초록 ▼

A carbon composite article and the method of making the article wherein selected carbon fibrous materials are formed into a basic starting substrate having a volume greater than the desired volume of the finished article. Very small amounts of a carbonaceous binder material are used to bond the fibr

A carbon composite article and the method of making the article wherein selected carbon fibrous materials are formed into a basic starting substrate having a volume greater than the desired volume of the finished article. Very small amounts of a carbonaceous binder material are used to bond the fibrous materials together at a multiplicity of bonding sites. The basic substrate is then subjected to controlled temperatures and pressures to form a shaped substrate characterized by having a high degree of open porosity, a predetermined shape and structural integrity sufficient to withstand subsequent substrate processing. The carbonaceous binder is applied to the fibrous material in a manner whereby substantial encapsulation of the individual fibers is avoided so that the portions of the fibers disposed intermediate the bonding sites are free to move to accommodate and effectively distribute stresses which may be generated within the substrate due to material shrinkage or other process related causes. The shaped substrate is then partially or fully densified in a freestanding configuration by chemical vapor deposition of pyrolytic materials interstitially of the substrate.

대표청구항 ▼

A composite article comprising a multiplicity of intercrossing fibers joined together at spaced apart bonding sites by a carbonaceous binder material, said individual fibers being uniformly coated with a pyrolytic material and being further joined together at their crossover points by a coating of p

A composite article comprising a multiplicity of intercrossing fibers joined together at spaced apart bonding sites by a carbonaceous binder material, said individual fibers being uniformly coated with a pyrolytic material and being further joined together at their crossover points by a coating of pyrolytic material, said article having a fiber volume of between approximately 5 volume percent and approximately 40 volume percent, the amount of said binder material being limited to betweeen approximately 1.0 weight percent and approximately 15.0 weight percent.