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US 12,134,582 B2Granted
Methods for producing metal carbide materials
AssigneeAdvanced Ceramic Fibers, LLC
InventorsJohn E. Garnier, George W. Griffith
Life of this patent
Estimating the term…
Abstract
Methods of producing silicon carbide, and other metal carbide materials. The method comprises reacting a carbon material (e.g., fibers, or nanoparticles, such as powder, platelet, foam, nanofiber, nanorod, nanotube, whisker, graphene (e.g., graphite), fullerene, or hydrocarbon) and a metal or metal oxide source material (e.g., in gaseous form) in a reaction chamber at an elevated temperature ranging up to approximately 2400° C. or more, depending on the particular metal or metal oxide, and the desired metal carbide being produced. A partial pressure of oxygen in the reaction chamber is maintained at less than approximately 1.01×102 Pascal, and overall pressure is maintained at approximately 1 atm.
Claims20
A method of forming metal carbide material, the method comprising:
- reacting a carbon material with at least one of a metal or metal oxide source material in a reaction zone of a continuous throughput tube furnace having one and only one reaction zone, the metal or metal oxide source material being in a form of a gaseous vapor, the metal or metal oxide source material comprising aluminum, beryllium, boron, calcium, cerium, chromium, dysprosium, erbium, europium, gadolinium, hafnium, holmium, iron, lanthanum, lithium, magnesium, manganese, molybdenum, niobium, neodymium, praseodymium, samarium, scandium, silicon, tantalum, terbium, thorium, titanium, tungsten, uranium, vanadium, ytterbium, yttrium, zirconium, aluminum oxide, beryllium oxide, boron oxide, calcium oxide, cerium oxide, chromium oxide, dysprosium oxide, erbium oxide, europium oxide, gadolinium oxide, hafnium oxide, holmium oxide, iron oxide, lanthanum oxide, lithium oxide, magnesium oxide, manganese oxide, molybdenum oxide, niobium oxide, neodymium oxide, praseodymium oxide, samarium oxide, scandium oxide, silicon oxide, tantalum oxide, terbium oxide, thorium oxide, titanium oxide, tungsten oxide, uranium oxide, vanadium oxide, ytterbium oxide, yttriumn oxide, zirconium oxide or a combination thereof, wherein the carbon material is continuously drawn through the continuous tube furnace so that only a portion of the carbon material being reacted is disposed within the reaction zone at any given time and the reaction zone is maintained at a temperature greater than:
- the melting temperature of the metal or metal oxide source material;
- or
- the vaporization temperature of the metal or metal oxide source material;
- so as to produce a metal carbide material as the carbon material is converted to metal carbide by reaction with the at least one of a metal or metal oxide;
- wherein the metal or metal oxide source material is converted to be in the form of a gaseous vapor in the same one and only one reaction zone in which the carbon material is reacted with the at least one of a metal or metal oxide source material.
3 more elements
A method of forming metal carbide material, the method comprising:
- reacting a carbon material with at least one of a metal or metal oxide source material in a reaction zone of a continuous throughput tube furnace having a single reaction zone, the metal or metal oxide source material being in a form of a gaseous vapor, the metal or metal oxide source material comprising aluminum, beryllium, boron, calcium, cerium, chromium, dysprosium, erbium, europium, gadolinium, hafnium, holmium, iron, lanthanum, lithium, magnesium, manganese, molybdenum, niobium, neodymium, praseodymium, samarium, scandium, silicon, tantalum, terbium, thorium, titanium, tungsten, uranium, vanadium, ytterbium, yttrium, zirconium, aluminum oxide, beryllium oxide, boron oxide, calcium oxide, cerium oxide, chromium oxide, dysprosium oxide, erbium oxide, europium oxide, gadolinium oxide, hafnium oxide, holmium oxide, iron oxide, lanthanum oxide, lithium oxide, magnesium oxide, manganese oxide, molybdenum oxide, niobium oxide, neodymium oxide, praseodymium oxide, samarium oxide, scandium oxide, silicon oxide, tantalum oxide, terbium oxide, thorium oxide, titanium oxide, tungsten oxide, uranium oxide, vanadium oxide, ytterbium oxide, yttrium oxide, zirconium oxide or a combination thereof, wherein the carbon material is continuously drawn through the continuous tube furnace so that only a portion of the carbon material being reacted is disposed within the reaction zone at any given time and the reaction zone is maintained at a temperature greater than:
- the melting temperature of the metal or metal oxide source material;
- or
- the vaporization temperature of the metal or metal oxide source material;
- so as to produce a metal carbide material as the carbon material is converted to metal carbide by reaction with the at least one of a metal or metal oxide;
- wherein reaction time to produce the metal carbide material as the carbon material is converted to metal carbide by reaction with the at least one of a metal or metal oxide within the single reaction zone ranges from about 1 second to about 10 minutes.
3 more elements
Dependencies are inferred from the claim text.