PAEK High-Temperature Composites With Fewer Pyrolysis Cycles
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Solution Overview
Problem
Traditional methods for producing high temperature composites like carbon carbon composites, carbon ceramic matrix composites, and carbon silica composites are labor-intensive, time-consuming, and prone to errors due to manual labor and low char yields, leading to long production times and potential defects.
Innovation Solution
Utilizing polyaryletherketones (PAEK), particularly polyetherketoneketones (PEKK), in a thermoplastic resin to create high temperature composites through automated methods, allowing for high char yields and reduced pyrolysis cycles, thereby shortening production time and improving quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual hand lay-up methods are used to place thermoset prepregs, then the process can be implemented with existing equipment, but significant manual labor is required leading to high costs, human error, and low quality
Solution Approach 1:
The patent changes the material parameter from thermoset prepregs to thermoplastic tapes, which fundamentally alters the processing requirements. Thermoplastic tapes can be processed using automated methods without requiring the manual hand lay-up process, thereby reducing manual labor while maintaining ease of manufacture through established automated equipment
Solution Approach 2:
The patent replaces the manual mechanical process of hand lay-up with automated mechanical systems such as automated tape placement machines and 3D printing technologies. This substitution eliminates human labor while maintaining manufacturing capability through automated equipment
2Reliability
If traditional pyrolysis processes are used with phenolic based solutions, then the process can be completed, but char yields are limited to 50-70% requiring multiple cycles and long production times
Solution Approach 1:
The patent changes the resin parameter from phenolic based solutions to thermoplastic resins (PAEK, PEKK), which fundamentally alters the pyrolysis characteristics. This material parameter change enables char yields of 70-95% in a single pyrolysis cycle, eliminating the need for multiple cycles and significantly reducing production time
Solution Approach 2:
The patent converts the previously harmful effect of low char yields (requiring multiple cycles and time) into a beneficial outcome by using thermoplastic resins that naturally provide high char yields. The single pyrolysis cycle with thermoplastic resins transforms what was previously a multi-step time-consuming process into a single efficient operation
3Manufacturing precision
If multiple pyrolysis cycles are performed to achieve fully dense parts, then the desired density is achieved, but each cycle is labor intensive and time consuming with potential for errors
Solution Approach 1:
The patent changes the resin parameter to thermoplastic materials that provide sufficient char yield (70-95%) in a single pyrolysis cycle. This single-cycle approach achieves fully dense parts without requiring multiple repetitive cycles, thereby maintaining manufacturing precision while dramatically improving production efficiency
Solution Approach 2:
The patent extracts and eliminates the unnecessary multiple pyrolysis cycles from the traditional multi-step process. By using thermoplastic resins with inherently higher char yields, the process achieves the desired part density in a single cycle, removing the repetitive labor-intensive steps while maintaining the required manufacturing precision
4Ease of manufacture
If thermoset composites are used, then the process can be completed with traditional methods, but refrigerated shipment and storage is required adding to complexity and cost
Solution Approach 1:
The patent changes the material parameter from thermoset composites to thermoplastic composites. This parameter change eliminates the requirement for refrigerated shipment and storage, as thermoplastic materials do not have the same temperature-sensitive storage requirements as thermoset materials, thereby reducing device complexity while maintaining ease of manufacture
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
The method enables the production of high temperature composites with char yields up to 95% and reduces production time to less than 200 hours, enhancing efficiency and quality while maintaining mechanical performance.
Implementation Method 1
A pyrolysis step (thermal treatment) can be used in the production of carbon carbon composites, carbon ceramic matrix composites, and carbon silica composites. The pyrolysis can be implemented to eliminate volatiles and/or non-carbon organic elements in the composites (such as in the polymer matrix) and retain the carbon elements.
Implementation Method 2
Thermoplastic composite materials have an advantage in their ability to be processed by automated methods, including automated tape placement and 3D printing.
Data Source
AI summary
A method for making a carbon carbon, carbon ceramic matrix, or carbon silica composite, comprising melt processing a resin comprising a polyaryletherketone (PAEK) and at least one reinforcing additive to make a precursor part, pyrolyzing the precursor part to make a pyrolyzed part, infusing a liquid second resin into the pyrolyzed part to make an infused part, and pyrolyzing the infused part. Other methods comprise processing aligned reinforcing additives and a resin comprising a PAEK to make an aligned reinforcing additives PAEK, aligned 1-2 dimensional flake material, or aligned 1-2 dimensional platelet material, to create a fabric, prepreg or tape comprising the aligned reinforcing additives and impregnated PAEK. Other methods comprise impregnating continuous fiber tape or fabric with a resin comprising PAEK and at least one reinforcing additive or co-weaving a continuous fiber or fabric with a PAEK fiber comprising PAEK and at least one reinforcing additive.