Composite Ceramics follow for material tailoring or management of its structural integrity.

Artificial combinations of elements with varying structures and compositions, composite materials are solid components bound by a binder. Although these materials can be utilized as fillers in composite materials, poor bonding between constituents and weak surfaces presents difficulties for the creation of them. Applications like missiles, reentry space vehicles, airplane brakes, furnace components, power plant components, and high-temperature industrial process components need for high-temperature materials including ceramics

Another class of high-temperature materials displaying sp2 hybridization in every carbon atom is elemental carbon found in the graphite family. Graphite is crystalline; its crystal structure consists of layers stacked in the AB sequence. Heating noncrystalline carbon at a sufficiently high temperature—known as the heat-treatment temperature—allows one to produce graphite. Higher degrees of crystallinity follow from this process—graphitization—which is known as Among the elemental carbon in the graphite family are carbon fibers, carbon nanotubes, graphene, graphite flakes, graphite nanoplatelets, intercalated graphite, exfoliated graphite, carbon black, and activated carbon.

Though it converts to elemental carbon in the graphite family at high temperatures, diamond is a high-temperature material. Applications needing heat dissipation, lightning protection, electromagnetic interference shielding, or electrical conduction find this oxidation unacceptable and causes mass loss. Although high-temperature use and the difference in thermal expansion coefficient between the coating material and the carbon material tend to cause separation, ceramic materials such as silicon carbide can improve oxidation resistance

Composite Ceramics commonly used are foaming ceramic materials and elemental carbon materials; fiber reinforcement is applied to lower brittleness and improve stiffness and strength. While fibers in carbon-matrix composites are carbon fibers, in ceramic-matrix composites the fibers are usually ceramic fibers. Another technique of manufacture is sintering, in which case sufficient thermal energy is generated by heating without melting to enable atom movement in the solid state.

Using a precursor material—which either undergoes heat transformation, chemical reactivity, or thermochemical breakdown—forms the intended ceramic or carbon material another way. A high yield is desired; the yield of the precursor is referred to as the ceramic or elemental carbon yield. Usually in liquid form, precursors are heated in the necessary lack of oxygen to prevent oxidation.

Ceramic-matrix and carbon-matrix composites can be fabricated differently depending on inert atmospheres like nitrogen gas, argon gas, and vacuum. Usually employed to create the matrix of these composites, the precursor technique is heated subsequently. On porosity, nevertheless, this approach has a drawback that could compromise the mechanical qualities of the material. Densification is the process by which porosity is lowered by impregnating pores with a precursor and pyrolyzing the just impregnated precursor. The expensive nature of these composites stems from the time-consuming and costly nature of this process.

Although their chemical/thermal process linked with the conversion of a ceramic precursor to a ceramic makes them more difficult to construct, Composites ceramics matrix are better in enduring high temperatures. Superior thermal stability of ceramic-carbon hybrids over carbon has been exploited. Mixing a ceramic precursor and a carbon precursor in a liquid form generates a multi-phase material that forms these hybrids. Nevertheless, the spatial distribution of phases in the multi-phase material is under no control, so the choice of ceramics phase in the material is constrained.

Although it also presents challenges in creating particular ceramic alloys and managing the hybrid configuration, a related approach is the pyrolysis of a suitable copolymer. A ceramic-carbon hybrid might also be a composite ceramics smatrix  with carbon fibers as reinforcement buried in the composite or a carbon-carbon composite with silicon carbide particles scattered throughout the matrix.

The invention relates to a hybrid material displaying strength, stiffness, and high temperature resistance. Component A and component B make up the hybrid material; each is chosen from a group comprising inorganic compounds, oxides, carbides, nitrides, borides, and combinations thereof. The carbon component is the carbon-carbon composite; component A is the matrix, or binder. Component B is the matrix with many units, each quite clearly displaying a shape. In a composite material including the hybrid and a specified matrix material binding the components together, Component A serves as reinforcement.

The ceramic-carbon hybrid is confined to the arrangement whereby a certain matrix material binds the two types of fibers together, therefore preventing direct contact between the fibers. Air gaps between the neighboring fibers cause the hybrid to show insufficient mechanical characteristics without the matrix material. Another type of ceramic-carbon hybrid is a calcium silicate hydrate with embedded carbon, made by introducing the carbon to the hydration before the hydrate sets, then the setting and curing of the hydrate.

Important for brake uses are wear and friction characteristics; so, during composite construction, ceramic powder such silica and silicon carbide can be added to the composite. Nevertheless, this approach does not help the densification process or offer enough favorable effects on the mechanical qualities. Although their filamentous form is not ideal for offering a great interfacial area, carbon nanotubes can be inserted to increase impact resistance.

In polymer-matrix composites, organoclay is utilized to provide increasing stiffness, strength, toughness, heat resistance, flame-retardant ability, and color stability. It also finds utility in aqueous dispersions to improve thermal shock resistance and in insulating polymer-matrix composites. By use of a hybrid material displaying strength, stiffness, and resistance to high temperatures, the invention seeks to overcome these and other shortcomings in the art.

This invention uses an organo-modified mineral composition with components I and II, each with a form that is virtually perpendicular to the direction of the long dimension to create a hybrid material. Relative to component I of the organo-modified mineral, component B and A respectively arise from each other. One can shape the hybrid material into sheets, fibers, tubes, or other forms. Among inorganic compounds include minerals, silicate minerals, organic compounds, organometallic compounds, organosilicon compounds, organosilicon compounds, organoboron compounds, organobismuth compounds, metallocene and combinations thereof.

Among the several groups—graphite, graphite nanoplatelet, turbostratic carbon, disordered carbon, glassy carbon, fullerene, graphene, chemically modified graphene, intercalated graphite, activated carbon, and others— elemental carbon is chosen. Furthermore offering a composite material with strength, rigidity, and resistance to high temperatures is the hybrid material. Comprising inorganic compounds, oxides, carbides, nitrides, borides, and combinations thereof, the composite material consists of a hybrid material plus another solid element.

The capacity of the hybrid material to withstand high temperatures and to prevent corrosion and wear define it. Designed to be highly temperature resistant, the composite material is also resistant to high temperatures. Electronics, automotive, and aerospace sectors among others find use for the hybrid material.

This invention offers a microstructured high-temperature hybrid material, its composite material, and a technique of composite material production. Comprising continuous carbon fibers, a carbon matrix, and a hybrid material, the hybrid material basically consists of a carbon-carbon composite material.

Comprising hybrid material, a carbon matrix, and continuous carbon fibers, the composite material is carbon-carbon composite material. Under essential absence of oxygen, the composite material is produced by heating a composition consisting of an organo-modified mineral and an extra solid ingredient under pressure. The organo-modified mineral consists basically of component I and component II; component I is chosen from the category comprising minerals, silicate minerals, and combinations thereof.

The illustrations show example flexural stress-strain curves of the C/C composites, thermogravimetric analysis (TGA) curves, and X-ray diffraction (XRD) patterns of the hybrid material generated by hot-pressing montmorillonite-based organoclay in the absence of any other ingredient. The Raman spectrum of the hybrid material generated by hot-pressing montmorillonite-based organoclay in the absence of any additional ingredient reveals disordered graphite peak at 1375 cm−1, ordered graphite peak at 1600 cm−1, and a wide peak at 2800 cm−1.