CN107011693A - 碳纤维预制体 - Google Patents
碳纤维预制体 Download PDFInfo
- Publication number
- CN107011693A CN107011693A CN201611080497.8A CN201611080497A CN107011693A CN 107011693 A CN107011693 A CN 107011693A CN 201611080497 A CN201611080497 A CN 201611080497A CN 107011693 A CN107011693 A CN 107011693A
- Authority
- CN
- China
- Prior art keywords
- precast body
- resin
- carbon
- fiber
- carbon fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229920000049 Carbon (fiber) Polymers 0.000 title claims abstract description 155
- 239000004917 carbon fiber Substances 0.000 title claims abstract description 154
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 136
- 229920005989 resin Polymers 0.000 claims abstract description 173
- 239000011347 resin Substances 0.000 claims abstract description 173
- 239000010410 layer Substances 0.000 claims abstract description 68
- 239000000203 mixture Substances 0.000 claims abstract description 57
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 46
- 239000002356 single layer Substances 0.000 claims abstract description 46
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 38
- 238000000034 method Methods 0.000 claims abstract description 29
- 238000007639 printing Methods 0.000 claims abstract description 20
- 239000002131 composite material Substances 0.000 claims description 77
- 238000000280 densification Methods 0.000 claims description 53
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 claims description 14
- 239000011203 carbon fibre reinforced carbon Substances 0.000 claims description 14
- 230000008859 change Effects 0.000 claims description 12
- 230000015572 biosynthetic process Effects 0.000 claims description 10
- 239000000835 fiber Substances 0.000 description 118
- 239000011295 pitch Substances 0.000 description 35
- 239000000463 material Substances 0.000 description 32
- 238000005516 engineering process Methods 0.000 description 20
- 238000003763 carbonization Methods 0.000 description 16
- 230000008569 process Effects 0.000 description 15
- 229920002239 polyacrylonitrile Polymers 0.000 description 14
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 12
- 238000000151 deposition Methods 0.000 description 12
- 239000005011 phenolic resin Substances 0.000 description 12
- 229920001568 phenolic resin Polymers 0.000 description 12
- 230000008021 deposition Effects 0.000 description 10
- 238000001125 extrusion Methods 0.000 description 10
- 150000001875 compounds Chemical class 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000011302 mesophase pitch Substances 0.000 description 7
- 238000010146 3D printing Methods 0.000 description 6
- 238000010276 construction Methods 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 230000016507 interphase Effects 0.000 description 6
- 230000015654 memory Effects 0.000 description 6
- 239000000654 additive Substances 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 230000003647 oxidation Effects 0.000 description 5
- 238000007254 oxidation reaction Methods 0.000 description 5
- 238000012546 transfer Methods 0.000 description 5
- 230000000996 additive effect Effects 0.000 description 4
- 238000005137 deposition process Methods 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 3
- 239000003575 carbonaceous material Substances 0.000 description 3
- 238000006555 catalytic reaction Methods 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 239000003822 epoxy resin Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000009527 percussion Methods 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- -1 Carbon fiber compound Chemical class 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- 239000010426 asphalt Substances 0.000 description 2
- 230000006399 behavior Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 150000001721 carbon Chemical group 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 239000011280 coal tar Substances 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000002783 friction material Substances 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 230000008595 infiltration Effects 0.000 description 2
- 238000001764 infiltration Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 244000025254 Cannabis sativa Species 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 1
- 241000237858 Gastropoda Species 0.000 description 1
- 229910003978 SiClx Inorganic materials 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 1
- 230000003064 anti-oxidating effect Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000009954 braiding Methods 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000002520 cambial effect Effects 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000011304 carbon pitch Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000006356 dehydrogenation reaction Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000005194 fractionation Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- RCHKEJKUUXXBSM-UHFFFAOYSA-N n-benzyl-2-(3-formylindol-1-yl)acetamide Chemical compound C12=CC=CC=C2C(C=O)=CN1CC(=O)NCC1=CC=CC=C1 RCHKEJKUUXXBSM-UHFFFAOYSA-N 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000009715 pressure infiltration Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000009745 resin transfer moulding Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 230000032258 transport Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/06—Making preforms by moulding the material
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
- C08K7/06—Elements
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
- C04B35/83—Carbon fibres in a carbon matrix
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
- F16D65/126—Discs; Drums for disc brakes characterised by the material used for the disc body the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
- F16D69/02—Composition of linings ; Methods of manufacturing
- F16D69/023—Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0058—Liquid or visquous
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K2105/14—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles oriented
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2279/00—Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain not provided for in groups B29K2261/00 - B29K2277/00, as reinforcement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/005—Oriented
-
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Abstract
本发明涉及碳纤维预制体。在一些示例中,一种方法包括经由三维打印***的打印头使树脂和多个碳纤维沉积来形成包括多个单个的碳纤维层的碳纤维预制体,其中,所述多个单个的碳纤维层中的每个单个的层包括树脂和碳纤维,并且其中,所述碳纤维预制体呈现出如下中的至少一种:在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向。
Description
技术领域
本公开涉及碳纤维预制体,例如,用于形成碳-碳复合材料的碳纤维预制体。
背景技术
碳纤维增强型碳材料,也被称为碳-碳(C-C)复合材料,是一种包括在碳材料的基体中被增强的碳纤维的复合材料。C-C复合材料能够用在许多高温应用中。例如,航空航天工业采用C-C复合材料作为用于商用和军用飞行器的摩擦材料,例如制动摩擦材料。
发明内容
描述了用于形成碳纤维预制体的设备、***以及技术。还描述了从该技术中得到的示例的碳纤维预制体和碳-碳复合部件。在一些示例中,碳纤维预制体可以包括多个单个的层,每个层包括多个碳纤维和树脂。可以由三维打印***的打印头来使树脂和多个碳纤维沉积。例如,可以经由打印头使树脂和碳纤维(例如作为包括与树脂混合的多个碳纤维的复合材料或作为涂覆有树脂的多个碳纤维)沉积在一起。附加地或替代地,可以经由打印头使树脂和碳纤维分开地进行沉积以形成碳纤维预制体的单个的层。
总体上,树脂和碳纤维的单个的层可以形成碳纤维预制体,该预制体呈现出如下中的至少一种:在预制体内的非一致的树脂的成分、在预制体内的不同的碳纤维的类型、或者在预制体内的非一致的纤维取向。例如,在碳纤维预制体的第一部分处的树脂可以不同于在碳纤维预制体的第二部分处的树脂。作为另外一个示例,在预制体的第一部分处的碳纤维的类型可以不同于在预制体的第二部分处的碳纤维的类型。作为另外一个示例,在预制体的第一部分处的碳纤维的取向(例如,相对于预制体的x-y平面)可以不同于在预制体的第二部分处的碳纤维的取向。如本文所使用的,碳纤维的取向可以指的是碳纤维的纵向轴线的取向。
可以例如经由化学气相渗透(CVI)/化学气相沉积(CVD)和或树脂致密化使碳纤维预制体致密化,以便形成致密化的C-C复合材料。可以选择如下中的至少一种来提供这样的致密化的C-C复合材料的一个或多个期望的性质:在预制体内的非一致的树脂的成分、在预制体内的不同的碳纤维的类型、或者在预制体内的非一致的纤维取向。例如,相比由不具有非一致的树脂的成分、不同的纤维的类型和/或不一致的纤维取向的碳纤维预制体形成的致密化的C-C复合材料,在预制体内的非一致的树脂的成分、在预制体内的不同的碳纤维的类型、或者在预制体内的非一致的纤维取向中的至少一种可以被构造成实现如下中的至少一种:修改由碳纤维预制体形成的致密化的C-C复合材料的摩擦性质、提高由碳纤维预制体形成的致密化的C-C复合材料的密度、或者提高由碳纤维预制体形成的致密化的C-C复合材料的强度。
在一个方面中,本公开涉及一种方法,所述方法包括经由三维打印***的打印头使树脂和多个碳纤维沉积来形成包括多个单个的碳纤维层的碳纤维预制体,其中,所述多个单个的碳纤维层中的每个单个的层包括树脂和碳纤维,并且其中,所述碳纤维预制体呈现出如下中的至少一种:在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向。
在另一个方面中,本公开涉及一种碳纤维预制体,所述碳纤维预制体包括多个单个的碳纤维层,其中,所述多个单个的层中的每个单个的层包括树脂和多个碳纤维,并且其中,所述碳纤维预制体呈现出如下的至少一种:在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向。
在另一个方面中,本公开涉及一种***,所述***包括打印头和控制器,所述打印头被构造成使树脂和多个碳纤维沉积,所述控制器被构造成控制所述树脂和所述多个碳纤维的沉积以形成包括多个单个的碳纤维层的碳纤维预制体,其中,所述多个单个的碳纤维层中的每个单个的层包括树脂和碳纤维,并且其中,所述碳纤维预制体呈现出如下中的至少一种:在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向。
在附图和下面的具体实施方式中将对一个或多个示例的细节进行阐明。从具体实施方式和附图,以及从权利要求中将明白本公开的其它特征、目的和优势。
附图说明
图1是示意性结构图,示出了示例的飞行器制动组件。
图2-4是概念图,示出了依照本公开的方面的示例的碳纤维预制体。
图5是示意图,示出了示例的三维打印***,该三维打印***可以用于制造图2-4的示例的预制体。
图6是流程图,示出了形成示例的碳纤维预制体以及由该碳纤维预制体形成致密化的碳-碳复合材料的示例的方法。
具体实施方式
本文对用于形成碳纤维预制体的示例的技术,连同碳纤维预制体、碳-碳复合材料以及由该碳纤维预制体形成的结构(在本文中也被称为“部件”)进行描述。例如在诸如制动盘的航空航天应用中所使用致密化的C-C复合材料可以由已经使用各种致密化技术进行致密化的碳纤维预制体形成。例如,碳纤维预制体可以通过层叠由编织或非编织碳纤维形成的织物片材来形成,该碳纤维预制体随后可以通过如下方式致密化:使用真空压力渗透(VPI)和/或树脂传递模塑(RTM)来用液体沥青渗透该预制体,然后对该沥青进行碳化,以获得呈现出期望的最终密度的C-C复合材料。附加地或替代地,CVI/CVD可以用于使纤维预制体或另一种碳预制体致密化。在飞行器制动衬垫的情况中,在一些示例中,碳化的预制体可以采用环形环的形式,不过在其它示例中也可以使用其它形状。
依照本公开的一个或多个示例,碳纤维预制体可以包括多个单个的层,每个层由碳纤维和树脂形成。可以经由三维打印***的打印头使每个单个的层的树脂和碳纤维沉积。使用该三维打印***,各个层可以沿三个维度基于逐层的方式顺序地形成以产生具有例如期望几何结构的预制体。打印头的三维位置可以例如通过控制器得到自动的控制,该控制器在加工期间对控制臂进行控制以使得树脂和碳纤维所沉积的位置和取向可以被精确地控制以便限定具有期望性质(例如,具有期望几何结构)的多层碳纤维预制体。
如本文所描述的,可以控制沉积过程以使得得到的预制体呈现出以下中的至少一种(例如,以下中的一种、两种或所有三种):在预制体内的非一致的树脂的成分、在预制体内的不同的碳纤维的类型、或者在预制体内的非一致的纤维取向。例如,预制体的整个体积内的树脂成分可以例如根据碳纤维预制体的体积内的位置来变化,而不是大体地保持一致。作为另一个示例,预制体的整个体积内的纤维的类型(例如,聚丙烯腈(PAN)纤维与沥青纤维)可以例如根据碳纤维预制体的体积内的位置来变化,而不是在整个预制体内大体地保持一致。作为另一个示例,预制体的整个体积内的碳纤维关于纤维纵向轴线的取向可以例如根据碳纤维预制体的体积内的位置来变化,而不是在整个预制体内大体地保持一致。
可以使用三维打印过程精确地控制预制体的整个体积内的可变化的树脂的成分、预制体的体积内的可变化的碳纤维的类型和/或预制体的整个体积内的可变化的纤维取向,以便影响由该预制体形成的致密化的碳-碳复合材料的一个或多个性质。例如,可以选择预制体的整个体积内的可变化的树脂的成分、预制体的体积内的可变化的碳纤维的类型和/或预制体的整个体积内的可变化的纤维取向,以实现如下中的至少一种:修改由碳纤维预制体形成的致密化的碳-碳复合材料的摩擦性质、提高由碳纤维预制体形成的致密化的碳-碳复合材料的密度、或者提高由碳纤维预制体形成的致密化的碳-碳复合材料的强度。
附加地或替代地,可以选择预制体的整个体积内的可变化的树脂的成分、预制体的体积内的可变化的碳纤维的类型和/或预制体的整个体积内的可变化的纤维取向来修改碳-碳材料的一部分或全部发生氧化(尤其是关于催化氧化)的倾向。例如,可以通过提高制动盘的非摩擦表面附近的密度和/或降低制动盘的非摩擦表面附近的孔隙度来实现减少碳-碳复合材料在非摩擦表面处发生氧化的倾向。在一些示例中,使用本文所描述的技术的一种或多种,致密化的C-C复合制动盘可以在该盘的中心处或该盘的中心附近呈现出相对低的密度(例如,近似1.7克每立方厘米(g/cc)或更低),但在更靠近致密化的复合盘的一个或多个表面(例如,非摩擦表面)处呈现出大体上更高的密度(例如,近似1.9g/cc或更高)和/或更低的孔隙度。
作为另一个示例,可以选择预制体的整个体积内的可变化的树脂的成分、预制体的体积内的可变化的碳纤维的类型和/或预制体的整个体积内的可变化的纤维取向来提高C-C复合盘(或其它结构)的摩擦表面附近的、沿大体上垂直于该摩擦表面的方向的导热率以便允许更佳的离开该摩擦表面的热量流动。
在每个例子中,通过经由三维打印过程控制预制体的整个体积内的树脂的成分、碳纤维的类型和/或可变化的纤维取向,可以例如基于致密化的碳纤维预制体的具体应用来调整由这样的碳纤维预制体形成的致密化的碳-碳复合材料的性质。在一些情况中,为了防止氧化,C-C复合盘在非摩擦表面处的密度相比具有相对低的孔隙度(例如,大体上封闭的孔隙)可具有较低的重要性。在摩擦表面处的密度是重要的,但为了使从摩擦表面向盘的中心的热量传递达到期望的水平,可以减小C-C复合盘在摩擦表面处的密度,盘的中心可呈现出相对高的密度和热容量。在一些示例中,可以采用示例的技术来获得:在C-C复合盘的中心处或C-C复合盘的中心附近的高密度和/或高密度以便实现期望的热量吸收;在C-C复合盘的摩擦表面处的期望的摩擦系数连同在摩擦表面处的高摩擦稳定性和低磨损;以及呈现出相对高的抗氧化性的非摩擦表面,包括对催化氧化的抗性。
本公开的示例可以允许一个或多个优势。例如,在一些例子中,利用三维打印过程对预制体内的树脂成分、碳纤维的类型和/或纤维的取向进行的控制可以允许将预制体设计并且制造成例如在C-C复合结构的不同部分具有优选的性质区分。例如,对于由预制体形成的碳-碳复合制动盘,相比该盘的中心处或该盘的中心附近、相比非摩擦表面,摩擦表面附近关于纤维纵向轴线的不同的纤维取向可以允许对远离该摩擦表面的热量传递以及对在该盘体积的主体内的热量吸收进行优化。这可以通过沉积具有相对高的传热系数的纤维以使得该纤维的纵向轴线在摩擦表面附近沿垂直于摩擦表面的方向来取向而实现。所得到的碳-碳复合盘在凸起区域(lug area)中的强度可以通过依照应力分析软件的结果对纤维进行排布来改善。非摩擦表面区域的表面附近的纤维可被布置成使得促进了导致高密度和低孔隙度(限制碳的氧化尤其是催化氧化的两个参数)的致密化过程。
图1是示出了示例的组件10的概念图,组件10可以包括一个或多个依照本公开的技术形成的C-C复合材料部件。为了便于描述,将主要地关于C-C复合材料所形成的飞行器制动盘来描述本公开的示例。然而,本公开的C-C复合材料和碳纤维预制体可以用于形成除了飞行器制动盘之外的部件。例如,C-C复合材料可以用作在其它类型的制动应用中的摩擦材料,也可以用在航空航天工业中的或其它工业中的其它应用中,例如热交换器和热屏障。
在图1的示例中,飞行器制动组件10包括轮12、致动器组件14、制动栈16和轴18。轮12包括轮毂20、轮悬臂支架凸缘22、胎圈密封部24A和24B、长平头螺栓(lug bolt)26以及凸耳螺母(lug nut)28。致动器组件14包括致动器壳体30、致动器壳体螺栓32和撞锤34。制动栈16包括交替的转子盘36和定子盘38;转子盘36被构造成相对于定子盘38移动。转子盘36安装到轮12,并且具体地由梁键(beam key)40安装到轮毂20。定子盘38安装到轴18,并且具体地由花键44安装到转矩管42。轮组件10可以支撑任何种类的私人、商用或军用飞行器。
轮组件10包括轮18,该轮18在图1的示例中由轮毂20和轮悬臂支架凸缘22来限定。轮悬臂支架凸缘22由长平头螺栓26和凸耳螺母28机械地固定到轮毂20。轮12限定了胎圈密封部24A和24B。在组装期间,可充气的轮胎(未示出)可以置于轮毂20上并且由轮悬臂支架凸缘22固定在相对侧上。此后,凸耳螺母28可被拧紧在长平头螺栓26上,并且可充气的轮胎可被充气,胎圈密封部24A和24B为可充气的轮胎提供了气密的密封。
轮组件10可以经由转矩管42和轴18安装到飞行器。在图1的示例中,转矩管42由多个螺栓46固定到轴18。转矩管42支撑致动器组件14和定子38。轴18可以安装在起落架(未示出)的撑杆上以便将轮组件10连接到飞行器。
在飞行器的运行期间,可能时常需要进行制动,例如在降落和滑行期间。轮组件10被构造成经由致动器组件14和制动栈16向飞行器提供制动作用。致动器组件14包括致动器壳体30和撞锤34。致动器组件14可以包括不同类型的致动器,例如以下中的一种或多种:电子-机械致动器、液压致动器、气动致动器,等等。在运行期间,撞锤34可以延伸离开致动器壳体30以轴向地挤压制动栈16使其抵靠压缩点48来进行制动。
制动栈16包括交替的转子盘36和定子盘38。转子盘36由梁键40安装到轮毂20以便共同旋转。定子盘38由花键44安装到转矩管42。在图1的示例中,制动栈16包括四个转子和五个定子。然而,在其它示例中,在制动栈16中可以包括不同数量的转子和/或定子。进一步,转子和定子的相对位置可以颠倒过来,例如使得转子盘36安装到转矩管42并且定子盘38安装到轮毂20。
转子盘36和定子盘38可以提供用于制动飞行器的相对的摩擦表面。随着移动中的飞行器的动能转变成为制动栈16中的热能,在制动栈16中温度会迅速地提高,例如超过200摄氏度。对于一些飞行器,紧急制动(例如中断起飞)可以导致超过500摄氏度的温度,并且在一些情况中,甚至超过800摄氏度。如此,形成制动栈16的转子盘36和定子盘38可包括能够在这样的温度中运转的坚固耐用的、热稳定的材料。
在一个示例中,转子盘36和/或定子盘38由根据一个或多个本公开的示例技术(例如关于图6所描述的技术)所制造的C-C复合材料形成。具体地,转子盘36中的至少一个和/或定子盘38中的至少一个可以由致密化的C-C材料形成,该致密化的C-C材料由碳纤维预制体制成,该碳纤维预制体经由本公开的示例技术中的一个或多个形成。转子盘36和定子盘38可以由相同的材料或不同的材料形成。例如,轮组件10可以包括金属转子盘36和C-C复合定子盘38,或者反过来。进一步,转子盘36中的每个盘和/或定子盘38中的每个盘可以由相同的材料形成,或者定子盘38和/或转子盘36中的至少一个盘可以由与定子盘38和/或转子盘36中的至少一个其它的盘相比不同的材料形成。
如简要提到的,在一些示例中,转子盘36和定子盘38可以分别被梁键40和花键44安装在轮组件10中。在一些示例中,梁键40可以绕轮毂20的内部分周向地间隔。梁键40可以例如成型成具有相对的端部(例如,矩形的相对侧)并且可以使一个端部机械地固定到轮毂20的内部分并且使相对的端部机械地固定到轮毂20的外部分。梁键40可以与轮毂20一体成型或者可以与轮毂20是分开的并且机械地固定到轮毂20,以便例如在转子盘36和轮毂20之间提供热障。为了该目的,在不同的示例中,轮组件10可以包括热屏障(未示出),该热屏障径向地且向外地延伸出来包围制动栈16,以便例如限制在制动栈16和轮12之间的热传递。
在一些示例中,花键44可以绕转矩管42的外部分周向地间隔。花键44可以例如与转矩管42一体成型或者可以与转矩管42是分开的并且机械地固定到转矩管42。在一些示例中,花键44可以在转矩管42中限定侧向的槽。如此,定子盘38可以包括多个径向向内设置的凹口,该凹口被构造成被***到花键中。
因为梁键40和花键44可以分别与转子盘36和定子盘38热接触,梁键40和/或花键33可以由热稳定材料制成,该热稳定材料包括例如上面关于转子盘36和定子盘38所讨论的那些材料。相应地,在一些示例中,本公开的示例的技术可以用于形成用于轮组件10的梁键和/或花键。
图1所示的示例的组件10仅仅是一个示例。在其它示例中,组件10和组件10的部件(例如轮10、致动器组件14、制动栈16和轴18)可以具有另一种适合的构造。此外,在其它示例中,本文所描述的从示例的碳纤维预制体得到的C-C复合材料可以用于形成除了盘36、38、键40和花键44中的一个或多个以外或者替代盘36、38、键40和花键44中的一个或多个的其它结构。
图2是示出了依照本公开的方面的示例碳纤维预制体50的概念图。如所示,预制体50是具有内直径(ID)、外直径(OD)和沿z轴方向(为了便于描述,图2中示出了正交的x-y-z轴)的厚度(T)的环形环。碳纤维预制体50由基体52限定,并且包括多个单个的层(没有在图2中示出),该多个单个的层近似地沿x-y平面延伸且包括碳纤维和树脂。可以经由三维打印设备的打印头来使碳纤维和树脂沉积。在一些示例中,预制体可以具有大约4英寸(大约10.16cm)到大约18英寸(大约45.72cm)的内直径(ID)、大约10英寸(大约25.4cm)到大约30英寸(大约76.2cm)的外直径(OD)以及大约0.5英寸(大约1.27cm)到大约2.5英寸(大约6.35cm)的厚度(T)。可构想出其它范围和几何结构。
图3是示意图,示出了沿图2所示的截面A-A截取的预制体50。如所示,预制体50包括多个单个的层54X1、54X2、54X3、54X4、…和54XN,其中,N是沿z轴方向的单个的层的总数。这些层将共同地被称为层54。总体上,这些单个的层限定了预制体50沿z轴方向的厚度T。每个单个的层54由多个碳纤维53和树脂55形成。单个的层54的厚度可以取决于用于给定应用的复合材料的设计意图。在一些示例中,单个的层的厚度可以在近似25密耳(近似0.635毫米(mm))和近似125密耳(近似3.175毫米(mm))之间,不过可构想出其它的厚度。在一些示例中,预制体50的总厚度T可以在近似0.5英寸(近似1.27厘米(cm))到近似2.5英寸(近似6.35cm)之间,不过可构想出其它的厚度。
图4是示意图,示出了预制体50的层54X4沿x方向的截面,其代表了预制体50的各个单个的层54中的每个的构造。如所示,层54X4包括沿x轴方向并排排列的多个单个的行56X1、56X2、56X3、56X4、…和54Xy,其中,y为沿x轴方向的单个的行的总数。此外,每个单个的行56包括由三维打印***的打印头所沉积的多个碳纤维53和树脂55。行56相结合以沿x-y平面形成层54X4,层54X4也包括沿z轴方向的厚度。
行56可以以任何适合的构造来沉积以便沿x-y平面形成层54X4。例如,行56可以是以网格图案形成的线性的行、例如从预制体50的ID到OD的同心圆或者例如从预制体50的ID到OD的盘绕图案,该盘绕图案相比同心圆的图案可以允许树脂55和碳纤维53的连续沉积。各个行56可以每个具有任何适合的宽度和截面形状,这两者可以取决于三维(3D)打印头的设计并且可以基于由预制体形成的复合材料的设计意图来进行选择。在一些示例中,各个行56可以具有大体上圆形的、椭圆的、矩形的、三角形的或其它适合形状的截面(该截面沿x-y平面截取)并且可以具有近似5/16英寸(近似7.9375毫米(mm))到近似1/8英寸(近似3.175mm)的宽度。在一些示例中,每个层54的行56可以在至少一个维度中是一致的,而在其它示例中,至少两个行56可以具有与彼此不同的构造(例如沿x轴方向测量的不同的宽度)。
预制体50可以包括多个碳纤维53。可以使用任何适合的类型的碳纤维,例如PAN纤维、沥青纤维、氧化的PAN、从PAN衍生的碳纤维、从沥青衍生的碳纤维、人造纤维等。碳纤维可以在制成的复合材料中提供结构强度。碳纤维可以每个为单一丝状体或为碳纤维束(fiber tow)。在一些示例中,纤维或纤维束的长度可从大约0.1英寸(大约2.54毫米)变化成大体上连续的(例如连续的)。此外,在一些示例中,每个碳丝状物的直径可以小于或等于例如大约20微米。在一些示例中,预制体50内的纤维的长度可以沿预制体的厚度T而变化。例如,预制体50的外表面附近的纤维可以每个具有近似0.25英寸(近似6.35mm)的长度,而预制体50的几何中心附近的纤维可以具有近似3英寸(近似7.62cm)或更短的长度。
预制体50还包括树脂55。可以使用用于形成预制体50的任何适合的树脂。例如,树脂可以是可碳化的树脂或沥青(例如各向同性沥青和/或中间相沥青)以使得在碳化过程期间从树脂形成碳。示例的树脂类型包括但不限于合成的煤焦油、石油、各向同性的和中间相的沥青、酚醛树脂、环氧树脂或其它碳产出树脂(carbon yielding resin)。
在一些示例中,树脂可以包括沥青。沥青可以是富烃材料,其可以从例如煤焦油和石油中提取。在一些示例中,沥青还可以被合成制造。在不同的示例中,沥青可以来自单一来源(例如煤)或可以是来自不同来源的不同沥青的组合。在一些示例中,沥青可以是中间相沥青。在其它示例中,沥青可以是各向同性的沥青。还可构想出中间相的和各向同性的沥青的组合。
在一些示例中,沥青55可以包括一种或多种添加材料。示例的添加物可以包括碳化硅粉末、炭黑、石墨粉、氧化钛、二氧化硅粉末(随后将经过合适的热处理转变成碳化硅)以及类似的材料。
如本文所描述,可以经由三维打印过程使层54的树脂55和碳纤维53沉积以使得碳纤维预制体50呈现出如下中的至少一种:在其体积内的非一致的树脂的成分、在其体积内的不同的碳纤维的类型、或者在其体积内的非一致的纤维取向。例如,树脂成分、碳纤维的类型和/或纤维取向可以关于预制体50内的各个层54基于逐层的方式而不同。附加地或替代地,树脂成分、碳纤维的类型和/或纤维取向在预制体50的单一个体的层54内可以不同。
可以基于具体的位置来选择预制体50的体积内的具***置处的具体的树脂成分、纤维类型和/或纤维取向。例如,沿z轴方向更靠近预制体50的中心处的树脂成分、纤维类型和/或纤维取向可以不同于沿z轴方向更靠近预制体50的顶部或底部表面处的树脂成分、纤维类型和/或纤维取向。在一些示例中,可以选择沿z轴方向更靠近预制体50的中心处的树脂成分、纤维类型和/或纤维取向来在由预制体50形成的致密化的C-C复合物中提供相对高的密度和热容量,而靠近预制体50的摩擦表面处的树脂成分、纤维类型和/或纤维取向可以在由预制体50形成的致密化的C-C复合物中提供较低密度的材料,该较低密度的材料提供了在摩擦和磨损性能之间的期望的平衡。作为另一个示例,可以选择预制体50在外周界(或OD)表面区域和内周界(或ID)区域(例如凸起区域)附近的部分中的树脂成分、纤维类型和/或纤维取向,以便相比致密化的C-C复合物的其它部分提高在致密化的C-C复合材料中的那些部分的强度。
在一些示例中,树脂55可以在成分方面从预制体50的一个部分到预制体50的另一个部分发生变化以使得树脂在预制体50内是非一致的而不是在整个预制体50内是大体上一致的。例如,单个层54X1中的预制体所具有的成分可以不同于单个层54X4中的预制体55的成分。替代地或附加地,单个层54X1的一个部分内的树脂55相比单个层54X1的另一个部分内的树脂55可以具有不同的成分。树脂成分就所使用的树脂的具体类型(例如沥青相比酚醛树脂)而言可以不同。例如,单个层54X1中的树脂55可以是沥青,而单个层54X4中的树脂55可以是酚醛树脂。
当树脂55包括多种树脂类型的混合物和/或树脂与一种或多种添加物的混合物时,树脂成分还可以就成分内的组分的浓度而言不同。例如,单个层54X1中的树脂55可以是80%重量百分比(wt%)的沥青与20 wt%的酚醛树脂的混合物,而单个层54X4中的树脂55可以是5 wt%的沥青与95 wt%的酚醛树脂的混合物。作为另一个示例,单个层54X1中的树脂55可以是80 wt%的沥青与20 wt%的添加物的混合物,而单个层54X4中的树脂55可以是95 wt%的沥青与5 wt%的添加物的混合物。
可以调整预制体50内的非一致的树脂55的成分以使得由预制体50形成的C-C复合材料可以呈现出一个或多个期望的性质。例如,相比由具有大体上一致的成分的预制体50会呈现出的性质,预制体50内的非一致的树脂55的成分可以导致通过对预制体50进行碳化和致密化(例如,经由CVI/CVD)而形成的C-C复合材料的一个或多个性质的修改。
作为一个示例,可以选择并控制预制体50内的非一致的树脂55的成分以便对由预制体50形成的致密化的C-C复合物内的一个或多个位置处的密度相比该致密化的C-C复合材料内的其它位置的密度进行提高。例如,可以选择沿z轴方向在预制体50的几何中心附近或在预制体50的几何中心处的预制体50的层54中的树脂55的成分,以便在预制体50已经被碳化并且致密化从而形成致密化的C-C盘之后在该位置处相比更靠近预制体50的顶部和底部表面的层提供相对高密度的材料(例如大于大约1.85g/cc)。作为一个示例,诸如中间相沥青的具有相对高的碳产出的树脂成分可以被沉积在更靠近几何中心的预制体50的层中,以便例如相比沉积在C-C复合盘的一个或多个其它部分处的具有相对低的碳产出的树脂成分,在由预制体50形成的致密化的C-C复合盘的对应位置中提供高的密度。在一些示例中,高碳产出树脂可以产出大约80%到90%的碳,并且/或者低碳产出树脂可以产出小于大约50%的碳。
在这种方式中,C-C复合盘可以形成为具有在整个体积内的经调整的密度。例如,相比从相对于更靠近外表面的那些部分提供了较低密度的中心部分的预制体制造C-C复合盘的其它制造技术,在预制体的中心部分处沉积的高碳产出树脂成分可以允许在由预制体形成的整个C-C复合盘内的大体上一致的密度。在一些示例中,示例的C-C复合盘的密度可以在盘的整个体积内以小于近似2个百分点进行变化。在一些示例中,由预制体50形成的C-C复合材料的中心部分中的比热容可以大于或等于近似0.72千焦/千克开尔文(kJ/kg K)。
还可以控制预制体50内的非一致的树脂55的成分,以便例如相比更靠近中心的部分来修改由预制体50形成的致密化的C-C复合材料在对应于沿z轴方向的预制体50的顶部和底部表面处或附近的各个层54的那些部分中的一个或多个摩擦性质。至于预制体50,沿z轴方向的顶部和底部表面可以对应于由预制体50形成的致密化的C-C复合材料的摩擦表面区域。摩擦表面区域(也被称为工作表面区域)通常对应于制动盘或其它摩擦部件的表面部分,不同于非摩擦表面区域,摩擦表面区域在制动操作期间与相对的制动盘或其它相对的摩擦部件摩擦性地接合。至于由预制体50形成的C-C复合制动盘,摩擦表面区域可以对应于环形环的外面,并且非摩擦表面区域54可以对应于外周界(或OD)表面区域和内周界(或ID)区域(例如凸起区域)。
在一些示例中,可以选择预制体50的对应于由预制体50所形成的C-C复合物的摩擦表面区域的那些部分处或附近的层中的树脂55的成分以便平衡C-C复合结构的摩擦和磨损性能。至于制动盘,除了相对低的并且一致的磨损率之外,C-C复合物的摩擦表面区域的期望的性质还可以包括呈现在该表面处的优选的摩擦系数(例如从大约0.1到大约0.3),但更重要地是摩擦的稳定性,即力矩曲线(作为制动器转动速度的函数而绘出的力矩)的稳定性。对于C-C复合制动盘,可能希望在从开始制动应用到飞行器或其它运输工具完全停止的每次制动接合期间维持稳定性,并且可能希望在制动接合的整个范围内关于速度、能量、温度、环境条件等维持制动应用的稳定性。
在一些示例中,在这样的部分中的树脂55的成分可以例如通过提高整个摩擦表面的磨损率的一致性来提高该摩擦表面的一致性。在一些示例中,特定的树脂成分可以导致摩擦表面的磨损率更少地取决于温度。例如,由预制体50形成的C-C复合材料在低操作温度与高操作温度下的摩擦表面的磨损率之间的差异可以小于由如下的预制体形成的C-C复合材料,该预制体使用该树脂成分,该树脂成分被用在更靠近预制体55的中心的那些部分中以提供相对高的密度和/或热容量。
在一个示例中,预制体50的对应于由预制体50所形成的C-C复合物的摩擦表面区域的那些部分处或附近的层中的树脂55的成分可以是酚醛树脂和沥青的混合物。在一些示例中,可以选择在所得到的致密化的C-C复合材料中提供了中间相结构的沥青。该沥青通常可以提供所得到的致密化的C-C复合材料的高密度、较低的磨损和高摩擦性能。例如相比沥青,酚醛树脂可以提供在所得到的致密化的C-C复合材料中主要是各向同性的碳并且可以提供期望的磨损性能而不是摩擦性能。
可以选择该混合物中的每种树脂的具体的量以便在摩擦表面区域处提供摩擦和磨损性能之间的平衡。在一些示例中,预制体50的对应于由预制体50所形成的C-C复合物的摩擦表面区域的那些部分处或附近的层中的树脂55的成分可以包括近似10 wt%到近似100wt%的中间相沥青(例如近似70 wt%到近似90 wt%的中间相沥青)以及近似0 wt%到近似90wt%的酚醛树脂(例如近似10 wt%到近似30 wt%的酚醛树脂)。在一些示例中,可以在树脂成分中使用环氧树脂来代替酚醛树脂或者除了酚醛树脂之外也使用环氧树脂。
在一些示例中,可以使用各向同性的沥青来代替中间相的沥青或作为中间相的沥青的替代物。通常地,中间相沥青可以被碳化以生成石墨化碳,而酚醛树脂生成各向同性的碳。可以修改这两种树脂类型之间的比率以实现期望的摩擦和磨损性能。来自中间相树脂的石墨碳在高能量条件下将趋于提高磨损并且提高摩擦,而来自酚醛树脂的各向同性的碳将趋于减小摩擦并且减小磨损率。
除了预制体50内的非一致的树脂成分之外或作为其替代,碳纤维53的纤维类型和/或纤维取向可以从预制体50的一个部分到预制体50的另一个部分发生变化,以使得纤维类型和/或纤维取向在预制体50内是非一致的而不是在整个预制体50内是大体上一致的。例如,单个的层54X1中的纤维53的类型可以不同于单个的层54X4中的纤维53的类型。纤维类型可以就纤维的成分(例如沥青纤维与PAN纤维)而言不同。例如,单个的层54X1中的纤维53可以是PAN纤维,而单个的层54X4中的纤维53可以是沥青纤维。
不同的纤维类型还可以包括两种或更多种纤维类型的混合物,在该混合物中各个纤维类型以不同的量存在。例如,单个的层54X1中的纤维53可以是80%重量百分比(wt%)的沥青纤维和20 wt%的PAN纤维的混合物,而单个的层54X4中的纤维53可以是5%wt%的沥青纤维和95 wt%的PAN纤维的混合物。替代地或附加地,单个的层54X1的一个部分内的纤维53相比单个的层54X1的另一个部分内的另一纤维53可以是不同的类型。
作为另一个示例,单个的层54X1中的纤维53的取向可以不同于单个的层54X4中的纤维53的取向。可以关于在图2-4中就预制体50示出的x-y-z轴来表示纤维53的取向。例如,单个的层54X1中的大体上所有的纤维53的纵向轴线可以大体上沿预制体50的x-y平面延伸,而单个的层54X4中的纤维53的纵向轴可以呈现出更大程度的z轴方向的取向,例如其中,单个的层中的一些纤维或大体上所有的纤维可以沉积成使得纤维的纵向轴线大体上沿着(例如沿着或几乎沿着)碳纤维的纵向轴线延伸到x-y平面外并且延伸到z轴方向中。替代地或附加地,单个的层54X1的一个部分内的纤维53相比单个的层54X1的另一个部分内的纤维取向可以具有不同的取向。
可以调整预制体50内的不同的纤维53的类型和/或非一致的纤维53的取向以使得由预制体50形成的C-C复合材料可以呈现出一个或多个期望的性质。例如,相比具有大体上相同的纤维53的类型和/或大体上一致的纤维53的取向的预制体50会呈现出的性质,预制体50内的不同的纤维53的类型和/或非一致的纤维53的取向可以导致通过对预制体50进行碳化和致密化(例如,经由CVI/CVD)而形成的C-C复合材料的一个或多个性质得到修改。
作为一个示例,可以控制预制体50内的不同的纤维53的类型和/或非一致的纤维53的取向以便对由预制体50形成的致密化的C-C复合物内的一个或多个位置处的密度相比该致密化的C-C复合材料内的其它位置的密度进行提高。例如,相比更靠近预制体50的顶部和底部表面的层54中的纤维的类型,沿z轴方向在预制体50的几何中心处或附近的预制体50的层54中的纤维53的类型可以呈现出相对高的密度,例如沥青纤维。高密度纤维的示例可以是由中间相沥青制造的碳纤维,其可以呈现出例如近似1.9g/cc到近似2.18g/cc的密度。
替代地或附加地,相比更靠近预制体50的顶部和底部表面的层54中的纤维53的纤维体积分数,沿z轴方向在预制体50的几何中心处或附近的预制体50的层54中的纤维53的取向可以提供相对高的纤维体积分数(例如近似30%到近似50%)。在这样的情况中,在预制体50已经被碳化并且致密化从而形成致密化的C-C复合物之后,致密化的C-C复合物相比更靠近顶部和底部表面的部分的密度可以在更靠近中心的部分处呈现出相对高的密度。例如,致密化的C-C复合物可以在中心处或附近呈现出近似1.9g/cc或更大的密度并且可以在更靠近顶部和底部表面的部分处呈现出近似1.85g/cc或更小的密度。
作为另一个示例,可以控制预制体50内的不同的纤维53的类型和/或非一致的纤维53的取向,以便例如相比更靠近中心的部分来修改由预制体50形成的致密化的C-C复合材料在对应于沿z轴方向的预制体50的顶部和底部表面处或附近的各个层54的那些部分中的一个或多个摩擦性质。如上面所描述的,至于预制体50,沿z轴方向的顶部和底部表面可以对应于由预制体50形成的致密化的C-C复合材料的摩擦表面区域,并且非摩擦表面区域可以对应于预制体50的外周界(或OD)表面区域和内周界(或ID)区域,例如凸起区域。
在一些示例中,可以选择预制体50的对应于由预制体50所形成的C-C复合物的摩擦表面区域的那些部分处或附近的层中的纤维53的取向和/或类型以便平衡摩擦和磨损性能。例如,这样的部分中的纤维53可以取向成使得纤维的纵向轴线大体上沿预制体50的x-y平面延伸。至于制动盘,例如,具有沿x-y取向的纵向轴线的纤维53,尤其是具有与使用中的制动盘的相对运动方向正切的纵向轴线的纤维53,将降低磨损率。相反,跨越预制体50的摩擦表面和中心之间的部分的纤维53可以取向成以便提高沿预制体50的z轴方向延伸的纤维的比例,以便例如促进从摩擦表面到预制体50的中心部分的热传导。
附加地或替代地,预制体50的对应于由预制体50所形成的C-C复合物的摩擦表面区域的那些部分处或附近的层中的纤维53可以是PAN纤维,而相比之下,更靠近预制体50的中心的纤维53可以是中间相沥青纤维。中间相沥青纤维在热处理后相比各向同性的PAN纤维可以具有更大的热导率,从而在预制体50的中心部分中相比更靠近摩擦表面的部分提供了更高的热导率。PAN纤维相比沥青纤维可以有更少的取向性,从而是更加各向同性的。而且,PAN纤维相比沥青纤维具有更高的强度,并且因此它们是更加耐磨损的。
作为另一个示例,可以控制预制体50内的不同的纤维53的类型和/或非一致的纤维53的取向以便提高由预制体50形成的致密化的C-C复合材料的选定部分的强度。例如,对应于由预制体50形成的C-C复合制动盘的凸起区域(例如在制动盘的ID和/或OD处)的预制体50的那些部分可以经由那些区域中的纤维53的类型和/或取向而被加强,以便有助于在作为C-C制动盘的操作期间承受施加到那些部分的相对大的力。在一些示例中,在对应于这样的凸起区域的预制体50的那些部分处,纤维53的纵向轴线可以大体上均匀地在预制体50的x-y平面和预制体50的z-方向之间取向,相比之下,在摩擦表面处或附近的部分中的那些纤维53可以大体上全部地沿大体上预制体50的x-y平面取向,或者更靠近预制体50的中心部分的纤维50可以取向成使得该纤维的纵向轴线大体上沿预制体50的z轴方向延伸。在这种方式中,由预制体50形成的致密化的C-C复合制动盘的凸起区域相比在摩擦表面处或附近的部分或更靠近复合物的中心的那些部分可以呈现出提高的强度。在一些情况中,PAN纤维由于该纤维的相对高的强度在凸起区域中可以是优选的。
可以采用任何合适的***和技术来经由3D打印***的打印头使树脂55和/或碳纤维53沉积以产生所描述的预制体50的示例和由其形成的致密化的C-C复合材料。下面进一步描述了可以采用的***和技术的示例。然而,可构想出其他示例和***。在一些示例中,可以采用各自均在2015年5月13日提交的美国专利申请序列号14/711,550、14/711,508、14/711,590中所描述的用于形成碳纤维预制体和致密化的C-C复合材料(例如C-C复合制动盘)的3D打印***和技术中的一个或多个来形成本文所描述的一个或多个示例的预制体和C-C复合材料。这些申请中的每个的全部内容通过引用合并到本文中。
在一些示例中,可以经由打印头使树脂55和碳纤维53以熔化的状态(熔化的复合材料)沉积(例如,沉积在已有的碳纤维的层上和/或使碳纤维与树脂和添加物粉末一起沉积),树脂55和碳纤维53随后可以固化以形成相应的层54(或例如以行的形式形成层的一部分),接着另外的树脂55和碳纤维53在该相应的层上进行沉积以便形成包括碳纤维和复合混合物的另外的层。在其它示例中,可以经由三维打印***的打印头通过使每个均涂覆有树脂55的多个单个的碳纤维53沉积来形成碳纤维预制体50的各个层54。在一些示例中,三维打印***可以采用挤出工艺来将树脂53涂覆于大体上连续的(例如连续的或几乎连续的)碳纤维丝,并且随后将该经涂覆的丝切割成涂覆有树脂55的单个的碳纤维53。在每种情况中,可以控制该三维打印沉积过程以使得预制体50在预制体50的体积内呈现出如本文所描述的如下中的至少一种:非一致的树脂成分、不同的纤维类型或非一致的纤维取向。
经由任一过程所产生的碳纤维预制体可以随后被碳化和致密化以产生致密化的碳-碳复合材料,例如碳制动盘。在一些示例中,在3D打印过程期间,碳纤维53和树脂55的各个层54可以例如基于逐层的形式形成并进行致密化,而不是形成碳纤维53和树脂55的所有层接着对这些层整体进行致密化。
图5是示意图,示出了示例的三维打印***60,该三维打印***60可以例如用于经由增材制造过程形成预制体50。可以使用构造成利用3D打印或其它增材制造技术来使树脂55和/或纤维53沉积而形成预制体50的任何适合的***。为了便于描述,按照挤出沉积***来描述***60。然而,可构想出用于形成预制体50的其它***。
如所示,***60包括第一树脂供给装置62和第二树脂供给装置63,第一树脂供给装置62被构造成将第一树脂供给到挤出装置64,第二树脂供给装置63被构造成将第二树脂供给到挤出装置64,第二树脂具有不同于第一树脂的成分。第一和第二树脂成分可以是预制的颗粒状物的形式或者是预制的树脂成分的盘绕环的形式。挤出装置64可以被构造成将每个树脂成分加热到使该树脂熔化(例如成为液体状态或者以其它方式使复合混合物55软化)的温度,在该温度下树脂熔化成使得允许被加热的材料流动到由可移动打印头68限定的一个或多个出口之外。在一些示例中,仅第一树脂供给装置62将树脂55供应给挤出装置64以便进行沉积,仅第二树脂供给装置63将树脂55供应给挤出装置64以便进行沉积,或者第一树脂供给装置62和第二树脂供给装置63两者同时均将树脂供应到挤出装置64,或者对于给定的层54(图2)允许对第一和第二树脂的混合物进行沉积。以这种方式,使用***60所形成的预制体50可以在整个预制体50内呈现出非一致的树脂成分。
流动到打印头68外的材料可以沉积在工作表面66上,例如要么直接地要么非直接地沉积在先前已沉积的树脂55和纤维53的一个或多个层上。可以允许所沉积的材料进行冷却以形成树脂和/或纤维的固体的层,并且可以通过在工作表面66上方沿三个维度调整打印头68的位置来重复该过程,该工作表面66在整个三维打印过程中支撑所沉积的层。在该打印过程期间,可以经由打印头66基于连续或非连续的方式使树脂55沉积。在一些示例中,可以以十字头挤出***实施该熔化和挤出步骤。
虽然主要关于树脂55的沉积对图5的打印***60的示例进行了描述,但在一些示例中,来自第一树脂供给装置62和/或第二树脂供给装置63的树脂55还可以包括与树脂55混合的碳纤维53,以使得经由打印头68进行的树脂55的沉积可以包括随同树脂55一起的碳纤维53的沉积。第一树脂供给装置62中的碳纤维的类型可以不同于第二树脂供给装置63中的碳纤维的类型,以便例如提供在整个预制体50内的不同类型的碳纤维53。替代地或附加地,可以使碳纤维53与树脂53分开地进行沉积,例如使碳纤维53作为预制的碳纤维织物段或作为经由打印头68通过使纤维材料沉积而形成的纤维53来进行沉积,以使得该纤维具有期望的取向和/或具有期望的纤维类型。
在图5所示出的示例中,***60包括控制器70,在3D打印过程期间,该控制器70可以控制***60的运行以便提供具有期望的几何结构和成分的预制体50。例如,在进行沉积期间,控制器70可以对附接到可移动打印头68的控制臂72的运动进行控制,以便控制可移动打印表面68相对于工作表面66的位置。在这种方式中,控制器70可以控制可移动打印头68相对于已经离开打印头68的树脂55的相对位置以便例如通过对树脂55和纤维53的各个行56进行沉积来形成预制体50的各个层54,以使得预制体50呈现出期望的三维几何结构。可以采用步进电机或伺服电机来使打印头68移动并且调整树脂55到打印头68外的流动。控制器70可以被构造成对控制器臂72的位置进行控制以便使打印头66沿x轴和y轴方向移动,并且在一些示例中,使打印头66沿z轴方向移动。此外,控制器70可以控制增材沉积过程的一个或多个其它的要素,例如***60内的一个多个位置处的树脂55的温度、从供给装置62到挤出装置64的复合树脂55的供给的时机、打印头68的位置和/或树脂55到打印头68外的流动速率。
在一些示例中,控制器70可以包括一个或多个微处理器,该一个或多个微处理器能够响应接收到的和/或所储存的数据来执行和/或输出命令信号。控制器70可以包括一个或多个处理器,该一个或多个处理器包括一个或多个微处理器、数字信号处理器(DSP)、专用集成电路(ASIC)、现场可编程门阵列(FPGA)或任何其它的等效的集成或分立逻辑电路,以及此类部件的任意组合。术语“处理器”或“处理电路”通常可以指的是任意前述的逻辑电路、逻辑电路自身或与其它逻辑电路的组合、或者任何其它的等效的电路。控制器70可以包括计算机可读存储器,例如只读存储器(ROM)、随机存取存储器(RAM)、和/或闪速存储器、或用于运行应用和处理数据以便控制涉及***60的操作的任何其它部件。因此,在一些示例中,控制器70可以包括指令和/或数据,这些指令和/或数据在一个或多个存储器、储存设备和/或微处理器内以硬件、软件和/或固件的形式进行储存。在一些示例中,控制器可以使用在微控制器上运行的计算机辅助制造(CAM)软件包来控制打印头66。控制器60可以包括多个控制器或仅包括单一控制器。
图6是流程图,示出了依照本公开的方面形成预制体50并且随后由该预制体50形成致密化的C-C复合材料的示例技术。为了简化说明,使图6的示例经由图5的***60进行执行来对图6的示例进行描述。然而,在一些示例中,图6所示的技术能够由适合用于实施碳预制体50的3D打印的其它***来执行。
如所示,在控制器70的控制下,打印头68使来自第一树脂供给装置62的第一树脂/碳纤维复合混合物沉积在例如沿x-y平面形成的碳纤维的层上,以便在工作表面66上形成树脂55和纤维53的第一层,例如层54X1(82)。这样的过程可以包括形成各个行(例如,对应于图4所示的用于层54X4的行56)以便沿x-y平面形成树脂55和纤维53的层54X1。控制器70可以在整个过程中控制打印头68的位置以便提供期望的层的几何结构。
在树脂55和碳纤维53的第一层已经冷却以固化该层之后,在控制器70的控制下,打印头68使来自第二树脂供给装置63的第二树脂/碳纤维复合混合物沉积以便在第一层54X1上形成复合材料52的第二层(层54X2)(84)。在这种方式中,在第一树脂供给装置62的树脂成分不同于第二树脂供给装置63的树脂成分的情况中,可以认为第一和第二层的组合中的树脂55的成分是非一致的。类似地,在第一树脂供给装置62中的纤维的类型不同于第二树脂供给装置63中的纤维的类型的情况中,可以认为第一和第二层的组合中的纤维53的类型是不同的。
重复该过程来形成预制体50的层54X1、54X2、54X3、54X4、…和54XN,其中,每一层形成自第一树脂供给装置62、第二树脂供给装置63或者形成自第一树脂供给装置62和第二树脂供给装置63的组合(86)。再者,控制器70可以在整个沉积过程中沿三个维度(或者更多维度)控制打印头68的位置,以使得树脂/碳纤维混合物的层54X1、54X2、54X3、54X4、…和54XN的组合形成具有期望的三维几何结构的预制体50。而且,控制器70可以在整个过程中控制被沉积的树脂成分的类型和/或纤维的类型,以便例如提供在整体上具有非一致的树脂成分和/或不同的树脂的类型的预制体,从而提供本文所描述的性质中的一个或多个。在对纤维进行沉积时,控制器70可以通过经由控制器70来控制打印头68的取向而控制纤维取向。
随后,可以例如通过将多层碳纤维预制体50的温度加热到近似550摄氏度至近似2450摄氏度而使该预制体50碳化(88)。在碳化过程期间,发生树脂和纤维组分的热解,并且更高分子量的组分被分解成各种气体和碳。碳保留在被碳化的组分中而气体被基本消除(例如被消除或几乎被消除)。
多层预制体50的碳化过程(88)之后,可以使用化学气相沉积(CVD)/化学气相渗透(CVI)来用含碳材料使碳化的预制体致密化(90)。例如,碳化的预制体可以经历一个或多个周期的CVD/CVI以便填充预制体50中的空隙,该空隙是在碳化过程期间由于气体的析出而产生的。碳化的预制体可以经历一个或多个周期的CVD/CVI直到材料呈现出期望的密度。例如,这样的材料可以呈现出大于1.7克每立方厘米(g/cc)的密度,例如在近似1.75g/cc和近似1.90g/cc之间的密度。
在一些CVD/CVI的示例中,在蒸馏瓶中、在惰性气体的覆盖下以例如低于100托的压力加热碳化的预制体。当碳化的预制体达到大约900摄氏度和大约1200摄氏度之间的温度时,惰性气体被替换成含碳的气体,例如天然气、甲烷、乙烷、丙烷、丁烷、丙烯、或乙炔、或这些气体中的至少两种的组合。当该含碳的气体围绕并流动通过碳化的预制体时,发生一系列复杂的脱氢、缩合和聚合反应,由此使碳原子在碳化的预制体内部沉积并且沉积到碳化的预制体的表面上。经过一段时间,随着越来越多的碳原子沉积到碳化的预制体中的孔隙的表面上,该碳化的预制体变得更加致密。这个过程可以被称为致密化,因为碳化的预制体中的间隙空间最终由碳基体填充,直到大体上形成固体的碳部分。美国专利No.7,332,195(Arico等)提供了能够与本文所描述的技术一起使用的示例的CVD/CVI过程的概述,该专利的全部公开内容通过引用合并到本文中。在其它示例中,可以使用其它技术来使预制体50致密化。
已经描述了用于形成碳纤维预制体的不同的技术的示例。在不同的示例中,可以在不同的硬件、软件、固件或这些的任意组合中实施本公开的技术。在一些示例中,可以在一个或多个处理器内实施本公开的技术,该一个或多个处理器包括一个或多个微处理器、数字信号处理器(DSP)、专用集成电路(ASIC)、现场可编程门阵列(FPGA)、或任何其它等效的集成或分立的逻辑电路,以及此类部件的任何组合。在一些示例中,本公开的技术还可以被具体体现或编码在计算机可读介质(例如计算机可读存储介质)中,从而包含指令。被嵌入或编码在计算机可读存储介质中的指令可以导致可编程处理器或其它处理器来执行该方法,例如当运行该指令时。计算机可读存储介质可以包括随机存取存储器(RAM)、只读存储器(ROM)、可编程只读存储器(PROM)、可擦可编程只读存储器(EPROM)、电可擦可编程只读存储器(EEPROM)、闪速存储器、硬盘、CD-ROM、软磁盘、盒带、磁性介质、光学介质、或其它计算机可读介质。
已经描述了各种示例。这些示例和其它示例在所附权利要求的范围内。
Claims (3)
1.一种方法,包括经由三维打印***的打印头使树脂和多个碳纤维沉积来形成包括多个单个的碳纤维层的碳纤维预制体,其中,所述多个单个的碳纤维层中的每个单个的层包括树脂和碳纤维,并且其中,所述碳纤维预制体呈现出如下中的至少一种:在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向。
2.如权利要求1所述的方法,其中,在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向中的至少一种被构造成实现如下中的至少一种:修改由所述碳纤维预制体形成的致密化的碳-碳复合材料的摩擦性质、提高由所述碳纤维预制体形成的致密化的碳-碳复合材料的密度、或者提高由所述碳纤维预制体形成的致密化的碳-碳复合材料的强度。
3.一种碳纤维预制体,包括多个单个的碳纤维层,其中,所述多个单个的层中的每个单个的层包括树脂和多个碳纤维,并且其中,所述碳纤维预制体呈现出如下中的至少一种:在所述预制体内的非一致的树脂的成分、在所述预制体内的不同的碳纤维的类型、或者在所述预制体内的非一致的纤维取向。
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