US10315960B2 – June 11, 2019 – Sacrificial fibers to create channels in a composite material

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Inventors :

Mark L. La Forest; Slawomir T. Fryska; David M. Wright

Owner :

C04B35 / 83; B29B11 / 16; B29K307 / 04; C01B32 / 05; C04B35 / 185; C04B35 / 195; C04B35 / 478; C04B35 / 52; C04B35 / 628; C04B38 / 00; C04B41 / 00; C04B41 / 45; D06M10 / 10; D06M15 / 37

Application Number :

US15285589

Document Number :

US10315960B2

Priority Date :

October 5, 2016

Filing Date :

October 5, 2016

Date of Grant/ Publication :

June 11, 2019

Class :

HONEYWELL INTERNATIONAL INC.

Abstract

A carbon fiber preform that includes a plurality of fibrous layers stacked together and a plurality of sacrificial fibers that bind the plurality of fibrous layers together, where at least one fibrous layer of the plurality of fibrous layers includes a plurality of carbon fibers or carbon fiber precursor fibers.

Claim(s)

1. A carbon fiber preform comprising: a plurality of fibrous layers stacked together, wherein at least one fibrous layer of the plurality of fibrous layers comprises a plurality of carbon fibers or carbon fiber precursor fibers and a first plurality of sacrificial fibers mixed with the plurality of carbon fibers or carbon fiber precursor fibers; and a second plurality of sacrificial fibers that bind the plurality of fibrous layers together, wherein the first plurality of sacrificial fibers is interwoven with the plurality of carbon fibers or carbon fiber precursor fibers, and wherein the plurality of fibrous layers further comprises a non-woven fibrous layer comprising a mixture of: a third plurality of sacrificial fibers, and a second plurality of carbon fibers or carbon fiber precursor fibers.;
5. A method of forming a carbon fiber preform, the method comprising: stacking plurality of fibrous layers together, wherein at least one fibrous layer comprises a plurality of carbon fibers or carbon fiber precursor fibers and a first plurality of sacrificial fibers mixed with the plurality of carbon fibers or carbon fiber precursor fibers; mechanically binding the fibrous layers by forming a second plurality of sacrificial fibers that bind the plurality of fibrous layers together wherein the first plurality of sacrificial fibers is interwoven with the plurality of carbon fibers or carbon fiber precursor fibers, and wherein the plurality of fibrous layers further comprises a non-woven fibrous layer comprising a mixture of: a third plurality of sacrificial fibers, and a second plurality of carbon fibers or carbon fiber precursor fibers.;
12. A carbon fiber preform comprising: a plurality of fibrous layers stacked and needled together, wherein the plurality of fibrous layers comprises at least one woven fibrous layer comprising a plurality of carbon fibers or carbon fiber precursor fibers interwoven with a plurality of sacrificial fibers, and wherein the plurality of fibrous layers comprises at least one non-woven fibrous layer stacked and needled to the at least one woven fibrous layer.;
17. A carbon fiber reform comprising: a plurality of fibrous layers stacked together, wherein at least one fibrous layer of the plurality of fibrous layers comprises a plurality of carbon fibers or carbon fiber precursor fibers and a first plurality of sacrificial fibers mixed with the plurality of carbon fibers or carbon fiber precursor fibers; and a second plurality of sacrificial fibers that bind the plurality of fibrous layers together, wherein the at least one fibrous layer comprises at least one tow of fibers, wherein the tow comprises the first plurality of sacrificial fibers mixed with the plurality of carbon fibers or carbon fiber precursor fibers.

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