Honeywell International Inc.

Laurie A Booker

Terence B Walker

Manuel Koucouthakis

Michelle L Shreve

Ilan Golecki

Ken A Thompson

Michael N Spross

Akshay Waghray

Apparatus including a carbon-carbon composite pressure plate () having a friction surface () on one side thereof, a non-friction surface () on the opposite side thereof, and a body () between said surfaces. A wear pin housing () containing a wear pin retainer () is located in the pressure plate body (), the wear pin housing opening to the non-friction surface () but not opening to the friction surface (). A wear pin (), preferably made of carbon-carbon composite material, is located in the wear pin retainer (). The wear pin retainer (), which may be made of carbon-carbon composite material, is held in place in the wear pin housing () by the interaction of threading in the wear pin housing () and threading in the wear pin retainer () and optionally also by a carbonizable resin adhesive located between the wear pin housing threading and the wear pin retainer threading.

Wear pin assemblies for carbon-carbon composite brake systems

This invention provides a stepped heating cycle for the pre-treatment of phenolic microballoons prior to carbonization thereof, wherein the heating cycle comprises the steps of sequentially: gradually elevating the temperature of the microballoons to a temperature in the range 100&#xb0; C.-170&#xb0; C.; holding the microballoons at the elevated temperature for 1-24 hours; and gradually cooling the microballoons. This invention also provides a heat-dissipation reactor () which comprises a walled reaction chamber having a bottom and no top, the reaction chamber being fitted with high thermal conductivity inserts. When used in accordance with this invention (), the volume within the walls of the reaction chamber is charged with phenolic resin microballoons. In a preferred embodiment, the reaction chamber () is subdivided into a plurality of subchambers by a vertical grid of aluminum plates (). In this embodiment, about half or more of the wall area of each subchamber comprises aluminum and a top edge () of the aluminum wall material communicates with atmosphere above the reaction chamber.

Apparatus for the manufacture of carbon microballoons

Coated article, e.g., a brake disc, comprising a carbon-carbon composite component or a carbon-carbon-silicon carbide component coated at least with a phosphorus-containing antioxidant undercoating, the undercoating being covered by a silicon carbide particle-containing overcoating of alkali or alkaline earth metal silicate, pH modifier, and silicon carbide particles. Also, method of protecting a carbon-carbon composite brake disc or a carbon-carbon-silicon carbide composite brake disc against oxidation, by: coating the composite brake disc with a first phosphoric acid-based penetrant system; curing the penetrant coating at a temperature of 200&#xb0; C. or above to form a first coating on the composite brake disc; applying the ceramic coating composition of claimover the first coating and curing the ceramic coating at a temperature below 200&#xb0; C. to form a second coating on the composite brake disc; and optionally coating the coated composite brake disc so obtained with a second phosphoric acid-based penetrant system; and curing the penetrant coating at a temperature of 200&#xb0; C. or above to form a third coating on the composite brake disc.

Bi-or tri-layer anti-oxidation system for carbon composite brakes

Method of improving humidity resistance in a coated article () comprising a carbon-carbon composite component (), a graphite component (), or a ceramic matrix composite component based on carbon fibers and/or graphite (). The component () is preferably configured as an aircraft landing system brake disc. The method includes the steps of: (A) providing a carbon-carbon composite component (), a graphite component (), or a ceramic matrix composite component based on carbon fibers and/or graphite (); (B) covering the component () with a phosphorus-containing antioxidant undercoating () having a thickness of approximately 1&#x2013;10 mil; and (C) covering the resulting undercoated component () with a boron-containing glass overcoating () having a thickness of approximately 1&#x2013;10 mil. The overcoating includes 20&#x2013;50 wt-% alkali or alkaline earth metal silicates, 3&#x2013;25 wt-% alkali metal hydroxide, up to 10 wt-% boron nitride, and one or both of 5&#x2013;40 wt-% elemental boron and 5&#x2013;40 wt-% boron carbide. The overcoating is substantially free of phosphoric acid and phosphates. Also, articles coated with the specified undercoating/overcoating combinations.

Antioxidant system for carbon&#x2014;carbon brake materials with enhanced resistance to humidity exposure

Coated articles () that comprise components, made of carbon fiber or carbon-carbon composites which may be configured, for example, as aircraft landing system brake discs. The components () are coated with a system that includes a phosphorus-containing undercoating () having a specified formulation and a boron-containing overcoating () having specified characteristics. The coated articles of the invention, e.g., aircraft brake discs, are protected against catalytic oxidation when the article is subjected to temperatures of 800&#xb0; C. (1472&#xb0; F.) or greater. Also, a method of protecting a component made of a carbon fiber or carbon-carbon composite simultaneously against catalytic oxidation (e.g., catalyzed by de-icer compositions) and high temperature non-catalytic oxidation.

High temperature oxidation inhibitors for carbon-carbon friction materials

This invention provides a stepped heating cycle for the pre-treatment of phenolic microballoons prior to carbonization thereof, wherein the heating cycle comprises the steps of sequentially: gradually elevating the temperature of the microballoons to a temperature in the range 100&#xb0; C.&#x2013;170&#xb0; C.; holding the microballoons at the elevated temperature for 1&#x2013;24 hours; and gradually cooling the microballoons. This invention also provides a heat-dissipation reactor () which comprises a walled reaction chamber having a bottom and no top, the reaction chamber being fitted with high thermal conductivity inserts. When used in accordance with this invention (), the volume within the walls of the reaction chamber is charged with phenolic resin microballoons. In a preferred embodiment, the reaction chamber () is subdivided into a plurality of subchambers by a vertical grid of aluminum plates (). In this embodiment, about half or more of the wall area of each subchamber comprises aluminum and a top edge () of the aluminum wall material communicates with atmosphere above the reaction chamber.

Process and apparatus for the manufacture of carbon microballoons

Carbon composite components (), which may be aircraft brake discs, heat exchanger cores, and so on, are covered by protective coating. Component () is immersed in liquid bath precursor of fluidized glass (step). After immersion step, glass-coated component () is removed and annealed. Heat treatment gradually increases temperature to 250-350&#xb0; C. at the rate of 1-2&#xb0; C. per minute (step). Heat treatment is followed by soak at temperature of 250-350&#xb0; C. for 1-10 hours (step). Temperature is then increased to 550-650&#xb0; C. (step). Temperature is maintained at 550-650&#xb0; C. for 1-10 hours (step). After completion of second prolonged heat treatment, the component is cooled until reaching room temperature (step). Upon completion of the annealing step, the fluidized glass coating converts to solid glass coating () enveloping and forming a protective barrier against undesirable oxidation of the C&#x2014;C component (). For application to thin-gauge composites, the glass precursor components contain 20-60 weight-% water, 25-50 weight-% phosphoric acid, 2-20 weight-% alkali metal hydroxide, 1-10 weight-% manganese phosphate, 1-10 weight-% boron nitride, 0-5 weight-% elemental boron, and 10-28 weight-% boron carbide.

Fluidizing oxidation protection systems

Antioxidant coating compositions containing 10-75 wt % HO, 20-65 wt % HPO, 0.1-20 wt % alkali metal mono-, di-, or tri-basic phosphate, 0-2 wt % hydrated boron oxide, 0-18 wt % KHPO, 3-10 wt % of a transition metal oxide, and 0-20 wt % hydrated manganese phosphate, 0-25 wt % Al(HPO), and 0-10 wt % Zn(PO), provided that at least one of Al(HPO), Zn(PO), and hydrated manganese phosphate is present. Also, brake discs made from carbon composite articles having their surface treated with certain antioxidant coatings. During a manufacturing process, carbon matrixof brake discis covered on its outer and inner edges with antioxidant layersand portions of the working surface of brake discmay also be covered with antioxidant layers, potentially decreasing the fitness of the brake disc for service. In accordance with this invention, brake discis manufactured from brake discby the removal from its working surface of antioxidant layers

Coated carbon brake disc materials

Coated articles () that comprise components, made of carbon fiber or carbon-carbon composites which may be configured, for example, as aircraft landing system brake discs. The components () are coated with a system that includes a phosphorus-containing undercoating () having a specified formulation and a boron-containing overcoating () having specified formulation. The coated articles of the invention, e.g., aircraft brake discs, are protected against catalytic oxidation when the article is subjected to temperatures of 800&#xb0; C. (1472&#xb0; F.) or greater. Also, a method of protecting a component made of a carbon fiber or carbon-carbon composite simultaneously against catalytic oxidation (e.g., catalyzed by de-icer compositions) and high temperature non-catalytic oxidation.

Method for simultaneously protecting carbon-containing components against catalytic oxidation and high temperature non-catalytic oxidation

Antioxidant coating compositions containing 10-75 wt % H O, 20-65 wt % H PO , 0.1-20 wt % alkali metal mono-, di-, or tri-basic phosphate, 0-2 wt % hydrated boron oxide, 0-18 wt % KH PO , 3-10 wt % of a transition metal oxide, and 0-20 wt % hydrated manganese phosphate, 0-25 wt % Al(H PO ) , and 0-10 wt % Zn (PO ) , provided that at least one of Al(H PO ) , Zn (PO ) , and hydrated manganese phosphate is present. Also, brake discs made from carbon composite articles having their surface treated with certain antioxidant coatings. During a manufacturing process, carbon matrix of brake disc is covered on its outer and inner edges with antioxidant layers and portions of the working surface of brake disc may also be covered with antioxidant layers potentially decreasing the fitness of the brake disc for service. In accordance with this invention, brake disc is manufactured from brake disc by the removal from its working surface of antioxidant layers

The invention provides for oxidatively resistant carbon/carbon composites and other graphite-like material, a method for the preparation of these materials, and their use in high temperature applications, preferably in brakes for airplanes. The carbon/carbon composite or graphite-like material, which is resistant to oxidation at high temperatures comprises a fiber-reinforced carbon/carbon composite or graphite in contact with a phosphoric acid based penetrant salt solution which contains the ions formed from the combination of the following: 10-80 wt % H O, 20-70 wt % H PO , 0-25 wt % MnHPO .1.6H O, 0-30 wt % Al(H PO ) , 0-2 wt % B O , 0-10 wt % Zn (PO ) and 0.1-25 wt % alkali metal mono-, di-, or tri-basic phosphate.

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South Bend, IN, United States of America

Laurie A Booker