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US4983451A
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Carbon fiber-reinforced carbon composite material and process for producing the same
Assignee: Kobe Steel Ltd
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Filing: 1988-04-04
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Granted: 1991-01-08
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Expires: 2008-04-04
Abstract
Abstract Disclosed herein are a carbon fiber-reinforced carbon composite material composed of carbon as a matrix and carbon fiber as a reinforcement, and also a process for producing the same. The composite material is produced by coating nonwoven fabrics of carbon fiber or a blend of carbon fiber and organic fiber with a filler-containing liquid, laminating the nonwoven fabrics one over another, and subjecting the laminated nonwoven fabrics to needle punching repeatedly with a plurality of needles, thereby yielding a prepreg of three-dimensional structure, and carbonizing and calcining the thus obtained prepreg.
Inventors
- 👤 Morihiko Sugino
- 👤 Yoshio Inoue
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 21:11
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/71; C04B35/78; C04B35/80; C04B35/83; Y; Y10; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913; Y10T428/2918; Y10T428/292; Y10T428/2982; Y10T428/30; Y10T442/00; Y10T442/20; Y10T442/2738; Y10T442/60; Y10T442/654; Y10T442/655; Y10T442/658; Y10T442/659; Y10T442/666; Y10T442/667; Y10T442/673
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
118 words
A process for producing a carbon fiber-reinforced carbon composite material, which comprises layering non-woven fabrics of carbon fiber or a blend of carbon fiber and organic fiber, which have been coated with a filler containing liquid, to obtain a layered material; and needle punching said layered material with a plurality of needles, to obtain a prepreg of three-dimensional structure; wherein said filler-containing liquid comprises a synthetic resin liquid and at least one filler selected from the group consisting of graphite powder, carbon black powder, carbon short fiber, graphite short fiber, synthetic resin powder, pitch powder, mesophase pitch powder, coke powder, ceramic powder, metal powder, metal short fiber, Si 3 N 4 whiskers, SiC whiskers, and ceramic short fibers.
Claim 2
Dependent Claim
118 words
A process for producing a carbon fiber-reinforced carbon composite material, which comprises layering non-woven fabrics of carbon fiber or a blend of carbon fiber and organic fiber, which have been coated with a filler containing liquid, to obtain a layered material; and needle punching said layered material with a plurality of needles, to obtain a prepreg of three-dimensional structure; wherein said filler-containing liquid comprises a synthetic resin liquid and at least one filler selected from the group consisting of graphite powder, carbon black powder, carbon short fiber, graphite short fiber, synthetic resin powder, pitch powder, mesophase pitch powder, coke powder, ceramic powder, metal powder, metal short fiber, Si 3 N 4 whiskers, SiC whiskers, and ceramic short fibers.
Claim 3
Dependent Claim
36 words
A process for producing a carbon fiber-reinforced carbon composite material as claimed in claim 1, wherein the prepreg is carbonized and calcined by at least one process of pressing, drying, heat curing, polymerization, carbonization, and infusibilization.
Claim 4
Dependent Claim
30 words
A process for producing a carbon fiber-reinforced carbon composite material as claimed in claim 1, wherein the needle punching is performed at a density of 5 needles/cm 2 or above.
Claim 5
Dependent Claim
60 words
A process for producing a carbon fiber-reinforced carbon composite material as claimed in claim 1, wherein the nonwoven fabric has a basis weight of 5 g/m 2 and above, the filler-containing liquid is in the form of paste or liquid, and the filler-containing liquid is used in an amount of 0.5 to 300 times the weight of the nonwoven fabric.
Claim 6
Dependent Claim
37 words
A process for producing a carbon fiber-reinforced carbon composite material as claimed in claim 2, wherein the pressing process is performed by isotactically pressing a plurality of prepregs at a pressure of 500 kgf/cms 2 or above.
Claim 7
Dependent Claim
39 words
A process for producing a carbon fiber-reinforced carbon composite material as claimed in claim 2, wherein the calcination is accomplished such that the carbon fibers are surrounded by vitreous carbon and the remaining space is filled with soft carbon.
Claim 8
Dependent Claim
35 words
A process for producing a carbon fiber-reinforced carbon composite material as claimed in claim 1, wherein the nonwoven fabric contains carbon fiber in an amount of 1 to 99 times the weight of organic fiber.
Claim 9
Dependent Claim
129 words
A carbon fiber-reinforced carbon composite material produced by the process, which comprises layering non-woven fabrics of carbon fiber or a blend of carbon fiber and organic fiber, which have been coated with a filler containing liquid, to obtain a layered material; needle punching said layered material with a plurality of needles, to obtain a prepreg of three-dimensional structure; and carbonizing and calcining said prepreg to obtain a carbonaceous matrix; wherein said filler containing liquid comprises a synthetic resin liquid and at least one filler selected from the group consisting of graphite powder, carbon black powder, carbon short fiber, graphite short fiber, synthetic resin powder, pitch powder, mesophase pitch powder, coke powder, ceramic powder, metal powder, metal short fiber, Si 3 N 4 whiskers, SiC whiskers, and ceramic short fibers.
Claim 10
Dependent Claim
129 words
A carbon fiber-reinforced carbon composite material produced by the process, which comprises layering non-woven fabrics of carbon fiber or a blend of carbon fiber and organic fiber, which have been coated with a filler containing liquid, to obtain a layered material; needle punching said layered material with a plurality of needles, to obtain a prepreg of three-dimensional structure; and carbonizing and calcining said prepreg to obtain a carbonaceous matrix; wherein said filler containing liquid comprises a synthetic resin liquid and at least one filler selected from the group consisting of graphite powder, carbon black powder, carbon short fiber, graphite short fiber, synthetic resin powder, pitch powder, mesophase pitch powder, coke powder, ceramic powder, metal powder, metal short fiber, Si 3 N 4 whiskers, SiC whiskers, and ceramic short fibers.
Claim 11
Dependent Claim
24 words
A carbon fiber-reinforced carbon composite material as claimed in claim 8, wherein the carbonaceous matrix material is composed of vitreous carbon and soft carbon.
Claim 12
Dependent Claim
27 words
A carbon fiber-reinforced carbon composite material as claimed in claim 8, wherein the amount of the filler is 0.5 to 300 times that of the reinforcing material.
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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) | 1994-01-07 | 1994-07-09 | 1995-01-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-01-07 | 1998-07-09 | 1999-01-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-01-07 | 2002-07-09 | 2003-01-08 | $7700.00 | Window Closed / Lapsed |