Method of producing a ceramic article, intermediate article and composition therefor

Patent metadata

Field	Value
Publication number	US-2016229754-A1
Application number	US-201415022588-A
Country	US
Kind code	A1
Filing date	Sep 5, 2014
Priority date	Sep 19, 2013
Publication date	Aug 11, 2016
Grant date	—

Abstract

A method of producing a ceramic material includes heating solid silicon monoxide to provide gaseous silicon monoxide, and exposing a structure having a free-carbon-containing material to the gaseous silicon monoxide to convert free carbon of the free-carbon-containing material to silicon carbide. Also disclosed is an intermediate article that includes a solid structure having free carbon and a solid, in-situ source of silicon monoxide gas. Also disclosed is a composition that includes a polymeric carrier phase and particulate of solid silicon monoxide dispersed in the polymeric carrier phase.

First claim

What is claimed is:

1 . A method of producing a ceramic article, the method comprising:
heating solid silicon monoxide to provide gaseous silicon monoxide; and exposing a structure having a free-carbon-containing material to the gaseous silicon monoxide to convert free carbon of the free-carbon-containing material to silicon carbide.

2 . The method as recited in claim 1 , further comprising providing the solid silicon monoxide as a particulate dispersed in a coating on at least a portion of the structure.

3 . The method as recited in claim 2 , wherein the coating includes a polymeric carrier phase and the particulate of the solid silicon monoxide is dispersed in the polymeric carrier phase.

4 . The method as recited in claim 3 , wherein the exposing includes heating the coated structure to convert the particulate of the solid silicon monoxide in the polymeric carrier phase to the gaseous silicon monoxide.

5 . The method as recited in claim 3 , wherein the particulate of the solid silicon monoxide is provided in an amount that is stoichiometrically equal to or greater than the amount of free carbon.

6 . The method as recited in claim 3 , wherein the polymeric carrier phase is a preceramic polymer, and further including converting the preceramic polymer phase to a ceramic material.

7 . The method as recited in claim 1 , wherein the free carbon is residual free carbon from a prior thermal process used to form the structure.

8 . The method as recited in claim 1 , wherein the free carbon is in a coating on the structure.

9 . The method as recited in claim 1 , wherein the structure is an elongated, uniform diameter fiber.

10 . The method as recited in claim 1 , wherein the structure is a porous body.

11 . An intermediate article comprising:
a solid structure having free carbon and a solid, in-situ source of silicon monoxide gas.

12 . The intermediate article as recited in claim 11 , wherein the solid structure is selected from the group consisting of an elongated, uniform diameter fiber and a porous body.

13 . The intermediate article as recited in claim 11 , wherein the solid, in-situ source of silicon monoxide gas is a particulate that is dispersed in a polymeric carrier phase.

14 . The intermediate article as recited in claim 13 , wherein the polymeric carrier phase is a preceramic polymer.

15 . The intermediate article as recited in claim 11 , wherein the free carbon is in a coating of the solid structure.

16 . A composition comprising:
a polymeric carrier phase; and particulate of solid silicon monoxide dispersed in the polymeric carrier phase.

17 . The composition as recited in claim 16 , wherein the polymeric carrier phase is a preceramic polymer.

Assignees

• United Technologies Corp

Inventors

• Sheedy Paul
• Schmidt Wayde R
• Kashyap Tania Bhatia
• Beals James T
• Magdefrau Neal

Classifications

• C04B38/0022

  obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors · CPC title

• C04B35/62884 Primary

  by gas phase techniques · CPC title

• C04B2235/48

  Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins · CPC title

• C04B2235/6587

  Influencing the atmosphere by vaporising a solid material, e.g. by using a burying of sacrificial powder · CPC title

• C04B2235/5244

  Silicon carbide · CPC title