US4824008A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Surface bonding of ceramic bodies
Assignee: Lanxide Technology Co LP
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Filing: 1987-04-17
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Granted: 1989-04-25
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Expires: 2007-04-17
Abstract
Abstract Ceramic bodies are bonded together via a layer of an oxidation reaction product of a molten metal, which metal is present in one or both of the ceramic bodies prior to bonding. At least one of the ceramic bodies comprises a ceramic product formed by the oxidation reaction of molten parent metal (e.g., alumina from molten aluminum) and grown as molten metal is transported through, and oxidized on the surface of, its own oxidation product. One or both of the ceramic bodies used in the bonding process contains surface-accessible channels of residual metal, i.e., metal channels which have resulted from molten-metal transport during the ceramic growth process. When the suitably assembled ceramic bodies are heated in an oxidizing atmosphere at a temperature above the melting point of the residual metal, molten metal at the surface of the ceramic body reacts with the atmosphereic oxidant so as to bond the facing surfaces together by a layer of the oxidation reaction product of the molten metal formed therebetween.
Inventors
- 👤 Stanley J. Luszcz
- 👤 Andrew W. Urquhart
- 👤 Marc S. Newkirk
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 23:18
CPC Classifications
C; C04; C04B; C04B37/00; C04B37/001; C04B35/00; C04B35/622; C04B35/64; C04B35/65; C04B35/652; C04B2235/00; C04B2235/65; C04B2235/656; C04B2235/6567; C04B2237/00; C04B2237/02; C04B2237/04; C04B2237/06; C04B2237/064; C04B2237/068; C04B2237/08; C04B2237/083; C04B2237/30; C04B2237/32; C04B2237/34; C04B2237/343; C04B2237/36; C04B2237/40; C04B2237/401; C04B2237/50; C04B2237/54; C04B2237/55; C04B2237/555; C04B2237/61; C04B2237/70; C04B2237/704; C04B2237/708; Y; Y10; Y10S; Y10S264/00; Y10S264/76
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
199 words
A method of bonding ceramic bodies along substantially congruent surfaces, comprising: (a) providing a first body of ceramic, said first body comprising a ceramic product formed by the oxidation reaction of molten parent metal and a vapor-phase oxidant and grown as molten metal is transported through, and oxidized on, the surface of its own previously formed oxidation reaction product, said ceramic body comprising a polycrystalline oxidation reaction product and interconnected residual metal; (b) assembling said first body of ceramic adjacent a second body of ceramic in a manner such that a pair of surfaces of said first and second bodies to be bonded together face one another at bonding surfaces of said first and second bodies of ceramic; and (c) heating the assembled ceramic bodies in the presence of a vapor-phase oxidant to a temperature above the melting point of said residual metal but below the melting point of the oxidation reaction product to be formed and below the melting point of the first and second body of ceramic, to induce transport of said residual metal toward said bonding surfaces where oxidation reaction product continues to grow as in step (a) thereby effecting a bond between said ceramic bodies.
Claim 2
Independent Claim
199 words
A method of bonding ceramic bodies along substantially congruent surfaces, comprising: (a) providing a first body of ceramic, said first body comprising a ceramic product formed by the oxidation reaction of molten parent metal and a vapor-phase oxidant and grown as molten metal is transported through, and oxidized on, the surface of its own previously formed oxidation reaction product, said ceramic body comprising a polycrystalline oxidation reaction product and interconnected residual metal; (b) assembling said first body of ceramic adjacent a second body of ceramic in a manner such that a pair of surfaces of said first and second bodies to be bonded together face one another at bonding surfaces of said first and second bodies of ceramic; and (c) heating the assembled ceramic bodies in the presence of a vapor-phase oxidant to a temperature above the melting point of said residual metal but below the melting point of the oxidation reaction product to be formed and below the melting point of the first and second body of ceramic, to induce transport of said residual metal toward said bonding surfaces where oxidation reaction product continues to grow as in step (a) thereby effecting a bond between said ceramic bodies.
Claim 3
Dependent Claim
29 words
The method of claim 1, wherein the parent metal comprises aluminum parent metal, the oxidant comprises air, the oxidation reaction product comprises alumina, and the residual metal comprises aluminum.
Claim 4
Dependent Claim
34 words
The method of claim 1 or claim 2, wherein said first body of ceramic, said second body of ceramic, of both comprise a composite formed by infiltrating a filler with said oxidation reaction product.
Claim 5
Dependent Claim
19 words
The method of claim 1 or claim 2, wherein a dopant is used in conjunction with said parent metal.
Claim 6
Dependent Claim
16 words
The method of claim 1, wherein said first and second bodies are assembled in intimate contact.
Claim 7
Dependent Claim
25 words
The method of claim 1, wherein said first and second bodies are assembled with their bonding surfaces at a small angle relative to each other.
Claim 8
Dependent Claim
37 words
The method of claim 1, wherein a barrier means is applied to all exposed surfaces of said first body of ceramic except a surface thereof to be bonded to a surface of said second body of ceramic.
Claim 9
Dependent Claim
28 words
The method of claim 7, wherein said barrier comprises a material selected from the group consisting of calcium sulfate, calcium silicate, portland cement, tricalcium phosphate, and mixtures thereof.
Claim 10
Dependent Claim
76 words
The method of claim 1, wherein a body of parent metal is positioned adjacent a free surface of said first body of ceramic and a barrier means is applied to at least a portion of remaining exposed surfaces of said body of parent metal and said first body of ceramic, whereby said body of parent metal melts during the heating step and molten metal is transported into said first body of ceramic toward said bonding surfaces.
Claim 11
Dependent Claim
22 words
The method of claim 1, wherein said second body of ceramic has substantially the same composition as said first body of ceramic.
Claim 12
Dependent Claim
25 words
The method of claim 1, wherein said second body of ceramic is made by a method other than the oxidation of a molten parent metal.
Claim 13
Dependent Claim
37 words
The method of claim 1, wherein said second body of ceramic is made by the oxidation of a molten parent metal and said second body of ceramic has a different composition from said first body of ceramic.
Claim 14
Dependent Claim
26 words
The method of claim 1, wherein said oxidation reaction product comprising a material selected from the group consisting of an oxide, a nitride, and a carbide.
Claim 15
Dependent Claim
24 words
The method of claim 1, wherein said parent metal comprises a material selected from the group consisting of titanium, silicon, zirconium, hafnium, or tin.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-04-24 | 1992-10-24 | 1993-04-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-04-24 | 1996-10-24 | 1997-04-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-04-24 | 2000-10-24 | 2001-04-25 | $7700.00 | Window Closed / Lapsed |