Abstract: Novel carbon-carbon laminate composite materials capable of significantly increased strengths in at least one predetermined direction of load are disclosed. The composites can comprise plies of resin impregnated woven carbon or graphite cloth material in combination with resin impregnated carbon or graphite filament unidirectional tape or can be fabricated from the unidirectional tape alone. Generally the unidirectional reinforcement of the tape plies provides higher strengths and moduli in specific directions which can be controlled during lay up of parts. The processes for obtaining the beneficial increase strength of unidirectional tape ply materials while avoiding fabrication problems resulting therefrom are also disclosed.

Abstract: A co-pyrolysis process is disclosed for forming carbonized composite bodies in which co-pyrolysis of organic fibrous and matrix components is effected during initial pyrolysis. Improved interfacial bonding of composite bodies is achieved by combining fibrous precursors, or reinforcements with a controlled pre-shrink state, with an appropriate matrix to insure shrinkage matching during processing. Processing involves the heat treatment of an organic fibrous component, impregnation of the heat treated fibrous component with a resinous binder, forming a layup of the resin impregnated fibrous component, subjecting the layup to molding and curing cycles to form a laminate, pyrolysis of the laminate, and post-pyrolysis heat treatment of the pyrolized laminate.