JP7029262B2 - 低密度、高気孔率のセラミック部分品の付加製造のための前駆体材料、及びそれを生産する方法 - Google Patents
低密度、高気孔率のセラミック部分品の付加製造のための前駆体材料、及びそれを生産する方法 Download PDFInfo
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Description
水系セラミック繊維スラリは、供給原料スラリ(feedstock slurry)として得られた。例示的な水系セラミック繊維スラリは、ボーイング社(The Boeing Company )に譲渡された米国特許第6,716,782号で開示されている。供給原料スラリとして使用し得る他の水系セラミック繊維スラリも可能である。
低密度、高気孔率のセラミック部分品の付加製造のための前駆体材料を生産する方法であって、
バインダーと、約50重量パーセントから約80重量パーセントのシリカ繊維及び約20重量パーセントから約50重量パーセントのアルミナ繊維を含むセラミック繊維の本体とを含む水系セラミック繊維スラリを得ることと、
低密度、高気孔率のセラミック部分品を製造するために、ノズルを通して押し出すことに適した粘度を有するスラリを供給するために、水系セラミック繊維スラリが加熱される前に、バインダー及びセラミック繊維の本体の重量の約0.25パーセントと約2.5パーセントとの間の重量を有するキサンタンガムを添加することと
を含む方法。
水系セラミック繊維スラリを得ることが、水系セラミック繊維スラリを加熱して、水系セラミック繊維スラリの水の約50重量パーセントを蒸発させることを含む、条項1に記載の方法。
キサンタンガムがバインダー及びセラミック繊維の本体に添加される前に、イソプロピルアルコールをキサンタンガムと混合することと、
約15秒から約180秒の間、イソプロピルアルコール、キサンタンガム、バインダー、及びセラミック繊維の本体の混合物を軸外れに遠心的に混合することと、
約0.25時間から約5.0時間の間、イソプロピルアルコール、キサンタンガム、バインダー、及びセラミック繊維の本体の混合物を撹拌混合することと、
イソプロピルアルコール、キサンタンガム、バインダー、及びセラミック繊維の本体の混合物が撹拌混合された後、イソプロピルアルコールを除去することと
を含む、条項1又は2に記載の方法。
約15秒から約180秒の間、イソプロピルアルコール、キサンタンガム、バインダー、及びセラミック繊維の本体の混合物を軸外れに遠心的に混合することが、約30秒間、イソプロピルアルコール、キサンタンガム、バインダー、及びセラミック繊維の本体の混合物を軸外れに遠心的に混合することを含む、条項3に記載の方法。
生成される前駆体材料の密度が、約4ポンド/立方フィートと約25ポンド/立方フィートとの間である、条項3又は4に記載の方法。
Claims (13)
- 低密度、高気孔率のセラミック部品の付加製造のための前駆体材料であって、
耐火繊維の本体、
前記耐火繊維の本体と混合されたバインダー、並びに
0.3センチポイズと150、000センチポイズとの間の粘度を有する全体的な混合物を供給するための、前記バインダー及び前記耐火繊維の本体と混合された粘度制御添加物であって、前記低密度、高気孔率のセラミック部品を製造するために、前記全体的な混合物がノズルを通して押し出され得る、粘度制御添加物
を含み、
前記耐火繊維の本体が、50重量パーセントから80重量パーセントのシリカ繊維及び20重量パーセントから50重量パーセントのアルミナ繊維を含むセラミック繊維の本体を含む、前駆体材料。 - 前記粘度制御添加物が、前記粘度制御添加物を前記バインダー及び前記セラミック繊維の本体と混合する前の、前記バインダー及び前記セラミック繊維の本体の重量の0.25パーセントと2.5パーセントとの間の重量を有するキサンタンガムを含む、請求項1に記載の前駆体材料。
- 前記粘度制御添加物が、前記粘度制御添加物を前記バインダー及び前記セラミック繊維の本体と混合する前の、前記バインダー及び前記セラミック繊維の本体の重量の0.25パーセントと2.5パーセントとの間の重量を有するポリエチレングリコールを含む、請求項1又は2に記載の前駆体材料。
- 前記粘度制御添加物が、前記粘度制御添加物を前記バインダー及び前記セラミック繊維の本体と混合する前の、前記バインダー及び前記セラミック繊維の本体の重量の0.25パーセントと2.5パーセントとの間の重量を有するポリエチレンオキサイドを含む、請求項1から3のいずれか一項に記載の前駆体材料。
- 前記バインダーが熱可塑性材料を含む、請求項1から4のいずれか一項に記載の前駆体材料。
- 請求項1から5のいずれか一項に記載の前駆体材料を使用して製造された、低密度、高気孔率のセラミック部品。
- 低密度、高気孔率のセラミック部品の付加製造のための前駆体材料を生産する方法であって、
耐火繊維スラリを得ることと、
低密度、高気孔率のセラミック部品を製造するために、前記スラリに、ノズルを通して押し出すことに適した粘度をもたらすように、粘度制御添加物を前記スラリに添加することと
を含み、
耐火繊維スラリを得ることが、
バインダーと、50重量パーセントから80重量パーセントのシリカ繊維及び20重量パーセントから50重量パーセントのアルミナ繊維を含むセラミック繊維の本体とを含む水系セラミック繊維スラリを加熱することを含む、方法。 - 水系セラミック繊維スラリを加熱することが、
前記水系セラミック繊維スラリを加熱して、前記水系セラミック繊維スラリの水の50重量パーセントを蒸発させることを含む、請求項7に記載の方法。 - 粘度制御添加物を前記スラリに添加することが、
前記水系セラミック繊維スラリが加熱される前に、前記バインダー及び前記セラミック繊維の本体の重量の0.25パーセントと2.5パーセントとの間の重量を有するキサンタンガムを添加することを含む、請求項7又は8に記載の方法。 - 前記キサンタンガムが前記バインダー及び前記セラミック繊維の本体に添加される前に、イソプロピルアルコールを前記キサンタンガムと混合することをさらに含む、請求項9に記載の方法。
- 15秒から180秒の間、前記イソプロピルアルコール、前記キサンタンガム、前記バインダー、及び前記セラミック繊維の本体の混合物を遠心的に混合することをさらに含む、請求項10に記載の方法。
- 0.25時間から5.0時間の間、前記イソプロピルアルコール、前記キサンタンガム、前記バインダー、及び前記セラミック繊維の本体の前記混合物を撹拌混合することをさらに含む、請求項11に記載の方法。
- 前記イソプロピルアルコール、前記キサンタンガム、前記バインダー、及び前記セラミック繊維の本体の前記混合物が撹拌混合された後、前記イソプロピルアルコールを除去することをさらに含む、請求項12に記載の方法。
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