WO2010035692A1 - SiC繊維結合型セラミックスの製造方法 - Google Patents
SiC繊維結合型セラミックスの製造方法 Download PDFInfo
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Abstract
Description
第1工程においては、前駆体重合体である金属元素含有有機ケイ素重合体を調製する。第1工程において用いられるポリシランは、例えば「有機ケイ素化合物の化学」化学同人(1972年)に記載の方法に従い、ナトリウムを用いて1種類以上のジクロロシランを脱塩素反応させることによって得られる鎖状又は環状の重合体であり、その平均分子量は、通常300~1000である。このポリシランは、化1に一般式を示すように、ケイ素の側鎖として、水素原子、低級アルキル基、フェニル基又はシリル基を有することができるが、いずれの場合も、ケイ素原子に対する炭素原子の割合がモル比で1.5以上であることが望ましい。ケイ素原子に対する炭素原子の割合がモル比で1.5より少ないと、繊維中の炭素が不融化の際に導入された酸素と共に、焼結に至るまでの昇温過程において炭酸ガスとして脱離するため、繊維間の境界炭素層が均一に形成されにくくなるので好ましくない。
第2工程においては、第1工程で得られた金属元素含有有機ケイ素重合体を溶融紡糸することによって、紡糸繊維を得る。紡糸繊維は、溶融紡糸及び乾式紡糸等のそれ自体公知の方法によって、前駆重合体である金属元素含有有機ケイ素重合体を紡糸することにより得ることができる。
第3工程においては、第2工程で得られた紡糸繊維を酸素含有雰囲気中50~170℃で加熱することによって、不融化繊維を調製する。不融化の目的は、紡糸繊維を構成するポリマー間に酸素原子による橋架点を形成させて、次工程の無機化工程において不融化繊維が溶融せず、かつ隣接する繊維同士が融着しないようにすることである。酸素含有雰囲気を構成するガスとしては、空気、酸素及びオゾンが例示される。不融化時間は不融化温度に依存するが、通常数分~30時間である。不融化繊維中の酸素の含有量は、8~16質量%になるように調整することが望ましい。この酸素の大部分は、次工程の無機化後も繊維中に残存し、最終の焼結に至るまでの昇温過程において、無機繊維中の余剰炭素をCOガスとして脱離させる重要な働きをする。なお、酸素含有量が8質量%より少ない場合は、無機繊維中の余剰炭素が必要以上に残存し、昇温過程においてSiC結晶の回りに偏析して安定化するため、β-SiC結晶同士が粒界第2相を介すことなく焼結することを阻害する。また、酸素含有量が16質量%よりも多い場合には、無機繊維中の余剰炭素が完全に脱離して、繊維間の境界炭素層が生成されない。いずれの場合も、得られる材料の力学的特性に悪影響を及ぼすので、好ましくない。
第4工程においては、第3工程で得られた不融化繊維を不活性ガス中において無機化することによって、無機繊維を得る。この不融化繊維の無機化は、連続式又は回分式により、アルゴン等の不活性ガス雰囲気中において、1000~1700℃の温度で加熱処理して行う。
本発明に係るSiC繊維結合型セラミックスの製造方法の実施例1について説明する。まず、無機繊維を以下の手順で調製した。窒素ガス気流下でナトリウム400gを含有する無水キシレンを加熱環流させながら、ジメチルジクロロシラン1Lを滴下し、引き続き10時間加熱環流して沈殿物を生成させた。この沈殿物をろ過し、メタノール、次いで水を用いて洗浄して、白色のポリジメチルシラン420gを得た。このポリジメチルシランの一般式を化2に示す。化2から明らかなように、得られたポリジメチルシランにおけるSi:Cの原子数比は1:2であり、従って、ケイ素原子数に対する炭素原子数の割合はモル比で1.5以上となる。次に、窒素ガス雰囲気下、n-ブチルエーテル中においてジフェニルジクロロシラン750g及びホウ酸124gを100~120℃で加熱し、生成した白色樹脂状物をさらに真空中400℃で1時間加熱処理することにより、フェニル基含有ポリボロシキサン530gを得た。得られたポリジメチルシラン100部に対してフェニル基含有ポリボロシロキサン4部を添加し、窒素ガス雰囲気中において、350℃で5時間熱縮合し、高分子量の有機ケイ素重合体を得た。この有機ケイ素重合体100部を溶解したキシレン溶液に、アルミニウム-トリ-(sec-ブトキシド)7部を添加し、窒素ガス気流下において310℃で架橋反応させることにより、ポリアルミノカルボシランを合成した。
本発明に係るSiC繊維結合型セラミックスの製造方法の実施例2について説明する。まず、実施例1と同様の手順によって、予備成形体を作製し、表1に示す雰囲気と温度で1時間加熱処理した。加熱処理後、一緒に入れておいた繊維の切れ端の酸素分析結果を同じく表1に示す。
本発明に係るSiC繊維結合型セラミックスの製造方法の実施例の効果を確認するために行った比較例1について説明する。まず、実施例1と同様の手順によって、予備成形体を作製し、アルゴン雰囲気の1100℃で1時間加熱処理した。加熱処理後、一緒に入れておいた繊維の切れ端の酸素分析を実施したところ13.0質量%であった。
本発明に係るSiC繊維結合型セラミックスの製造方法の実施例の効果を確認するために行った比較例2について説明する。まず、実施例1と同様の手順によって、予備成形体を作製し、アルゴン雰囲気の1850℃で1時間加熱処理した。加熱処理後、一緒に入れておいた繊維の切れ端の酸素分析を実施したところ0.4質量%であり、C原子数/Si原子数は1.01であった。
2 SiC繊維結合型セラミックス部分
3 Ta容器
4 SiC繊維結合型セラミックスを構成するSiC繊維
5 SiC繊維結合型セラミックスを構成するSiC繊維の境界に生成した炭素層
6 ガラス
Claims (6)
- ポリシラン又はその加熱反応物に、2A族、3A族及び3B族の金属元素のうち少なくとも1種以上の金属元素を含有する化合物を添加し、不活性ガス中で加熱反応して得られた金属元素含有有機ケイ素重合体を溶融紡糸・不融化・焼成して製造された炭化珪素系無機繊維を所定形状にした予備成形物を、カプセルに真空封入して熱間等方加圧処理する、SiCからなる無機繊維と炭素を主成分とする境界層とからなるSiC繊維結合型セラミックスの製造方法において、前記予備成形物中の炭素原子数の珪素原子数に対する比(C原子数/Si原子数)が、1.02~1.20であり、前記熱間等方加圧処理前に、前記予備成形物を不活性ガス雰囲気または還元性ガス雰囲気で1200℃から1800℃の温度範囲で加熱処理し、無機繊維中の酸素含有量を6.0質量%以下にした後、熱間等方加圧処理することを特徴とするSiC繊維結合型セラミックスの製造方法。
- 前記SiC繊維結合型セラミックスが筒状であり、前記予備成形物は、前記炭化珪素系無機繊維を製織した織物シートを耐熱性中子に巻きつけることにより形成することを特徴とする請求項1記載のSiC繊維結合型セラミックスの製造方法。
- 前記耐熱性中子が、セラミックス、カーボン、または繊維結合型セラミックスであることを特徴とする請求項2記載のSiC繊維結合型セラミックスの製造方法。
- 前記カプセルが、Ta製カプセルであり、該カプセルの肉厚が、前記筒状SiC繊維結合型セラミックスの肉厚の1/3~5倍であることを特徴とする請求項2記載のSiC繊維結合型セラミックスの製造方法。
- 前記カプセルが、1500℃以上の軟化点を有するガラス製カプセルであり、該カプセルの肉厚が、前記筒状SiC繊維結合型セラミックスの肉厚の1/3~5倍であることを特徴とする請求項2記載のSiC繊維結合型セラミックスの製造方法。
- 前記SiC繊維結合型セラミックスが筒状の一端を塞いだ形状物であり、前記耐熱性中子の一部を残して除去することを特徴とする請求項2記載のSiC繊維結合型セラミックスの製造方法。
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EP09816107A EP2361897B1 (en) | 2008-09-24 | 2009-09-17 | PROCESS FOR PRODUCING SiC FIBER BONDED CERAMIC |
US13/120,000 US8906288B2 (en) | 2008-09-24 | 2009-09-17 | Process for producing SiC fiber-bonded ceramics |
JP2010530825A JP5434922B2 (ja) | 2008-09-24 | 2009-09-17 | SiC繊維結合型セラミックスの製造方法 |
CA2738277A CA2738277A1 (en) | 2008-09-24 | 2009-09-17 | Process for producing sic fiber-bonded ceramics |
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Cited By (3)
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JP4801789B1 (ja) * | 2010-10-07 | 2011-10-26 | 株式会社超高温材料研究センター | 加熱炉の熱効率改善方法及び加熱炉の熱効率改善装置 |
JP2012206901A (ja) * | 2011-03-30 | 2012-10-25 | Ube Industries Ltd | チューブ状炭化ケイ素繊維結合型セラミックス部材の製造方法 |
US10683572B2 (en) | 2018-10-15 | 2020-06-16 | Goodrich Corporation | Silane recirculation for rapid carbon/silicon carbide or silicon carbide/silicon carbide ceramic matrix composites |
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WO2014150393A2 (en) | 2013-03-15 | 2014-09-25 | Lazur Andrew J | Method for producing high strength ceramic matrix composites |
JP6411448B2 (ja) * | 2013-03-15 | 2018-10-24 | ロールス−ロイス コーポレイション | セラミックスマトリックス複合材料及びセラミックスマトリックス複合材料を製造する製造方法 |
WO2019080106A1 (zh) * | 2017-10-27 | 2019-05-02 | 深圳市大富科技股份有限公司 | 碳化硅铝基复合结构件及碳化硅增强预制件的制备方法 |
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- 2009-09-17 JP JP2010530825A patent/JP5434922B2/ja not_active Expired - Fee Related
- 2009-09-17 US US13/120,000 patent/US8906288B2/en not_active Expired - Fee Related
- 2009-09-17 EP EP09816107A patent/EP2361897B1/en not_active Not-in-force
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JP4801789B1 (ja) * | 2010-10-07 | 2011-10-26 | 株式会社超高温材料研究センター | 加熱炉の熱効率改善方法及び加熱炉の熱効率改善装置 |
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US10683572B2 (en) | 2018-10-15 | 2020-06-16 | Goodrich Corporation | Silane recirculation for rapid carbon/silicon carbide or silicon carbide/silicon carbide ceramic matrix composites |
US11255015B2 (en) | 2018-10-15 | 2022-02-22 | Goodrich Corporation | Silane recirculation for rapid carbon/silicon carbide or silicon carbide/silicon carbide ceramic matrix composites |
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JPWO2010035692A1 (ja) | 2012-02-23 |
EP2361897B1 (en) | 2013-03-27 |
US20110187030A1 (en) | 2011-08-04 |
US8906288B2 (en) | 2014-12-09 |
CA2738277A1 (en) | 2010-04-01 |
EP2361897A4 (en) | 2012-05-23 |
EP2361897A1 (en) | 2011-08-31 |
JP5434922B2 (ja) | 2014-03-05 |
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