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

Patent metadata

Field	Value
Publication number	US-2016348262-A1
Application number	US-201615236308-A
Country	US
Kind code	A1
Filing date	Aug 12, 2016
Priority date	Apr 13, 2010
Publication date	Dec 1, 2016
Grant date	—

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 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 gradient of the second layer 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 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 gradient being a transition from at least one of: a first composition, a first microstructure, and a first density of the first layer to at least one of: a second composition, a second microstructure, and a second density of the second layer.

8 . The product as recited in claim 7 , wherein the gradient from the first layer to the second layer is abrupt.

9 . The product as recited in claim 7 , wherein the gradient from the first layer to the second layer is gradual.

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 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 ceramic as recited in claim 11 , 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.

15 . A product, comprising:
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 at least one of: a second composition, a second microstructure, and a second density, wherein a gradient in at least one of composition, microstructure, and density exists between the first layer and the second layer.

16 . The product as recited in claim 15 , wherein the gradient is a transition from at least one of: the first composition, the first microstructure, and the first density, to the at least one of: the second composition, the second microstructure, and the second density.

17 . The product as recited in claim 15 , wherein the gradient from the first layer to the second layer is abrupt.

18 . The product as recited in claim 15 , wherein the gradient from the first layer to the second layer is gradual.

19 . The product as recited in claim 15 , wherein the first layer and the second layer are each deposited above a non-planar electrode.

20 . The product as recited in claim 15 , wherein the first layer comprises a relatively harder, heavier material and the second layer comprises a relatively lighter material.

Assignees

• L Livermore Nat Security Llc

Inventors

• Rose Klint Aaron
• Kuntz Joshua D
• Worsley Marcus

Classifications

• C04B37/001

  directly with other burned ceramic articles · CPC title

• Y10T428/12458

  having composition, density, or hardness gradient · CPC title

• C04B2235/9653

  Translucent or transparent ceramics other than alumina · CPC title

• C04B2237/32

  Ceramic · CPC title

• C04B2237/402

  Aluminium · CPC title