Methods for hermetically sealing ceramic to metallic surfaces and assemblies incorporating such seals

• US 6,221,513 B1
• Filed: 05/12/1998
• Issued: 04/24/2001
• Est. Priority Date: 05/12/1998
• Status: Expired due to Term

• Current Assignee: Pacific Aerospace & Electronics Incorporated (Qnnect LLC)
• Original Assignee: Pacific Coast Technologies, Inc. (Qnnect LLC)
• Inventors: Lasater, Brian J.
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): STEIN, STEPHEN J
• Application Number:
  US09/076,230
• Time in Patent Office: 1,078 Days
• Field of Search: 428/627, 428/632, 428/633, 428/660, 428/680, 428/469, 428/472, 428/699, 428/701, 428/702, 428/629, 420/917, 228/122.1, 228/124.6, 228/56.3, 228/262.72
• US Class Current: 428/629
• CPC Class Codes: B23K 35/325 Ti as the principal constituent
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: C04B 2237/122 based on refractory metals
• CPC Class Codes: C04B 2237/123 based on iron group metals, e.g. steel
• CPC Class Codes: C04B 2237/343 Alumina or aluminates
• CPC Class Codes: C04B 2237/348 Zirconia, hafnia, zirconates or hafnates
• CPC Class Codes: C04B 2237/36 Non-oxidic
• CPC Class Codes: C04B 2237/363 Carbon
• CPC Class Codes: C04B 2237/365 Silicon carbide
• CPC Class Codes: C04B 2237/366 Aluminium nitride
• CPC Class Codes: C04B 2237/368 Silicon nitride
• CPC Class Codes: C04B 2237/403 Refractory metals
• CPC Class Codes: C04B 2237/407 Copper
• CPC Class Codes: C04B 2237/708 of one or more of the interlayers
• CPC Class Codes: C04B 2237/765 at least one member being a tube
• CPC Class Codes: C04B 2237/82 Two substrates not completely covering each other, e.g. two plates in a staggered position
• 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 37/026 consisting of metals or metal salts
• CPC Class Codes: Y10T 428/1259 Oxide
• CPC Class Codes: Y10T 428/12611 Oxide-containing component
• CPC Class Codes: Y10T 428/12806 : Refractory [Group IVB, VB, or VIB] metal-base component
• CPC Class Codes: Y10T 428/12944 : Ni-base component

Abstract

Methods for hermetically sealing an interface surface of ceramic materials, such as zirconia, to an interface surface of metallic materials, such as titanium alloys, using a titanium-nickel alloy filler material are disclosed. Preferred ceramic materials include stabilized zirconia materials; preferred metallic materials include titanium-niobium alloys; and a preferred titanium-nickel filler material is a 50-50 titanium-nickel alloy. At least one of the interfaces is contacted by the titanium-nickel alloy filler material and sealing is accomplished under vacuum conditions at temperatures of from 900 to 1200° C. during application of pressure to the joint. The methods are especially suitable for use in hermetically sealing ceramic and metallic components for applications such as implantable medical devices, electrical connectors, electronic packages, sporting goods, structural components, and the like.

Claims

1. A component assembly composed of a metallic component comprising a titanium-containing alloy, the metallic component in contact with a metallic filler material comprising a titanium-nickel material, the filler material additionally in contact with a ceramic component comprising zirconia, whereby the titanium-nickel material is capable of forming a liquidus at a temperature of less than 1100°

C. in the presence of the metallic component and the ceramic component.

2. A component assembly according to claim 1, wherein the metallic filler material comprises at least about 35% nickel.

3. A component assembly according to claim 2, wherein the metallic filler material comprises a 50-50 titanium-nickel alloy material.

4. A component assembly of claim 1, wherein the ceramic material comprises a material selected from the group consisting of:

stabilized zirconia;

partially stabilized zirconia;

tetragonal zirconia;

yttria-stabilized zirconia;

magnesia-stabilized zirconia;

ceria-stabilized zirconia; and

calcia-stabilized zirconia.

5. A component assembly of claim 1, wherein the titanium-nickel metallic filler material is in the form of metallic beads.

6. A component assembly of claim 1, wherein the titanium-nickel metallic filler material is in the form of metallic powder.

7. A component assembly of claim 1, wherein the titanium-nickel metallic filler material is in the form of a paste in which finely divided metallic powders are combined with a compatible solvent and binder.

8. A component assembly of claim 1, wherein the titanium-nickel metallic filler material is in the form of a metallic preform having a thickness of about 0.001 to about 0.006 inch.

9. A component assembly comprising a titanium-containing metallic component and a ceramic component, wherein an interface surface of the metallic component is hermetically sealed to an adjacent interface surface of the ceramic component by means of an intermediate layer of a metallic material comprising at least about 35% nickel and having a melting point, in the presence of the interface surfaces of the metallic component and the ceramic component, of less than 1100°

C.

10. A component assembly according to claim 9, wherein the ceramic component comprises a material selected from the group consisting of:

zirconia;

alumina;

silicon nitride;

silicon carbide;

titanium carbide;

tungsten carbide;

titanium-nitride;

silicon aluminum oxy-nitride;

graphite;

titanium di-boride;

boron carbide; and

molybdenum disilicide.

11. A component assembly according to claim 9, wherein the intermediate layer of metallic material comprises a 50-50 titanium-nickel material.

12. A component assembly according to claim 9, wherein the ceramic component comprises zirconia.

13. An assembly comprising a metallic component composed of a titanium-containing alloy and a ceramic material, wherein an interface surface of the metallic component is hermetically sealed to an adjacent interface surface of the ceramic component, the assembly having an interface zone comprising a metallic filler material comprising titanium and nickel, wherein the metallic component comprises nickel in its interface zone, and wherein the metallic filler material has a melting point of less than 1100°

C. in the presence of the interface surfaces of the metallic component and the ceramic component.

14. An assembly according to claim 13, wherein the ceramic component comprises a zirconia ceramic.