Ceramic composite materials with high mechanical and heat resistance and their preparation

Claim 2

In ceramized composite materials comprising a reinforcing substrate formed of weavable ceramic fibres, with high thermomechanical properties, which have not undergone mechanical or chemical alteration, into which there has been introduced, by injection by the liquid route, a ceramic material precursor for the purpose of developing a matrix occupying at least the major part of the free space of the substrate, said matrix being formed from a ceramic oxide selected from the group consisting of silica (SiO 2 ), chromic oxide (Cr 2 O 3 ) and magnesium oxide (MgO), and the cohesion of the oxide particles being such that it permits, under stress, a microfissurization which progresses to the level of the fibres, the improvement consisting in that they comprise at least one second matrix, or supermatrix constituted by an organic polymer, capable of reinforcing the cohesion of the matricial material, and the fibre-matrix bonds in the field of thermostability of the material used for the development of the supermatrix.

Claim 3

Materials according to claim 1, wherein the ceramic fibres of the substrate have a multidirectional architecture, with different directional reinforcing ratios.

Claim 4

Materials according to claim 1, wherein the ceramic fibres are selected from the group consisting of quartz silica, silica, silicon carbide and alumina fibres.

Claim 5

Materials according to claim 2, wherein the ceramic fibres are selected from the group consisting of quartz silica, silica, silicon carbide and alumina fibres.

Claim 6

Materials according to any one of claims 1 to 4, wherein the organic polymer is a phenolic polymer or a polystyrenepyridine.

Claim 7

Method of producing ceramized composite materials by injection into a reinforcing substrate formed of ceramic fibres of a precursor, in the liquid state, of ceramic material, in order to develop a ceramic matrix, which comprises: (a) conducting the injection step under vacuum with a substrate formed from weavable ceramic fibres, with considerable thermomechanical properties, and a matrix precursor, in liquid form, constituted by a compound capable, by pyrolysis, of resulting in an oxide selected from the group consisting of SiO 2 , Cr 2 O 3 , or MgO; (b) subjecting the whole to conditions of pressure and temperature enabling homogeneous filling, at least of the major part of the free space of the substrate, by the precursor, and the conversion in situ of the precursor into one of the above-defined ceramic oxides, this conversion being carried out so as to lead to a ceramic material with weak mechanical properties, of which the cohesion of the particles must permit, under stress, microfissurization to the level of the fibres, and ensure the mechanical integrity of the fibres; these steps (a) and (b) being as necessary repeated until the production of a composite possessing the desired density, said method comprising the additional step according to which a material, in the liquid state, constituted by an organic resin, is injected, under vacuum, into the ceramized composite as obtained after step (b), then conditions of temperature and pressure enabling polymerization of the resin are established.

Claim 8

Method of producing ceramized composite materials by injection into a reinforcing substrate formed of ceramic fibres of a precursor, in the liquid state, of ceramic material, in order to develop a ceramic matrix, which comprises: (a) conducting the injection step under vacuum with a substrate formed from weavable ceramic fibres, with considerable thermomechanical properties, and a matrix precursor, in liquid form, constituted by a compound capable, by pyrolysis, of resulting in an oxide selected from the group consisting of SiO 2 , Cr 2 O 3 , or MgO; (b) subjecting the whole to conditions of pressure and temperature enabling homogeneous filling, at least of the major part of the free space of the substrate, by the precursor, and the conversion in situ of the precursor into one of the above-defined ceramic oxides, this conversion being carried out so as to lead to a ceramic material with weak mechanical properties, of which the cohesion of the particles must permit, under stress, microfissurization to the level of the fibres, and ensure the mechanical integrity of the fibres; these steps (a) and (b) being as necessary repeated until the production of a composite possessing the desired density, said method comprising the additional step according to which a material, in the liquid state, constituted by an organic resin, is injected, under vacuum, into the ceramized composite as obtained after step (b), then conditions of temperature and pressure enabling polymerization of the resin are established.

Claim 9

Method according to claim 6, wherein there is applied in step (a), at ambiant temperature, colloidal silica in aqueous suspension, chromic anhydride in aqueous solution or under fusion, or hydrated magnesium nitrate under fusion, the viscosity of the precursor not exceeding about 100 poises.

Claim 10

Method according to claim 6, wherein the pyrolytic conversion is carried out at temperatures not exceeding 550° C., operating at atmospheric pressure.