Method for manufacturing ceramic-based composite material
First Claim
1. A method for manufacturing a ceramic-based composite material, comprising the following steps:
- forming a fiber fabric from inorganic fibers;
forming a coating layer on a surface of the fabric;
forming a matrix between the fibers of the fabric, wherein the step of matrix forming includes heating the fabric in the presence of methyltrichlorosilane by chemical vapor infiltration to form silicon carbide, forming a co-polymer by mixing at least two different organic polymers to form mixed organic polymers wherein the at least two organic polymers include polycarbosilane (PCS) and polymethylsilane (PMS) and crosslinking the mixed organic polymers by holding the mixed organic polymers for a predetermined time at an intermediate temperature which is lower than a firing temperature sufficient to form silicon carbide, impregnating the co-polymer into the fabric to form an impregnated fabric, and firing the impregnated fabric in an inert gas environment at the firing temperature.
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Accused Products
Abstract
A matrix formation process 10 is configured with CVI process 12 and PIP process 14, 15, 16 in which a co-polymer containing at least polycarboxysilane (PCS) and polymethylsilane (PMS) is applied. Crosslinking of each polymer is performed at an intermediate temperature which is lower than the pyrolysis temperature of the polymeres. Polymer impregnation process 15 for infiltrating the co-polymer into a matrix, and inert gas firing process 16 for firing the material at a high temperature in an inert gas atmosphere. In the crosslink process, the mixed polymer is held at about 573K to 723K for a predetermined time. The conversion ratio of the co-polymer crosslinked into SiC in the subsequent firing process is increased, efficiency of filling SiC in the PIP process is increased, and an airtight ceramic-based composite material can be manufactured efficiently within a short time.
20 Citations
2 Claims
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1. A method for manufacturing a ceramic-based composite material, comprising the following steps:
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forming a fiber fabric from inorganic fibers;
forming a coating layer on a surface of the fabric;
forming a matrix between the fibers of the fabric, wherein the step of matrix forming includes heating the fabric in the presence of methyltrichlorosilane by chemical vapor infiltration to form silicon carbide, forming a co-polymer by mixing at least two different organic polymers to form mixed organic polymers wherein the at least two organic polymers include polycarbosilane (PCS) and polymethylsilane (PMS) and crosslinking the mixed organic polymers by holding the mixed organic polymers for a predetermined time at an intermediate temperature which is lower than a firing temperature sufficient to form silicon carbide, impregnating the co-polymer into the fabric to form an impregnated fabric, and firing the impregnated fabric in an inert gas environment at the firing temperature. - View Dependent Claims (2)
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Specification
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- Resources
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Current AssigneeIshikawajima-Harima Heavy Industries Company Limited
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Original AssigneeIshikawajima-Harima Heavy Industries Company Limited
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InventorsNishide, Shigeto, Yoshida, Takashi
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Primary Examiner(s)Beck, Shrive P.
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Assistant Examiner(s)Fletcher, III, William P.
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Application NumberUS09/536,761Time in Patent Office672 DaysField of Search427/212, 427/255.12, 427/248.1, 427/230, 427/301, 427/249.1, 427/249.2, 427/249.3, 427/900, 264/603, 264/241, 252/182.11, 501/1, 528/35US Class Current427/255.12CPC Class CodesC04B 35/571 obtained from Si-containing...C04B 35/80 Fibres, filaments, whiskers...Y10S 427/10 Chemical vapor infiltration...
