Silicon Core Infiltration for Adhesive-Free Ceramic Channels
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Solution Overview
Problem
Conventional methods for creating ceramic components with internal features, such as channels, face issues with excess adhesive forming beads that clog small features and result in poor bonding materials with inadequate thermal and electrical conductivity.
Innovation Solution
A method using a silicon consumable core to form internal features without adhesives, where the silicon melts and infiltrates into the preform, creating open channels and avoiding the formation of glue beads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If SiC-based glue or adhesive is used to bond preform pieces, then bonding strength is improved, but excess adhesive forms beads that clog small internal channels and features
Solution Approach 1:
The patent removes the adhesive bonding step entirely from the process. Instead of using SiC-based glue to bond preform pieces, the invention uses a consumable silicon core that is melted and reacted with carbon to form SiC, eliminating the source of excess adhesive that clogs channels.
Solution Approach 2:
The patent introduces a consumable silicon core that is intentionally designed to be destroyed or transformed during the bonding process. The silicon core melts and reacts with carbon to form SiC, sacrificing the temporary silicon structure to create the final bonded component without adhesive residue.
2Strength
If SiC-based glue is used for bonding, then bonding is achieved, but thermal and electrical conductivity are reduced due to poor bonding material properties
Solution Approach 1:
The patent changes the material composition parameter by using pure silicon and carbon reactants that form SiC through reaction bonding, rather than using pre-mixed SiC-based adhesive. This results in superior thermal and electrical conductivity because the bonding region consists of reaction-formed SiC rather than composite adhesive material.
Solution Approach 2:
The patent creates a composite structure where silicon and carbon react to form SiC at the bonding interface. This reaction-formed SiC composite has superior thermal and electrical conductivity compared to conventional SiC-based adhesives, while maintaining strong bonding.
3Manufacturing precision
If glass bonding is used to avoid adhesive beads, then channel clogging is avoided, but corrosion resistance, thermal conductivity, electrical conductivity, and elevated temperature strength are compromised
Solution Approach 1:
The patent changes the bonding mechanism from glass bonding to reaction bonding using silicon and carbon. This results in superior material properties including better corrosion resistance, thermal conductivity, electrical conductivity, and elevated temperature strength, while maintaining clean channels.
Solution Approach 2:
The patent applies different material properties to different regions: the bulk ceramic maintains its inherent properties, while the bonding interface uses reaction-formed SiC with superior thermal and electrical conductivity. This localized optimization eliminates the need for glass bonding while achieving both channel cleanliness and material reliability.
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
Enables the production of ceramic components with ultra-small features and improved thermal and electrical conductivity, while maintaining homogenous material properties and hermeticity.
Implementation Method 1
the silicon melts and infiltrates into the preform
Implementation Method 2
infiltrates into the preform
Implementation Method 3
reaction bonded ceramic components
Data Source
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AI summary
A method of making reaction bonded ceramic components having one or more internal features comprising: producing a Si consumable core shape representative of the features to be formed; assembling the mold maintaining the location of the Si consumable core; casting a preform slurry around the Si consumable core to create a preform piece; and reaction bonding said preform piece to yield said ceramic components having internal features.