US5874175A — Ceramic composite

Claim 1

Independent Claim 137 words

A ceramic composite structure comprising: a ceramic body and a substrate; said substrate being selected from the group consisting of a metal and a ceramic, and having a top surface including a first portion; said ceramic body including a first bottom surface overlying said first portion of the top surface of said substrate for establishing a contact area therewith; said contact area defining a first brazed bonding layer comprising a braze material between the top surface of said substrate and the first bottom surface of said ceramic body; said first brazed bonding layer including a bonding metal which forms a chemical compound of said bonding metal in said first brazed bonding layer; and said first brazed bonding layer being microscopically void-free so as to be substantially free of voids visible at a magnification of up to 1000×.

Claim 2

Dependent Claim 137 words

A ceramic composite structure comprising: a ceramic body and a substrate; said substrate being selected from the group consisting of a metal and a ceramic, and having a top surface including a first portion; said ceramic body including a first bottom surface overlying said first portion of the top surface of said substrate for establishing a contact area therewith; said contact area defining a first brazed bonding layer comprising a braze material between the top surface of said substrate and the first bottom surface of said ceramic body; said first brazed bonding layer including a bonding metal which forms a chemical compound of said bonding metal in said first brazed bonding layer; and said first brazed bonding layer being microscopically void-free so as to be substantially free of voids visible at a magnification of up to 1000×.

Claim 3

Dependent Claim 62 words

A ceramic composite structure as in claim 1 wherein said chemical compound is a metal carbide and said bonding metal is a carbide-forming metal; said bonding layer comprising a bonding material for directly bonding, without braze or any other intermediate layer, to both the first portion of the top surface of said substrate and the first bottom surface of said ceramic body.

Claim 4

Dependent Claim 18 words

A ceramic composite structure as in claim 2 wherein said carbide-forming metal consists essentially of a single metal.

Claim 5

Dependent Claim 68 words

A ceramic composite structure as in claim 3 wherein said substrate consists essentially of a single material selected from the group consisting of Mo, W, Si, Fe, Ni, SiC, and diamond; and at least a portion of said bonding layer consists essentially of an alloy of a material of said ceramic body with said single metal selected from the group consisting of Mo, W, Si, Fe, and Ni.

Claim 6

Dependent Claim 36 words

A ceramic composite structure as in claim 2 wherein said carbide-forming metal is selected from the group consisting of Au, B, Ir, La, Li, Mn, Mo, Os, Re, Rh, Ru, Si, Th, U, V, and W.

Claim 7

Dependent Claim 84 words

A ceramic composite structure as in claim 1 wherein said ceramic body and said substrate have different coefficients of thermal expansion thereby generating thermal mismatch stress at said contact area between said substrate and said ceramic body; and wherein said first bonding layer comprises a yieldable, stress-suppressing substance which divides said first bonding layer into a plurality of bonding regions to thereby minimize the transmission of said thermal mismatch stress from one of said bonding regions to at least one of its neighboring regions.

Claim 8

Dependent Claim 21 words

A ceramic composite structure as in claim 1 wherein said first bonding layer comprises said chemical compound in a resolidified form.

Claim 9

Dependent Claim 66 words

A ceramic composite structure as in claim 7 wherein said ceramic body contains microscopic surface defects in a surface region thereof; and wherein said chemical compound has a molten form, and in its molten form is microscopically wettable to said microscopic surface defects contained in said ceramic surface region; and additionally including solid strengtheners formed by resolidification of said chemical compound in said microscopic surface defects.

Claim 10

Dependent Claim 60 words

A ceramic composite structure as in claim 1 wherein: said first bonding layer comprises a braze material which alloys with said bonding metal to form said first bonding layer; said chemical compound being chemically formed and coated on a surface area of said ceramic body; and said chemical compound-coated surface area of said ceramic body is brazed onto said substrate.

Claim 11

Dependent Claim 51 words

A ceramic composite structure as in claim 1 wherein said braze material comprises a material selected from the group consisting of Ag, Al, Au, Bi, Cd, Co, Cr, Cu, Fe, Ga, In, Mg, Mn, Ni, Pb, Sb, Sn, Pt, Pd, Ti, Zn, compounds of these metals, and mixtures or combinations thereof.

Claim 12

Dependent Claim 86 words

A ceramic composite structure of claim 1 wherein: said ceramic body is selected from the group consisting of alumina, boron carbide, boron nitride, diamond, boron carbide, silicon carbide, silicon nitride, titanium boride, titanium carbide, zirconia, and zirconium carbide; said ceramic composite structure forms at least a part of a ceramic cutting or abrading tool; and said first bonding layer: (a) is capable of practical uses above 630° C.; (b) is at least 1.5 mm on a length thereof; and (c) is thermochemically stable above 630° C.

Claim 13

Dependent Claim 51 words

A ceramic composite structure as in claim 1 wherein said ceramic body is selected from the group consisting of diamond and SiC; and said ceramic composite structure is a ceramic heat sink which is capable of practical use above 630° C. and is at least 1.5 mm on a length thereof.

Claim 14

Dependent Claim 30 words

A ceramic composite structure as in claim 12 wherein said bonding metal consists essentially of a single metal selected from the group consisting of Si, Mo, W, Ni, and Fe.

Claim 15

Dependent Claim 160 words

A ceramic composite structure as in claim 12 wherein: said substrate is selected from the group consisting of Ag, AlN, Au, C, BeO, Fe, graphite, Mo, Ni, Pt, Si, SiC, Al, Co, Cr, Cu, Ir, Mn, Os, Rd, Rh, V, W, steel, diamond, alumina, boron carbide, boron nitride, silicon nitride, silicon oxide, tungsten carbide, ceramic insulators, ceramic superconductors, thermally conductive composite, and a combination thereof; said ceramic body is a first diamond body having a first side surface and a first top major surface, and the first bottom surface is a first bottom major surface of said first diamond body which is in contact with the first portion of the top surface of said substrate; said chemical compound comprises a carbide of said bonding metal; and said first bonding layer comprising a bonding material for microscopically substantially perfectly bonding the first portion of the top surface of said substrate to the first bottom major surface of said first diamond body.

Claim 16

Dependent Claim 22 words

A ceramic composite structure as in claim 14 wherein said first bonding layer has a thickness of no more than 100 Angstroms.

Claim 17

Dependent Claim 38 words

A ceramic composite structure as in claim 14 including a second bonding layer which comprises a bonding metal for microscopically substantially perfectly bonding to the first side surface of said first diamond body with no microscopic pores therein.

Claim 18

Dependent Claim 62 words

A ceramic composite structure as in claim 16 wherein said second bonding layer extends upward from the first bottom major surface of said first diamond body to at least a location substantially above the first top major surface of said first diamond body so that outward heat spreading from said first diamond body has a significant component in a sidewise, upward direction.

Claim 19

Dependent Claim 162 words

A ceramic composite structure as in claim 16 including a similar, second diamond body having a second side surface, a second top major surface, and a second bottom major surface; said second diamond body being positioned laterally next to said first diamond body with the second bottom major surface thereof in contact with a second portion of the top surface of said substrate; said first side surface of said first diamond body oppositely facing said second side surface of said second diamond body; said second bonding layer comprising a bonding material for microscopically substantially perfectly bonding together said oppositely facing side surfaces of said first and second diamond bodies to achieve efficient lateral heat spreading from one of said first and second diamond bodies to the other; and a third bonding layer comprising a bonding material for microscopically substantially perfectly bonding the second bottom major surface of said second diamond body onto the second potion of the top surface of said substrate.

Claim 20

Dependent Claim 119 words

A ceramic composite structure as in claim 18 wherein the top major surfaces of said first and second diamond bodies share a common coplanar top surface having a flatness of better than one micron for mounting thereon an electrical circuit chip; said electrical circuit chip has a bottom area which is greater than either one of the top major surfaces of said first and second diamond bodies but less than the combined areas of the two top major surfaces; and a part of said electrical circuit chip is mounted on one of said first and second diamond bodies and another part of said electrical circuit chip is mounted on the other one of said first and second diamond bodies.

Claim 21

Dependent Claim 38 words

A bonded ceramic structure as in claim 1 wherein said bonding metal comprises at least one carbide-forming metal and the specific chemical reaction is a carbide-forming reaction for producing a carbide of the metal for the bonding layer.

Claim 22

Dependent Claim 105 words

A braze-bonded ceramic composite structure comprising: a ceramic body and a substrate; said substrate having a top major surface and consisting essentially of a single pure metal; said ceramic body having a bottom surface overlying the top major surface of said substrate; a braze-bonding layer including a bonding metal which forms a chemical compound of said bonding metal in said braze-bonding layer; said braze-bonding layer being microscopically pore-free so that substantially no pores are visible in said bonding layer at magnification of up to 1000× and directly and continuously bonding the top major surface of said substrate to the bottom surface of said ceramic body.

Claim 23

Dependent Claim 105 words

A braze-bonded ceramic composite structure comprising: a ceramic body and a substrate; said substrate having a top major surface and consisting essentially of a single pure metal; said ceramic body having a bottom surface overlying the top major surface of said substrate; a braze-bonding layer including a bonding metal which forms a chemical compound of said bonding metal in said braze-bonding layer; said braze-bonding layer being microscopically pore-free so that substantially no pores are visible in said bonding layer at magnification of up to 1000× and directly and continuously bonding the top major surface of said substrate to the bottom surface of said ceramic body.

Claim 24

Dependent Claim 35 words

A ceramic composite structure as in claim 21 wherein said bonding metal consists essentially of a single pure metal selected from those metals which are capable of forming, with said ceramic body, said chemical compound.

Claim 25

Dependent Claim 23 words

A ceramic composite structure as in claim 22 wherein said bonding metal comprises a metal for forming a eutectic with said ceramic body.

Claim 26

Dependent Claim 25 words

A ceramic composite structure as in claim 22 wherein both said substrate metal and said single bonding metal consist essentially of said same single metal.

Claim 27

Dependent Claim 25 words

A ceramic composite structure as in claim 24 wherein said single metal is selected from the group consisting of Mo, Si, Fe, Ni, and W.

Claim 28

Dependent Claim 40 words

A ceramic composite structure as in claim 24 wherein said single metal comprises a metal for reacting with said ceramic body to form a eutectic of said single metal; and said bonding layer comprises said eutectic of said single metal.

Claim 29

Dependent Claim 35 words

A ceramic composite structure as in claim 21 wherein said ceramic body consists essentially of a material selected from the group consisting of diamond, carbon, graphite, silicon carbide, silicon nitride, carbon composite, and graphite composite.

Claim 30

Dependent Claim 134 words

A ceramic composite structure comprising: a ceramic body and a substrate; said substrate having a top surface which includes a portion and consisting essentially of a material selected from the group consisting of a metal and a ceramic; said ceramic body having a bottom surface overlying the portion of the top surface of the substrate for establishing a contact area therewith; said contact area defining a continuous bonding layer comprising a bonding metal between the top surface of said substrate and the bottom surface of said ceramic body; said bonding layer being substantially free of pores visible at magnification up to 1000×; said bonding layer bonding together the portion of the top surface of said substrate to the bottom surface of said ceramic body and having a thickness to an accuracy of 100 Angstroms.

Claim 31

Dependent Claim 134 words

A ceramic composite structure comprising: a ceramic body and a substrate; said substrate having a top surface which includes a portion and consisting essentially of a material selected from the group consisting of a metal and a ceramic; said ceramic body having a bottom surface overlying the portion of the top surface of the substrate for establishing a contact area therewith; said contact area defining a continuous bonding layer comprising a bonding metal between the top surface of said substrate and the bottom surface of said ceramic body; said bonding layer being substantially free of pores visible at magnification up to 1000×; said bonding layer bonding together the portion of the top surface of said substrate to the bottom surface of said ceramic body and having a thickness to an accuracy of 100 Angstroms.

Claim 32

Dependent Claim 25 words

A ceramic composite structure as in claim 28 wherein said bonding layer has a maximum thickness of 1000 Å to an accuracy of 10 Angstroms.

Claim 33

Dependent Claim 41 words

A ceramic composite structure as in claim 28 wherein: said ceramic body is a diamond or silicon carbide body; and said bonding layer consists essentially of a single metal selected from the group consisting of Fe, Si, Ni, Mo, and W.

Claim 34

Dependent Claim 22 words

A ceramic composite structure as in claim 28 wherein both said substrate and said bonding layer consist essentially of a single metal.

Claim 35

Dependent Claim 57 words

A ceramic composite structure as in claim 28 wherein said ceramic body is a diamond or silicon carbide body; said substrate is selected from the group consisting of Fe, Ni, Mo, Si, W, diamond, silicon carbide, and ceramic superconductor; and said bonding layer is less than 1000 Angstroms thick and controlled in thickness to within 10 Angstroms.

Claim 36

Dependent Claim 68 words

A ceramic composite structure as in claim 28 wherein said substrate is selected from the group consisting of Cu, Ag, Fe, Si, W, Mo, Au, Pt, Ni, Si 3 N 4 , SiC, AlN, graphite, C, diamond, BeO, Al, Co Cr Ir, Mn, Os, Rd, Rh, V steel, alumina, boron carbide, boron nitride, silicon oxide, tungsten carbide, ceramic insulators, ceramic superconductors, thermally conductive composite, and a combination thereof.

Claim 37

Dependent Claim 112 words

A diamond composite structure comprising: a plurality of diamond bodies chemically bonded into a laterally extending diamond layer of at least 1.5 mm on a length thereof; each of said diamond bodies having side surfaces, and neighboring diamond bodies having their side surfaces opposite to and intimately contacting each other at a respective contact area; a first continuous and void-free bonding layer comprising a first bonding composition and produced by a first chemical reaction of said first bonding matter with said diamond bodies; said first bonding layer bonding said diamond bodies together over the respective entire contact area directly, continuously and substantially free of voids visible at magnification of up to 1000×.

Claim 38

Dependent Claim 112 words

A diamond composite structure comprising: a plurality of diamond bodies chemically bonded into a laterally extending diamond layer of at least 1.5 mm on a length thereof; each of said diamond bodies having side surfaces, and neighboring diamond bodies having their side surfaces opposite to and intimately contacting each other at a respective contact area; a first continuous and void-free bonding layer comprising a first bonding composition and produced by a first chemical reaction of said first bonding matter with said diamond bodies; said first bonding layer bonding said diamond bodies together over the respective entire contact area directly, continuously and substantially free of voids visible at magnification of up to 1000×.

Claim 39

Dependent Claim 27 words

A diamond composite structure as in claim 34 wherein said bonded diamond bodies share a common coplanar top surface having a flatness of better than one micron.

Claim 40

Dependent Claim 96 words

A ceramic composite structure as in claim 35 wherein said bonded diamond bodies also share a common coplanar bottom surface having a flatness also of better than one micron; including a substrate having a top surface in contact with said common coplanar bottom surface of said chemically bonded diamond bodies; and a second bonding layer comprising a second bonding composition and positioned between the top surface of said substrate and the common coplanar bottom surface of said chemically bonded diamond bodies for directly bonding, microscopically substantially perfectly and without pores, said substrate to said diamond bodies.

Claim 41

Dependent Claim 22 words

A ceramic composite structure as in claim 34 wherein said first bonding layer has a thickness to an accuracy of 100 Angstroms.

Claim 42

Dependent Claim 17 words

A diamond composite structure as in claim 34 wherein said chemically bonded diamond layer is 100% dense.

Claim 43

Dependent Claim 40 words

A ceramic composite structure as in claim 34 including a substrate selected from the group consisting of W, Mo, Fe, Ni, Si, and diamond; said diamond layer being a diamond monolayer which is microscopically substantially perfectly bonded onto said substrate.

Claim 44

Dependent Claim 61 words

A ceramic composite structure as in claim 34 including a substrate selected from the group consisting of carbon, graphite, diamond, SiC, silicon nitride, Cu, Ag, Fe, Si, W, Mo, Au, Pt, Ni, AlN, superconductor, Cu, BeO, Fe, Mo, Ni, Pt, steel, diamond, alumina, boron carbide, boron nitride, silicon oxide, tungsten carbide, insulators, ceramic superconductors, thermally conductive composite, and a combination thereof.

Claim 45

Dependent Claim 70 words

A ceramic composite structure comprising: a substrate; a ceramic body having a bottom surface overlying said substrate; and a bonding composition chemically bonding said bottom surface of said ceramic body onto said substrate; said bonding composition being substantially free of pores visible at magnification up to 1000× and being interposed between said ceramic body and said substrate for defining an interfacial bonding layer having a maximum thickness of 3.5 mm.

Claim 46

Dependent Claim 70 words

A ceramic composite structure comprising: a substrate; a ceramic body having a bottom surface overlying said substrate; and a bonding composition chemically bonding said bottom surface of said ceramic body onto said substrate; said bonding composition being substantially free of pores visible at magnification up to 1000× and being interposed between said ceramic body and said substrate for defining an interfacial bonding layer having a maximum thickness of 3.5 mm.

Claim 47

Dependent Claim 68 words

A ceramic composite structure as in claim 41 for practical operation above 630° C. and additionally comprising: a plurality of microscopic reinforcing elements dispersed in a matrix of said ceramic body; said reinforcing elements being selected from the group consisting of reinforcing particulates, reinforcing fibers, reinforcing sheets, and a mixture thereof; and metallized layer microscopically substantially perfectly braze-bonding surface of each of said reinforcing elements to said matrix.

Claim 48

Dependent Claim 51 words

A ceramic composite structure as in claim 41 wherein said substrate and said ceramic body are mismatched in coefficients of thermal expansion; and said bonding layer is laterally graded in at least one thermomechanical property selected from the group consisting of thermal conductivity, thermal expansion coefficient, and softness or shock-absorbing ability.

Claim 49

Dependent Claim 61 words

A ceramic composite structure as in claim 41 wherein said substrate and said ceramic body are mismatched in coefficients of thermal expansion; and said bonding layer is laterally monotonically graded from a central portion thereof to a periphery thereof in at least one select thermomechanical property from the group consisting of thermal conductivity, thermal expansion coefficient, and softness or shock-absorbing ability.

Claim 50

Dependent Claim 61 words

A ceramic composite structure as in claim 41 wherein said substrate and said ceramic body are mismatched in coefficients of thermal expansion; across a thickness thereof and for a chemical element, said bonding layer has a concentration gradient of said select chemical element; said concentration gradient being of a type selected from the group consisting of erfc type and exponential types.

Claim 51

Dependent Claim 90 words

A ceramic composite structure as in claim 41 wherein said substrate and said ceramic body are mismatched in coefficients of thermal expansion thereby generating thermal mismatch stress in an interfacial bonding region between said substrate and said ceramic body; and a metallized layer located at least in a surface region of said ceramic body near said interfacial bonding region to divide a surface region of said ceramic body near said interfacial bonding region into a plurality of smaller surface regions thereby reducing said thermal mismatch stress in said ceramic body.

Claim 52

Dependent Claim 115 words

A ceramic composite structure as in claim 41 wherein said substrate and said ceramic body are mismatched in coefficients of thermal expansion thereby generating thermal mismatch stress in an interfacial bonding region between said substrate and said ceramic body; a surface region of said ceramic body adjacent to said bonding layer consisting of a plurality of laterally spaced-apart surface subregions of a first material; neighboring spaced-apart subregions being laterally separated from each other by a second, physically yieldable material; all said spaced-apart subregions having sizes which are sufficiently small so that said thermal mismatch stress in each spaced-apart subregion is sufficiently small to prevent failure of said ceramic body due to said thermal mismatch stresses.

Claim 53

Dependent Claim 43 words

A ceramic composite structure as in claim 41 including a plurality of elongated reinforcing elements dispersed in said ceramic body near said interfacial bonding layer; said elongated reinforcing elements being at least locally oriented at approximately 45° relative to said interfacial bonding layer.

Claim 54

Dependent Claim 42 words

A ceramic composite structure as in claim 41 wherein said ceramic body has pores in the surface regions thereof; and said bonding layer completely fills, without microscopic voids, a plurality of said pores thereby forming effective reinforcing elements in said ceramic body.

Claim 55

Dependent Claim 19 words

A ceramic composite structure as in claim 41 and characterized by its ability for practical operation above 1,550° C.

Claim 56

Dependent Claim 25 words

A ceramic composite structure as in claim 41 wherein said bonding layer is a braze-bonding layer having a thickness to an accuracy of 100 Angstroms.

Claim 57

Dependent Claim 54 words

A ceramic composite structure as in claim 41 wherein said ceramic body consists essentially of the chemical element carbon; said substrate consists essentially of a single metal selected from the group consisting of Mo, W, Si, Fe, and Ni; and said bonding layer consists essentially of an alloy of carbon with said single metal.

Claim 58

Dependent Claim 42 words

A ceramic composite structure as in claim 41 wherein said ceramic is porous with controlled pores and density; inner surfaces of a plurality of said pores being uniformly covered with a metallized layer which is capable of practical use at 630° C.

Claim 59

Dependent Claim 55 words

A ceramic composite structure as in claim 41 wherein said substrate is an elongated body terminating at one end thereof in the form of a single pointed end; said bonding layer braze-bonding said ceramic body onto said single pointed end so that practically all surface area of said ceramic body is exposed to the ambient.

Claim 60

Dependent Claim 35 words

A ceramic composite structure as in claim 41 wherein said ceramic body consists essentially of a ceramic superconductor; and said bonding layer has a maximum thickness of 1 mil to an accuracy of 100 Angstroms.

Claim 61

Dependent Claim 37 words

A ceramic composite structure as in claim 55 wherein said ceramic superconductor consists essentially of a material selected from the group consisting of copper oxide, barium oxide, yttrium oxide, calcium oxide, tellurium oxide, and a mixture thereof.

Claim 62

Dependent Claim 34 words

A ceramic composite structure as in claim 55 wherein said ceramic superconductor is a polycrystalline material having a columnar microstructure with elongated grains; boundaries of said elongated grains being oriented in a common direction.

Claim 63

Dependent Claim 91 words

A ceramic composite structure for practical operation above 630° C. comprising: a substrate; a ceramic body having a bottom surface overlying a portion of a top surface of said substrate for establishing a contact area therewith; and a bonding composition bonding said ceramic body onto said substrate at said portion; said bonding composition being interposed, continuously and substantially free of pores visible at magnification up to 1000× between said ceramic body and said substrate for defining a continuous interfacial bonding layer; said bonding layer having a maximum thickness of 1 micron.

Claim 64

Dependent Claim 91 words

A ceramic composite structure for practical operation above 630° C. comprising: a substrate; a ceramic body having a bottom surface overlying a portion of a top surface of said substrate for establishing a contact area therewith; and a bonding composition bonding said ceramic body onto said substrate at said portion; said bonding composition being interposed, continuously and substantially free of pores visible at magnification up to 1000× between said ceramic body and said substrate for defining a continuous interfacial bonding layer; said bonding layer having a maximum thickness of 1 micron.

Claim 65

Dependent Claim 32 words

A ceramic composite structure as in claim 58 wherein said bonding layer has a thickness which is controlled to an accuracy selected from the group consisting of 100 Angstroms and 10 Angstroms.

Claim 66

Dependent Claim 115 words

A chemically bonded ceramic composite structure comprising: a first solid body of a first solid material consisting essentially of a first ceramic material and having a first surface; a second solid body of a second solid material having a second surface contacting the first surface of said first solid body to define a contact area; and a chemically bonding layer at said contact area to directly bond the first surface of said first solid body to the second surface of the second solid body; said bonding layer being sufficiently free of bonding defects to retain bond integrity after at least one thermal shock by quenching in water from a temperature of at least 630° C.

Claim 67

Dependent Claim 115 words

A chemically bonded ceramic composite structure comprising: a first solid body of a first solid material consisting essentially of a first ceramic material and having a first surface; a second solid body of a second solid material having a second surface contacting the first surface of said first solid body to define a contact area; and a chemically bonding layer at said contact area to directly bond the first surface of said first solid body to the second surface of the second solid body; said bonding layer being sufficiently free of bonding defects to retain bond integrity after at least one thermal shock by quenching in water from a temperature of at least 630° C.

Claim 68

Dependent Claim 54 words

A chemically bonded ceramic composite as in claim 60 wherein said first and second solid bodies are elongated and have approximately equal lengths, said first and second surfaces being respective longitudinal surfaces of said solid bodies and extending over respective at least major portions of the approximately equal lengths of said two solid bodies.

Claim 69

Dependent Claim 32 words

A chemically bonded ceramic composite as in claim 61 wherein said bonding layer is no more than 3.5 mm in thickness which is controlled to an accuracy of better than one micron.

Claim 70

Dependent Claim 27 words

A chemically bonded ceramic composite as in claim 62 wherein said elongated ceramic grains are columnar ceramic grains and are at least locally parallel to one another.

Claim 71

Dependent Claim 36 words

A chemically bonded ceramic composite as in claim 63 wherein said elongated columnar ceramic grains are oriented normally of the top surface of said substrate, to thereby form oriented columnar ceramic grains in the ceramic layer.

Claim 72

Dependent Claim 25 words

A chemically bonded ceramic composite in claim 64 wherein said columnar ceramic grains are uniform in size and are less than one micron in length.

Claim 73

Dependent Claim 35 words

A chemically bonded ceramic composite as in claim 60 wherein said bonding layer is 100% dense and said ceramic first body is selected from the group consisting of a ceramic superconductor, diamond, and silicon carbide.

Claim 74

Dependent Claim 177 words

A heat-resistant ceramic bonded article of manufacture for practical use above 630° C., comprising: a first solid material having a first exposed surface thereon; a second solid material having a second exposed surface thereon; at least one of said first and second solid materials consisting essentially of a ceramic; said article having components including said first and second solid materials and all said components being independently operable for said practical use; said first exposed surface on said first solid material being sufficiently adjacent to at least a portion of said second exposed surface on said second solid material to thereby form therebetween a contact interface having a dimension of at least 1.5 mm; and a ceramic bonding layer positioned at said contact interface for chemically and physically bonding together said first and second solid materials; and said ceramic bonding layer being no more than 3.5 mm thick and microscopically sufficiently free of voids visible at a magnification of 1,000 times to withstand said practical use without failure, whereby said article is made heat-resistant for said practical use.

Claim 75

Dependent Claim 177 words

A heat-resistant ceramic bonded article of manufacture for practical use above 630° C., comprising: a first solid material having a first exposed surface thereon; a second solid material having a second exposed surface thereon; at least one of said first and second solid materials consisting essentially of a ceramic; said article having components including said first and second solid materials and all said components being independently operable for said practical use; said first exposed surface on said first solid material being sufficiently adjacent to at least a portion of said second exposed surface on said second solid material to thereby form therebetween a contact interface having a dimension of at least 1.5 mm; and a ceramic bonding layer positioned at said contact interface for chemically and physically bonding together said first and second solid materials; and said ceramic bonding layer being no more than 3.5 mm thick and microscopically sufficiently free of voids visible at a magnification of 1,000 times to withstand said practical use without failure, whereby said article is made heat-resistant for said practical use.

Claim 76

Dependent Claim 65 words

The heat-resistant article of manufacture of claim 67 in which said first solid material forms a first part of said article, and said second solid material forms a second part of said article; and wherein said ceramic bonding layer comprises a solid material which seals surface defects on said solid ceramic material at said contact interface to thereby strengthen and toughen said solid ceramic material.

Claim 77

Dependent Claim 111 words

The heat-resistant article of manufacture of claim 67, selected from the group consisting of machine tools, heat-sink microelectronics, automobiles and electronic equipment and appliances; and further comprising another solid material for dividing said ceramic bonding layer into a plurality of laterally separated smaller regions for reducing thermal mismatch stresses due to the smaller dimensions of said laterally separated smaller regions of said ceramic bonding layer; said another solid material containing a yieldable metallic material for adsorbing therein at least a significant portion of the already reduced thermal mismatch stresses whereby cracks in the ceramic solid material are prevented allowing the use of a larger ceramic bonding layer on a larger article.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2002-02-22	2002-08-24	2003-02-23	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2006-02-22	2006-08-24	2007-02-23	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2010-02-22	2010-08-24	2011-02-23	$7700.00	Window Closed / Lapsed

Ceramic composite

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