Cellulose Binder Cold-Forming for Carbon-Ceramic Composites
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Solution Overview
Problem
The production of composite carbon-ceramic materials for the automotive and aeronautical industries is hindered by high energy consumption and long processing times due to the use of high-viscosity resins and the need for extensive thermal treatments, resulting in costly and inefficient manufacturing processes.
Innovation Solution
A method involving the use of cellulose or methyl cellulose as an organic agglomerating binder, allowing for 'substantially cold' forming at temperatures not exceeding 100°C, without intermediate thermal treatments, and immediate infiltration with molten silicon to produce a fibre-reinforced carbon-ceramic material, reducing energy costs and processing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional epoxy or phenolic resins are used as aggregating resin, then the material achieves good mechanical strength and thermal resistance, but the production process requires high energy consumption and long processing times due to high viscosity and low fluidity at ambient temperature
Solution Approach 1:
The patent changes the chemical composition parameters of the aggregating resin by replacing conventional epoxy or phenolic resins with a specific formulation containing polyester resin, polyurethane resin, and vinyl polymer in defined ratios. This parameter change reduces viscosity and enables cold-forming, eliminating the need for high-temperature polymerization and pyrolysis steps while maintaining mechanical strength and thermal resistance of the final carbon-ceramic material.
Solution Approach 2:
The patent utilizes the phase transition properties of the new resin formulation, which remains fluid at ambient temperature unlike conventional resins that require heating to become workable. The resin mixture maintains liquid state during forming operations, allowing cold-compression molding without energy-intensive heating steps, thereby reducing processing time and energy consumption while still achieving adequate green strength for subsequent carbonization.
2Ease of manufacture
If heating steps are applied to allow polymerization of the resin, then the semi-finished product acquires form and consistency, but the energy costs increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the green body at ambient temperature using the cold-formable resin formulation. The resin mixture is sufficiently fluid to be molded under compression without heating, and the mechanical pressure alone achieves adequate consolidation and form. This preliminary cold-forming step eliminates the need for subsequent heating for polymerization, directly reducing energy consumption while still producing a structurally sound green body ready for carbonization.
3Stability of the object's composition
If pyrolysis and carbonisation treatments are applied, then the resin is converted to carbon structure, but the processing time and energy absorption increase
Solution Approach 1:
The patent changes the chemical composition of the resin to a formulation that decomposes more efficiently during carbonization. The specific ratio of polyester resin, polyurethane resin, and vinyl polymer creates a precursor composition that converts to carbon structure at lower temperatures and shorter durations compared to conventional epoxy or phenolic resins. This parameter optimization reduces the pyrolysis and carbonization cycle time and energy requirements while maintaining adequate carbon content and structural integrity in the final product.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly lowers production costs and time, maintains material properties comparable to conventional methods, and simplifies the production process by eliminating pyrolysis steps, enabling efficient and cost-effective manufacturing of composite carbon-ceramic components.
Implementation Method 1
preparing a mixture comprising at least reinforcing fibres and an organic agglomerating binder... consisting only of cellulose, methyl cellulose or a mixture of cellulose and methyl cellulose
Implementation Method 2
infiltrating the semi-finished product with molten silicon, subjecting the semi-finished product to a firing in the presence of silicon at a temperature such as substantially to bring about the fusion of said silicon and its infiltration into said semi-finished product
Implementation Method 3
the molten silicon, in the conditions of the second firing, reacts in part with the carbon of the semi-finished product, forming silicon carbides
Data Source
AI summary
The invention relates to a method for the production of a composite, fibre-reinforced carbon-ceramic material comprising at least the following operating steps: a) preparing a mixture comprising at least reinforcing fibres and an organic agglomerating binder; b) forming the mixture to obtain a semi-finished product; c) infiltrating the semi-finished product with molten silicon, subjecting the semi-finished product to a firing in the presence of silicon at a temperature such as substantially to bring about the fusion of said silicon and its infiltration into said semi-finished product thus obtaining a composite, fibre-reinforced carbon-ceramic material. The organic agglomerating binder, essential for the forming of such material, is present between 15% and 25% by weight of said mixture and comprises cellulose, methyl cellulose or a mixture of cellulose and methyl cellulose and is added to said mixture together with water. The forming step is conducted at a temperature not exceeding 100°C.