Method for forming a self-supporting body using vapor-phase parent metals and solid oxidants
First Claim
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1. A method for forming a self-supporting body comprising:
- providing at least one solid oxidant-containing material;
providing at least one vapor-phase parent metal,heating said at least one vapor-phase parent metal and said at least one solid oxidant-containing material to substantially the same temperature;
contacting at least a portion of said solid oxidant-containing material with said at least one vapor-phase parent metal; and
permitting said at least one vapor-phase parent metal and said at least a portion of said solid oxidant-containing material to form at lest one reaction product on said at least a portion of said at least one solid oxidant-containing material.
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Abstract
This invention relates generally to a novel directed metal oxidation process which is utilized to produce self-supporting bodies. In some of the more specific aspects of the invention, a parent metal (e.g., a parent metal vapor) is induced to react with at least one solid oxidant-containing material to result in the directed growth of a reaction product which is formed from a reaction between the parent metal and the solid oxidant-containing material. The inventive process can be utilized to form bodies having substantially homogeneous compositions, graded compositions, and macrocomposite bodies.
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20 Claims
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1. A method for forming a self-supporting body comprising:
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providing at least one solid oxidant-containing material; providing at least one vapor-phase parent metal, heating said at least one vapor-phase parent metal and said at least one solid oxidant-containing material to substantially the same temperature; contacting at least a portion of said solid oxidant-containing material with said at least one vapor-phase parent metal; and permitting said at least one vapor-phase parent metal and said at least a portion of said solid oxidant-containing material to form at lest one reaction product on said at least a portion of said at least one solid oxidant-containing material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method for forming a self-supporting body comprising:
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providing a reaction chamber; placing at least one solid parent metal in at least a portion of said reaction chamber; placing at least a portion of at least one solid oxidant-containing material in said reaction chamber; heating said reaction chamber, said at least one parent metal, and said at least one solid oxidant containing material to a temperature so as to achieve an adequate vapor pressure of said parent metal within said reaction chamber, wherein said adequate vapor pressure of said parent metal comprises an amount of vapor parent metal so as to substantially completely surround said at least a portion of said at least one solid oxidant-containing material or substantially fill said reaction chamber; maintaining said reaction chamber, said at least one parent metal, and said at least one solid oxidant-containing material at substantially the same temperature; and permitting said at least one vapor-phase parent metal and said solid oxidant-containing material to form at least one reaction product on said at least a portion of said at least one solid oxidant-containing material. - View Dependent Claims (15, 16, 17, 18, 19)
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20. A method for forming a self-supporting body comprising:
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providing a reaction system comprising (1) a reaction chamber;
(2) at least one solid oxidant-containing material, and (3) at least one vapor-phase parent metal source, wherein said at least one parent metal vapor-source and at least a portion of said at least one solid oxidant containing material are contained within said reaction chamber thereby forming a reaction system;heating said reaction system to a temperature to achieve a vapor pressure of said vapor-phase parent metal to create a parent metal cloud within said reaction system, wherein said parent metal cloud substantially completely surrounds said at least a portion of said at least one solid oxidant-containing material; maintaining said at least one vapor-phase parent metal source and said at least one solid oxidant-containing material at substantially the same temperature; and permitting said parent metal cloud and said at least one solid oxidant-containing material to form at least one reaction product on said at least a portion of said at least one solid oxidant-containing material.
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Specification