Patent ID: 7112547
Filing Date: 2006-09-26
Classification: B32B,B82Y,C04B,Y10T

Abstract:
1. A component of an inorganic fiber-bonded ceramics (A) composed of (i) inorganic fibers comprising (a) and/or (b), (a) an amorphous substance comprising Si, M, C and O (M is Ti or Zr), (b) an assembly of (1) crystalline fine particles of β-SiC, MC and C and (2) amorphous substances of SiO (ii) an inorganic substance comprising (c) and/or (d) and optionally comprising (e) dispersed therein, which substance fills interstices between the above inorganic fibers, (c) an amorphous substance comprising Si and O and optionally comprising M, (d) a crystalline substance comprising crystalline SiO (e) a crystalline fine particle inorganic substance comprising MC having a particle diameter of 100 nm or less, and (iii) boundary layers with thickness of 1 to 100 nm comprising carbon as a main component and optionally comprising crystalline particles of MC having a particle diameter of 100 nm or less dispersed therein, the boundary layers being formed on the surfaces of the inorganic fibers, wherein the component of the inorganic fiber-bonded ceramics (A) is obtained by preparing a laminate material (B) of inorganic fibers comprising an internal layer and a surface layer each, as a raw material, the internal layer being composed of an inorganic substance containing (a) and/or (b), (a) an amorphous substance comprising Si, M, C and O (M is Ti or Zr), (b) an assembly of (1) crystalline ultrafine particles of β-SiC, MC and C and (2) amorphous substances of SiO the surface layer being composed of an inorganic substance containing (c) and/or (d), (c) an amorphous substance comprising Si and O and optionally comprising M, (d) a crystalline substance comprising crystalline SiO the surface layer having a thickness T (unit: μm) satisfying T=aD (in which a is a number in the range of from 0.023 to 0.053 and D is a diameter (unit: μm) of the inorganic fiber), and disposing the laminate material (B) around a carbon core having a predetermined shape to produce a preliminary shaped material, or disposing the laminate material (B) on a surface of a component which is obtained by processing a bulk material of the inorganic fiber-bonded ceramics to a size smaller than a predetermined component size, to produce a preliminary shaped material, setting the preliminary shaped material in a carbon die, covering the preliminary shaped material with a carbon powder, and then, loading a pseudo-isotropic pressure on the preliminary shaped material by hot-pressing in an inert gas atmosphere at a temperature in the range of from 1,500 to 2,000° C. under a pressure of 10 to 100 MPa, and wherein the component has a curved surface and/or an inclined surface and the fibers are aligned in a surface shape of the curved surface and/or the inclined surface.