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Compression/injection molding of polymer-derived fiber reinforced ceramic matrix composite materials

  • US 5,738,818 A
  • Filed: 08/28/1996
  • Issued: 04/14/1998
  • Est. Priority Date: 08/28/1996
  • Status: Expired due to Term
First Claim
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1. A method of making a fiber reinforced ceramic matrix composite (FRCMC) part comprising the steps of:

  • (a) injecting a quantity of bulk molding compound comprising a pre-ceramic resin and fibers into a mold having a cavity with walls which form the exterior surfaces of the FRCMC part being molded and at least one resin outlet port connecting the mold cavity to the exterior of the mold, wherein the quantity of said fibers injected corresponds to the maximum percent by volume of fibers capable of being packed within the mold cavity, and the quantity of pre-ceramic resin injected exceeds that necessary to fill the mold cavity in conjunction with the fibers and is sufficient to cause the fibers to flow with the resin and thereafter pack together within the mold cavity, and wherein excess resin exceeding that needed in conjunction with the fibers to fill the mold cavity, flows through the packed fibers and is expelled through the at least one resin outlet port;

    (b) heating the mold at a temperature and for a time associated with the pre-ceramic resin which polymerizes the resin remaining in the mold cavity to form a fiber-reinforced polymer composite structure;

    (c) removing the polymerized composite structure from the mold; and

    (d) heating the polymerized composite structure at a temperature and for a time associated with the polymerized resin which pyrolizes it to form a FRCMC structure.

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