US 6,113,982 A · Composite bodies and methods for making same

Abstract

This invention relates generally to a novel directed metal oxidation process which is utilized to produce self-supporting bodies. In some of the more specific aspects of the invention, a parent metal (e.g., a parent metal vapor) is induced to react with at least one solid oxidant-containing material to result in the directed growth of a reaction product which is formed from a reaction between the parent metal and the solid oxidant-containing material. The inventive process can be utilized to form bodies having substantially homogeneous compositions, graded compositions, and macrocomposite bodies. In a preferred embodiment, the reaction product may be chemically modified or a different reaction product may be coated thereon. Specifically, once a first reaction product is formed on a solid oxidant-containing material, the formed body may be exposed to a vapor-phase parent metal different from the first parent metal. Alternatively the formed body may be exposed to a vapor-phase oxidant having a different chemical composition then the solid oxidant-containing material. Still further, a non-stoichiometric reaction product deficient in the oxidant component may be made more stoichiometric by heating the self-supporting body in the absence of reaction product growth conditions at a temperature and for a time sufficient to effect diffusion of additional oxidant from the solid oxidant-containing material into the sub-stoichiometric reaction product, thereby increasing its stoichiometry.

Claims21

Dependent claims

A method for forming a self-supporting body, comprising:

providing at least one solid oxidant-containing material;
providing at least one first vapor-phase parent metal;
contacting at least a portion of said at least one solid oxidant-containing material with said at least one first vapor-phase parent metal;
permitting said at least one first vapor-phase parent metal and said portion of said at least one solid oxidant-containing material to form at least one first reaction product on said portion of said at least one solid oxidant-containing material;
subsequent to said permitting of said at least one first reaction product to form, providing at least one second vapor-phase parent metal having a different chemical composition from said at least one first vapor-phase parent metal;
contacting at least a portion of said at least one first reaction product with said at least one second vapor phase parent metal;
and
reacting said at least one second vapor-phase parent metal with said at least one reaction product, thereby forming at least one second reaction product having a different chemical composition from said first reaction product.

5 more elements

Dependencies are inferred from the claim text.

Composite bodies and methods for making same

Life of this patent

Composite bodies and methods for making same

Life of this patent

Abstract

Claims21