Allen H Simpson

US Patent:

7438839, Oct 21, 2008

Filed:

Oct 1, 2004

Appl. No.:

10/956582

Inventors:

Allen H. Simpson - Buchanan MI, US
Slawomir T. Fryska - Granger IN, US
Mark L. La Forest - Granger IN, US
Barry P. Soos - Mishawaka IN, US

Assignee:

Honeywell International Inc. - Morris Township NJ

International Classification:

B29C 43/02

US Classification:

264 292, 264 291, 264240, 264241, 428408, 4234472

Abstract:

Method for manufacturing a carbonized carbon-carbon composite preform, by: mixing (a) chopped carbon fiber, chopped stabilized pitch fiber, or chopped oxidized polyacrylonitrile (PAN) fiber, (b) thermoplastic pitch binder powder, and (c) activated carbon powder to form a mixture of 15-60 parts by weight of chopped carbon fiber or chopped stabilized pitch fiber or chopped oxidized PAN, 28-83 parts by weight of thermoplastic pitch binder powder, and 1-12 parts by weight of activated carbon powder; depositing this mixture into a mold; pressing/heating the materials in the mold to form a preform by compaction; removing the compacted preform from the mold; and carbonizing the compacted preform. The preform is preferably configured in the form of an aircraft landing system brake disc.

US Patent:

7575799, Aug 18, 2009

Filed:

Mar 15, 2006

Appl. No.:

11/375119

Inventors:

Slawomir T. Fryska - Granger IN, US
Mark L. La Forest - Granger IN, US
Allen H. Simpson - Buchanan MI, US

Assignee:

Honeywell International Inc. - Morris Township NJ

International Classification:

B32B 17/12

US Classification:

4282934, 428 662, 428408

Abstract:

Small ceramic particles (e. g. , of TiC) are incorporated into fibers. The ceramic particles enhance the friction and/or wear properties of a carbon-carbon composite article made with the impregnated or coated fibers. The impregnated fibers can be, e. g. , polyacrylonitrile (PAN) fibers, pitch fibers, and other such fibers as are commonly employed in the manufacture of C-C friction materials. The impregnated fibers can be used to make woven, nonwoven, or random fiber preforms or in other known preform types. Preferred products are brake discs and other components of braking systems. The particles may be included in the fibers by mixing them with the resin employed to make the fibers and/or by applying them to the surfaces of the fibers in a binder.

US Patent:

7588179, Sep 15, 2009

Filed:

Mar 30, 2007

Appl. No.:

11/730373

Inventors:

Allen H. Simpson - Buchanan MI, US
Mark L. La Forest - Granger IN, US
Alexander Mukasyan - Granger IN, US
Douglas J. Steinke - South Bend IN, US

Assignee:

Honeywell International Inc. - Morris Township NJ

International Classification:

B23K 31/02

US Classification:

2282343

Abstract:

Resin-impregnated carbon fiber composites containing metal inserts. Carbon fibers or a carbon fiber preform are bonded to a metal structural member. Once the carbon fiber-metal bond is established, the fiber-metal assembly or hybrid preform is impregnated with resin, to form an article in which bonding between the metal structural member and the composite remainder of the article is greatly enhanced. In a process embodiment, a metal insert, e. g. a steel insert, is provided in contact with particulate carbide-forming metal, e. g. titanium, and with carbon fiber segments. Then an electric current is passed through the carbide-forming metal particles and carbon fibers to heat them to a temperature above the melting point of the carbide-forming metal. This initiates an exothermic reaction, which forms liquid phase metal carbide. Subsequently the liquid phase metal carbide is cooled and solidified, thereby bonding the carbon fiber segments to the metal insert.

US Patent:

7632435, Dec 15, 2009

Filed:

May 18, 2006

Appl. No.:

11/435734

Inventors:

Allen H. Simpson - Buchanan MI, US
Slawomir T. Fryska - Granger IN, US
Mark L. La Forest - Granger IN, US
Barry P. Soos - Mishawaka IN, US

Assignee:

Honeywell International Inc. - Morristown NJ

International Classification:

C01B 31/00

US Classification:

264 291

Abstract:

Method of carbonizing pitch-infiltrated fibrous annular preform by: infiltrating the preform with pitch; placing the pitch-infiltrated preform in a constraint fixture having an ejector base plate, an inner wall, an outer wall, and a top press plate; selecting the relative sizes of the preform and the constraint fixture so that a layer of inert friable material may be situated between the preform and walls of the constraint fixture; placing inert friable material (e. g. , activated carbon) between the preform and the top, bottom, and walls of the constraint fixture; and subjecting the pitch-infiltrated fibrous preform to carbonization in the constraint fixture. The activated carbon or other inert friable material adsorbs pitch molecules that escape the preform during carbonization, which reduces problems with foaming. The layer of activated carbon or other friable material between the fibrous preform and the constraint fixture also provides an easily crushable region that facilitates removal of the preform from the constraint fixture after carbonization.

US Patent:

7632436, Dec 15, 2009

Filed:

Jun 20, 2006

Appl. No.:

11/455743

Inventors:

Allen H. Simpson - Buchanan MI, US
Slawomir T. Fryska - Granger IN, US
Mark L. La Forest - Granger IN, US

Assignee:

Honeywell International Inc. - Morristown NJ

International Classification:

C01B 31/00

US Classification:

264 296, 264257

Abstract:

Process of manufacturing carbon-carbon composite preform by: (i. ) arranging batch of carbon fiber preforms in infiltration vessel; (ii. ) flooding vessel with hot liquid phase pitch at atmospheric pressure in inert atmosphere; (iii. ) raising pressure in infiltration vessel to elevated pressure, and then slowly lowering pressure; and (iv. ) repeating step (iii. ). An apparatus that may be used is a heated infiltration vessel capable of operating at pressures above 100 psi, possible equipped with means to circulate heated pitch inside the vessel, in order to facilitate heat transfer into the carbon fiber preforms being infiltrated by the pitch. The need for a vacuum pump is eliminated, and the time spent heating the preform is substantially reduced. Instead of vacuum, cycled high pressure is employed to infiltrate carbon fiber preforms with pitch. The use of preheated pitch as a heat transfer agent avoids the slow transfer of heat into the preform prior to infiltration.

US Patent:

7686904, Mar 30, 2010

Filed:

Oct 20, 2006

Appl. No.:

11/583922

Inventors:

Slawomir T. Fryska - Granger IN, US
Mark C. James - South Bend IN, US
Mark L. LaForest - Granger IN, US
Allen H. Simpson - Buchanan MI, US
Barry P. Soos - Mishawaka IN, US

Assignee:

Honeywell International Inc. - Morristown NJ

International Classification:

C03B 29/00
A61F 13/15
C04B 37/00
B27G 11/02
B32B 27/00
B29C 65/00

US Classification:

156 8913, 156 8911, 156276, 156325, 1563796, 1563798, 156536, 156537

Abstract:

This invention generally pertains to self propagating high temperature synthesis or combustion synthesis as a way of bonding materials. The present invention provides methods and an apparatus for bonding, preferably carbon-carbon composite materials, by combustion synthesis. Generally, the invention involves providing at least two carbon-carbon composite parts to be bonded and interspersing a combustion synthesis material in between the parts with each part in contact with the combustion synthesis material. The combustion synthesis material is then ignited, which initiates the combustion synthesis reaction. Typically, a ceramic material is formed which immediately freezes, bonding the parts together.

US Patent:

7700014, Apr 20, 2010

Filed:

Apr 13, 2006

Appl. No.:

11/402791

Inventors:

Allen H. Simpson - Buchanan MI, US
Slawomir T. Fryska - Granger IN, US
Mark L. La Forest - Granger IN, US
Barry P. Soos - Mishawaka IN, US

Assignee:

Honeywell International Inc. - Morris Township NJ

International Classification:

C01B 31/00

US Classification:

264 295, 264 297

Abstract:

Method of manufacturing dense carbon-carbon composite material by: infiltrating a fibrous preform with pitch to form pitch-infiltrated preform; carbonizing the pitch-infiltrated preform; injecting resin or pitch into the preform in a mold; oxygen stabilizing the filled preform and carbonizing and heat-treating the oxygen-stabilized impregnated preform; and subjecting the preform to a single final cycle of chemical vapor deposition. This process reduces densification time as compared to comparable conventional carbon-carbon composite manufacturing procedures.

US Patent:

7763192, Jul 27, 2010

Filed:

Mar 27, 2006

Appl. No.:

11/389022

Inventors:

Allen H. Simpson - Buchanan MI, US
Mark L. La Forest - Granger IN, US
Slawomir T. Fryska - Granger IN, US

Assignee:

Honeywell International Inc. - Morris Township NJ

International Classification:

B29C 45/14
C01B 31/02
B64C 25/00

US Classification:

264 295, 264162, 264279, 4272494

Abstract:

Method of manufacturing composite wheel beam key by: forming entirely from carbon fiber precursors or from carbon fiber precursors and ceramic materials a fibrous preform blank in a shape of a desired wheel beam key, wherein the fiber volume fraction of the preform blank is at least 50%; carbonizing the carbon fiber precursors; rigidifying the carbonized preform blank by subjecting it to at least one cycle of CVD; grinding the surface of the preform blank to open pores on its surface; and subjecting the open-pored preform blank to RTM processing with pitch. Also, carbon-carbon composite or carbon-ceramic composite wheel beam key produced by this process, having a density of from 1. 5 g/cc to 2. 1 g/cc and a maximum internal porosity of 10% or less.