US5106789A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making ceramic composites
Assignee: Lanxide Technology Co LP
•
Filing: 1990-01-16
•
Granted: 1992-04-21
•
Expires: 2010-01-16
Abstract
Abstract The invention relates to a method for producing ceramic composites obtained by oxidation of a parent metal to form a polycrystalline ceramic material by providing a filler having a coating of a silicon source on at least a portion of the filler different in composition from the primary composition of the filler, said silicon source possessing intrinsic doping properties. A body of molten parent metal, adjacent a mass of the filler material, reacts with an oxidant to form an oxidation reaction product which infiltrates the adjacent mass of filler, thereby forming the ceramic composite.
Inventors
- 👤 Harold D. Lesher
- 👤 Christopher R. Kennedy
- 👤 Danny R. White
- 👤 Andrew W. Urquhart
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 21:38
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/71; C04B35/622; C04B35/64; C04B35/65; C04B35/652; Y; Y10; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913; Y10T428/2933; Y10T428/2938
Claims Analysis
Total Claims: 16
Claim 1
Independent Claim
292 words
A method for producing a self-supporting ceramic composite comprising (1) an oxidation reaction product of a parent metal and an oxidant and (2) at least one filler material, said method comprising the steps of: (a) orienting said parent metal and a permeable mass of said at least one filler material relative to each other so that formation of the oxidation reaction product will occur in a direction towards and into said mass of filler material, said filler material having a coating of a silicic precursor on at least a portion of said filler; heating said coated filler material to result in said silicic precursor dissociating to form a silicon source coating on at least a portion of said filler, said silicon source being present during formation of said oxidation reaction product, said coating being different in composition from a primary composition of said filler, and possessing intrinsic doping properties; (b) heating said parent metal to a temperature above its melting point but below the melting point of the oxidation reaction product to form a body of molten parent metal; (c) reacting the molten parent metal with an oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and between said body of molten metal and said oxidant, to progressively draw molten metal through the oxidation reaction product towards the oxidant and the filler material so that the oxidation reaction product continues to form within said filler at an interface between the oxidant and previously formed oxidation reaction product; and (d) continuing said oxidation reaction for a time sufficient to infiltrate at least a portion of said mass of filler material with said oxidation reaction product.
Claim 2
Independent Claim
292 words
A method for producing a self-supporting ceramic composite comprising (1) an oxidation reaction product of a parent metal and an oxidant and (2) at least one filler material, said method comprising the steps of: (a) orienting said parent metal and a permeable mass of said at least one filler material relative to each other so that formation of the oxidation reaction product will occur in a direction towards and into said mass of filler material, said filler material having a coating of a silicic precursor on at least a portion of said filler; heating said coated filler material to result in said silicic precursor dissociating to form a silicon source coating on at least a portion of said filler, said silicon source being present during formation of said oxidation reaction product, said coating being different in composition from a primary composition of said filler, and possessing intrinsic doping properties; (b) heating said parent metal to a temperature above its melting point but below the melting point of the oxidation reaction product to form a body of molten parent metal; (c) reacting the molten parent metal with an oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and between said body of molten metal and said oxidant, to progressively draw molten metal through the oxidation reaction product towards the oxidant and the filler material so that the oxidation reaction product continues to form within said filler at an interface between the oxidant and previously formed oxidation reaction product; and (d) continuing said oxidation reaction for a time sufficient to infiltrate at least a portion of said mass of filler material with said oxidation reaction product.
Claim 3
Dependent Claim
22 words
The method of claim 1 wherein said coating of said silicon source is produced by oxidation or dissociation of a silicic precursor.
Claim 4
Dependent Claim
20 words
The method of claim 1, wherein said permeable mass of said at least one filler material comprises a shaped preform.
Claim 5
Dependent Claim
59 words
The method of claim 1, wherein a concentration of said silicon source is not constant within said permeable mass of said at least one filler material resulting in a concentration gradient of said silicon source within said permeable mass of said at least one filler material, thereby causing said self-supporting composite resulting from said method to have graded properties.
Claim 6
Dependent Claim
16 words
The method of claim 4, wherein said permeable mass of filler material comprises a shaped preform.
Claim 7
Dependent Claim
19 words
The method of claim 1, wherein said silicon source is at least partially reduced by said molten parent metal.
Claim 8
Dependent Claim
19 words
The method of claim 1, wherein said silicon source is at least partially dissolved by said molten parent metal.
Claim 9
Dependent Claim
11 words
The method of claim 1, wherein said silicon source comprises silica.
Claim 10
Dependent Claim
20 words
The method of claim 1, wherein said silicic precursor comprises at least one of tetraethyl orthosilicate and ethyl silicate glass.
Claim 11
Dependent Claim
19 words
The method of claim 9, wherein said silicic precursor comprises tetraethyl orthosilicate and said filler material comprises zirconium oxide.
Claim 12
Dependent Claim
19 words
The method of claim 9, wherein said silicic precursor comprises ethyl silicate glass and said filler material comprises alumina.
Claim 13
Dependent Claim
32 words
The method of claim 1, wherein at least a portion of said filler material comprises at least one material selected from the group consisting of silicon carbide, boron nitride, and silicon nitride.
Claim 14
Dependent Claim
18 words
The method of claim 1, further comprising providing said coating of a silicic precursor by chemical vapor deposition.
Claim 15
Dependent Claim
24 words
The method of claim 1, wherein said oxidant comprises at least one material selected from the group consisting of liquid, solid, and vapor-phase oxidants.
Claim 16
Dependent Claim
24 words
The method of claim 5, wherein at least a portion of at least one surface of said preform is contacted with a barrier means.
References Cited (Backward Citations)
US2741822A
Cited
US3255027A
Cited
US3298842A
Cited
US3296002A
Cited
US3419404A
Cited
US3473987A
Cited
US3421863A
Cited
US3437468A
Cited
US3789096A
Cited
US3473938A
Cited
US3538231A
Cited
US3864154A
Cited
US3973977A
Cited
EP0116809A1
Cited
US4713360A
Cited
EP0155831A2
Cited
EP0169067A2
Cited
US4853352A
Cited
EP0193292A2
Cited
US4851375A
Cited
US4859640A
Cited
US4847220A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-04-21 | 1995-10-21 | 1996-04-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-04-21 | 1999-10-21 | 2000-04-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-04-21 | 2003-10-21 | 2004-04-21 | $7700.00 | Window Closed / Lapsed |