# US 12,006,267 B2 · Ceramic composites and methods of making and using the same

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- Number: US 12,006,267 B2
- Document ID: US12006267B2
- Status: Granted
- Kind: B2
- Application number: 17/490,164
- Filed: 2021-09-30
- Published: 2022-04-21
- Granted: 2024-06-11
- Earliest claimed: 2020-10-19
- Assignees: North Carolina State University
- Applicants: North Carolina State University
- Inventors: Chengying Xu
- Web page: https://patentgrep.com/patent/US12006267B2

## CPC

- C04B 35/6267: {Pyrolysis, carbonisation or auto-combustion reactions}
- C04B 35/62823: {Zirconium or hafnium oxide}
- C04B 35/5603: {with a well-defined oxygen content, e.g. oxycarbides}
- C04B 35/571: obtained from {Si-containing} polymer precursors {or organosilicon monomers}
- C04B 35/589: obtained from {Si-containing} polymer precursors {or organosilicon monomers}
- C04B 35/62615: {High energy or reactive ball milling}
- C04B 35/6268: {characterised by the applied pressure or type of atmosphere, e.g. in vacuum, hydrogen or a specific oxygen pressure}
- C04B 35/6269: {Curing of mixtures}
- C04B 2235/3244: Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
- C04B 2235/3813: Refractory metal borides
- C04B 2235/483: Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
- C04B 2235/5454: nanometer sized, i.e. below 100 nm
- C04B 2235/656: characterised by specific heating conditions during heat treatment
- C04B 2235/6562: Heating rate
- C04B 2235/80: Phases present in the sintered or melt-cast ceramic products other than the main phase
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

The present disclosure provides for ceramic composite materials and methods of making ceramic composite materials. In an aspect, the ceramic composite materials can be made of polymer derived ceramics (PDCs) as the matrix, while substrates can be used as the microwave absorbing phases.

## Claims

### Claim 1

A ceramic composite material comprising:
a matrix comprising a polymer-derived ceramic;
one or more of substrates selected from: an ultra-high temperature ceramic (UHTC), an electrically-conductive material, magnetic-conductive material, and a combination of these.

### Claim 2 (depends on 1)

The ceramic composite material of claim 1, wherein the solid substrate is selected from a particle, a fiber, a whisker, a flake, a mat, or a plate.

### Claim 3 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the electrically-conductive material, wherein the electrically-conductive material is selected from copper, aluminum, magnesium, silver, gold, molybdenum, zinc, lithium, brass, platinum, tungsten, tin, lead, or titanium.

### Claim 4 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the magnetic-conductive material, wherein the magnetic-conductive material is selected from iron, steel, nickel, cobalt, or a rare earth metal.

### Claim 5 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the ultra-high temperature ceramic substrate, wherein the ultra-high temperature ceramic substrates comprise a boride, a carbide, or a nitride.

### Claim 6 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the ultra-high temperature ceramic substrate, wherein the ultra-high temperature ceramic substrates comprise HfB2, ZrB2, TiB2, NbB2, TaB2, or a combination thereof.

### Claim 7 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the ultra-high temperature ceramic substrate wherein the ultra-high temperature ceramic substrates comprise TaC, HfC, ZrC, NbC, TiC, or a combination thereof.

### Claim 8 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the ultra-high temperature ceramic substrate, wherein the ultra-high temperature ceramic substrates comprise TaN, HfN, TiN, ZrN, NbN, or a combination thereof.

### Claim 9 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the ultra-high temperature ceramic substrate, wherein the ultra-high temperature ceramic substrates comprise ZrB2, where the ultra-high temperature ceramic substrate has a ZrO2 coating.

### Claim 10 (depends on 1)

The ceramic composite material of claim 1, wherein the substrate is the ultra-high temperature ceramic substrate, wherein the ultra-high temperature ceramic substrates comprise TfB2, where the ultra-high temperature ceramic substrate has a TfO2 coating.

### Claim 11 (depends on 1)

The ceramic composite material of claim 1, wherein the polymer-derived ceramic SbN4, SiC, BN, AlN, SiCN, SiCO, BCN, SiCNO, SiBCN, SiBCO, SiAICN, SiAICO, or a combination thereof.

### Claim 12 (depends on 1)

The ceramic composite material of claim 1, wherein the normalized weight of one or more substrates is about 10-70% of the total weight of the ceramic composite material.

### Claim 13 (depends on 1)

The ceramic composite material of claim 1, wherein the ceramic composite material has a microwave absorption bandwidth, wherein the microwave absorption bandwidth is S-band C-band, X-band, Ku-band, K-band, Ka-band, V-band, W-band.

### Claim 14

A method of forming a ceramic composite comprising:
a) providing a mixture comprising:
1) A liquid preceramic precursor, and
2) One or more substrates, wherein the one or more substrates is selected from a solid substrate, a liquid substrate, or both the solid substrate and the liquid substrate, wherein the solid substrates and liquid substrates are independently selected from the group consisting of: an ultra-high temperature ceramic (UHTC), carbon, an electrically-conductive material, magnetic-conductive material, and a combination of these,
b) heating the mixture at a temperature for a time effective to cure the liquid preceramic precursor to form a solid mixture;
c) subjecting the solid mixture to one or more forces to form particles of the solid mixture;
d) pressing the particles of the solid mixture into a mold having a pre-selected shape to form compacts of the solid mixture; and
e) pyrolyzing the solid mixture in step (b) or the compacts in step (d) or both at a temperature for a time effective to form the ceramic composite material.

### Claim 15 (depends on 14)

The method of claim 14, wherein the liquid preceramic precursor comprises an organosilicon polymer, wherein the organosilicon polymer is selected from the group consisting of: polysilanes, polycarbosilanes, polysilazanes, polysiloxanes, polycarbosilanes, polycarbosiloxanes, polysilylcarbodiimides, and a combination thereof.

### Claim 16 (depends on 14)

The method of claim 14, wherein pyrolyzing is at about 400-2000° C.

### Claim 17 (depends on 14)

The method of claim 14, wherein the mixture is heated at about 100-400° C.

### Claim 18 (depends on 14)

The method of claim 14, wherein the subjecting of the solid mixture to one or more forces comprises compressing the solid mixture, grinding the solid mixture, or a combination thereof.

### Claim 19 (depends on 14)

The method of claim 14, wherein the solid substrate is selected from a particle, a fiber, a whisker, a flake, a mat, or a plate and wherein the liquid substrate is selected from a precursor liquid, a gel, or a paste.

### Claim 20 (depends on 1)

The ceramic composite material of claim 1, further comprising an oxide on surface of at least one of the substrates, wherein the oxide is derived from the aforementioned substrates.