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US4696827A
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Silicon carbide-carbon composite molded product and process for manufacturing the same
Assignee: Research Institute for Special Inorganic Materials
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Filing: 1983-03-11
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Granted: 1987-09-29
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Expires: 2003-03-11
Abstract
Abstract PCT No. PCT/JP83/00076 Sec. 371 Date Nov. 9, 1983 Sec. 102(e) Date Nov. 9, 1983 PCT Filed Mar. 11, 1983.A molded product consisting mainly of silicon carbide and a process for manufacturing the same. This invention is to provide a product having a desired or complicated shape and a process which enables the manufacture of any such product at a drastically lower temperature than any conventional process. This object is attained by applying an organic silicon polymer having a skeleton composed mainly of carbon-silicon bonds by impregnation or adherence to a base material having a desired shape, and by burning the base material at a temperature of 700 DEG C. to 2,000 DEG C. in a vacuum or in a nonoxidizing gas atmosphere. The product of this invention has a fibrous, granular and/or firmly carbon structure in the matrix consisting mainly of SiC. The product of this invention is useful for a wide variety of applications, for example, for making heat-resistant structural members of electronic devices.
Inventors
- 👤 Kiyohito Okamura
- 👤 Yoshio Hasegawa
- 👤 Yoshiyasu Kuroo
- 👤 Masana Ugaji
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 01:07
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/515; C04B35/56; C04B35/565; C04B35/571; C04B35/71; C04B35/78; C04B35/80
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
115 words
A process for manufacturing a silicon carbide-carbon composite molded product, comprising the first step of securing an organic silicon polymer having a skeleton consisting mainly of carbon-silicon bonds to an organic polymer base material having a desired shape and capable of forming a fibrous, granular or filmy carbon structure when it is burned in a non-oxidizing atmosphere, and the second step of burning said base material at a temperature ranging from 700° C. to 2,000° C. in a vacuum or in a non-oxidizing gas atmosphere to thereby thermally decompose said organic silicon polymer and create an inorganic matrix consisting mainly of SiC in which said fibrous, granular or filmy carbon structure exists in amorphous form.
Claim 2
Dependent Claim
115 words
A process for manufacturing a silicon carbide-carbon composite molded product, comprising the first step of securing an organic silicon polymer having a skeleton consisting mainly of carbon-silicon bonds to an organic polymer base material having a desired shape and capable of forming a fibrous, granular or filmy carbon structure when it is burned in a non-oxidizing atmosphere, and the second step of burning said base material at a temperature ranging from 700° C. to 2,000° C. in a vacuum or in a non-oxidizing gas atmosphere to thereby thermally decompose said organic silicon polymer and create an inorganic matrix consisting mainly of SiC in which said fibrous, granular or filmy carbon structure exists in amorphous form.
Claim 3
Dependent Claim
22 words
A process according to claim 1, wherein said base material is burned at a temperature ranging from 800° C. to 1,800° C.
Claim 4
Dependent Claim
22 words
A process according to claim 1, wherein said base material is burned at a temperature ranging from 1,000° C. to 1,500° C.
Claim 5
Dependent Claim
26 words
A process according to claim 1, wherein said first step is carried out by dipping said base material in a solution of said organic silicon polymer.
Claim 6
Dependent Claim
27 words
A process according to claim 1, wherein said first step is carried out by dipping said base material in a molten bath of said organic silicon polymer.
Claim 7
Dependent Claim
34 words
A process according to claim 1, further comprising between said first and second steps the step subjecting said base material at a low temperature to an oxidizing atmosphere, thereby insolubilizing said organic silicon polymer.
Claim 8
Dependent Claim
40 words
A process according to claim 1, further comprising between said first and second steps the step of radiating ultraviolet rays, gamma rays or an electron beam on said base material in a non-oxidizing atmosphere, thereby insolubilizing said organic silicon polymer.
Claim 9
Dependent Claim
17 words
A process according to claim 6 or 7, wherein said first step is repeated after said insolubilization.
Claim 10
Dependent Claim
24 words
A process according to claim 1, wherein said organic silicon polymer is a polysilmethylene, a polysilphenylene, a poly(silpolymethylene), carbosiloxane polymer or a mixture thereof.
Claim 11
Dependent Claim
21 words
A process according to claim 9, wherein said organic silicon polymer has a number-average molecular weight ranging from 100 to 1,000,000.
Claim 12
Dependent Claim
21 words
A process according to claim 10, wherein said organic silicon polymer has a number-average molecular weight ranging from 500 to 20,000.
Claim 13
Dependent Claim
100 words
A process according to claim 1, wherein said base material is composed of an organic high polymer selected from the group consisting of a cellulose polymer, a protein polymer, an isoprene polymer, a pitch polymer, a lignin poval polymer, a polyvinyl alcohol polymer, a polyvinyl chloride polymer, a polyvinylidene chloride polymer, a polyacrylonitrile polymer, a furfuryl alcohol polymer, a polyester polymer, a polyolefin polymer, a polystyrene polymer, a phenol polymer, a polyamide polymer, a polyimide polymer, a polyamideimide polymer, a polybenzimidazole polymer, a polyurethane polymer, a polyphenylene sulfide polymer, a polyphenylene oxide polymer, a polysulfone polymer and a polyfluoroethylene polymer.
Claim 14
Dependent Claim
51 words
A process according to claim 1, wherein said base material is composed fo a heat-resistant organic high polymer selected from the group consisting of a polyamide polymer, a polyimide polymer, a polyamideimide polymer, a phenol polymer, a polybenzimidazole polymer, a polyphenylene sulfide polymer, a polyphenylene oxide polymer or a polysulfone polymer.
Claim 15
Dependent Claim
167 words
A process for the manufacture of an integrated silicon carbide-carbon product which comprises: forming a moldable high polymer capable of being reduced to a carbonaceous skeleton when burned in a non-oxidizing atmosphere into a predetermined shape, applying to said polymer a polysiloxane polymer having at least one of the following repeating groups: ##STR10## where R is an alkyl group, an aryl group, hydrogen, or an alkoxy group, and n is an integer, said polysiloxane polymer being in liquid form and having an average molecular weight in the range from about 100 to 1,000,000, said polysiloxane polymer adhering to said high polymer, and burning the resulting shaped product at a temperature of from 700° C. to 2000° C. under non-oxidizing conditions to form a composite inorganic silicon carbide-carbon composite including a matrix containing β-SiC and substantially amorphous carbon, said composite containing 40 to 65% by weight Si, from 25 to 45% by weight C, from 0.1 to 30% by weight O, and 0.01 to 2% by weight H.
Claim 16
Dependent Claim
167 words
A process for the manufacture of an integrated silicon carbide-carbon product which comprises: forming a moldable high polymer capable of being reduced to a carbonaceous skeleton when burned in a non-oxidizing atmosphere into a predetermined shape, applying to said polymer a polysiloxane polymer having at least one of the following repeating groups: ##STR10## where R is an alkyl group, an aryl group, hydrogen, or an alkoxy group, and n is an integer, said polysiloxane polymer being in liquid form and having an average molecular weight in the range from about 100 to 1,000,000, said polysiloxane polymer adhering to said high polymer, and burning the resulting shaped product at a temperature of from 700° C. to 2000° C. under non-oxidizing conditions to form a composite inorganic silicon carbide-carbon composite including a matrix containing β-SiC and substantially amorphous carbon, said composite containing 40 to 65% by weight Si, from 25 to 45% by weight C, from 0.1 to 30% by weight O, and 0.01 to 2% by weight H.
Claim 17
Dependent Claim
28 words
The method of claim 14 wherein the shrinkage of said high polymer and said polysiloxane polymer are sufficiently close so as not to deform the shape during burning.
Claim 18
Dependent Claim
20 words
The method of claim 14 wherein said average molecular weight is in the range from about 500 to about 20,000.
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