# US 12,595,558 B2 · Method of making composite articles from silicon carbide > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,595,558 B2 - Document ID: US12595558B2 - Status: Granted - Kind: B2 - Application number: 17/731,458 - Filed: 2022-04-28 - Published: 2022-08-11 - Granted: 2026-04-07 - Earliest claimed: 2018-08-06 - Assignees: Advanced Silicon Carbide Materials - Applicants: Advanced Silicon Carbide Materials - Inventors: William F. Fischer, III; Walter Wrigglesworth, III; Lauren Montgomery - Web page: https://patentgrep.com/patent/US12595558B2 ## CPC - C23C 16/325: {Silicon carbide} - C01B 32/963: Preparation from compounds containing silicon - C23C 16/01: on temporary substrates, e.g. substrates subsequently removed by etching - C23C 16/045: {Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates} - C23C 16/56: After-treatment - G02B 5/0891: {Ultraviolet [UV] mirrors (apparatus for microlithography exposure G03F7/70; X-ray multilayer structures G21K1/06)} - G21K 1/06: using diffraction, refraction or reflection, e.g. monochromators (G21K1/10, G21K7/00 take precedence) - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - G21K: HANDLING OF PARTICLES OR IONISING RADIATION NOT OTHERWISE PROVIDED FOR; IRRADIATION DEVICES; GAMMA RAY OR X-RAY MICROSCOPES ## Abstract A transparent composite article may include a first domed surface having a first integral freeform mirror and an opposed second surface having a second integral freeform primary mirror and supporting the first domed surface. The first domed surface and opposed domed surface may include a chemical vapor deposition (CVD) matrix. The CVD matrix may include a silicon carbide material. The CVD matrix may be transparent to visible light. The CVD matrix may include a columnar grain structure. ## Claims ### Claim 1 A transparent composite article comprising: a first domed surface having a first integral freeform mirror and an opposed second surface having a second integral freeform primary mirror and supporting the first domed surface; wherein the first domed surface and opposed domed surface each comprise a chemical vapor deposition (CVD) matrix comprising a silicon carbide material having 140-12,000 mesh solid silicon carbide particles dispersed therein; wherein the CVD matrix is transparent to visible light; and wherein the CVD matrix comprises a columnar grain structure. ### Claim 2 (depends on 1) The transparent composite article of claim 1, wherein at least one of the first domed surface and the opposed second surface comprise an integral mounting feature configured to couple the at least one of the first domed surface and the opposed second surface to a bulkhead of the transparent composite article. ### Claim 3 (depends on 1) The transparent composite article of claim 1, comprising an aerodynamic surface opposed to at least one of the first domed surface and the opposed second surface. ### Claim 4 (depends on 1) The transparent composite article of claim 1, comprising up to two mirrors. ### Claim 5 (depends on 1) The transparent composite article of claim 1, configured for use in environments having a temperature from 1500-3000°. ### Claim 6 (depends on 1) The transparent composite article of claim 1, wherein the CVD matrix is formed independent of any reaction with the solid silicon carbide particles. ### Claim 7 (depends on 1) The transparent composite article of claim 1, wherein the silicon carbide material comprises moissanite having a purity greater than 10 ppm. ### Claim 8 (depends on 1) The transparent composite article of claim 1, wherein the silicon carbide material comprise fibers. ### Claim 9 (depends on 1) The transparent composite article of claim 1, wherein the solid silicon carbide particles comprise 400-600 mesh size. ### Claim 10 (depends on 1) The transparent composite article of claim 1, wherein the CVD matrix has a thickness greater than 3 mm. ### Claim 11 (depends on 1) The transparent composite article of claim 1, wherein the CVD matrix comprises a grain size less than 100 micrometers. ### Claim 12 (depends on 1) The transparent composite article of claim 1, wherein the CVD matrix comprises a ratio of silicon to carbon from less than 60:40. ### Claim 13 (depends on 1) The transparent composite article of claim 1, wherein the CVD matrix is translucent to at least one of ultraviolet radiation and infrared radiation. ### Claim 14 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article comprises equiaxial grain structure, a grain size from 10-100 micrometers, a thickness from 3-10 mm, and a ratio of silicon to carbon from 50:50-60:40. ### Claim 15 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article is intrinsically stress free and at least partially lacks subsurface microcracks, dislocation, and deformation due to residual stresses as measured by the variation from a flat surface or by the degree of cracking from the surface through the thickness of the transparent composite article. ### Claim 16 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article at least partially lacks substantial particle pull out as measured by white light interferometry and lacks substantial light scattering as measured by white light interferometry. ### Claim 17 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article has a stiffness greater than 140 kN-m/g, a thermal conductivity greater than 180 W/m-K, and a coefficient of thermal expansion greater than 2×10−6/K. ### Claim 18 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article has a fracture resistance from 2.75-4 MPa-m1/2, a tensile strength from 35-60 ksi, a compression strength from 360-900 ksi, and a bi-axial strength in water from 27-37 ksi. ### Claim 19 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article comprises a conformal shape selected from an exhaust duct shape, a nozzle shape, a fan cowl shape, a thrust reverser shape, an auxiliary power unit shape, a fuselage shape, a tapered wing skin shape, or a nose cone shape or similar geometry. ### Claim 20 (depends on 1) The transparent composite article of claim 1, wherein the transparent composite article is reflective to at least a portion of wavelengths from radio waves, microwaves, infrared, visible light, ultraviolet, X-rays, and gamma rays.