COMPOSITE MANUFACTURE PROCESS Russian patent published in 2003 - IPC

FIELD: composites. SUBSTANCE: application areas: motor-car construction, shipbuilding, power engineering, chemical, light, food, and electrochemical industries. Invention can be utilized in production of current collectors of fuel elements with membrane-electrode block, porous electrochemical electrodes, filter elements employing porous composites with carbon-containing matrix. Method includes manufacturing reinforcing framework from carbon fibers, impregnating it with binder solution, and polymerization of binder followed by carbonization of prepreg. Method is distinguished by preliminarily preparing specified amount of slip by mixing dispersed filler and polymer binder, said slip being further used to fill carbonized prepreg. Thereafter, simultaneously progressive external contact pressure to 100 kPa and heating to 160-200 C are imposed in combination with vibrations with amplitude 1-10 mm and frequency 3-10 Hz during 30-60 sec. Specified amount of slip selected from condition of exceeding of hollow volume of single-layer cloth is calculated in terms of formula: where m_s is slip mass, d_s slip density, a prepreg length, b prepreg width, h prepreg thickness, m_pr prepreg mass, and d_fib fiber density. Prepreg is further subjected to thermal hardening at 200-400 C or to carbonization. The latter operation is carried out for 1-2 h within temperature range 800 to 1100 C using temperature raise with velocity no larger than 2 C/min. Amount of slip exceeds hollow volume of single-layer cloth by 3-10%. Filler for slip is powdered fluoroplastic added in amount 3 to 10 wt % and having particle size not exceeding dimensions of hollows of prepreg cloth. EFFECT: enabled manufacture of composite with predetermined properties, controlled porosity, increased permeability in terms of gas and liquids, and increased mechanical strength, and reduced manufacture expenses. 5 cl, 7 dwg, 4 ex