Method for producing inorganic fiber-bonded ceramic material

Patent metadata

Field	Value
Publication number	US-9701587-B2
Application number	US-201314387713-A
Country	US
Kind code	B2
Filing date	Mar 21, 2013
Priority date	Mar 29, 2012
Publication date	Jul 11, 2017
Grant date	Jul 11, 2017

Abstract

Provided is a method for producing an inorganic fiber-bonded ceramic material, which can produce, at a high yield, an inorganic fiber-bonded ceramic material with fewer defects, and with an end part and a central part equivalent to each other in microstructure and mechanical properties, and also makes it possible to increase the ceramic material in size. The method for producing an inorganic fiber-bonded ceramic material is characterized in that it includes: a first pressing step of setting, in a carbon die, a laminate to be surrounded by a ceramic powder, the laminate obtained by stacking a coated inorganic fiber shaped product including an inorganic fiber part of inorganic fibers that have a pyrolysis initiation temperature of 1900° C. or lower, and a surface layer of an inorganic substance for bonding the inorganic fibers to each other, and pressing the laminate at a temperature of 1000 to 1800° C. and a pressure of 5 to 50 MPa in an inert gas atmosphere; and a second pressing step of pressing a ceramic coated laminate obtained in the first pressing step at a temperature of 1600 to 1900° C., which is higher than that in the first pressing step, and at a pressure of 5 to 100 MPa in an inert gas atmosphere.

First claim

The invention claimed is:

1. A method for producing an inorganic fiber-bonded ceramic part, comprising:
a first pressing step of setting a laminate in a carbon die so as to be surrounded by an alumina powder, the laminate being obtained by stacking a coated inorganic fiber shaped product including an inorganic fiber part formed of inorganic fibers having a pyrolysis initiation temperature of 1900° C. or lower and a surface layer formed of an inorganic substance for bonding the inorganic fibers to each other, and pressing the laminate at a temperature of 1000 to 1800° C. and a pressure of 5 to 50 MPa in an inert gas atmosphere to obtain the laminate coated with densified alumina powder in a sealed condition to such an extent that an emission of pyrolysis gas is suppressed; and
a second pressing step of pressing the alumina coated laminate obtained in the first pressing step at a temperature of 1600 to 1900° C., which is higher than that in the first pressing step, and at a pressure of 5 to 100 MPa in an inert gas atmosphere.

2. The method for producing an inorganic fiber-bonded ceramic part according to claim 1 , wherein the inorganic fiber part is formed of an inorganic substance containing:
(a) an amorphous substance containing Si, M, C, and O (M represents Ti or Zr);
(b) an aggregate of a crystalline particle containing β-SiC, MC, and C and an amorphous substance containing SiO 2 and MO 2 (M is the same as in (a)); or
(c) a mixture of the (a) amorphous substance and the (b) aggregate, and the surface layer is formed of an inorganic substance containing:
(d) an amorphous substance containing Si, O, and optionally M (M represents Ti or Zr);
(e) a crystalline substance containing crystalline SiO 2 and/or MO 2 (M is the same as in (d)); or
(f) a mixture of the (d) amorphous substance and the (e) crystalline substance.

3. The method for producing an inorganic fiber-bonded ceramic part according to claim 1 , wherein the surface layer has a thickness T (μm) from T=aD in which a is a numerical value in a range of 0.023 to 0.090, and D denotes a fiber diameter (μm) of the inorganic fiber part.

4. The method for producing an inorganic fiber-bonded ceramic part according to claim 1 , wherein an ambient pressure in the first pressing step and the second pressing step ranges 0.01 to 1 MPa.

5. A method for producing an inorganic fiber-bonded ceramic part, comprising:
a first pressing step of setting a laminate in a carbon die so as to be surrounded by a ceramic powder, the laminate being obtained by stacking a coated inorganic fiber-shaped product including an inorganic fiber part formed of inorganic fibers having a pyrolysis initiation temperature of 1900° C. or lower and a surface layer formed of an inorganic substance for bonding the inorganic fibers to each other, and pressing the laminate at a temperature of 1000 to 1800° C. and a pressure of 5 to 50 MPa in an inert gas atmosphere to obtain the laminate coated with the ceramic powder in a sealed condition to such an extent that an emission of pyrolysis gas is suppressed; and
a second pressing step of pressing the ceramic coated laminate obtained in the first pressing step at a temperature of 1600 to 1900° C., which is higher than that in the first pressing step, and at a pressure of 5 to 100 MPa in an inert gas atmosphere,
wherein the ceramic powder includes a mixture of an inorganic substance, which melts at 1800° C. or lower, and an inorganic substance having a higher melting temperature than the pressing temperature in the second pressing step.

6. The method for producing an inorganic fiber-bonded ceramic part according to claim 5 , wherein the inorganic substance, which melts at 1800° C. or lower, is glass containing SiO 2 as its main constituent, and the inorganic substance having a higher melting temperature than the pressing temperature in the second pressing step is carbon or BN.

Assignees

• Ube Industries

Inventors

• Matsunaga Kenji
• Kajii Shinji
• Suizu Shohei
• Kodama Tsutomu

Classifications

• C04B2237/38

  Fiber or whisker reinforced · CPC title

• B32B18/00

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• C04B35/62849

  Silica or silicates · CPC title

• C04B2235/5256

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

• C04B35/6268

  characterised by the applied pressure or type of atmosphere, e.g. in vacuum, hydrogen or a specific oxygen pressure · CPC title