Secondary polymer layered impregnated tile

• US 6,955,853 B1
• Filed: 06/09/2004
• Issued: 10/18/2005
• Est. Priority Date: 06/09/2004
• Status: Expired due to Fees

• Current Assignee: NASA As Represented By The Administrator of The, USA As Represented By The Administrator Of The NASA
• Original Assignee: United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration
• Inventors: Rasky, Daniel J., Tran, Huy K., Hsu, Ming-ta S., Szalai, Christine E., Carroll, Joseph A.
• Primary Examiner(s): DIXON, MERRICK L
• Application Number:
  US10/868,450
• Time in Patent Office: 496 Days
• Field of Search: 428/408, 428/34.1, 428/34.4, 428/212, 428/213, 428/34.5, 428/325, 428/36.4, 428/220, 428/312.4, 428/315.5, 428/317.9, 428/339
• US Class Current: 428/325
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5232 Silica or silicates other than aluminosilicates, e.g. quartz
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/6567 Treatment time
• CPC Class Codes: C04B 2235/658 Atmosphere during thermal treatment
• CPC Class Codes: C04B 2237/341 Silica or silicates
• CPC Class Codes: C04B 2237/343 Alumina or aluminates
• CPC Class Codes: C04B 2237/365 Silicon carbide
• CPC Class Codes: C04B 2237/58 Forming a gradient in composition or in properties across the laminate or the joined articles
• CPC Class Codes: C04B 35/14 based on silica
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: Y10T 428/1372 Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/249968 Of hydraulic-setting material
• CPC Class Codes: Y10T 428/249978 Voids specified as micro
• CPC Class Codes: Y10T 428/249986 Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A low density organic polymer impregnated preformed fibrous ceramic article includes a plurality of layers. A front layer includes ceramic fibers or carbon fibers or combinations of ceramic fibers and carbon fibers, and is impregnated with an effective amount of at least one organic polymer. A middle layer includes polymer impregnated ceramic fibers. A back layer includes ceramic fibers or carbon fibers or combinations of ceramic fibers and carbon fibers, and is impregnated with an effective amount of at least one low temperature pyrolyzing organic polymer capable of decomposing without depositing residues.

Claims

1. A low density organic polymer impregnated preformed fibrous ceramic article comprising a plurality of layers wherein (A) a front layer of the article comprises fibers selected from the group consisting of ceramic fibers, carbon fibers and combinations of ceramic and carbon fibers;

said front layer being impregnated with an amount of at least one organic polymer;

(B) a middle layer comprising polymer impregnated ceramic fibers; and

(C) a back layer comprising fibers selected from the group consisting of ceramic fibers, carbon fibers, and combinations of ceramic and carbon fibers;

said back layer of the article comprising fibers impregnated with an amount of at least one low temperature pyrolyzing organic polymer capable of decomposing without depositing residues, wherein said polymer impregnated ceramic fibers in said middle layer include one of the following groups of fibers;

(1) 12–

15 weight percent Nextel fibers, 20 weight-percent alumina and 63–

65 weight-percent silica fibers and having a void fraction in a range of about 95–

95 percent;

(2) 12–

15 weight percent Nextel fibers, 50 weight-percent alumina and 35 weight-percent silica fibers and having a void fraction in a range of about 95–

96 percent;

(3) about 98.5 percent ultra microquartz and about 1.5 percent silicon carbide, having a density of 0.15–

0.17 gm/cm³, and having a void fraction in a range of about 92–

94 percent;

(4) about 98.5 percent ultra microquartz and about 1.5 percent silicon carbide, having a density of 0.12–

0.14 gm/cm³, and having a void fraction in a range of about 93–

95 percent; and

(5) all carbon fibers and having a void fraction in a range of 88–

93 percent.

2. The organic polymer impregnated preformed fibrous ceramic article of claim 1, wherein the front layer of the article comprises ceramic fibers impregnated with a thermoplastic polymer.

3. The organic polymer impregnated preformed fibrous ceramic article of claim 1, wherein the front layer of the article comprises ceramic fibers impregnated with a thermosetting polymer.

4. The organic polymer impregnated preformed fibrous ceramic article of claim 1, wherein the front layer comprises ceramic fibers impregnated with a material which forms a gel.