Multi-functional composite structures

• US 6,805,946 B2
• Filed: 12/04/2001
• Issued: 10/19/2004
• Est. Priority Date: 12/04/2000
• Status: Expired due to Fees

• Current Assignee: Advanced Ceramics Research LLC
• Original Assignee: Advanced Ceramics Research, Inc. (Rtx Corporation)
• Inventors: Halloran, John, Popovich, Dragan, Rigali, Mark J., Knittel, Kenneth L., Fulcher, Michael L., Vaidyanathan, K. Ranji, Mulligan, Anthony C., Sutaria, Manish P.
• Primary Examiner(s): Zimmerman, John J.
• Assistant Examiner(s): Savage, Jason L
• Application Number:
  US10/005,085
• Publication Number:
  US 20020127384A1
• Time in Patent Office: 1,050 Days
• Field of Search: 428/292.4, 428/293.1, 428/293.4, 264/104, 264/211.18
• US Class Current: 428/292.4
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/304 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: H10N 30/084 by moulding or extrusion
• CPC Class Codes: H10N 30/1061 based on piezoelectric or electrostrictive fibres
• CPC Class Codes: H10N 30/8548 Lead-based oxides
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249925 Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
• CPC Class Codes: Y10T 428/249927 Fiber embedded in a metal matrix
• CPC Class Codes: Y10T 428/249928 Fiber embedded in a ceramic, glass, or carbon matrix
• CPC Class Codes: Y10T 428/249929 Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/2933 Coated or with bond, impregnation or core

Abstract

Fibrous monolith processing techniques to fabricate multifunctional structures capable of performing more than one discrete function such as structures capable of bearing structural loads and mechanical stresses in service and also capable of performing at least one additional non-structural function.

Claims

1. A multi-functional fibrous monolith structure including one or more components comprising:

an inner ceramic phase;

an intermediate metal phase; and

an outer ceramic phases, the phases being arranged in a predetermined manner and at least one of the phases is effective for performing at least one non-structural function and at least one of the phases capable of bearing mechanical loads and stresses.

2. The multi-functional fibrous monolith structure in claim 1 wherein the intermediate phase is an interface strip deposited in a controlled array format to allow for strain measurement.

3. The multi-functional fibrous monolith structure in claim 2 incorporated in a drill bit insert capable of measuring strain during drilling operation.

4. The multi-functional fibrous monolith structure in claim 2 incorporated in a machine tool capable of measuring strain.

5. The multi-functional fibrous monolith structure in claim 1 wherein the intermediate phase is an interface strip deposited in a controlled array format to allow for temperature measurement.

6. The multi-functional fibrous monolith structure in claim 1 wherein the intermediate phase is an interface strip deposited in a controlled array format to allow the measurement of damage propagation.

7. The multi-functional fibrous monolith structure in claim 1 wherein the intermediate-phase is an interface strip deposited in a controlled array format to allow for temperature measurement and strain measurement.

8. The multi-functional fibrous monolith structure in claim 1 wherein the intermediate phase comprises W and Re.

9. The multi-functional fibrous monolith structure in claim 1 wherein the inner ceramic phase is ZrB₂, the intermediate phase is BN, and the outer ceramic phase is B₄C.

10. The multi-functional fibrous monolith structure in claim 1 wherein the inner ceramic phase is Tungsten Carbide, the intermediate phase is a Tungsten-Iron-Nickel Alloy, and the outer ceramic phase is Tungsten Carbide.

11. The multi-functional fibrous monolith structure in claim 1 incorporated in rocket nozzle capable of generating an electric current.

12. The multi-functional fibrous monolith structure in claim 1 incorporated in a rocket nozzle capable of measuring temperature.

13. The multi-functional fibrous monolith structure in claim 1 incorporated in a drill bit capable of measuring temperature and strain during drilling operation.

14. The multi-functional fibrous monolith structure in claim 1 incorporated in an electronic casing to prevent neutron-related damage of electronics behind the casing.

15. The multi-functional fibrous monolith structure of claim 1 wherein one or more of the phases contains an electro-mechanically active ceramic material.

16. The multi-functional fibrous monolith structure in claim 15 wherein one or more of the phases contains electrically insulating material.

17. The multi-functional fibrous monolith structure of claim 1 wherein one or more of the phases is piezoelectric.

18. The multi-functional fibrous monolith structure of claim 17 where one or more of the phases contains a ceramic material selected from the group consisting of lead zirconate titanate, lead lanthanum zirconate titanate, lead barium zirconate titanate, lead stannate zirconate titanate, lead magnesium niobate, and mixtures thereof.

19. The multi-functional fibrous monolith structure of claim 18 wherein at least one other phase includes a conductive ceramic, metallic or ceramic-metallic material.

20. The multi-functional fibrous monolith structure of claim 19 wherein the conductive material is generally embedded within the structure and functions as one or more electrodes.

21. The multi-functional fibrous monolith structure of claim 1 wherein the inner ceramic phase and the outer ceramic phase include the essentially same material composition.

22. The multi-functional fibrous monolith structure of claim 1 wherein the structure is capable of generating an electric current.

23. A fibrous monolith composite structure including one or more components comprising:

a first material including a conductive ceramic;

a second material generally surrounding the first material, the second material including a metal alloy; and

a third material generally surrounding the second material, the third material selected from the group consisting of piezoelectric ceramics and electrostrictive ceramics and mixtures thereof.

24. The composite structure of claim 23 where the second material is selected from the group consisting of lead zirconate titanate, lead lanthanum zirconate titanate, lead barium zirconate titanate, lead stannate zirconate titanate, lead magnesium niobate, and mixtures thereof.

25. The composite structure of claim 24 wherein the first material includes silver.

26. The composite structure of claim 23 wherein at least one of the first material and second material is generally embedded within the structure and functions as one or more electrodes.

27. The composite structure of claim 23 wherein the third material includes an electrically insulating material.