Chemical Vapor Infiltration (i.e., Cvi) Of Porous Base (e.g., Fiber, Fibrous Web, Etc.) Patents (Class 427/249.2)
  • Patent number: 10913687
    Abstract: A composite material part includes a fiber preform forming fiber reinforcement including a stack of at least two fiber plies, each of the fiber plies being made of an interlock weave three-dimensional fabric and each of the fiber plies having a number of warp yarn layers or a number of weft yarn layers that is greater than or equal to three; and a matrix present in the pores of the fiber preform.
    Type: Grant
    Filed: September 15, 2016
    Date of Patent: February 9, 2021
    Assignee: SAFRAN AIRCRAFT ENGINES
    Inventor: Bruno Jacques Gérard Dambrine
  • Patent number: 10710341
    Abstract: The present invention concerns a shaped composite material and a method for producing it. More specifically, the invention concerns a disc for a disc brake made from ceramic composite materials, usually known as “CMC”, i.e. “Carbon Material Ceramic” or “CCM”, i.e. “Carbon Ceramic Material”. These materials consist of carbon matrices containing carbon fibres usually infiltrated with silicon and a product of reaction between C and Si, silicon carbide (SiC). More specifically, the invention concerns a shaped composite material comprising a inner layer (3; 103) of CCM C/SiC/Si material comprising disorderly short filaments consisting mainly of carbon and respective outer layers (2, 2?; 102, 102?) of C/SiC/Si material and having an orderly fabric structure of mainly carbon fibres.
    Type: Grant
    Filed: May 16, 2012
    Date of Patent: July 14, 2020
    Assignee: Petroceramics S.p.A.
    Inventor: Massimiliano Valle
  • Patent number: 10676824
    Abstract: An enclosed-channel reactor system is provided, which includes: a reactor body having a plurality of enclosed channels therein; an upper cap disposed at one end of the reactor body and having an inlet port communicating with the plurality of enclosed channels; a lower cap disposed at the other end of the reactor body opposite to the upper cap and having an outlet port communicating with the plurality of enclosed channels; and at least a conduit plate disposed between the upper cap and the reactor body for guiding a precursor injected from the inlet port into the plurality of enclosed channels uniformly.
    Type: Grant
    Filed: April 18, 2016
    Date of Patent: June 9, 2020
    Assignee: National Tsing Hua University
    Inventors: Tsong-Pyng Perng, Chi-Chung Kei, Chien-Pao Lin, Mrinalini Mishra, Sheng-Hsin Huang, Kuang-I Liu, Yu-Hsuan Yu
  • Patent number: 10443124
    Abstract: A process and an apparatus for densifying a porous structure is disclosed. The porous structure comprises a first surface, a second surface, an inner diameter surface and an outer diameter surface. The process may comprise progressive densification in conjunction with thermal gradient and/or pressure gradient densification processes.
    Type: Grant
    Filed: September 9, 2010
    Date of Patent: October 15, 2019
    Assignee: GOODRICH CORPORATION
    Inventors: Mark James Purdy, John Edgar Finley, Mark Russell Wolke, James Warren Rudolph, Timothy Patrick Smith
  • Patent number: 10392696
    Abstract: An installation for chemical vapor infiltration of porous preforms of three-dimensional shape extending mainly in a longitudinal direction, the installation comprising a reaction chamber of parallelepiped shape, the side walls of the reaction chamber including heater means and a plurality of stacks of loader devices arranged in the reaction chamber. Each loader device being in the form of an enclosure of parallelepiped shape provided with support elements for receiving porous preforms for infiltrating.
    Type: Grant
    Filed: July 12, 2013
    Date of Patent: August 27, 2019
    Assignee: SAFRAN CERAMICS
    Inventors: Sebastien Bertrand, Franck Lamouroux, Stephane Goujard, Cedric Descamps
  • Patent number: 9695089
    Abstract: Method for producing shaped bodies from reaction-bonded, silicon-infiltrated silicon carbide and/or boron carbide, characterized in that a monolithic preliminary body is built up in layers using a formless granulation to which a physical or chemical hardening or melt process is applied, wherein the granulation has a weight fraction of at least 95% silicon carbide and/or boron carbide with an average grain size of 70 to 200 ?m, the so-created preliminary body is impregnated at least once by the introduction of a carbon black suspension or via a gas-phase separation and secondary silicon carbide is created in contact with liquid or gaseous silicon by a subsequent reaction firing that solidifies an engagement composite produced.
    Type: Grant
    Filed: August 6, 2014
    Date of Patent: July 4, 2017
    Assignee: Schunk Ingenieurkeramik GmbH
    Inventors: Arthur Lynen, Jens Larsen, Michael Clemens
  • Patent number: 9249669
    Abstract: A ceramic matrix composite blade for use in a gas turbine engine having an airfoil with leading and trailing edges and pressure and suction side surfaces, a blade shank secured to the lower end of each airfoil, one or more interior fluid cavities within the airfoil having inlet flow passages at the lower end which are in fluid communication with the blade shank, one or more passageways in the blade shank corresponding to each one of the interior fluid cavities and a fluid pump (or compressor) that provides pressurized fluid (nominally cool, dry air) to each one of the interior fluid cavities in each airfoil. The fluid (e.g., air) is sufficient in pressure and volume to maintain a minimum fluid flow to each of the interior fluid cavities in the event of a breach due to foreign object damage.
    Type: Grant
    Filed: April 5, 2012
    Date of Patent: February 2, 2016
    Assignee: General Electric Company
    Inventors: Andres Garcia-Crespo, Jerome Walter Goike
  • Patent number: 9145338
    Abstract: A method for producing a part made of ceramic matrix and ceramic fibers composite material. It comprises: the formation of a fibrous preform by intertwining threads constituted of ceramic material fibers on a contact surface of a support element reproducing the internal and/or external shape of the part to be produced; the partial densification of the fibrous preform at a temperature below the melting temperature of the material of the support element and below the melting temperature of the material of the fibers of the preform, said partial densification resulting in a consolidated fibrous preform comprising a matrix volume fraction above 5% and at the most equal to 40% of the matrix volume of the part to be produced; the removal of the support element from the consolidated fibrous preform by chemical attack of the contact surface of the material of the support element; the densification of the consolidated preform, carried out at a temperature below the melting temperature of the fibers of said preform.
    Type: Grant
    Filed: January 23, 2012
    Date of Patent: September 29, 2015
    Assignee: COMMISSARIAT A L'ENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES
    Inventors: Cédric Sauder, Christophe Lorrette
  • Publication number: 20150128828
    Abstract: In one example, a method comprises densifiying a carbonized preform via at least one of resin transfer molding (RTM), vacuum pitch infiltration (VPI) and chemical vapor infiltration/chemical vapor deposition (CVI/CVD), heat treating the densified preform to open internal pores of the densified preform, and infiltrating the internal pores of the densified preform with low viscosity resin to increase the density of the preform.
    Type: Application
    Filed: July 16, 2012
    Publication date: May 14, 2015
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Mark L. La Forest, Slawomir Fryska
  • Patent number: 9017761
    Abstract: Carbon-carbon composites made by needling together woven or nonwoven fabric made from carbon-containing fibers followed by carbonizing the fabric preforms are described. The carbon fiber preforms can be needled either in a carbonized or in an uncarbonized state. The uncarbonized fiber preforms would go through a carbonization/heat-treat step following the needling process. Final preform thickness and fiber volume is also controlled at carbonization, for instance by varying the level of pressure applied to the preforms during carbonization. For example, the preforms may be unconstrained during carbonization (i.e., no pressure is applied to them) or the preforms may be constrained during carbonization, typically by means for applying pressure (e.g., weight placed on top of the preforms).
    Type: Grant
    Filed: May 20, 2009
    Date of Patent: April 28, 2015
    Assignee: Honeywell International Inc.
    Inventors: Mark L. La Forest, Neil Murdie, Mark C. James
  • Patent number: 9017760
    Abstract: The present invention relates to a method for hydrophobization of a fabric surface comprising providing a stream of a substantially anhydrous gas, passing said gas over or through a substantially anhydrous liquid of an alkylsilane, preferably a fluorinated alkylsilane to provide an alkylsilane, preferably a fluorinated alkylsilane vapor and bringing said vapor in contact with the fabric surface, thereby allowing the optionally fluorinated alkylsilane to bind covalently to the fabric surfaced. The present invention further relates to a fabric comprising a superhydrophobic surface finish prepared by a method of the invention and to a device for carrying out the method of the invention.
    Type: Grant
    Filed: November 10, 2008
    Date of Patent: April 28, 2015
    Assignee: Nederlandse Organisatie voor toegepast-natuurwetenschappelijk onderzoek TNO
    Inventors: Aike Wypke Wijpkema, Timme Lucassen, Lawrence Fabian Batenburg
  • Patent number: 8920871
    Abstract: Porous nuclear fuel elements for use in advanced high temperature gas-cooled nuclear reactors (HTGR's), and to processes for fabricating them. Advanced uranium bi-carbide, uranium tri-carbide and uranium carbonitride nuclear fuels can be used. These fuels have high melting temperatures, high thermal conductivity, and high resistance to erosion by hot hydrogen gas. Tri-carbide fuels, such as (U,Zr,Nb)C, can be fabricated using chemical vapor infiltration (CVI) to simultaneously deposit each of the three separate carbides, e.g., UC, ZrC, and NbC in a single CVI step. By using CVI, the nuclear fuel may be deposited inside of a highly porous skeletal structure made of, for example, reticulated vitreous carbon foam.
    Type: Grant
    Filed: August 27, 2013
    Date of Patent: December 30, 2014
    Assignee: Sandia Corporation
    Inventors: Dennis L. Youchison, Brian E. Williams, Robert E. Benander
  • Publication number: 20140356534
    Abstract: Method for chemical vapor infiltration of refractory substances, wherein a porous structure is subjected in a reaction zone to the flow of a gas containing at least one gaseous precursor, wherein the partial pressure of the precursor and the dwell time of the gas are set at a given temperature in such a manner that a deposition reaction of the precursor occurs in the porous structure in the partial pressure range of the saturation adsorption and the reaction of the precursor is limited in each stage of the infiltration in such a manner that during the flow through the reaction zone no more than 50% of the precursor are deposited as a solid phase in the porous structure, and the exposure of the porous structure to the flow occurs in a stack of superimposed layers through ring-shaped vertical circumferential gaps (A, B) as well as through transverse gaps (C) which are open towards the circumferential gaps (A, B).
    Type: Application
    Filed: January 9, 2013
    Publication date: December 4, 2014
    Applicant: CVT GmbH & Co. KG
    Inventors: Rainer Hegermann, Philipp Goetz
  • Patent number: 8859040
    Abstract: A method of depositing a conformal coating on a porous non-ceramic substrate requires reactive gases to flow through the substrate so as to leave a conformal coating behind. The process can be used to leave a hydrophilic surface on the interior pores of the substrate, even when the substrate is of a naturally hydrophobic, e.g., olefinic material. The method can be used in a roll-to-roll process, or in a batch process. In some convenient embodiments of the latter case, the batch reactor and the conformally coated substrate or substrates can together go on to be come part of the end product, e.g., a filter body and the filter elements respectively.
    Type: Grant
    Filed: September 15, 2010
    Date of Patent: October 14, 2014
    Assignee: 3M Innovative Properties Company
    Inventor: Bill H. Dodge
  • Patent number: 8846147
    Abstract: A method of fabricating a complex part out of composite material including three-dimensional woven fiber reinforcement densified by a matrix, the method including three-dimensionally weaving a continuous fiber strip including a succession of fiber blanks for preforms of a plurality of parts that are to be fabricated; subsequently cutting individual fiber blanks out from the strip, each blank being a one-piece blank; shaping a cut-out blank to obtain a one-piece fiber preform having a shape that is close to the shape of a part that is to be fabricated; consolidating the preform in the desired shape; and densifying the consolidated preform by forming a matrix by chemical vapor infiltration.
    Type: Grant
    Filed: November 26, 2009
    Date of Patent: September 30, 2014
    Assignees: Herakles, Snecma
    Inventors: Nicolas Eberling-Fux, Eric Bouillon, Clément Roussille, Stéphane Otin, Dominique Coupe
  • Publication number: 20140287249
    Abstract: The invention relates to a method for coating, by means of a chemical vapour deposition (CVD) technique, a part with a coating (PAO) for protecting against oxidation. The method enables the preparation of a refractory coating for protecting against oxidation, having a three-dimensional microstructure, which ensures the protection against oxidation at a high temperature, generally at a temperature above 1200° C., for materials that are sensitive to oxidation, such as composite materials, and in particular carbon/carbon composite materials.
    Type: Application
    Filed: November 23, 2012
    Publication date: September 25, 2014
    Inventors: Alexandre Allemand, Olivier Szwedek, Jean-Francois Epherre, Yann Le Petitcorps
  • Publication number: 20140010997
    Abstract: A process for the production of pyrolytic carbon comprising the steps of: (A) depositing pyrolytic carbon on a substrate, and (B) controlling the structure of the deposited pyrolytic carbon through use of a Volmer-Weber island growth model.
    Type: Application
    Filed: May 29, 2013
    Publication date: January 9, 2014
    Applicant: Commonwealth Scientific and Industrial Research Organisation
    Inventors: Jim PATEL, James GUNNING
  • Patent number: 8545938
    Abstract: A method of fabricating a ceramic component includes using vapor infiltration to deposit a ceramic coating within pores of a porous structure to form a preform body with residual interconnected porosity. Transfer molding is then used to deposit a heated, liquid glass or glass/ceramic material into the residual interconnected porosity. The liquid ceramic or ceramic/glass material is then solidified to form a ceramic component.
    Type: Grant
    Filed: October 3, 2011
    Date of Patent: October 1, 2013
    Assignee: United Technologies Corporation
    Inventors: Wayde R. Schmidt, David C. Jarmon
  • Patent number: 8529995
    Abstract: A method of fabricating a thermostructural composite material part includes making a fiber preform formed of yarns or tows and impregnated by a consolidating composition containing a carbon- or ceramic-precursor, transforming the carbon- or ceramic-precursor by pyrolysis, and then densifying the preform by chemical vapor infiltration. A consolidating composition is used that additionally contains refractory solid fillers in the powder form presenting mean grain size less than 200 nanometers and leaving, after pyrolysis, a consolidated solid phase in which the carbon or the ceramic derived from the precursor occupies a volume representing 3% to 10% of the apparent volume of the preform, and the solid fillers occupy a volume representing 0.5% to 5% of the apparent volume of the preform.
    Type: Grant
    Filed: September 23, 2009
    Date of Patent: September 10, 2013
    Assignee: Snecma Propulsion Solide
    Inventors: Nicolas Eberling-Fux, Eric Bouillon, Eric Philippe, Henri Tawil
  • Patent number: 8491963
    Abstract: To densify thin porous substrates (1) by chemical vapor infiltration, the invention proposes using loading tooling (10) comprising a tubular duct (10) disposed between first and second plates (12, 13) and around which the thin substrates for densification are disposed radially. The tooling as loaded in this way is then placed inside a reaction chamber (20) in an infiltration oven having a reactive gas admission inlet (21) connected to the tubular duct (11) to enable a reactive gas to be admitted into the duct which distributes the gas along the main faces on the substrates (1) in a flow direction that is essentially radial. The reactive gas can also flow in the opposite direction, i.e. it can be admitted into the tooling (10) from its outer envelope (16) and can be removed via the duct (11).
    Type: Grant
    Filed: March 14, 2012
    Date of Patent: July 23, 2013
    Assignee: Snecma Propulsion Solide
    Inventors: Franck Lamouroux, Sébastien Bertrand, Stéphane Goujard, Alain Caillaud, Francis Bagilet, Stéphane Mazereau
  • Patent number: 8221836
    Abstract: The method comprises: using chemical vapor infiltration to form a first continuous interphase on the fibers of a fiber structure made of refractory fibers, the interphase having a thickness of no more than 100 nanometers; impregnating the fiber structure with a consolidation composition comprising a carbon or ceramic precursor resin; forming a fiber preform that is consolidated by shaping the impregnated fiber structure and using pyrolysis to transform the resin into a discontinuous solid residue of carbon or ceramic; using chemical vapor infiltration to form a second continuous interphase layer; and densifying the preform with a refractory matrix. This preserves the capacity of the fiber structure to deform so as to enable a fiber preform to be obtained that is of complex shape, while nevertheless guaranteeing the presence of a continuous interphase between the fibers and the matrix.
    Type: Grant
    Filed: July 13, 2009
    Date of Patent: July 17, 2012
    Assignee: Snecma Propulsion Solide
    Inventors: Eric Philippe, Eric Bouillon
  • Patent number: 8216641
    Abstract: A method of fabricating a composite material part having carbon fiber reinforcement densified by a matrix, including making a coherent fiber preform of carbon fibers presenting holes formed from at least a first face of the preform, and densifying the preform by depositing therein a material constituting a matrix by means of a chemical vapor infiltration type process. The holes are formed by causing a plurality of non-rotary elongate tools to penetrate simultaneously, the tools being substantially mutually parallel and presenting on their surfaces roughnesses or portions in relief suitable for breaking and/or transferring fibers they encounter, the tools being caused to penetrate simultaneously by moving a support carrying the tools, and the tools being selected to have a cross-section that makes it possible to obtain in the carbon fiber preform holes that present a cross-section with a mean dimension lying in the range 50 ?m to 500 ?m.
    Type: Grant
    Filed: January 28, 2008
    Date of Patent: July 10, 2012
    Assignee: Messier Bugatti
    Inventors: Eric Bouchard, Eric Lherm
  • Patent number: 8172061
    Abstract: A friction material is provided for a friction member of a torque-transmitting mechanism. The friction member has a woven carbon fiber fabric base. A coating is applied to the base to form a portion of a contact surface positioned to contact a reaction member during engagement of the torque-transmitting mechanism. The coating is a mixture of a resin binder and a friction modifier. A method of forming a friction material is also provided.
    Type: Grant
    Filed: September 26, 2008
    Date of Patent: May 8, 2012
    Assignees: GM Global Technology Operations LLC, Ballard Material Products
    Inventors: John Gaffney, David Giannelli, Roger Masse, Timothy Anguish
  • Patent number: 8142845
    Abstract: A method of producing a densified SiC article is provided. Near-net shape porous silicon carbide articles are produced and densified using the developed method. A substantial number of pores within the porous near-net shape silicon carbide article are filled (impregnated) with a carbon precursor, a silicon carbide precursor, or a mixture of both. The carbon precursor can be liquid or gas. The filled SiC preform is heated to convert the carbon or silicon carbide precursor to porous carbon or SiC preform inside the pores of the net-shape silicon carbide article. The impregnation/pyrolysis cycle is repeated until the desired amount of carbon and/or silicon carbide is achieved. In case of a carbon or a mixture of silicon carbide/carbon precursor is used, the pyrolyzed near-net shape silicon carbide article is then contacted with silicon in an inert atmosphere.
    Type: Grant
    Filed: September 13, 2010
    Date of Patent: March 27, 2012
    Assignee: POCO Graphite, Inc.
    Inventors: Abuagela H. Rashed, Rex G. Sheppard, Donald J. Bray
  • Patent number: 8133532
    Abstract: The present invention describes a method of CVI densification in which particular arrangements and mixtures of undensified porous substrates and partially densified porous substrates are arranged in particular ways in order to use the thermal characteristics of the partially densified porous substrates to better distribute heat throughout a CVI furnace and thereby improve densification.
    Type: Grant
    Filed: October 24, 2007
    Date of Patent: March 13, 2012
    Assignee: Messier-Bugatti-Dowty
    Inventors: Kenny Chang, Patrick Loisy, Yvan Baudry
  • Patent number: 8084079
    Abstract: A method of densifying a porous substrate with pyrolytic carbon includes loading the substrate into an oven, admitting a reaction gas mixture to the oven, extracting an effluent gas from the oven, and recycling components of the effluent gas into the reaction gas mixture. The reaction gas mixture contains a pyrolytic carbon precursor gas together with a vector gas. The effluent gas contains residual components of the reaction gas mixture together with reaction products, including hydrogen. The recycling is performed after eliminating heavy hydrocarbons contained in the effluent gas.
    Type: Grant
    Filed: January 23, 2006
    Date of Patent: December 27, 2011
    Assignee: Snecma Propulsion Solide
    Inventors: Jacques Thebault, Sébastien Bertrand, Christian Robin-Brosse, Bruno Bernard, Jean-Luc Domblides
  • Publication number: 20110293828
    Abstract: A method of fabricating a complex part out of composite material including three-dimensional woven fiber reinforcement densified by a matrix, the method including three-dimensionally weaving a continuous fiber strip including a succession of fiber blanks for preforms of a plurality of parts that are to be fabricated; subsequently cutting individual fiber blanks out from the strip, each blank being a one-piece blank; shaping a cut-out blank to obtain a one-piece fiber preform having a shape that is close to the shape of a part that is to be fabricated; consolidating the preform in the desired shape; and densifying the consolidated preform by forming a matrix by chemical vapor infiltration.
    Type: Application
    Filed: November 26, 2009
    Publication date: December 1, 2011
    Applicant: SNECMA PROPULSION SOLIDE
    Inventors: Nicolas Eberling-Fux, Eric Bouillon, Clément Roussille, Stéphane Otin, Dominique Coupe
  • Patent number: 8057855
    Abstract: A process for densifying porous structures inside a furnace using non-pressure gradient CVI/CVD includes disposing a number of porous structures in a stack within a furnace. The stack has a center opening region extending through the porous structures and an outer region extending along the outside of the porous structures. Channels provide fluid communication between the center opening region and the outer region. A first portion of a gas composition is introduced to the center opening region. A second portion of the gas composition is introduced to the outer region. The porous structures are densified from an average density of less than 0.60 g/cm3 to an average density of greater than 1.70 g/cm3 in a single cycle of non-pressure gradient CVI/CVD.
    Type: Grant
    Filed: July 7, 2008
    Date of Patent: November 15, 2011
    Assignee: Goodrich Corporation
    Inventors: James W. Rudolph, Vincent R. Fry
  • Patent number: 8039053
    Abstract: An interphase coating is formed by chemical vapor infiltration (CVI) on the fibers constituting a fiber preform, the interphase coating comprising at least an inner layer in contact with the fibers for embrittlement relief to the composite material, and an outer layer for bonding with the ceramic matrix. The fiber preform is then kept in its shape by the fibers provided with the interphase coating and is consolidated by being impregnated with a liquid composition containing a ceramic precursor, and by transforming the precursor into a ceramic matrix consolidation phase. The consolidated preform is then densified by an additional ceramic matrix phase. No support tooling is needed for forming the interphase coating by CVI or for densification after consolidation using the liquid technique.
    Type: Grant
    Filed: February 22, 2006
    Date of Patent: October 18, 2011
    Assignee: SNECMA Propulsion Solide
    Inventors: Eric Philippe, Sébastien Bertrand, Eric Bouillon, Alain Caillaud, Jean-Christophe Ichard, Robert Bagat
  • Publication number: 20110200748
    Abstract: A method of fabricating a thermostructural composite material part includes making a fiber preform formed of yarns or tows and impregnated by a consolidating composition containing a carbon- or ceramic-precursor, transforming the carbon- or ceramic-precursor by pyrolysis, and then densifying the preform by chemical vapor infiltration. A consolidating composition is used that additionally contains refractory solid fillers in the powder form presenting mean grain size less than 200 nanometers and leaving, after pyrolysis, a consolidated solid phase in which the carbon or the ceramic derived from the precursor occupies a volume representing 3% to 10% of the apparent volume of the preform, and the solid fillers occupy a volume representing 0.5% to 5% of the apparent volume of the preform.
    Type: Application
    Filed: September 23, 2009
    Publication date: August 18, 2011
    Applicant: SNECMA PROPULSION SOLIDE
    Inventors: Nicolas Eberling-Fux, Eric Bouillon, Eric Philippe, Henri Tawil
  • Patent number: 7993703
    Abstract: A process for making nanostructures on a support, including: supplying a support including a surface layer on one of its faces, covering the surface layer by a catalyst layer structured according to a pattern exposing areas of the surface layer covered by the catalyst and areas of the surface layer not covered by the catalyst, etching the thickness of the surface layer in the areas not covered by the catalyst layer, and selectively growing nanostructures on the areas of the surface layer covered by the catalyst. The process can also be used to make cathode structures with electrically independent nanostructures.
    Type: Grant
    Filed: May 29, 2006
    Date of Patent: August 9, 2011
    Assignee: Commissariat a l'Energie Atomique
    Inventors: Thomas Goislard De Monsabert, Jean Dijon
  • Patent number: 7959973
    Abstract: Method of chemical vapor infiltration of a deposable carbon material into a porous carbon fiber preform in order to densify the carbon fiber preform. The method includes the steps of: situating the porous carbon fiber preform in the reaction zone; providing a linear flow of a reactant gas comprising deposable carbon material in the reaction zone at an initial reaction pressure of at most 50 torr to produce deposition of the deposable carbon material into the preform; and adjusting the pressure of the gas to reaction pressures lower than said initial reaction pressure while deposable carbon material continues to be deposited into the porous carbon fiber preform. This method enables attainment of a target increased density in a carbon fiber preform much more quickly than known processes. A programmed pressure swing throughout the CVI/CVD run may be set in order to provide a linear increase in density.
    Type: Grant
    Filed: November 29, 2006
    Date of Patent: June 14, 2011
    Assignee: Honeywell International Inc.
    Inventors: Akshay Waghray, Terence B. Walker
  • Publication number: 20110111123
    Abstract: Economically attractive method of making carbon-carbon composite brake disc or pad. The manufacturing method herein provides lowered manufacturing cycle time and reduced cost of manufacturing while enabling increased density of the final composite. The method includes: providing a fibrous nonwoven fabric segment produced from high basis weight fabric; optionally needling sequential layers of the fabric segments together to construct a brake disc or pad preform; carbonizing the fibrous preform to obtain a carbon-carbon preform; and infiltrating the resulting carbonized needled fibrous fabric preform via pitch or pitch and CVD/CVI processing in order to produce a carbon-carbon composite brake disc or pad which has a final density of 1.60 to 1.90 grams per cubic centimeter.
    Type: Application
    Filed: November 12, 2009
    Publication date: May 12, 2011
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Mark L. LA FOREST, Mark Criss James, Neil Murdie
  • Patent number: 7919143
    Abstract: A carrier for an object, preferably a substrate of a semiconductor component such as a wafer, includes a receiving element for the object and gas outlets arranged below the receiving element along the object received. At least sections of the carrier are made of a material which including stabilizing fibers and having a porosity which forms the gas outlets, in order to enable a desired gas to exit from the gas outlets in a dosed and finely distributed manner.
    Type: Grant
    Filed: December 6, 2004
    Date of Patent: April 5, 2011
    Assignee: Schunk Kohlensteofftechnik GmbH
    Inventor: Stefan Schneweis
  • Publication number: 20110071013
    Abstract: A ceramic matrix composite is formed from a non-oxide ceramic and continuous ceramic fibers. The matrix includes a hafnium donor in the matrix in an amount sufficient to harden the composite at elevated temperatures to prevent ablation of the composite. The matrix also includes a boron donor in the matrix in an amount sufficient to lower the glass transition temperature of the composite to flow over cracks formed in the composite. The method to form the matrix is selected from polymer infiltration pyrolysis, chemical vapor infiltration, and sequential polymer infiltration pyrolysis and chemical vapor infiltration.
    Type: Application
    Filed: September 24, 2009
    Publication date: March 24, 2011
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Kirk C. Newton, Michael A. Kmetz
  • Publication number: 20110059240
    Abstract: A method of producing a densified SiC article is provided. Near-net shape porous silicon carbide articles are produced and densified using the developed method. A substantial number of pores within the porous near-net shape silicon carbide article are filled (impregnated) with a carbon precursor, a silicon carbide precursor, or a mixture of both. The carbon precursor can be liquid or gas. The filled SiC preform is heated to convert the carbon or silicon carbide precursor to porous carbon or SiC preform inside the pores of the net-shape silicon carbide article. The impregnation/pyrolysis cycle is repeated until the desired amount of carbon and/or silicon carbide is achieved. In case of a carbon or a mixture of silicon carbide/carbon precursor is used, the pyrolyzed near-net shape silicon carbide article is then contacted with silicon in an inert atmosphere.
    Type: Application
    Filed: September 13, 2010
    Publication date: March 10, 2011
    Inventors: Abuagela H. Rashed, Rex G. Sheppard, Donald J. Bray
  • Publication number: 20110033622
    Abstract: Method of making carbon-carbon composite brake disc or pad. The manufacturing method herein benefits from lowered manufacturing cycle time, reduced cost of manufacturing, and at the same time increased density of the final composite. The method includes: providing a fibrous nonwoven fabric segment comprised of OPAN fibers, the segment being produced from high basis weight fabric; providing a needler to needle layers of the fabric segments to one another; needling two layers of the fabric segments to one another and then needling sequential layers of the fabric segments on top of the layers thereof which have previously been needled together, to construct a brake disc or pad preform; carbonizing the fibrous preform to obtain a carbon-carbon preform; and infiltrating the resulting carbonized needled fibrous fabric preform via CVD/CVI processing in order to produce a carbon-carbon composite brake disc or pad which has a density of at least 1.70 grams per cubic centimeter.
    Type: Application
    Filed: August 6, 2009
    Publication date: February 10, 2011
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Mark L. LA FOREST, Mark Criss James, Neil Murdie
  • Publication number: 20100266461
    Abstract: Methods for generating and applying coatings to filters with porous material in order to reduce large pressure drop increases as material accumulates in a filter, as well as the filter exhibiting reduced and/or more uniform pressure drop. The filter can be a diesel particulate trap for removing particulate matter such as soot from the exhaust of a diesel engine. Porous material such as ash is loaded on the surface of the substrate or filter walls, such as by coating, depositing, distributing or layering the porous material along the channel walls of the filter in an amount effective for minimizing or preventing depth filtration during use of the filter. Efficient filtration at acceptable flow rates is achieved.
    Type: Application
    Filed: April 8, 2010
    Publication date: October 21, 2010
    Applicant: MASSACHUSETTS INSTITUTE OF TECHNOLOGY
    Inventors: Alexander Sappok, Victor Wong
  • Patent number: 7799375
    Abstract: A method of producing a densified SiC article is provided. Near-net shape porous silicon carbide articles are produced and densified using the developed method. A substantial number of pores within the porous near-net shape silicon carbide article are filled (impregnated) with a carbon precursor, a silicon carbide precursor, or a mixture of both. The carbon precursor can be liquid or gas. The filled SiC preform is heated to convert the carbon or silicon carbide precursor to porous carbon or SiC preform inside the pores of the net-shape silicon carbide article. The impregnation/pyrolysis cycle is repeated until the desired amount of carbon and/or silicon carbide is achieved. In case of a carbon or a mixture of silicon carbide/carbon precursor is used, the pyrolyzed near-net shape silicon carbide article is then contacted with silicon in an inert atmosphere.
    Type: Grant
    Filed: June 29, 2005
    Date of Patent: September 21, 2010
    Assignee: Poco Graphite, Inc.
    Inventors: Abuagela H. Rashed, Rex G. Sheppard, Donald J. Bray
  • Publication number: 20100167007
    Abstract: An integrally woven three-dimensional preform with stiffeners in two or more directions constructed from a woven fabric having a first, second and optional third woven fabric layer. A plurality of yarns are interwoven over a region between the first and second fabric layers such that the first fabric layer is foldable relative to the second fabric layer. An additional plurality of yarns are interwoven over a region between the second and third fabric layers such that the third fabric layer is foldable relative to the second fabric layer. Upon folding of the woven fabric layers, the integrally woven three-dimensional preform with stiffeners in two or more directions is formed.
    Type: Application
    Filed: December 30, 2008
    Publication date: July 1, 2010
    Inventor: Jonathan Goering
  • Patent number: 7727591
    Abstract: A load comprising one or more porous substrates (10) for densification is heated in an oven into which a reaction gas containing at least one carbon-precursor hydrocarbon is admitted, the effluent gas being extracted from the oven via an extraction pipe (26) connected to an outlet from the oven. The content in the effluent gas of at least one compound selected from allene, propine, and benzene is measured, and as a function of the measured content, the process is controlled by adjusting at least one parameter selected from the rate at which the reaction gas is admitted into the oven, the rate at least one component of the reaction gas is admitted into the oven, the transit time of the gas through the oven, the temperature to which the substrate(s) is/are heated, and the pressure that exists inside the oven. The at least one parameter is adjusted in such a manner as to maintain the measured content at a value which is substantially constant.
    Type: Grant
    Filed: April 27, 2004
    Date of Patent: June 1, 2010
    Assignee: Messier-Bugatti
    Inventors: Eric Sion, Paul-Marie Marquaire, René Fournet, Guy-Marie Come
  • Patent number: 7691443
    Abstract: A method for densifying porous structures inside a furnace using non-pressure gradient CVI/CVD in a single cycle is described. A hardware assembly for use in the single cycle non-pressure gradient CVI/CVD process is provided as well are process and process conditions are described.
    Type: Grant
    Filed: May 31, 2005
    Date of Patent: April 6, 2010
    Assignee: Goodrich Corporation
    Inventors: James W. Rudolph, Vincent Fry
  • Patent number: 7666475
    Abstract: A method for forming interphase layers in ceramic matrix composites. The method forms interphase layers in ceramic matrix composites thereby enabling higher matrix densities to be achieved without sacrificing crack deflection and/or toughness. The methods of the present invention involve the use fugitive material-coated fibers. These fibers are then infiltrated with a ceramic matrix slurry. Then, the fugitive material is removed and the resulting material is reinfiltrated with an interphase layer material. The ceramic matrix composite is then fired. Additional steps may be included to densify the ceramic matrix or to increase the strength of the interphase layer. The method is useful for the formation of three dimensional fiber-reinforced ceramic matrix composites envisioned for use in gas turbine components.
    Type: Grant
    Filed: December 14, 2004
    Date of Patent: February 23, 2010
    Assignee: Siemens Energy, Inc.
    Inventor: Jay Morrison
  • Patent number: 7666463
    Abstract: Methods for manufacturing porous nuclear fuel elements for use in advanced high temperature gas-cooled nuclear reactors (HTGR's). Advanced uranium bi-carbide, uranium tri-carbide and uranium carbonitride nuclear fuels can be used. These fuels have high melting temperatures, high thermal conductivity, and high resistance to erosion by hot hydrogen gas. Tri-carbide fuels, such as (U,Zr,Nb)C, can be fabricated using chemical vapor infiltration (CVI) to simultaneously deposit each of the three separate carbides, e.g., UC, ZrC, and NbC in a single CVI step. By using CVI, a thin coating of nuclear fuel may be deposited inside of a highly porous skeletal structure made, for example, of reticulated vitreous carbon foam.
    Type: Grant
    Filed: May 17, 2006
    Date of Patent: February 23, 2010
    Assignee: Sandia Corporation
    Inventors: Dennis L. Youchison, Brian E. Williams, Robert E. Benander
  • Patent number: 7662437
    Abstract: A template (10) configured for use with an annular preform (26) having a periphery (32) and an inner opening (34), the template (10) having an annular body with an outer periphery (16) and an inner opening (18) and a plurality of spacer openings (12) through its body each for receiving a spacer (25), one of the template inner opening (18) and the template outer periphery (16) having a width equal to the width of the preform inner opening (34) or the preform outer periphery (32). Also a method for densifying preforms that includes a step of positioning spacers using a template.
    Type: Grant
    Filed: March 21, 2006
    Date of Patent: February 16, 2010
    Assignee: Honeywell International Inc.
    Inventors: Alan A. Arico, David E. Parker, Akshay Waghray
  • Publication number: 20100018815
    Abstract: Carbon-carbon composite brake discs are manufactured by processes that include the use of PAN or pitch fibers and their combinations, combined with pitch, resin, or CVD/CVI matrix carbons. An additional process step is provided, in which a controlled amount of a carbon additive, such as carbon black and/or activated carbon, is infiltrated in to the bulk porosity of the composite prior to one or more of the densification cycles. Typical methods of infiltration include use of a solution or suspension of the powdered carbon in water or solvent solution so as to uniformly distribute the particulates throughout porosity within the carbon fiber preform prior to one or more of the densification cycles. The presence of the activated carbon and/or carbon black additive, distributed throughout the carbon-carbon composite brake disc, facilitates the adsorption and retention of available moisture in the composite.
    Type: Application
    Filed: July 28, 2008
    Publication date: January 28, 2010
    Inventor: Neil MURDIE
  • Publication number: 20100015428
    Abstract: The method comprises: using chemical vapor infiltration to form a first continuous interphase on the fibers of a fiber structure made of refractory fibers, the interphase having a thickness of no more than 100 nanometers; impregnating the fiber structure with a consolidation composition comprising a carbon or ceramic precursor resin; forming a fiber preform that is consolidated by shaping the impregnated fiber structure and using pyrolysis to transform the resin into a discontinuous solid residue of carbon or ceramic; using chemical vapor infiltration to form a second continuous interphase layer; and densifying the preform with a refractory matrix. This preserves the capacity of the fiber structure to deform so as to enable a fiber preform to be obtained that is of complex shape, while nevertheless guaranteeing the presence of a continuous interphase between the fibers and the matrix.
    Type: Application
    Filed: July 13, 2009
    Publication date: January 21, 2010
    Applicant: SNECMA PROPULSION SOLIDE
    Inventors: Eric Philippe, Eric Bouillon
  • Publication number: 20100000831
    Abstract: Highly effective carbon fibre-reinforced ceramic automotive brake and clutch discs are manufactured by siliconising incompletely densified carbon-carbon fibre preforms produced by a single stage and relatively short duration (e.g. 7-14 day) chemical vapour infiltration process.
    Type: Application
    Filed: July 28, 2006
    Publication date: January 7, 2010
    Applicant: SURFACE TRANSFORMS PLC
    Inventors: Julio Joseph Faria, Kevin Johnson, Geoffrey Gould
  • Publication number: 20090297707
    Abstract: Method for making carbon-carbon composite friction product, by: fabricating carbon fiber preform; heat-treating the carbon fiber preform; infiltrating the carbon fiber preform with a high carbon-yielding pitch using VPI (vacuum pressure infiltration) or resin transfer molding (RTM) processing; carbonizing the preform with an intermediate heat-treatment at 800-2000° C.; repeating the pitch infiltration and carbonization steps to achieve a final density of >1.75 g/cc; machining the surfaces of the preform; and applying an oxidation protection system. This approach overcomes problems inherent in lower density carbon-carbon composites by employing high carbon-yielding pitches to densify the carbon-carbon composites to a high density. The high carbon yielding pitches may include isotropic pitches, 100% anisotropic (mesophase) pitches, or mixtures of the two. They may be derived from petroleum, coal tar, or synthetic feedstocks.
    Type: Application
    Filed: May 28, 2008
    Publication date: December 3, 2009
    Inventors: Mark LA FOREST, Neil Murdie, David R. Cole
  • Patent number: 7592254
    Abstract: The present invention provides methods for conformally or superconformally coating and/or uniformly filling structures with a continuous, conformal layer or superconformal layer. Methods of the present invention improve conformal or superconformal coverage of surfaces and improve fill in recessed features compared to conventional physical deposition and chemical deposition methods, thereby minimizing formation of voids or gaps in a deposited conformal or superconformal layer. The present methods are capable of coating or filling features useful for the fabrication of a broad class of electronic, electrical and electromechanical devices.
    Type: Grant
    Filed: October 31, 2006
    Date of Patent: September 22, 2009
    Assignee: The Board of Trustees of the University of Illinois
    Inventors: John R. Abelson, Sreenivas Jayaraman, Gregory S. Girolami, Yu Yang, Do Young Kim