US4904424A
Expired / Lapsed
US
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Ceramic alloys from colloidal metal alloy suspensions
Assignee: Hoechst Celanese Chemical Co
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Filing: 1987-05-29
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Granted: 1990-02-27
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Expires: 2007-05-29
Abstract
Abstract Ceramic alloys or solid solutions are formed by dispersing a powdery metal alloy or intimate mixture of two alloying metals in a precarbonaceous polymer such as polyacrylonitrile, forming the mixture into a molded article such as fibers, and heating the molded articles at a temperature and in a pyrolyzation atmosphere sufficient to carbonize the polymer and cause reaction of the metals with carbon and/or the pyrolyzation gas.
Inventors
- 👤 Robert E. Johnson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 21:37
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/632; C04B35/634; C04B35/63404; C04B35/63444; C04B35/515; C04B35/56; C04B35/563; C04B35/565; C04B35/573; C04B35/58; C04B35/581; C04B35/583; C04B35/584; C04B35/591; C04B35/62227; C04B35/62272; C04B35/62277; C04B35/62281; C04B35/62286; C04B35/6229; C04B35/62295; C04B35/62605; C04B35/6261; C04B35/62645; C04B35/6268; C04B35/64; C04B35/65; D; D01; D01F; D01F9/00; D01F9/08; D01F9/10; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/38; C04B2235/3817; C04B2235/3821; C04B2235/40; C04B2235/402; C04B2235/42; C04B2235/421; C04B2235/428; C04B2235/46; C04B2235/465; C04B2235/50; C04B2235/54; C04B2235/5418; C04B2235/5436; C04B2235/5445; C04B2235/65; C04B2235/658; Y; Y10; Y10S; Y10S264/00; Y10S264/19
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
169 words
A process for preparing molded products of ceramic alloys which comprised molding a preceramic composition comprising (a) from about 5 to 95% by weight based on the composition of at least one powdery metal alloy or a unitary powdery intimate mixture of alloying metals or alloying metallic compounds, said powdery metal alloy or intimate mixture comprising at least one refractory metal or metal compound selected from silicon, boron and compounds of silicon or boron and a second alloying metal comprising aluminum which lowers the melting point of said alloy below the melting point of said refractory metal or metal compound and, wherein the average particle size of said powdery metal alloy or unitary powdery intimate mixture is not greater than about 50 microns, and (b) a precarbonaceous polymer, curing said molded preceramic composition to harden some and, heating said cured molded preceramic composition at a temperature and in a pyrolyzation atmosphere sufficient to carbonize said polymer and cause reaction between said powdery metal alloy or intimate mixture and carbon.
Claim 2
Dependent Claim
169 words
A process for preparing molded products of ceramic alloys which comprised molding a preceramic composition comprising (a) from about 5 to 95% by weight based on the composition of at least one powdery metal alloy or a unitary powdery intimate mixture of alloying metals or alloying metallic compounds, said powdery metal alloy or intimate mixture comprising at least one refractory metal or metal compound selected from silicon, boron and compounds of silicon or boron and a second alloying metal comprising aluminum which lowers the melting point of said alloy below the melting point of said refractory metal or metal compound and, wherein the average particle size of said powdery metal alloy or unitary powdery intimate mixture is not greater than about 50 microns, and (b) a precarbonaceous polymer, curing said molded preceramic composition to harden some and, heating said cured molded preceramic composition at a temperature and in a pyrolyzation atmosphere sufficient to carbonize said polymer and cause reaction between said powdery metal alloy or intimate mixture and carbon.
Claim 3
Dependent Claim
38 words
The process of claim 1 wherein said powdery metal alloy or intimate mixture is present in an amount of at least about 40% up to about 95% by weight based on the total weight of said preceramic composition.
Claim 4
Dependent Claim
25 words
The process of claim 1 wherein said powdery metal alloy or intimate mixture has an average particle size of not greater than about 10 microns.
Claim 5
Dependent Claim
25 words
The process of claim 1 wherein said powdery metal alloy or intimate mixture has an average particle size of not greater than about 1 micron.
Claim 6
Dependent Claim
15 words
The process of claim 1 wherein said molding comprises spinning said preceramic composition into fiber.
Claim 7
Dependent Claim
14 words
The process of claim 1 wherein said polymer is carbonized in a non-oxygen-containing atmosphere.
Claim 8
Dependent Claim
20 words
The process of claim 6 wherein said non-oxygen-containing atmosphere is capable of reacting with at least one of said metals.
Claim 9
Dependent Claim
22 words
The process of claim 7 wherein said non-oxygen-containing atmosphere is selected from the group consisting of nitrogen, ammonia, phosphine and metal hydrides.
Claim 10
Dependent Claim
25 words
The process of claim 7 wherein said non-oxygen-containing atmosphere is capable of reacting with at least one of said metals to form a metal nitride.
Claim 11
Dependent Claim
10 words
The process of claim 9 wherein said atmosphere is ammonia.
Claim 12
Dependent Claim
11 words
The process of claim 8 wherein said non-oxygen-containing atmosphere is phosphine.
Claim 13
Dependent Claim
12 words
The process of claim 8 wherein non-oxygen-containing atmosphere is a metal hydride.
Claim 14
Dependent Claim
22 words
The process of claim 1 wherein said metal alloy is a eutectic alloy of about 12% silicon and 88% aluminum by weight.
Claim 15
Dependent Claim
22 words
The process of claim 1 wherein said metal alloy or intimate mixtures comprises an alloy or mixture of aluminum with boron carbide.
Claim 16
Dependent Claim
17 words
The process of claim 1 wherein the melting point of said alloy is below about 100° C.
Claim 17
Dependent Claim
165 words
A process for preparing ceramic alloy fibers which comprises spinning into fiber a preceramic composition comprising (a) from about 5 to 95% by weight based on the composition of at least one powdery metal alloy or unitary powdery intimate mixture of alloying metals or alloying metallic compounds, said powdery metal alloy or intimate mixture comprising at least one refractory metal or metal compound selected from silicon, boron and compounds of silicon or boron and a second alloying metal comprising aluminum which lowers the melting point of said alloy below the melting point of said refractory metal or metal compound and wherein the average particle size of said powdery metal alloy or unitary powdery intimate mixture is not greater than about 50 microns, and (b) an acrylonitrile polymer, curing said preceramic fiber to harden same and, heating said cured fiber in a non-oxygen-containing atmosphere and at a temperature sufficient to carbonize said polymer and cause reaction between said powdery metal alloy or intimate mixture and carbon.
Claim 18
Dependent Claim
165 words
A process for preparing ceramic alloy fibers which comprises spinning into fiber a preceramic composition comprising (a) from about 5 to 95% by weight based on the composition of at least one powdery metal alloy or unitary powdery intimate mixture of alloying metals or alloying metallic compounds, said powdery metal alloy or intimate mixture comprising at least one refractory metal or metal compound selected from silicon, boron and compounds of silicon or boron and a second alloying metal comprising aluminum which lowers the melting point of said alloy below the melting point of said refractory metal or metal compound and wherein the average particle size of said powdery metal alloy or unitary powdery intimate mixture is not greater than about 50 microns, and (b) an acrylonitrile polymer, curing said preceramic fiber to harden same and, heating said cured fiber in a non-oxygen-containing atmosphere and at a temperature sufficient to carbonize said polymer and cause reaction between said powdery metal alloy or intimate mixture and carbon.
Claim 19
Dependent Claim
25 words
The process of claim 16 wherein said non-oxygen-containing atmosphere is a gas capable of reacting with one of said metals to form a metal nitride.
Claim 20
Dependent Claim
20 words
The process of claim 16 wherein said non-oxygen-containing atmosphere is capable of reacting with at least one of said metals.
Claim 21
Dependent Claim
22 words
The process of claim 16 wherein said non-oxygen-containing atmosphere is selected from the group consisting of nitrogen, ammonia, phosphine and metal hydrides.
Claim 22
Dependent Claim
10 words
The process of claim 16 wherein said atmosphere is ammonia.
Claim 23
Dependent Claim
10 words
The process of claim 16 wherein non-oxygen-containing atmosphere is phosphine.
Claim 24
Dependent Claim
13 words
The process of claim 16 wherein said non-oxygen-containing atmosphere is a metal hydride.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1993-02-26 | 1993-08-28 | 1994-02-27 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-02-26 | 1997-08-28 | 1998-02-27 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-02-26 | 2001-08-28 | 2002-02-27 | $7700.00 | Window Closed / Lapsed |