PROCESS FOR MANUFACTURING A COMPOSITE PART

• US 20200131090A1
• Filed: 06/13/2018
• Published: 04/30/2020
• Est. Priority Date: 06/13/2017
• Status: Active Grant

• Current Assignee: ArianeGroup SAS, Safran Ceramics
• Original Assignee: ArianeGroup SAS, Safran Ceramics
• Inventors: EBERLING-FUX, Nicolas, BOUILLON, Eric, JACOB, Guy, GOUILLIANNE, Eddy
• Granted Patent: US 10,882,795 B2
• Time in Patent Office: Days
• CPC Class Codes: C04B 2235/483 Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 35/515 based on non-oxide ceramics
• CPC Class Codes: C04B 35/571 obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/6269 Curing of mixtures
• CPC Class Codes: C04B 35/62863 Silicon carbide
• CPC Class Codes: C04B 35/62868 Boron nitride
• CPC Class Codes: C04B 35/62871 Silicon nitride
• CPC Class Codes: C04B 35/62873 Carbon
• CPC Class Codes: C04B 35/62884 by gas phase techniques
• CPC Class Codes: C04B 35/62897 Coatings characterised by their thickness
• CPC Class Codes: C04B 35/632 Organic additives
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 41/4503 having an adhesive layer
• CPC Class Codes: C04B 41/4539 as a emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/4554 the coating or impregnating material being an organic or organo-metallic precursor of an inorganic material
• CPC Class Codes: C04B 41/4558 : Coating or impregnating involving the chemical conversion of an already applied layer, e.g. obtaining an oxide layer by oxidising an applied metal layer
• CPC Class Codes: C04B 41/457 : Non-superficial impregnation or infiltration of the substrate
• CPC Class Codes: C04B 41/4584 : Coating or impregnating of particulate or fibrous ceramic material C04B20/10, C04B35/628 take precedence
• CPC Class Codes: C04B 41/4922 : applied to the substrate as monomers, i.e. as organosilanes RnSiX4-n, e.g. alkyltrialkoxysilane, dialkyldialkoxysilane
• CPC Class Codes: C04B 41/4955 : Polyorganosilanes, i.e. polymers with a Si-Si-Si- chain
• CPC Class Codes: C04B 41/4961 : Polyorganosiloxanes, i.e. polymers with a Si-O-Si-O-chain; "silicones"
• CPC Class Codes: C04B 41/4983 : Polycarbosilanes, i.e. polymers with a -Si-C-Si-chain; Polysilazanes, i.e. polymers with a -Si-N-Si-chain; Polysilathianes, i.e. polymers with a -Si-S-Si-chain

Abstract

A process for manufacturing a composite part includes introducing an adhesion promoter into the pores of a fibrous preform formed by threads covered with a coating having —OH groups on its surface, the adhesion promoter including an electron-withdrawing group G1 that is reactive according to a reaction of substitution or of nucleophilic addition with the —OH groups, and a reactive group G2; grafting the adhesion promoter to the surface of the coating by a reaction of substitution or nucleophilic addition of the —OH groups on the group G1; introducing a ceramic precursor resin into the pores of the fibrous preform; polymerizing the resin introduced and bonding the grafted adhesion promoter to the resin by chemical reaction between these two compounds at the level of the group G2, and forming a ceramic matrix phase in the pores of the fibrous preform by pyrolysis of the polymerized resin.

Claims

1. A process for manufacturing a composite part comprising:

introducing an adhesion promoter into the pores of a fibrous preform formed by threads covered with a coating having —

OH groups on its surface, the adhesion promoter comprising an electron-withdrawing group G1 that is reactive according to a reaction of substitution or of nucleophilic addition with the —

OH groups, and a reactive group G2 selected from;

a hydroxyl function, an epoxide, a halogen atom, an amine function, a carbonyl function, a carbon-carbon double bond or a carbon-carbon triple bond,

grafting the adhesion promoter to the surface of the coating by a reaction of substitution or nucleophilic addition of the —

OH groups on the group G1, this grafting being carried out by a first heating of the fibrous preform into which the adhesion promoter has been introduced,

introducing a ceramic precursor resin into the pores of the fibrous preform, after the step of grafting the adhesion promoter,

polymerizing the resin introduced and bonding the grafted adhesion promoter to the resin by chemical reaction between these two compounds at the level of the group G2, said polymerizing and said bonding being carried out by a second heating of the fibrous preform into which the resin has been introduced, and

forming a ceramic matrix phase in the pores of the fibrous preform by pyrolysis of the polymerized resin.

2. The process as claimed in claim 1, further comprising, before introduction of the promoter, a step of forming the coating on the threads by chemical vapor deposition or infiltration.

3. The process as claimed in claim 1, further comprising, before introduction of the promoter, a step of forming the coating on the threads by introducing a precursor compound into the pores of the preform and pyrolysis of this precursor compound.

4. The process as claimed in claim 1, wherein the material forming the surface of the coating is selected from:

carbon, carbon doped with boron, silicon carbide, boron nitride, boron nitride doped with silicon, or silicon nitride.

5. The process as claimed in claim 1, wherein the group G1 is selected from:

an epoxide, a carboxyl function, a halogen atom, a carbon-carbon double bond or a carbon-carbon triple bond.

6. The process as claimed in claim 1, in wherein the group G2 is selected from:

a hydroxyl function, an amine function or a carbon-carbon double bond.

7. The process as claimed in claim 1, wherein, in the monomeric state, the adhesion promoter has the following general formula:

G1-E-G2, where E denotes a carbon chain comprising between 1 and 10 carbon atoms or a silane, siloxane, silazane or carbosilane chain comprising between 1 and 10 silicon atoms.

8. The process as claimed in claim 7, wherein E denotes a carbon chain comprising between 1 and 5 carbon atoms, or in which E denotes a silane, siloxane, silazane or carbosilane chain comprising between 1 and 5 silicon atoms.

9. The process as claimed in claim 7, wherein the adhesion promoter is a halosilane.

10. The process as claimed in claim 1, wherein the resin is selected from:

polysiloxane resins, polysilazane resins, polycarbosiloxane resins, polycarbosilane resins, and mixtures of such resins.