Methods for producing novel ceramic composites
First Claim
1. A process for making a composite comprising the steps of:
- a) forming a polymer composition into a three-dimensional mold;
b) filling said three-dimensional mold with at least one ceramic containing compositions, said at least one ceramic containing composition having a higher melting point than said polymer composition;
c) drying, gelling or curing said at least one ceramic containing composition in the mold to harden the at least one ceramic containing composition in the three-dimensional mold;
d) removing the three-dimensional mold from the hardened material thereby forming voids;
e) sintering the hardened material to provide a slntered ceramic structure; and
f) filling the voids with a second composition which has a piezoelectric coefficient which is substantially different from the piezoelectric coefficient of said ceramic structure;
wherein steps a-e yield a controlled, non-random piezoelectric ceramic composite having 2-3, 3-2 or 3-3 connectivity with respect to the sintered ceramic and the second composition throughout the composite.
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Abstract
A process for making ceramic composites includes the steps of: a) forming a polymer composition into a three-dimensional mold; b) filling said three-dimensional mold with one or more ceramic containing compositions; c) heating said filled mold to dry and sinter the ceramic; d) removing at least a portion of said three-dimensional mold thereby forming voids; and e) filling the voids with a second composition which has a piezoelectric coefficient which is substantially different from the piezoelectric coefficient of said ceramic structure. Steps a through e yield a controlled, non-random piezoelectric ceramic composite having 2-3, 3-2 or 3--3 connectivity with respect to the sintered ceramic and the second composition throughout the composite.
57 Citations
14 Claims
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1. A process for making a composite comprising the steps of:
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a) forming a polymer composition into a three-dimensional mold; b) filling said three-dimensional mold with at least one ceramic containing compositions, said at least one ceramic containing composition having a higher melting point than said polymer composition; c) drying, gelling or curing said at least one ceramic containing composition in the mold to harden the at least one ceramic containing composition in the three-dimensional mold; d) removing the three-dimensional mold from the hardened material thereby forming voids; e) sintering the hardened material to provide a slntered ceramic structure; and f) filling the voids with a second composition which has a piezoelectric coefficient which is substantially different from the piezoelectric coefficient of said ceramic structure; wherein steps a-e yield a controlled, non-random piezoelectric ceramic composite having 2-3, 3-2 or 3-3 connectivity with respect to the sintered ceramic and the second composition throughout the composite. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A process for making a controlled, non-random piezoelectric ceramic composite having 2-3, 3-2 or 3-3 connectivity comprising the steps of:
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a) forming a polymer composition into a three-dimensional mold; b) filling said three-dimensional mold with at least one ceramic containing compositions, said at least one ceramic containing composition having a higher melting point than said polymer composition; c) drying, gelling or curing said at least one ceramic containing composition in the mold to harden the at least one ceramic containing composition in the three-dimensional mold; d) removing the three-dimensional mold from the hardened material thereby forming voids; e) sintering the hardened material to provide a sintered ceramic structure; and f) filling the voids with a second composition which has a piezoelectric coefficient which is substantially different from the piezoelectric coefficient of said ceramic structure. - View Dependent Claims (14)
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Specification