Fiber reinforced composite product

Claim 1

A METHOD OF FORMING A HIGH STRENGTH FIBER REINFORCED COMPOSITE PRODUCT COMPRISING THE STEPS OF: A. CONSTRUCTING A BASIC SUBSTRATE FROM THEGROUP CONSISTING OF BON FIBROUS MATERIAL SELECTED FROM THE GROUP CONSISTING OF PYROLYZED WOOL, RAYON, POLYACRYLONITRILE AND PITCH FIBERS, THE FIBER VOLUME OF SAID FIBROUS MATERIAL BEING KNOWN AND THE VOLUME OF SAID BASIC SUBSTRATE BEING GREATER THAN THE VOLUME OF THE FINAL PRODUCT, B. COMPRESSING SAID BASIC SUBSTRATE BY A PRESSURE COMPACTION MEANS FOR REDUCING THE VOLUME OF SAID BASIC SUBSTRATE INTO A SHAPED SUBSTRATE SO THAT SAID SHAPED SUBSTRATE WILL HAVE A SHAPE SUBSTANTIALLY CORRESPONDING TO THE SHAPE OF THE FINAL PRODUCT, WILL HAVE A FIBER VOLUME OF BETWEEN 8% AND 69%, AND WILL HAVE SUFFICIENT INTERNAL POROSITY TO PERMIT THE PASSAGE OF GAS THERETHROUGH, AND C. FORMING SAID SHAPED SUBSTRATE INTO A BONDED SUBSTRATE BY CONSTRAINING SAID SHAPED SUBSTRATE WITHIN SAID PRESSURE COMPACTION MEANS TO SUBSTANTIALLY MAINTAIN ITS SHAPE AND FIBER VOLUME WHILE INTERSTITIALLY DEPOSITING PYROLYTIC MATERIAL TO STRUCTURALLY BOND TOGETHER THE COMPRESSIBLE FIBROUS CARBON MATERIAL WITH PYROLYTIC MATERIAL, SAID PYROLYTIC MATERIAL BEING SELECTED FROM A GROUP CONSISTING OF PYROLYTIC CARBON, PYROLYTIC GRAPHITE, BORON NITRIDE, TANTALUM, TUNGSTEN, MOLYBDENUM, COLUMBIUM, TANTALUM CARBIDE, NIOBIUM CARBIDE, ZIRCONIUM CARBIDE, HAFNIUM CARBIDE AND SILICON CARBODE.

Claim 2

A METHOD OF FORMING A HIGH STRENGTH FIBER REINFORCED COMPOSITE PRODUCT COMPRISING THE STEPS OF: A. CONSTRUCTING A BASIC SUBSTRATE FROM THEGROUP CONSISTING OF BON FIBROUS MATERIAL SELECTED FROM THE GROUP CONSISTING OF PYROLYZED WOOL, RAYON, POLYACRYLONITRILE AND PITCH FIBERS, THE FIBER VOLUME OF SAID FIBROUS MATERIAL BEING KNOWN AND THE VOLUME OF SAID BASIC SUBSTRATE BEING GREATER THAN THE VOLUME OF THE FINAL PRODUCT, B. COMPRESSING SAID BASIC SUBSTRATE BY A PRESSURE COMPACTION MEANS FOR REDUCING THE VOLUME OF SAID BASIC SUBSTRATE INTO A SHAPED SUBSTRATE SO THAT SAID SHAPED SUBSTRATE WILL HAVE A SHAPE SUBSTANTIALLY CORRESPONDING TO THE SHAPE OF THE FINAL PRODUCT, WILL HAVE A FIBER VOLUME OF BETWEEN 8% AND 69%, AND WILL HAVE SUFFICIENT INTERNAL POROSITY TO PERMIT THE PASSAGE OF GAS THERETHROUGH, AND C. FORMING SAID SHAPED SUBSTRATE INTO A BONDED SUBSTRATE BY CONSTRAINING SAID SHAPED SUBSTRATE WITHIN SAID PRESSURE COMPACTION MEANS TO SUBSTANTIALLY MAINTAIN ITS SHAPE AND FIBER VOLUME WHILE INTERSTITIALLY DEPOSITING PYROLYTIC MATERIAL TO STRUCTURALLY BOND TOGETHER THE COMPRESSIBLE FIBROUS CARBON MATERIAL WITH PYROLYTIC MATERIAL, SAID PYROLYTIC MATERIAL BEING SELECTED FROM A GROUP CONSISTING OF PYROLYTIC CARBON, PYROLYTIC GRAPHITE, BORON NITRIDE, TANTALUM, TUNGSTEN, MOLYBDENUM, COLUMBIUM, TANTALUM CARBIDE, NIOBIUM CARBIDE, ZIRCONIUM CARBIDE, HAFNIUM CARBIDE AND SILICON CARBODE.

Claim 15

A method of forming a high strength fiber reinforced composite product comprising the sTeps of: a. stacking a plurality of compressible carbon fibrous members formed from material selected from the group consisting of pyrolyzed wool, rayon, polyacrylonitrile and pitch fibers into a basic substrate, the volume of solid material in each of said compressible members being known and the volume of the basic substrate thus formed being greater than is desired in the final product, said compressible members being oriented with respect to one another to obtain the desired substrate internal fiber orientation; b. compressing said basic substrate to reduce the volume thereof so that the compressed substrate will have a shape substantially corresponding to the desired shape of the final product, will have a fiber volume of between approximately 8% and 36% and will have the desired internal fiber orientation; c. bonding together the fibrous material of said compressed substrate to form a one-piece bonded substrate by interstitially depositing pyrolytic material while said compressed substrate is being held in a compressed condition, said pyrolytic material being selected from a group consisting of pyrolytic carbon, pyrolytic graphite, boron nitride, tantalum, tungsten, molybdenum, columbium, tantalum carbide, niobium carbide, zirconium carbide, hafnium carbide and silicon carbide; d. removing the outer surface from said bonded substrate and thereafter densifying said bonded substrate by further deposition of pyrolytic material selected from a group consisting of pyrolytic carbon, pyrolytic graphite, boron nitride, tantalum, tungsten, molybdenum, columbium, tantalum carbide, niobium carbide, zirconium carbide, hafnium carbide and silicon carbide; and e. sizing said densified bonded substrate to its final size and shape.

Claim 16

A method of forming a high strength fiber reinforced composite product comprising the sTeps of: a. stacking a plurality of compressible carbon fibrous members formed from material selected from the group consisting of pyrolyzed wool, rayon, polyacrylonitrile and pitch fibers into a basic substrate, the volume of solid material in each of said compressible members being known and the volume of the basic substrate thus formed being greater than is desired in the final product, said compressible members being oriented with respect to one another to obtain the desired substrate internal fiber orientation; b. compressing said basic substrate to reduce the volume thereof so that the compressed substrate will have a shape substantially corresponding to the desired shape of the final product, will have a fiber volume of between approximately 8% and 36% and will have the desired internal fiber orientation; c. bonding together the fibrous material of said compressed substrate to form a one-piece bonded substrate by interstitially depositing pyrolytic material while said compressed substrate is being held in a compressed condition, said pyrolytic material being selected from a group consisting of pyrolytic carbon, pyrolytic graphite, boron nitride, tantalum, tungsten, molybdenum, columbium, tantalum carbide, niobium carbide, zirconium carbide, hafnium carbide and silicon carbide; d. removing the outer surface from said bonded substrate and thereafter densifying said bonded substrate by further deposition of pyrolytic material selected from a group consisting of pyrolytic carbon, pyrolytic graphite, boron nitride, tantalum, tungsten, molybdenum, columbium, tantalum carbide, niobium carbide, zirconium carbide, hafnium carbide and silicon carbide; and e. sizing said densified bonded substrate to its final size and shape.