Fabricating ceramic structures

Patent metadata

Field	Value
Publication number	US-12128621-B2
Application number	US-202318460917-A
Country	US
Kind code	B2
Filing date	Sep 5, 2023
Priority date	Apr 23, 2020
Publication date	Oct 29, 2024
Grant date	Oct 29, 2024

Abstract

A fabrication apparatus for fabricating ceramic structures of controlled size and composition is provided. The fabrication apparatus includes an additive manufacturing machine configured to dispense preceramic materials in a printed pattern, the printed pattern corresponding to the ceramic structures of the controlled size and composition, a radiation emitter configured to emit curing radiation toward the printed pattern to cure the preceramic materials and a lamp element configured to shine light on the preceramic materials to convert the preceramic materials to ceramics.

First claim

What is claimed is:

1. A fabrication apparatus for fabricating ceramic structures of controlled size and composition, the fabrication apparatus comprising:
an additive manufacturing machine configured to dispense preceramic materials in a printed pattern by electrohydrodynamic (EHD) deposition such that, the printed pattern corresponds to the ceramic structures of the controlled size and composition;
a radiation emitter configured to emit curing radiation toward the printed pattern to cure the preceramic materials; and
a lamp element configured to shine light on the preceramic materials to convert the preceramic materials to ceramics.

2. The fabrication apparatus according to claim 1 , wherein the printed pattern corresponding to the ceramic structures of the controlled size and composition has features with sizes of about 10 microns or less.

3. The fabrication apparatus according to claim 1 , wherein the printed pattern is dispensed on a substrate and the substrate comprises at least one or more of metallic materials, polymeric materials, carbon-based materials, composite materials, ceramic materials, glass materials, and glass/ceramic materials.

4. The fabrication apparatus according to claim 1 , wherein the additive manufacturing machine comprises a heating element to heat the preceramic materials and a stage heater to heat a substrate on which the printed pattern is dispensed.

5. The fabrication apparatus according to claim 1 , wherein the preceramic materials comprise resins with or without fillers, the resins comprising at least one or more of polysilanes, polysiloxanes, polycarbosilanes, polysilazanes, polycarbosiloxanes, polycarbosilazanes, polyborosiloxanes, and metal-modified derivatives of the at least one or more of the polysilanes, the polysiloxanes, the polycarbosilanes, the polysilazanes, the polycarbosiloxanes, the polycarbosilazanes, and the polyborosiloxanes, and the fillers comprise at least one or more of carbides, nitrides, borides, phosphides, carbonitrides, oxides, glasses, glass-ceramics, or metals, wherein the metals comprise one or more of aluminum, copper, silicon, titanium, vanadium, chromium, iron, cobalt, nickel, zinc, hafnium, zirconium, yttrium, lanthanum, ytterbium, gadolinium, niobium, tantalum, boron, tungsten, rhenium, molybdenum, gold, silver, platinum, and palladium.

6. The fabrication apparatus according to claim 1 , wherein the lamp element comprises a xenon flash lamp operable to generate intense pulsed light (IPL) to convert the preceramic materials to ceramics in about 1 second or less.

7. A fabrication apparatus for fabricating ceramic structures of controlled size and composition, the fabrication apparatus comprising:
an additive manufacturing machine configured to execute electrohydrodynamic (EHD) deposition to dispense preceramic materials in a printed pattern, the printed pattern corresponding to the ceramic structures of the controlled size and composition;
a radiation emitter configured to emit curing radiation toward the printed pattern to cure the preceramic materials; and
a lamp element configured to shine light on the preceramic materials to convert the preceramic materials to ceramics in about 1 second or less by intense pulsed light (IPL) processing.

8. The fabrication apparatus according to claim 7 , wherein the printed pattern corresponding to the ceramic structures of the controlled size and composition has features with sizes of about 10 microns or less.

9. The fabrication apparatus according to claim 7 , wherein the printed pattern is dispensed on a substrate and the substrate comprises at least one or more of metallic materials, polymeric materials, carbon-based materials, composite materials, ceramic materials, glass materials, and glass/ceramic materials.

10. The fabrication apparatus according to claim 7 , wherein the additive manufacturing machine comprises a heating element to heat the preceramic materials and a stage heater to heat a substrate on which the printed pattern is dispensed.

11. The fabrication apparatus according to claim 7 , wherein the preceramic materials comprise resins with or without fillers, the resins comprising at least one or more of polysilanes, polysiloxanes, polycarbosilanes, polysilazanes, polycarbosiloxanes, polycarbosilazanes, polyborosiloxanes, and metal-modified derivatives of the at least one or more of the polysilanes, the polysiloxanes, the polycarbosilanes, the polysilazanes, the polycarbosiloxanes, the polycarbosilazanes, and the polyborosiloxanes, and the fillers comprise at least one or more of carbides, nitrides, borides, phosphides, carbonitrides, oxides, glasses, glass-ceramics, or metals, wherein the metals comprise one or more of aluminum, copper, silicon, titanium, vanadium, chromium, iron, cobalt, nickel, zinc, hafnium, zirconium, yttrium, lanthanum, ytterbium, gadolinium, niobium, tantalum, boron, tungsten, rhenium, molybdenum, gold, silver, platinum, and palladium.

12. The fabrication apparatus according to claim 7 , wherein the lamp element comprises a xenon flash lamp operable to generate IPL to convert the preceramic materials to the ceramics in about 1 second or less.

13. A fabrication apparatus for fabricating ceramic structures of controlled size and composition, the fabrication apparatus comprising:
an additive manufacturing machine configured to execute electrohydrodynamic (EHD) deposition to dispense preceramic materials in a printed pattern, the printed pattern corresponding to the ceramic structures of the controlled size and composition;
a radiation emitter configured to emit curing radiation toward the printed pattern to cure the preceramic materials; and
a lamp element configured to shine light on the preceramic materials to convert the preceramic materials to ceramics.

14. The fabrication apparatus according to claim 13 , wherein the printed pattern corresponding to the ceramic structures of the controlled size and composition has features with sizes of about 100 microns or less.

15. The fabrication apparatus according to claim 13 , wherein the printed pattern corresponding to the ceramic structures of the controlled size and composition has features with sizes of about 10 microns or less.

16. The fabrication apparatus according to claim 13 , wherein the printed pattern is dispensed on a substrate and the substrate comprises at least one or more of metallic materials, polymeric materials, carbon-based materials, composite materials, ceramic materials, glass materials, and glass/ceramic materials.

17. The fabrication apparatus according to claim 13 , wherein the additive manufacturing machine comprises a heating element to heat the preceramic materials and a stage heater to heat a substrate on which the printed pattern is dispensed.

18. The fabrication apparatus according to claim 13 , wherein the preceramic materials comprise resins with or without fillers, the resins comprising at least one or more of polysilanes, polysiloxanes, polycarbosilanes, polysilazanes, polycarbosiloxanes, polycarbosilazanes, polyborosiloxanes, and metal-modified derivatives of the at least one or more of the polysilanes, the polysiloxanes, the polycarbosilanes, the polysilazanes, the polycarbosiloxanes, the polycarbosilazanes, and the polyborosiloxanes, and the fillers comprise at least one or more of carbides, nitrides, borides, phosphides, carbonitrides, oxides, glasses, glass-ceramics, or metals, wherein the metals comprise one or more of aluminum, copper, silicon, titanium, vanadium, chromium, iron, cobalt, nickel, zinc, hafnium, zirconium, yttrium, lanthanum

Assignees

• Rtx Corp

Inventors

• Schmidt Wayde R
• Sheedy Paul
• Sharon John A
• Magdefrau Neal

Classifications

• C04B2235/667

  Sintering using wave energy, e.g. microwave sintering · CPC title

• C04B2235/6026

  Computer aided shaping, e.g. rapid prototyping · CPC title

• C04B41/81

  Coating or impregnation · CPC title

• C04B41/009

  characterised by the material treated · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title