Elastic Ceramic Matrix Composite Manufacturing Method
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Solution Overview
Problem
Conventional ceramic composites are extremely fragile and lack mechanical durability, especially under stress or deformation, limiting their application in light structures that require significant thermal range and cost-effectiveness.
Innovation Solution
A method for producing ceramic composites with an elastic matrix, involving the dispersion of an alkali or acid in water to form an adjuvant solution, followed by the creation of a mineral hardener, fluid silicone homopolymer, and mineral resin powder, which are then mixed and impregnated with fibrous reinforcements, incorporating a micro-reinforcement network of dendritic nanofractals to enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional ceramic matrices are used in composite structures, then thermal resistance and chemical inertia are improved, but mechanical strength and deformation tolerance deteriorate
Solution Approach 1:
The patent creates a composite matrix system combining ceramic micro-domains (for thermal resistance and chemical inertia) with silicone polymer elastic chains (for mechanical flexibility and deformation tolerance). This dual-material composite approach allows the final material to simultaneously exhibit both thermal stability and mechanical ductility, resolving the contradiction between thermal performance and mechanical strength.
Solution Approach 2:
The patent changes the chemical and physical parameters of the matrix by introducing active-terminated silicone homopolymers that can form elastic networks. The silicone chains with specific terminations (OH, H, or hybrid) enable the matrix to transition from rigid ceramic behavior to elastic-ceramic behavior, improving deformation tolerance while maintaining thermal properties.
2Temperature
If conventional ceramic matrices are used in composite structures, then thermal resistance and chemical inertia are improved, but reliability under stress deteriorates
Solution Approach 1:
The elastic-ceramic matrix composite combines the thermal stability of ceramic micro-domains with the damage tolerance of elastic silicone networks. The silicone chains can undergo reversible deformation and energy dissipation, significantly improving reliability under stress and shock conditions while maintaining operation across wide thermal ranges.
Solution Approach 2:
The elastic silicone network acts as a cushioning mechanism that absorbs and dissipates mechanical energy before it can propagate through the ceramic structure. This beforehand cushioning effect protects the ceramic micro-domains from stress concentration and catastrophic failure, improving overall reliability.
3Temperature
If conventional ceramic manufacturing processes are used, then thermal resistance is improved, but manufacturing complexity increases due to fragility handling
Solution Approach 1:
The patent changes the processing parameters by using lower curing temperatures (60-120°C) compared to traditional ceramic sintering. The elastic-ceramic matrix can be cured at these lower temperatures while maintaining thermal resistance properties, simplifying manufacturing and reducing handling complexity associated with high-temperature fragile materials.
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
The resulting ceramic composite exhibits improved mechanical properties, including great chemical inertia, high thermal resistance, excellent UV resistance, and superior fire resistance, while maintaining a lower cost of ownership and wider thermal range.
Implementation Method 1
an admixture comprising at least one of the following elements is dispersed in water: an alkali (or) an acid, to obtain 'an adjuvant in aqueous solution'
Implementation Method 2
said mineral hardener is poured and intimately mixed in said mineral resin powder to form a 'ceramic mixture'
Implementation Method 3
the active-terminated fluid silicone homopolymer is then dispersed in the ceramic mixture to obtain said 'elastic ceramic mixture'
Implementation Method 4
a step 7, consisting in impregnating said 'elastic ceramic mixture' obtained at the end of step 6, with means of 'fibrous reinforcements'
Implementation Method 5
a step 8, consisting in dispersing, in the mixture, a micro-reinforcement network constituted by 'dendritic nanofractals'
Data Source
AI summary
Disclosed are: damage-resistant ECMCs that need to work and remain elastic between minus 120° C. and positive 300° C.; ECMCs that need to be able to contain a flame of 1900° C. for more than 90 minutes; and composite structures, especially highly stressed structures. One of the characteristic problems of ceramic matrices is their fragility. Indeed, when a fracture starts, it propagates easily in the matrix. Disclosed are elastic ceramic matrix composites (ECMCs), for which: the ceramic matrix is split into solid “ceramic microdomains” (CMDs); the CMDs are connected to one another by a dense network of “elastic microelements” (EMEs); and the bonds between the EMEs and the CMDs are strong chemical bonds, preferably covalent.