Si-SiC Composite Shape Control via Deformation Suppression

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Solution Overview

Problem

The challenge in manufacturing Si-SiC-based composite structures is that they often deform due to their own weight or the load from the impregnation metal supply body, making it difficult to achieve the desired shape.

Innovation Solution

A method involving a deformation suppressing member, such as a cradle with a support surface that covers at least 30% of the molded body's outer surface, is used to prevent deformation during the impregnation process by supporting the molded body and maintaining its shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the molded body is heated under contact with the impregnation metal supply body, then the molten metal containing Si is impregnated into the molded body, but the molded body deforms due to its own weight and the load from the supply body

Engineering Contradiction:

Improveshape accuracy of Si-SiC-based composite structureVSAvoidstructural stability of molded body

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The molded body is pre-heated to a temperature of 100°C to 500°C before the impregnation process. This preliminary heating reduces the thermal shock and differential expansion during subsequent high-temperature impregnation, thereby preventing deformation while maintaining the molded body's structural stability throughout the manufacturing process

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If the molded body is supported during heating, then deformation is suppressed, but the heating efficiency and heat distribution may be affected

Engineering Contradiction:

Improveshape accuracy of molded bodyVSAvoidheating efficiency

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

A support member is introduced as an intermediary between the molded body and the heating apparatus. This support member allows the molded body to be properly supported during heating to prevent deformation, while being thermally conductive enough to maintain efficient heat transfer and distribution throughout the molded body

Inventive Principle:

Principle #24Intermediary (Mediator)

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 allows for the successful manufacturing of Si-SiC-based composite structures with desired shapes by stabilizing the molded body during the impregnation of molten metal, enhancing the filling efficiency and manufacturing efficiency of the composite structure.

Implementation Method 1

by heating a supply body containing Si to a temperature sufficient to melt the metal

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

impregnating a molten metal containing Si into a molded body containing SiC

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS20230303460A1METHOD OF MANUFACTURING Si-SiC-BASED COMPOSITE STRUCTURE

Publication Date: 2023.09.28 NGK INSULATORS LTD

AI summary

Provided is a method of manufacturing a Si-SiC-based composite structure capable of manufacturing a Si-SiC-based composite structure having a desired shape while suppressing the deformation of a molded body. The method of manufacturing a Si-SiC-based composite structure includes a step of impregnating a molten metal containing Si into a molded body containing SiC by heating a supply body containing Si under a state in which the molded body is in contact with a deformation suppressing member configured to suppress deformation of the molded body and in which the supply body is in contact with the molded body.