Method for manufacturing an elastic ceramic matrix composite

Abstract

Disclosed are: damage-resistant ECMCs that need to work and remain elastic between minus 120° C. and positive 300° C.; ECMCs that need to be able to contain a flame of 1900° C. for more than 90 minutes; and composite structures, especially highly stressed structures. One of the characteristic problems of ceramic matrices is their fragility. Indeed, when a fracture starts, it propagates easily in the matrix. Disclosed are elastic ceramic matrix composites (ECMCs), for which: the ceramic matrix is split into solid “ceramic microdomains” (CMDs); the CMDs are connected to one another by a dense network of “elastic microelements” (EMEs); and the bonds between the EMEs and the CMDs are strong chemical bonds, preferably covalent.

1 . A production method of a ceramic composite with an elastic matrix, the method comprises the following steps:
 Step 1: an admixture comprising at least one of the following elements is dispersed in water an alkali an acid, to obtain “an adjuvant in aqueous solution”,   Step 2: then, in the said adjuvant in aqueous solution, an additive is reacted to obtain a “mineral hardener”   Step 3: Finally we prepare a “mineral resin powder”   Step 4: said mineral hardener is poured and intimately mixed into said mineral resin powder to form a “ceramic mixture” the said process is characterized by the fact that the following steps that can be performed, either following or before some of the preceding steps, are added:   Step 5: the preparation of a “fluid silicone homopolymer with active terminations” is carried out,   Step 6: during this step, the dispersion of a homopolymer of fluid silicone with active terminations, is realized, either after step 3 or after step 4 to obtain said “elastic ceramic mixture”   
     
     
         2 . The method according to  claim 1 , further comprising: Step 7, consisting in impregnating said “elastic ceramic mixture” obtained at the end of step 6, with means of “fibrous reinforcements”, we then obtain a “ceramic composite with elastic matrix” 
     
     
         3 . The method according to  claim 2 , further comprising an additional step 8, of dispersing, in the mixture, a micro reinforcement network consisting of “dendritic nanofractals”. 
     
     
         4 . The method according to  claim 3 , wherein: “dendritic nanofractals” have so-called nanopatatoid forms ( 16 ) of 10 to 50 nanometers in diameter aggregated together by covalent bonds to thereby form dendrites ( 13 ,  15 ), circumscribed in a patatoid volume of 50 to 1000 nanometers in diameter, (the values of the surface of said dendritic nanofractals being included in a range of values whose lower limit is approximately 10 square meters per gram and whose limit higher, is about 750 square meters per gram (measured according to the BET) 
     
     
         5 . The method according to  claim 3 , wherein the dendritic nanofractals are formed based on a combination of at least one of the following products:
 Metal oxides, not functionalized   Metal oxides, functionalized   Metalloid oxide, functionalized   Metalloid oxide, unfunctionalized   Nonmetals, not functionalized.   
     
     
         6 . The method according to  claim 1  wherein: —said alkali is constituted by a combination and at least one of the following bases: KOH=potassium hydroxide, NaOH=sodium hydroxide, CsOH=cesium hydroxide, LiOH=lithium hydroxide and the said acid being constituted by minus one of the following acids: HCl=hydrochloric acid, H2SO4=sulfuric acid, HF=hydrofluoric acid, H 3 PO 4 =phosphoric acid, to obtain an “adjuvant in aqueous solution”
 said additive is constituted by at least one of the following elements: an oxide (silicon, aluminum, magnesium, zirconium, calcium), a metal (aluminum, magnesium, zirconium, of calcium) a metalloid (of silicon), to obtain a “mineral hardener” 
 said mineral resin powder consists of at least one of the following elements:
 a mineral polymer [consisting of a poly(sialate), (Si/Ai ratio=1)], a mineral polymer [consisting of a poly (sialate-siloxo), (Si/Ai ratio=2)], a polymer mineral [consisting of an aluminosilicate, poly(sialate-disiloxo), (Si/Ai ratio=3) namely (—Si—O—Al—O—) n  such as metakaolin (Si 2 O 5 ,Al 2 O 2 ) n ; A mineral polymer [consisting of an aluminosilicate, poly(sialate-disiloxo), namely (—Si—O—Al—O—) n  such as metakaolin Si 2 O 5 ,Al 2 O 2 ) n  supplemented with aluminum phosphate (AlPO 4 ); a complex mineral polymer [consisting of a poly(sialate-disiloxo) aluminosilicate, (Si/Ai ratio=3) namely (—Si—O—Al—O—) n  such as metakaolin (Si 2 O 5 ,Al 2 O 2 ) n  and of a micronized alumina namely (Al 2 O 3 )]; A complex mineral polymer [consisting of a poly(sialate-disiloxo) aluminosilicate, (Si/Ai ratio=3) namely (—Si—O—Al—O—) n  such as metakaolin (Si 2 O 5 ,Al 2 O 2 ) n  and d a micronized zirconium oxide, namely. (ZrO 2 )]; a complex mineral polymer [consisting of a poly(sialate-disiloxo) aluminosilicate, (Si/Ai ratio=3) namely (—Si—O—Al—O—) n  such as metakaolin (Si 2 O 5 ,Al 2 O 2 ) n  of micronized magnesium oxide namely (MgO)]; a complex mineral polymer [consisting of a poly(sialate-disiloxo) aluminosilicate, (Si/Al ratio=3) namely (—Si—O—Al—O—) n  such as metakaolin (Si 2 O 5 ,Al 2 O 2 ) n  of a micronized calcium oxide namely (CaO)] 
 
 said active-terminated liquid silicone homopolymer of step 6 consists of at least one of the following terminations: OH-terminus, H-terminus, H-terminal hybrid on one side and OH on the other, termination alcohol (methanol), alcohol (ethanol) terminus, to obtain said “flexible ceramic mixture”. 
 
     
     
         7 . The method according to  claim 3 , wherein the “fibrous reinforcements” are chosen from at least one of the following functionalized fibers: *Bore fibers. *Silica functionalized. *Quartz functionalized. *Basalt preferentially functionalized. *Functionalized glass. *Carbon not functionalized. *Silicon carbide not functionalized. *Functionalized ceramics (eg alumina, alumina mullite). *Non-functionalized zirconium. *Stainless steel functionalized. * Inconel not functionalized. *Functionalized polysilazane. *Aramid, non-functionalized. *Polyethylene HD (Example DYNEEMA). 
     
     
         8 . The method according to  claim 1 , further comprising an additional step 8, of dispersing, in the mixture, a micro reinforcement network consisting of “dendritic nanofractals”. 
     
     
         9 . The method of  claim 5 , wherein the dendritic nanofractals are formed based on a combination comprising a functionalized metal oxide selected from a group consisting of titanium oxide and zirconium oxide. 
     
     
         10 . The method of  claim 5 , wherein the dendritic nanofractals are formed based on a combination comprising a functionalized metal oxide in the form of alumina. 
     
     
         11 . The method of  claim 5 , wherein the dendritic nanofractals are formed based on a combination comprising a functionalized metalloid oxide selected from a group consisting of silicon oxide, boron oxide, and boric anhydride. 
     
     
         12 . The method of  claim 5 , wherein the dendritic nanofractals are formed based on a combination comprising a unfunctionalized metalloid oxide in the form of silicon carbide. 
     
     
         13 . The method according to  claim 3 , wherein the dendritic nanofractals are formed based on a combination of at least one of the following products:
 Metal oxides, not functionalized   Metal oxides, functionalized   Metalloid oxide, functionalized   Metalloid oxide, unfunctionalized   Nonmetals, not functionalized.   
     
     
         14 . The method according to  claim 3 , wherein the dendritic nanofractals are formed based on a combination of at least one of the following products:
 a metal oxides, selected from the group consisting of TiO 2  titanium oxide and ZrO 2  zirconium oxide, not functionalized;   alumina Al2O3, functionalized;   a metalloid oxide, selected from the group consisting of silicon oxide, boron oxide, and boric anhydride, functionalized;   SiC silicon carbide, unfunctionalized; and   a nonmetal, selected from the group consisting of phosphorus oxide, phosphoric anhydride (P 2 O 5 ), and carbon black, not functionalized.   
     
     
         15 . The method according to  claim 4 , wherein the dendritic nanofractals are formed based on a combination of at least one of the following products:
 a metal oxides, selected from the group consisting of TiO 2  titanium oxide and ZrO 2  zirconium oxide, not functionalized;   alumina Al2O3, functionalized;   a metalloid oxide, selected from the group consisting of silicon oxide, boron oxide, and boric anhydride, functionalized;   SiC silicon carbide, unfunctionalized; and   a nonmetal, selected from the group consisting of phosphorus oxide, phosphoric anhydride (P 2 O 5 ), and carbon black, not functionalized.