Honeywell International Inc.

Barry P Soos

Mark L La Forest

Slawomir T Fryska

Allen Simpson

Mark L LaForest

Christopher S Wahlers

Mark Criss James

A method of manufacturing a carbon-carbon brake disc uses a restraint fixture () that includes a preform retention region configured to limit contracting forces applied against a preform () in the preform retention region when the restraint fixture () thermally contracts. In one embodiment, the restraint fixture () comprises a band () having a first surface defining the preform retention region and a first expansion portion () adapted to deform upon application of a force to the band ().

Method of manufacturing a carbon-carbon brake disc

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.

VPI-RTM-CVD brake disc preform densification

This invention generally pertains to self propagating high temperature synthesis or combustion synthesis as a way of bonding materials. The present invention provides methods and an apparatus for bonding, preferably carbon-carbon composite materials, by combustion synthesis. Generally, the invention involves providing at least two carbon-carbon composite parts to be bonded and interspersing a combustion synthesis material in between the parts with each part in contact with the combustion synthesis material. The combustion synthesis material is then ignited, which initiates the combustion synthesis reaction. Typically, a ceramic material is formed which immediately freezes, bonding the parts together.

Carbon filament ignition of combustion synthesis materials

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.

Activated carbon to immobilize pitch in constraint fixture during carbonization

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.

Formulation for the manufacture of carbon-carbon composite materials

Molding apparatus for rapid transfer of molten resin or pitch in an infiltration molding process. The apparatus includes e.g. an extruder () for melting and conveying a resin or pitch and a mold () arranged so that resin or pitch is conveyed to a mold insert cavity () within the mold. The mold insert contains an internal protrusion such as a locating ring () for positioning a porous body () within the mold insert cavity in a position that brings about unidirectional flow of the molten resin or pitch through the porous body. Also, rapid resin or pitch infiltration molding process that includes injecting a high melting point, high viscosity, molten resin or pitch into the mold to effect a unidirectional impregnation of a heated preform via a pressure gradient in the mold.

Growing community of inventors

Mishawaka, IN, United States of America

Barry P Soos