WO2012114061A1 - Structure fibreuse de carbone ou pouvant être carbonée et son procédé de fabrication - Google Patents

Structure fibreuse de carbone ou pouvant être carbonée et son procédé de fabrication Download PDF

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Publication number
WO2012114061A1
WO2012114061A1 PCT/GB2012/000155 GB2012000155W WO2012114061A1 WO 2012114061 A1 WO2012114061 A1 WO 2012114061A1 GB 2012000155 W GB2012000155 W GB 2012000155W WO 2012114061 A1 WO2012114061 A1 WO 2012114061A1
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WIPO (PCT)
Prior art keywords
substrate
former
pile
layers
layer
Prior art date
Application number
PCT/GB2012/000155
Other languages
English (en)
Inventor
Neil Saville
John Lynn Payne
Original Assignee
Marathon Belting Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Marathon Belting Limited filed Critical Marathon Belting Limited
Publication of WO2012114061A1 publication Critical patent/WO2012114061A1/fr

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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
    • B32B1/00—Layered products having a non-planar shape
    • B32B1/08—Tubular products
    • 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
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
    • 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
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • 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
    • 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
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • 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
    • 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
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63448—Polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/6346—Polyesters
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63448—Polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63468—Polyamides
    • 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
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63448—Polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63488—Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]
    • 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
    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/008—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
    • D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
    • D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
    • D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • 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
    • B32B2605/00—Vehicles
    • 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
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/04—Ceramic interlayers
    • C04B2237/08—Non-oxidic interlayers
    • C04B2237/086—Carbon interlayers
    • 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
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/38—Fiber or whisker reinforced
    • C04B2237/385—Carbon or carbon composite
    • 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
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/66—Forming laminates or joined articles showing high dimensional accuracy, e.g. indicated by the warpage
    • 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
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/76—Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
    • 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
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/84—Joining of a first substrate with a second substrate at least partially inside the first substrate, where the bonding area is at the inside of the first substrate, e.g. one tube inside another tube

Definitions

  • the present invention relates to a carbon or carbonizable fibrous structure and to a method of manufacturing such a fibrous structure.
  • the invention is particularly, though not exclusively, applicable to the manufacture of preforms that are used to produce friction products such as discs for use in brake mechanisms, and hollow, heat- resistant structures such as cones, nozzles and the like for projectiles and aircraft.
  • Use of the term "fibrous" indicates that the structure is made from fibres that may be either loose fibres or fibres that that have been spun into yarn which is then used to produce the structure.
  • Such fibres or yarns may be made of carbon fibres or yarns or of precursor, carbonizable materials.
  • 'carbonizable' indicates that fibrous structures in accordance with the present invention are heated in an autoclave in a methane or acetylene atmosphere at an appropriate temperature for an appropriate period of time in order to produce a hardened carbonaceous structure or carbon billet.
  • This structure or billet is then further processed to produce the desired products.
  • Suitable precursor carbonizable fibres for use in the manufacture of such a structure are well known to those in the art and are, for example, sold under the registered trade mark PANOX ® . These fibres comprise oxidized polyacrylonitrile fibers or precursors of polyactylonitrile fibers of various types. They are converted to carbon fibres by the heat treatment and produce carbon particles which enter and fill voids in the preform to density the structure.
  • Such fibres may be produced in a yarn form and comprise a large number of flexible filaments, for example between 3,000 and 25,000 filaments, in order that the preform can be manufactured using textile techniques, which in the present invention is weaving.
  • Conventional carbon or carbonizable fibrous structures are manufactured in various ways. Typically they are produced by felting or by needling punching braided tapes or mats of loose fibre to produce a cylindrical stack. See, for example EP0748781 (B.F. Goodrich), W098/49382 (B. F. Goodrich), EP0232059 (P. G. Lawton
  • the fibre fraction is calculated by measuring the volume and weight of a fabric sample and comparing it with the weight the sample would have been if that volume had been 100% carbon. For example, if the sample weighs 20 g and that volume of carbon would weigh 100 g, then the fibre fraction of the sample is 20%.
  • a fibrous structure comprising a tube made up of a plurality of layers of woven material wrapped around one another with an outer layer comprising a sheath in the form of a seamless woven tube.
  • Such a structure being made of woven material rather than via needle punching, is easier and more economical to produce than the needle-punched structures produced hitherto. It also has the advantage that it can be woven from carbon yarn rather than yarns made of carbonizable fibres. The former have the tendency to be britde and unsuitable for use in needle punched structures. However, most woven fabrics have a fibre fraction of between 35% and 50%, with the rest being trapped air.
  • Such a fibre fraction is too high for a carbon or carbonizable fibrous structure for use in the manufacture of preforms that are used to produce friction products.
  • the carbon fibre that makes up the woven material is around 50% denser than normal textile fibres.
  • the high fibre fraction of fibrous structures made from layers of woven material is a significant disadvantage and a desired fibre fraction required can only be achieved by a careful combination of the choice of yarns used to make the woven material and an appropriate method of construction of the structure.
  • a carbon or carbonizable fibrous structure comprising a layered tube including an innermost layer, an outer layer and at least one intermediate layer, said intermediate layer being formed from a material comprising carbon yarn or precursor carbon yarn in the form of a substrate with a pile projecting from at least one side thereof.
  • a pile in the intermediate layer or layers of this structure means that it has fibres that extend longitudinally (x direction), chordally (y direction) and radially (z direction) with respect to one another so that it uses the 'xyz' principle, which also enables a more homogeneous low density woven structure to be produced.
  • the substrate comprises a woven, nonwoven or knitted layer.
  • the pile has been raised from th e substrate by fracturing the yarns making up the substrate.
  • the fracturing has been carried out by needling of the substrate.
  • the fracturing has been carried out by carding or by abrading the surface of the substrate.
  • the material comprises a substrate with piles projecting from both sides thereof.
  • the material comprises two back-to-back layers of a substrate with piles projecting from one side thereof such that the material has piles projecting from both sides thereof.
  • the back-to-back layers of the substrate are bonded togeth er, for example by a thermoplastic bonding material applied to at least one of the layers in the form of a sheet or a net.
  • the back- to-back layers of the substrate are formed by a single layer of the substrate that is folded over itself.
  • the innermost layer comprises a seamless woven tube.
  • the outer layer comprises a sheath or band that is also in the form of a seamless woven tube.
  • the structure comprises at least one intermediate layer that comprises a seamless woven tube.
  • the fibrous structure comprises at least two intermediate layers in the form of a substrate with a pile projecting from at least one side, the projecting pile of one of these layers mtermeshing with the pile of at least one other of these layers.
  • at least regions of the structure are bonded or fused together by incorporation of a thermoplastic bonding medium into the material or between layers of the material prior to a heat treatment during manufacture of the structure.
  • thermoplastic bonding material is incorporated into the substrate or the pile in the form of a thermoplastic yarn.
  • the substrate comprises braided carbon yarn and/or braided precursor carbon yarn.
  • the pile comprises carbon yarn or precursor carbon yarn in conjunction with yarns made of any or a mixture of polyether ether ketone (PEEK), polyphenylene sulpliide (PPS), polyester, nylon 6-6 and nylon 6.
  • a method of manufacturing a preform fibrous structure for use in the manufacture of friction products comprising
  • the method comprises the additional initial steps of producing said one or more sheets of material by providing one or more sheets of a substrate and raising a pile on at least one surface of the sheet or sheets of substrate by fracturing the yarns making up the substrate.
  • the fracturing of the yarns making up the substrate is carried out by at least one of needling of the substrate, carding one or both surfaces of the substrate and abrading one or both surfaces of the substrate.
  • the method comprises the additional step of folding said sheet or sheets of material over itself prior to wrapping it around said innermost layer so that it comprises two back-to-back layers of substrate with piles projecting from both sides thereof.
  • the method comprises the further step of placing two sheets of said material together prior to wrapping it around said innermost layer so that it comprises two back-to-back layers of substrate with piles projecting from both sides thereof.
  • said material having piles projecting from both sides thereof is wrapped around said innermost layer to form a plurality of intermediate lavers wherein the pile of one intermediate layer is enmeshed with the pile of another intermediate layer.
  • the method comprises the additional step of providing a seamless woven tube and using it as an intermediate layer of the structure between intermediate layers formed by said material.
  • a th ermoplastic bonding medium is incorporated into at least one of the sheets of material or is located between layers of said material prior to wrapping of said material around the innermost layer, and the method comprises the additional step of subjecting the structure to a heat treatment to fuse or bond at least regions of the structure together.
  • thermoplastic bonding material is incorporated into the substrate or the pile in the form of a thermoplastic yarn.
  • thermoplastic bonding material is incorporating into the structure in the form of a sheet or net.
  • the heat treatment comprises the additional step of heating the fibrous structure immediately before or after the tube or band has been located over the structure.
  • the heat treatment comprises the additional step of heating the fibrous structure once it has been removed from the former.
  • the heat treatment is carried out as the material is being wrapped around the former.
  • the heat treatment may be carried out by blowing hot air over the material as it is being wrapped around the former.
  • the former is mounted on a shaft and the method comprises the additional steps of rotating the shaft as each layer of said material is wound around the former to tension the material so that it conforms to the profile of the underlying layer.
  • the former is expandable and collapsible to facilitate the location of the tube or band around the former and to facilitate removal of the former from the completed fibrous strucmre.
  • the former is adapted to be inflatable and deflatable.
  • a carbon or carbonizable fibrous structure manufactured in accordance with the method of the second aspect of the present invention.
  • Fig. 1 is a perspective view of an embodiment of fibrous structure according to the first aspect of the present invention
  • Figs- 2 to 7 are diagrams showing sequentially steps in the manufacture of the structure shown in Fig. 1 in accordance with the second aspect of the present invention, of which Figs. 2 to 4 are perspective views of steps in the production of a material used in the manufacture of said structure and Figs. 5 to 7 are perspective views showing steps in the manufacture of the structure itself.
  • a structure in accordance with the invention is made of carbon yarn or precursor carbon yarn.
  • the fibrous structure of the invention may be made of carbon yarn in conjunction with yarns made of any or a mixture of polyether ether ketone (PEEK), polyphenylene sulphide (PPS), polyester, nylon 6-6 and nylon 6. Such combinations made be co-mingled, blended, twisted, braided or interwoven together.
  • the yarn may also be used in a braided form. This has two advantages, particularly if pure carbon yarn is used.
  • Second braiding improves the product because it reduces the shedding of fibres from the fibrous structure during and after manufacture, which improves its wear resistance.
  • any of these yarns or others as appropriate for the ultimate use of the structure may be used to make carbon or carbonizable fibrous structures in accordance with the invention.
  • Various embodiments of such structures will now be described. All of them comprise a layered tube made up of a plurality of layers of material, all of which are preferably made from yarns as described above that are suitable for the end purpose for which the structure is to be used.
  • the fibre fraction required for the structure is achieved by a combination of an appropriate choice of the yarns used to make the material used in the structure together with an appropriate method of construction of the material itself as is described in more detail below.
  • an embodiment of fibrous structure 1 comprises a layered tube with an innermost layer 2 and an outer layer 3.
  • both the innermost layer 2 and the outer layer 3 comprise a sheath in the form of a seamless woven tube.
  • these tubes are formed from a multi-ply woven web that by virtue of the weave pattern can be opened out to form a tube.
  • weave patterns are known to persons skilled in the art.
  • Between the layers 2 and 3 are intermediate layers 4 that are formed by a single piece of material 5 that is rolled-up around the layer 2 before being secured in position by location of the outer layer 3 over the top of it.
  • This material 5 is in the form of a substrate 6 with a pile 7 projecting from at least one side thereof.
  • the substrate 6 comprises a woven substrate as shown in Fig. 2.
  • the substrate 6 of the material may comprise a nonwoven material, such as a felt mat, an airlaid mat, or a knitted material. In all of these cases, the fibres forming the substrate 6 will still provide fibres that extend in the "x-y" planes of the structure 1 .
  • th e yarns or fibres used to produce the substrate 6 will be made of carbon or precursor carbon. If such yarn is to be used that is either woven or knitted to produce the substrate 6, then its will preferably be used in a braided or wrapped form to make it easier to handle. However, in all cases the quantity of yarn or fibre used to make the substrate 6 is carefully controlled, for example by controlling the number and spacing of the ends and picks in a woven fabric, so that the required carbon fibre fraction can be achieved.
  • the substrate 6 is further processed to apply the pile 7 to at least one side as shown in Fig. 3.
  • the substrate 6 it is possible to tuft the substrate 6 to produce the pile 7, for example by injecting the pile 7 into the substrate 6, or a tufted substrate 6 could be produced in a single operation by weaving it using a carpet loom. In either case the pile 7 may be cut or remain uncut.
  • the yarn fotming the pile 7 may be used in an unbraided or unwrapped form to allow the individual fibres to separate and to occupy any cavity within the structure 1 when it has been formed. This allows a more even dispersion of fibres throughout the structure 1 as a whole.
  • the pile 7 is raised by fracturing the yarns making up the substrate 6. This can be carried out by needling of the substrate 6, carding one or both surfaces of the substrate 6 and/or by abrading one or both surfaces of the substrate 6.
  • Needling of the substrate 6 is carried out using a needle loom wherein barbed needles penetrate the substrate 6 by passing through it a vertical manner while the substrate 6 is retained horizontal and indexed forward, no horizontal tension being applied during penetration by the needles so as not to distort the substrate 6.
  • the barbed needles break the yarns making up and pull the broken ends out of the plane of the substrate 6 so that they form the pile 7 on the surface.
  • fracturing or the yarns making up the substrate to raise th e pile 7 may be carried out by passing th e substrate 6 against a rotating abrasive surface.
  • This abrasive surface materia] mav be formed silicon carbide chippings on a Carborundum 1 M wheel or similar.
  • the rotating abrasive surface may comprise card clothing of either a flexible or a fixed metallic profile.
  • the pile 7 projects outwards from the substrate 6 and provides the fibres that extend radially in the "z" directions of the structure. If tufted, the density of the tufts making up the pile 7 is carefully controlled to ensure a required carbon fibre fraction is achieved in the finished structure 1 . Preferably, however, the density of the substrate 7 is reduced by fracturing the yarns making up the substrate 6 to make the pile 7, which also enables a more homogeneous, low density structure 1 to be produced.
  • Normal woven apparel fabrics ate atound 35% - 50% fibre with 65% - 50% entrapped air.
  • a homogeneous carbon fibre fraction of between 1 5% and 35% is required, and a fibre fraction between 1 5% and 20% is the most preferable for the production of preforms that are used to produce friction products.
  • the fracturing of the yarns making up the substrate 6 to make the pile 7 reduces the density of these yarns and the substrate 6 itself by breaking down the yarns and increasing the thickness of the resulting piled material 5 to a point where the desired fibre fraction can be achieved.
  • this material 5 can be used directly to produce the structure 1 , as will be described below.
  • this material 5 is further processed to provide a pile 10 on the other side of the substrate 6, as shown in Fig. 4.
  • This doubled-sided piled material may be produced in several ways. First, it could be produced by treating the other side of the substrate 6 in exactiy the same way as the pile 7 was produced. Alternatively, two lengths of tufted substrate 6 may be joined together having been k id back-to-back so that their piles 7 project outwards on both sides.
  • the substrates 6 may be joined together by tacking, stitching or by being bonded together, for example by sandwiching between them a thermoplasdc bonding material, for example a polyester, preferably in the form of a sheet or net, and subjecting the resulting "sandwich" to a heat treatment to melt the bonding material and to fuse the two substrate layers 6 together.
  • the tufted substrate 6 may be simply folded over itself, preferably in half along the warp direction, so that th e pile 7 is outermost and projects outwards on both sides of the folded subsuate 6.
  • the folded back-to-back substrate 6 may be secured by tacking, stitching or be use of a suitable adhesive such as a thermoplastic bonding medium.
  • a doubled-sided piled material 5 has been formed, as shown in Fig. 4, then it can be used to form the fibrous structure 1 as shown in Fig. 1.
  • a method of accomplishing this will now be described.
  • a thermoplastic bonding medium is incorporated into the material 5 or between layers of the material so that on heat treatment the bonding medium will melt to fuse parts of the structure 1 together.
  • thermoplastic bonding material may be incorporated between back-to-back layers of the substrate 6.
  • thermoplastic yarn may be incorporated into the weave of the substrate 6 by using it for some of the warp and/ or weft yarns.
  • some of the pile 7, 10 may comprise a thermoplastic yarn.
  • Such yarns may comprise polyester yarns.
  • manufacture of the structure 1 commences widi the location over a former 1 1 of the innermost layer 2.
  • the former 1 ⁇ will be cylindrical with a circular cross-sectional profile but it should be appreciated that it could be made with any cross-sectional profile that may vary along its length and that may taper long its length. If the profile is complex, then it is likely all the layers of structure 1 will be made thin enough to enable them to closely follow the profile as they are built up on the former 1 1 .
  • the latter may be mounted on a rotatable shaft 12 and made expandable and collapsible, for example by being inflatable and deflatable. In its deflated state it is possible to locate the innermost layer 2 around the former 1 1 with ease and without damage. Inflation of the former 1 1 to a predetermined cross-sectional size in conformity with the inner diameter of the tubular layer 2 then holds this layer rigid.
  • the intermediate layers 4 made of the double-sided tufted material 6 as shown in Fig. 4 are then formed by winding the material 6 around the innermost layer 2 and then around itself as shown in Fig. 6. Any number of intermediate layers 4 can be built up.
  • the stability of the structure 1 can also be improved by subjecting the structure 1 to a heat treatment to melt these yarns and fuse regions of the structure 1 together.
  • This heat treatment may be carried out as the structure 1 is being formed.
  • the material 5 is being wound around the former 1 1 it could be subjected to a blast of blown hot air from a hot air "knife" of a temperature typically around 200°c, which is sufficient to soften and melt the thermoplastic yarns so that the layers 4 of material 5 are bonded together as they are being wrapped.
  • a heat treatment may be carried out towards the end of the manufacturing process, as described below.
  • the number of intermediate layers 4 equating to the number of turns of the material 5 in the structure 1 together with the thickness of the material comprising the layers 4 determines the diameter of the finished structure 1 and the latter is chosen according to the structure's end purpose.
  • the inner diameter of the tubular structure 1 is expected to be of the order of 10 to 15 mm, its outer diameter to be of the order of 45 mm and its length to be of the order of 50 - 55 mm. This means that if the material 5 is made by folding over the substrate 6, then the width of the substrate is a tape of the order of 100 to 1 10 mm wide.
  • the material 6 used for the layers 4 is relatively narrow and may be described as a tape even if it is woven and folded in half to produce the material being.
  • the structure 1 can be made in any dimensions using appropriately sized material 5.
  • the depth of the pile 7, 10, the thickness of the substrate 6 and the tension of the winding around the former 1 1 may also be controlled to produce the required carbon fibre fraction.
  • the outer layer 3 is applied to the former 1 1 over the top of the layers 4, as shown in Fig. 7.
  • This layer 3 may be in the form of a tube or a band and to facilitate its location over the intermediate layers 4 the former 1 1 may be deflated slighdy.
  • the former 1 1 is inflated back to its previous state to tension all the layers 2, 3 and 4.
  • the structure 1 may then be subjected to a heat treatment or to a further heat treatment if heat has already been applied during winding of the material 4. This will again soften and melt any thermoplastic yarns used in the structure 1 so that the layers 2, 3, and 4 bonded together.
  • a heat treatment could be carried out after the structure 1 has been removed from the former 1 1 . The latter operation is carried out by deflating the former 1 1 so that it can be readily withdrawn from the finished structure 1.
  • the innermost layer 2 is not made from a seamless woven tube but from a single piece of material that is rolled so that two opposite edges butt up to one another. The material is then secured in this position by a tie, for example a length of the same yarn as is being used to weave the layer 2, or a peg or staple made from a material such as wood that will burn away or carbonize when the structure 1 itself is carbonized.
  • a tie for example a length of the same yarn as is being used to weave the layer 2
  • a peg or staple made from a material such as wood that will burn away or carbonize when the structure 1 itself is carbonized.
  • the structure 1 may be consolidated by the inclusion of a seamless woven tube as one of the intermediate layers 4.
  • several layers 4 made of doubled-sided piled material 6 are wound around the innermost layer 2 before a seamless woven tube is applied over them.
  • Several furth er layers 4 are then applied made of double-sided piled material 6 before the outer layer 3 is applied as described above.
  • the intermediate seamless woven tube may be applied in the same way as the outer layer 3, the former 1 1 being deflated slighdy to facilitate its location over the underlying layers 4. It will be appreciated th at the layers 4 applied to the former may be wound so that the diameter of the structure 1 varies along its length.
  • Fibrous structures 1 have several advantages, as follows. 1. Their production is simple and minimises waste of yarn and material, which is important as the yarn may be expensive to produce. 2.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Textile Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Braking Arrangements (AREA)
  • Woven Fabrics (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention se rapporte à une structure (1) fibreuse de carbone ou pouvant être carbonée telle qu'une structure qui particulièrement, mais pas exclusivement, s'appliquer à la fabrication de préformes à utiliser dans la production de produits de friction et à des structures creuses résistant à la chaleur. La structure (1) comprend un tube en couches comprenant une couche intérieure (2), une couche extérieure (3) et au moins une couche intermédiaire (4). La couche intermédiaire (4) est constituée d'un matériau (5) comprenant un fil de carbone ou un fil de carbone précurseur sous la forme d'un substrat (6) avec un poil (7 ; 10) dépassant d'au moins un côté de celui-ci. De préférence, le substrat (6) est tissé et comporte des poils (7, 10) dépassant des deux côtés de celui-ci. Le poil (7 ; 10) a également de préférence été soulevé du substrat (6) par fracture des fils composant le substrat (6), par exemple par aiguilletage, cardage ou abrasion du substrat (6). L'invention se rapporte également à un procédé de fabrication d'une telle structure (1).
PCT/GB2012/000155 2011-02-22 2012-02-16 Structure fibreuse de carbone ou pouvant être carbonée et son procédé de fabrication WO2012114061A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
GBGB1103002.0A GB201103002D0 (en) 2011-02-22 2011-02-22 A carbon or carbonizable fibrous structure and a method of manufacturing same
GB1103002.0 2011-02-22
GBGB1110372.8A GB201110372D0 (en) 2011-02-22 2011-06-20 A carbon or carbonizable fibrous structure and a method of manufacturing same
GB1110372.8 2011-06-20

Publications (1)

Publication Number Publication Date
WO2012114061A1 true WO2012114061A1 (fr) 2012-08-30

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GB (3) GB201103002D0 (fr)
WO (1) WO2012114061A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103317733A (zh) * 2012-10-12 2013-09-25 北京航空航天大学 仿蚕茧缠绕编织结构的复合材料车厢蒙皮及其制备方法
EP2674576A1 (fr) * 2012-02-09 2013-12-18 General Electric Company Revêtements renforcés et leurs procédés de fabrication
EP3804967A1 (fr) * 2019-10-08 2021-04-14 Honeywell International Inc. Procédé de fabrication d'une préforme en fibre composite pour freins à disque
US11293507B2 (en) 2019-10-08 2022-04-05 Honeywell International Inc. Composite fiber preform for disc brakes

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1004476A (en) 1961-04-29 1965-09-15 Manilal Mohanlal Improvements in or relating to capacitors and methods of making capacitors
GB1215589A (en) * 1966-12-13 1970-12-09 Carborundum Co Laminated, reinforced carbon articles
GB2099365A (en) * 1981-06-02 1982-12-08 Lorraine Carbone Process for the production of friction discs
EP0232059A2 (fr) 1986-01-28 1987-08-12 Aerospace Preforms Limited Production d'une structure en forme, composée de filaments
EP0748781A2 (fr) 1991-08-15 1996-12-18 The B.F. Goodrich Company Structures de fibres pressées et moulées et procédé de fabrication
WO1998049382A1 (fr) 1997-04-30 1998-11-05 The B.F.Goodrich Company Procede simplifie permettant de fabriquer des structures fibreuses epaisses
GB2428253A (en) 2005-07-09 2007-01-24 P G Lawton Production of shaped filamentary structures

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4790052A (en) * 1983-12-28 1988-12-13 Societe Europeenne De Propulsion Process for manufacturing homogeneously needled three-dimensional structures of fibrous material
GB2478768B (en) * 2010-03-18 2013-01-30 Marathon Belting Ltd A fibrous structure and a method of manufacturing same

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1004476A (en) 1961-04-29 1965-09-15 Manilal Mohanlal Improvements in or relating to capacitors and methods of making capacitors
GB1215589A (en) * 1966-12-13 1970-12-09 Carborundum Co Laminated, reinforced carbon articles
GB2099365A (en) * 1981-06-02 1982-12-08 Lorraine Carbone Process for the production of friction discs
EP0232059A2 (fr) 1986-01-28 1987-08-12 Aerospace Preforms Limited Production d'une structure en forme, composée de filaments
EP0748781A2 (fr) 1991-08-15 1996-12-18 The B.F. Goodrich Company Structures de fibres pressées et moulées et procédé de fabrication
WO1998049382A1 (fr) 1997-04-30 1998-11-05 The B.F.Goodrich Company Procede simplifie permettant de fabriquer des structures fibreuses epaisses
GB2428253A (en) 2005-07-09 2007-01-24 P G Lawton Production of shaped filamentary structures

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2674576A1 (fr) * 2012-02-09 2013-12-18 General Electric Company Revêtements renforcés et leurs procédés de fabrication
CN103317733A (zh) * 2012-10-12 2013-09-25 北京航空航天大学 仿蚕茧缠绕编织结构的复合材料车厢蒙皮及其制备方法
EP3804967A1 (fr) * 2019-10-08 2021-04-14 Honeywell International Inc. Procédé de fabrication d'une préforme en fibre composite pour freins à disque
US11293507B2 (en) 2019-10-08 2022-04-05 Honeywell International Inc. Composite fiber preform for disc brakes
US11655870B2 (en) 2019-10-08 2023-05-23 Honeywell International Inc. Method for manufacturing composite fiber preform for disc brakes

Also Published As

Publication number Publication date
GB201202647D0 (en) 2012-04-04
GB201103002D0 (en) 2011-04-06
GB2489076A (en) 2012-09-19
GB201110372D0 (en) 2011-08-03

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