Methods of three-dimensional electrophoretic deposition for ceramic and cermet applications and systems thereof

Patent metadata

Field	Value
Publication number	US-10533261-B2
Application number	US-201615236308-A
Country	US
Kind code	B2
Filing date	Aug 12, 2016
Priority date	Apr 13, 2010
Publication date	Jan 14, 2020
Grant date	Jan 14, 2020

Abstract

A product according to one embodiment includes a first layer comprising a first material, the first layer having a gradient in composition, microstructure and/or density in an x-y plane, and the x-y plane being oriented parallel to a plane of deposition of the first layer. The first material includes non-spherical particles; and the product is optically transparent. A ceramic according to another embodiment includes a plurality of layers comprising non-spherical particles of a non-cubic material. Each layer is individually characterized by the non-spherical particles thereof being aligned in a common direction. A product in another embodiment includes a first layer having a first composition, a first microstructure, and a first density; and a second layer above the first layer, the second layer having: a second composition, a second microstructure, and/or a second density. A gradient in composition, microstructure, and/or density exists between the first layer and the second layer.

First claim

What is claimed is:

1. A product, comprising:
a first layer comprising a first material, the first layer having a gradient in composition, microstructure and/or density in an x-y plane, and the x-y plane being oriented parallel to a plane of deposition of the first layer;
wherein the first material includes non-spherical particles; and
wherein the product is optically transparent.

2. The product as recited in claim 1 , wherein the first layer comprises the first material arranged in a first pattern.

3. The product as recited in claim 1 , wherein the first material is deposited above a non-planar electrode.

4. The product as recited in claim 1 , further comprising a second layer above the first layer, wherein the second layer has a second gradient in composition, microstructure and/or density in the x-y plane.

5. The product as recited in claim 4 , wherein the second layer comprises a second material and/or the first material arranged in a second pattern.

6. The product as recited in claim 4 , wherein the second gradient is defined by the first material being arranged in a third pattern within the second layer, and a second material being arranged in a fourth pattern within the second layer;
wherein the third pattern is complementary to the fourth pattern;
wherein the first material is arranged in a first pattern in the first layer; and
wherein the first pattern is different from the third pattern.

7. The product as recited in claim 4 , wherein a third gradient exists between the first layer and the second layer in a z-direction perpendicular to the x-y plane of the first layer, the third gradient being from: a first composition, a first microstructure, and/or a first density of the first layer to: a second composition, a second microstructure, and/or a second density of the second layer.

8. The product as recited in claim 7 , wherein the third gradient is defined by a series of discrete, incremental steps.

9. The product as recited in claim 7 , wherein the third gradient is defined by a smooth transition from the first composition, the first microstructure, and/or the first density of the first layer to the second composition, the second microstructure, and/or the second density of the second layer.

10. The product as recited in claim 7 , wherein at least one of the following provisos is satisfied:
the first composition and the second composition are different;
the first microstructure and the second microstructure are different; and
the first density and the second density are different.

11. A ceramic, comprising:
a plurality of layers comprising non-spherical particles of a non-cubic material,
wherein the non-spherical particles are characterized by a longitudinal length that is at least three times longer than a width of the non-spherical particles, and
wherein each layer is individually characterized by the non-spherical particles thereof being aligned in a common direction.

12. The ceramic as recited in claim 11 , wherein the plurality of layers are deposited above a non-planar electrode.

13. The ceramic as recited in claim 11 , wherein the ceramic is transparent.

14. The product as recited in claim 1 , further comprising a second layer above the first layer, wherein the product is functionally graded in three dimensions.

Assignees

• L Livermore Nat Security Llc

Inventors

• Rose Klint Aaron
• Kuntz Joshua D
• Worsley Marcus

Classifications

• C04B2237/32

  Ceramic · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C04B37/025

  consisting of glass or ceramic material · CPC title

• B32B15/00

  Layered products comprising {a layer of} metal · CPC title

• C04B2237/402

  Aluminium · CPC title