EP0230959A2
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Fabrication of atomically alloyed synthetic materials
Assignee: Energy Conversion Devices Inc
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Filing: 1987-01-20
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Granted: —
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Expires: 2007-01-20
Abstract
Abstract A method of forming a synthetically engineered composite mateiral. The composite mateiral has sub-micron scale ceramic zones and interior zones of different composition then the ceramic zones. The synthetically engineered composite material is prepared by a process that includes forming a body comprising at least two different materials. The materials are a relatively reactive first material and a relatively nonreactive second material. The body is then contacted with a highly excited reactant, i.e., an oxidant. This causes the relatively reactive first material to react with the reactant to form the sub-micron scale ceramic zones. The process leaves zones enriched in relatively nonreactive material content. In one exemplification the product is a synthetically engineered cermet type material.
Inventors
- 👤 Stanford R. Ovshinsky
- 👤 Stephen J. Hudgens
- 👤 Russel C. Custer
- 👤 Robert Burkhardt
- 👤 Richard C. Bergeron
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-09 03:49
CPC Classifications
B; B22; B22F; B22F9/00; B22F9/02; B22F9/06; B22F9/08; B22F9/082; B22D; B22D11/00; B22D11/008; B22D11/06; B22F1/00; B22F1/06; B22F1/062; C; C03; C03B; C03B37/00; C03B37/01; C03B37/02; C03B37/022; C03B37/023; C03C; C03C13/00; C03C13/04; C04; C04B; C04B35/00; C04B35/622; C04B35/64; C04B35/65; C22; C22C; C22C47/00; C22C47/08; C23; C23C; C23C26/00; C23C26/02; B22F2998/00
Claims Analysis
Total Claims: 139
Claim 1
Independent Claim
105 words
A method of fabricating a synthetically engineered solid material, comprising the steps of providing the first component and providing the second component in a diffusable form CHARACTERIZED IN THAT said method comprises the steps of: providing the first component (2) of the synethetically engineered solid material; subjecting the first component (2) to an energized, diffusable second component of the material; and diffusing said second component through at least a portion of the first component, whereby the second component interacts with the first component so as to form the synthetically engineered solid material exhibiting a range of properties different from the properties of either individual component.
Claim 2
Independent Claim
105 words
A method of fabricating a synthetically engineered solid material, comprising the steps of providing the first component and providing the second component in a diffusable form CHARACTERIZED IN THAT said method comprises the steps of: providing the first component (2) of the synethetically engineered solid material; subjecting the first component (2) to an energized, diffusable second component of the material; and diffusing said second component through at least a portion of the first component, whereby the second component interacts with the first component so as to form the synthetically engineered solid material exhibiting a range of properties different from the properties of either individual component.
Claim 3
Dependent Claim
39 words
A method as in Claim 1, wherein the first component is a fluidic stream (7) and the step of providing a fluidic stream (7) of a first component (2) comprises the step of providing a liquid fluidic stream (7).
Claim 4
Dependent Claim
28 words
A method as in claim 2, wherein the step of providing a liquid fluidic stream (7) comprises the step of providing a stream of an atomized metallic material.
Claim 5
Dependent Claim
28 words
A method as in Claim 2, wherein the step of providing a liquid fluidic stream (7) comprises the step of providing a stream of an atomized semiconductor material.
Claim 6
Dependent Claim
28 words
A method as in Claim 2, wherein the step of providing a liquid fluidic stream (7) comprises the step of providing a stream of an atomized ceramic material.
Claim 7
Dependent Claim
45 words
A method as in Claim 2, wherein the step of providing a fluidic stream (7) of the first component (2) comprises providing a stream of a material chosen from the group consisting essentially of metallic materials, semiconductor materials, semi-metallic materials, ceramic materials, and combinations thereof.
Claim 8
Dependent Claim
50 words
A method as in Claim 2, wherein the step of subjecting the fluidic stream (7) of the first component (2) to an energized, diffusable second component (11) comprises the step of directing a stream (11) of an energized gaseous material to impinge upon the fluidic stream of the first component.
Claim 9
Dependent Claim
49 words
A method as in Claim 7, wherein the step of directing an energized stream (11) of a gaseous material includes the further step of selecting the energized gaseous material from the group consisting essentially of nitrogen, oxygen, halogens, hydrocarbon gases, inert gases, hydrogen, vaporized alkali metals, and combinations thereof.
Claim 10
Dependent Claim
47 words
A method as in Claim 8, wherein the step of subjecting the fluidic stream (7) of the first component (2) to an energized, diffusable second component, comprises the step of directing the fluidic stream (7) of the first component (2) through a plasma containing said second component.
Claim 11
Dependent Claim
19 words
A method as in Claim 8, including the further step of ionizing the second component of the synthetic material.
Claim 12
Dependent Claim
19 words
A method as in Claim 8, including the further step of radicallizing the second component of the synthetic material.
Claim 13
Dependent Claim
20 words
A method as in Claim 8, including the further step of thermally activating the second component of the synthetic material.
Claim 14
Dependent Claim
19 words
A method as in Claim 8, including the further step of energizing the second component by a photoactivation process.
Claim 15
Dependent Claim
20 words
A method as in Claim 8, including the further step of energizing the second component by a catalytic activation process.
Claim 16
Dependent Claim
20 words
A method as in Claim 1, including the further step of providing the second component in a high pressure environment.
Claim 17
Dependent Claim
51 words
A method as in Claim 7, including the further step of directing said energized gaseous stream (11) to impinge upon the fluidic stream (7) of said first component substantially in the direction of movement of the first component so that momentum is transferred to said fluidic stream of said first component.
Claim 18
Dependent Claim
37 words
A method as in Claim 7, including the further step of maintaining contact between the fluidic stream (7) and the energized gaseous stream (11) for a sufficient length of time to attain the desired degree of diffusion.
Claim 19
Dependent Claim
50 words
A method as in Claim 2, wherein the step of providing a fluidic stream (7) of a first component (2) of material includes the steps of: melting said first component (2) in a crucible (3); and, ejecting said first component (2) from said crucible (3) in a fluidic stream (7).
Claim 20
Dependent Claim
35 words
A method as in Claim 2, wherein the step of providing a fluidic stream (7) of a first component (2) comprises the step of ejecting said first component (2) through a nozzle (5) under pressure.
Claim 21
Dependent Claim
35 words
A method as in Claim 2, wherein the step of providing a fluidic stream (7) of a first component (2) comprises the step of allowing said first component (2) to overflow from said crucible (3).
Claim 22
Dependent Claim
36 words
A method as in Claim 18, wherein the step of providing a fluidic stream (7) of said first component (2) comprises the step of ejecting said first component (2) from a aperture (5) in said crucible.
Claim 23
Dependent Claim
19 words
A method as in Claim 21, including the further step of providing said aperture (5) with a regular shape.
Claim 24
Dependent Claim
19 words
A method as in Claim 21, including the further step of providing said aperture (5) with an irregular shape.
Claim 25
Dependent Claim
51 words
A method as in Claim 2, further including the step of subjecting said fluidic stream (7) of said first component (2) to at least one burst of energy for enhancing diffusion of said second component through at least a portion of the bulk of the host matrix of the first component.
Claim 26
Dependent Claim
36 words
A method as in Claim 24, including the further step of utilizing electromagnetic energy so as to establish eddy currents within said fluidic stream (7) of the first component (2) so as to enhance said diffusion.
Claim 27
Dependent Claim
20 words
A method as in Claim 24, including the further step of utilizing thermal energy so as to enhance said diffusion.
Claim 28
Dependent Claim
30 words
A method as in Claim 2, including the further step of subjecting the fluidic stream (7) of the first component (2) to an energized, diffusable third component of the material.
Claim 29
Dependent Claim
38 words
A method as in Claim 27, whereint he step of subjecting the fluidic stream (7) of the first component to the third component includes the further step of providing said third component as an energized, fluidic stream (11b).
Claim 30
Dependent Claim
31 words
A method as in Claim 27, including the further step of sequentially exposing the fluidic stream (7) of said first component (2) to said second and said third energized diffusable components.
Claim 31
Dependent Claim
30 words
A method as in Claim 27, including the further step of simultaneously subjecting the fluidic stream (7) of said first component to the second and the third energized, diffusable components.
Claim 32
Dependent Claim
38 words
A method as in Claim 2, further including the step of directing said fluidic stream (7) of said first component (2) and said second component (11) onto a quench surface (24) after the interaction therebetween has been completed.
Claim 33
Dependent Claim
32 words
A method as in Claim 31, wherein the step of directing said first and second components onto a quench surface (24) includes the further step of a moving said quench surface (24).
Claim 34
Dependent Claim
22 words
A method as in Claim 31, including the further step of providing for the control of temperature of said quench surface (24).
Claim 35
Dependent Claim
38 words
A method as in Claim 2, wherein the step of providing a fluidic stream (7) of a first component (2) comprises the step of directing said fluidic stream (7) so as to substantially surround a core member (7a).
Claim 36
Dependent Claim
17 words
A method as in Claim 9, including the further step of forming said plasma with AC energy.
Claim 37
Dependent Claim
17 words
A method as in Claim 9, including the further step of forming said plasma with microwave energy.
Claim 38
Dependent Claim
17 words
A method as in Claim 9, including the further step of forming said plasma with DC energy.
Claim 39
Independent Claim
154 words
A method of fabricating a relatively thick, synthetically engineered solid material, comprising the steps of depositing first and second components of the solid materia on a core member, CHARACTERIZED IN THAT said material comprises the steps of: providing the core member (71); directing the core member (71) through at least one deposition station, each of said at least one station adapted to perform the operations of: providing a fluidic stream (7b) of the first component (2b) of the material; subjecting the fluidic stream (7b) of the first component (2b) to an energized, diffusable second component (2a) of the material; and diffusing said second component through at least a portion of the fluidic stream (7b), whereby the second component (2a) interacts with the first component (2) so as to deposit a layer of a synthetically engineered solid material (7b), exhibiting a range of properties different from the properties of either individual component, upon the core.
Claim 40
Independent Claim
154 words
A method of fabricating a relatively thick, synthetically engineered solid material, comprising the steps of depositing first and second components of the solid materia on a core member, CHARACTERIZED IN THAT said material comprises the steps of: providing the core member (71); directing the core member (71) through at least one deposition station, each of said at least one station adapted to perform the operations of: providing a fluidic stream (7b) of the first component (2b) of the material; subjecting the fluidic stream (7b) of the first component (2b) to an energized, diffusable second component (2a) of the material; and diffusing said second component through at least a portion of the fluidic stream (7b), whereby the second component (2a) interacts with the first component (2) so as to deposit a layer of a synthetically engineered solid material (7b), exhibiting a range of properties different from the properties of either individual component, upon the core.
Claim 41
Dependent Claim
28 words
A method as in Claim 38, including the further step of providing a plurality of deposition stations and sequentially directing the core through said plurality of deposition stations.
Claim 42
Dependent Claim
51 words
A method as in Claim 39, wherein the step of providing a fluidic stream (7b) of a first component (2) comprises the step of providing a fluidic stream (7b) of the first component (2) formed fromed from a material of substantially similar composition in each of said plurality of deposition stations.
Claim 43
Dependent Claim
32 words
A method as in Claim 40, further including the step of forming the second component in each of said plurality of deposition stations of a material which is of substantially similar composition.
Claim 44
Dependent Claim
48 words
A method as in Claim 40, including the further step of forming the second component in at least one of said plurality of deposition stations of a material differing in composition from the material of the second component formed in the remainder of said plurality of deposition stations.
Claim 45
Dependent Claim
46 words
A method as in Claim 39, including the further step of forming said first component in at least one of said plurality of deposition stations of a material differing in composition from the material of said first component in the remainder said plurality of deposition stations.
Claim 46
Dependent Claim
30 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of a first component (2) comprises the step of providing a liquid fluidic stream (7).
Claim 47
Dependent Claim
32 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of a first component (2) comprises the step of providing a stream of an atomized metallic material.
Claim 48
Dependent Claim
27 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) comprises the step of providing a stream of an atomized semiconductor material.
Claim 49
Dependent Claim
27 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) comprises the step of providing a stream of an atomized ceramic material.
Claim 50
Dependent Claim
45 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of a first component (2) comprises providing a stream of a material chosen from the group consisting essentially of metallic materials, semiconductor materials, semi-metallic materials, ceramic materials, and combinations thereof.
Claim 51
Dependent Claim
52 words
A method as in Claim 38, wherein the step of subjecting the fluidic stream (7) of the first component (2) to an energized, diffusable second component (9) comprises the step of directing a stream (11) of energized gaseous material (9) to impinge upon the fluidic stream (7) of the first component (2).
Claim 52
Dependent Claim
51 words
A method as in Claim 49, wherein the step of directing an energized stream (11) of a gaseous material (9) includes the further step of selecting the energized gaseous material (9) from the group consisting essentially of nitrogen, oxygen, halogens, hydrocarbon gases, inert gases, hydrogen, vaporized alkaline metals, and combinations thereof.
Claim 53
Dependent Claim
48 words
A method as in Claim 50, wherein the step of subjecting the fluidic stream (7) of the first component (2) to an energized, diffusable second component (9), comprises the step of directing the fluidic stream (7) of the first component (2) through a plasma containing the second component.
Claim 54
Dependent Claim
19 words
A method as in Claim 51, including the further step of ionizing the second component of the synthetic material.
Claim 55
Dependent Claim
19 words
A method as in Claim 51, including the further step of radicallizing the second component of the synthetic material.
Claim 56
Dependent Claim
20 words
A method as in Claim 51, including the further step of thermally activating the second component of the synthetic material.
Claim 57
Dependent Claim
23 words
A method as in Claim 51, including the further step of energizing the second component of the synthetic material by a photoactivation process.
Claim 58
Dependent Claim
20 words
A method as in Claim 51, including the further step of energizing the second component by a catalytic activation process.
Claim 59
Dependent Claim
20 words
A method as in Claim 38, including the further step of providing the second component in a high pressure environment.
Claim 60
Dependent Claim
33 words
A method as in Claim 57, including the further step of adapting said core member (2) to function as a template for the accretion of subsequent layers of synthetically, engineered solid material thereupon.
Claim 61
Dependent Claim
40 words
A method as in Claim 49, including the further step of directing said energized gaseous stream to impinge upon the fluidic stream of said first component so that momentum is transferred to said fluidic stream (7) of said first component(2).
Claim 62
Dependent Claim
50 words
A method as in Claim 49, including the further step of maintaining contact between the first stream (7) and the second stream (9) for a sufficient length of time to obtain a desired degree of diffusion of the second component (11) into the host matrix of the first component (2).
Claim 63
Dependent Claim
56 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of a first component (2) in at least one of said deposition station includes the steps of: melting said first component (2) in a crucible (3); and ejecting said first component (2) from said crucible (3) in a fluidic stream (7).
Claim 64
Dependent Claim
43 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of a first component (2) in at least one of said deposition stations comprises the step of ejecting said first component (2) through a nozzle (5) under pressure.
Claim 65
Dependent Claim
42 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of a first component (2) in at least one of said deposition stations comprises the step of allowing said first component (2) to overflow from said crucible.
Claim 66
Dependent Claim
43 words
A method as in Claim 38, wherein the step of providing a fluidic stream (7) of said first component (2) in at least one of said deposition stations comprises the step of ejecting said first component from an aperature (5) in said crucible.
Claim 67
Dependent Claim
19 words
A method as in Claim 64, including the further step of providing said aperature (5) with a regular shape.
Claim 68
Dependent Claim
78 words
A method as in Claim 64, including the further step of providing said aperature (5) with an irregular shape, and interacting said second component (9) with said first component (2) so as to form a synthetically engineered solid material having a corresponding cross-sectional shape, said material adapted to function as a template for the accretion of subsequent layers of synthetically engineered material thereupon in succeeding deposition stations so as to produce a finished article of predetermined cross-sectional shape.
Claim 69
Dependent Claim
57 words
A method as in Claim 38, further including the step of subjecting said fluidic stream (7) of said first component (2) in at least one of said deposition stations to at least one burst of energy for enhancing diffusion of said second component (11) through at least a portion of the host matrix of the first component.
Claim 70
Dependent Claim
30 words
A method as in Claim 67, including the further step of utilizing electromagnetic energy so as to establish eddy currents within said fluidic stream (7) of the first component (2).
Claim 71
Dependent Claim
20 words
A method as in Claim 68, including the further step of utilizing thermal energy so as to promote said diffusion.
Claim 72
Dependent Claim
38 words
A method as in Claim 38, including the further step of subjecting the fluidic stream (7) of the first component (2) in at least one of said deposition stations to an energized, diffusable third component of the material.
Claim 73
Dependent Claim
38 words
A method as in Claim 70, wherein the step of subjecting the fluidic stream (7) of the first component (2) to the third component includes the further step of providing said third component as an energized, fluidic stream.
Claim 74
Dependent Claim
31 words
A method as in Claim 70, including the further step of sequentially exposing the fluidic stream (7) of said first component (2) to said second and said third energized diffusable components.
Claim 75
Dependent Claim
31 words
A method as in Claim 70, including the further step of simultaneously subjecting the fluidic stream (7) of said first component (2) to the second and the third energized, diffusable components.
Claim 76
Dependent Claim
42 words
A method as in Claim 38, further including the step of directing said fluidic stream (7) of said first component (7) after being modified by said second component (9) onto a quench surface (24) in at least one of said deposition stations.
Claim 77
Dependent Claim
34 words
A method as in Claim 74, wherein the step of directing said first (2) and second (9) components onto a quench surface (24) includes the further step of rapidly moving said quench surface (24).
Claim 78
Dependent Claim
23 words
A method as in Claim 74, including the further step of providing for the control of the temperature of said quench surface (24).
Claim 79
Dependent Claim
17 words
A method as in Claim 57, including the further step of forming said plasma with AC energy.
Claim 80
Dependent Claim
17 words
A method as in Claim 57, including the further step of forming said plasma with microwave energy.
Claim 81
Dependent Claim
17 words
A method as in Claim 51, including the further step of forming said plasma with DC energy.
Claim 82
Dependent Claim
34 words
A method as in Claim 38, including the further steps of: forming said relatively thick, synthetically engineered solid material as an elongated fiber (7); and collecting said fiber (7) upon a take-up spool (21).
Claim 83
Dependent Claim
46 words
A method as in Claim 80, including the further step of adapting said take-up spool (21) to provide a biasing force along the longitudinal direction of movement of said fiber (7), said force facilitating the passage of the fiber (7) through the plurality of deposition stations.
Claim 84
Independent Claim
98 words
A method of fabricating optically transmissive fibers, comprising reacting a stream of a first component with second component to form the fiber, CHARACTERIZED IN THAT said method include the steps of: providing a fluidic stream (7) of a first component (2), said first component selected from one or more group IV elements; subjecting the fluidic stream (7) to energized oxygen (9); and diffusing said energized oxygen (9) through at least a portion of the fluidic stream (7), whereby the energized oxygen (9) interacts with the first component so as to form a synthetically engineered optically transmissive fiber (7).
Claim 85
Independent Claim
98 words
A method of fabricating optically transmissive fibers, comprising reacting a stream of a first component with second component to form the fiber, CHARACTERIZED IN THAT said method include the steps of: providing a fluidic stream (7) of a first component (2), said first component selected from one or more group IV elements; subjecting the fluidic stream (7) to energized oxygen (9); and diffusing said energized oxygen (9) through at least a portion of the fluidic stream (7), whereby the energized oxygen (9) interacts with the first component so as to form a synthetically engineered optically transmissive fiber (7).
Claim 86
Dependent Claim
27 words
A method as in Claim 82, wherein the step of providing a fluidic stream (7) comprises the step of providing a fluidic stream (7) of silicon (7).
Claim 87
Dependent Claim
24 words
A method as in Claim 82, wherein the step of providing a fluidic stream (7) comprises providing a fluidic stream (7) of germanium (2).
Claim 88
Dependent Claim
29 words
A method as in Claim 82, wherein the step of providing a fluidic stream (7) comprises the step of providing a fluidic stream (7) of a silicon-germanium compound (2).
Claim 89
Dependent Claim
31 words
A method as in Claim 82, wherein the step of providing a fluidic stream (7) comprises the further step of including an additional multivalent metal (2) in that fluidic stream (7).
Claim 90
Dependent Claim
40 words
A method as in Claim 82, including the further step of subjecting the fluidic stream (7) to an energized third component containing one or more elements selected from the group consisting essentially of halogens, multivalent metals, nitrogen and alkali metals.
Claim 91
Dependent Claim
153 words
A metod of fabricating a synthetically engineered solid material, reacting a first component with a second component n a moving surface, CHARACTERIZED IN THAT said method comprise the steps of: providing a moving surface; contacting at least a portion of the moving surface with a fluidic first component of the material; contacting the first component portion of the moving surface with a fluidic second component of the material; catalytically introducing an energized third component of the material, said third component diffusable into a component selected from the group consisting essentially of (1) the first component , (2) the second component, and (3) the first and second components; and diffusing the third component through at least a portion of the selected component, whereby the third component catalytically interacts with the selected component so as to form a synthetically engineered solid material exhibiting a range of properties different from the properties of any individual component.
Claim 92
Dependent Claim
153 words
A metod of fabricating a synthetically engineered solid material, reacting a first component with a second component n a moving surface, CHARACTERIZED IN THAT said method comprise the steps of: providing a moving surface; contacting at least a portion of the moving surface with a fluidic first component of the material; contacting the first component portion of the moving surface with a fluidic second component of the material; catalytically introducing an energized third component of the material, said third component diffusable into a component selected from the group consisting essentially of (1) the first component , (2) the second component, and (3) the first and second components; and diffusing the third component through at least a portion of the selected component, whereby the third component catalytically interacts with the selected component so as to form a synthetically engineered solid material exhibiting a range of properties different from the properties of any individual component.
Claim 93
Dependent Claim
24 words
A method as in Claim 88, wherein the step of providing a moving surface includes the further step of providing a rotatably moving surface.
Claim 94
Dependent Claim
48 words
A method as in Claim 88, wherein the step of contacting at least a portion of the moving surface with a fluidic first component further comprises the steps of liquifying the first component in a crucible and ejecting the first component from the crucible in a fluidic stream.
Claim 95
Dependent Claim
39 words
A method as in Claim 88, wherein the step of contacting at least a portion of the moving surface with a fluidic first component further comprises the further step of providing the fluidic first component in an immersible bath.
Claim 96
Dependent Claim
48 words
A method as in Claim 88, wherein the step of contacting the first component portion of the moving surface with a fluidic second component further comprises the steps of melting the second component in a crucible and ejecting the second component from the crucible in a fluidic stream.
Claim 97
Dependent Claim
38 words
A method as in Claim 88, wherein the step of contacting the first component portion of the moving surface with a fluidic second component further comprises the step of providing the fluidic second component in an immersible bath.
Claim 98
Dependent Claim
38 words
A method as in Claim 88, wherein the step of contacting at least a portion of the moving surface with a fluidic first component further comprises the step of providing the fluidic first component in a spray bath.
Claim 99
Dependent Claim
38 words
A method as in Claim 88, wherein the step of contacting the first component portion of the moving surface with a fluidic second component further comprises the step of providing the fluidic second component in a spray bath.
Claim 100
Dependent Claim
25 words
A method as in Claim 88, wherein the step of catalytically introducing an energized third component further includes the step of selecting the first component.
Claim 101
Dependent Claim
25 words
A method as in Claim 88, wherein the step of catalytically introducing an energized third component further includes the step of selecting the second component.
Claim 102
Dependent Claim
27 words
A method as in Claim 88, wherein the step of catalytically introducing an energized third component further includes the step of selecting the first and second components.
Claim 103
Dependent Claim
25 words
A method as in Claim 88, wherein the step of providing a moving surface includes the further step of providing an energized, diffusable moving surface.
Claim 104
Dependent Claim
95 words
A method as in Claim 88, including the further steps of: catalytically introducing an energized, fourth component of the material, said material diffusable into a component selected from the group consisting essentially of (1) the first component, (2) the second component, (3) the third component, and (4) combinations thereof; and diffusing the fourth component through at least a portion of the selected component, whereby the fourth component catalytically interacts with the selected componet so as to form a synthetically engineered solid material exhibiting a range of properties different from the properties of any individual component.
Claim 105
Dependent Claim
58 words
A method as in Claim 88, including the further step of providing a plurality of moving surfaces, whereby a portion of at least one of the plurality of moving surfaces is contacted with a component slected from the group consisting essentially of (1) the first component, (2) the second component, (3) the third component, and (4) combinations thereof.
Claim 106
Dependent Claim
37 words
A method as in Claim 88, including the further step of utilizing a field of magnetic energy so as to establish eddy currents within said fluidic stream of the first component so as to enhance said diffusion.
Claim 107
Dependent Claim
35 words
A method as in Claim 88, wherein said second component is ionized and said method including the further step of utilizing an electromagnetic field to enhance the diffusion of said ions into the first material.
Claim 108
Dependent Claim
22 words
A method as in Claim 2 including the further step of subjecting the fluidic stream to a non-energized component of the material.
Claim 109
Independent Claim
107 words
A method of forming a composite characterized in that said composite is a synthetically engineered composite having sub-micron to micron scale ceramic zones and interior zones of different composition then the ceramic zones, and that said method comprises the steps of: a. forming a body (101) comprising at least two different materials including a relatively reactive first material and a relatively nonreactive second material; b. contacting the body (101) with a highly excited reactant whereby to cause the relatively reactive first material to react with the reactant to form the sub-micron to micron scale ceramic zones (105), leaving interior zones (103) enriched in relatively nonreactive material content.
Claim 110
Independent Claim
107 words
A method of forming a composite characterized in that said composite is a synthetically engineered composite having sub-micron to micron scale ceramic zones and interior zones of different composition then the ceramic zones, and that said method comprises the steps of: a. forming a body (101) comprising at least two different materials including a relatively reactive first material and a relatively nonreactive second material; b. contacting the body (101) with a highly excited reactant whereby to cause the relatively reactive first material to react with the reactant to form the sub-micron to micron scale ceramic zones (105), leaving interior zones (103) enriched in relatively nonreactive material content.
Claim 111
Dependent Claim
23 words
The method of claim 105 wherein the composition of the zones is a function of depth from the surface of the body (101).
Claim 112
Dependent Claim
10 words
The method of claim 105 wherein the zones are islands.
Claim 113
Dependent Claim
12 words
The method of claim 105 wherein the zones are layers (103, 105).
Claim 114
Dependent Claim
14 words
The method of claim 105 wherein the body further includes a porosity enhancing component.
Claim 115
Dependent Claim
28 words
The method of claim 105 comprising exciting the highly excited oxidant by a method chosen from the group consisting of ion beam excitation, thermal excitation, and electrical excitation.
Claim 116
Dependent Claim
14 words
The method of Claim 6 comprising exciting the highly excited oxidant by microwave radiation.
Claim 117
Dependent Claim
101 words
The method of Claim 105 wherein the synthetically engineered composite (101) is a synthetically engineered cermet type material having sub-micron to micron scale ceramic zones (105) and metallic zones (102), comprising the steps of: a. forming a body (101) comprising at least two materials, a relatively reactive first material and a relatively nonreactive, metallic, second material; b. contacting the body (101) with a highly excited oxidant whereby to cause the relatively reactive first material to react with the oxidant to form the sub-micron to micron scale ceramic zones (105), leaving an interior zone (103) enriched in the relatively nonreactive metallic material.
Claim 118
Dependent Claim
29 words
The method of Claim 112 where the relatively nonreactive metallic material has a lower nitride reaction rate then the relatively reactive material at the same temperature and nitrogen activity.
Claim 119
Dependent Claim
30 words
The method of Claim 112 where the relatively nonreactive metallic material has a lower oxide forming reaction rate then the relatively reactive material at the same temperature and oxygen activity.
Claim 120
Dependent Claim
30 words
The method of claim 112 where the relatively nonreactive metallic material has a lower carbide forming reaction rate then the relatively reactive material at the same temperature and carbon activity.
Claim 121
Dependent Claim
52 words
The method of Claim 113 wherein the relatively reactive material is chosen from the group consisting of at least one of Mg, Ti, V, Cr, Zr, Y, Nb, Hf, Ta, Al, and Si, and the relatively nonreactive metallic material is chosen from the group consisting of Mo, W, Fe, Co, and Ni.
Claim 122
Dependent Claim
136 words
The method of Claim 116 wherein the relatively reactive material is a first metal chosen from the group consisting of at least one of Ti, V, Zr, Hf and Nb, the relatively nonreactive metal is chosen from the group consisting of at least one of Fe, Co, and Ni, the oxidant is nitrogen, and the process comprises: a. forming a body (102) comprising the relatively reactive first metal and the relatively nonreactive second metal; b. contacting the body (101) with microwave excited nitrogen whereby to cause the relatively reactive first metal to migrate to the surface of the body and react with the nitrogen to form a nitride layer (105) having a thickness of about 1 to 20 microns thickness, and leaving a subjacent layer (103) of relatively nonreactive metal enriched in relatively nonreactive metal content.
Claim 123
Dependent Claim
27 words
The method of Claim 112 comprising forming body (101) comprising the relatively reactive first metal and the relatively nonreactive second metal, said having a fine grained microstructure.
Claim 124
Dependent Claim
28 words
The method of Claim 14 wherein the body (101) has a fine grained microstructure chosen from the group consisting of at least one of amorphous, microcrystalline, and polycrystalline.
Claim 125
Dependent Claim
15 words
The method of Claim 118 comprising forming the fine grain microstructure body by rapid solidification.
Claim 126
Dependent Claim
43 words
The method of Claim 120 comprising forming the fine grain microstructure body by a rapid solidification method chosen from the group consisting of atomization, melt spinning, sputtering, chemical vapor deposition, plasma assisted chemical vapor deposition, and microwave excited plasma assisted chemical vapor deposition.
Claim 127
Dependent Claim
15 words
The method of Claim 121 comprising forming the fine grain microstructure body by melt spinning.
Claim 128
Dependent Claim
166 words
The method of Claim 112 comprising forming a layered nitride cermet type synthetically engineered composite material (101) having a sub-micron scale outer nitride layer (105) and an interior metallic layer (103), comprising the steps of: a. forming a molten alloy comprising a relatively reactive first metal chosen from the group consisting of at least one of Ti, V, Zr, Hf, and Nb, and a relatively nonreactive second metal chosen from the group consisting of at least one of Fe, Co, and Ni; b. rapidly solidifying the alloy whereby to form a body of solid alloy having a fine grain microstructure chosen from the group consisting of amorphous, microcrystalline, and polycrystalline; c. contacting the body with microwave excited nitrogen whereby to cause the relatively reactive first metal to migrate to the surface of the body and react with the nitrogen to form a nitride layer having a thickness of 1 to 20 microns, leaving a subjacent layer of relatively nonreactive metal depleted in relatively reactive metal content.
Claim 129
Dependent Claim
26 words
The method of Claim 123 comprising incorporating dispersed particulate carbon in the solid alloy, and pelletizing the carbon containing alloy to form a solid carbide-nitride cermet.
Claim 130
Dependent Claim
164 words
The method of Claim 112 comprising forming a layered oxide cermet (101) having a sub-micron scale outer oxide layer (105) and interior metallic layer (103), comprising the steps of: a. forming a molten alloy comprising a relatively reactive first metal chosen from the group consisting of at least one of Ti, V, Zr, and Nb, and a relatively nonreactive second metal chosen from the group consisting of at least one of Fe, Co, and Ni; b. rapidly solidifying the alloy whereby to form a body (101) of a solid alloy having a fine grain microstructure chosen from the group consisting of amorphous, microcrystalline, and polycrystalline; c. contacting the body (101) with microwave excited oxygen whereby to cause the relatively reactive first metal to migrate to the surface of the body and react with the oxygen to form an oxide layer (105) having a thickness of 1 to 20 microns, leaving a subjacent layer (103) of relatively nonreactive metal depleted in relatively reactive metal content.
Claim 131
Dependent Claim
30 words
The method of Claim 105 wherein the body comprising at least two different materials including a relatively reactive first material and a relatively nonreactive second material comprises micron scale flakes.
Claim 132
Dependent Claim
55 words
The method of Claim 126 comprising: a. first contacting the body (101) with a highly excited reactant whereby to cause the relatively reactive first material to react with the reactant to form the micron scale ceramic zones (105), leaving the zones enriched in relatively nonreactive material content; and b. thereafter bonding the micron scale flakes.
Claim 133
Dependent Claim
14 words
The method of Claim 127 comprising bonding the micron scale flakes by plasma sintering.
Claim 134
Dependent Claim
31 words
The method of Claim 105 wherein the body (101) comprising at least two different materials including a relatively reactive first material and a relatively nonreactive second material comprises substantially filamentary material.
Claim 135
Dependent Claim
29 words
The method of Claim 129 comprising: a. forming a web of the substantially filamentary material; and b. bonding the web with a bonding agent to form a bonded body.
Claim 136
Dependent Claim
13 words
The method of Claim 130 where the bonding agent is a molten metal.
Claim 137
Dependent Claim
106 words
The method of claim 131 comprising the steps of: a. forming a web of the substantially filamentary material comprising at least two different materials including a relatively reactive first material and realtively nonreactive second material; and b. contacting the filamentary material with a highly excited oxidant whereby to cause the relatively reactive first material to react with the oxidant to form sub-micron scale ceramic zones, leaving other zones within the filament enriched in relatively nonreactive material content; c. forming a web of the filamentary material; d. contacting the web with a molten metallic bond agent; and e. cooling the web whereby to form a bonded composite.
Claim 138
Dependent Claim
13 words
the method of Claim 132 wherein the bonding agent is a organic polymer.
Claim 139
Dependent Claim
29 words
The method of Claim 105 wherein the body comprising at least two different materials including a relatively reactive first material and a relatively non-reactive second material comprises a powder.
References Cited (Backward Citations)
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