Monolithic ceramic/fiber reinforced ceramic composite

• US 5,391,428 A
• Filed: 02/16/1994
• Issued: 02/21/1995
• Est. Priority Date: 06/12/1992
• Status: Expired due to Fees

• Current Assignee: Minnesota Mining and Manufacturing Co (3M Company)
• Original Assignee: Minnesota Mining and Manufacturing Co (3M Company)
• Inventors: Zender, Mark D.
• Primary Examiner(s): Ryan, Patrick J.
• Assistant Examiner(s): YAMNITZKY, MARIE ROSE
• Application Number:
  US08/197,351
• Time in Patent Office: 370 Days
• Field of Search: 428/297, 428/34.4, 428/34.5, 428/301, 428/302, 428/367, 428/368, 428/375, 428/408, 428/698, 428/34.1, 428/34.6, 428/384, 428/427, 428/428, 501/95, 264/30, 264/60, 264/241
• US Class Current: 428/34.4
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5228 Silica and alumina, including aluminosilicates, e.g. mullite
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 2237/341 Silica or silicates
• CPC Class Codes: C04B 2237/348 Zirconia, hafnia, zirconates or hafnates
• CPC Class Codes: C04B 2237/365 Silicon carbide
• CPC Class Codes: C04B 2237/38 Fiber or whisker reinforced
• CPC Class Codes: C04B 2237/704 of one or more of the ceramic layers or articles
• CPC Class Codes: C04B 2237/765 at least one member being a tube
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 35/185 Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/571 obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/62873 Carbon
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/806 The matrix of the ceramic products consisting of non-oxides only
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/4529 : applied from the gas phase
• 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 41/4596 : with fibrous materials or whiskers
• CPC Class Codes: C04B 41/5001 : with carbon or carbonisable materials
• CPC Class Codes: C04B 41/5025 : with ceramic materials copper oxide or solid solutions thereof C04B41/5074
• CPC Class Codes: C04B 41/5059 : Silicon carbide
• CPC Class Codes: C04B 41/52 : Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/524 : Multiple coatings, comprising a coating layer of the same material as a previous coating layer
• CPC Class Codes: C04B 41/89 : for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: Y10T 428/131 : Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
• CPC Class Codes: Y10T 428/1314 : Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/2918 : including free carbon or carbide or therewith [not as steel]
• CPC Class Codes: Y10T 428/292 : In coating or impregnation
• CPC Class Codes: Y10T 428/2933 : Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/2949 : Glass, ceramic or metal oxide in coating
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 442/2549 : Coating or impregnation is chemically inert or of stated nonreactance
• CPC Class Codes: Y10T 442/2631 : Coating or impregnation provides heat or fire protection
• CPC Class Codes: Y10T 442/2975 : Coated or impregnated ceramic fiber fabric

Abstract

A shaped ceramic-ceramic composite article comprising a ceramic monolith, preferably in the shape of a hollow tube, having a ceramic fiber matrix thereover, coated with carbonaceous material and overcoated with silicon carbide.

Claims

1. A shaped ceramic-ceramic composite article comprising a shaped ceramic monolith, a ceramic fiber matrix thereover, a carbonaceous coating on said matrix, and overlying said coating a coating of silicon carbide, said shaped ceramic monolith being selected from the group consisting of a shaped alumina ceramic monolith, a shaped mullite ceramic monolith, a shaped silicon carbide ceramic monolith, and a shaped zirconia ceramic monolith.

2. The article of claim 1 wherein said ceramic monolith is in the shape of a hollow tube.

3. The article of claim 1 wherein said ceramic fiber matrix comprises ceramic fibers selected from aluminoborosilicate fibers, aluminosilicate fibers, alumina fibers, mixtures thereof, and silicon carbide fibers.

4. The article of claim 1 wherein said ceramic fiber matrix is grouped to form a yarn.

5. The article of claim 1 wherein said ceramic fiber matrix comprises braided, knitted or woven yarn.

6. The article of claim 1 wherein said carbonaceous coating is derived from a phenolic resin.

7. The article of claim 4 wherein said yarn has a diameter from about 0.2 to about 1.5 mm.

8. The article of claim 4 wherein said yarn is ply-twisted.

9. The article of claim 1 wherein said coating of silicon carbide is present in an amount equal to from about 50 to about 75 percent by weight of said ceramic fiber matrix.

10. The article of claim 1 wherein said article comprises from about 15 to about 50 percent by weight of said coating of silicon carbide.

11. The article of claim 1 wherein said shaped ceramic monolith is a shaped alumina ceramic monolith.

12. The article of claim 11 wherein said ceramic fiber matrix comprises ceramic fibers selected from aluminoborosilicate fibers, aluminosilicate fibers, alumina fibers, and mixtures thereof.

13. The article of claim 1 wherein said shaped ceramic monolith is a shaped mullite ceramic monolith.

14. The article of claim 13 wherein said ceramic fiber matrix comprises ceramic fibers selected from aluminoborosilicate fibers, aluminosilicate fibers, alumina fibers, and mixtures thereof.

15. A shaped ceramic-ceramic composite article comprising a shaped ceramic monolith, one of a ceramic fiber matrix or a carbon fiber matrix thereover, a carbonaceous coating on said matrix, and overlying said coating a coating of silicon carbide, said shaped ceramic monolith being selected from the group consisting of a shaped alumina ceramic monolith, a shaped mullite ceramic monolith, a shaped silicon carbide ceramic monolith, and a shaped zirconia ceramic monolith.

16. The article of claim 15 wherein said ceramic monolith is in the shape of a hollow tube.

17. The article of claim 15 wherein said carbonaceous coating is derived from a phenolic resin.

18. The article of claim 15 wherein said coating of silicon carbide is present in an amount equal to from about 50 to about 75 percent by weight of said ceramic fiber matrix or said carbon fiber matrix.

19. The article of claim 15 wherein said article comprises from about 15 to about 50 percent by weight of said coating of silicon carbide.