US4780363A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Carbon fibre materials
Assignee: Dunlop Ltd
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Filing: 1987-12-28
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Granted: 1988-10-25
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Expires: 2007-12-28
Abstract
Abstract A sheet of parallel carbon or carbon-precursor filaments is supported by a carrier sheet of fugitive backing material and needle punched. The fugitive backing material is subsequently destroyed leaving displaced or broken portions of the filaments entangled together to provide a stable sheet for composite manufacture, particularly for reinforcement of a carbon-carbon composite.
Inventors
- 👤 Maurice J. Evans
- 👤 Keith A. Williams
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 03:04
CPC Classifications
D; D04; D04H; D04H3/00; D04H3/08; D04H3/10; D04H3/105; D01; D01F; D01F11/00; D01F11/10; D01F11/14; D04H1/00; D04H1/40; D04H1/42; D04H1/4209; D04H1/4242; D04H1/4374; D04H1/58; D04H1/64; D04H1/645; D04H3/002; D04H3/02; D04H3/04; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/30; Y10T442/00; Y10T442/60; Y10T442/643; Y10T442/659; Y10T442/666; Y10T442/667
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
34 words
A sheet of needled carbon or carbon-precursor continuous filaments for use in the reinforcement of a carbon-carbon composite, said filaments being bound together in side by side relationship by means of a fugitive material.
Claim 2
Dependent Claim
34 words
A sheet of needled carbon or carbon-precursor continuous filaments for use in the reinforcement of a carbon-carbon composite, said filaments being bound together in side by side relationship by means of a fugitive material.
Claim 3
Dependent Claim
35 words
A sheet of needled carbon or carbon-precursor continuous filaments for use in the reinforcement of a carbon-carbon composite, said filaments being bound together in side by side relationship to a sheet of fugitive backing material.
Claim 4
Dependent Claim
35 words
A sheet of needled carbon or carbon-precursor continuous filaments for use in the reinforcement of a carbon-carbon composite, said filaments being bound together in side by side relationship to a sheet of fugitive backing material.
Claim 5
Dependent Claim
48 words
A sheet of needled carbon or carbon-precursor continuous filaments for use in the reinforcement of a carbon-carbon composite, said filaments being bound together in side by side relationship and bound to a sheet of fugitive backing fabric by means of interengaged looped or broken portions of adjacent filaments.
Claim 6
Dependent Claim
48 words
A sheet of needled carbon or carbon-precursor continuous filaments for use in the reinforcement of a carbon-carbon composite, said filaments being bound together in side by side relationship and bound to a sheet of fugitive backing fabric by means of interengaged looped or broken portions of adjacent filaments.
Claim 7
Dependent Claim
29 words
A sheet of carbon-precursor filaments according to claim 1 wherein the filaments are treated with a carbonisable substance to produce on heating a char to help bind the filaments.
Claim 8
Dependent Claim
13 words
A sheet in accordance with claim 1 having an oxidation inhibitor deposited thereon.
Claim 9
Dependent Claim
17 words
A sheet of carbon-precursor filaments according to claim 4 wherein the carbonisable substance contains an oxidation inhibitor.
Claim 10
Dependent Claim
20 words
A stack of sheets in accordance with claim 1 needled together as a preform for manufacture of a carbon-carbon composite.
Claim 11
Dependent Claim
25 words
A stack of sheets in accordance with claim 7 wherein the alignment of filaments in one sheet crosses that of the filaments in another sheet.
Claim 12
Dependent Claim
24 words
A multi-layer sheet formed from sheets in accordance with claim 1 by the needling together of such sheets and removal of the fugitive material.
Claim 13
Dependent Claim
23 words
A multi-layer sheet formed from sheets of carbon-precursor filaments in accordance with claim 1 by the needling together of such sheets before carbonisation.
Claim 14
Dependent Claim
34 words
A multi-layer sheet in accordance with claim 9 in which the alignment of the filaments in one ply of the multi-layer sheet crosses that of the filaments in another ply of the multi-layer sheet.
Claim 15
Dependent Claim
31 words
A carbon-carbon composite comprising at least one sheet of needled carbon continuous filaments bound together in side by side relationship by means of interengaged looped or broken portions of adjacent filaments.
Claim 16
Dependent Claim
31 words
A carbon-carbon composite comprising at least one sheet of needled carbon continuous filaments bound together in side by side relationship by means of interengaged looped or broken portions of adjacent filaments.
Claim 17
Dependent Claim
18 words
A carbon-carbon composite comprising at least one sheet of carbon or carbon-precursor filaments in accordance with claim 1.
Claim 18
Independent Claim
76 words
A method for producing a stable sheet of needled carbon or carbon-precursor continuous filaments in side by side relationship comprising preparing a sheet of said continuous filaments, applying a fugitive backing material to the continuous filaments, needle-punching said continuous filaments and backing material to bind the filaments to the backing material, and destroying the fugitive backing material so as to leave the filaments bound together by means of interengaged looped or broken portions of adjacent filaments.
Claim 19
Independent Claim
76 words
A method for producing a stable sheet of needled carbon or carbon-precursor continuous filaments in side by side relationship comprising preparing a sheet of said continuous filaments, applying a fugitive backing material to the continuous filaments, needle-punching said continuous filaments and backing material to bind the filaments to the backing material, and destroying the fugitive backing material so as to leave the filaments bound together by means of interengaged looped or broken portions of adjacent filaments.
Claim 20
Dependent Claim
28 words
A method according to claim 14 wherein the fugitive backing material is destroyed by a high-temperature treatment which also serves to carbonise carbon-precursor continuous filaments of said sheet.
Claim 21
Dependent Claim
24 words
A method according to claim 14 comprising the step of needling together sheets to form a multiple-layer sheet before removal of the fugitive backing.
Claim 22
Dependent Claim
33 words
A method according to claim 14 comprising the step of needling together sheets to form a multiple layer stack before removal of the fugitive backing to provide a multiple-layer preform for composite manufacture.
Claim 23
Dependent Claim
23 words
A method according to claim 16 wherein the alignment of the filaments in one sheet crosses that of the filaments in another sheet.
Claim 24
Dependent Claim
22 words
A stable single- or multi-layer sheet of needled carbon or carbon-precursor continuous filaments prepared by a method in accordance with claim 14.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-10-25 | 1992-04-25 | 1992-10-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-10-25 | 1996-04-25 | 1996-10-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-10-25 | 2000-04-25 | 2000-10-25 | $7700.00 | Window Closed / Lapsed |