SiOC Nanocomposite Materials Eliminating Nano-voids
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Solution Overview
Problem
There is a long-standing need for materials that offer high performance characteristics at lower costs and greater manufacturing flexibility compared to existing ceramics and plastics, with enhanced features that cannot be achieved with prior silicon-based products.
Innovation Solution
Development of nanocomposite materials comprising silicon and carbon with specific compositions and structures, including polymer-derived ceramic compositions, that provide unique properties such as high bulk density, specific gravity, and absence of nano-voids, enabling applications in various forms and uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional ceramics are used to achieve high performance characteristics, then material strength and durability are improved, but manufacturing flexibility and cost are worsened
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating silicon, oxygen, and carbon in specific ratios to create a nanocomposite material that maintains ceramic strength while enabling new manufacturing approaches. The specific composition (SiO2, SiO, SiC, free carbon) allows the material to be processed differently than traditional ceramics.
Solution Approach 2:
The invention creates a composite material system combining multiple phases (amorphous SiO2, crystalline SiO, SiC, and free carbon) within a single material matrix. This composite structure provides the strength of ceramics while the organic-inorganic hybrid nature enables greater manufacturing flexibility compared to traditional inorganic ceramics.
2Ease of manufacture
If traditional plastics are used to achieve manufacturing flexibility and cost-effectiveness, then ease of manufacture is improved, but material strength and performance characteristics are worsened
Solution Approach 1:
The patent creates an organic-inorganic hybrid composite that combines the processing advantages of plastics with the strength of ceramics. The material contains organic components (free carbon, hydrocarbon groups) that enable plastic-like manufacturability while incorporating inorganic phases (SiO2, SiO, SiC) that provide ceramic-level strength and durability.
Solution Approach 2:
The invention distributes different phases locally within the material matrix - amorphous SiO2 and crystalline SiO provide structural strength in specific regions, while free carbon and hydrocarbon groups provide flexibility and ease of processing in other regions. This local differentiation of properties allows simultaneous achievement of strength and manufacturability.
3Quantity of substance
If existing silicon-based products are used to achieve certain properties, then material availability is improved, but enhanced performance characteristics and new features are worsened
Solution Approach 1:
The patent changes the silicon-based material parameters by creating a multi-phase composition with specific ratios of SiO2, SiO, SiC, and free carbon. This parameter modification transforms conventional silicon-based products into a nanocomposite material with enhanced performance characteristics and new functional properties not available in traditional silicon materials.
Solution Approach 2:
The invention creates a composite silicon-based material that incorporates multiple phases (amorphous and crystalline silicon oxides, silicon carbide, and free carbon) to achieve performance characteristics that cannot be obtained with conventional silicon-based products. This composite structure provides both availability (based on common silicon chemistry) and enhanced versatility.
Data Source
AI summary
Nanocomposite silicon and carbon compositions. These compositions can be made from polymer derived ceramics, and in particular, polysilocarb precursors. The nanocomposite can have non-voids or be nano-void free and can form larger macro-structures and macro-composite structures. The nanocomposite can contain free carbon domains in an amorphous SiOC matrix.