Emulsion Processing for Dense Polymer Derived Ceramic Particles
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Solution Overview
Problem
Current methods for producing Polymer Derived Ceramic (PDC) particles are limited in achieving fully dense sizes above 200 μm, with existing technologies resulting in inconsistent and poorer quality particles due to tedious washing schemes and the use of partially cross-linked resins, making it difficult to manufacture large, high-quality PDC particles and compositions.
Innovation Solution
The development of a novel emulsion processing method that uses a liquid pre-catalyzed polymeric ceramic precursor resin, introducing it to a continuous phase liquid emulsion, curing, and incorporating enhancement particles to create fully dense PDC particles ranging from 200 μm to 100 mm in diameter, with multiple coating layers to form a multi-functional composite, avoiding traditional sol-gel and flame pyrolysis processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sol-gel and flame pyrolysis methods are used to produce ceramic particles, then the particles can be made, but they exhibit porosity and flaws that result in poor surface characteristics and increased crack propagation
Solution Approach 1:
The patent changes the fundamental processing parameters by using emulsion polymerization instead of traditional sol-gel or flame pyrolysis. This parameter change enables the formation of fully dense particles without porosity or flaws, directly resolving the contradiction between particle production and surface quality
Solution Approach 2:
The patent creates composite ceramic particles by incorporating enhancement particles (such as metal oxides, ceramic powders, or carbon materials) into the polymer-derived ceramic matrix during the emulsion polymerization process. This composite approach improves surface characteristics and reduces crack propagation while maintaining full density
2Productivity
If emulsion processing with partially cross-linked resins is used to make ceramic particles, then particles can be produced, but the washing scheme becomes tedious and the product quality becomes inconsistent
Solution Approach 1:
The patent applies preliminary action by using pre-catalyzed polymeric ceramic precursor resins that are prepared in advance with controlled composition and molecular weight. This preliminary preparation ensures consistent particle formation during emulsion polymerization, eliminating the need for tedious washing and improving product consistency
Solution Approach 2:
The patent extracts and removes the problematic partially cross-linked resin component from the emulsion system. By using fully cross-linked or non-cross-linked pre-catalyzed resins instead, the patent eliminates the source of inconsistency and reduces the need for extensive washing procedures
3Volume of moving object
If conventional methods are used to produce large PDC particles above 200 μm, then particles can be made, but they remain porous and of poor quality
Solution Approach 1:
The patent transitions from producing particles in the traditional size range to creating large particles above 200 μm by controlling the emulsion droplet size and polymerization kinetics. This dimensional expansion is achieved by adjusting the water-to-monomer ratio, surfactant concentration, and reaction temperature, resulting in fully dense large particles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of fully dense PDC particles with improved surface characteristics and reduced crack propagation, achieving unique sizes and compositions not previously possible, with lower costs and energy requirements, suitable for applications such as proppants and ball bearings.
Implementation Method 1
curing a gelatinous polymer ceramic precursor material
Implementation Method 2
pyrolizing the coated gelatinous polymer ceramic precursor material to produce a plurality of enhanced polymer derived ceramic (PDC) particles
Data Source
AI summary
Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 μm to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. Nano-sized ceramic particles are formed from the green body produced by methods for making bulk, dense composite ceramics. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.