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Abstract

An apparatus and method for forming a densified carbon-carbon composite. The apparatus includes: a green part molding station for forming a green part; a carbonization station for carbonizing the green part; and an impregnation station for impregnating the carbonized part with a substantially curing by-product free, high carbon yield resin. The impregnation station includes a mold forming a sealed enclosure configured in the shape of the carbonized part for receiving the carbonized part and a vacuum source for evacuating the mold. At least one resin injection port is in the mold and a supply of substantially curing by-product free, high carbon yield resin is connected to the resin injection port for injection into the mold. In the preferred embodiment, the substantially curing by-product free, high carbon yield resin is a cyanate ester having a viscosity of less than about 100 cps at 250.degree. F. and a carbon yield value of greater than about 60 wt. %. The combination of a high carbon yield resin and a pressurized impregnation station configured to the shape of the composite part for use with a curing by-product free resin provides for a substantial reduction in the number of carbonization cycles required to reach final density while, at the same time avoids the environmental and safety problems of a solvent-based system.

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