PATTERNED ABRADABLE COATING AND METHODS FOR THE MANUFACTURE THEREOF

• US 20160236995A1
• Filed: 02/17/2016
• Published: 08/18/2016
• Est. Priority Date: 02/17/2015
• Status: Active Application

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Lai, Benjamin John Bowin, Lee, Kang N., Thomas, David J.
• Granted Patent: US 10,273,192 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 2235/3213 Strontium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3215 Barium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/945 Products containing grooves, cuts, recesses or protusions
• CPC Class Codes: C04B 2237/062 based on silica or silicates
• CPC Class Codes: C04B 2237/08 Non-oxidic interlayers
• CPC Class Codes: C04B 2237/10 Glass interlayers, e.g. frit or flux
• CPC Class Codes: C04B 2237/16 Silicon interlayers
• CPC Class Codes: C04B 2237/341 Silica or silicates
• CPC Class Codes: C04B 2237/343 Alumina or aluminates
• CPC Class Codes: C04B 2237/36 Non-oxidic
• CPC Class Codes: C04B 2237/365 Silicon carbide
• CPC Class Codes: C04B 2237/368 Silicon nitride
• CPC Class Codes: C04B 2237/38 Fiber or whisker reinforced
• CPC Class Codes: C04B 2237/708 of one or more of the interlayers
• CPC Class Codes: C04B 2237/72 Forming laminates or joined articles comprising at least two interlayers directly next to each other
• CPC Class Codes: C04B 2237/86 Joining of two substrates at their largest surfaces, one surface being complete joined and covered, the other surface not, e.g. a small plate joined at it's largest surface on top of a larger plate
• CPC Class Codes: C04B 35/00 Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 35/16 based on silicates other than clay zircon C04B35/48
• CPC Class Codes: C04B 35/195 : Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 35/62218 : obtaining ceramic films, e.g. by using temporary supports
• CPC Class Codes: C04B 35/6264 : Mixing media, e.g. organic solvents
• CPC Class Codes: C04B 35/6342 : Polyvinylacetals, e.g. polyvinylbutyral [PVB]
• CPC Class Codes: C04B 35/645 : Pressure sintering
• CPC Class Codes: C04B 37/005 : consisting of glass or ceramic material
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/4578 : Coating or impregnating of green ceramics or unset concrete
• CPC Class Codes: C04B 41/53 : involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 41/91 : involving the removal of part of the materials of the treated articles, e.g. etching
• CPC Class Codes: F01D 11/122 : with erodable or abradable material blades having cutting or grinding tips F01D5/20
• CPC Class Codes: F01D 5/288 : Protective coatings for blades

Abstract

A ceramic article includes a flexible backing selected from paper, woven fabric, non-woven fabric, polymeric films, metal foils, and combinations thereof. A green ceramic layer is on a first side of the flexible backing, wherein the green ceramic layer includes a ceramic material and a polymeric binder. A major surface of the green ceramic layer includes a pattern of features.

Claims

1. A ceramic article, comprising:

a flexible backing selected from paper, woven fabric, non-woven fabric, polymeric films, metal foils, and combinations thereof; and

a green ceramic layer on a first side of the flexible backing, wherein the green ceramic layer comprises a ceramic material and a polymeric binder, and wherein a major surface of the green ceramic layer comprises a pattern of features.

2. The ceramic article of claim 1, wherein the backing comprises a polymeric film.

3. The ceramic article of claim 1, wherein the ceramic material comprises silicates selected from the group consisting of rare earth (RE) disilicates, RE monosilicates, barium strontium aluminum silicate, and mixtures and combinations thereof.

4. The ceramic article of claim 1, wherein the binder in the green ceramic layer comprises polyvinyl buteral.

5. The ceramic article of claim 1, wherein the green ceramic layer further comprises a solvent selected from the group consisting of alcohols, acetone, and methyl ethyl ketone (MEK), and mixtures and combinations thereof.

6. The ceramic article of claim 1, further comprising a support layer on a second side of the backing opposite the first side.

7. The ceramic article of claim 1, further comprising a release liner on the major surface of the green ceramic layer and overlying the pattern.

8. The ceramic article of claim 1, wherein the pattern comprises an array of grooves, an array of blocks, an array of apertures, a honeycomb pattern, and combinations thereof.

9. The ceramic article of claim 8, wherein the features comprise hemispherically-shaped depressions.

10. The ceramic article of claim 9, wherein each row of depressions in the array is offset with respect to an adjacent row of depressions, and wherein each column of depressions is offset with respect to an adjacent column of depressions.

11. The ceramic article of claim 9, wherein the depressions in a first row are a distance r apart, and the depressions in a second row adjacent to the first row are positioned a distance r/2 between the depressions in the first row.

12. The ceramic article of claim 9, wherein the ratio of the diameter of the depressions (x) to the distance between the depressions (r) is about 0.25 to about 0.75.

13. The ceramic article of claim 9, wherein the depressions are selected and arranged on the surface to provide the layer with a porosity of about 25% to about 75%.

14. The ceramic article of claim 9, wherein the coating has a porosity of about 25% to about 50%.

15. A method, comprising:

forming a slurry comprising a ceramic material, a polymeric binder, and at least one solvent;

coating the slurry on a flexible backing to form a green ceramic layer with a disperse phase of the ceramic material in a matrix of the polymeric binder; and

machining an array of features into a surface of the green ceramic layer to form a machined green ceramic article.

16. The method of claim 15, further comprising drying the slurry after coating the slurry on the flexible backing.

17. The method of claim 15, wherein the flexible backing comprises a polymeric film.

18. The method of claim 15, wherein the ceramic material comprises a silicate.

19. The method of claim 18, wherein the silicate is selected from the group consisting of rare earth (RE) disilicates, RE monosilicates, barium strontium aluminum silicate, and mixtures and combinations thereof.

20. The method of claim 15, wherein the polymeric binder comprises polyvinyl buteral.