EP0121797A2
Expired / Lapsed
EP
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Carbon composite article and method of making same
Assignee: Refractory Composites Inc
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Filing: 1984-03-09
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Granted: —
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Expires: 2004-03-09
Abstract
Abstract A composite structural ceramic article and method of fabrication thereof. The article of the invention is specifically designed for use in high temperature, corrosive and erosive environments such as those found in heat engines, heat exchangers, stationary power equipments and industrial process equipments. The article comprises a porous carbon fibrous substrate or other suitable high temperature fibrous substrate which may include: a pyrolytic carbon or appropriate chemically vapor deposited sheath formed about each fiber of the substrate; a chemically vapor deposited metallic carbide, oxide, boride or nitride coating over the coated fibers of the substrate; and an impermeable metallic carbide, oxide, boride or nitride outer protective layer formed about the entire periphery of the coated substrate. In accordance with the method of the invention, the metallic coating is applied to the fibers in such a manner such that internal porosity of the article is precisely controlled and a flaw resistant, though, non-catastrophic failing structural ceramic body is formed.
Inventors
- 👤 James W. Warren
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-23 08:03
CPC Classifications
F; F16; F16D; F16D69/00; F16D69/02; F16D69/023; C; C04; C04B; C04B35/00; C04B35/01; C04B35/14; C04B35/515; C04B35/56; C04B35/565; C04B35/571; C04B35/573; C04B35/58; C04B35/5805; C04B35/58064; C04B35/58071; C04B35/584; C04B35/589; C04B35/622; C04B35/626; C04B35/628; C04B35/62844; C04B35/62857; C04B35/6286; C04B35/62863; C04B35/62865; C04B35/62871; C04B35/62873; C04B35/62884; C04B35/71; C04B35/78; C04B35/80; C04B35/83; C04B41/00; C04B41/009; C04B41/45; C04B41/50; C04B41/5053; C04B41/5057; C04B41/5059; C04B41/5062; C04B41/5066; C04B41/80; C04B41/81; C04B41/85; C04B41/87; C22; C22C; C22C49/00; C22C49/02; C22C49/10; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/38; C04B2235/3817; C04B2235/3826; C04B2235/42; C04B2235/422; C04B2235/425; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/524; C04B2235/5248; C04B2235/60; C04B2235/608; C04B2235/612; C04B2235/614; C04B2235/616; C04B2235/65; C04B2235/656; C04B2235/6562; C04B2235/70; C04B2235/80; C04B2235/96; C04B2235/9607
Claims Analysis
Total Claims: 44
Claim 1
Independent Claim
74 words
A composite article comprising: a substrate formed from a plurality of discrete elements defining a porous relationship, the substrate having anisotropic properties and having a first coefficient of thermal expansion; and a matrix disposed on the substrate and having a second coefficient of thermal expansion different from the first coefficient of thermal expansion and freely movable relative to the substrate to accommodate the different coefficients of thermal expansion of the substrate and the matrix.
Claim 2
Dependent Claim
74 words
A composite article comprising: a substrate formed from a plurality of discrete elements defining a porous relationship, the substrate having anisotropic properties and having a first coefficient of thermal expansion; and a matrix disposed on the substrate and having a second coefficient of thermal expansion different from the first coefficient of thermal expansion and freely movable relative to the substrate to accommodate the different coefficients of thermal expansion of the substrate and the matrix.
Claim 3
Dependent Claim
25 words
The combination set forth in claim 1, wherein the discrete members in the plurality define interstices and wherein the matrix is disposed in such interstices.
Claim 4
Dependent Claim
16 words
The combination set forth in claim 1, wherein the matrix is disposed directly on the substrate.
Claim 5
Dependent Claim
24 words
The combination set forth in claim 1, 2 or 3, wherein the matrix is pervious and an impervious layer is disposed on the matrix.
Claim 6
Dependent Claim
25 words
The combination set forth in claim 4, wherein said impervious layer is selected from a group consisting of silicon nitride, silicon carbide and silicon oxide.
Claim 7
Dependent Claim
51 words
The combination set forth in any one of the preceding claims, wherein the substrate is formed from discrete elements of a material containing carbon, and the matrix is formed from a material selected from a group consisting of silicon carbide, silicon nitride, silicon oxide, hafnium 10 tantalum, titanium diboride and tungsten.
Claim 8
Dependent Claim
23 words
The combination of any one of the preceding claims including means disposed on the substrate for promoting a load transfer throughout the substrate.
Claim 9
Dependent Claim
15 words
The combination set forth in claim 7, wherein the promoting means constitutes a pyrolized binder.
Claim 10
Dependent Claim
17 words
The combination set forth in claim 7 or 8, wherein the promoting means constitutes a pyrolyzed carbon.
Claim 11
Dependent Claim
24 words
The combination set forth in any one of the preceding claims, wherein the substrate is formed from discrete elements of a material containing carbon.
Claim 12
Dependent Claim
24 words
The combination set forth in any one of the preceding claims, wherein the density of said article is between 0.3 gm/cc and 4.0 gm/cc.
Claim 13
Independent Claim
80 words
A method of forming a refractory composite material, including the steps of: forming a plurality of discrete elements into a substrate, the discrete elements having a first coefficient of thermal expansion; shaping the substrate formed from the discrete elements; heating the substrate; and passing gases through the substrate to apply to the substrate a matrix having a different coefficient of thermal expansion than that of the substrate and providing for a free movement of the matrix relative to the substrate.
Claim 14
Independent Claim
80 words
A method of forming a refractory composite material, including the steps of: forming a plurality of discrete elements into a substrate, the discrete elements having a first coefficient of thermal expansion; shaping the substrate formed from the discrete elements; heating the substrate; and passing gases through the substrate to apply to the substrate a matrix having a different coefficient of thermal expansion than that of the substrate and providing for a free movement of the matrix relative to the substrate.
Claim 15
Dependent Claim
19 words
The method as set forth in claim 12, wherein the substrate and the matrix are formed with porous characteristics.
Claim 16
Dependent Claim
21 words
The method as set forth in claim 12 or 13, wherein the discrete elements constitute fibers disposed in an anisotropic relationship.
Claim 17
Dependent Claim
16 words
The method as set forth in claim 12 or 13, wherein the discrete elements constitute grains.
Claim 18
Independent Claim
25 words
The method as set forth in any one of the preceding claims 12 to 15, wherein a hard, impermeable coating is applied on the matrix.
Claim 19
Dependent Claim
34 words
The method as set forth in claim 16, wherein the matrix is permeable and said coating is formed by heating the substrate and the matrix and passing gases through the substrate and the matrix.
Claim 20
Independent Claim
78 words
A method of forming a refractory composite material, including the steps of: providing a substrate having a first coefficient of thermal expansion and formed from a plurality of discrete elements and having porous characteristics; disposing the substrate in a particular shape; and producing on the substrate a chemical vapor deposition of a material having a second coefficient of thermal expansion different from the first coefficient of thermal expansion and defining a matrix freely movable relative to the substrate.
Claim 21
Independent Claim
78 words
A method of forming a refractory composite material, including the steps of: providing a substrate having a first coefficient of thermal expansion and formed from a plurality of discrete elements and having porous characteristics; disposing the substrate in a particular shape; and producing on the substrate a chemical vapor deposition of a material having a second coefficient of thermal expansion different from the first coefficient of thermal expansion and defining a matrix freely movable relative to the substrate.
Claim 22
Dependent Claim
33 words
The method as set forth in claim 18, wherein the chemical vapor deposition is provided with pervious characteristics; and a chemical vapor deposition of an impervious material is produced on the pervious deposition.
Claim 23
Dependent Claim
30 words
The method as set forth in claim 19, wherein the impervious layer is formed from a material selected from a group consisting of silicon carbide, silicon nitride and silicon oxide.
Claim 24
Dependent Claim
38 words
The method as set forth in claim 18, 19 or 20, wherein the matrix is formed from a material selected from a group consisting of silicon carbide, silicon nitride, silicon oxide, hafnium 10 tantalum, titanium diboride and tungsten.
Claim 25
Independent Claim
35 words
The method set forth in any one of preceding claims 18 to 21, wherein prior to the vapor disposition step a layer of a pyrolyzed material is produced on the discrete members of the substrate.
Claim 26
Dependent Claim
41 words
The method set forth in claim 22, wherein the layer of the pyrolyzed material on the discrete members of the substrate is produced by coating a binder on the discrete elements of the substrate, and pyrolyzing the binder after such coating.
Claim 27
Dependent Claim
43 words
The method set forth in claim 22 or 23, wherein the discrete elements in the substrate define iterstices, the pyrolyzed binder is disposed at the interstices defined by the discrete elements, and the matrix is disposed on the discrete elements at the interstices.
Claim 28
Dependent Claim
31 words
The method set forth in claim 22, wherein the layer of the pyrolyzed material on the substrate is formed by depositing the pyrolyzed material on the discrete elements of the substrate.
Claim 29
Dependent Claim
27 words
The method set forth in claim 25, wherein the pyrolyzed material deposited on the discrete elements encase the discrete elements, and the matrix encases the pyrolyzed material.
Claim 30
Independent Claim
135 words
A method of making a composite article comprising the steps of: forming a starting substrate from a multiplicity of high temperature resistant fibers selected from a group consisting of ceramic, pyrolyzed wool, rayon, polyacrylonitrile and pitch fibers; exposing said starting substrate to an elevated temperature of about 1800° F. for a period of time sufficient to thermally stabilize said substrate; suspending said starting substrate within a controlled environment; heating said starting substrate in a second controlled environment to a temperature of between approximately 1350° F. and approximately 2500° F.; and forming a coated article having a controlled degree of open porosity by depositing about said fibers of said starting substrate through chemical vapor deposition, a metal capable of reacting with carbon, oxygen, boron, silicon and nitrogen to form a carbide, oxide, boride, silicide and nitride.
Claim 31
Independent Claim
135 words
A method of making a composite article comprising the steps of: forming a starting substrate from a multiplicity of high temperature resistant fibers selected from a group consisting of ceramic, pyrolyzed wool, rayon, polyacrylonitrile and pitch fibers; exposing said starting substrate to an elevated temperature of about 1800° F. for a period of time sufficient to thermally stabilize said substrate; suspending said starting substrate within a controlled environment; heating said starting substrate in a second controlled environment to a temperature of between approximately 1350° F. and approximately 2500° F.; and forming a coated article having a controlled degree of open porosity by depositing about said fibers of said starting substrate through chemical vapor deposition, a metal capable of reacting with carbon, oxygen, boron, silicon and nitrogen to form a carbide, oxide, boride, silicide and nitride.
Claim 32
Dependent Claim
20 words
A method as defined in claim 27, in which said starting substrate includes granular silicon carbide intermixed with said fibers.
Claim 33
Dependent Claim
19 words
A method as defined in claim 27, in which said starting substrate includes granular graphite intermixed with said fibers.
Claim 34
Independent Claim
122 words
A method of making a composite article comprising the steps of: forming a starting substrate from a granular material selected from a group consisting of silicon carbide and graphite; exposing said starting substrate to an elevated temperature of about 1600-2200° F. for a period of time sufficient to thermally stabilize said substrate; suspending said starting substrate within a controlled environment; heating said shaped substrate to a temperature of between approximately 1350° F. and approximately 2500° F.; and forming a coated article having a controlled degree of open porosity by depositing about said fibers of said starting substrate through chemical vapor deposition, a metal capable of reacting with carbon, oxygen, boron, silicon and nitrogen to form a carbide, oxide, boride, silicide and nitride.
Claim 35
Independent Claim
122 words
A method of making a composite article comprising the steps of: forming a starting substrate from a granular material selected from a group consisting of silicon carbide and graphite; exposing said starting substrate to an elevated temperature of about 1600-2200° F. for a period of time sufficient to thermally stabilize said substrate; suspending said starting substrate within a controlled environment; heating said shaped substrate to a temperature of between approximately 1350° F. and approximately 2500° F.; and forming a coated article having a controlled degree of open porosity by depositing about said fibers of said starting substrate through chemical vapor deposition, a metal capable of reacting with carbon, oxygen, boron, silicon and nitrogen to form a carbide, oxide, boride, silicide and nitride.
Claim 36
Dependent Claim
109 words
The method as set forth in claim 27, 28 or 29, including the step of forming an intermediate substrate by heating said starting substrate to a temperature of between approximately 1500° F. and approximately 4200° F. while exposing said starting substrate to a hydrocarbon gas to form a uniform layer of pyrolytic carbon about each of the fibers in said starting substrate; removing said intermediate substrate from said first controlled environment, and forming said intermediate substrate into a shaped substrate having the approximate shape desired of the end product composite article prior to heating said shaped substrate to said temperature of between aporoximately 1350° F. and approximately 2500° F.
Claim 37
Dependent Claim
103 words
The method set forth in claim 31, including the step of removing said chemical vapor deposition coated article from said second controlled environment, placing it in a third controlled environment, and heating said article to a temperature of between approximately 1800° F. and approximately 3200° F.; and exposing said article to a halide gas containing carbon and silicon selected from a group consisting of methyl trichlorosilane, dimethyldichlorosilane, silicon tetrachloride, trimethylchlorosilane, dichlorosilane, silicon dichloride, silicon tetrabromide, tribromosi- lane, dibromosilan-e and silicon dibromide to form a uniform chemical vapor deposition coating of silicon carbide over the coated fibers and periphery of said diffusion coated article.
Claim 38
Dependent Claim
53 words
The method set forth in claim 31 or 32, wherein said chemical vapor deposition coated article is formed by placing said shaped substrate into a controlled depositon environment, continuously varying the pressure within said environment, and depositing on the fibers of said shaped substrate a coating of silicon carbide of a predetermined thickness.
Claim 39
Dependent Claim
28 words
The method set forth in claim 31 or 32, wherein said coated article is formed by depositing said coating onto said shaped substrate fabricated from silicon carbide fibers.
Claim 40
Dependent Claim
33 words
The method set forth in claim 31, including the step of removing said coated article from said second controlled environment and controllably introducing a metal oxide into the pores of said coated article.
Claim 41
Independent Claim
33 words
The method set forth in any one of preceding claims 31 to 35, in which said hydrocarbon gas is selected from a group consiting of methane, propane, ethane, butane, ethylene, acetylene and benzine.
Claim 42
Independent Claim
37 words
The method set forth in any one of preceding claims 31 to 36, in which said multiplicity of carbon fibers are formed into a starting substrate having a fiber volume of between about 5% and about 65%.
Claim 43
Independent Claim
23 words
The method set forth in any one of preceding claims 30 to 37, wherein said first controlled environment is a vacuum-pressure controlled environment.
Claim 44
Dependent Claim
24 words
The method set forth in claim 38, in which the pressure within the second controlled environment is fluctuated from approximately .01 to .6 atmospheres.
References Cited (Backward Citations)
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