Polysilocarb Materials and Methods
AssigneeMelior Technology, Inc.
InventorsWalter Sherwood, Mark Land, Brian Benac, Michael Mueller, George Keith, Oliver Wilding, Jr., Douglas Dukes
Life of this patent
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Abstract
Silicon (Si) based materials and methods of making those materials. More specifically, methods and materials having silicon, oxygen and carbon that form filled and unfilled plastic materials and filled and unfilled ceramics.
Claims102
A solvent free method for making a ceramic material, the method comprising:
- a. mixing a first liquid polysilocarb precursor with a second liquid precursor in the absence of a solvent to form a solvent free liquid polysilocarb precursor formulation, whereby the first liquid polysilocarb precursor is not chemically reacted with the second liquid precursor;
- b. curing the polysilocarb precursor formulation to form a sold material, whereby the first liquid polysilocarb precursor and the second liquid precursor chemically react to form the solid material;
- and,
- c. pyrolzing the sold material to form a ceramic material.
A solvent free method for making a neat ceramic material, the method comprising:
- a. preparing a mixture of a first liquid polysilocarb precursor with a second liquid precursor in the absence of a solvent to form a solvent free liquid polysilocarb precursor formulation, whereby the first liquid polysilocarb precursor is not chemically reacted with the second liquid precursor;
- b. curing the polysilocarb precursor formulation to form a neat sold material, whereby the first liquid polysilocarb precursor and the second liquid precursor chemically react to form the neat solid material;
- and,
- c. pyrolzing the neat sold material to form a neat ceramic material.
A solvent free method for making a neat solid material, the method comprising:
- a. preparing a mixture of a first liquid polysilocarb precursor with a second liquid precursor in the absence of a solvent to form a solvent free liquid polysilocarb precursor formulation, whereby the first liquid polysilocarb precursor is not chemically reacted with the second liquid precursor;
- and,
- b. curing the polysilocarb precursor formulation to form a neat sold material, whereby the first liquid polysilocarb precursor and the second liquid precursor chemically react to form the neat solid material.
A reaction free method for making a polysilocarb material, the method comprising:
- a. obtaining a first liquid polysilocarb precursor;
- b. obtaining a second liquid polysilocarb precursor comprising a first reactive group;
- c. obtaining a third liquid polysilocarb precursor comprising a second reactive group;
- and,
- d. mixing the first liquid polysilocarb precursor, the second liquid polysilocarb precursor and the third liquid polysilocarb precursor to form a liquid polysilocarb precursor formulation, wherein the first reactive group is unreacted;
- and the first liquid polysilocarb precursor is not chemically reacted with the second liquid precursor;
- and,
- e. curing the polysilocarb precursor formulation to form a neat sold material, whereby the first liquid polysilocarb precursor and the second liquid precursor chemically react to form the neat solid material.
A method for making a polysilocarb material, the method comprising:
- a. obtaining a first liquid polysilocarb precursor;
- b. obtaining a second liquid polysilocarb precursor comprising a first reactive group;
- c. obtaining a third liquid polysilocarb precursor comprising a second reactive group;
- d. mixing the first liquid polysilocarb precursor, the second liquid polysilocarb precursor and the third liquid polysilocarb precursor to form a liquid polysilocarb precursor formulation, wherein the first reactive group is unreacted;
- and,
- e. curing the polysilocarb precursor formulation, whereby the first reactive group and the second reactive group chemically react to form a sold material.
A method for making a neat polysilocarb material, the method comprising:
- a. obtaining a first liquid polysilocarb precursor;
- b. obtaining a second liquid polysilocarb precursor comprising a first reactive group;
- c. obtaining a third liquid polysilocarb precursor comprising a second reactive group;
- d. mixing the first liquid polysilocarb precursor, the second liquid polysilocarb precursor and the third liquid polysilocarb precursor to form a liquid polysilocarb precursor formulation, wherein the first reactive group is unreacted;
- and,
- e. curing the polysilocarb precursor formulation, whereby the first reactive group and the second reactive group chemically react to form a neat sold material.
A method of making a polysilocarb precursor formulation, the method comprising:
- a. providing an amount of a first precursor to a reaction vessel, the first precursor comprising silicon;
- b. providing an amount of a source of thermal mass to the reaction vessel;
- c. providing an amount of water to the reaction vessel;
- d. providing an amount of a proton source to the reaction vessel;
- e. thereby forming a reaction mixture comprising the first precursor, the source of thermal mass, water and the proton source;
- f. heating the reaction mixture, whereby the activation energy for the reaction mixture is reached, wherein an exothermic reaction takes place in the reaction vessel;
- g. controlling the exothermic reaction to form a polysilocarb precursor formulation;
- h. separating the polysilocarb precursor formation.
A method of making a polysilocarb precursor formulation, the method comprising:
- a. providing an amount of a first precursor, the first precursor comprising silicon and an ethoxy group, to a reaction vessel;
- b. providing a reactant to the reaction vessel;
- c. thereby forming a reaction mixture comprising the first precursor and the reactant;
- and,
- d. obtaining the activation energy for the reaction mixture, wherein an exothermic reaction takes place, the exothermic reaction comprising the formation of a hydroxy group on the first precursor and the reaction of the hydroxy group with an ethoxy group on the first precursor;
- thereby forming a polysilocarb precursor.
A polysilocarb derived ceramic material resulting from the pyrolysis of a polymeric precursor comprising a backbone having the formula —R1—Si—C—C—Si—O—Si—C—C—Si—R2—, where R1 and R2 comprise materials selected from the group consisting of methyl, hydroxyl, vinyl and allyl.
A solid, solvent-free composition comprising:
- a cross-linked polymer matrix having a density of from 0.99 g/cc to 1.25 g/cc, a hardness from Shore D35 to Shore D85, and a flexural strength of up to 3 ksi, the composition being free of ester, carbonate, carbamate or urea linkages.
A method of synthesizing a solid material in the absence of solvent comprising:
- mixing liquid components in the absence of a solvent to form a premixture, the premixture including between 2 and 50% addition reaction cross-linkable groups;
- and 15 crosslinking the premixture in the absence of a solvent to form a solid structure free of ester, carbonate, carbamate or urea linkages.
Dependencies are inferred from the claim text.