Ceramic composites with improved interfacial properties and methods to make such composites
First Claim
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1. A ceramic composite comprising:
- a ceramic substrate;
a ceramic bonded directly to said ceramic substrate via a direct covalent bond along an interface between said ceramic and said ceramic substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;
said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; and
said interface between said ceramic substrate and said ceramic being essentially absent of any intermetallic eutectic or adhesive agent.
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Abstract
A ceramic composite having a substrate bonded to a ceramic oxide member through a covalent bond formed at temperatures less than 880° C., and ceramic composites that are so constructed that to control internal stress or increase crack-resistance within the ceramic member under applied thermal or mechanical loads to the composite, such composite with alumina bonded sets of such metal-ceramic computers and end use devices including printed circuit boards, and higher level assemblies including such devices.
159 Citations
35 Claims
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1. A ceramic composite comprising:
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a ceramic substrate; a ceramic bonded directly to said ceramic substrate via a direct covalent bond along an interface between said ceramic and said ceramic substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; and said interface between said ceramic substrate and said ceramic being essentially absent of any intermetallic eutectic or adhesive agent. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method of making ceramic composites, comprising the steps of:
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providing a substrate; temporarily bonding an adhesion resistant material to the substrate at preselected surface regions of said substrate; spray pyrolizing the ceramic over the substrate and the adhesion resistant material to directly covalently bond the ceramic to said substrate at surface regions of said substrate, other than said preselected surface regions, via a direct covalent bond along an interface between said ceramic and said substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite, said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level;dissipating the adhesion resistant material to form at least one cavity at the ceramic-substrate interface; and said surface regions of said substrate, other than said preselected surface regions, at the interface between said substrate and said ceramic being essentially absent of any intermetallic eutectic or adhesive agent.
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21. A ceramic composite comprising:
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a substrate; a ceramic bonded directly to said substrate via a direct covalent bond along an interface between said ceramic and said substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; said interface between said substrate and said ceramic being absent of any intermetallic eutectic or adhesive agent; and said substrate having holes therein to reduce effects of stress and/or thermal expansion of said substrate.
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22. A ceramic composite comprising:
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a substrate; a ceramic bonded directly to said substrate via a direct covalent bond along an interface between said ceramic and said substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; said interface between said substrate and said ceramic being essentially absent of any intermetallic eutectic or adhesive agent; and wherein said ceramic contains secondary phase material particles dispersed throughout a substantial portion of its volume, the secondary phase material particles comprising material selected from the group consisting of metals, metal alloys, glass, shape memory alloys, graphite, oxides, non-oxide inert compounds, crystalline ceramics, a single crystalline phase, and combinations of these materials phases. - View Dependent Claims (23, 24, 25, 26, 27, 28)
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29. A ceramic composite comprising:
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a substrate; a ceramic bonded directly to said substrate via a direct covalent bond along an interface between said ceramic and said substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; said interface between said substrate and said ceramic being essentially absent of any intermetallic eutectic or adhesive agent; and adhesion-resistant means dispersed at least at one preselected location along said interface between said ceramic and said substrate for preventing said covalent bond to take place at said at least one preselected location along said interface between said ceramic and said substrate. - View Dependent Claims (30, 31)
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32. A ceramic composite comprising:
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a substrate; a ceramic bonded directly to said substrate via a direct covalent bond along an interface between said ceramic and said substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; said interface between said substrate and said ceramic being essentially absent of any intermetallic eutectic or adhesive agent; and wherein the substrate comprises an electrical and/or thermal conductivity material selected from the group consisting of; (a) elemental metals, (b) metal alloys, and (c) metal composites of aluminum, copper, gold, or silver, bonded to a constraining-metal member that is 1/20th to 1/3rd the thickness of the high electrical and/or thermal conductivity substrate, wherein the constraining-metal member comprises a metal, metal alloy, or metal composite, of antimony, chromium, iridium, molybdenum, tantalum, tin, titanium, tungsten, or vanadium. - View Dependent Claims (33)
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34. A ceramic composite comprising:
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a substrate; a ceramic bonded directly to said substrate via a direct covalent bond along an interface between said ceramic and said substrate, said covalent bond being effected by dispersion of a metal organic precursor of said ceramic and pyrolysis of said metal organic precursor at a temperature of 500°
C. or less to form the ceramic composite;said ceramic comprising a ceramic medium whose primary phase precursors have been mixed at the molecular level; said interface between said substrate and said ceramic being absent of any intermetallic eutectic or adhesive agent; and the ceramic composite being in combination with a ceramic component, said ceramic composite and said ceramic component forming two adjacent pieces, the two pieces bonded at respective ceramic surfaces by an intermediate low-melting temperature oxide phase. - View Dependent Claims (35)
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Specification