Preparing ceramic matrix composites that are useful in e.g. aerospace industry, comprises preparing thermoplastic fiber-plastic composite material, molding, converting into thermoset fiber-plastic material, and reacting with carbon matrix

Simple SummaryContent extracted from patent full text and abstract with AI.

This invention describes a method for preparing ceramic matrix composites (CMCs) using a novel process that involves forming a fiber-reinforced thermoplastic composite, molding it, converting it into a thermoset composite, and then reacting it with a carbon matrix. The process also includes a step to infiltrate cracks with silicon-based materials to improve the final composite’s properties. The resulting CMCs have enhanced strength, durability, and resistance to high temperatures.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing components for aircraft engines and turbines in the aerospace industry
• Producing heat-resistant parts for automotive or industrial applications
• Fabricating lightweight, strong structures for rockets and spacecraft
• Making protective covers and heat shields requiring high thermal stability
• Developing advanced engineering materials for high-stress mechanical parts

BenefitsContent extracted from patent full text and abstract with AI.

• Improved heat resistance and thermal stability compared to traditional composites
• Higher strength-to-weight ratio, making materials lighter yet strong
• Enhanced durability and resistance to cracking thanks to crack infiltration
• Production process allows for better shaping and molding of complex parts
• Potential to integrate different types of fibers and matrices for tailored properties

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The method comprises preparing a thermoplastic fiber-plastic composite material having viscosity of 100-500 Pa.s with a fibrous reinforcement and a thermoplastic matrix polymer comprising phenol-based polymers such as novolacs or their mixtures with furfuryl components, molding the material without cross-linking, converting thermoplastic fiber-plastic composite material into a thermoset fiber-plastic composite material immediately after the injection molding, and reacting the polymer matrix with carbon matrix for forming fiber-reinforced carbon to form ceramic matrix composites. The method comprises preparing a thermoplastic fiber-plastic composite material having viscosity of 100-500 Pa.s with a fibrous reinforcement and a thermoplastic matrix polymer comprising phenol-based polymers such as novolacs or their mixtures with furfuryl components, molding the thermoplastic material without cross-linking, converting thermoplastic fiber-plastic composite material into a thermoset fiber-plastic composite material immediately after the injection molding, and reacting the polymer matrix with carbon matrix for forming fiber-reinforced carbon to form ceramic matrix composites. The composite material preparation step is performed with or without additives. The molding and the conversion steps are carried out simultaneously in a molding tool for the processing of thermoplastics. The conversion step is carried out by integrating a formaldehyde equivalent crosslinker in the thermoplastic fiber-plastic composite. The reacting step is carried out by pyrolysis to form a crack region. The method further comprises carrying out infiltration of the crack region using silcon-based group to form silicon carbide or its other compounds such boron, silicon carbonitride, siliconborocarbonitride, silicon oxycarbide, where the infiltration step is performed in the region near crack.