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US4178413A Expired / Lapsed US ⏱️ 0.0 years remaining

Fiber reinforced carbon and graphite articles and a method of producing said articles

Assignee: Unifrax I LLC
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Filing: 1977-10-03
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Granted: 1979-12-11
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Expires: 1997-10-03
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Abstract

Abstract The present invention relates to fiber reinforced carbon and graphite articles that are characterized by a matrix of fibrous carbon material bonded together by a deposited pyrolytic material and having the residue of a carbonized filler material dispersed within the article in contact with the pyrolytic material. Fiber reinforced carbon and graphite articles are produced by (1) Forming reinforcing fibers into a shape without any binder material, (2) Infiltrating the fibers with a pyrolytic material in a manner to deposit pyrolytic material on the fibers and bond together the fibers, to form a bonded body, (3) Subsequently impregnating the bonded body with a carbonizable filler material, and, (4) Curing and carbonizing the filler material. The articles are substantially free of internal cracks and voids and are of high strength even at relatively low densities. As such, the articles are particularly useful in the aerospace industry where strong, lightweight materials are required. The articles of the present invention are found to have substantially improved freedom of internal stresses which prior art carbon or graphite articles have been particularly susceptible.

Inventors

  • 👤 Gabriel P. DeMunda

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-10-28 18:40
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/71; C04B35/78; C04B35/80; C04B35/83; Y; Y10; Y10T; Y10T428/00; Y10T428/30

Claims Analysis

Total Claims: 19
Claim 1
Independent Claim 50 words
A fiber reinforced article composed of a matrix of fibrous carbon material bonded together by a deposited pyrolytic material and having the residue of a carbonizable filler material deposited on said pyrolytic material, said residue produced by initially depositing and subsequently carbonizing said carbonizable filler material on said pyrolytic material.
Claim 2
Dependent Claim 50 words
A fiber reinforced article composed of a matrix of fibrous carbon material bonded together by a deposited pyrolytic material and having the residue of a carbonizable filler material deposited on said pyrolytic material, said residue produced by initially depositing and subsequently carbonizing said carbonizable filler material on said pyrolytic material.
Claim 3
Dependent Claim 19 words
The article of claim 1 wherein the said fibrous carbon material is substantially entirely coated by said pyrolytic material.
Claim 4
Dependent Claim 11 words
The article of claim 1 wherein the pyrolytic material is carbon.
Claim 5
Dependent Claim 13 words
The article of claim 1 wherein the pyrolytic material has been vapor deposited.
Claim 6
Dependent Claim 11 words
The article of claim 4 wherein the pyrolytic material is carbon.
Claim 7
Dependent Claim 12 words
The article of claim 1 wherein the article is substantially entirely carbon.
Claim 8
Dependent Claim 12 words
The article of claim 1 wherein the article is substantially entirely graphite.
Claim 9
Dependent Claim 17 words
The article of claim 1 wherein the carbonized filler material substantially entirely interconnects said deposited pyrolytic material.
Claim 10
Dependent Claim 13 words
The article of claim 1 wherein the fibrous carbon material is carbonized rayon.
Claim 11
Independent Claim 78 words
A method of producing fiber reinforced carbon articles by: (a) forming a fibrous carbon material into a shape without the use of a binder material, (b) infiltrating said fibers with a pyrolytic material in a manner to deposit said pyrolytic material on said fibers and bond together said fibers to form a bonded body, (c) subsequently impregnating said bonded body with a carbonizable filler material, and, (d) curing and subsequently carbonizing said filler material within said bonded body.
Claim 12
Independent Claim 78 words
A method of producing fiber reinforced carbon articles by: (a) forming a fibrous carbon material into a shape without the use of a binder material, (b) infiltrating said fibers with a pyrolytic material in a manner to deposit said pyrolytic material on said fibers and bond together said fibers to form a bonded body, (c) subsequently impregnating said bonded body with a carbonizable filler material, and, (d) curing and subsequently carbonizing said filler material within said bonded body.
Claim 13
Dependent Claim 29 words
The method of claim 10 wherein the pyrolytic material is a product of the vapor deposition of a gas selected from the group of methane, ethane, butane and propane.
Claim 14
Dependent Claim 18 words
The method of claim 10 wherein steps (c) and (d) are repeated to produce a substantially solid product.
Claim 15
Dependent Claim 11 words
The method of claim 10 wherein the pyrolytic material is carbon.
Claim 16
Dependent Claim 14 words
The method of claim 10 wherein the fibers are in the form of cloth.
Claim 17
Dependent Claim 11 words
The method of claim 14 wherein the cloth is carbonized rayon.
Claim 18
Dependent Claim 30 words
The method of claim 10 wherein the product of step (d) is heat treated in a range of between about 2600° C. and 2700° C. to substantially graphitize the article.
Claim 19
Dependent Claim 13 words
The method of claim 10 wherein the fibrous carbon material is carbonized polyacrylonitrile.

References Cited (Backward Citations)

US3027278A Cited
US3542582A Cited
DE2042647A1 Cited
US3991248A Cited
US3980105A Cited
US4064207A Cited

USPTO Annuity & Maintenance Windows

Annuity Stage Window Opens Payment Deadline Surcharge Period Until Estimated Fee Status
3.5 Years (Year 4) 1982-12-10 1983-06-11 1983-12-11 $2000.00 Window Closed / Lapsed
7.5 Years (Year 8) 1986-12-10 1987-06-11 1987-12-11 $3760.00 Window Closed / Lapsed
11.5 Years (Year 12) 1990-12-10 1991-06-11 1991-12-11 $7700.00 Window Closed / Lapsed

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