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KR-102960623-B1 - Surface treatment of ceramic-coated/impregnated materials

KR102960623B1KR 102960623 B1KR102960623 B1KR 102960623B1KR-102960623-B1

Abstract

The present invention relates to a surface-treated prepreg composite and a corresponding method for surface-treating an inorganic fabric to form a surface-treated fabric-reinforced prepreg composite. The method comprises the steps of: infiltrating a first slurry mixture into an inorganic fabric to form an infiltrated fabric; optionally, drying the infiltrated fabric; infiltrating a second slurry mixture into an inorganic paper to form an infiltrated paper; optionally, drying the infiltrated paper; and applying the infiltrated paper to at least one surface of the infiltrated fabric to form a surface-treated prepreg composite.

Inventors

  • 다완 제이. 라즈 케이.
  • 톤티사키스 안토니오스
  • 심슨 와일리
  • 링컨 존

Assignees

  • 액시엄 머티어리얼스 인코포레이티드

Dates

Publication Date
20260507
Application Date
20200410
Priority Date
20190411

Claims (20)

  1. A method for forming a surface-treated fabric-reinforced prepreg composite, A step of providing an inorganic fabric having a thickness of 5 mm to 75 mm; A step of providing inorganic paper formed of randomly oriented inorganic fibers having a thickness of 0.1 mm to 4.99 mm; A step of forming an infiltrated fabric by infiltrating a first slurry mixture comprising an oxide component and a liquid medium into the above-mentioned inorganic fabric; A step of forming an infiltrated paper by infiltrating the inorganic paper with a second slurry mixture comprising an oxide component and a liquid medium; and A method comprising the step of applying the impregnated paper to the surface of the impregnated fabric to form a surface-treated fabric-reinforced prepreg composite.
  2. A method according to claim 1, further comprising the step of drying the infiltrated fabric before applying the infiltrated paper to the surface of the infiltrated fabric.
  3. A method according to claim 1, further comprising the step of simultaneously drying the impregnated fabric and the impregnated paper.
  4. A method according to any one of claims 1 to 3, wherein the inorganic fabric comprises a plurality of fibers including alumina, silica, mullite, zirconia, or any combination thereof.
  5. A method according to any one of claims 1 to 3, wherein the inorganic fabric is a woven fabric, a nonwoven fabric, or any combination thereof.
  6. A method according to any one of claims 1 to 3, wherein the inorganic paper comprises alumina, silica, mullite, zirconia, or any combination thereof.
  7. A method according to any one of claims 1 to 3, wherein the oxide component of the first slurry mixture and/or the second slurry mixture comprises one or more oxides of aluminum, silicon, boron, zirconium, yttrium, or any combination thereof.
  8. A method according to claim 7, wherein one or more oxides of the first slurry mixture and/or the second slurry mixture are provided as particles comprising spheres, hollow spheres, fibers, whiskers, or any combination thereof.
  9. The method of claim 7, wherein the first slurry mixture and/or the second slurry mixture further comprises colloidal silica having an average particle diameter of 1 nanometer to 10 microns.
  10. The method of claim 7, wherein the first slurry mixture and/or the second slurry mixture further comprises colloidal alumina having an average particle diameter of 1 nanometer to 10 microns.
  11. A method according to any one of claims 1 to 3, wherein the liquid medium of the first slurry mixture and/or the second slurry mixture is water, alcohol, or any combination thereof.
  12. In any one of claims 1 to 3, the first slurry mixture and/or the second slurry mixture Colloidal silica 0.1 wt% to 40 wt%; 0.1 wt% to 10 wt% of a liquid medium-soluble polymer; 40 wt% to 85 wt% of aluminum oxide powder; and Water 10wt% to 60wt% A method comprising an aqueous slurry mixture.
  13. In paragraph 12, the first slurry mixture and/or the second slurry mixture 15 to 30 wt% colloidal silica; 0.1 to 4 wt% of a liquid medium-soluble polymer; 45 to 65 wt% of aluminum oxide powder; and Water 20 to 40 wt% A method comprising an aqueous slurry mixture.
  14. In claim 7, the method wherein the liquid medium-soluble polymer is polyvinyl alcohol.
  15. In any one of claims 1 to 3, the first slurry mixture and/or the second slurry mixture 0.1 wt% to 50 wt% of one or more organic binders comprising silicone resin, polyvinyl butyral, polyvinyl acetate, polylactic acid, or any combination thereof; 40 wt% to 85 wt% of aluminum oxide powder; and 5 wt% to 60 wt% of alcohol comprising methanol, ethanol, n-propanol, isopropanol, n-butanol, t-butanol, secondary-butanol, C5 - C8 alcohol, or any combination thereof A method comprising an alcohol-based slurry.
  16. In paragraph 15, the first slurry mixture and/or the second slurry mixture 5 wt% to 25 wt% of one or more organic binders comprising silicone resin, polyvinyl butyral, polyvinyl acetate, polylactic acid, or any combination thereof; 45 wt% to 65 wt% of aluminum oxide powder; and 30 wt% to 50 wt% of alcohol comprising methanol, ethanol, n-propanol, isopropanol, n-butanol, t-butanol, secondary-butanol, C5 - C8 alcohol, or any combination thereof A method comprising an alcohol-based slurry.
  17. A method according to any one of claims 1 to 3, wherein the pH of the first slurry mixture and/or the second slurry mixture is adjusted to pH 3 to 5 using a proton acid.
  18. A method according to any one of claims 1 to 3, wherein the first slurry mixture and/or the second slurry mixture further comprises 0.1 wt% to 2 wt% of a protonated acid.
  19. In claim 18, the method wherein the first slurry mixture and/or the second slurry mixture further comprises 0.1 wt% to 1 wt% of a protonated acid.
  20. A method according to any one of claims 1 to 3, wherein the first slurry mixture and/or the second slurry mixture further comprises one or more additives comprising an inorganic polymer material, an organic polymer material, one or more surfactants, one or more viscosity modifiers, a glycol, a polyol, or any combination thereof.

Description

Surface treatment of ceramic-coated/impregnated materials Cross-reference regarding related applications This PCT application claims the benefit of U.S. Provisional Application No. 62/832,586 filed April 11, 2019. The full text of the said document is incorporated herein by reference. Technology field The present invention provides a novel surface-treated fabric-reinforced prepreg composite, a ceramic matrix composite ("CMC") material, and a method for manufacturing the composite and the material. Fabric-reinforced CMC materials are highly suitable for structural applications, particularly in the aerospace industry, due to their mechanical properties (e.g., structural flexibility or lack thereof), thermal durability, and chemical stability. Conventional techniques used in the manufacture of fabric-reinforced CMCs involve molding fibrous materials to produce a preform. The voids of the preform are then filled with a ceramic slurry and subsequently cured and/or sintered to form the CMC material. A problem associated with these CMC materials is that additional coatings must be applied to the ceramic-coated surfaces before their final use. These additional coatings typically require additional drying, sintering, or other processing steps (e.g., painting) that are time, resource, and energy-intensive. Therefore, both improved technology and corresponding ceramic slurry compositions are required to provide an alternative to applying additional coating layers to CMC materials. In addition to more efficient application technology, the development of surface treatments capable of imparting improved toughness, heat resistance, and high-temperature strength to inorganic fabric materials will provide more choices for managing materials used in applications based on their physical properties at high temperatures. One aspect of the present invention provides a method for forming a surface-treated fabric-reinforced prepreg composite, comprising the steps of: infiltrating a first slurry mixture into an inorganic fabric to form an infiltrated fabric (wherein the slurry mixture comprises an oxide component and a liquid medium); infiltrating a second slurry mixture into an inorganic paper to form an infiltrated paper (wherein the second slurry mixture comprises an oxide component and a liquid medium); and applying the infiltrated paper to the surface of the infiltrated fabric to form a surface-treated fabric-reinforced prepreg composite. Some implementations additionally include a step of drying the impregnated fabric before applying the impregnated paper to the surface of the impregnated fabric. Some implementations additionally include a step of drying the impregnated fabric and the impregnated paper simultaneously. In some embodiments, the inorganic fabric comprises a number of fibers comprising alumina, silica, mullite, zirconia, or any combination thereof. For example, the fibers are essentially composed of alumina, silica, mullite, zirconia, or any combination thereof. In some implementations, the inorganic fabric has a thickness of about 5 mm to about 75 mm before being infiltrated into the first slurry mixture. In some implementations, the inorganic fabric is a woven fabric, a nonwoven fabric, or any combination thereof. In some embodiments, the inorganic paper comprises alumina, silica, mullite, zirconia, or any combination thereof. For example, the inorganic paper is essentially composed of alumina, silica, mullite, zirconia, or any combination thereof. In some implementations, the inorganic paper has a thickness of about 0.1 mm to about 4.99 mm before being infiltrated into the second slurry mixture. In some embodiments, the oxide component of the first slurry mixture and/or the second slurry mixture comprises one or more oxides of aluminum, silicon, boron, zirconium, yttrium, or any combination thereof. In some embodiments, one or more oxides of the first slurry mixture and/or the second slurry mixture are provided as particles comprising spheres, hollow spheres, fibers, whiskers, or any combination thereof. In some embodiments, the first slurry mixture and/or the second slurry mixture further comprises colloidal silica having an average particle diameter of about 1 nanometer to about 10 microns. In some embodiments, the first slurry mixture and/or the second slurry mixture further comprises colloidal alumina having an average particle diameter of about 1 nanometer to about 10 microns. In some embodiments, the liquid medium of the first slurry mixture and/or the second slurry mixture is water, alcohol, or any combination thereof. For example, the first slurry mixture and/or the second slurry mixture is an aqueous slurry mixture comprising about 0.1 wt% to about 40 wt% colloidal silica; about 0.1 wt% to about 10 wt% liquid medium-soluble polymer; about 40 wt% to about 85 wt% aluminum oxide powder; and about 10 wt% to about 60 wt% water. In another example, the first slurry mixture and/or the second slurry mixture c