US2005106373A1PendingUtilityA1

High density boron nitride matrix composites

37
Priority: Nov 19, 2003Filed: Nov 19, 2003Published: May 19, 2005
Est. expiryNov 19, 2023(expired)· nominal 20-yr term from priority
Inventors:James EconomyChristian MangunSteven Seghi
C04B 35/80D04H 1/43838C04B 2235/486C04B 35/6268C04B 2235/5248F16D 69/023F16D 2200/0047Y10T428/249924C04B 2235/614C04B 35/583D04H 1/42D04H 1/46C04B 35/83C04B 2235/5264C04B 2235/422C04B 2235/96C04B 2235/77
37
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Claims

Abstract

A method of manufacturing a composite material comprises forming a mixture comprising a plurality of fibers and a borazine oligomer; subjecting the mixture to a first heating, for 12 hours to 56 hours; and subjecting the mixture to a second heating. The temperature of the first heating is 60° C. to 80° C., and the pressure during the first heating is at least 0.5 MPa, the temperature of the second heating is at most 400° C., and the greatest pressure of the second heating is at least 15 MPa.

Claims

exact text as granted — not AI-modified
1 . A method of manufacturing a composite material comprising: 
 forming a mixture comprising a plurality of fibers and a borazine oligomer;    subjecting the mixture to a first heating, for 12 hours to 56 hours; and    subjecting the mixture to a second heating;    wherein the temperature of the first heating is 60° C. to 80° C., and the pressure during the first heating is at least 0.5 MPa,    the temperature of the second heating is at most 400° C., and the greatest pressure of the second heating is at least 15 MPa.    
   
   
       2 . The method of  claim 1 , further comprising subjecting the mixture to a third heating, wherein the temperature of the third heating is at least 1200° C.  
   
   
       3 . The method of  claim 1 , wherein the borazine oligomer is obtained by heating borazine for 24 to 48 hours, at a temperature of 60° C. to 80° C.  
   
   
       4 . The method of  claim 1 , wherein the fibers are carbon fibers.  
   
   
       5 . The method of  claim 1 , wherein the pressure during the first heating is 1 MPa to 6 MPa.  
   
   
       6 . The method of  claim 1 , wherein the temperature of the first heating is 65° C. to 75° C., and the pressure during the first heating is 1.5 MPa to 5 MPa.  
   
   
       7 . The method of  claim 1 , wherein the temperature of the first heating is 68° C. to 72° C., and the pressure during the first heating is 2.0 MPa to 4.6 MPa.  
   
   
       8 . The method of  claim 1 , wherein the temperature of the second heating is increased at a rate of 0.25° C./min to 3° C./min.  
   
   
       9 . The method of  claim 1 , wherein the temperature of the second heating is increased at a rate of 0.75° C./min to 1.25° C./min.  
   
   
       10 . The method of  claim 1 , wherein the temperature of the second heating is increased at a rate of 0.9° C./min to 1.1° C./min.  
   
   
       11 . The method of  claim 1 , wherein the greatest temperature reached during the second heating is 130° C. to 170° C., and the greatest pressure is 12 MPa to 32 MPa.  
   
   
       12 . The method of  claim 1 , wherein the greatest temperature reached during the second heating is 140° C. to 160° C., and the greatest pressure is 16 MPa to 26 MPa.  
   
   
       13 . The method of  claim 1 , wherein the greatest temperature reached during the second heating is 148° C. to 152° C., and the greatest pressure is 21 MPa to 23 MPa.  
   
   
       14 . The composite material made according to the method of  claim 1 .  
   
   
       15 . The composite material made according to the method of  claim 2 .  
   
   
       16 . The composite material made according to the method of  claim 3 .  
   
   
       17 . A composite material comprising carbon fibers in a boron nitride matrix, wherein the composite material has a density of at least 1.62 g/cc.  
   
   
       18 . The composite material of  claim 17 , wherein the composite material has a density of 1.62 to 1.75 g/cc.  
   
   
       19 . A composite material comprising carbon fibers in a boron nitride matrix, wherein the composite material has a wear rate of at most 0.4 mg/m at an energy level of 100 kJ/kg to 1100 kJ/kg, and a coefficient of friction of at least 0.22 at an energy level of 100 kJ/kg to 1200 kJ/kg.  
   
   
       20 . A method of manufacturing a composite material comprising boron nitride, comprising: 
 forming a mixture comprising a preform and a borazine oligomer;    subjecting the mixture to a first heating, for 12 hours to 56 hours; and    subjecting the mixture to a second heating;    wherein the temperature of the first heating is 60° C. to 80° C., and the pressure of the first heating is at least 0.5 MPa, and    the temperature of the second heating is at most 400° C., and the greatest pressure of the second heating is at least 15 MPa.    
   
   
       21 . The method of  claim 20 , further comprising subjecting the mixture to a third heating, wherein the temperature of the third heating is at least 1200° C.  
   
   
       22 . The method of  claim 20 , wherein the borazine oligomer is obtained by heating borazine for 24 to 48 hours, at a temperature of 60° C. to 80° C.  
   
   
       23 . The method of  claim 20 , wherein the preform is a 3D needled carbon fiber preform.  
   
   
       24 . The method of  claim 20 , wherein the preform is a CVI-infiltrated 3D needled carbon fiber preform.  
   
   
       25 . The composite material made according to the method of  claim 20 .  
   
   
       26 . The composite material made according to the method of  claim 21 .  
   
   
       27 . A composite material comprising a 3D needled carbon fiber preform impregnated with boron nitride having a density of at least 1.63 g/cc.  
   
   
       28 . The composite material of  claim 27 , having a density of 1.63 g/cc to 1.72 g/cc.  
   
   
       29 . A composite material, comprising CVI-infiltrated carbon fiber preform impregnated with boron nitride having a density of at least 1.62 g/ cc.  
   
   
       30 . The composite material of  claim 29 , having a density of 1.62 to 1.80 g/cc.  
   
   
       31 . A composite material comprising a 3D needled carbon fiber preform impregnated with boron nitride having a wear rate of at most 0.05 mg/m at an energy level of 100 kJ/kg to 1000 kJ/kg, and a coefficient of friction of at least 0.12 at an energy level of 100 kJ/kg to 900 kJ/kg.  
   
   
       32 . A brake for aircraft comprising the composite material of  claim 17 .  
   
   
       33 . A brake for aircraft comprising the composite material of  claim 27 .  
   
   
       34 . An aircraft comprising the brake of  claim 32 .  
   
   
       35 . An aircraft comprising the brake of  claim 33 .  
   
   
       36 . A method for decelerating an aircraft comprising braking the aircraft with the brake of  claim 32 .  
   
   
       37 . A method for decelerating an aircraft comprising braking the aircraft with the brake of  claim 33.

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