# US 2018/0025919 A1 · Method for producing silicon carbide composite material

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- Number: US 2018/0025919 A1
- Document ID: US20180025919A1
- Status: Published application
- Kind: A1
- Application number: 15/535,627
- Filed: 2015-12-10
- Published: 2018-01-25
- Earliest claimed: 2014-12-18
- Assignees: Denka Company Limited
- Applicants: Denka Company Limited
- Inventors: Takeshi MIYAKAWA; Daisuke GOTO
- Web page: https://patentgrep.com/patent/US20180025919A1

## CPC

- H10W 99/00: Subject matter not provided for in other groups of this subclass
- B22D 19/16: for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills (casting compound ingots B22D7/02)
- B22D 21/007: {with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C}
- B28B 1/14: by simple casting, the material being neither forcibly fed nor positively compacted (for molten material B28B1/54)
- B28B 11/243: {Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence)}
- C04B 35/565: based on silicon carbide
- C04B 35/6263: {characterised by their solids loadings, i.e. the percentage of solids}
- C04B 35/63432: {Polystyrenes}
- C04B 35/63488: {Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]}
- C04B 38/06: by burning-out added substances {by burning natural expanding materials or by sublimating or melting out added substances}
- C04B 41/009: {characterised by the material treated}
- C04B 41/5155: {Aluminium}
- C04B 41/88: Metals
- C22C 1/1015: {by preparing or treating a non-metallic additive preform}
- C22C 29/065: {based on SiC}
- H10W 40/259: {Ceramics or glasses (H10W40/254, H10W40/257, H10W40/255, H10W40/251, H10W40/253 take precedence)}
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- C04B 2111/00844: {for electronic applications}
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/3826: Silicon carbides
- C04B 2235/402: Aluminium
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/5472: Bimodal, multi-modal or multi-fraction
- C04B 2235/602: Making the green bodies or pre-forms by moulding
- C04B 2235/6027: Slip casting
- C04B 2235/606: Drying
- C04B 2235/61: Mechanical properties, e.g. fracture toughness, hardness, Young's modulus or strength
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- C04B 2235/9607: Thermal properties, e.g. thermal expansion coefficient
- H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER

## Abstract

A silicon carbide composite that is lightweight and has high thermal conductivity as well as a low thermal expansion coefficient close to that of a ceramic substrate, particularly a silicon carbide composite material suitable for heat dissipating components that are required to be particularly free of warping, such as heat sinks. A method for manufacturing a silicon carbide composite obtained by impregnating a porous silicon carbide molded body with a metal having aluminum as a main component, wherein the method for manufacturing a silicon carbide composite material is characterized in that the porous silicon carbide molded article is formed by a wet molding method, and preferably the wet molding method is a wet press method or is a wet casting method.

## Claims

### Claim 1

A method for manufacturing a silicon carbide composite formed by impregnating a metal having aluminum as a main component in a porous silicon carbide molded body, wherein the porous silicon carbide molded body is formed by obtaining a slurry from a silica sol; a silica sol gelling agent which is a polyalkylene glycol including a styrene-maleic anhydride copolymer or a derivative thereof; and a silicon carbide powder having a particle size of 10-200 μm, drying a wet preform obtained from the slurry via a wet press method or a wet casting method at a drying temperature of no less than 80° C. to less than 100° C., followed by further firing the dried wet preform at 800° C. to 1100° C., and impregnating the porous silicon carbide molded body with a metal having aluminum as a main component.