Microlaminated composites and method
AssigneeCorning Incorporated
InventorsThomas D. Ketcham, Leroy S. Share, Dell J. St. Julien
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Abstract
Microlaminated composite articles are made by combining one or more sheets of flexible sintered crystalline ceramic foil with one or multiple inorganic substrate layers, e.g., of metal foil, to form a stack which is then heated below the melting temperatures of the foil and substrate layers, and under slight or moderate pressure, to provide a well-bonded composite article which is essentially free of interlaminar cementing or sealing materials.
Claims18
A method for making a microlaminated composite article which essentially consists the steps of:
- providing at least one sheet of flexible sintered crystalline ceramic foil;
- providing at least one inorganic substrate layer of a metal, intermetallic compound or crystalline ceramic material;
- stacking the ceramic foil on the substrate layer;
- and
- heating the stack under pressure at a temperature and for a time at least sufficient to obtain permanent bonding of the ceramic foil sheet directly to the inorganic substrate layer.
A method for making a microlaminated composite article which essentially consists the steps of:
- providing a plurality of sheets of flexible sintered crystalline ceramic foil;
- providing one or a plurality of inorganic substrate layers of a metal, intermetallic compound or crystalline ceramic material;
- forming a sheet stack wherein at least some of the sheets of ceramic foil are in contact with one or more of the inorganic substrate layers;
- and
- heating the sheet stack under pressure to a temperature and for a time at least sufficient to obtain permanent bonding of the ceramic foil sheets directly to the one or more inorganic substrate layers in contact therewith.
A method for making a composite article which essentially consists the steps of:
- providing one or more sheets of a flexible sintered crystalline ceramic foil;
- providing one or more inorganic substrate sheets of metallic or intermetallic composition;
- forming the sheets of foil and substrate sheets into a sheet stack wherein one or more sheets of the ceramic foil are positioned adjacent one or more of the inorganic substrate sheets;
- heating the ceramic foil and substrate sheets to a temperature in the range from about 300 .degree. C. below the lowest sintering temperature of the ceramic foil and inorganic substrate sheets to just below lowest melting temperature of the ceramic foil and inorganic substrate sheets;
- while
- applying pressure to the sheet stack, said pressure being at least sufficient to insure full surface contact between the foil and substrate sheets;
- said heating being continued for a time at least sufficient to obtain direct physical bonding of the ceramic foil to the inorganic substrate sheets.
A microlaminated composite article comprising:
- a plurality of layers of ceramic foil partly or wholly interleaved by a plurality of metallic or intermetallic substrate layers, wherein:
- the layers of ceramic foil are directly bonded to the substrate layers in contact therewith at ceramic foil-substrate interfaces therebetween;
- the layers of ceramic foil and the substrate layers have thicknesses not exceeding about 250 micrometers, and at least one dimension of length or breadth in excess of 1 cm;
- the ceramic foil layers and metallic substrate layers are essentially free of pin-hole defects the ceramic foil-substrate interfaces are essentially free of added adhesive interlayer material.
Dependencies are inferred from the claim text.