US5685936A
Expired / Lapsed
US
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Method for preparing carbon honeycomb structure
Assignee: Showa Aircraft Industry Co Ltd
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Filing: 1995-10-10
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Granted: 1997-11-11
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Expires: 2015-10-10
Abstract
Abstract Disclosed is a method for preparing a carbon honeycomb structure that includes the steps of: alternately stacking a plurality of corrugated sheets each of which is produced by corrugating a supporting base of carbon fibers impregnated with an epoxy resin prepolymer and then curing the prepolymer, and a plurality of flat sheets, each of which is prepared by curing a supporting base of carbon fibers impregnated with an epoxy resin prepolymer, through a node bond adhesive; curing the adhesive to form a honeycomb structure; dipping the resulting honeycomb structure in a phenolic resin prepolymer solution; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the coated honeycomb structure to a predetermined thickness. In other embodiments, instead of alternatively stacking the plurality of corrugated sheets and the plurality of flat sheets, either a plurality of the corrugated sheets are stacked or a honeycomb expanding technique is used with the supporting bases.
Inventors
- 👤 Takaya Komine
- 👤 Kimitoshi Katoh
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 12:52
CPC Classifications
B; B29; B29D; B29D99/00; B29D99/0089; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1003; Y10T156/1007; Y10T156/1016; Y10T156/1018; Y10T156/1025; Y10T156/1052; Y10T428/00; Y10T428/24; Y10T428/24149
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
144 words
A method for preparing a carbon honeycomb structure comprising the steps of alternately stacking a plurality of corrugated sheets, each of which is produced by corrugating a supporting base of carbon fibers impregnated with an epoxy resin prepolymer and then curing the prepolymer, and a plurality of flat sheets, each of which is prepared by impregnating a supporting base of carbon fibers with an epoxy resin prepolymer and then curing the prepolymer, through a node bond adhesive; curing the adhesive to form a honeycomb structure; dipping the resulting honeycomb structure in a solution of a phenolic resin prepolymer in a solvent; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the honeycomb structure carrying the cured phenolic resin to a predetermined thickness.
Claim 2
Independent Claim
144 words
A method for preparing a carbon honeycomb structure comprising the steps of alternately stacking a plurality of corrugated sheets, each of which is produced by corrugating a supporting base of carbon fibers impregnated with an epoxy resin prepolymer and then curing the prepolymer, and a plurality of flat sheets, each of which is prepared by impregnating a supporting base of carbon fibers with an epoxy resin prepolymer and then curing the prepolymer, through a node bond adhesive; curing the adhesive to form a honeycomb structure; dipping the resulting honeycomb structure in a solution of a phenolic resin prepolymer in a solvent; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the honeycomb structure carrying the cured phenolic resin to a predetermined thickness.
Claim 3
Dependent Claim
20 words
The method of claim 1 wherein the supporting base of carbon fibers is a supporting base of polyacrylonitrile carbon fibers.
Claim 4
Dependent Claim
16 words
The method of claim 1 wherein the supporting base of carbon fibers is a woven fabric.
Claim 5
Dependent Claim
30 words
The method of claim 1 wherein the epoxy resin prepolymer is represented by the following general formula (1): ##STR3## wherein n is a numerical value ranging from 1 to 2.
Claim 6
Independent Claim
114 words
A method for preparing a carbon honeycomb structure comprising the steps of stacking a plurality of corrugated sheets, each of which is produced by corrugating a supporting base of carbon fibers impregnated with an epoxy resin prepolymer and then curing the prepolymer, through a node bond adhesive; curing the adhesive to form a honeycomb structure; dipping the resulting honeycomb structure in a solution of a phenolic resin prepolymer in a solvent; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the honeycomb structure carrying the cured phenolic resin to a predetermined thickness.
Claim 7
Independent Claim
114 words
A method for preparing a carbon honeycomb structure comprising the steps of stacking a plurality of corrugated sheets, each of which is produced by corrugating a supporting base of carbon fibers impregnated with an epoxy resin prepolymer and then curing the prepolymer, through a node bond adhesive; curing the adhesive to form a honeycomb structure; dipping the resulting honeycomb structure in a solution of a phenolic resin prepolymer in a solvent; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the honeycomb structure carrying the cured phenolic resin to a predetermined thickness.
Claim 8
Dependent Claim
20 words
The method of claim 5 wherein the supporting base of carbon fibers is a supporting base of polyacrylonitrile carbon fibers.
Claim 9
Dependent Claim
16 words
The method of claim 5 wherein the supporting base of carbon fibers is a woven fabric.
Claim 10
Dependent Claim
18 words
The method of claim 5 wherein the epoxy resin prepolymer is represented by the general formula (1): ##STR4##
Claim 11
Independent Claim
118 words
A method for preparing a carbon honeycomb structure comprising the steps of applying a node bond adhesive to a supporting base of carbon fibers impregnated with an epoxy resin prepolymer; stacking a plurality of the supporting bases; curing the adhesive; then expanding the stacked bases and curing the epoxy resin prepolymer with heating to form a honeycomb structure; further dipping the resulting honeycomb structure in a solution of a phenolic resin prepolymer in a solvent; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the honeycomb structure carrying the cured phenolic resin to a predetermined thickness.
Claim 12
Independent Claim
118 words
A method for preparing a carbon honeycomb structure comprising the steps of applying a node bond adhesive to a supporting base of carbon fibers impregnated with an epoxy resin prepolymer; stacking a plurality of the supporting bases; curing the adhesive; then expanding the stacked bases and curing the epoxy resin prepolymer with heating to form a honeycomb structure; further dipping the resulting honeycomb structure in a solution of a phenolic resin prepolymer in a solvent; evaporating the solvent; then curing the phenolic resin prepolymer; repeating these dip, evaporation and curing processes to coat the honeycomb structure with a predetermined amount of the phenolic resin; and cutting the honeycomb structure carrying the cured phenolic resin to a predetermined thickness.
Claim 13
Dependent Claim
20 words
The method of claim 9 wherein the supporting base of carbon fibers is a supporting base of polyacrylonitrile carbon fibers.
Claim 14
Dependent Claim
16 words
The method of claim 9 wherein the supporting base of carbon fibers is a woven fabric.
Claim 15
Dependent Claim
18 words
The method of claim 9 wherein the epoxy resin prepolymer is represented by the general formula (1): ##STR5##
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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) | 2000-11-10 | 2001-05-12 | 2001-11-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-11-10 | 2005-05-12 | 2005-11-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-11-10 | 2009-05-12 | 2009-11-11 | $7700.00 | Window Closed / Lapsed |