Process for producing a filament-containing composite in a ceramic matrix

Claim 1

A process for producing a composite containing a layer of filaments embedded in a ceramic matrix which comprises the following steps: (a) providing matrix-forming ceramic material; (b) admixing said matrix-forming material with an organic binding material; (c) forming the resulting mixture into a tape; (d) providing a filament having a diameter of at least about 50 microns and a length at least about 10 times its diameter; (e) forming a plurality of said filaments into a layer wherein said filaments are spaced from each other and at least substantially parallel to each other; (f) disposing said layer of filaments intermediate the faces of two of said tapes forming a layered structure; (g) laminating the layered structure to form a laminated structure; (h) heating said laminate structure to remove said organic binding material leaving no significant deleterious residue; and (i) hot pressing the resulting porous structure at a sufficient temperature under a sufficient pressure for a sufficient period of time to consolidate said structure to produce said composite having a porosity of less than about 5% by volume, said composite containing no significant reaction product of said filaments and said matrix, said matrix having a thermal expansion coefficient which ranges from lower than that of said filaments to less than about 15% higher than that of said filaments, at least about 10% by volume of said composite being comprised of spaced filaments.