JPWO2020046687A5

JPWO2020046687A5 -

Info

Publication number: JPWO2020046687A5
Application number: JP2021510722A
Authority: JP
Publication date: 2022-09-02
Anticipated expiration: 2039-08-22

Claims

A method for manufacturing a non-oxide ceramic component, comprising:
a) obtaining a photopolymerizable slurry, said photopolymerizable slurry comprising a plurality of non-oxide ceramic particles, at least one radiation curable monomer, a solvent, a photoinitiator and an inhibitor; , at least one sintering aid and an optional dispersant ;
b) selectively curing the photopolymerizable slurry to obtain a gelled article;
c) drying the gelled article to form an airgel or xerogel article;
d) heat treating said airgel article or said xerogel article to form a porous ceramic article;
e) sintering said porous ceramic article to obtain a sintered ceramic article;
A manufacturing method, including:

2. The method of claim 1, wherein said drying is performed by applying a supercritical fluid drying process.

wherein said photopolymerizable slurry comprises less than 30 weight percent of said non-oxide ceramic particles based on the total weight of said photopolymerizable slurry, preferably from 20 weight percent to 20 weight percent based on the total weight of said photopolymerizable slurry; 3. The method of claim 1 or 2 , comprising less than 30 weight percent non-oxide ceramic particles .

The non-oxide ceramic particles are silicon carbide, silicon nitride, boron carbide, titanium diboride, zirconium diboride, boron nitride, titanium carbide, zirconium carbide, aluminum nitride, calcium hexaboride, MAX phase, and A method according to any one of claims 1 to 3 , selected from the group consisting of combinations.

5. The non-oxide ceramic particles of any one of claims 1-4 , wherein the non-oxide ceramic particles have an average particle size of 250 nanometers to 1 micrometer, 500 nanometers to 1.5 micrometers, or 1 micrometer to 10 micrometers. The method described in section.

The method of any one of claims 1-5 , wherein the photoinitiator comprises a system comprising an iodonium salt, a visible light sensitizer, and an electron donor compound.

7. Any of claims 1-6 , wherein said selectively curing said photopolymerizable slurry comprises curing a portion of said photopolymerizable slurry having a thickness of between 3 micrometers and 50 micrometers. The method according to item 1.

A method according to any preceding claim, wherein the sintered ceramic article exhibits a density of 95% or greater relative to the theoretical density of the non-oxide ceramic particles.

is an airgel,
a) an organic material;
b) non-oxide ceramic particles in the range of 29 to 75 weight percent based on the total weight percent of the airgel;
c) at least one sintering aid;
airgel, including

is a xerogel,
a) an organic material;
b) non-oxide ceramic particles in the range of 29 to 75 weight percent based on the total weight percent of said xerogel;
c) at least one sintering aid;
A xerogel, comprising:

A porous ceramic article comprising:
a) non-oxide ceramic particles in the range of 90 to 99 weight percent based on the total weight of the porous ceramic article;
b) at least one sintering aid;
including
The non-oxide ceramic particles form one or more serpentine or arcuate channels, one or more internal architectural voids, one or more undercuts, one or more or a combination thereof, wherein the porous ceramic article has at least one feature essential to the porous ceramic article having a dimension of 0.5 mm or less in length;
A porous ceramic article.

A non-oxide ceramic article,
one or more serpentine or arcuate channels, one or more internal architectural voids, one or more undercuts, one or more perforations, or combinations thereof in the non-oxide ceramic article. wherein the non-oxide ceramic article exhibits a density of 95% or greater relative to the theoretical density of the non-oxide ceramic material, the non-oxide ceramic article having a length of 0 having at least one feature essential to said non-oxide ceramic article having a size of 0.5 mm or less;
Non-oxide ceramic articles.

a method,
a) receiving, by a manufacturing device having one or more processors, a digital object containing data defining multiple layers of an article;
b) producing said article based on said digital object using said manufacturing device by an additive manufacturing process, said article comprising a gelled article obtained by selectively curing a photopolymerizable slurry; , the photopolymerizable slurry is
1) a plurality of non-oxide ceramic particles;
2) at least one radiation-curable monomer;
3) a solvent;
4) a photoinitiator;
5) an inhibitor;
6) producing, including at least one sintering aid;
A method, including

a non-transitory machine-readable medium containing data representing a three-dimensional model of an article, which when accessed by one or more processors interfacing with a 3D printer to the 3D printer, a plurality of non-oxide ceramic particles; forming an article comprising the reaction product of a photopolymerizable slurry comprising at least one radiation curable monomer, a solvent, a photoinitiator, an inhibitor, and at least one sintering aid; A non-transitory machine-readable medium.