Fiber-reinforced silicon carbide composite materials, method for producing the fiber-reinforced silicon carbide composite materials, and uses of the fiber-reinforced silicon carbide composite materials

Patent metadata

Field	Value
Publication number	US-9975814-B2
Application number	US-201414450444-A
Country	US
Kind code	B2
Filing date	Aug 4, 2014
Priority date	Feb 3, 2012
Publication date	May 22, 2018
Grant date	May 22, 2018

Abstract

Silicon carbide composite materials contain CSiC with a density of 2.95 to 3.05 g/cm −3 and a fiber bundle content of 2 to 10 wt. %. The fiber bundles have a length of 6 to 20 mm, a width of 0.2 to 3 mm, and a thickness of 0.1 to 0.8 mm. The fiber bundles are filled with a cured phenolic resin content of up to 45 wt. %, and the protected fiber bundles are integrated into an SiC matrix. A method produces the silicon carbide composite materials.

First claim

The invention claimed is:

1. A silicon carbide composite material having a density from 2.95 to 3.05 g/cm 3 , comprising:
a SiC matrix;
starting materials including fiber bundles impregnated with phenolic resin with a proportion of 0.5 to 10% by weight relative to a total weight of said starting materials used for a manufacture of green bodies, said fiber bundles having a length of 6 to 20 mm, a width of 0.2 to 3 mm and a thickness of 0.1 to 0.8 mm, and said fiber bundles used for manufacture of said green bodies contain a proportion of cured phenolic resin of up to 45% by weight; and
the silicon carbide composite material containing said SiC matrix and said starting materials being formed into protective armor for use in ballistic applications.

2. The silicon carbide composite materials according to claim 1 , wherein said fiber bundles have said length of 8 to 12 mm, said width of 0.5 to 2 mm and said thickness of 0.2 to 0.7 mm.

3. The silicon carbide composite materials according to claim 1 , wherein said fiber bundles have said length of 8 to 12 mm, said width of 0.5 to 1 mm and said thickness of 0.2 to 0.5 mm.

4. The silicon carbide composite materials according to claim 1 , wherein said SiC matrix contains as starting materials which are mixed together:
a SiC powder with a granularity of F150 and/or F360;
a carbonized cellulose fiber; and
at least one further raw material selected from the group consisting of acetylene coke, charcoal, a further phenolic resin in liquid form and a further phenolic resin in powder form.

5. A method for producing silicon carbide composite materials having a density from 2.95 to 3.05 g/cm 3 , which comprises the steps of:
a) mixing/blending resin and fiber bundles impregnated with a phenolic resin and cured and containing a proportion of the phenolic resin of up to 45% by weight and having a length from 6 to 20 mm, a width from 0.2 to 3 mm and a thickness from 0.1 to 0.8 mm, a proportion of the fiber bundles in the step a) is 0.5 to 10% relative to a total weight of starter substances, and additionally at least one further material mixture selected from the group consisting of charcoal, acetylene coke, SiC powder in grain sizes F150 and/or F360, Abrocarb, SiC powder in grain sizes F150 and/or F360 and Abrocarb, SiC powder in grain sizes F150 and/or F360, and Abrocarb and acetylene coke;
b) compacting in a mold under high pressure and temperature;
c) carbonizing under a shielding gas in a temperature range from 850 to 950° C.;
d) forming material thus obtained into protective armor for use in ballistic applications;
e) silicating in a vacuum in a temperature range from 1600 to 1750° C. and a dwell time of 60 to 90 minutes.

6. The method for producing silicon carbide composite materials according to claim 5 , which further comprises:
f) impregnating with a liquid phenolic resin in an autoclave under high pressure and temperature;
g) graphitizing under the shielding gas in a temperature range from 1850 to 2100° C.; and
h) machining and milling out the material thus obtained into the protective armor.

7. The method for producing silicon carbide composite materials according to claim 5 , which further comprises graphitizing under a shielding gas in a temperature range from 1850 to 2100° C.

8. The method for producing silicon carbide composite materials according to claim 5 , which further comprises impregnating with a liquid phenolic resin in an autoclave under high pressure and temperature.

9. The method for producing silicon carbide composite materials according to claim 5 , which further comprises providing a backing selected from the group consisting of metal panels and woven fabric of fibers, the backing being stuck to panel-shaped silicon carbide composite materials, and the backing can be up to 15 mm thick.

10. The method for producing silicon carbide composite materials according to claim 5 , wherein the charcoal has a medium grain size.

11. The method for producing silicon carbide composite materials according to claim 5 , which further comprises producing components directly in a shape of a desired structural component.

12. A method of forming components, which comprises the steps of:
forming a silicon carbide composite material having a density from 2.95 to 3.05 g/cm 3 and containing a SiC matrix and starting materials including fiber bundles impregnated with phenolic resin with a proportion of 0.5 to 10% by weight relative to a total weight of the starting materials used for a manufacture of green bodies, the fiber bundles having a length of 6 to 20 mm, a width of 0.2 to 3 mm and a thickness of 0.1 to 0.8 mm, and the fiber bundles used for manufacture of the green bodies contain a proportion of cured phenolic resin of up to 45% by weight; and
producing a protective armour for use against ballistic effects or gunshots from the silicon carbide composite material.

13. The method according to claim 12 , which further comprises modifying the protective armour for automobiles, military vehicles, tanks, aircraft, helicopters, ships, railcars, spacecraft, safes and fixed-position objects.

14. The method according to claim 12 , which further comprises producing bullet-proof vests which include the protective armour.

Assignees

• Sgl Carbon Se

Inventors

• Damjanovic Tanja
• Kienzle Andreas
• Kraetschmer Ingrid

Classifications

• C04B2235/5212

  Organic · CPC title

• C04B35/83

  Carbon fibres in a carbon matrix · CPC title

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title

• C04B2235/616

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

• E05G1/024

  Wall or panel structure · CPC title