US5221558A
Expired / Lapsed
US
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Method of making ceramic composite bodies
Assignee: Lanxide Technology Co LP
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Filing: 1991-08-16
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Granted: 1993-06-22
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Expires: 2011-08-16
Abstract
Abstract The present invention relates to methods for producing self-supporting ceramic and ceramic composite bodies having a protective surface region on at least a portion of the surface of the formed bodies, and bodies produced thereby.
Inventors
- 👤 Birol Sonuparlak
- 👤 Kenneth S. Hatton
- 👤 Dennis J. Landini
- 👤 Sylvia J. Canino
- 👤 Michael K. Aghajanian
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 17:00
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/64; C04B35/65; C04B35/652; C04B41/00; C04B41/0018
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
282 words
A method for producing a self-supporting ceramic structure comprising (i) a ceramic matrix obtained by oxidation of a parent metal to form a polycrystalline material comprising an oxidation reaction product and at least one additional constituent, and (ii) a protective surface region on at least a portion of a surface of the ceramic matrix comprising a primary chemical constituent different from the primary chemical constituent of the ceramic matrix, comprising the steps of: (a) heating a parent metal in the presence of an oxidant to a temperature above the melting point of said parent metal but below the melting point of said oxidation reaction product to form a body of molten parent metal; (b) reacting said body of molten parent metal with said oxidant at said temperature to permit said oxidation reaction product to form; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten parent metal and said oxidant at said temperature to progressively draw molten parent metal through said oxidation reaction product towards said oxidant to permit fresh oxidation reaction product to continue to form at an interface between said oxidant and previously formed oxidation reaction product, thereby forming said polycrystalline material; (d) providing at least one external material on at least a portion of said polycrystalline material; and (e) heating said polycrystalline material to a second temperature, said second temperature being sufficient to induce at least two constituents of said polycrystalline material to react with at least a portion of said at least one external material to form at least one protective surface region on at least a portion of the surface of the ceramic matrix to form said ceramic structure.
Claim 2
Independent Claim
282 words
A method for producing a self-supporting ceramic structure comprising (i) a ceramic matrix obtained by oxidation of a parent metal to form a polycrystalline material comprising an oxidation reaction product and at least one additional constituent, and (ii) a protective surface region on at least a portion of a surface of the ceramic matrix comprising a primary chemical constituent different from the primary chemical constituent of the ceramic matrix, comprising the steps of: (a) heating a parent metal in the presence of an oxidant to a temperature above the melting point of said parent metal but below the melting point of said oxidation reaction product to form a body of molten parent metal; (b) reacting said body of molten parent metal with said oxidant at said temperature to permit said oxidation reaction product to form; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten parent metal and said oxidant at said temperature to progressively draw molten parent metal through said oxidation reaction product towards said oxidant to permit fresh oxidation reaction product to continue to form at an interface between said oxidant and previously formed oxidation reaction product, thereby forming said polycrystalline material; (d) providing at least one external material on at least a portion of said polycrystalline material; and (e) heating said polycrystalline material to a second temperature, said second temperature being sufficient to induce at least two constituents of said polycrystalline material to react with at least a portion of said at least one external material to form at least one protective surface region on at least a portion of the surface of the ceramic matrix to form said ceramic structure.
Claim 3
Independent Claim
349 words
A method for producing a self-supporting ceramic composite structure comprising (i) a ceramic matrix obtained by oxidation of a parent metal to form a polycrystalline material comprising an oxidation reaction product and at least one additional constituent, (ii) a filler material, and (iii) a protective surface region on at least a portion of a surface of the ceramic matrix comprising a primary chemical constituent different from the primary chemical constituent of the ceramic matrix, comprising the steps of: (a) heating a parent metal in the presence of an oxidant to a temperature above the melting point of said parent metal but below the melting point of said oxidation reaction product to form a body of molten parent metal; (b) providing a filler material in contact with said parent metal; (c) reacting said body of molten parent metal with said oxidant at said temperature to permit said oxidation reaction product to form which at least partially embeds said filler material; (d) maintaining at least a portion of said oxidation reaction product in contact with and between said molten parent metal and said oxidant at said temperature to progressively draw molten parent metal through said oxidation reaction product towards said oxidant to permit fresh oxidation reaction product to continue to form at an interface between said oxidant and previously formed oxidation reaction product, thereby forming said polycrystalline material at least partially embedding said filler material; (e) providing at least one external material on at least a portion of said polycrystalline material; and (f) heating said polycrystalline material at least partially embedding said filler material to a second temperature, said second temperature being sufficient to induce at least one of (i) at least two constituents of said polycrystalline material or (ii) at least one constituent of said polycrystalline material and at least a portion of said at least partially embedded filler material to react with at least a portion of said at least one external material to form at least one protective surface region on at least a portion of the surface of the ceramic matrix to form said ceramic composite structure.
Claim 4
Independent Claim
349 words
A method for producing a self-supporting ceramic composite structure comprising (i) a ceramic matrix obtained by oxidation of a parent metal to form a polycrystalline material comprising an oxidation reaction product and at least one additional constituent, (ii) a filler material, and (iii) a protective surface region on at least a portion of a surface of the ceramic matrix comprising a primary chemical constituent different from the primary chemical constituent of the ceramic matrix, comprising the steps of: (a) heating a parent metal in the presence of an oxidant to a temperature above the melting point of said parent metal but below the melting point of said oxidation reaction product to form a body of molten parent metal; (b) providing a filler material in contact with said parent metal; (c) reacting said body of molten parent metal with said oxidant at said temperature to permit said oxidation reaction product to form which at least partially embeds said filler material; (d) maintaining at least a portion of said oxidation reaction product in contact with and between said molten parent metal and said oxidant at said temperature to progressively draw molten parent metal through said oxidation reaction product towards said oxidant to permit fresh oxidation reaction product to continue to form at an interface between said oxidant and previously formed oxidation reaction product, thereby forming said polycrystalline material at least partially embedding said filler material; (e) providing at least one external material on at least a portion of said polycrystalline material; and (f) heating said polycrystalline material at least partially embedding said filler material to a second temperature, said second temperature being sufficient to induce at least one of (i) at least two constituents of said polycrystalline material or (ii) at least one constituent of said polycrystalline material and at least a portion of said at least partially embedded filler material to react with at least a portion of said at least one external material to form at least one protective surface region on at least a portion of the surface of the ceramic matrix to form said ceramic composite structure.
Claim 5
Independent Claim
282 words
A method for producing a self-supporting ceramic structure comprising (i) a ceramic matrix comprising alumina obtained by oxidation of an aluminum metal to form a polycrystalline material comprising an oxidation reaction product and at least one additional constituent, and (ii) a protective surface region on at least a portion of a surface of the ceramic matrix comprising a primary chemical constituent different from the primary chemical constituent of the ceramic matrix comprising alumina, comprising the steps of: (a) heating an aluminum metal in the presence of an oxidant comprising air to a temperature above the melting point of said aluminum metal but below the melting point of said oxidation reaction product to form a body of molten aluminum metal; (b) reacting said body of molten aluminum metal with said oxidant comprising air at said temperature to permit said oxidation reaction product to form; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten aluminum metal and said oxidant comprising air at said temperature to progressively draw molten aluminum metal through said oxidation reaction product towards said oxidant to permit fresh oxidation reaction product to continue to form at an interface between said oxidant and previously formed oxidation reaction product, thereby forming said polycrystalline material; (d) providing at least one external material on at least a portion of said polycrystalline material; and (e) heating said polycrystalline material to a second temperature, said second temperature being sufficient to induce at least two constituents of said polycrystalline material to react to form at least one protective surface region on at least a portion of the surface of the ceramic matrix comprising alumina to form said ceramic structure.
Claim 6
Independent Claim
282 words
A method for producing a self-supporting ceramic structure comprising (i) a ceramic matrix comprising alumina obtained by oxidation of an aluminum metal to form a polycrystalline material comprising an oxidation reaction product and at least one additional constituent, and (ii) a protective surface region on at least a portion of a surface of the ceramic matrix comprising a primary chemical constituent different from the primary chemical constituent of the ceramic matrix comprising alumina, comprising the steps of: (a) heating an aluminum metal in the presence of an oxidant comprising air to a temperature above the melting point of said aluminum metal but below the melting point of said oxidation reaction product to form a body of molten aluminum metal; (b) reacting said body of molten aluminum metal with said oxidant comprising air at said temperature to permit said oxidation reaction product to form; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten aluminum metal and said oxidant comprising air at said temperature to progressively draw molten aluminum metal through said oxidation reaction product towards said oxidant to permit fresh oxidation reaction product to continue to form at an interface between said oxidant and previously formed oxidation reaction product, thereby forming said polycrystalline material; (d) providing at least one external material on at least a portion of said polycrystalline material; and (e) heating said polycrystalline material to a second temperature, said second temperature being sufficient to induce at least two constituents of said polycrystalline material to react to form at least one protective surface region on at least a portion of the surface of the ceramic matrix comprising alumina to form said ceramic structure.
Claim 7
Dependent Claim
24 words
The method of claim 1, wherein said parent metal comprises a material selected from the group consisting of aluminum, silicon, titanium, tin and zirconium.
Claim 8
Dependent Claim
24 words
The method of claim 2, wherein said parent metal comprises a material selected from the group consisting of aluminum, silicon, titanium, tin and zirconium.
Claim 9
Dependent Claim
16 words
The method of claim 1, wherein said parent metal is provided with at least one dopant.
Claim 10
Dependent Claim
24 words
The method of claim 2, wherein at least one dopant is provided to at least one of said parent metal and said filler material.
Claim 11
Dependent Claim
38 words
The method of claim 6, wherein said at least one dopant comprises at least one material selected from the group consisting of magnesium, zinc, silicon, germanium, tin, lead, sodium, lithium, calcium, boron, phosphorous, yttrium and rare earth metals.
Claim 12
Dependent Claim
38 words
The method of claim 7, wherein said at least one dopant comprises at least one material selected from the group consisting of magnesium, zinc, silicon, germanium, tin, lead, sodium, lithium, calcium, boron, phosphorous, yttrium and rare earth metals.
Claim 13
Dependent Claim
43 words
The method of claim 6, wherein said at least one dopant is applied as a layer of dopant onto a surface of said parent metal, and including forming the oxidation reaction product through and beyond the depth of the applied layer of dopant.
Claim 14
Dependent Claim
43 words
The method of claim 7, wherein said at least one dopant is applied as a layer of dopant onto a surface of said parent metal, and including forming the oxidation reaction product through and beyond the depth of the applied layer of dopant.
Claim 15
Dependent Claim
41 words
The method of claim 1, wherein said at least one external material comprises at least one material selected from group consisting of aluminum titanate, titanium oxide, mono-aluminum phosphate, calcium silicate, alumina, silica, chromium oxide, calcium phosphate, calcium carbonate and mixtures thereof.
Claim 16
Dependent Claim
41 words
The method of claim 2, wherein said at least one external material comprises at least one material selected from group consisting of aluminum titanate, titanium oxide, mono-aluminum phosphate, calcium silicate, alumina, silica, chromium oxide, calcium phosphate, calcium carbonate and mixtures thereof.
Claim 17
Dependent Claim
41 words
The method of claim 3, wherein said at least one external material comprises at least one material selected from group consisting of aluminum titanate, titanium oxide, mono-aluminum phosphate, calcium silicate, alumina, silica, chromium oxide, calcium phosphate, calcium carbonate and mixtures thereof.
Claim 18
Dependent Claim
15 words
The method of claim 14, wherein said at least one external material comprises mono-aluminum phosphate.
Claim 19
Dependent Claim
16 words
The method of claim 14, wherein said at least one external material comprises alumina and silica.
Claim 20
Dependent Claim
17 words
The method of claim 14, wherein said at least one external material comprises aluminum titanate and titania.
Claim 21
Dependent Claim
14 words
The method of claim 14, wherein said at least one external material comprises alumina.
Claim 22
Dependent Claim
25 words
The method of claim 1, wherein said providing of said at least one external material comprises substantially completely coating said surface of said ceramic matrix.
Claim 23
Dependent Claim
25 words
The method of claim 2, wherein said providing of said at least one external material comprises substantially completely coating said surface of said ceramic matrix.
Claim 24
Dependent Claim
25 words
The method of claim 3, wherein said providing of said at least one external material comprises substantially completely coating said surface of said ceramic matrix.
Claim 25
Dependent Claim
45 words
The method of claim 2, wherein said filler material comprises at least one material selected from the group consisting of aluminum oxide, silicon carbide, silicon aluminum oxynitride, zirconium oxide, zirconium boride, titanium nitride, barium titanate, boron nitride, silicon nitride, magnesium aluminate spinel, and mixtures thereof.
Claim 26
Dependent Claim
28 words
The method of claim 2, wherein said filler material comprises silicon carbide, said parent metal comprises aluminum, and said at least one external material comprises alumina and silica.
Claim 27
Dependent Claim
29 words
The method of claim 2, wherein said filler material comprises silicon carbide, said parent metal comprises aluminum, and said at least one external material comprises aluminum titanate and titania.
Claim 28
Dependent Claim
30 words
The method of claim 2, wherein said filler material comprises silicon carbide, said parent metal comprises aluminum, and said at least one external material comprises mono-aluminum phosphate and calcium carbonate.
Claim 29
Dependent Claim
27 words
The method of claim 2, wherein said filler material comprises silicon carbide, said parent metal comprises aluminum, and said at least one external material comprises mono-aluminum phosphate.
Claim 30
Dependent Claim
55 words
The method of claim 1, wherein prior to providing said at least one external material on at least a portion of said polycrystalline material, said polycrystalline material is subjected to a treatment to remove at least portion of said at least one additional constituent, wherein said at least one additional constituent comprises a metallic constituent.
Claim 31
Dependent Claim
55 words
The method of claim 2, wherein prior to providing said at least one external material on at least a portion of said polycrystalline material, said polycrystalline material is subjected to a treatment to remove at least portion of said at least one additional constituent, wherein said at least one additional constituent comprises a metallic constituent.
Claim 32
Dependent Claim
53 words
The method of claim 3, wherein prior to providing said at least one external material on at least a portion of said polycrystalline material, said polycrystalline material is subjected to a treatment to remove at least portion of said at least one additional constituent, wherein said at least one additional constituent comprises aluminum.
Claim 33
Dependent Claim
27 words
The method of claim 27, wherein said treatment comprises at least one treatment selected from the group consisting of thermal etching, chemical etching, vacuum etching and vaporization.
Claim 34
Dependent Claim
27 words
The method of claim 28, wherein said treatment comprises at least one treatment selected from the group consisting of thermal etching, chemical etching, vacuum etching and vaporization.
Claim 35
Dependent Claim
27 words
The method of claim 29, wherein said treatment comprises at least one treatment selected from the group consisting of thermal etching, chemical etching, vacuum etching and vaporization.
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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) | 1996-06-21 | 1996-12-21 | 1997-06-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-06-21 | 2000-12-21 | 2001-06-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-06-21 | 2004-12-21 | 2005-06-22 | $7700.00 | Window Closed / Lapsed |