Composite material, flying body and composite material manufacturing method

Patent metadata

Field	Value
Publication number	US-12415764-B2
Application number	US-202017632628-A
Country	US
Kind code	B2
Filing date	Dec 22, 2020
Priority date	Feb 28, 2020
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

A composite material manufacturing method includes: laminating a first sheet ( 210 ) including a first slurry ( 214 ) and a third sheet ( 230 ) including a third slurry ( 234 ); and heating the first sheet ( 210 ) and the third sheet ( 230 ) that are laminated to a temperature of transforming to ceramics by pyrolysis to form an intermediate body ( 300 ). The manufacturing method further includes impregnating the intermediate body ( 300 ) with a slurry and heating at a temperature lower than a temperature of transforming to ceramics by pyrolysis.

First claim

The invention claimed is:

1. A composite material manufacturing method including:
laminating a first sheet including a first slurry and a second sheet including a second slurry;
heating the first sheet and the second sheet that are laminated to a first temperature at which the first slurry and the second slurry transform to ceramics by pyrolysis to form an intermediate body; and
impregnating the intermediate body with a third slurry and heating the impregnated intermediate body at a second temperature, the second temperature being lower than a third temperature at which the third slurry transforms to ceramics by pyrolysis,
wherein a first composition of the first slurry is different from a second composition of the second slurry, and
wherein the first slurry includes a ceramic precursor, the second slurry includes a ceramic precursor, and the third slurry includes a ceramic precursor.

2. The composite material manufacturing method according to claim 1 ,
wherein the second temperature is a temperature at which a mass loss of the third slurry due to heating becomes in a desired ratio to a mass of the third slurry before heating.

3. The composite material manufacturing method according to claim 2 ,
wherein the desired ratio is a ratio less than or equal to 10%.

4. The composite material manufacturing method according to claim 1 , wherein a first heat resistance of a first sintered body in which the first slurry is thermally decomposed is higher than a second heat resistance of a second sintered body in which the second slurry is thermally decomposed.

5. The composite material manufacturing method according to claim 4 ,
wherein a second strength of the second sintered body is higher than a first strength of the first sintered body.

6. The composite material manufacturing method according to claim 1 ,
wherein the laminating includes laminating a third sheet including a fourth slurry between the first sheet and the second sheet,
wherein the heating of the first sheet and the second sheet includes heating the third sheet to the first temperature, the first temperature being a temperature at which the fourth slurry transforms to ceramics by pyrolysis,
wherein a third composition of the fourth slurry is different from the first composition of the first slurry and the second composition of the second slurry, and
wherein the fourth slurry includes a ceramic precursor.

7. The composite material manufacturing method according to claim 6 , wherein a second thermal insulation performance of a second sintered body in which the fourth slurry is thermally decomposed is higher than a first thermal insulation performance of a first sintered body in which the first slurry is thermally decomposed.

8. The composite material manufacturing method according to claim 6 ,
wherein a first thermal insulation performance of a first sintered body in which the fourth slurry is thermally decomposed is higher than a second thermal insulation performance of a second sintered body in which the second slurry is thermal decomposed.

9. A flying body comprising a composite material at a part where aerodynamic heating is applied, the composite material comprising:
a first layer that includes a first matrix; and
a second layer that includes a second matrix and is provided below the first layer,
wherein the first layer includes a precursor of the first matrix, and
wherein the first matrix includes Ultra High Temperature Ceramics (UHTC) particles that have a melting point or a decomposition temperature greater than or equal to 2750° C., a composition of the second matrix is different from a composition of the first matrix, and the first matrix includes more UHTC particles than the second matrix.

10. The flying body according to claim 9 ,
wherein a heat resistance of the first layer is higher than a heat resistance of the second layer.

11. The flying body according to claim 9 ,
wherein a strength of the second layer is higher than a strength of the first layer.

12. The flying body according to claim 9 , further comprising a third layer with a third matrix, the third layer provided between the first layer and the second layer,
wherein a heat resistance of the third layer is higher than a heat resistance of the first layer.

13. The flying body according to claim 12 ,
wherein the heat resistance of the third layer is higher than a heat resistance of the second layer.

14. The flying body according to claim 9 ,
wherein the first layer forms an outer surface, and
wherein the outer surface regulates an air flow.

15. The flying body according to claim 14 ,
wherein the air flow is faster than or equal to a speed of sound.

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Nishikawa kosuke

Classifications

• C04B2235/661

  Multi-step sintering · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B2235/5256

  Two-dimensional, e.g. woven structures · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B35/62844

  Coating fibres · CPC title