Polymer-Derived Ceramic Composite Structures for Low-Temperature Processing
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Solution Overview
Problem
Current methods for producing Ceramic Matrix Composites (CMCs) are time-consuming, expensive, and energy-inefficient, limiting the use of low-melting point materials due to high temperature processes, and restricting the creation of novel composite structures.
Innovation Solution
The development of processes using Polymer-Derived Ceramics (PDCs) that allow for the production of ceramic composite structures at lower temperatures, enabling the use of plastics and low-melting point metals by creating a ceramic network first and infiltrating fillers, which provides a continuous pore and ceramic network for interpenetrating structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high temperature processes (chemical vapor deposition, melt infiltration, polymer injection pyrolysis) are used to produce CMCs, then ceramic matrix formation is achieved, but manufacturing cost increases, energy consumption increases, and manufacturing time increases
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperature (>1000°C) to lower temperature range (below 1000°C), enabling the use of low-melting-point materials while reducing energy consumption and manufacturing costs
Solution Approach 2:
The patent creates a porous ceramic green body structure in advance through polymer-derived ceramic processes, then infiltrates filler materials into the pre-formed porous structure, avoiding the need for high temperature sintering and reducing overall energy consumption
2Reliability
If conventional high temperature processes are used to produce CMCs, then ceramic matrix formation is achieved, but manufacturing time increases to months
Solution Approach 1:
The patent reduces processing temperature from conventional high temperature to lower temperature range, which significantly accelerates the manufacturing process and reduces cycle time from months to shorter durations
Solution Approach 2:
The patent pre-forms the ceramic green body structure before infiltration, allowing subsequent filler materials to be introduced at lower temperatures and shorter times, thereby reducing total manufacturing duration
3Reliability
If conventional high temperature processes are used to produce CMCs, then ceramic matrix formation is achieved, but manufacturing cost increases
Solution Approach 1:
The patent changes temperature parameter to lower range, reducing energy consumption and enabling the use of cost-effective low-melting-point materials, thereby decreasing manufacturing cost
Solution Approach 2:
The patent uses polymer-derived ceramic precursors that can be processed at lower temperatures compared to conventional ceramic powders, reducing processing costs and enabling more economical manufacturing
4Reliability
If high temperature processes are used to produce CMCs, then ceramic matrix formation is achieved, but low-melting point materials cannot be used
Solution Approach 1:
The patent changes the temperature parameter from high temperature to lower temperature range, which enables the use of low-melting-point materials such as plastics and low-melting metals that would otherwise be incompatible with ceramic matrix formation
Solution Approach 2:
The patent creates composite structures combining ceramic matrix with low-melting-point filler materials (plastics, metals, glasses) that are mutually incompatible at high temperatures but can be combined at lower temperatures through the porous infiltration process
5Temperature
If conventional CMC production processes are used, then high temperature resistance is achieved, but the processes are expensive and energy inefficient
Solution Approach 1:
The patent maintains the heat resistance performance by using ceramic matrix formation at lower temperatures through polymer-derived ceramic processes, significantly improving energy efficiency while preserving thermal performance
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 reduces manufacturing costs and time, enables the production of lightweight, high-performance ceramic composites with novel structures not previously possible, and allows for the inclusion of materials previously incompatible with high-temperature ceramic formation.
Implementation Method 1
polymer-derived ceramic (PDC) precursor resin to a ceramic material through pyrolysis at an elevated temperature
Implementation Method 2
creating a ceramic network first and infiltrating fillers, which provides a continuous pore and ceramic network for interpenetrating structures
Data Source
AI summary
Methods, systems, and processes are used to prepare novel ceramic composite structures that are strong, durable, light-weight, high performance and suitable for a myriad of industrial applications, including, but not limited to, ceramic plates of material suitable for use as ballistic armor. The low manufacturing costs of the processes disclosed provide cheaper, faster ways of producing ceramic matrix composites at lower temperatures and allow for the existence of composite materials and structures which currently are not available.