Stabilization of green bodies via sacrificial gelling agent during electrophoretic deposition

Patent metadata

Field	Value
Publication number	US-9290855-B2
Application number	US-201213453933-A
Country	US
Kind code	B2
Filing date	Apr 23, 2012
Priority date	Apr 22, 2011
Publication date	Mar 22, 2016
Grant date	Mar 22, 2016

Abstract

In one embodiment, a method for electrophoretic deposition of a three-dimensionally patterned green body includes suspending a first material in a gelling agent above a patterned electrode of an electrophoretic deposition (EPD) chamber, and gelling the suspension while applying a first electric field to the suspension to cause desired patterning of the first material in a resulting gelation. In another embodiment, a ceramic, metal, or cermet includes a plurality of layers, wherein each layer includes a gradient in composition, microstructure, and/or density in an x-y plane oriented parallel to a plane of deposition of the plurality of layers along a predetermined distance in a z-direction perpendicular to the plane of deposition.

First claim

What is claimed is:

1. A product, comprising:
a plurality of layers, each of the plurality of layers comprising non-spherical particles,
wherein each layer comprises a gradient in composition, microstructure, and/or density of the non-spherical particles in an x-y plane oriented parallel to a plane of deposition of the plurality of layers along a predetermined distance in a z-direction perpendicular to the plane of deposition,
wherein each of the non-spherical particles has a longitudinal axis, the longitudinal axes of the non-spherical particles being oriented in a single common direction.

2. The product as recited in claim 1 , wherein the gradient in at least one of the layers is defined by a first plurality of non-spherical particles being arranged in a first pattern and a second material plurality of non-spherical particles being arranged in a second pattern, wherein the first pattern is complementary to the second pattern.

3. The product as recited in claim 2 , wherein the first-plurality of non-spherical particles and the second plurality of non-spherical particles have a characteristic of being deposited through an electrophoretic deposition (EPD) process utilizing at least one patterned electrode, the patterned electrode being configured to facilitate deposition of the first plurality of non-spherical particles according to the first pattern and the second plurality of non-spherical particles according to the second pattern.

4. The product as recited in claim 2 , wherein at least one other layer comprises a gradient defined by a third plurality of non-spherical particles being arranged in a third pattern and a fourth plurality of non-spherical particles being arranged in a fourth pattern, wherein the third pattern is complementary to the fourth pattern, wherein the first pattern is different from the third pattern.

5. The product as recited in claim 2 , wherein the first plurality of non-spherical particles is comprised of a first non-cubic crystalline material, and the second plurality of non-spherical particles is comprised of a second non-cubic crystalline material, the first non-cubic crystalline material being different than the second non-cubic crystalline material.

6. The product as recited in claim 1 , wherein the non-spherical particles each have a longitudinal length that is at least three times longer than a width thereof.

7. A high-powered laser comprising the product as recited in claim 1 as a ceramic optic in the laser.

8. The product as recited in claim 1 , wherein the product is transparent.

9. The product as recited in claim 1 , wherein the non-spherical particles comprise fluorapatite.

10. The product as recited in claim 1 , wherein the fluorapatite particles each have a diameter of about 100 nm and a length of about 500 nm.

Assignees

• Worsley Marcus A
• Kuntz Joshua D
• Rose Klint A
• L Livermore Nat Security Llc

Inventors

• Worsley Marcus A
• Kuntz Joshua D
• Rose Klint A

Classifications

• C25D13/02 Primary

  with inorganic material · CPC title

• Y10T428/24926

  including ceramic, glass, porcelain or quartz layer · CPC title

• C25D5/10

  Electroplating with more than one layer of the same or of different metals (for bearings C25D7/10) · CPC title

• H01S3/0612

  Non-homogeneous structure (H01S3/07 takes precedence) · CPC title

• Y10T428/12021

  having composition or density gradient or differential porosity · CPC title