Carbon foam and high density carbon foam composite tooling
Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, carbon foam and high density carbon foam are described. In some embodiments, a surface of the carbon foam or high density carbon foam may comprise a tool face. In other embodiments, the carbon foam or high density carbon foam may support an other material, referred to as tool face material, wherein a surface of the tool face material may comprise a tool face. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.
1. A tool for the production of at least one composite part, the tool comprising a tool body having a tool face wherein the tool body is comprised of at least one piece of carbon foam and at least one piece of high density carbon foam having a thermal conductivity between about 5 to 70 W/mK, and wherein the tool face defines a surface that is a three dimensional negative mirror image of a surface of the at least one composite part, wherein the carbon foam has a density ranging from about 0.05 g/cc to about 0.8 g/cc and the high density carbon foam has a density ranging from above about 1. g/cc to about 1.6 g/cc.
2. The tool of claim 1 wherein a surface of said tool body defines a tool face, and wherein a portion of said tool face is at least partially a surface of said carbon foam comprising said tool body.
3. The tool of claim 1 , wherein a surface of said tool body defines a tool face, and wherein a portion of said tool face is at least partially a surface of said high density carbon foam comprising said tool body.
4. The tool of claim 1 , wherein at least a portion of cells of said carbon foam are at least partially filled with a filling material.
5. The tool of claim 1 , wherein at least a portion of the porosity of said high density carbon foam is at least partially filled with a filling material.
6. The tool of claim 4 , wherein said filling material is at least one of a cured resin, a pitch, a cured ceramic, a carbonized resin, or a carbonized pitch.
7. The tool of claim 5 , wherein said filling material is at least one of a cured resin, a pitch, a cured ceramic, a carbonized resin, or a carbonized pitch.
8. The tool of claim 1 , wherein the coefficient of thermal expansion of said tool face is substantially similar to the coefficient of thermal expansion of the composite part.
9. The tool of claim 1 , wherein at least a portion of said carbon foam comprising said tool body at least partially supports a tool face material.
10. The tool of claim 1 , wherein at least a portion of said high density carbon foam comprising said tool body at least partially supports a tool face material.
11. The tool of claim 9 , wherein at least a portion of a surface of said tool face material comprises at least a portion of a tool face.
12. The tool of claim 10 , wherein at least a portion of a surface of said tool face material comprises at least a portion of a tool face.
13. The tool of claim 9 , wherein said tool face material is selected from the group consisting of metals and ceramics.
14. The tool of claim 10 , wherein said tool face material is selected from the group consisting of metals and ceramics.
15. The tool of claim 9 , wherein said tool face material is selected from the group consisting of metal, silicon carbide, and zirconia ceramics.
16. The tool of claim 10 , wherein said tool face material is selected from the group consisting of metal, silicon carbide, and zirconia ceramics.
17. The tool of claim 9 , wherein said tool face material is selected from the group consisting of a cured resin, a fiber composite, and a particulate composite.
18. The tool of claim 10 , wherein said tool face material is selected from the group consisting of a cured resin, a fiber composite, and a particulate composite.
19. The tool of claim 9 , wherein said tool face material comprises a carbon fiber composite.
20. The tool of claim 10 , wherein said tool face material comprises a carbon fiber composite.
21. The tool of claim 1 , the high density carbon foam has a density ranging from about 1.3 g/cc to about 1.6 g/cc.
22. A method for producing at least one composite part, comprising the steps of:
providing a tool body having a tool face, wherein said tool body is comprised of carbon foam and high density carbon foam adhered together, and wherein the tool face defines a surface that is a three dimensional negative mirror image of a surface of the at least one composite part, wherein the carbon foam has a density ranging from about 0.05 g/cc to about 0.8 g/cc and the high density carbon foam has a density ranging from above about 1. g/cc to about 1.6 g/cc, and wherein the high density carbon foam has a thermal conductivity between about 5 to 70 W/mK;
placing composite forming material on said tool face; and
curing said composite forming material thereby producing the composite part.
23. The method of claim 22 , wherein at least a portion of said tool face is a surface of said carbon foam comprising said tool body.
24. The method of claim 22 , wherein at least a portion of said tool face is a surface of said high density carbon foam comprising said tool body.
25. The method of claim 22 , wherein said composite forming material is a mixture of a resin and at least one selected from the group consisting of a particulate reinforcing material and a fibrous reinforcing material.
26. The method of claim 22 , wherein the composite part is a carbon fiber composite part.
27. The method of claim 22 , further comprising the step of placing a parting film between said composite forming materials and said tool face prior to placing composite forming material on said tool face.
28. The method of claim 22 , further comprising the step of coating at least a portion of said tool face with a release agent prior to placing composite forming material on said tool face.
29. The method of claim 22 , wherein at least a portion of cells of said carbon foam forming the at least a portion of said tool body are at least partially filled with a filling material.
30. The method of claim 22 , wherein at least a portion of the porosity of said high density carbon foam forming the at least a portion of said tool body are at least partially filled with a filling material.
31. The method of claim 22 , wherein at least a portion of said tool face comprises a surface of a tool face material, wherein at least a portion of said tool face material is supported by said carbon foam.
32. The method of claim 22 , wherein at least a portion of said tool face comprises a surface of a tool face material, wherein at least a portion of said tool face material is supported by said high density carbon foam.
33. The method of claim 31 , wherein said tool face material is selected from the group consisting of metals and ceramics.
34. The method of claim 31 , wherein said tool face material is selected from the group consisting of metal, silicon carbide, and zirconia ceramics.
35. The method of claim 31 , wherein said tool face material is selected from the group consisting of a cured resin, a fiber composite, and a particular composite.
36. The method of claim 31 , wherein said tool face material comprises a carbon fiber composite.
37. The method of claim 32 , wherein said tool face material is selected from the group consisting of metals and ceramics.
38. The method of claim 32 , wherein said tool face material is selected from the group consisting of metal, silicon carbide, and zirconia ceramics.
39. The method of claim 32 , wherein said tool face material is selected from the group consisting of a cured resin, a fiber composite, and a particular composite.
40. The method of claim 32 , wherein said tool face material comprises a carbon fiber composite.