of a robotic process for chopping continuous fiber tows and spraying the chopped fiber tows - with control ov er fiber type, fiber lengths, fiber output rates, and fiber orientation - into a suit ably-shaped vacuum apparatus.
  • Cutting of the continuous tow of fibers may be accomplished within a computer- controlled chopper head having rotation knives mounted on a six-axis robot.
  • the chopped fibers are deposited onto a perforated screen through which a vacuum is drawn.
  • a reconfigurable form (tool) is positioned on a vacuum screen, to provide the desired inner (if any) and outer outline of the fiber mat.
  • a computer program controls the motion of the spray within the area between the inner and outer boundary of the fiber mat, such that the desired fiber coverage as well as fiber orientation is obtained.
  • Fiber orientation is accomplished by the use of a fiber orientation device attached to the chopping device, or by a programmed interaction of the fiber spray with the walls defining the inner and outer mat boundary.
  • a system to dispense binder in powder form on the chopped fibers may also be included in this invention, along with a system to melt or cure the binder such that a fiber mat is provided which can be handled.
  • a binder such as a polymeric binder may be sprayed on along with the fibers.
  • the apparatus for producing the fiber mats involves reconfigurable tools to provide the outer and inner contour of the desired fiber mat.
  • Three-dimensionally shaped fiber mats are obtained by the use of vacuum screens, having a perforated screen in the form of a three- dimensional surface.
  • a computer may be used to direct the fiber spray to follow a sequence of desired paths in the area between the outer and inner contours of the reconfigurable tool defining the inner and outer contours of the fiber mat.
  • the tooling providing the inner (if any) and outer boundaries of the mat are removed, and the fiber mat is consolidated by melting or curing the binder. The mat then retains its predefined shape and the fibers are held in position.
  • Curing or melting the binder may be accomplished by means such as heat or the application of ultra-violet Ijght.
  • a series of shaped fiber mats prepared as described above are stacked and assembled in a predefined sequence, as depicted for instance in Figure 5.
  • shaped fiber mats 51 , 52, and 53 are combined to form the preform for the thick multi-layer composite part 55.
  • the fibrous mats are assembled into a preform in the substantial absence of cutting or other mechanical modification. That is, the fibrous mats are shaped by the tool in which they are formed into the desired shape, and when multiple sheets are combined to make a preform, little or no trimming or smoothing of the preform is necessary.
  • This invention also contemplates a reconfigurable tool to sequentially assemble the fiber mats and resin layers into stacks. During the assembly process, slots and tabs for interlayer connectivity are appropriately aligned. Stitching or needling can be used to increase the interlaminar connectivity within the multi-layer preform. Additional binder (typically, phenolic resin for carbon-carbon brake preform applications) is placed between the individual layers, for instance in the form of sheets of phenolic resin by a process of Resin Film Infusion or by spraying the binder in liquid form or in powder deposition Depending on the resin system used as binder, a consolidation step is then conducted.
  • binder typically, phenolic resin for carbon-carbon brake preform applications
  • the stack of multiple layers of fiber mats is compacted in a heat-press to achieve the desired density within the part.
  • the heat-pressing operation is normally conducted in a mold, preferably a reconfigurable mold, having the shape of the desired preform.
  • vacuum bagging is used to consolidate the preform.
  • the multi-layer stack can be placed into a constraint fixture and inserted into a Resin Transfer Molding apparatus for densification.
  • this invention provides a method of making a preform, which comprises the steps of: a.) providing a tool (or "mold"), preferably a reconfigurable tool, containing a perforated screen through which a vacuum can be drawn, b.) delivering chopped fiber to the tool while drawing vacuum through said tool, to form a fibrous object, c.) delivering binder to the fibrous object, d.) melting and/or curing the binder to make a fibrous mat, e.) assembling a plurality of the fibrous mats, together with additional binder, into the shape of a preform, and f.) heat-pressing the resulting mat assembly into a finished preform. Processing will generally include a subsequent step of g.) carbonizing and densifying the preform, for instance by resin infusion. Aspects of this process are depicted schematically in Figure 4.
  • a technical advantage of the present invention is its enablement of the fabrication of parts with a predefined internal composite architecture.
  • Each individual layer used to build up the composite preform could be designed to possess its own beneficial structural characteristics.
  • This internal microstructure can be based on variations in fiber volume fraction, fiber type, fiber length, and fiber orientation.
  • useful fillers can be embedded into the preform between layers.
  • pitch and PAN fibers can be mixed, and fiber orientation can be adjusted to preferred load transfer conditions, especially in lug areas and heat transfer directions.
  • Another technical advantage of the present invention is its extension of the capabilities of Laminated Object Manufacturing.
  • the use of fiber mats which each individually possesses a defined outer and inner contour eliminates the need for cutting processes during the LOM assembly step. This also reduces the amount of waste material, the amount of material to be densified by costly heat treatment processes and chemical vapor deposition, and facilitates the construction of laminated objects with internal cavities.
  • this invention enables the fabrication of objects assembled from non-planar microstructures.
  • fibrous mats can be produced on contoured or three- dimensional vacuum screens as well as on flat screens. This permits the design of complex microstructures that are not achievable with other processes.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

L'invention concerne une préforme pour une partie composite carbone-carbone (55) qui comporte de multiples couches de mats fibreux (51, 52, 53), caractérisée en ce que chacun des mats fibreux (51, 52, 53) comporte une matrice fibreuse contenant du carbone aléatoire (11) à l'intérieur de laquelle est distribué un liant polymérique, et caractérisée en ce que les couches de mats adjacentes (51, 52, 53) sont liées ensemble par un liant polymérique supplémentaire, des piqûres et des agrafes entrecroisées. La préforme de la présente invention peut être un disque de frein de système d'atterrissage d'aéronef. De plus, l'invention concerne un procédé de fabrication d'une préforme composite épaisse multicouche. Le procédé comporte les étapes suivantes : disposer d'un outil reconfigurable optionnel incorporant un écran perforé à travers lequel un vide peut être réalisé ; placer des fibres coupées (b), telles que des fibres de brai, des fibres de polyacrylonitrile, ou mélanges de celles-ci, dans l'outil en même temps qu'un vide est réalisé, pour former un objet fibreux ; mettre un liant (c), par exemple sous une forme de pulvérisation, sur ledit objet fibreux ; faire fondre ou durcir ledit liant (d), par exemple en appliquant de la chaleur ou de la lumière ultraviolette, afin de fabriquer un mat fibreux (51, 52, 53) ; assembler, de préférence sans les couper sensiblement ou les modifier mécaniquement de toute autre façon, une pluralité desdits mats fibreux (51, 52, 53) et un liant supplémentaire ayant la forme d'une préforme (e) ; et comprimer à la chaleur l'assemblage de mats résultant (f) de façon à obtenir une préforme épaisse finie (55).
PCT/US2005/018353 2005-05-25 2005-05-25 Fabrication de composites preformes epais au moyen de couches de mats fibreux preformes multiples Ceased WO2006127002A1 (fr)

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US10/852,992 2005-05-25

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011007184A3 (fr) * 2009-07-17 2011-04-14 Carbon Fibre Preforms Ltd Matrice fibreuse et son procédé de fabrication
US10167913B2 (en) 2015-04-29 2019-01-01 Goodrich Corporation High performance carbon fiber
EP3325839B1 (fr) 2015-07-22 2021-06-09 Freni Brembo S.p.A. Materiau forme et procede de manufacture d'un tel materiau

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4396663A (en) * 1979-06-11 1983-08-02 The B. F. Goodrich Company Carbon composite article and method of making same
US4454190A (en) * 1981-09-29 1984-06-12 Isolite Babcock Refractories Co., Ltd. Expandable ceramic fiber felt with graphite flakes
US4514240A (en) * 1980-10-30 1985-04-30 Societe Europeenne De Propulsion Method for adhesively bonding parts made of refractory materials
US5282734A (en) * 1990-06-13 1994-02-01 Aerospatiale Societe Nationale Industrielle Mandrel for manufacturing a hollow composite material body

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4396663A (en) * 1979-06-11 1983-08-02 The B. F. Goodrich Company Carbon composite article and method of making same
US4514240A (en) * 1980-10-30 1985-04-30 Societe Europeenne De Propulsion Method for adhesively bonding parts made of refractory materials
US4454190A (en) * 1981-09-29 1984-06-12 Isolite Babcock Refractories Co., Ltd. Expandable ceramic fiber felt with graphite flakes
US5282734A (en) * 1990-06-13 1994-02-01 Aerospatiale Societe Nationale Industrielle Mandrel for manufacturing a hollow composite material body

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011007184A3 (fr) * 2009-07-17 2011-04-14 Carbon Fibre Preforms Ltd Matrice fibreuse et son procédé de fabrication
US8580169B2 (en) 2009-07-17 2013-11-12 Carbon Fibre Preforms Ltd Fibre matrix and a method of making a fibre matrix
US10273610B2 (en) 2009-07-17 2019-04-30 Cfp Composites Limited Fibre matrix and a method of making a fibre matrix
US10167913B2 (en) 2015-04-29 2019-01-01 Goodrich Corporation High performance carbon fiber
US10830297B2 (en) 2015-04-29 2020-11-10 Goodrich Corporation High performance carbon fiber
EP3325839B1 (fr) 2015-07-22 2021-06-09 Freni Brembo S.p.A. Materiau forme et procede de manufacture d'un tel materiau
US11649865B2 (en) 2015-07-22 2023-05-16 Brembo S.P.A. Shaped material and manufacturing method

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