Filament-containing composite

Claim 2

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) providing infiltration-promoting material in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) contacting a plurality of said boron nitride-coated filaments with said infiltration-promoting material to produce a preform wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform; (e) providing an infiltrant comprised of boron and silicon containing elemental boron in solution in silicon in an amount of at least about 0.1% by weight of elemental silicon; (f) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 3

The process according to claim 1 wherein said preform has an open porosity ranging from about 35% by volume to about 80% by volume.

Claim 4

The process according to claim 1 wherein said infiltration-promoting material is comprised of elemental carbon.

Claim 5

The process according to claim 1 wherein said filament is comprised of elemental carbon.

Claim 6

The process according to claim 1 wherein said filament is comprised of silicon carbide.

Claim 7

The process according to claim 1 wherein said matrix phase is comprised of said silicon carbide formed in situ and said elemental silicon.

Claim 8

The process according to claim 1 wherein said infiltration-promoting material is formed into a suspension in a liquid vehicle, wherein a layer of said boron nitride-coated filaments is pre-formed in which said filaments are spaced and substantially parallel, and wherein said layer of filaments is immersed in said suspension and said liquid vehicle is extracted therefrom to produce said preform.

Claim 9

The process according to claim 1 wherein said infiltration-promoting material is formed into a suspension, a part of said suspension is slip cast until a pliable mass of said infiltration-promoting material is formed, said boron nitride-coated filaments are pressed into said mass and additional suspension is slip cast on at least the exposed portions of said filaments to produce said preform.

Claim 10

A composite comprised of boron nitride-coated carbon-containing filaments and a matrix phase, said matrix phase containing silicon carbide phase and/or boron-containing silicon carbide phase and a solution phase comprised of a solution of boron and silicon wherein boron is present in an amount of at least about 0.1% by weight of silicon, said carbide phase being present in an amount of at least about 5% by volume of said composite, said solution phase being present in an amount of at least about 1% by volume of said composite, said filament component of said boron nitride-coated filaments being present in an amount of at least about 10% by volume of said composite, said boron nitride coating being at least detectable by scanning electron microscopy, said boron nitride-coated filaments being at least substantially parallel to each other and spaced from each other, said filament component of said boron nitride-coated filaments having a diameter of at least about 50 microns, said boron nitride-coated filaments being spaced from each other by at least about 50 microns, said matrix phase being continuous, interconnecting and enveloping each of said boron nitride-coated filaments, said composite having a porosity of less than about 10% by volume.

Claim 11

A composite comprised of boron nitride-coated carbon-containing filaments and a matrix phase, said matrix phase containing silicon carbide phase and/or boron-containing silicon carbide phase and a solution phase comprised of a solution of boron and silicon wherein boron is present in an amount of at least about 0.1% by weight of silicon, said carbide phase being present in an amount of at least about 5% by volume of said composite, said solution phase being present in an amount of at least about 1% by volume of said composite, said filament component of said boron nitride-coated filaments being present in an amount of at least about 10% by volume of said composite, said boron nitride coating being at least detectable by scanning electron microscopy, said boron nitride-coated filaments being at least substantially parallel to each other and spaced from each other, said filament component of said boron nitride-coated filaments having a diameter of at least about 50 microns, said boron nitride-coated filaments being spaced from each other by at least about 50 microns, said matrix phase being continuous, interconnecting and enveloping each of said boron nitride-coated filaments, said composite having a porosity of less than about 10% by volume.

Claim 12

The composite according to claim 9 wherein a compound of boron and silicon is present ranging up to about 10% by volume of said composite.

Claim 13

The composite according to claim 9 wherein said filament component is comprised of elemental carbon.

Claim 14

The composite according to claim 9 wherein said filament component is comprised of silicon carbide.

Claim 15

The composite according to claim 9 wherein said matrix phase is comprised of said silicon carbide phase and said solution phase.

Claim 16

The composite according to claim 9 wherein said filament component is present in an amount of at least about 50% by volume of said composite.

Claim 17

A composite comprised of at least a layer of boron nitride-coated filaments and a matrix phase, said filament component of said boron nitride-coated filaments ranging from about 10% by volume to about 70% by volume of the composite and being selected from the group consisting of elemental carbon, a SiC-containing material containing by weight of the SiC-containing material at least about 50% by weight of silicon and at least about 25% by weight of carbon, and a combination thereof, said boron nitride coating being at least detectable by scanning electron microscopy, said boron nitride-coated filaments being at least substantially parallel to each other and spaced from each other, said filament component of said boron nitride-coated filaments having a diameter of at least about 50 microns, said boron nitride-coated filaments being spaced from each other by at least about 50 microns, said matrix phase being continuous, interconnecting and enveloping each of said boron nitride-coated filaments, said coated filaments being distributed through said composite, said matrix phase being comprised of a phase of silicon carbide and/or boron-containing silicon carbide and a solution phase, said solution phase being comprised of a solution of boron and silicon wherein boron is present in an amount of at least about 1% by weight of silicon, said carbide phase being present in an amount of at least about 10% by volume of said composite, said solution phase being present in an amount of at least about 1% by volume of said composite, said matrix phase enveloping each of said boron nitride-coated filaments, said composite having a porosity of less than about 10% by volume.

Claim 18

A composite comprised of at least a layer of boron nitride-coated filaments and a matrix phase, said filament component of said boron nitride-coated filaments ranging from about 10% by volume to about 70% by volume of the composite and being selected from the group consisting of elemental carbon, a SiC-containing material containing by weight of the SiC-containing material at least about 50% by weight of silicon and at least about 25% by weight of carbon, and a combination thereof, said boron nitride coating being at least detectable by scanning electron microscopy, said boron nitride-coated filaments being at least substantially parallel to each other and spaced from each other, said filament component of said boron nitride-coated filaments having a diameter of at least about 50 microns, said boron nitride-coated filaments being spaced from each other by at least about 50 microns, said matrix phase being continuous, interconnecting and enveloping each of said boron nitride-coated filaments, said coated filaments being distributed through said composite, said matrix phase being comprised of a phase of silicon carbide and/or boron-containing silicon carbide and a solution phase, said solution phase being comprised of a solution of boron and silicon wherein boron is present in an amount of at least about 1% by weight of silicon, said carbide phase being present in an amount of at least about 10% by volume of said composite, said solution phase being present in an amount of at least about 1% by volume of said composite, said matrix phase enveloping each of said boron nitride-coated filaments, said composite having a porosity of less than about 10% by volume.

Claim 19

The composite according to claim 15 wherein a compound of boron and silicon is present ranging up to about 10% by volume of said composite.

Claim 20

The composite according to claim 15 wherein said silicon carbide phase ranges from about 10% by volume to less than about 79% by volume of said composite.

Claim 21

The composite according to claim 15 wherein said filament component is comprised of elemental carbon.

Claim 22

The composite according to claim 15 wherein said filament component is comprised of silicon carbide.

Claim 23

The process according to claim 1, wherein said infiltration-promoting material in step (c) contains molybdenum in an amount of at least about 1% by volume of said infiltration-promoting material.

Claim 24

The composite according to claim 9, wherein said matrix phase contains molybdenum silicide ranging up to about 50% by volume of the composite.

Claim 25

The composite according to claim 15, wherein said matrix phase contains molybdenum silicide ranging up to about 50% by volume of the composite.

Claim 26

A composite comprised of boron nitride-coated carbon-containing filaments and a matrix phase, said matrix phase containing silicon carbide phase and/or boron-containing silicon carbide phase and a solution phase comprised of a solution of boron and silicon wherein boron is present in an amount of at least about 0.1% by weight of silicon, said carbide phase being present in an amount of at least about 5% by volume of said composite, said solution phase being present in an amount of at least about 1% by volume of said composite, said filament component of said boron nitride-coated filaments being present in an amount of at least about 10% by volume of said composite, said boron nitride coating being at least detectable by scanning electron microscopy, said boron nitride-coated filaments being at least substantially parallel to each other and spaced from each other, said filament component of said boron nitride-coated filaments having a diameter of at least about 50 microns, said matrix phase being continuous, interconnecting and enveloping each of said boron nitride-coated filaments, said composite having a porosity of less than about 10% by volume.

Claim 27

A composite comprised of boron nitride-coated carbon-containing filaments and a matrix phase, said matrix phase containing silicon carbide phase and/or boron-containing silicon carbide phase and a solution phase comprised of a solution of boron and silicon wherein boron is present in an amount of at least about 0.1% by weight of silicon, said carbide phase being present in an amount of at least about 5% by volume of said composite, said solution phase being present in an amount of at least about 1% by volume of said composite, said filament component of said boron nitride-coated filaments being present in an amount of at least about 10% by volume of said composite, said boron nitride coating being at least detectable by scanning electron microscopy, said boron nitride-coated filaments being at least substantially parallel to each other and spaced from each other, said filament component of said boron nitride-coated filaments having a diameter of at least about 50 microns, said matrix phase being continuous, interconnecting and enveloping each of said boron nitride-coated filaments, said composite having a porosity of less than about 10% by volume.

Claim 28

The composite according to claim 23, wherein said filament component is comprised of elemental carbon.

Claim 29

The composite according to claim 23, wherein said filament component is comprised of silicon carbide.

Claim 30

The composite according to claim 23, wherein said matrix phase contains molybdenum silicide ranging up to about 50% by volume of the composite.

Claim 31

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) providing infiltration-promoting material in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) contacting a plurality of said boron nitride-coated filaments with said infiltration-promoting material to produce a preform wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform; (e) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon; (f) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in silicon in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 32

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) providing infiltration-promoting material in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) contacting a plurality of said boron nitride-coated filaments with said infiltration-promoting material to produce a preform wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform; (e) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon; (f) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform; (g) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in silicon in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (h) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 33

The process according to claim 27, wherein said filament is comprised of elemental carbon.

Claim 34

The process according to claim 27, wherein said filament is comprised of silicon carbide.

Claim 35

The process according to claim 27, wherein said infiltration-promoting material in step (c) contains molybdenum in an amount of at least about 1% by volume of said infiltration-promoting material.

Claim 36

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) forming a preform comprised of infiltration-promoting material and a plurality of said boron nitride-coated filaments wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform, said infiltration-promoting material being in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) providing an infiltrant comprised of boron and silicon containing elemental boron in solution in silicon in an amount of at least about 0.1% by weight of elemental silicon; (e) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform; (f) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (g) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 37

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) forming a preform comprised of infiltration-promoting material and a plurality of said boron nitride-coated filaments wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform, said infiltration-promoting material being in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) providing an infiltrant comprised of boron and silicon containing elemental boron in solution in silicon in an amount of at least about 0.1% by weight of elemental silicon; (e) contacting said preform with infiltrant-associated infiltrating means whereby said infiltrant is infiltrated into said preform; (f) heating the resulting structure to a temperature at which said infiltrant is molten and infiltrating said molten infiltrant into said preform to produce an infiltrated product having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (g) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 38

The process according to claim 31, wherein said preform has an open porosity ranging from about 35% by volume to about 80% by volume.

Claim 39

The process according to claim 31, wherein said infiltration-promoting material in step (c) is comprised of elemental carbon.

Claim 40

The process according to claim 31, wherein said filament is comprised of elemental carbon.

Claim 41

The process according to claim 31, wherein said filament is comprised of silicon carbide.

Claim 42

The process according to claim 31, wherein said infiltration-promoting material in step (c) contains molybdenum in an amount of at least about 1% by volume of said infiltration-promoting material.

Claim 43

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) forming a preform comprised of infiltration-promoting material and a plurality of said boron nitride-coated filaments wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform, said infiltration-promoting material being in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon; (e) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform; (f) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in silicon in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated produce having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (g) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 44

A process for producing a composite with a porosity of less than about 10% by volume comprised of boron nitride-coated filaments and a matrix phase, said filament component of said coated filaments comprising at least about 10% by volume of the composite, said matrix phase containing silicon carbide and/or boron-containing silicon carbide formed in situ in an amount of at least about 5% by volume of the composite and a solution of elemental boron and elemental silicon in an amount of at least about 1% by volume of the composite, which comprises the following steps: (a) providing a carbon-containing filament having a diameter of at least about 50 microns; (b) depositing a coating of boron nitride on said filament leaving no significant portion thereof exposed; (c) forming a preform comprised of infiltration-promoting material and a plurality of said boron nitride-coated filaments wherein said infiltration-promoting material envelops each coated filament preventing contact therebetween and wherein said coated filaments are at least substantially parallel to each other, said preform having an open porosity ranging from about 25% by volume to about 85% by volume of the preform, said infiltration-promoting material being in the form of particulates and/or fibers, said infiltration-promoting material containing elemental carbon; (d) providing an infiltrant composition comprised of boron and silicon wherein boron ranges from about 0.1% by weight to about 10% by weight of elemental silicon; (e) contacting said preform and said infiltrant composition with infiltrating means whereby molten infiltrant is infiltrated into said preform; (f) heating the resulting structure to a temperature at which said infiltrant composition is molten resulting in a molten infiltrant containing elemental boron in solution in silicon in an amount ranging from about 0.1% by weight of silicon to an amount which forms a saturated solution with silicon and infiltrating said molten infiltrant into said preform to produce an infiltrated produce having the composition of said composite, said preform containing sufficient elemental carbon to react with said infiltrant to form said composite; and (g) cooling said product to produce said composite, said boron nitride-coated filaments being enveloped by said infiltration-promoting material to enable said infiltration by molten infiltrant.

Claim 45

The process according to claim 37, wherein said filament is comprised of elemental carbon.

Claim 46

The process according to claim 37, wherein said filament is comprised of silicon carbide.

Claim 47

The process according to claim 37, wherein said infiltration-promoting material in step (c) contains molybdenum in an amount of at least about 1% by volume of said infiltration-promoting material.

Claim 48

The process according to claim 1, wherein said infiltration-promoting material in step (c) contains molybdenum carbide in an amount of at least about 1% by volume of said infiltration-promoting material.

Claim 49

The process according to claim 27, wherein said infiltration-promoting material in step (c) contains molybdenum carbide in an amount of at least about 1% by volume of said infiltration-promoting material.

Claim 50

The composite according to claim 9, wherein said matrix phase contains molybdenum carbide ranging up to about 50% by volume of the composite.

Claim 51

The composite according to claim 23, wherein said matrix phase contains molybdenum carbide ranging up to about 50% by volume of the composite.