PRESSED AND SELF SINTERED POLYMER DERIVED SiC MATERIALS, APPLICATIONS AND DEVICES

• US 20160207836A1
• Filed: 09/24/2015
• Published: 07/21/2016
• Est. Priority Date: 05/02/2013
• Status: Active Grant

• Current Assignee: Pallidus, Inc.
• Original Assignee: Melior Innovations, Inc.
• Inventors: Land, Mark S., Diwanji, Ashish P., Hopkins, Andrew R., Sherwood, Walter J., Dukes, Douglas M., Sandgren, Glenn, Benac, Brian L.
• Granted Patent: US 9,919,972 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: C01B 32/956 Silicon carbide
• CPC Class Codes: C01B 32/977 Preparation from organic compounds containing silicon
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint glass constituents C04B2235/36
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/44 Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
• CPC Class Codes: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 2235/483 Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
• CPC Class Codes: C04B 2235/528 Spheres
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/6581 Total pressure below 1 atmosphere, e.g. vacuum
• CPC Class Codes: C04B 2235/72 Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
• CPC Class Codes: C04B 2235/721 Carbon content
• CPC Class Codes: C04B 2235/727 Phosphorus or phosphorus compound content
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 2235/785 Submicron sized grains, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/94 Products characterised by their shape
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 35/515 based on non-oxide ceramics
• CPC Class Codes: C04B 35/56 : based on carbides or oxycarbides containing free metal binder C22C29/00
• CPC Class Codes: C04B 35/5603 : with a well-defined oxygen content, e.g. oxycarbides
• CPC Class Codes: C04B 35/571 : obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C08G 77/12 : containing silicon bound to hydrogen C08G77/045 takes precedence
• CPC Class Codes: C08G 77/20 : containing silicon bound to unsaturated aliphatic groups C08G77/045 takes precedence
• CPC Class Codes: C08G 77/50 : by carbon linkages C08G77/485 takes precedence
• CPC Class Codes: C08G 77/80 : Siloxanes having aromatic substituents, e.g. phenyl side groups
• CPC Class Codes: C08L 83/00 : Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 83/04 : Polysiloxanes

Abstract

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Claims

1. An article, the article comprising:

a. a self sintered polysilocarb derived silicon carbide composition;

b. the self sintered polysilocarb derived silicon carbide composition comprising sintered submicron size silicon carbide particles, wherein the composition is substantially free from sintering aids.

2. The article of claim 1, wherein the polysilocarb has a molar ratio of about 30% to 85% carbon, about 5% to 40% oxygen, and about 5% to 35% silicon.

3. The article of claim 1, wherein the polysilocarb has a molar ratio of about 50% to 65% carbon, about 20% to 30% oxygen, and about 15% to 20% silicon.

4. The article of claim 1, wherein the silicon carbide particles have impurities of less than about 100 ppm total of the elements selected from the group consisting of Al, Fe, B, P, Pt, Ca, Mg, Li, Na, Ni, V, Pr, Ce, Cr, S and As.

5. The article of claim 1, wherein the silicon carbide particles have impurities of less than about 10 ppm total of the elements selected from the group consisting of Al, Fe, B, P, and Ti.

6. The article of claim 1, wherein the silicon carbide particles have impurities of less than about 1 ppm total of the elements selected from the group consisting of Al, Fe, B, Ti and P.

7. The article of claim 1, wherein the silicon carbide particles are at least 99.999% pure.

8. The article of claim 1, wherein the silicon carbide particles are at least 99.9999% pure.

9. The article of claim 1, wherein the silicon carbide particles are at least 99.99999% pure.

10. The articles of claim 1, 2, 5, or 9, wherein the article is selected from the group consisting of armor, ballistic materials, blast shields, penetration resistant materials, windows, lenses, fibers, internal reflection optics, total internal reflection optics, optics, brake rotors, brake assemblies, brake disks, brake pads, gemstones, semiprecious stones, and jewelry.

11. The articles of claim 1, 2, 5, or 9, having a layer of material, the layer comprising the self sintered polysilocarb derived silicon carbide composition.

12. A silicon carbide composition comprising:

a. polymer derived silicon carbide particles;

b. the particles having a mean particle size of about 0.5 μ

m or smaller;

c. the particles consisting essentially of silicon and carbon in an SiC₄ configuration, wherein the particles have less than 0.5% excess carbon, and are at least 99.99999% pure.

13. The composition of claim 12, wherein the mean particle size is about 0.2 μ

m or smaller.

14. The composition of claim 12, wherein the mean particle size is about 0.1 μ

m or smaller.

15. A self sinterable silicon carbide composition comprising:

a. polymer derived silicon carbide particles;

b. the particles having a mean particle size of about 0.5 μ

m or smaller;

c. the particles consisting essentially of silicon and carbon in an SiC₄ configuration, wherein the particles have less than 0.1% excess carbon, and are at least 99.99999% pure;

d. wherein the particles are capable of being formed into a solid SiC volumetric shape without the need for a sintering aid.

16. The composition of claim 15, wherein the volumetric shape is a layer.

17. The composition of claim 15, wherein the volumetric shape, is selected from the group of shapes consisting of a window, a lens, and a fiber.

18. The composition of claim 15, wherein the volumetric shape is an article selected from the group consisting of armor, ballistic materials, blast shields, penetration resistant materials, windows, lenses, fibers, internal reflection optics, and optics.

19. A sinterable silicon carbide composition comprising:

a. a plurality of silicon carbide particles, the plurality of particles having a total weight of greater than at least about 10 grams;

b. the particles having a mean particle size of about 0.5 μ

m or smaller;

c. the composition consisting essentially of silicon and carbon in an SiC₄ configuration, wherein the particles have less than 0.5% excess carbon, and are at least 99.99999% pure;

d. wherein the particles are capable of being sintered into a solid SiC article without the need for a sintering aid, the sintered SiC article having at least one strength properties at least 90% as strong as elemental SiC.

20. A silicon carbide composition comprising:

a. polymer derived silicon carbide particles;

b. the particles having a mean particle size of about 0.5 μ

m or smaller, each particle having a surface, wherein the surfaces are free from an oxide layer;

c. the particles consisting essentially of silicon and carbon, wherein the particles have less than 0.5% excess carbon, and are at least 99.99999% pure.

21. A silicon carbide composition comprising:

a. polymer derived silicon carbide particles;

b. the particles having a particle size smaller than about 5 μ

m, each particle having a surface, wherein the surfaces are free from an oxide layer; and

,

c. the particles consisting essentially of SiC, wherein the particles are at least 99.99999% pure.

22. The composition of claim 21, wherein the particle size is smaller than about 1 μ

m.

23. The composition of claim 21, wherein the particle size is smaller than about 0.5 μ

m.

24. The composition of claim 21, wherein the particle size is smaller than about 0.1 μ

m.

25. The composition of claim 21, wherein the particle size is smaller than about 0.05 μ

m.

26. The composition of claim 21, comprising a refractory ceramic powder, whereby the composition is a blend.

27. The composition of claim 21, wherein the refractory ceramic powder comprises a material selected from the group consisting of AlN, BC, BN, Al2O3, ZrO2, and Si.