US 4,898,631 A · Method for fabricating ceramic filaments and high density tape casting method

Abstract

An apparatus and method is disclosed for fabricating mats of ceramic material comprising preparing a slurry of ceramic particles in a binder/solvent, charging the slurry into a vessel, forcing the slurry from the vessel into spinneret nozzles, discharging the slurry from the nozzles into the path of airjets to enhance the sinuous character of the slurry exudate and to dry it, collecting the filaments on a moving belt so that the filaments overlap each other thereby forming a mat, curing the binder therein, compressing and sintering the mat to form a sintered mat, and crushing the sintered mat to produce filament shaped fragments. A process is also disclosed for producing a tape of densely packed, bonded ceramic particles comprising forming a slurry of ceramic particles and a binder/solvent, applying the slurry to a rotating internal molding surface, applying a large centrifugal force to the slurry to compress it and force excess binder/solvent from the particles, evaporating solvent and curing the binder thereby forming layers of bonded ceramic particles and cured binder, and separating the binder layer from the layer of particles. Multilayers of ceramic particles are cast in an analogous manner on top of previously formed layers. When all of the desired layers have been cast the tape is fired to produce a sintered tape. For example, a three-layer tape is produced having outer layers of highly compressed filament shaped fragments of strontium doped lanthanum ("LSM") particles and a center layer of yttria stabilized zicronia ("YSZ") particles.

Claims21

Dependent claims

A method of forming a mat of overlying sinuous filaments having a predetermined thickness comprising:

(a) blending a mixture comprising
(i) finely divided solid particles,
(ii) a binder operable for bonding said solid particles together, and
(iii) a solvent for said binder, into an uniformly dispersed slurry;
(b) transforming said slurry into a plurality of downwardly falling filaments;
(c) deflecting said plurality of downwardly falling filaments with a plurality of impinging gas streams operative for deflecting and bending said filaments into a plurality of downwardly falling sinuous filaments while simultaneously removing said solvent therefrom by evaporation;
and
(d) collecting said plurality of sinuous filaments on a moving surface in such a manner that said plurality of sinuous filaments overlap each other a predetermined amount thereby forming a mat of overlying sinuous filaments having a predetermined thickness.

5 more elements

A method of producing a tape of densely packed, bonded solid particles comprising:

(a) blencing a mixture comprising
(i) finely divided solid particles,
(ii) a binder operable upon curing for bonding said finely divided solid particles together, and
(iii) a solvent for said binder, into a uniformly dispersed slurry;
(b) introducing said thusly blended uniformly dispersed slurry onto a rotating internal molding surface;
(c) applying an effective centrifugal force to said slurry thusly introduced onto said rotating internal molding surface which is operable for transforming said slurry into an outer, densely packed, annular layer of said solid particles coated with a small amount of said solvent and said binder which is compressed against said molding surface by said centrifugal force and an inner annular layer of said solvent and said binder which is compressed against said outer, densely packed, annular layer of said solid particles by said centrifugal force, the amount of binder used for forming said uniformly dispersed slurry in step (a) being in excess of an amount required to bond said solid particles together;
(d) after forming said outer and inner annular layers and while applying said centrifugal force, removing said solvent from said outer and inner annular layers by evaporation;
(e) allowing said binder coating said solid particles in said outer annular layer to bond said solid particles together thereby forming an outer, densely packed, bonded, annular layer of said solid particles, and allowing said binder in said inner annular layer to cure into a solid state thereby forming an inner annular layer of cured binder;
(f) removing said applied centrifugal force from said outer and inner annular layer and thereafter separating said inner annular layer of cured binder from said outer, densely packed, bonded, annular layer of said solid particles;
and
(g) separating said outer densely packed, bonded, annular layer of said solid particles from said molding surface thereby producing a tape of densely packed, bonded solid particles.

8 more elements

A mehtod of producing a multilayer tape of sensely packed, bonded solid particles comprising:

(a) blending a first mixture comprising
(i) finely divided first solid particles having a chemical composition,
(ii) a first binder operable upon curing for bonding said finely divided first solid particles together, and
(ii) a first solvent for said first binder, into an uniformly dispersed first slurry;
(b) introducing said thusly blended uniformly dispersed first slurry onto a rotating internal molding surface;
(c) applying an effective centrifugal force to said first slurry thusly introduced onto said rotating internal molding surface which is operable for transforming said first slurry into an outer, densely packed, annular layer of said, first solid particles coated with a small amount of said firt solvent and said firt binder which is compressed against said molding surface by said centrifugal force, and an inner annular layer of said first solvent and said first binder which is compressed against said outer, densely packed, annular layer of said first solid particles by said centrifugal force, the amount of said first binder used for forming said uniformly dispersed first slurry in step (a) being in excess of an amount required to bond said first solid particles together;
(d) aftr forming said outer and inner layers and while applying said centrifugal force, removing said first solvent from said outer and inner annular layers by evaporation;
(e) allowing said first binder coating said first solid particles in said outer, densely packed, annular layer to bond said first solid particles together thereby forming an outer densely packed, bonded, annular layer of said first solid particles, and allowing said first binder in said inner annular layer to cure into a solid state thereby forming an inner annular layer of cured first binder;
(f) removing said applied centrifugal force from said outer and inner annular layers and thereafter separating said inner annular layer of cured first binder from said outer, densely packed, bonded annular layer of said first solid particles;
(g) blending a second mixture comprising
(i) finely divided second solid particles having a chemical composition which is different from said chemical composition of said first solid particles,
(ii) a second binder operable upon curing for bonding said finely divided second solid particles together, and
(ii) a second solvent for said second binder, into an uniformly dispersed second slurry, said second binder and said second solvent not being capable of chemically attacking said first binder in said thusly produced outer, densely packed, bonded, annular layer of said first solid particles;
(h) rotating said internal solding surface containing said outer, densely packed, bonded, annular layer of said first solid particles;
(i) introducing said thusly blended uniformly dispersed second slurry onto said rotating outer, densely packed, bonded, annular layer of said first solid particles;
(j) applying an effective centrifugal force to said second slurry thusly introduced onto said rotating outr, densely packed, bonded, annular layer of said first solid particles which is operable for transforming said second slurry into a second, densely packed, annular layer of said second solid particles coated with a small amount of said second solvent and said second binder which is compressed against said outer, densely packed, bonded, annular layer of said first solid particles by said last mentioned centrigugal force, and an inner annulr layer of said second solvent and said second binder which is compressed against said second, densely packed, annular layer of said second solid particles by said last mentioned centrifugal force, the amount of said second binder used for forming said uniformly dispersed second slurry in step (g) being in excess of an amount required to bond said second solid particles together;
(k) aftr forming said second, densely packed, annular layer of said second solid paticles and said inner annular layer of said second solvent and said second binder, removing said second solvent therefrom by evaporation;
(l) allowing said second binder coating said second solid particles in said second, densely packed, annular layer of said second solid particles to bond said second solid particles thereof together thereby forming a second, densely packed, bonded, annular layer of said second solid particles, and allowing said second binder in said last mentioned inner annular layer to cure into a solid state thereby forming an inner annular layer of cured second binder;
(m) removing said last mentioned applied centrifugal force from said annular layers and thereafter separating said inner annular layer of cured second binder from said second, densely packed, bonded, annular layer of said second solid particles thereby forming a composite layer of said second solid particles thereby forming a composite layer structure which comprises said outer, densely packed, bonded, annular layer of said first solid particles and bonded thereto said second, densely packed, bonded annular layer of said second solid particles;
and
(n) separating said composite layer structure from said internal molding surface thereby producing a multilayer tape of densely packed, bondedf solid particles.

18 more elements

A method of producing a multilayer tape of densely packed, bonded solid particles comprising:

(a) blending a first mixture comprising
(i) finely divided first solid particles having a chemical composition,
(ii) a first binder operable upon curing for bonding said finely divided first solid particles together, and
(ii) a first solvent for said first binder, into an uniformly dispersed first slurry;
(b) introducing said thusly blended uniformly dispersed first slurry onto a rotating internal molding surface;
(c) applying an effective centrifugal force to said first slurry thusly introduced onto said rotating internal molding surface which is operable for transforming said first slurry into an outer, densely packed, annular layer of said, first solid particles coated with a small amount of said first solvent and said first binder which is compressed against said molding surface bvy said centrifugal force, and an inner annular layer of said first solvent and said first binder which is compressed against said outer, densely packed, annular layer of said first solid particles by said centrifugal force, the amount of said first binder used for forming said uniformly dispersed first slurry in step (a) being in excess of an amount required to bond said first solid particles together;
(d) after forming said outer and inner layers and while applying said centrifugal force, removing said first solvent from said outer and inner annular layers by evaporation;
(e) allowing said first binder coating said first solid particles in said outer, densely packed, annular layer to bond said first solid particles together thereby forming an outer densely packed, bonded, annular layer of said first solid particles, and allowing said first binder in said inner annular layer to cure into a solid state thereby forming an inner annular layer of cured first binder;
(f) removing said applied centrifugal force from said outer and inner annular layers and thereafter separating said inner annular layer of cured first binder from said outer, densely packed, bonded annular layer of said first solid particles;
(g) blending a second mixture comprising
(i) finely divided second solid particles having a chemical composition which is different from said chemical composition of said first solid particles,
(ii) a second binder operable upon curing for bonding said finely divided second solid particles together, and
(iii) a second solvent for said second binder, into an uniformly dispersed second slurry, said second binder and said second solvent not being capable of chemically attacking said first binder in said thusly produced outer, densely packed, bonded, annular layer of said first solid particles;
(h) rotating said internal molding surface containing said outer, densely packed, bonded, annular layer of said first solid particles;
(i) introducing said thusly blended uniformly dispersed second slurry onto said rotating outer, densely packed, bonded, annular layer of said first solid particles;
(j) applying an effective centrifugal force to said second slurry thusly introduced onto said rotating outer, densely packed, bonded, annular layer of said first solid particles which is operable for transforming said second slurry into a second, densely packed, annular layer of said second solid particles coated withf a small amount of said second solvent and said second binder which is compressed against said outer, densely packed, bonded, annular layer of said first solid particles by said last mentioned centrifugal force, and an inner annular layer of said second solvent and said second binder which is compressed against said second, densely pakced, annular layer of said second solid particles by said last mentioned centrifugal force, the amount of said second binder used for forming said uniformly dispersed second slurry in step (g) being in excess of an amount required to bond said second solid particles together;
(k) after forming said second, densely packed, annular layer of said second solid aprticles and said inner annular layer of said second solvent and said second binder, removing said second solvent therefrom by evaporation;
(l) allowing said second binder coating said second solid particles in said second, densely packed, annular layer of said second solid particles to bond said second solid particles thereof together thereby forming a second, densely packed, bonded, annular layer of said second solid particles, and allowing said second binder in said last mentioned inner annular layer to cure into a solid state thereby forming an inner annular layer of cured second binder;
(m) removing said last mentioned applied centrifugal force from said annular layers and thereafter separating said inner annular layer of cured second binder from said second, densely packed, bonded, annular layer of said second solid particles;
(n) blending a thirs mixture comprising
(i) finely divided third solid particles having a chemical composition which is different from said chemical composition of said second solid particles,
(ii) a third binder operable for bonding said finely divided third solid particles together, and
(iii) a third solvent for said third binder, into an uniformly dispersed third slurry, said third binder and said third solvent not being capable of chemically attacking said second binder in said thusly formed second, densely pakced, bonded, annular layer of said second solid particles;
(o) rotating said internal molding surface containing said outer, densely packed, bonded annular layer of said first solid particles and said second, densely packed, bonded, annular layer of said second solid particles;
(p) introducing said thusly blended uniformly dispersed third slurry onto said rotating second, densely packed, bonded, annular layer of said second solid particles;
(q) applying an effective centrifugal force to said second slurry thusly introduced onto said rotating seocnd, densely packed, bonded, annular layer of said second solid particles which is operable for transforming said third slurry into a third, densely packed, annular layer of said third solid particles coated with a small amount of said third solvent and said third binder which is compressed against said second, densely packed, bonded, annular layer of said second solid particles by said last mentioned centrifugal force, and an inner annular layer of said third solvent and said third binder which is compressed against said third, densely packed, annular layer of said third solid particles by said last mentioned centrifugal force, the amount of said third binder used for forming said uniformly dispersed third slurry in step (n) being in excess of an amount required to bond said third solid particles together;
(r) after forming said third, densely packed, annular layer of said third solid particles and said inner annular layer of said third solvent and said third binder, removing said third solvent threfrom by evaporation;
(s) allowing said third binder coating said third solid particles in said third, densely packed, annular layer of said third solid particles to bond said third solid particles thereof together thereby forming a third, densely packed, bonded, annular layer of said third solid particles, and allowing said third binder in said last mentioned inner annular layer to cure into a solid state thereby forming an inner annular layer of cured third binder;
(t) removing said last mentioned applied centrifugal force from said annular layers and thereafter separating said inner annular layer of cured third binder from said third, densely packed, bonded, annular layer of said third solid particles thereby forming a composite layer structure which comprises said outer, densely packed, bonded, annular layer, of said first solid particles which is bonded to said second, densely packed, bonded, annular layer of said second solid particles, which is bonded to said third, densely packed, bonded, annular layer of said third solid particles;
and
(u) separating said composite layer structure from said internal molding surface thereby producing a multilayer tape of densely packed, bonded solid particles.

28 more elements

A method of producing a multilayer tape of sensely packed, bonded solid particles comprising a layer of yttria stabilized zirconia particles sandwiched between and bonded to layers of ilament shaped fragments of bonded agglomerates of strontium lanthanum manganite particles comprising:

(a) blending a mixture comprising
(i) finely divided solid particles of strontium lanthanum manganite,
(ii) a binder operable for bonding said solid particles together, and
(iii) a solvent for said binder, into an uniformly dispersed slurry;
(b) transforming said slurry into a plurality of downwardly falling filaments;
(c) deflecting and drying said plurality of downwardly falling filaments with a plurality of impinging gas streams operative for deflecting and bending said filaments into a plurality of downwardly falling sinuous filaments while simultaneously removing said solvent therefrom by evaporation;
(d) collecting said plurality of sinuous filaments on a moving surface in such a manner that said plurality of sinuous filaments overlap each other in a predetermined amount thereby forming a mat of overlying sinuous filaments having a predetermine thickness;
(e) compressing said mat to increase the filament-to-filament contact therein thereby producing a pressed mat;
(f) sintering said pressed mat at a temperature operable for increasing the amount of filament-to-filament bonding therein thereby providing a bonded mat;
(g) comminuting said bonded mat thereby producing filament shaped fragments of bonded agglomerates of strontium lanthanum manganite particles;
(h) blending a first mixture comprising
(i) said filament shaped fragments produced in step (g),
(ii) a first binder operable upon curing for bonding said filament shaped fragments together, and
(iii) a first solvent for said first binder, into an uniformly dispersed first slurry;
(i) introducing said thusly blended uniformly dispersed first slurry onto a rotating internal molding surface;
(j) applying an effective centrifugal force to said first slurry thusly introduced onto said rotating internal molding surface which is operable for transforming said first slurry into an outer, densely packed, annular layer of said filament shaped fragments coasted with a small amount of said first solvent and said first binder which is compressed against said molding surface by said centrifugal force, and an inner annular layer of said first solvent and said first binder which is compressed against said outer, densely packed, annular layer of said filament shaped fragments by said centrifugal force, the amount of said first binder used for forming said uniformly dispersed first slurry in step (h) being in excess of an amount required to bond said filament shaped fragments together;
(k) after forming said outer and inner layers and while applying said centrifugal force, removing said first solvent from said outer and inner annular layers by evaporation;
(l) allowing said first binder coating said filament shaped fragments in said outer, densely packed, annular layer to bond said filament shaped fragments together thereby forming an outer densely packed, bonded, annular layer of said filament shaped fragments, and allowing said first binder in said inner annular layer to cure into a solid state thereby forming an inner annular layer of cured first binder;
(m) removing said applied centrifugal force from said outer and inner annular layers and thereafter separating said inner annular layer of cured first binder from said outer, densely packed, bonded annular layer of said filament shaped fragments;
(n) blending a second mixture comprising
(i) finely divided yttria stabilized zirconia particles,
(ii) a second binder operable upon curing for bonding said finely divided yttria stabilizied zirconia particles together, and
(iii) a second solvent for said second binder, into an uniformly dispersed second slurry, said second binder and said second solvent not being capable of chemically attacking said first binder in said thusly produced outer, densely packed, bonded, annular layer of said filament shaped fragments;
(o) rotating said internal molding surface containing said outer,f densely packed, bonded, annular layer of said filament shaped fragments;
(p) introducing said thusly blended uniformly dispersed second slurry onto said rotating outer, densely packed, bonded, annular layer of said filament shaped fragments;
(q) applying an effective centrifugal force to said second slurry thusly introduced onto said rotating outer, densely packed, bonded, annular layer of said filament shaped fragments which is operable for transforming said second slurry into a second, densely packed, annular layer of said yttria stabilized zirconia particles coated with a small amount of said second solvent and said second binder which is compressed against said outer, densely packed, bonded, annular layer of said filament shaped fragments by said last mentioned centrifugal force, and an inner annular layer of said second solvent and said second binder which is compressed against said second, densely packed, annular layer of said yttria stabilized zirconia particles by said last mentioned centrifugal force, the amount of said second binder used for forming said uniformly dispersed second slurry in step (n) being in excess of an amount required to bond said yttria stabilized zirconia particles together;
(r) after forming said second, densely packed, annular layer of said yttria stabilized zirconia particles and said inner annular layer of said second solvent and said second binder, removing said second solvent therefrom by evaporation;
(s) allowing said second binder coating said yttria stabilized zirconia particles in said second, densely packed, annular layer of said yttria stabilized zirconia particles to bond said yttria stabilized zirconia particles thereof together thereby forming a second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles, and allowing said second binder in said last mentioned inner annular layer to cure into a solid state thereby forming an inner annular layer of cured second binder;
(t) removing said last mentioned applied centrifugal force from said annular layers and thereafter separating said inner annular layer of cured second binder from said second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles;
(u) blending a third mixture comprising
(i) said filament sahped fragments produced in step (g),
(ii) a third binder operable for bonding said filament shaped fragments together, and
(iii) a third solvent for said third binder, into an uniformly dispersed third slurry, said third binder and said third solvent not being capable of chemically attacking said second binder in said thusly formed second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles;
(v) rotating said internal molding surface containing said outer, densely packed, bonded annular layer of said filament shaped fragments and said second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles;
(w) introducing said thusly blended uniformly dispersed third slurry onto said rotating second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles;
(x) applying an effective centrifugal force to said second slurry thusly introduced onto said rotating second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles which is operable for transforming said third slurry into a third, densely packed, annular layer of said filament shaped fragments coated with a small amount of said third solvent and said third binder which is compressed against said second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles by said last mentioned centrifugal force, and an inner annular layer of said third solvent and said third binder which si compressed against said third, densely packed, annular layer of said filament shaped fragments by said last mentioned centrifugal force, the amount of said third binder used for forming said uniformly dispersed third slurry in step (u) being in excess of an amount required to bond said filament shaped fragments together;
(y) after forming said third, densely packed, annular layer of said filament shaped fragments and said inner annular layer of said third solvent and said third binder, removing said third solvent therefrom by evaporation;
(z) allowing said third binder coating said filament shaped fragments in said third, densely packed,f annular layer of said filament shaped fragments to bond said filament shaped fragments thereof together thereby forming a third, densely packed, bonded, annular layer of said filament shaped fragments, and allowing said third binder in said last mentioned inner annular layer to cure into a solid state thereby forming an inner annular layer of cured third binder;
(aa) removing said last mentioned applied centrifugal force from said annular layers and thereafter separating said inner annular layer of cured third binder from said third, densely packed, bonded, annular layer of said filament shaped fragments thereby forming a composite layer structure which comprises said outer, densely packed, bonded, annular layer, of said filament shaped fragments which is bonded to said second, densely packed, bonded, annular layer of said yttria stabilized zirconia particles, which is bonded to said third, densely packed, bonded, annular layer of said filament shaped fragments;
and
(bb) separating said composite layer structure from said internal molding surface thereby producing a multilayer tape of densely packed, bonded solid particles comprising a layer of yttria stabilized zirconia particles sandwiched between and bonded to layers of filament shaped fragments of bonded agglomerates of strontium lanthanum manganite particles.

38 more elements

Dependencies are inferred from the claim text.

Method for fabricating ceramic filaments and high density tape casting method

Life of this patent

Method for fabricating ceramic filaments and high density tape casting method

Life of this patent

Abstract

Claims21