Patent ID: 7374709
Filing Date: 2008-05-20
Classification: C04B,F16D

Abstract:
1. A method of making a ceramic matrix composite and correlating the resulting composite with vehicle braking performance requirements, the method comprising the steps of: (a) infiltrating a first carbon fiber substrate with pyrolytic carbon to reach a porosity level suitable for impregnation with a pre-ceramic polymer to form a porous precursor substrate; (b) impregnating said porous precursor substrate with a pre-ceramic polymer to form a first impregnated part; (c) heating said first impregnated part within an inert gaseous atmosphere to a temperature of about 400 degrees C. for about one hour to form a first cured part; (d) heating said first cured part to a temperature of about 1,000 degrees C. for about one hour to form a first impregnated preform; (e) impregnating said first impregnated preform with a pre-ceramic polymer to form a further impregnated first impregnated preform; (f) heating said further impregnated first preform within an inert gaseous atmosphere to a temperature of about 400 degrees C. for about one hour to form a cured second impregnated preform; (g) heating said cured second impregnated preform to a temperature of about 1,000 degrees C. for about one hour to form a pyrolyzed second impregnated preform; (h) machining said pyrolyzed second impregnated preform to form a third impregnated preform; (i) impregnating said third impregnated preform with a pre-ceramic polymer to form a further impregnated third impregnated preform; (j) heating said further impregnated third impregnated preform within an inert gaseous atmosphere to a temperature of about 400 degrees C. for about one hour to form a cured fourth impregnated preform; (k) heating said cured fourth impregnated preform to about 1600 degrees C. for about eight hours to produce a fifth impregnated preform; (l) machining said fifth impregnated preform to form a sixth impregnated preform; (m) heating said sixth impregnated preform to a temperature of about 1000 degrees C. to form a heated sixth impregnated preform; (n) infiltrating said heated sixth impregnated preform with methane gas to form a first friction disc; (o) machining said first friction disc to final dimensions to form a final friction disc; (p) subjecting said final friction disc to dynamic testing to determine its strength and friction characteristics; and (q) subjecting said final friction disc to further testing to determine the level of the carbon vapor infiltration and the distribution of SiC within said final friction disc.