CN105732069B - 连接陶瓷泡沫同时维持粘结表面上的结构和物理特性的方法和配方 - Google Patents

连接陶瓷泡沫同时维持粘结表面上的结构和物理特性的方法和配方 Download PDF

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CN105732069B
CN105732069B CN201510968329.1A CN201510968329A CN105732069B CN 105732069 B CN105732069 B CN 105732069B CN 201510968329 A CN201510968329 A CN 201510968329A CN 105732069 B CN105732069 B CN 105732069B
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bonding
cured
fibers
borosilicate
bonding surface
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CN105732069A (zh
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T·H·克鲁克斯
M·S·穆恩齐
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Boeing Co
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Abstract

本发明涉及连接陶瓷泡沫同时维持粘结表面上的结构和物理特性的方法和配方。陶瓷粘结材料包括至少一种纤维材料、助熔剂和增稠剂，其中陶瓷粘结材料在设定温度下被煅烧以粘结两个邻近的基底面。

Description

连接陶瓷泡沫同时维持粘结表面上的结构和物理特性的方法 和配方
技术领域
本发明涉及连接陶瓷泡沫同时维持粘结表面上的结构和物理特性的方法和配方。
背景技术
本发明一般地涉及同时使用粘结组合物的粘结陶瓷泡沫材料，该粘结组合物包含一种或多种纤维材料、粘结助熔剂和增稠剂以形成良好粘结的界面。
在该部分中的陈述仅提供了与本公开内容相关的背景信息并且可以不构成现有技术。
陶瓷泡沫材料的优越的机械性质和在高温下的稳定性是众所周知的，并且已经在许多领域中——包括在航空领域中——被广泛地用作高温结构材料。由于制造约束和/或不同的三维表面，难以由单片陶瓷材料制造大的陶瓷泡沫结构。因此，大的陶瓷泡沫结构通常由多个彼此粘结的陶瓷块或片构成。
将两个或更多个陶瓷块粘结在一起以形成单个结构存在挑战。传统的连接或粘结技术比如机械连结、扩散粘结和钎焊被用于陶瓷与陶瓷连结。然而，每个这些已知的技术都有缺点。
将两个或多个陶瓷泡沫片粘结在一起的另一种方法是使用起永久粘合剂作用的粘结材料。在当前实践下，当使用粘结材料时，将粘结至邻近陶瓷面的每个陶瓷面密封，以便形成牢固的粘结表面。然而，将陶瓷面粘结表面密封抑制空气流动通过陶瓷泡沫材料，并因此抑制陶瓷泡沫结构的加热或冷却。此外，粘结材料可以是连续的材料并且从而充当邻近的陶瓷片之间的密封。
虽然粘结多孔陶瓷构件的已知方法已经存在有限的成功，但是仍然存在挑战。因此，存在对于能够粘结至陶瓷泡沫物品而不严重地影响材料的孔隙率和空气流动特性的改进的粘结组合物和粘结方法的需要。
发明内容
本发明一般涉及同时使用组合物的粘结陶瓷泡沫材料，该组合物包含一种或多种纤维材料、粘结助熔剂和增粘剂以建立良好粘结的界面，并在粘结的界面区域处维持材料性质和基线母体材料的特性。纤维材料在CTE特性方面类似于陶瓷泡沫，并且可以是相同的材料。
公开的实施方式提供了方法和组合物，这些方法和组合物对于将陶瓷泡沫基底粘结在一起以形成较大的泡沫结构，同时在位于单个泡沫片之间的粘结界面处维持一致的材料性质尤其有用。
在一个方面，本发明包括包含纤维材料、助熔剂和增粘剂的粘结材料，其中纤维材料具有与被粘结材料粘结的至少一个基底构件的CTE基本上相似的CTE。
本发明的另一方面是粘结材料，所述粘结材料包含大约50wt％到大约90wt％的短切硼硅酸铝纤维——其具有从大约1/16英寸至大约1/2英寸的平均长度、小于大约0.01wt％到大约5wt％的偏硼酸锂、和大于大约0wt％到大约10wt％的甲基纤维素的水性混合物，其中硼硅酸铝具有与被粘结材料粘结的至少一个基底的CTE基本上相似的CTE。
本发明的仍另一方面是复合材料结构，该复合材料结构包含具有粘结表面的第一基底、具有粘结表面的第二基底、和位于第一基底粘结表面和第二基底粘结表面之间的间隙处的粘结材料，第一和第二基底具有不同的热膨胀系数(CTE)，粘结材料将第一基底粘结至第二基底，粘结材料包括纤维材料、助熔剂和增稠剂的固化的混合物，其中纤维材料具有位于第一基底的CTE和第二基底的CTE之间的CTE。
本发明的又另一方面是复合材料结构，该复合材料结构包含具有粘结表面的第一陶瓷泡沫基底、具有粘结表面的第二陶瓷泡沫基底、和位于第一基底粘结表面和第二基底粘结表面之间的粘结材料，第一基底和第二基底具有基本上相同的CTE，粘结材料将第一基底粘结至第二基底，粘结材料包括纤维材料、助熔剂和增稠剂的固化的混合物，其中纤维材料具有与第一和第二陶瓷泡沫基底的CTE基本上相似的CTE。
附图说明
从下面呈现的更详细的描述和附图——其仅通过图解的方式呈现，并因此不是对本公开内容的限制——将更完全地理解本公开内容，并且其中：
图1A是基底构件10和14的侧视图，包括位于所述基底之间的粘结材料18；
图1B是图1中显示的两个基底构件在粘结材料已经在基底构件之间形成生的(green)粘结之后的侧视图；
图2是大的陶瓷材料结构的俯视图，所述陶瓷材料结构包括多个被固化的粘结材料层分开的单个基底；和
图3是用于形成陶瓷材料结构的方法的流程图。
在所有附图中，相应的部分利用相同的参考符号标记。
具体实施方式
本发明的一方面是粘结材料，所述粘结材料包括纤维材料和适当比例的粘结助熔剂，以及增稠剂。当施加“生的”(未固化的)粘结材料至基底的相对粘结表面时，粘结材料足够粘以防止粘结材料深渗透进入基底。随后在处于固化温度的炉中煅烧基底和生的粘结材料将生的粘结材料转化为固化的粘结材料，并且从而在两个相对的基底表面之间形成永久的粘结。固化的粘结材料是多孔的并且不显著干扰多孔基底材料的孔隙率和空气流动特性。
本发明的方法将参照图1A、图1B和图3进行讨论。图1A和图1B显示了两个基底构件10和14。每个基底构件10和14进一步包括互补的粘结表面12和16。基底粘结表面12和16可以是未经处理的或者他们可以在经受粘结之前进行预处理。因此，如图3中所显示，形成本发明的陶瓷材料结构的方法中的初始步骤40是为了确定粘结表面预处理是否是必要的。如果粘结表面预处理是必要的，则在步骤42中，预处理可以通过已知的方法比如机械或化学过程——其增强粘结表面与粘结材料粘结的能力——完成。例如，粘结表面可以使用砂、砂砾、锉刀、喷砂打磨法等机械地粗糙化或抛光。在另一个实例中，粘结表面可以在施加粘结材料之前被化学蚀刻和/或清洁。
在步骤44中，粘结材料层18——在图1A中的基底构件10和14之间的空间中显示——可被施加至粘结表面12、粘结表面16中的任一个、或被施加至基底粘结表面12和16二者。粘结材料层将通常被施加至一个或两个邻近的粘结表面上大约0.1密尔到大约10密尔(0.0001英寸到0.01英寸)的厚度。一旦粘结材料层18被施加至一个或两个基底粘结表面，表面在步骤46中彼此接触，并且可以垂直于大致平的粘结材料层任选地施加轻微压力以形成包括未固化的粘结材料层的组件19。轻微压力可以例如如图1B所显示而施加，通过定向两个基底构件使得一个基底构件停留在另一个的上面，使得上面的基底构件的重量的力指向或朝向粘结材料层。可选地，可以通过使用橡皮筋、细绳、小重量物体等施加轻微压力以使基底构件保持在一起。在过程步骤48处，作出是否完成了未固化的陶瓷材料结构的制造，或在结构完成之前是否需要联合额外的粘结表面的决定。如果需要额外的粘结，则重复步骤40-46直到完成固化的陶瓷材料结构。
在一些情况下，可以通过使粘结材料进行步骤50中的静置和生的固化而形成充分的临时的“生的粘结”(通过未固化的粘结材料形成的粘结)，在所述步骤50之后，可任选地释放施加以使基底构件保持在一起的任何压力。可选地，可以维持提供至基底构件10和14的轻微压力或约束直到粘结材料层18被完全固化。
在步骤52中，固化未固化的陶瓷材料结构或组件。包括生的粘结材料层18的组件19通常通过将它放置在通常在环境压力下操作的固化装置比如炉、窑、煅烧炉、高压釜或类似的加热装置中进行固化。固化装置温度可以根据粘结材料构件的选择改变。然而，可以预期，炉温将在大约120°F到大约500°F的范围内，并且更优选地在大约160°F到大约370°F的范围内。而且，可以使用单步或多步加热廓线完成固化。包括生的粘结材料层的组件应当保留在固化装置中持续足以形成固化的粘结材料层的时间。固化时间可以根据在组件中使用的材料——基底(一个或多个)和粘结材料成分——的选择而改变。可以预期，固化温度将在大约2到大约12小时的范围内，并且更可能在大约4到大约10小时的范围内。固化的组件可以在热的同时从固化装置中移去并使其冷却，或者可以通过在固化装置被关掉之后使组件留在固化装置中而使它缓慢地冷却。
本发明的粘结材料可用于形成复合组件，其通过将多个基底片粘结在一起形成复合组件。图2是包括多个单个基底20的复合组件25的俯视图，每个基底具有一个或多个粘结表面。当复合组件25形成时，本发明的粘结材料将作为层被施加至粘结表面。一旦完成，复合组件将作为单个片被放置在炉中并且被煅烧以形成包括多个固化的粘结材料层24的固化的复合组件25。
本发明的粘结材料包括至少一种纤维材料、至少一种助熔剂和至少一种增稠剂。纤维材料包括在粘结材料中以帮助形成多孔的固化的粘结材料。固化的粘结材料可以具有在从50％到高达98％范围内并且更通常地在从大约85％到95％范围内的孔隙率。
当单个纤维片与剩余的粘结材料成分混合并且固化时，并且当它们以随机方式彼此粘附时，多孔的固化的粘结材料形成。多孔的材料可以是可保持粘结材料固化条件的任何类型的纤维。根据纤维构件的性质，纤维可以或不可以完全或部分熔融(即SiO2对ZrO2)。在本发明的一方面，粘结材料将经历表面助熔，从而使纤维彼此交叉粘结。纤维材料中的单个纤维将通常具有长度“L”，长度“L”显著大于其直径“D”，L∶D比率大于大约10并且优选地大于大约100。可选地，或此外，纤维材料将是短切纤维或晶须，所述短切纤维或晶须具有从大约1/16英寸至大约1/2英寸并且可选地从1/8英寸到大约1/4英寸的平均短切长度。
一种或多种纤维材料可以选自多种陶瓷纤维或陶瓷金属纤维。有用的纤维包括，但不限于二氧化硅(SiO2)、矾土(Al2O3)、氧化锆(ZrO2)、氧化钛(TiO2)、硅酸铝(Al-Si-氧化物)、具有或不具有碱金属的硅硼酸铝、碳、硼硅酸盐、氮化硅(SiN)、碳化硅(SiC)的纤维和这些纤维的组合。在另一实施方式中，纤维可以由与粘结材料被施加至其的基底材料相同的材料制造。此外，当使用玻璃纤维时，纤维可以处于结晶相和玻璃相中的一个或两个。
纤维材料可以选自具有与粘结材料被施加至其的至少一个基底的CTE基本上类似的热膨胀系数“CTE”的材料。“基本上类似”意思是两种材料的CTE应当在彼此的±20％之内并更优选地在彼此的±10％之内。“基本上相同”意思是两种材料的CTE在彼此的±5％之内。通过平衡两种材料的CTE，由固化的粘结材料形成的粘结更有可能承受一个或多个温度循环而不失效。这是因为当组件在固化期间和/或使用中经历显著的温度循环时，具有基本上类似CTE的固化的粘结材料和基底材料将以基本上相同的速率膨胀和收缩。在一些结构中，邻近的基底(具有邻接的粘结表面的基底)将具有不同的CTE。在这样的结构中，选择具有位于邻近的基底的CTE之间某处的CTE的纤维材料是令人满意的。这允许粘结材料在具有不类似CTE的基底之间形成CTE过渡、或CTE过渡区。在这种情况下，使纤维材料与基底材料的CTE平衡以及使固化的粘结材料与基底材料的CTE平衡是有用的。
应当注意的是，本发明的复合结构可以指示多种基底，其中的一些基底具有相等的CTE，并且其中的一些基底具有不同的CTE。因此，可以预期，复合结构将使用不同的粘结材料配方形成，即在其中调整纤维材料的选择以具有特定的CTE和特定的粘结表面的粘结材料。
纤维材料可以以从大约50wt％到大约90wt％并且更可能从大约70wt％到大约90wt％的范围内的未固化材料的量存在于本发明的粘结材料中。这将相当于从大约60wt％到大约95wt％范围内的固化的粘结材料的量。
粘结材料进一步包括至少一种助熔剂。助熔剂可以选自降低粘结材料接触的基底构件(一个或多个)的粘结表面处的基体材料的熔点或软化温度的任何材料。助熔剂与粘结表面的表面分子结构相互作用并逐个分子地拉动它们离开(溶解它们)，从而为粘结材料成分提供粘结位点。
因此，助熔剂(一种或多种)的选择可取决于正被粘结材料粘结的基底材料。一种或多种助熔剂可通常选自任何硼化的、碳化的、或碳化物碱或碱土金属盐。有用的助熔剂的一些实例包括，但不限于，碳酸钠、碳化硼、偏硼酸锂、硼酸镉、硼酸锂、硼化硅、硼硅酸镉、氧化铋、硼硅酸铅、四硼酸锂、硼酸镉、硼硅酸镉、硼硅酸铅或其组合。
一种或多种助熔剂通常作为颗粒材料被提供，并且可以以从小于大约0.01wt％到大约5wt％，并且更通常地从大约小于0.05wt％到大约1wt％的范围被并入粘结材料。这通常相当于固化的粘结材料中的从大约小于0.01wt％到大约5wt％范围的助熔材料。
本发明的粘结材料将进一步包括一种或多种增稠剂。为了调节粘结材料粘性，将增稠剂加入到粘结材料，以便其可被施加至基底粘结表面，使得基底表面可完全被粘结材料覆盖，并且使得在粘结材料被施加之后粘结材料不移动进入基底材料太远。就这一点而言，增稠剂可用于控制粘结材料的粘性。在本发明的一方面中，生的粘结材料的粘性将被调节以便粘结材料可以渗入多孔基底至从大约1/32英寸至大约1/2英寸并且更理想地从大约1/16英寸至大约1/4英寸的深度。
一种或多种增稠剂可选自已知在控制粘性材料的粘性中有用的任何材料。增稠剂可以参与粘结材料固化期间基底片之间的粘结的形成，或者增稠剂在粘结过程中可以是惰性的。增稠剂的一些实例包括：天然化合物比如淀粉——其包括竹芋粉、玉米淀粉、西米和木薯淀粉；树胶比如藻胶(alginin)、瓜尔豆胶和黄原胶；糖类比如琼脂和角叉菜胶；蛋白质比如胶原蛋白和酪蛋白；果胶；纤维素材料；和明胶。也可以使用合成的增稠剂。有用的合成的增稠剂的实例包括聚乙二醇、聚丙烯酸、有机硅树脂、磺酸钠和磺酸钙和聚乙烯醇。
一种特别有用的增稠剂的种类是源自纤维素的纤维素材料。例如，有用的纤维素材料包括微晶纤维素和改性纤维素，比如包括甲基纤维素的纤维素醚。纤维素材料是有用的，部分因为水可用于润湿改性纤维素。改性纤维素材料主要由多糖组成，多糖在粘结固化热处理期间最终挥发。改性纤维素作为水溶液(例如，2％甲基纤维素和DI水的溶液)被供应，并且它与其他粘结材料成分以足以提供期望的粘结材料粘性的量混合。如上所述，期望的粘结材料粘性可取决于多种因素，比如基底的孔隙率和粘结材料渗入基底的期望的深度。可影响粘结材料粘性的因素包括，但不限于，粘结材料组合物、粘结材料施加期间的环境条件比如温度和湿度、以及基底性质比如基底孔隙率。改性纤维素也可以将一些“生的强度”赋予粘结组合物，其使邻近的基底构件在热固化之前彼此粘附。一种特别有用的改性纤维素是甲基纤维素或由Dow Chemical制造并出售的Methocel。
最终粘结材料中使用的改性纤维素的总量可以在从大于大约0wt％到大约10wt％的范围内。水，优选是冷的去离子水，可以被加入到粘结材料构件的混合物中以实现期望的粘结材料粘性。
本发明的粘结材料在粘结多种基底材料中是有用的。粘结材料主要被配制为粘结陶瓷基底材料。在本发明的基底中有用的陶瓷材料包括传统的和新型的陶瓷材料并包括无机结晶材料，该无机结晶材料由金属和固体的(并且并可能形成为泡沫)和惰性的非金属合成。陶瓷通常可承受非常高的温度，比如从1,000℃到1,600℃(1,800°F到3,000°F)范围内的温度。
传统的陶瓷来源于包括粘土矿物的原材料，并且其包括，例如瓷。新型的陶瓷材料包括但不限于氧化铝、碳化硅、碳化钨、氧化锌、锆钛酸铅、钛酸钡、硅铝氮氧化物(siliconaluminum oxynitride)、硅酸镁、碳化钛、氧化锆等。
在本发明的一个方面中，基底可以是开孔陶瓷泡沫材料。开孔陶瓷泡沫基底可以使用上面列举的陶瓷材料或者其它陶瓷材料通过多种方法制造。陶瓷泡沫制造技术包括利用陶瓷浆料内部地浸渍开孔聚合物泡沫，然后在窑中煅烧，仅剩下陶瓷材料。泡沫可以由几种陶瓷材料组成，比如氧化铝(矾土)、硅酸盐泡沫瓷砖和由SiO2制成的泡沫瓷砖、二氧化硅-矾土(SiO2-Al2O3-x)、SiN、ZrO和任何其它有用的高温陶瓷材料。基底也可由与助熔剂组合的任何纤维或多孔材料形成。
由于材料内的许多微小的充气孔，陶瓷材料具有有用的隔热性质。开孔聚合物泡沫材料的实例包括热固性树脂-陶瓷，比如聚酯和矾土，二氧化硅和滑石；热塑性树脂，热塑性酚醛树脂和矾土，二氧化硅和滑石；热塑性环氧树脂和矾土，二氧化硅和滑石；聚氨酯和矾土，二氧化硅和滑石；纤维素和矾土，二氧化硅和滑石；聚酯和矾土，二氧化硅和滑石；热塑性酚醛树脂和矾土，二氧化硅和氧化镁；热塑性环氧树脂和矾土，二氧化硅和氧化镁；聚氨酯和矾土，二氧化硅和氧化镁；纤维素和矾土，二氧化硅和氧化镁；热塑性烷基树脂和矾土，二氧化硅和氧化镁；或其任意组合。完成的开孔陶瓷基底可以由γ-矾土、莫来石、锂辉石、二氧化硅等制造。将进一步理解，前面提及的开孔陶瓷泡沫基底仅是这样的基底的种类的代表。
实施例：
生的粘结材料通过组合下面的成分而制备：
NextelTM312(矾土-氧化硼-二氧化硅)短切纤维-12wt％；
偏硼酸锂粉末-0.1wt％；
甲基纤维素-88wt％；
按需的水。
生的粘结材料用于粘结具有大约90-95％孔体积的两种富二氧化硅纤维瓷砖基底。
用刮铲在两个粘结瓷砖基底的每个的粘结表面上涂抹或者擦生的粘结材料，其后粘结表面立即被粘结面对粘结面地连接。粘结面然后轻微地被扭动或“磨”在一起以确保面与面接触和纤维面的潜在的共混合(co-mingling)。将重物放置在一个粘结构件的上面并且风干粘合剂以形成生的粘结。然后使生的粘结材料固化以形成固化的粘结。
在两个瓷砖基底面之间的所得的粘结在视觉上难以区分。固化的粘结足以允许材料处理和可能地机械加工。
粘结材料包括纤维材料、助熔剂和增稠剂，其中纤维材料具有与被粘结材料粘结的至少一个基底构件的CTE基本上相似的CTE。粘结材料中的纤维材料是具有从大约1/16英寸至大约1/2英寸的平均长度的短切纤维。粘结材料中的纤维材料选自二氧化硅(SiO2)、矾土(Al2O3)、氧化锆(ZrO2)、氧化钛(TiO2)、硅酸铝(Al-Si-氧化物)、具有或不具有碱金属的硅硼酸铝、碳、硼硅酸盐、氮化硅(SiN)或碳化硅(SiC)的纤维和这些纤维的组合。粘结材料中的纤维材料是硼硅酸铝。
粘结材料中的纤维材料在它被固化之前以从大约50wt％到大约90wt％范围内的量存在于粘结材料中。粘结材料中的助熔剂是碳酸钠、碳化硼、偏硼酸锂、硼酸镉、硼酸锂、硼化硅、硼硅酸镉、氧化铋、硼硅酸铅、四硼酸锂、硼酸镉、硼硅酸镉、或硼硅酸铅和其组合。粘结材料中的助熔剂是偏硼酸锂。粘结材料中的助熔剂在它被固化之前以从大约小于大约0.01wt％到大约5wt％范围内的量存在于粘结材料中。
粘结材料中的增稠剂是淀粉、树胶、糖、蛋白质、果胶、纤维素材料、明胶、合成的增稠剂和其组合。粘结材料中的增稠剂是甲基纤维素。粘结材料中的增稠剂在它被固化之前以从大于大约0wt％到大约10wt％范围内的量存在于粘结材料中。粘结材料包括从大约50wt％到大约90wt％的短切硼硅酸铝纤维——其具有从大约1/16英寸到大约1/2英寸的平均长度；从小于大约0.01wt％到大约5wt％的偏硼酸铝；和从大于大约0wt％到大约10wt％的甲基纤维素的水性混合物，其中硼硅酸铝具有与被粘结材料粘结的至少一个基底的CTE基本上相似的CTE。
复合结构包括具有粘结表面的第一基底、具有粘结表面的第二基底，第一基底和第二基底具有不同的热膨胀系数(CTE)；粘结材料位于第一基底粘结表面和第二基底粘结表面之间，粘结材料将第一基底粘结至第二基底，粘结材料包括纤维材料、助熔剂和增稠剂的固化的混合物；其中纤维材料具有位于第一基底的CTE和第二基底的CTE之间的CTE。
复合结构中的纤维材料是具有从大约1/16英寸到大约1/2英寸的平均长度的短切纤维。复合结构中的纤维材料选自二氧化硅(SiO2)、矾土(Al2O3)、氧化锆(ZrO2)、氧化钛(TiO2)、硅酸铝(Al-Si-氧化物)、具有或不具有碱金属的硅硼酸铝、碳、硼硅酸盐、氮化硅(SiN)、或碳化硅(SiC)的纤维和这些纤维的组合。复合结构中的纤维材料是硼硅酸铝。
复合结构中的纤维材料在它被固化之前以从大约50wt％到大约90wt％范围内的量存在于粘结材料中。复合结构中的助熔剂是碳酸钠、碳化硼、偏硼酸锂、硼酸镉、硼酸锂、硼化硅、硼硅酸镉、氧化铋、硼硅酸铅、四硼酸锂、硼酸镉、硼硅酸镉或硼硅酸铅和其组合。复合结构中的助熔剂是偏硼酸锂。
复合结构中的助熔剂在它被固化之前以从小于大约0.01wt％到大约5wt％范围内的量存在于粘结材料中。复合结构中的增稠剂是淀粉、树胶、糖、蛋白质、果胶、纤维素材料、明胶或合成的增稠剂和其组合。复合结构中的增稠剂是甲基纤维素。复合结构中的增稠剂在它被固化之前以从大于0wt％到大约10wt％范围内的量存在于粘结材料中。复合结构中的第一基底和第二基底各自是陶瓷泡沫基底。
复合结构包括具有粘结表面的第一陶瓷泡沫基底、具有粘结表面的第二陶瓷泡沫基底，第一基底和第二基底具有基本上相同的CTE；粘结材料位于第一基底粘结表面和第二基底粘结表面之间，粘结材料将第一基底粘结至第二基底，粘结材料包括纤维材料、助熔剂和增稠剂的固化的混合物，其中纤维材料具有与第一和第二陶瓷泡沫基底的CTE基本上相似的CTE。
用于形成固化的陶瓷结构的方法包括以下步骤：将粘结材料施加至至少一个粘结表面，该粘结表面选自第一基底片的第一粘结表面和第二基底片的第二粘结表面，其中粘结材料进一步包括纤维材料、助熔剂和增稠剂，其中纤维材料具有与第一和第二基底的至少一个的CTE基本上相似的CTE；连接第一粘结表面和第二粘结表面，使得粘结材料被放置在第一粘结表面和第二粘结表面之间以形成包括未固化的粘结材料的陶瓷结构；和在从大约1,000℃至大约1,600℃的温度下加热陶瓷结构持续足以形成包括固化的粘结材料的陶瓷结构的时间。
该方法中的至少一个粘结表面被预处理以形成预处理的粘结表面，其后将粘结材料施加至该预处理的粘结表面。重复该方法中的步骤(a)和(b)以形成具有多于两个基底片的陶瓷结构。该方法中的纤维材料是具有从大约1/16英寸到大约1/2英寸的平均长度的短切纤维。该方法中的纤维材料选自二氧化硅(SiO2)、矾土(Al2O3)、氧化锆(ZrO2)、氧化钛(TiO2)、硅酸铝(Al-Si-氧化物)、具有或不具有碱金属的硅硼酸铝、碳、硼硅酸盐、氮化硅(SiN)、或碳化硅(SiC)的纤维和这些纤维的组合。
该方法中的纤维材料在它被固化之前以从大约50wt％到大约90wt％范围内的量存在于粘结材料中。该方法中的助熔剂是碳酸钠、碳化硼、偏硼酸锂、硼酸镉、硼酸锂、硼化硅、硼硅酸镉、氧化铋、硼硅酸铅、四硼酸锂、硼酸镉、硼硅酸镉或硼硅酸铅和其组合。该方法中的助熔剂在它被固化之前以从小于大约0.01wt％到大约5wt％范围内的量存在于粘结材料中。该方法中的增稠剂是淀粉、树胶、糖、蛋白质、果胶、纤维素材料、明胶、合成的增稠剂和其组合。
该方法中的增稠剂在它被固化之前以从大于大约0wt％到大约10wt％范围内的量存在于粘结材料中。该方法中的粘结材料是包括从大约50wt％到大约90wt％的短切硼硅酸铝纤维——其具有从大约1/16英寸到大约1/2英寸的平均长度；从小于大约0.01wt％到大约5wt％的偏硼酸铝；和从大于大约0wt％到大约10wt％的甲基纤维素的水性混合物，其中硼硅酸铝具有与被粘结材料粘结的至少一个基底的CTE基本上相似的CTE。
具体实施方式的上面的描述将揭示本公开内容的一般性质，因此通过应用当前知识，其它人可以容易地对这些具体实施方式修改和/或将其适用于各种应用，而不背离一般概念，并且因此这种适用和修改意欲包括在所公开的实施方式的等价物的含义和范围之内。应当理解，本文的措辞和术语是为了描述的目的，并不是限制性的。

Claims (7)

1.一种粘结材料，其包括：
纤维材料，
助熔剂；和
增稠剂，其中所述纤维材料具有与被所述粘结材料粘结的至少一个基底构件的CTE基本上相似的CTE，
其中所述纤维材料选自二氧化硅、矾土、氧化锆、氧化钛、硅酸铝、具有或不具有碱金属的硅硼酸铝、碳、硼硅酸盐、氮化硅或碳化硅的纤维和这些纤维的组合，
其中所述纤维材料在它被固化之前以从50wt％到90wt％范围内的量存在于所述粘结材料中，
其中所述助熔剂是碳酸钠、碳化硼、偏硼酸锂、硼酸镉、硼酸锂、硼化硅、硼硅酸镉、氧化铋、硼硅酸铅、四硼酸锂和其组合，和
其中所述增稠剂是淀粉、树胶、糖、蛋白质、果胶、纤维素材料、明胶、合成的增稠剂和其组合，并且其中所述增稠剂在它被固化之前以从大于0wt％到10wt％范围内的量存在于所述粘结材料中。
2.权利要求1所述的粘结材料，其中所述纤维材料是具有1/16英寸到1/2英寸的平均长度的短切纤维。
3.权利要求1或2所述的粘结材料，其中所述助熔剂在它被固化之前以从小于0.01wt％到5wt％范围内的量存在于所述粘结材料中。
4.用于形成固化的陶瓷结构的方法，包括以下步骤：
(a)将粘结材料施加至至少一个粘结表面，所述粘结表面选自第一基底片的第一粘结表面和第二基底片的第二粘结表面，其中所述粘结材料进一步包括纤维材料、助熔剂和增稠剂，其中所述纤维材料具有与所述第一基底和第二基底的至少一个的CTE基本上相似的CTE；
(b)连接所述第一粘结表面和所述第二粘结表面，使得所述粘结材料被放置在所述第一粘结表面和所述第二粘结表面之间以形成包含未固化的粘结材料的陶瓷结构；和
(c)在从1,000℃至1,600℃的温度下加热所述陶瓷结构持续足以形成包含固化的粘结材料的陶瓷结构的时间，
其中所述纤维材料选自二氧化硅、矾土、氧化锆、氧化钛、硅酸铝、具有或不具有碱金属的硅硼酸铝、碳、硼硅酸盐、氮化硅或碳化硅的纤维和这些纤维的组合，
其中所述纤维材料在它被固化之前以从50wt％到90wt％范围内的量存在于所述粘结材料中，
其中所述助熔剂是碳酸钠、碳化硼、偏硼酸锂、硼酸镉、硼酸锂、硼化硅、硼硅酸镉、氧化铋、硼硅酸铅、四硼酸锂和其组合，并且所述助熔剂在它被固化之前以从小于0.01wt％到5wt％范围内的量存在于所述粘结材料中，和
其中所述增稠剂是淀粉、树胶、糖、蛋白质、果胶、纤维素材料、明胶、合成的增稠剂和其组合，并且所述增稠剂在它被固化之前以从大于0wt％到10wt％范围内的量存在于所述粘结材料中。
5.权利要求4所述的方法，其中所述纤维材料是具有从1/16英寸到1/2英寸的平均长度的短切纤维。
6.权利要求4所述的方法，其中所述粘结材料是水性混合物，其包括：
从50wt％到90wt％的短切硼硅酸铝纤维，所述短切硼硅酸铝纤维具有从1/16英寸到1/2英寸的平均长度；
从小于0.01wt％到5wt％的偏硼酸锂；和
从大于0wt％到10wt％的甲基纤维素，其中所述硼硅酸铝具有与被所述粘结材料粘结的至少一个基底的CTE基本上相似的CTE。
7.一种复合结构，其包含具有粘结表面的第一陶瓷泡沫基底、具有粘结表面的第二陶瓷泡沫基底，具有基本上相同CTE的所述第一基底和第二基底通过权利要求4-6中任一项所述的方法连接。
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