Ceramic Matrix Composite Precursor Slurry Compositions And Sheet Molding Compound

• US 20110151248A1
• Filed: 06/30/2010
• Published: 06/23/2011
• Est. Priority Date: 12/23/2009
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Ronk, Warren Rosal, Manicke, Paul Stephen, Walker, Bryant Edward
• Application Number:
  US12/827,841
• Publication Number:
  US 20110151248A1
• Time in Patent Office: Days
• US Class Current: 428/339
• CPC Class Codes: C04B 2235/421 Boron
• CPC Class Codes: C04B 2235/422 Carbon
• CPC Class Codes: C04B 2235/424 Carbon black
• CPC Class Codes: C04B 2235/425 Graphite
• CPC Class Codes: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5276 Whiskers, spindles, needles or pins
• CPC Class Codes: C04B 2235/5292 Flakes, platelets or plates
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/6567 Treatment time
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 35/573 obtained by reaction sintering or recrystallisation
• CPC Class Codes: C04B 35/6263 characterised by their solids loadings, i.e. the percentage of solids
• CPC Class Codes: C04B 35/6264 Mixing media, e.g. organic solvents
• CPC Class Codes: C04B 35/6269 Curing of mixtures
• CPC Class Codes: C04B 35/63448 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 35/63452 Polyepoxides
• CPC Class Codes: C04B 35/6346 Polyesters
• CPC Class Codes: C04B 35/71 : Ceramic products containing macroscopic reinforcing agents C04B35/66 takes precedence ; infiltration of a porous ceramic matrix with a material forming a non-ceramic phase C04B41/00, reaction infiltration with Si in order to form SiC C04B35/573, in order to form Si3N4 C04B35/591
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C08K 3/04 : Carbon
• CPC Class Codes: C08K 3/34 : Silicon-containing compounds
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/31721 : Of polyimide
• CPC Class Codes: Y10T 428/31725 : Of polyamide
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A ceramic matrix composite precursor slurry composition includes a thermosetting resin, a suitable curing agent, a ceramic component, a carbonaceous solids component, and optionally, a suitable solvent. The thermosetting resin may be a polyester, a vinyl ester, an epoxy resin, a bismaleimide resin, and/or a polyamide resin. The carbonaceous solids component provides a suitable amount of carbon char upon pyrolization. The precursor slurry composition may comprise up to about 70 volume % solids after removal of the solvent, and prior to cure. A sheet molding compound first and second outer films comprising the precursor slurry composition and randomly dispersed reinforcing material carried between the first and second outer films.

Claims

1. A precursor slurry composition comprising a thermosetting resin;

a suitable curing agent;

a ceramic component;

a carbonaceous solids component; and

optionally, a suitable solvent;

wherein the thermosetting resin is at least one member selected from a polyester, a vinyl ester, an epoxy resin, a bismaleimide resin, and a polyimide resin, and wherein the carbonaceous solids component provides a suitable amount of carbon char upon pyrolization, and wherein the precursor slurry composition comprises up to about 70 volume % solids after removal of the solvent, and prior to cure.

2. The precursor slurry composition according to claim 1 wherein the selected thermosetting resin is able to be cured in less than 15 minutes.

3. The precursor slurry composition according to claim 1 wherein the carbonaceous solids component includes at least one member of the group consisting of graphite particles, graphite flakes, graphite whiskers, amorphous, single crystal or poly-crystalline carbon, carbonized plant fibers, lamp black, finely divided coal, charcoal, carbonized polymer fibers or felt for the carbonaceous solids component.

4. The precursor slurry composition according to claim 1 comprising:

a suitable amount of one or more additives selected from dispersants, thickening agents, crosslinking monomers, low profile additives and pigments.

5. The precursor slurry composition according to claim 1 comprising:

about 48 volume % acetone, about 16 volume % of the carbonaceous solids component;

about 9 volume % of the ceramic component, a remainder being the thermosetting resin and the suitable solvent, if present.

6. A sheet molding compound including:

first and second outer films comprising a precursor slurry composition; and

randomly dispersed reinforcing material being carried between the first and second outer films;

wherein the precursor slurry composition comprises;

a thermosetting resin, a ceramic component, a carbonaceous solids component, and optionally, a suitable solvent, and a suitable curing agent, if present,

wherein the thermosetting resin is at least one member selected from a polyester, a vinyl ester, an epoxy resin, a bismaleimide resin, and a polyimide resin, and wherein the carbonaceous solids component provides a suitable amount of carbon char upon pyrolization, and wherein the precursor slurry composition comprises up to about 70 volume % solids after removal of the solvent, and prior to cure.

7. The sheet molding compound according to claim 6 wherein the reinforcing material comprises SiC tow bundles of between about 1 to about 5 cm in length.

8. The sheet molding compound according to claim 6 exhibiting a sufficient green strength following a compression molding process.

9. The sheet molding compound according to claim 6 wherein the carbonaceous solids component includes at least one member of the group consisting of graphite particles, graphite flakes, graphite whiskers, amorphous, single crystal or poly-crystalline carbon, carbonized plant fibers, lamp black, finely divided coal, charcoal, carbonized polymer fibers or felt for the carbonaceous solids component.

10. The sheet molding compound according to claim 6 wherein the precursor slurry composition comprises about 48 volume % acetone, about 16 volume % of the carbonaceous solids component;

about 9 volume % of the ceramic component, a remainder being the thermosetting resin and the suitable curing agent, if present.