Abstract

Foam compositions comprising an inorganic resin matrix or a polymer-derived ceramic matrix are provided, as well as methods of fabricating the same. The foams may or may not contain additional functional fillers to control mechanical and/or thermophysical properties. The foam materials can include a novel combination of tailorable inorganic siloxane resins with unique fillers, and unique methods of producing the desired porosity. Unlike related art foams, the foams of embodiments of the subject invention can be inorganic-resin-based, and can be closed cell foams or semi-closed cell foams.

IPC Classes  ?

• C04B 38/06 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by burning-out added substances
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
• C04B 38/02 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by adding chemical blowing agents
• C04B 38/10 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by using foaming agents

IPC Classes  ?

• C01B 32/907 - OxycarbidesSulfocarbidesMixture of carbides
• C01B 32/956 - Silicon carbide
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/634 - Polymers
• C04B 35/636 - Polysaccharides or derivatives thereof
• C04B 35/64 - Burning or sintering processes
• H01M 4/1393 - Processes of manufacture of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• H01M 4/1397 - Processes of manufacture of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy

Abstract

A composite electrode is made by combining a compatible polymer derived ceramic resin with a bioderived source of carbon and pyrolyzing the mixture. The resulting composite may be milled into a spherodized particulate powder and formed into an electrode of a battery with or without preionization of the electrode. For example, the bioderived source of carbon is selected from a polysaccharide.

IPC Classes  ?

• H01M 4/04 - Processes of manufacture in general
• H01M 4/587 - Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals

Goods & Services

Paints; Primers

Abstract

Synthetic aggregate that includes a plurality of agglomerations. Each of the plurality of agglomerations may include a core; and a shell material disposed on the core. According to various embodiments, the construction aggregate may be non-flammable. According to various embodiments, at least one agglomeration of the plurality of agglomerations may have a plurality of cores. The core may include coal, a coal byproduct, and combinations thereof. According to various embodiments, the coal may be a type such as lignite, sub-bituminous, bituminous, and anthracite. The coal byproduct may be fly ash, bottom ash, shale coal, or coal gob.

IPC Classes  ?

• C04B 20/10 - Coating or impregnating
• C04B 14/02 - Granular materials
• C04B 18/02 - Agglomerated materials
• C04B 18/08 - Flue dust
• C04B 28/04 - Portland cements

Abstract

A composite material, compositions, processes and methods of using coal and coal by-products composite ceramics is provided for use as a safe, non-toxic material for construction, building and architecture components. The composite material disclosed herein is formed from resin/coal aggregates that contain and prevent the release of harmful impurities that naturally occur in both coal and coal by-products while the advantages of coal-based composites are made available to the building industry. The strength, density and porosity of the composites can be tailored within a wide range to fit the final application by controlling the materials, form factor and processing parameters during fabrication.

IPC Classes  ?

• C04B 35/532 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components containing a carbonisable binder
• C04B 35/628 - Coating the powders
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 18/02 - Agglomerated materials
• C04B 35/634 - Polymers

Abstract

Polymer derived ceramic (PDC) materials, compositions and methods of making high capacity, long cycle, long life battery anodes to improve the performance of batteries of all types, including but not limited to coin cell batteries, electric vehicle (EV) batteries, hybrid electric vehicle (HEV) batteries, plug-in hybrid electric vehicle (PHEV) batteries, battery electric vehicle (BEV) batteries, lithium cobalt (LCO) batteries, lithium iron (LFP) batteries; and lithium-ion (Li) batteries, and lead acid batteries. Silicon is incorporated in the PDC material at a molecular level when reacting a polymer derived ceramic precursor and a silicon hydride constituent or a silicon alkoxide constituent to form a PDC composition useful as a powdered battery anode material. A predetermined amount of divinylbenzene is added as a crosslinker and a modifier to increase free carbon content. The resulting battery anode materials increase the specific capacity of a battery measured in milliampere-hours per gram (mAh/g) and increase the life cycle of a battery while minimizing distortion and stress of the anode structure.

IPC Classes  ?

• H01M 4/36 - Selection of substances as active materials, active masses, active liquids
• C01B 33/021 - Preparation
• C08G 77/20 - Polysiloxanes containing silicon bound to unsaturated aliphatic groups
• H01M 4/38 - Selection of substances as active materials, active masses, active liquids of elements or alloys
• H01M 4/60 - Selection of substances as active materials, active masses, active liquids of organic compounds
• H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• H01M 4/02 - Electrodes composed of, or comprising, active material

Abstract

A polymer derived ceramic precursor is selected and mixed with a contaminated recycled electrode material or materials. The mixture is pyrolyzed to form a ceramic or ceramic-carbon composite, reduced to a powder and formed into an electrode of a battery, such as a lithium ion battery.

IPC Classes  ?

• H01M 10/54 - Reclaiming serviceable parts of waste accumulators
• H01M 4/04 - Processes of manufacture in general
• H01M 4/58 - Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFySelection of substances as active materials, active masses, active liquids of polyanionic structures, e.g. phosphates, silicates or borates
• H01M 10/05 - Accumulators with non-aqueous electrolyte
• H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
• H01M 4/587 - Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals

Abstract

Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of ceramic materials and components with a thickness greater than three millimeters (3 mm). A sulfur-free 3D printable formulation comprises a liquid inorganic polymer resin using Stereolithograpy (SLA) printers and Digital Light Processing (DLP) curing of the polymer resin via the chemical bonding of the materials rather than sintering. Thus, the process has shorter manufacturing intervals, significantly lower energy use and produces larger scale ceramic components having less linear shrinkage, less mass loss and high ceramic yield with no corrosive sulfur compounds present in the ceramic component.

IPC Classes  ?

• B28B 1/00 - Producing shaped articles from the material
• C08L 83/16 - Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen, or carbon onlyCompositions of derivatives of such polymers in which all the silicon atoms are connected by linkages other than oxygen atoms
• C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
• C04B 35/01 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides
• C04B 35/632 - Organic additives
• C04B 40/02 - Selection of the hardening environment
• C09C 1/00 - Treatment of specific inorganic materials other than fibrous fillers Preparation of carbon black
• C09C 1/48 - Carbon black
• C09C 1/64 - Aluminium
• C08L 83/04 - Polysiloxanes
• B33Y 10/00 - Processes of additive manufacturing
• B33Y 70/00 - Materials specially adapted for additive manufacturing
• C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
• C04B 35/74 - Ceramic products containing macroscopic reinforcing agents containing shaped metallic materials

Abstract

PDC resins are mixed with various sources of carbon to form electrodes through pyrolysis of the mixture of PDC resins and coal dust derived materials with or without other sources of carbon, substrates and the like. For example, a PDC resin—coal dust mixture produces a material for use as an anode in lithium ion batteries and supercapacitors when pyrolyzed to form a porous, electrically conductive ceramic composite.

IPC Classes  ?

• H01M 4/04 - Processes of manufacture in general
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/64 - Burning or sintering processes
• H01G 11/38 - Carbon pastes or blendsBinders or additives therein
• H01G 11/44 - Raw materials therefor, e.g. resins or coal
• H01G 11/86 - Processes for the manufacture of hybrid or EDL capacitors, or components thereof specially adapted for electrodes
• H01M 4/1393 - Processes of manufacture of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• H01M 4/587 - Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
• H01M 4/62 - Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
• H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries

Goods & Services

Fire resistant non-metal facade panels for construction purposes and decorative building facing plaster made from carbon-ceramic composite materials

Goods & Services

Engineered coal carbon-ceramic composite mortar mix and mortar for building used as fastening agents and adhesives for bricks and blocks used in construction of building walls for infrastructure construction and commercial buildings

Abstract

A PDC precursor resin is selected and mixed with a contaminated recycled electrode material or materials. The mixture is pyrolyzed to form a ceramic or ceramic-carbon composite, reduced to a powder and formed into an electrode of a battery, such as a lithium ion battery.

IPC Classes  ?

• H01M 10/54 - Reclaiming serviceable parts of waste accumulators

Abstract

A PDC precursor resin is selected and mixed with a contaminated recycled electrode material or materials. The mixture is pyrolyzed to form a ceramic or ceramic-carbon composite, reduced to a powder and formed into an electrode of a battery, such as a lithium ion battery.

IPC Classes  ?

• H01M 10/54 - Reclaiming serviceable parts of waste accumulators

Goods & Services

Engineered coal core composite building materials, namely, structural panels, construction bricks, coal-derived masonry units, building panels and bridge supports used in roads, bridges and building foundations

Abstract

A composite tile is comprised of coal dust and a pre-ceramic polymer that are mixed together and pyrolyzed to form a ceramic composite. For example, a chemical reaction during pyrolysis chemically converts at least a portion of the coal dust and pre-ceramic polymer to a fire proof ceramic composite suitable for use as a roofing tile either as pyrolyzed or as post-treated to seal cracks and pores formed during pyrolysis.

IPC Classes  ?

• C04B 35/532 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components containing a carbonisable binder
• C04B 35/628 - Coating the powders
• C04B 35/638 - Removal thereof
• C04B 35/64 - Burning or sintering processes
• C04B 41/00 - After-treatment of mortars, concrete, artificial stone or ceramicsTreatment of natural stone
• C04B 41/50 - Coating or impregnating with inorganic materials
• C04B 41/86 - GlazesCold glazes

Abstract

A complex ceramic particle and ceramic composite material may be made of a pretreated coal dust and a polymer derived ceramic that is mixed together and pyrolyzed in a nonoxidizing atmosphere. Constituent portions of the particle mixture chemically react causing particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for a plurality of uses including composite articles and proppants.

IPC Classes  ?

• B28B 1/00 - Producing shaped articles from the material
• B33Y 80/00 - Products made by additive manufacturing
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 35/628 - Coating the powders
• C04B 35/64 - Burning or sintering processes
• B33Y 10/00 - Processes of additive manufacturing
• B33Y 70/00 - Materials specially adapted for additive manufacturing

Goods & Services

Engineered coal core composite building materials, namely, structural panels, construction bricks, coal-derived masonry units, building panels and bridge supports

Goods & Services

Engineered coal core composite brick used to build walls, pavements, and related components in masonry construction

Goods & Services

Engineered coal core composite block primarily in the construction of building walls, for infrastructure construction and commercial buildings

Abstract

PDC resins are mixed with various sources of carbon to form electrodes through pyrolysis of the mixture of PDC resins and coal dust derived materials with or without other sources of carbon, substrates and the like. For example, a PDC resin - coal dust mixture produces a material for use as an anode in lithium ion batteries and supercapacitors when pyrolyzed to form a porous, electrically conductive ceramic composite.

IPC Classes  ?

• C01B 33/025 - Preparation by reduction of silica or silica-containing material with carbon or a solid carbonaceous material, i.e. carbo-thermal process
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C08G 77/00 - Macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon
• H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators

Abstract

A complex composite particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant or in a composite structure.

IPC Classes  ?

• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• C04B 41/00 - After-treatment of mortars, concrete, artificial stone or ceramicsTreatment of natural stone
• C04B 41/50 - Coating or impregnating with inorganic materials
• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open

Abstract

A composite tile is comprised of coal dust and a pre-ceramic polymer that are mixed together and pyrolyzed to form a ceramic composite. For example, a chemical reaction during pyrolysis chemically converts at least a portion of the coal dust and pre-ceramic polymer to a fire proof ceramic composite suitable for use as a roofing tile either as pyrolyzed or as post-treated to seal cracks and pores formed during pyrolysis.

IPC Classes  ?

• C07F 7/21 - Cyclic compounds having at least one ring containing silicon but no carbon in the ring
• B82B 1/00 - Nanostructures formed by manipulation of individual atoms or molecules, or limited collections of atoms or molecules as discrete units
• C08K 3/04 - Carbon
• C08L 9/06 - Copolymers with styrene

Abstract

A composite article is comprised of coal dust, as defined herein, and a polymer derived ceramic material that is pyrolyzed in a substantially non-oxidizing atmosphere. For example, the composite article may be made of a mixture of the coal dust and polymer derived ceramic, from particles formed of a mixture of coal dust and polymer derived ceramic or from complex particle composites comprising a plurality of particles formed of a mixture of coal dust and polymer derived ceramic.

IPC Classes  ?

• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• B29B 13/06 - Conditioning or physical treatment of the material to be shaped by drying
• B29B 13/08 - Conditioning or physical treatment of the material to be shaped by using wave energy or particle radiation
• C04B 35/528 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components
• C04B 35/628 - Coating the powders
• C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 38/08 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by adding porous substances
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
• B29B 13/02 - Conditioning or physical treatment of the material to be shaped by heating

Abstract

A material useful as a proppant comprises a core chemically reacted in situ from coal dust and a polymer derived ceramic material, such that at least a portion of the coal dust is chemically converted to a ceramic, nanoparticles, graphene, nanofibers or combinations of any of these.

IPC Classes  ?

• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• E21B 43/267 - Methods for stimulating production by forming crevices or fractures reinforcing fractures by propping
• C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 35/528 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components

Goods & Services

Composite materials, namely, carbon-ceramic composite materials used for roof covering, roofing, and fire resistant panels, and roofing tiles made of carbon-ceramic composite materials

Goods & Services

Engineered ceramic and composite materials for electrical conductivity and energy storage applications; Electrically conductive ceramic and composite materials for cathode and anode applications; Ceramic and composite materials for battery and energy storage applications

Abstract

Methods, systems, and processes are used to prepare novel ceramic composite structures that are strong, durable, light-weight, high performance and suitable for a myriad of industrial applications. The low manufacturing costs of the processes disclosed provide cheaper, faster ways of producing ceramic matrix composites at lower temperatures and allow for the existence of composite materials and structures which currently are not available.

IPC Classes  ?

• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
• C04B 35/584 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon nitride

Abstract

A complex composite particle is made by mixing coal dust and a binder to form a particle. The binder may be a polymer derived ceramic material, for example. A shell may enclose the particles, and the shell may be made of the same or a different polymer derived ceramic, for example. A complex composite particle may be made by combining a plurality of these particles.

IPC Classes  ?

• C04B 35/626 - Preparing or treating the powders individually or as batches
• C01B 32/914 - Carbides of single elements
• C01B 32/956 - Silicon carbide
• C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products

Abstract

A complex proppant particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant.

IPC Classes  ?

• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• C01B 32/956 - Silicon carbide
• C04B 35/626 - Preparing or treating the powders individually or as batches

Abstract

A composite article is comprised of coal dust, as defined herein, and a polymer derived ceramic material that is pyrolyzed in a substantially non-oxidizing atmosphere. For example, the composite article may be made of a mixture of the coal dust and polymer derived ceramic, from particles formed of a mixture of coal dust and polymer derived ceramic or from complex particle composites comprising a plurality of particles formed of a mixture of coal dust and polymer derived ceramic.

IPC Classes  ?

• C04B 35/528 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components
• C04B 35/532 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components containing a carbonisable binder
• C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• C04B 35/63 - Preparing or treating the powders individually or as batches using additives specially adapted for forming the products
• C04B 35/64 - Burning or sintering processes
• C04B 38/06 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by burning-out added substances
• B29B 13/02 - Conditioning or physical treatment of the material to be shaped by heating

Abstract

A material useful as a proppant comprises a core chemically reacted in situ from coal dust and a polymer derived ceramic material, such that at least a portion of the coal dust is chemically converted to a ceramic, nanoparticles, graphene, nanofibers or combinations of any of these.

IPC Classes  ?

• C04B 35/515 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides
• C09K 8/588 - Compositions for enhanced recovery methods for obtaining hydrocarbons, i.e. for improving the mobility of the oil, e.g. displacing fluids characterised by the use of specific polymers
• E21B 43/267 - Methods for stimulating production by forming crevices or fractures reinforcing fractures by propping

Abstract

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.

IPC Classes  ?

• C04B 35/597 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon oxynitrides
• C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
• C10M 159/00 - Lubricating compositions characterised by the additive being of unknown or incompletely defined constitution
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 35/583 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on boron nitride
• C04B 38/06 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by burning-out added substances
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
• C04B 35/589 - Fine ceramics obtained from polymer precursors
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/00 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• C04B 35/584 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon nitride
• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open

Abstract

Methods, systems, and processes are used to prepare novel ceramic composite structures that are strong, durable, light-weight, high performance and suitable for a myriad of industrial applications, including, but not limited to, ceramic plates of material suitable for use as ballistic armor. The low manufacturing costs of the processes disclosed provide cheaper, faster ways of producing ceramic matrix composites at lower temperatures and allow for the existence of composite materials and structures which currently are not available.

IPC Classes  ?

• C04B 35/71 - Ceramic products containing macroscopic reinforcing agents
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/589 - Fine ceramics obtained from polymer precursors
• C04B 35/597 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon oxynitrides
• C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
• C04B 38/06 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by burning-out added substances
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 35/628 - Coating the powders
• C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• C10M 159/00 - Lubricating compositions characterised by the additive being of unknown or incompletely defined constitution

Abstract

Methods, systems, and processes are used to prepare strong, durable, light-weight, mirrors, aspheric mirrors, disk drives and component parts using polymer-derived ceramics (PDCs), such as silicon oxycarbide (SiOC) as a substrate for the mirror blank or disk drive. Very high performance mirrors and machine components are produced at much lower costs; thus increasing their usage in applications as varied as extra-terrestrial space applications to machine vision used by robots to stationary terrestrial mirrors and machines.

IPC Classes  ?

• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 41/51 - Metallising
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
• C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides

Abstract

Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of novel ceramic composites. Additive manufacture or 3D printing of bulk ceramic and ceramic composite components occurs at considerably lower temperatures and shorter manufacturing intervals than the current state of the art. The methods, processes, systems, devices and apparatus and selection of precursor resins produce ceramic and ceramic composite material systems which have not been produced before by 3D printing.

IPC Classes  ?

• B28B 17/00 - Details of, or accessories for, apparatus for shaping the materialAuxiliary measures taken in connection with such shaping
• B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
• B29C 35/08 - Heating or curing, e.g. crosslinking or vulcanising by wave energy or particle radiation
• B29C 41/08 - Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
• B29C 67/04 - Sintering
• B29C 67/06 - Coagulating
• B29C 70/64 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only the filler influencing the surface characteristics of the material, e.g. by concentrating near the surface or by incorporation into the surface by force

Abstract

Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of novel ceramic composites. Additive manufacture or 3D printing of bulk ceramic and ceramic composite components occurs at considerably lower temperatures and shorter manufacturing intervals than the current state of the art. The methods, processes, systems, devices and apparatus and selection of precursor resins produce ceramic and ceramic composite material systems which have not been produced before by 3D printing.

IPC Classes  ?

• B29C 64/106 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• B28B 1/00 - Producing shaped articles from the material
• B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
• B33Y 10/00 - Processes of additive manufacturing
• B33Y 70/00 - Materials specially adapted for additive manufacturing
• B29C 67/00 - Shaping techniques not covered by groups , or
• B23K 26/342 - Build-up welding
• B23K 26/00 - Working by laser beam, e.g. welding, cutting or boring
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/589 - Fine ceramics obtained from polymer precursors
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
• C10M 159/00 - Lubricating compositions characterised by the additive being of unknown or incompletely defined constitution
• C04B 35/01 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides
• C04B 35/52 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite
• C04B 35/532 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components containing a carbonisable binder
• C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
• C04B 35/634 - Polymers
• C22C 29/00 - Alloys based on carbides, oxides, borides, nitrides or silicides, e.g. cermets, or other metal compounds, e. g. oxynitrides, sulfides
• B23K 103/00 - Materials to be soldered, welded or cut
• B23K 103/18 - Dissimilar materials
• B23K 103/16 - Composite materials
• B23K 103/08 - Non-ferrous metals or alloys
• B23K 103/02 - Iron or ferrous alloys
• C04B 111/00 - Function, property or use of the mortars, concrete or artificial stone

Abstract

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. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

IPC Classes  ?

• C04B 35/597 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon oxynitrides
• C04B 35/584 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon nitride
• C10M 159/00 - Lubricating compositions characterised by the additive being of unknown or incompletely defined constitution
• C04B 35/583 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on boron nitride
• C09K 8/80 - Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
• C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
• C04B 35/571 - Fine ceramics obtained from polymer precursors
• C04B 35/589 - Fine ceramics obtained from polymer precursors
• C04B 35/626 - Preparing or treating the powders individually or as batches
• C04B 38/00 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof
• C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides

Abstract

Methods, processes, and systems for producing bulk ceramics from agglomerations of partially cured gelatinous polymer ceramic precursor resin droplets, without using sponge materials to form gas pathways in the polymer bodies. Ceramics can be formed in hours. Resin droplets can be produced with a sprayer where liquid polymer precursors, mixed with a curing agent, are sprayed forming droplets which are partially cured, collected, and compressed into shapes. Ceramic porosity can be varied, droplet particle sizes can be controlled by adjusting liquid and gas pressure, orifice size, during spraying. Partially cured droplets can be formed via an emulsion process and size controlled by emulsion liquid and surfactant selection parameters.

IPC Classes  ?

• C04B 35/584 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on silicon nitride
• C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
• C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides

Abstract

Methods, processes, and systems for producing bulk ceramics from agglomerations of partially cured gelatinous polymer ceramic precursor resin droplets, without using sponge materials to form gas pathways in the polymer bodies. Ceramics can be formed in hours. Resin droplets can be produced with a sprayer where liquid polymer precursors, mixed with a curing agent, are sprayed forming droplets which are partially cured, collected, and compressed into shapes. Ceramic porosity can be varied, droplet particle sizes can be controlled by adjusting liquid and gas pressure, orifice size, during spraying. Partially cured droplets can be formed via an emulsion process and size controlled by emulsion liquid and surfactant selection parameters.

IPC Classes  ?

• C04B 38/06 - Porous mortars, concrete, artificial stone or ceramic warePreparation thereof by burning-out added substances
• B29B 13/02 - Conditioning or physical treatment of the material to be shaped by heating
• B05D 3/02 - Pretreatment of surfaces to which liquids or other fluent materials are to be appliedAfter-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking

Goods & Services

Polymer derived ceramics and composites made with same used in the manufacture of commercial and industrial goods; ceramic and polymer linkage and linkages of particles with the nature of the linkages being chemically bonded or attached, for use in the manufacture of devices comprised of engineered materials