Carbon/Carbon Preforms via EDAM for Fiber Orientation and Shape Stability
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Solution Overview
Problem
Existing manufacturing methods for carbon/carbon composites face challenges in efficiently producing complex geometries and orientations of carbon fibers, leading to high costs and structural issues due to laborious preform processing and scalability limitations in additive manufacturing techniques.
Innovation Solution
The use of extrusion deposition additive manufacturing (EDAM) to form carbon/carbon preforms by extruding a polymer composite material and heating it via pyrolysis, allowing for the orientation of carbon fibers and formation of complex-shaped composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods (filament winding, resin transfer molding, autoclave curing) are used to produce carbon fiber preforms, then fiber orientation and preform formation can be achieved, but the process becomes laborious and complex, reducing productivity and increasing manufacturing cost
Solution Approach 1:
The patent changes the physical state and processing parameters of carbon fibers by impregnating them with a binder solution to form a slurry, then drying and firing the slurry to create a green preform. This parameter transformation enables automated handling and processing of carbon fibers that would otherwise be too delicate and difficult to manipulate in conventional wet-layup processes, thereby improving both precision and productivity
Solution Approach 2:
The patent replaces manual mechanical operations (hand layup, filament winding, autoclave curing) with an automated extrusion-based additive manufacturing system. The slurry is extruded layer-by-layer to build up complex preform geometries automatically, eliminating labor-intensive steps while maintaining precise fiber orientation control through programmed deposition paths
2Ease of manufacture
If additive manufacturing techniques are used to manufacture carbon fiber preforms, then complex geometries can be produced with reduced labor, but residual stresses and dimensional stability issues arise during pyrolysis
Solution Approach 1:
The patent performs preliminary actions before pyrolysis by carefully controlling the extrusion process to minimize residual stresses in the green preform, and by implementing a staged firing schedule that gradually removes the binder and converts organic material to carbon. This preliminary preparation ensures dimensional stability is maintained throughout the subsequent pyrolysis process, preventing distortion of complex geometries
Solution Approach 2:
The patent controls the chemical composition and physical structure of the green preform through parameter optimization during extrusion and drying. By adjusting slurry viscosity, fiber-to-binder ratio, and drying conditions, the preform achieves optimal mechanical properties and stress distribution before pyrolysis, ensuring dimensional stability is preserved during the thermal conversion process
3Manufacturing precision
If multiple infiltration and pyrolysis cycles are performed to densify carbon/carbon composites, then porosity is reduced and material density is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent performs preliminary densification by extruding the carbon fiber slurry with controlled void content and arranging fibers in densely packed configurations during additive manufacturing. This pre-densification reduces the initial porosity of the green preform before pyrolysis, so that fewer subsequent infiltration cycles are needed to achieve the target density, thereby reducing total manufacturing time and cost
Solution Approach 2:
The patent uses the binder material in the slurry as a temporary placeholder that is later replaced by carbon during pyrolysis. The binder creates a continuous matrix that holds fibers in position and maintains preform shape during processing. During controlled pyrolysis, the binder converts to carbon, copying its original structure and density characteristics into the final C/C composite, eliminating the need for multiple infiltration cycles to achieve dense structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
EDAM enables the production of complex-shaped carbon/carbon composites with improved dimensional stability and reduced manufacturing costs by orienting fibers and minimizing residual stresses, facilitating scalable and cost-effective manufacturing.
Implementation Method 1
extruding a polymer composite material using an extrusion deposition additive manufacturing process to form a preform
Implementation Method 2
heating the preform via pyrolysis to form the carbon/carbon composite
Data Source
AI summary
Methods of manufacturing carbon/carbon preforms and carbon/carbon composites formed therefrom. Such a method includes extruding a polymer composite material using an extrusion deposition additive manufacturing process to form a preform, and heating the preform via pyrolysis to form the carbon/carbon composite.