Manufacture and use of engineered carbide and nitride composites

a technology of nitride and carbide, which is applied in the field of carbide and nitride composite materials, can solve the problems of high cost, limited use of glass and ceramic manufacturing, and high production cost of technical grade products, which are generally less expensive than commercial grade products, and achieve the effect of reducing production cost and cos

Inactive Publication Date: 2009-06-18
JAMES HARDIE INT FINANCE BV
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  • Abstract
  • Description
  • Claims
  • Application Information

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Benefits of technology

[0013]According to another embodiment of the invention a blowing agent comprises carbide and/or nitride composite containing a diluent, wherein the diluent is a functional component of a glass, ceramic, or metal composite. The diluent may comprise, by weight percent, at least about 5, 10, 20, 40, 50, 80, or more of the blowing agent even up to about 99%. The diluent is preferably silica, carbon, alumina, boron oxide, calcium oxide, magnesium oxide, alkali metal oxides, iron oxide, titanium oxide, zirconium oxide, phosphorous oxide, or combinations thereof The blowing agent may further comprise a binder, which may be an alkali metal containing binder comprising greater than about 3 wt. % of the blowing agent. According to some embodiments, the binder may be alkali metal silicates, alkali metal borates, alkali metal phosphates, polymer emulsions, polyvinyl alcohol emulsions, cellulose ethers, methylcellulose, or sugar.
[0014]Another embodiment of the present invention teaches a method of forming a silicon carbide composite material, wherein the method comprises forming a precursor material comprising at least one silicate material and at least one carbon bearing material; pyrolyzing said precursor to form a carboneous mixture; and reacting carbons in said carboneous mixture with silicon from said silicate material in the presence of nitrogen or hydrogen, inert gases, or vacuum, to form silicon carbide and a controlled amount of at least one diluent, wherein said diluent makes up at least about 10% by weight of the silicon carbide composite material. The method may further include the step of drying sai

Problems solved by technology

Despite the known utility of carbides and nitrides, their widespread use in glass and ceramic manufacturing has been limited to a large extent by their production cost.
Even the technical grade products, which are generally less expensive than commercial grade products, are still costly when compared to conventional oxides such as

Method used

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  • Manufacture and use of engineered carbide and nitride composites
  • Manufacture and use of engineered carbide and nitride composites
  • Manufacture and use of engineered carbide and nitride composites

Examples

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example 1

[0058]Example 1 illustrates a method of manufacturing a mostly amorphous silicon carbide product by using a pyrolyzed carbonaceous source and a siliceous source.

[0059]A mixture was made from 1 part by weight of silica fume, three parts of sugar, and sufficient water to form a slurry with a syrupy consistency. The slurry was dried at 105° C. to form a brittle solid cake. The solid cake was then coarsely ground into a precursor powder having a nominal size of 500 um.

[0060]An enclosed graphite crucible was filled with the precursor powder and heated at 200° C. for 1 hour, and then at 400° C. for 3 hours to melt and pyrolyze the sugar. The crucible was then heated at 1500° C. for 5 hours to allow graphite formation, and then cooled to room temperature. The graphite wall of the crucible acted as an oxygen scavenger and ensured a non-oxidizing atmosphere within the crucible for sugar pyrolysis and carbide formation.

[0061]A sample of the powder formed in the crucible was then subjected to ...

example 2

[0066]Example 2 illustrates the use of a binder with siliceous and carbonaceous starting materials used to produce silicon carbide in a crystallite form.

[0067]A mixture was prepared from 3 parts by weight of a silica fume, 6 parts of graphite powder, and 1 part of sodium silicate. The mixture was then placed into an alumina crucible. An extra 3 parts of graphite powder was then placed on top of the mixture to completely fill the crucible. A lid was placed on top to enclose the crucible. The crucible was then heated at 1500° C. for 4 hours, and then allowed to cool to room temperature.

[0068]The extra graphite acted as an oxygen scavenger to ensure a non-oxidizing environment in the crucible during the carbide formation. The sodium silicate is used as a fluxing and binding agent to bind the silicon carbide and unreacted carbon and silica in a uniform mass.

[0069]The powder formed in the crucible was then subjected to XRD analysis. FIG. 4 shows the XRD pattern for the sample, together w...

example 3

[0070]Example 3 was prepared my mixing 7.5 parts by weight of a powdered commercial montmorillonite clay containing 60% by weight silica with an average particle size of 5 microns with 1 part sugar in water to form pumpable slurry. The slurry was simultaneously spray dried and pyrolyzed in air using a conventional spray drier to form round pellets with an average diameter of 50 microns. The spray drier outlet temperature was maintained at 275° C. The pellets were subsequently heated at 1200° C. in nitrogen to form a powdered material containing silicon carbide dispersed in a diluent of alumina and calcined montmorillonite clay. This SiC rich material is suitable for addition to ceramics or glasses using montmorillonite clays as a raw material.

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Abstract

Carbides and nitrides are provided containing a controlled amount of pre-determined diluents and methods for their manufacture and use are disclosed. The pre-determined diluents include at least one of the silica, silicon metal, carbon, alumina, boron oxide, alkaline earth oxides such as calcium oxide, magnesium oxide, alkali oxides such as sodium oxide, potassium oxide, iron oxide, titanium oxide, and other components typically present in glass, ceramics, or metals. The carbides and nitrides with pre-determined diluents are formed by optionally pyrolyzing a precursor material to form a carboneous mixture and heat treating the carboneous mixture for a pre-determined time and at an elevated temperature during which carbon and/or nitrogen reacts with silica in the mixture to form carbides and/or nitrides and controlled amounts of pre-determined diluents. The carbides and nitrides disclosed herein may be used as blowing agents in a glass, ceramic, or metal forming processes or for promoting dispersion of the carbides and nitrides throughout a glass, ceramic, or metal composite.

Description

RELATED APPLICATIONS[0001]This application claims priority to U.S. Provisional Patent Application having Ser. No. 60 / 515,863, filed on Oct. 29, 2003 entitled “MANUFACTURE AND USE OF CARBIDES AND NITRIDES CONTAINING IMPURITIES,” the entire contents of which is expressly incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates generally to carbide and nitride composite materials, the manufacture of such composites, and their use in the glass making process.[0004]2. Description of the Related Art[0005]Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.[0006]Carbides and nitrides are commonly used to form various articles that can withstand high temperature and stress without substantial deterioration. They are particularly suitable for applications in which oxidation at h...

Claims

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Application Information

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IPC IPC(8): C03C14/00C04B35/565C04B35/577
CPCC03C11/007C03C14/00C04B35/18C04B2235/3826C04B35/522C04B2235/3418C04B2235/3427C04B35/19
Inventor BISCAN, GIANGHOJAJI, HAMIDMELMETH, DAVID LESLIEPHAM, THINHSTEVENS, MARK G.ZHANG, HUAGANG
Owner JAMES HARDIE INT FINANCE BV
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