WO2017011696A1 - Appareil de formation, systèmes et procédés de fabrication de structures en céramique dérivée de polymère - Google Patents

Appareil de formation, systèmes et procédés de fabrication de structures en céramique dérivée de polymère Download PDF

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Publication number
WO2017011696A1
WO2017011696A1 PCT/US2016/042347 US2016042347W WO2017011696A1 WO 2017011696 A1 WO2017011696 A1 WO 2017011696A1 US 2016042347 W US2016042347 W US 2016042347W WO 2017011696 A1 WO2017011696 A1 WO 2017011696A1
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WIPO (PCT)
Prior art keywords
polymer derived
derived ceramic
forming
precursor
liquid
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PCT/US2016/042347
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English (en)
Inventor
Andrew Hopkins
Ashish P. Diwanji
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Melior Innovations, Inc.
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Publication of WO2017011696A1 publication Critical patent/WO2017011696A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/20—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by expressing the material, e.g. through sieves and fragmenting the extruded length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B9/00—Making granules
    • B29B9/02—Making granules by dividing preformed material
    • B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
    • B29B9/065—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion under-water, e.g. underwater pelletizers

Definitions

  • the present inventions relate to methods and systems for
  • Polymer derived ceramics are ceramic materials that are derived from, e.g., obtained by, the pyrolysis of polymeric materials. These materials are typically in a solid or semi-solid state that is obtained by curing an initial liquid polymeric precursor, e.g., PDC precursor, PDC precursor formulation, precursor batch, and precursor.
  • the cured, but unpyrolized, polymer derived material can be referred to as a preform, a PDC preform, the cured material, and similar such terms.
  • Polymer derived ceramics may be derived from many different kinds of precursor formulations, e.g., starting materials, starting formulations.
  • PDCs may be made of, or derived from, carbosilane or polycarbosilane (Si-C), silane or polysilane (Si-Si), silazane or polysilazane (Si-N-Si), silicon carbide (SiC), carbosilazane or polycarbosilazane (Si-N- Si-C-Si), siloxane or polysiloxanes (Si-O), to name a few.
  • a preferred PDC is "polysilocarb", e.g., material containing silicon (Si), oxygen (O) and carbon (C).
  • Polysilocarb materials may also contain other elements.
  • Polysilocarb materials can be made from one or more polysilocarb precursor formulation or precursor formulation.
  • the polysilocarb precursor formulations can contain, for example, one or more functional ized silicon polymers, other polymers, non- silicon based cross linking agents, monomers, as well as, potentially other ingredients, such as for example, inhibitors, catalysts, initiators, modifiers, dopants, fillers, reinforcers and combinations and variations of these and other materials and additives.
  • %, weight % and mass % are used interchangeably and refer to the weight of a first component as a percentage of the weight of the total, e.g., formulation, mixture, material or product.
  • volume % and % volume and similar such terms refer to the volume of a first component as a percentage of the volume of the total, e.g., formulation, material or product.
  • a hybrid fluid mechanical forming system for making small volumetric cured structures from a polymer derived ceramic precursor, the system having: a polymer derived ceramic precursor delivery apparatus, the delivery apparatus having a delivery in-feed, the delivery in-fluid in fluid communication with a delivery port; wherein the delivery in-feed and the delivery port contain a liquid polymer derived ceramic precursor; a formation head, the formation head having a die assembly and a forming chamber; the forming chamber defining a forming and curing cavity; the die assembly having a channel and a nozzle; the channel defining a inlet opening and a forming opening; the inlet opening in fluid communication with the delivery port; the nozzle in fluid communication with the channel forming opening and the forming and curing cavity; the forming and curing cavity containing a forming fluid; wherein the liquid polymer derived ceramic precursor is contained in the inlet opening, the die assembly channel, the forming opening, and the nozzle; and, the forming fluid contacting liquid polymer
  • a hybrid fluid mechanical system where the volumetric shapes are formed underwater, and thus the system is a hybrid under-liquid mechanical forming system; and when water is the liquid, the system would be a hybrid underwater mechanical forming system.
  • the extrusion, and the cutters, and cutting are located and take place under a liquid, e.g., water.
  • the systems and methods having one or more of the following features: wherein the liquid precursor in the nozzle is partially cured; wherein the die assembly has a plurality of channels and nozzles; wherein the die assembly has at least 100 channels and nozzles; wherein the forming fluid has water; wherein the forming fluid essentially consist of water; wherein the liquid polymer derived ceramic precursor has about 30 weight % to about 60 weight % silicon, from about 5 weight % to about 40 weight % oxygen, and from about 3 weight % to about 35 weight % carbon; wherein the liquid polymer derived ceramic precursor has at least one precursor selected from the group consisting of methyl terminated vinyl polysiloxane, vinyl terminated vinyl polysiloxane, hydride terminated vinyl polysiloxane, vinyl terminated dimethyl polysiloxane, hydroxy terminated dimethyl polysiloxane, phenyl terminated dimethyl polysiloxane, methyl terminated phenylethyl polysiloxan
  • a hybrid fluid mechanical forming system for making small volumetric cured structures from a polymer derived ceramic precursor, the system having: a polymer derived ceramic precursor delivery apparatus, the delivery apparatus having a delivery in-feed, the delivery in-fluid in fluid communication with a delivery port; wherein the delivery in-feed and the delivery port contain a liquid polymer derived ceramic precursor; the liquid polymer derived ceramic has a first viscosity; a formation head, the formation head having a die assembly and a forming chamber; the forming chamber defining a forming and curing cavity; the die assembly having a channel and a nozzle; the channel defining a inlet opening and a forming opening; the inlet opening in fluid communication with the delivery port; the nozzle in fluid
  • the forming and curing cavity containing a forming fluid; wherein the liquid polymer derived ceramic precursor is contained in the inlet opening, the die assembly channel, the forming opening, and the nozzle; wherein the liquid polymer derived ceramic precursor in the die assembly channel has a second viscosity; and , the forming fluid contacting an extending portion of the liquid polymer derived ceramic precursor extending from and continuous with the liquid polymer derived ceramic in the nozzle; and the forming fluid containing a volumetric shape of cured polymer derived ceramic precursor; whereby the extending portion of the liquid polymer derived ceramic precursor has a third viscosity; wherein, the third viscosity is greater than the second viscosity; wherein the second viscosity is greater than the first viscosity; wherein the second viscosity is greater than the first viscosity; wherein the liquid polymer derived ceramic precursor has a catalyst; wherein the liquid polymer derived ceramic precursor has a catalyst; wherein the liquid polymer derived ceramic precursor has
  • a hybrid underwater mechanical forming system for making small volumetric cured structures from a polymer derived ceramic precursor, the system having: a delivery apparatus, the delivery apparatus having a liquid polymer derived ceramic precursor, wherein the liquid polymer derived ceramic precursor consists essentially of carbon, silicon and; a die assembly and a curing chamber; the curing chamber defining a curing cavity; the die assembly having a channel and a nozzle; the channel defining a inlet opening and a outlet opening; the inlet opening in fluid communication with the delivery apparatus; the nozzle in fluid communication with the outlet opening and the curing cavity; the curing cavity containing a curing fluid; wherein the liquid polymer derived ceramic precursor is contained in the inlet opening, the die assembly channel, the outlet opening, and the nozzle; and, the forming fluid contacting an extending portion of the liquid polymer derived ceramic precursor extending from and continuous with the liquid polymer derived ceramic in the nozzle; and the forming fluid containing a volumetric shape of cured
  • volumetric shape is selected from the group consisting of hollow spheres, blocks, sheets, coatings, balls, and squares; wherein the volumetric shape is selected from the group consisting of spheres, prolate spheroids, ellipsoids, spheroids, films, skins, and particulates; and wherein the volumetric shape is a proppant; and, wherein the volumetric shape is a fiber.
  • a fiber forming system for making fibers from a polymer derived ceramic precursor having: a polymer derived ceramic delivery apparatus, the apparatus having a liquid polymer derived ceramic precursor, a chamber and a port, wherein the chamber is capable of holding a liquid polymer derived ceramic precursor for delivery by the port into fiber having a
  • a precursor solidifying apparatus having : a cavity; a temperature control apparatus; wherein the cavity is maintained at a predetermined temperature sufficient to cure the polymer derived ceramic precursor fiber to form a preform; the cavity have sufficient depth that the fibers break into sections; and, the port in fluid communication with the cavity; whereby, the system is capable of forming and curing the liquid polymer derived ceramic precursor into fibers.
  • an extrusion system preferably an under- liquid and more preferably an underwater system, for making elongate volumetric structures from a polymer derived ceramic precursor material
  • the system having: a polymer derived ceramic delivery apparatus, the apparatus having a first chamber in fluid communication with a delivery port, and an amount of a liquid polymer derived ceramic precursor; a forming and curing apparatus, the forming and curing apparatus having a forming chamber having an opening; and the chamber defining a cavity, wherein the cavity is in fluid communication with the chamber opening and contains an elongate volumetric shape of a polymer derived ceramic precursor, the chamber having water; the chamber opening in fluid communication with the delivery port; a temperature control source thermally associated with the forming apparatus; wherein the cavity is maintained at a predetermined temperature sufficient to cure the elongate volumetric shape of the polymer derived ceramic precursor; and, whereby, the system is capable of providing a liquid polymer derived ceramic precursor material into the cavity in a predetermined elongate volume
  • a hybrid underwater mechanical forming system for making small volumetric structures from a polymer derived ceramic precursor, the system having: a polymer derived ceramic precursor delivery apparatus, the apparatus having a chamber in fluid communication with a delivery port; wherein the chamber is capable of delivering a liquid polymer derived ceramic precursor; a forming apparatus, the forming apparatus having a forming chamber having an opening; the chamber defining a cavity; wherein the cavity is in fluid communication with the chamber opening; the chamber opening in fluid communication with the delivery port; whereby the system is capable of delivering the liquid polymer derived ceramic from the delivery port to the cavity as a liquid; a temperature control apparatus thermally associated with the forming apparatus; wherein the cavity is capable of being maintained at a
  • the system is capable of providing a liquid polymer derived ceramic precursor to the cavity in a predetermined volumetric shape; and wherein the system is capable of curing the polymer derived ceramic precursor in the cavity.
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a liquid holding receptacle; the liquid holding receptacle containing a forming liquid; a precursor delivery apparatus, having a precursor, a channel, and a delivery port, the channel in fluid communication with the delivery port, whereby the precursor can be delivered from the delivery port; and, the delivery port in fluid communication with the liquid holding receptacle.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: providing a liquid polymer derived ceramic precursor to a delivery apparatus, the apparatus having a chamber in fluid communication with a delivery port; forming the liquid precursor into a predetermined liquid volumetric shape; and delivering the liquid volumetric shape to a chamber defining a cavity, the cavity having a forming fluid; and, curing the liquid volumetric shape in the cavity to form a polymer derived ceramic preform.
  • the preform is the same shape as the volumetric shape; wherein the preform is substantially the same shape as the volumetric shape; wherein the preform is green cured; wherein the preform is hard cured; wherein the preform is final cured; and pyrolizing the preform to form a ceramic.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: a step for forming a small volumetric shaped structure of polymer derived ceramic precursor by extrusion from a die face into a forming fluid; a step for cutting the polymer derived ceramic precursor at the die face to thereby form an initial shaped volumetric structure; and, a step for curing the initial shaped volumetric structure.
  • the systems and methods having one or more of the following features: wherein the die face is in the forming fluid; whereby the extrusion is directly into the forming fluid, without exposure to air; wherein a plurality of initial shapes are made; wherein the initial shaped volumetric structure is hard cured; wherein the initial shaped volumetric structure is green cured; and, wherein the forming fluid is water; wherein the forming fluid has water.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: a step for forming an elongate volumetric shaped structure of polymer derived ceramic precursor by extrusion from a die face into a forming fluid; a step for curing the elongate structure; and, a step for sectioning the cured elongate structure.
  • the methods and systems having one or more of the following features: wherein the section occurs by the weight of the elongate structure causing breakage; wherein the volumetric shape has a volume of less than about 0.25 inch 3 ; wherein the volumetric shape has a volume of less than about 500 mm 3 ; wherein the volumetric shape has a volume of less than about 100 mm 3 ; wherein the volumetric shape has a volume of less than about 4,000 microns 3 ; wherein the volumetric shape has a volume of less than about 50 microns 3 ; and, wherein the volumetric shape has a volume of less than about 10 microns 3 .
  • an fluid pelletizing system preferably an under-liquid system and more preferably an underwater system, for making volumetric structures from a polymer derived ceramic precursor
  • the system having: a polymer derived ceramic delivery apparatus, the apparatus having a liquid polymer derived ceramic precursor, a chamber and a port, wherein the chamber is capable of holding a liquid polymer derived ceramic precursor for delivery by the port into a volumetric shape having a predetermined volume; a precursor solidifying apparatus, the solidifying apparatus having: a cavity; a temperature control apparatus; wherein the cavity is maintained at a predetermined temperature sufficient to cure the volumetric shape of polymer derived ceramic precursor to form a preform; a forming and cutting head having a fluid cavity; and the port in fluid communication with the cavity; whereby, the system is capable of forming and curing the liquid polymer derived ceramic precursor into a predetermined volumetric shape structure.
  • an extrusion system preferably an under-liquid system and more preferably an underwater system, for making volumetric structures from a polymer derived ceramic precursor material
  • the system having: a polymer derived ceramic delivery apparatus, the apparatus having a first chamber in fluid communication with a delivery port, and an amount of a liquid polymer derived ceramic precursor; a forming and curing apparatus, the forming and curing apparatus havin a forming chamber having an opening; and the chamber defining a cavity, wherein the cavity is in fluid communication with the chamber opening and contains a volumetric shape of a polymer derived ceramic precursor, the chamber having flowing water; the chamber opening in fluid communication with the delivery port; a temperature control source thermally associated with the forming apparatus; wherein the cavity is maintained at a predetermined temperature sufficient to cure the volumetric shape of the polymer derived ceramic precursor; and, whereby, the system is capable of providing a liquid polymer derived ceramic precursor material into the cavity in a predetermined volumetric shape, and wherein the polymer derived
  • the liquid polymer derived ceramic precursor is selected from the group consisting of silanes, polysilanes, silazanes, polysilazanes, carbosilanes, polycarbosilanes, siloxanes, and polysiloxanes; wherein the liquid polymer derived ceramic precursor is a polysilocarb; wherein the liquid polymer derived ceramic precursor is a neat polysilocarb; wherein the liquid polymer derived ceramic precursor has a polysilocarb and contains hydride groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb, is solvent free, and contains hydride groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb and contains vinyl groups; and wherein the liquid polymer derived ceramic precursor has a polysilocarb having hydride and vinyl groups and wherein the molar ratio of hydride groups to vinyl groups is
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a polymer derived ceramic delivery apparatus, the apparatus having a first chamber in fluid communication with a delivery port; wherein the first chamber is capable of holding a liquid polymer derived ceramic precursor; a means for forming a volumetric shaped structure, the forming means having a forming chamber having an opening; and the chamber defining a cavity, wherein the cavity is in fluid communication with the chamber opening; the chamber opening in fluid communication with the delivery port, whereby the system is capable of delivering the liquid polymer derived ceramic from the delivery port into the cavity, as a liquid; a temperature control source thermally associated with the forming apparatus, wherein the cavity is maintained at a predetermined
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a means for delivering a liquid polymer derived ceramic; a means for forming a volumetric shaped structure, the forming means having a forming chamber having an opening; and the chamber defining a cavity, wherein the cavity is in fluid communication with the chamber opening; the chamber opening in fluid communication with the delivery port, whereby the system is capable of delivering the liquid polymer derived ceramic from the delivery port into the cavity, as a liquid; a temperature control source thermally associated with the forming apparatus, wherein the cavity is maintained at a predetermined
  • the system is capable of providing a liquid polymer derived ceramic precursor material into the cavity in a predetermined volumetric shape, and wherein the polymer derived ceramic precursor material is cured in the cavity.
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a means for forming a small volumetric shaped structure of polymer derived ceramic precursor; and, a means for curing the small volumetric shaped structure of polymer derived ceramic precursor material into a volumetric shaped preform.
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a means for forming a small volumetric shaped structure of polymer derived ceramic precursor; a means for curing the small volumetric shaped structure of polymer derived ceramic precursor material into a volumetric shaped preform; and, a means for pyrolizing the preform.
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a liquid holding receptacle; the liquid holding receptacle containing a forming liquid; a precursor delivery apparatus, having a precursor, a channel, and a delivery port, the channel in fluid communication with the delivery port, whereby the precursor can be delivered from the delivery port; and, the delivery port in fluid communication with the liquid holding receptacle.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: providing a liquid polymer derived ceramic precursor to a delivery apparatus, the apparatus having a chamber in fluid communication with a delivery port; forming the liquid precursor into a predetermined liquid volumetric shape; and delivering the liquid volumetric shape to a chamber defining a cavity; and, curing the liquid volumetric shape in the cavity to form a polymer derived ceramic preform.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: a step for forming a small volumetric shaped structure of polymer derived ceramic precursor by extrusion into a water bath and then cutting the extruded member into an initial shape; a step for curing the small volumetric shaped structure of polymer derived ceramic precursor material in a flowing channel in a die to form an initial volumetric shaped preform; cutting the initial volumetric shaped preform from the die face; further curing and shaping the preform in a water bath; and, a step for pyrolizing the preform.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: forming a neat small volumetric shaped structure of polymer derived ceramic precursor; curing the neat small volumetric shaped structure of polymer derived ceramic precursor material into a volumetric shaped preform; and, pyrolizing the preform.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: providing a polymer derived ceramic precursor to a liquid holding receptacle; the liquid holding receptacle containing a forming liquid; the precursor forming essentially upon contact with the forming liquid a predetermined volumetric shape; and curing the volumetric shape to form a preform.
  • the methods and systems having one or more of the following features: wherein the volumetric shape is a bead; pyrolizing the preform; wherein the volumetric shape is a sphere and pyrolizing the sphere.
  • a method for making small volumetric shaped polysilocarb preform including initially curing a polysilocarb formulation as it is flowing through a chancel in a die; the initially cured preform being extruded into a liquid bath, the extruded preform being cut off adjacent to the die face, and the liquid bath continuing to cure the preform.
  • liquid polymer derived ceramic precursor is selected from the group consisting of silanes, polysilanes, silazanes, polysilazanes, carbosilanes,
  • liquid polymer derived ceramic precursor is a polysilocarb; wherein the liquid polymer derived ceramic precursor is a neat polysilocarb; wherein the liquid polymer derived ceramic precursor is a reinforced polysilocarb; wherein the liquid polymer derived ceramic precursor is a polysilocarb; wherein the liquid polymer derived ceramic precursor has a polysilocarb and contains hydride groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb, is solvent free, and contains hydride groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb and contains vinyl groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb, is solvent free, and contains vinyl groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb and contains vinyl groups; wherein the liquid polymer derived ceramic precursor has a polysilocarb, is solvent free, and contains vinyl groups; wherein the liquid polymer derived ceramic precursor has
  • the cavities has a forming liquid; wherein the cavity has a forming liquid consisting essentially of water and a surfactant; wherein the cavity has a forming liquid and a mixer; wherein the cavity is an extruder cavity; wherein the cure is conducted with a predetermined cure temperature profile; and, wherein the cure is conducted with a predetermined cure temperature profile having a first heating rate, a first hold time, a second heating rate and a second hold time.
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a means for forming a small volumetric shaped structure of polymer derived ceramic precursor; a means for curing the small volumetric shaped structure of polymer derived ceramic precursor material into a volumetric shaped preform; and, a means for pyrolizing the preform.
  • a system for making small volumetric structures from a polymer derived ceramic precursor having: a liquid holding receptacle; the liquid holding receptacle containing a forming liquid; a precursor delivery apparatus, having a precursor, a channel, and a delivery port, the channel in fluid communication with the delivery port, whereby the precursor can be delivered from the delivery port; and, the delivery port in fluid communication with the liquid holding receptacle.
  • a method for making small volumetric structures from a polymer derived ceramic precursor having: providing a liquid polymer derived ceramic precursor to a delivery apparatus, the apparatus having a chamber in fluid communication with a delivery port; forming the liquid precursor into a predetermined liquid volumetric shape; and delivering the liquid volumetric shape to a chamber defining a cavity; and, curing the liquid volumetric shape in the cavity to form a polymer derived ceramic preform.
  • FIG. 1 is a perspective view of an embodiment of a PDC forming system in accordance with the present inventions.
  • FIG. 2 is a cross section view of an embodiment of a PDC forming system in accordance with the present inventions.
  • FIGS. 3A to 3D are sequential illustrations of an embodiment of a process for PDC forming in accordance with the present inventions.
  • FIG. 4 is a cross sectional view of an embodiment of a PDC forming system for forming fibers in accordance with the present inventions.
  • FIG. 5 is a cross sectional view of a forming apparatus for performing a process for PDC forming in accordance with the present inventions
  • FIG. 5A is plan view of the cutter assembly of the embodiment of FIG. 5.
  • FIG. 5B is a cross sectional view taken along line 5B— 5B of FIG. 5A.
  • FIG. 5C is a cross sectional view taken along line 5C— 5C of FIG. 5A.
  • FIG. 5D is a perspective exploded view of the cutter assembly of the embodiment of FIG. 5.
  • FIG. 6 is a cross sectional view of a forming apparatus for performing a process for PDC forming in accordance with the present inventions.
  • FIG. 6 is a cross sectional view taken along line 6— 6 of FIG. 6B.
  • FIG. 6A is a cross sectional view taken along line 6A— 6A of FIG. 6.
  • FIG. 6B is a phantom line plan view of components of the apparatus of
  • FIG. 6C is a cross sectional view of components of the apparatus of
  • FIG. 7 is a cross sectional view of a forming apparatus for performing a process for PDC forming in accordance with the present inventions.
  • FIG. 7A is a cross sectional view taken along line Ik— Ik of FIG. 7.
  • FIG. 7B is a cross sectional view taken along line 7B— 7B of FIG. 7.
  • FIG. 7C is a detailed cross sectional view of a component of the embodiment of FIG. 7.
  • FIG. 8 is a perspective cross sectional view of a forming apparatus for performing a process for PDC forming in accordance with the present inventions.
  • FIG. 8A is a phantom line cross sectional view of the embodiment of
  • FIG. 8B is a cross sectional view of components of the embodiment of
  • FIG. 8C is a cross sectional view taken along line 8C— 8C of FIG. 8B.
  • FIG. 8D is a plan view of components of the embodiment of FIG. 8.
  • FIG. 8E is a phantom line plan view of components of the embodiment of FIG. 8.
  • FIG. 8F is a phantom line plan view of components of the embodiment of FIG. 8.
  • FIG. 9 is a schematic view of an embodiment of a solution formation system and process in accordance with the present inventions.
  • FIG. 10 is a schematic view of an embodiment of a solution formation system and process in accordance with the present inventions.
  • FIG. 1 1 is a perspective view of an embodiment of a solution forming system and process in accordance with the present inventions.
  • FIG. 12 is a process flow diagram of an embodiment of solution forming system and processes in accordance with the present inventions.
  • the present inventions relate to methods, systems, apparatus, and process for making small volumetric shapes from PDC precursors, and to provide small volumetric shaped PDC preforms and polymer derived ceramics.
  • embodiments of the present inventions make small shapes from PDC precursors with, good, high, and exceeding high uniformity and reproducibility.
  • Embodiments of the present inventions make volumetric shapes of PDC precursors, PDC preforms, and polymer derived ceramics, at high rates of production, in large quantities, and with long run times.
  • volumetric shapes made by embodiments of the present invention are small, e.g., having cross sections from about 2 inches to 0.01 microns, of less than about 1 inch, less than about 3 ⁇ 4 inch, less than about 1/3 inch, less than about 5,000 microns, less than about 4,000 microns, less than about 2,000 microns, less than about 1 ,000 microns, less than about 500 microns, less than about 100 microns, less than about 10 microns, less than about 1 micron, less than about 0.5 microns and about 0.1 micron.
  • the volumetric shapes may have volumes of from about 4.25 inch 3 to about 0.0004 microns 3 , of less than about 0.25 inch 3 , of less than about 525 mm 3 , of less than about 100 mm 3 , of less than about 50 mm 3 , of less than about 4,000 microns 3 , of less than about 2,000 microns 3 , of less than about 100 microns 3 , of less than about 50 microns 3 , of less than about 0.5 microns 3 and of less than about 0.00005 microns 3 .
  • the small volumetric shapes may individually weight, less than about 30 grams, less than about 15 grams, less than about 10 grams, less than about 1 gram, less than about 0.5 grams, less than about 0.1 grams, and less than about 0.01 grams, less than about 0.0001 grams, less than about 0.00001 grams, less then about 10 "8 g, less than about 10 "10 g, and less than about 10 "15 g.
  • the small volumetric shapes, made by embodiments of the present inventions may be substantially uniform, they may be entirely random, they may be within a
  • predetermined range for one of more physical property, e.g., shape, size, weight, roughness, density, porosity, strength, electrical, conductivity, optical, thermodynamic, ionic, etc., and combinations and variations of these.
  • physical property e.g., shape, size, weight, roughness, density, porosity, strength, electrical, conductivity, optical, thermodynamic, ionic, etc., and combinations and variations of these.
  • the volumetric shapes may be any shape, including for example, spheres, pellets, rings, lenses, disks, panels, cones, frustoconical shapes, squares, rectangles, trusses, angles, channels, hollow sealed chambers, hollow spheres, blocks, sheets, coatings, balls, squares, prolate spheroids, ellipsoids, spheroids, eggs, cones, multifaceted structures, films, skins, particulates, beams, rods, angles, columns, fibers, staple fibers, tubes, cups, pipes, polyhedrons (e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism), and combinations and various of these and other more complex shapes, both engineering and architectural.
  • polyhedrons e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron
  • the polymer derived ceramics and their cured preforms may be any volumetric shape, and preferably are any predetermined volumetric shape.
  • the cured preforms may be the same shape, or a different volumetric shape, from the ceramics.
  • a precursor batch may be shaped into, for example, balls, spheres, squares, prolate spheroids, ellipsoids, spheroids, eggs, cones, rods, boxes, multifaceted structures, and polyhedrons (e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism), as well as, other such structures for, or upon, curing, and pyrolysis.
  • polyhedrons e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism
  • the polymeric derived ceramics may be made into the shape of any particle, that is used as, or suggested to be used as, for example, a pigment, an additive, an abrasive, a filler, and an hydraulic fracturing proppant.
  • Spherical type structures are examples of a presently preferred shape for proppants.
  • Sphere and spherical shall mean, and include unless expressly stated otherwise, any structure that has at least about 90% of its total volume within a "perfect sphere," i.e., all points along the surface of the structure have radii of equal distance.
  • An essentially perfect sphere has at least about 98% of its total volume within a perfect sphere.
  • a substantially perfect sphere has at least about 95% of its total volume within a perfect sphere.
  • a "known geometric shape” e.g., a “cube” means that at least about 90% of the total volume of the shape is within the perfect known, defined, geometric shape, e.g., for a cube - six sides of equal length, width and height, all connecting at right angles.
  • a “substantially perfect shape,” e.g., a “substantially perfect cube” is at least 95% within the shape of a perfect cube
  • an "essentially perfect shape”, e.g., an "essentially perfect cube” is at least 95% within the shape of a perfect cube.
  • Embodiments of the systems, apparatus and methods provide the ability to make highly random sized particles of the same type, e.g., all shapes are substantially perfect spheres but have random and varied volumes, to make highly random shapes with high random particle sizes, e.g., many different shapes with varied volumes, and combinations and variations of these.
  • Embodiments of the systems, apparatus and methods preferably provide the ability to make highly uniform shapes, as to type, as to volume and both.
  • embodiments of the process produce spheres that are within at least 90% of the targeted size, at least 95% of the targeted size, and at least 99% of the targeted size, or more.
  • embodiments of the process can produce spherical beads, spherical type beads, essentially perfect spherical beads, and substantially perfect spherical beads, each of which can have at least about 90% of their size within a 10 mesh range, at least about 95% of their size within a 10 mesh range, at least about 98% of their size within a 10 mesh range, and at least about 99% of their size within a 10 mesh range.
  • the process can produce spherical beads, spherical type beads, essentially perfect spherical beads, and substantially perfect spherical beads, each of which can have at least about 90% of their size within a 5 mesh range, at least about 95% of their size within a 5 mesh range, at least about 98% of their size within a 5 mesh range, and at least about 99% of their size within a 5 mesh range.
  • these levels of uniformity in the production of the volumetric shapes, both the ceramic and cured preform is obtained without the need for filtering, sorting or screening the cured shapes, and without the need for filtering, sorting or screening the pyrolized shapes.
  • embodiments of the present processes provide the ability to make a large number of highly uniform predetermined shapes, e.g., at least about 90%, at least about 95% and at least about 99% of the shapes produced meet the targeted or predetermined shape.
  • a large number of highly uniform predetermined shapes e.g., at least about 90%, at least about 95% and at least about 99% of the shapes produced meet the targeted or predetermined shape.
  • at least about 98% of the beads, e.g., proppants, made from a precursor batch can be essentially spherical.
  • the precursor formulation is initially a liquid, or if not, it is liquefied. This liquid precursor formulation is then cured to form a solid or semi-sold material, e.g., a plastic, which is also called the preform or cured preform. The preform is then pyrolized into a ceramic.
  • FIG. 1 there is shown a perspective view of an underwater pelletizing system 1 .
  • the system 1 has a pumping unit 2 that has a base 4 and a liquid PDC precursor feed line 3.
  • the feed line 3 is connected to a PDC precursor source, e.g., a make up system, tank, etc. (not shown in the figure).
  • a transfer assembly 5 e.g., a line, pipe, pump discharge, etc., provides the PDC precursor to the formation section or formation head 6.
  • the formation section 6 has a die assembly 7 and a cutter assembly 8, and a fluid in-flow line 14, and a fluid out-flow line 15.
  • the formation section 6 has a cutter force unit 9 and a cutter drive system 10. Those units have a power/control line 1 1 .
  • the formation section 6 has a heater powered by line 13 and a temperature sensor having a temperature sensor line 12.
  • line 13, line 12 and line 1 1 are in communication with a control system, that controls the operation of the system.
  • the volumetric shapes may also be processed to form platelets, flakes and essentially plainer shapes, e.g., where the surface area (e.g., x-y area) is 10 times or more, 20 times or more, and 100 times or more, greater than their thickness (e.g., z direction).
  • the more rounded or thicker shapes such as a fiber, bead or sphere, can be flattened. The flattening can take place at any point prior to the point where the cure is so hard as to prevent the shape from deforming without undue breakage, e.g., prior to a hard cure.
  • the pumping unit 2, the transfer assembly 5, and both are an extruder.
  • the extruder can further be used to admix, mix, react, blend and other wise combine several different starting materials to provide a PDC precursor batch.
  • the PDC processor formulation is made at the forming unit.
  • extrusion and underwater, i.e., in liquid, extrusion and cutting are focused on in this section of the specification, it should be understood that the extrusion can take place in any fluid, including liquid, gas, water, air, nitrogen, under reduced pressure, under increased pressure, in a flowing fluid environment, and other forming environments disclose and taught in the disclosures that are incorporated into this specification by reference.
  • the extruder and in particular when used as a blending or reaction device to make a PDC formulation does not require and in embodiments may not have a die.
  • the liquid PDC precursor formulation is feed into the pumping unit 2 where it is feed into the die assembly 7.
  • the liquid PDC precursor is feed into the die assembly 7 by pumps, gravity, metering pumps, pressurized tanks etc.
  • the flow rate of the liquid PDC precursor is preferably controlled and preselected to correspond with the die's structure, a particular PDC formulation's cure rate, the cutter speed, the heating rates in the formation section 6, and other factors.
  • the liquid PDC precursor is feed into the die assembly 7 where curing is preferably initiated.
  • the partially cured PDC precursor exits the die e.g., is extruded from the die's openings, it is cut off into sectioned partially cured PDC volumetric shapes, e.g., initially cured pellets.
  • the length of the pellets is determined by the rate at which the initially cured PDC leaves the die, e.g., the extrusion rate, and the speed of the cutters.
  • the fluid can be water, water with a surfactant, and any of the other liquids, types of liquids, and mixtures of liquids discussed in this specification, or otherwise know to the art or later developed.
  • the fluid acts to shape the initially cured PDC sectioned shape into a bead and preferably a perfect sphere, while also preferably continuing to cure the sphere, e.g., to a final cure, or to a hard cure.
  • FIG. 2 there is shown a cross sectional view of a PDC water-pelletizing formation head 206.
  • Liquid polysilocarb precursor 200 is feed into a pump 220 where it is discharged via line 205 into a die assembly 204.
  • the die assembly 204 has a distribution header 202 that is in fluid communication with die plate channels 216a, 216b, 216c, 216d, 261 e, 216f, 216g, 216h, 216i, 216j, 216k.
  • the liquid polysilocarb precursor 200 is feed into the distribution header 204 and then into the channels, e.g., 216a etc.
  • the die assembly 204 has heating zones 217, 218, 219.
  • the polysilocarb precursor is at least partially cured and exist the die channel as a fiber or rod like structure, e.g., 222.
  • the polysilocarb precursor exist the die channels 216a, etc., into water 221 .
  • the water 221 is flowed through a cutting-curing chamber 223 having water inlet line 214 and water outlet line 215.
  • the formation head 206 has a cutter assembly 208.
  • the cutter assembly 208 and the die assembly form the cutting-curing chamber 223.
  • the cutter assembly 206 has a cutter wheel 209 that has one, two, three, four or more cutting blades, e.g., 21 1 (only a single cutting blade is shown in the figure for simplicity and clarity).
  • the cutting blades 21 1 are mounted to the cutting wheel 209 by cutting blade mount 212.
  • the cutter 21 1 is pushed against the die face 224, as illustrated by arrow 213.
  • the force of the cutter 21 1 against the die face 224 is preferably controlled to provide clean cutting of the rod like structures 222, while minimizing, and preferably partially avoiding the wearing of the die face 224.
  • the cutter wheel 209, and the blades 21 1 rotate as shown by arrows 210.
  • the rod like structures 222 are cut by the blades, e.g., 21 1 and are then in, and preferably free floating in, the water as pellets, e.g., 201. These pellets are then further cured and shaped in the water to form preferably perfect spheres. These pellets may also be further processed, prior to further curing, such as by for example, mechanically flattened them to form platelets or flakes.
  • an embodiment of the process provides for the continuous initial curing of a PDC precursor in a die 304 channel 316 to form an initially cured fiber or rod structure 322, which is advanced directly into water 321.
  • the initially cured fiber in the water is then section off, into cylindrical pellet like structures 322a, having a length, and a diameter.
  • This process can also be viewed as a hybrid liquid-liquid process, and the subsequent teachings, theories, and discussion regarding bead formation in a liquid-liquid system are applicable to the water peptization processes and systems.
  • heating zones can be electric, steam, water, or any other means to heat the die, and thus the liquid PDC formulation, to provide for preferably a controlled and predetermined cure.
  • the PDC formulation when it is shaped into the first initial volumetric structure when leaving the die channel and entering the fluid in the cutting-curing chamber can be uncured, partially cured (e.g., from about 0% of hard cure, to about 99% hard cure, less than 90% hard cure, less than 80% hard cure, less than 70% hard cure, less than 60% hard cure, less than 50% hard cure, less than 40% hard cure, less than 30% hard cure, less than 30% hard cure and less than 10% hard cure).
  • the RPM of the cutting blades can vary depending upon the size of the unit and the flow rate of the PDC out of the die channels.
  • the number of channels in the die can be one, tens, hundreds and more.
  • the opening of the die into the cutting-curring can be tapered inwardly, tapered outwardly, at a sharp right angle, at a right angle with a small radius, curved, and combinations and variations of these and other opening configurations and shapes.
  • the die openings are all the same, however slight variations may be preferable in larger die faces to accommodate for radial position of the die and the various speed of the cutting blade. Variations in the die openings may also be used to provide different volumetric shapes, from a single die.
  • the diameter of the channels in the die e.g., the die orifice diameter or channel internal diameter, can be less than about 2000 ⁇ , from about 100 ⁇ to about 1500 ⁇ , from about 1 to about 1000 ⁇ , from about 200 to about 2,000 ⁇ , from about 210 to about 750 ⁇ , Submicron diameters and diameters larger than 2,000 ⁇ may also be used.
  • the temperature of the water bath can be any of the temperatures at which the PDC formulation can cure. These curing temperatures, conditions and factors are discussed through this specification.
  • Hybrid underwater mechanical forming systems can be used to form elongate volumetric shapes, such as fibers, staple fibers, tow, rods, etc. Further, and preferably, the fluid environment will further shape the sectioned PDC into a predetermined cured shape.
  • the formation head of the under underwater pelletizing system of FIG. 1 is substantially vertical.
  • elongate structures can also be formed by the embodiments of the systems of FIGS. 1 and 4. However the cutters will be eliminated, not operated, or the rotational timing of the cutter slowed to allow for the formation of longer, e.g., elongate structures, instead of beads.
  • the fibers or rods can be further mechanically shaped into ribbons, elongate flatten structures, and ribbon like shapes.
  • the flattening can take place at any point prior to the point where the cure is so hard as to prevent the shape from deforming without undue breakage, e.g., prior to a hard cure.
  • FIG. 4 there is shown a cross sectional view of a vertical PDC water-fiber formation head 406 and chamber 450 for use with a system such as the embodiment of FIG.1 .
  • Liquid polysilocarb precursor 400 is feed into a pump 420 where it is discharged via line 405 into a die assembly 404.
  • the die assembly 404 has a distribution header 402 that is in fluid communication with die plate channels 416a, 416b, 416c, 416d, 461 e, 416f, 416g, 416h, 416i, 416j, 416k.
  • the liquid polysilocarb precursor 400 is feed into the distribution header 404 and then into the channels, e.g., 416a etc.
  • the die assembly 404 has heating zones 417, 418, 419. These zones provide heating to the liquid polysilocarb precursor 400 as it flows through the channels 416a, etc.
  • the polysilocarb precursor preferably is at least partially, or initially cured and exist the die channel as a fiber or rod like structure, e.g., 422.
  • polysilocarb precursor exist the die channels 416a, etc., into curing fluid, e.g., water 421 , having a surface 451.
  • curing fluid e.g., water 421
  • the die face 424 is above the surface 451 of the water 421 . It being understood that this distance 452 can be varied. Thus, the distance 452 above the surface 451 of the water 421 can be about a millimeter, to millimeters to about a meter or more.
  • the atmosphere and environment in this area 452 between the die face 424 of the die and the surface of the water 451 can be controlled, and can have temperatures, energies (e.g., optical, IR, microwave) and gasses (e.g., O2 rich, inert, carrying additives) and thus designed to have a predetermined effect on the polysicocarb precursor 422 as it initially emerges from the die face. Additionally, and preferably, for some embodiments the die face 424 is submerged under the surface of the water 451 .
  • the water 421 is maintained at a controlled temperature, and is preferably quiescent.
  • temperatures, extrusion rate and water temperatures are selected so that as the fibers are formed in the water they will break from their own weight at predetermined lengths.
  • a degree of flow, or agitation, or some other form of mechanical force may be used to break or cut the forming fibers.
  • the conditions and depth of the tank are such that the fibers do not break and form long continuous fibers.
  • the chamber 450 has a collection and removal assembly 453 at its bottom. This can either be a continuous, or batch system, that removes the fibers once they have been sufficiently cured.
  • the formation head 406 is used without the chamber
  • the fibers are formed and cured in air (or a controlled atmosphere, e.g. N 2 , Ar, etc.).
  • the length of the fibers can be determined based upon the viscosity and cure rate of the PDC precursor.
  • the cured fibers can drop to a conveyor, or other collection device, where they will be removed.
  • that assembly can be used to further shape the fibers into ribbons, elongate flatten structures and ribbon like shapes.
  • an embodiment of the process provides for the continuous initial curing of a PDC precursor in a die channel to form an initially cured fiber or rod structure, which is advanced directly into water.
  • the initially cured fiber or rod is then further cured in the water.
  • the water, the conditions of the water e.g., temperature, agitation, lack of agitation, surfactants, etc.
  • This process can also be viewed as a hybrid liquid-liquid process, and the subsequent teachings, theories, and discussion regarding formation in a liquid-liquid system are applicable to the water-fiber processes and systems.
  • heating zones can be electric, steam, water, or any other means to heat the die, and thus the liquid PDC formulation, to provide for preferably a controlled and predetermined cure.
  • the head while preferably being positioned vertical, e.g. , may be at any angle from vertical.
  • the fibers may be extracted upward (for example, in an embodiment where the fibers have neutral buoyancy, or are buoyant in the forming fluid).
  • the PDC formulation when it is shaped into the first initial volumetric structure, e.g. a fiber or rod, when leaving the die channel and entering the fluid in the chamber can be uncured, partially cured (e.g. , from about 0% of hard cure, to about 99% hard cure, less than 90% hard cure, less than 80% hard cure, less than 70% hard cure, less than 60% hard cure, less than 50% hard cure, less than 40% hard cure, less than 30% hard cure, less than 30% hard cure and less than 10% hard cure).
  • the number of channels in the die can be one, tens, hundreds and more.
  • the opening of the die into the cure-cutting chamber can be tapered inwardly, outwardly, at a sharp right angle, at a right angle with a small radius, curved, and combinations of these and other opening configurations and shapes.
  • the diameter of the channels in the die can be less than about 2000 ⁇ , from about 100 ⁇ to about 1500 ⁇ , from about 1 to about 1000 ⁇ , from about 200 to about 2,000 ⁇ , from about 210 to about 750 ⁇ . Submicron diameters and diameters larger than 5,000 ⁇ may also be used.
  • the orifice of the die channels can be slits, having length (x direction) longer than its height (y direction).
  • the slits can have lengths from about 5 ⁇ to about 4000 ⁇ , and have thickness less than about 1000 ⁇ , less than about 100 ⁇ , less than about 50 ⁇ , less than about ⁇ ⁇ ⁇ , less than about 5 ⁇ , less than about 2 ⁇ , about 2 ⁇ , about 1 ⁇ , and less than about 1 ⁇ .
  • the slits can have x-y dimensions in microns ( ⁇ ) of about 1 -10, 1 -100, 1 - 1000, 2-10, 2, 100, 2-1000, 2-2000, 3-200, and 5-100, to name a few.
  • the temperature of the water bath can be any of the temperatures at which the PDC formulation can cure. These curing temperatures, conditions and factors are discussed through this specification.
  • the conditions are such that the fibers or rod like structures have uniform diameters. It is noted, however, that formation conditions can be such as to produce continuous, or semi-continuous fibers with varying diameters, e.g. , bulges, or neck down sections, along their length.
  • the polymer derived cured elongate structures may have diameters from about 1 to about 1000 ⁇ , about 100 to about 5,000 ⁇ , about 200 to about 2,000 ⁇ , about 100 to about 1 ,000 ⁇ , and about 200 to about 750 ⁇ . Submicron diameters and diameters larger than 5,000 ⁇ may also be made.
  • the polymer derived cured elongate structures may have lengths from about 1 .5x the structure's diameter to about 10,000x the structure's diameter and longer, about 50 ⁇ to about 5,000 ⁇ , about 500 mm, about 1 ,000 mm, about 1 mm, about 10 mm, about 10 meters, and lengths longer and shorter.
  • a batch or collection of these fibers may ail have the same, or essentially the same diameter and length, or they may have essentially the same diameter and different lengths.
  • the cured volumetric structures from this embodiment may be further pyroiized.
  • Underwater pelletizers for forming PDC pellets by the use of an extrusion die having orifices through which liquid PDC precursor is extruded through a die face for engagement by cutter blades mounted on a rotatable cutter hub and driven by a drive shaft is well known. It is desirable to maintain the cutters and die face in properly aligned relation in order that the cutting edge of the blades on the cutter hub move in very close parallel relation to the die face to efficiently cut the extruded PDC into pellets as it is discharged from the orifices in the extrusion die plate.
  • patents relate to underwater pelletizers, cutter hub assemblies and structures for positioning the cutters and cutter hub in desired relation to the die face of the die plate: 4, 123,207; 4,621 ,996; 4,251 ,198; 4, /28,276; 4,500,2/1 ; 5,059, 103, the entire disclosures of each of which are incorporated herein by reference
  • a liquid precursor is formed into a bead, droplet, ribbon or particle, in a liquid, and then preferably cured in that liquid.
  • the precursor bead, droplet, ribbon or particle may be initially exposed to a gas before being placed in the liquid; however, for these types of processes, it is preferred that the bead, droplet, ribbon or particle be formed directly in the liquid, with the precursor not being exposed to any gas during formation and initial curing, or being exposed to only a minimal and preferably controlled gas environment, before entry into the liquid.
  • Polymer emulsification, solution polymerization, solution bead forming, nano- emulsification, and similar types of system can be used to make small volumetric shapes from precursor formulations.
  • a liquid phase - liquid phase process forms small, and very small, i.e., a few inches, to microns, to submicron, size beads, droplets or particles, of the precursor formulation; and then preferably cures them in the second liquid phase.
  • these types of systems in general form beads of liquid precursor material in another liquid, e.g., bulk liquid phase, second liquid, continuous phase, or continuum.
  • the beads upon forming, are then sufficiently cured in the second liquid phase, e.g., the continuous phase, so that their shape, and other predetermined properties, are locked in, to the extent needed for subsequent
  • processing or use e.g., storage, pyrolysis, machining, etc. Larger and smaller size beads may also be made.
  • liquid-liquid techniques can be combined with other forming and curing techniques.
  • a liquid-liquid precursor suspension could be spray-dry to initiate cure and simultaneously drive off the excess H 2 0.
  • the liquid-liquid precursor suspension could be used in the other forming and curing techniques and technologies, among those provided in this specification and others.
  • the beads or particles can be formed in the liquid, cured in the liquid, formed in a non-liquid environment, cured in a non-liquid environment and combinations and variations of these.
  • Beads formed with the first and second liquid phase can be added to a third or fourth liquid phase to coat the particles or beads with another polymer, a surfactant and combinations of these and other materials, as well as to cure the particles.
  • Embodiments of the present systems control parameters relating to particle size distribution in these liquid-liquid systems, which include among other parameters, surface tension, viscosity, temperature, volume fraction of dispersed phase (e.g., the precursor), polymerization (e.g., curing), process, surfactants, the action of adsorbed surfactants, and the hydrodynamic flow conditions of the system.
  • the ultimate particle size distribution is a result of the steady state formed between droplet break-up and droplet coalescence phenomena.
  • emulsions can be driven to smaller and smaller average particle sizes.
  • the polymer upon polymerization, e.g., curing, the polymer will exhibit solid colloidal properties that are distinct from the starting material phase, e.g., a monomer precursor, or for polysilocarb precursors a liquid polymer.
  • the starting material phase e.g., a monomer precursor, or for polysilocarb precursors a liquid polymer.
  • Consideration should preferably be made of the adsorption and agglomeration properties of the cured precursor with respect to the liquid precursor to preferably ensure that the cured particles do not aggregate. For some embodiments aggregation or agglomeration may not be an undesirable result.
  • the agglomerate can be readily broken apart at a later time, such agglomeration can be very beneficial, both from safety issues, e.g., avoids handing very small particles and dusting issues, and from performance issues, e.g., requires little energy to break the agglomerate down to a smaller particle size preferred or required for use in some application.
  • Particle sizes preferably obtained via liquid-liquid systems, e.g., emulsion and solution systems, can range from about 0.1 microns ( ⁇ ) to about 4 mm (5 U.S. Mesh), although large and smaller sized may be obtained.
  • Embodiments of various particle size systems would include for example: micro-systems (e.g., about 10-100 nm dispersed particle size); mini-systems (e.g., about 100-1000 nm dispersed particle size); macro-systems (e.g., about 0.5-200 ⁇ dispersed particle size; and, about 400 mesh (37 ⁇ ) to about 10 mesh (2,000 ⁇ )). It should be noted that this nomenclature is to define a particle size range, and does not necessarily limit the process used to obtain that particle size.
  • Suspension polymerization type processes e.g., the initiator of polymerization is soluble in the dispersed monomer phase
  • emulsion polymerization type processes e.g., the initiator is soluble in the continuous phase
  • small volumetric precursor shapes which can already be cured, or can then be cured, and pyrolized.
  • the minimum free-energy state requires a minimization of the surface area for a constant volume system.
  • the presence of a global minimum in the Gibbs Free Energy surface does not preclude the formation of a metastable emulsion if the global minimum condition (i.e. bulk separation) is not kinetically accessible.
  • the first general type is a metastable emulsion. Via mechanisms that will be discussed below, the free energy of a particle in a continuous medium can have a local minimum. If this minimum is deep enough, the kinetic path to establishing the global minimum condition (or bulk condition) is inaccessible energetically and
  • metastable emulsion consequently a local equilibrium condition requiring no additional energy input, or metastable emulsion, can be produced.
  • true metastability is rare in practical systems.
  • the emulsion remains in tact for sufficient time to cure the beads, or otherwise prevent their agglomeration prior to subsequent use or processing, e.g., hard curing, further curing, milling, or pyrolysis.
  • the to-be-dispersed phase e.g., the monomer, or the polysilocarb precursor polymer
  • the continuous phase e.g., an aqueous phase
  • energy generally should be added to the system to induce the break-up of the to-be-dispersed phase into smaller and smaller droplets due to the increase in surface area associated with smaller droplets.
  • the minimum energy shape of a droplet is a sphere due to the local minimization of surface area.
  • a droplet in order to break-up a droplet it generally should first be made into a non-spherical shape, or elongated.
  • the Laplace Pressure ⁇ -
  • D is the particle diameter
  • the force applied to elongate the droplet is called the disruptive force and is typically described in terms of shear stresses.
  • p is the density, v the velocity, and / the length scale of the system, can be a useful tool for understanding whether a droplet will be broken up when a certain energy input is provided.
  • the Weber Number gives the ratio between disrupting forces and maintaining forces, such that above a certain Weber Number (achieved for a sufficient period of time), droplet breakup is induced.
  • the shear force can be provided in shear laminar flow conditions, turbulent eddies, or convergent/divergent flow systems, to name a few.
  • Different homogenization/emulsification technologies leverage different mechanisms to induce shear-break-up.
  • Various systems and apparatus can be utilized to provide these forces in larger systems, e.g. , 100 gallons, 200 gallons, 500, gallons, 1 ,000 gallons and greater.
  • a particle will experience significant shear force if the length scales of the flow conditions are comparable to the diameter of the particle.
  • a system without attractive or repulsive forces would have a flat potential as a function of separation of two particles, with the exception of a point of overlap where the potential would be substantially negative with respect to the non- agglomerated particles (representing coalescence).
  • the driving forces for motion between particles are thermal and hydrodynamic (flow conditions of the medium). If two particles happen to come in contact, they will coalesce and remain in contact in the lower-energy state unless sufficient disruptive force is supplied.
  • Van-der-Waals forces (or induced dipole oscillation forces) act over very short distances and serve to attract non-polar particles to each other.
  • coalescence is energetically favorable, typically, sufficient energy generally should be imparted to the system to overcome AG.
  • This energy can come from, for example, hydrodynamic forces or thermal motion.
  • the source of charged surfaces in the system can be varied. Surface species can be directly ionized resulting in residual charge. This can be brought about via numerous mechanisms, but is typically pH dependent. Thus, modifying the pH of the continuous phase can result in charge-repulsion affects.
  • the permittivity of the intervening medium (the continuous phase) between particles modifies the effect of the coulomb repulsion in a standard fashion.
  • the presence of the continuous phase has the additional impact of generating a charged-double layer. This effect serves to shield the surface charge by proximously locating inversely charged species.
  • the surface of the dispersed phase is negatively charged, positive charges in the continuous phase will form a double-layer to counter the negative charge.
  • the thickness of this layer depends on the ionic concentration of the solution - the more ions present in the continuous phase, the thinner the layer due to the greater availability of shielding ions.
  • the thicker the double-layer the greater the repulsive effect due to charge on the system.
  • a lower ionic concentration of the continuous phase results in greater electric repulsion and thus enhanced stability of the emulsion.
  • the resulting potential of the double layer is known as the zeta potential.
  • steric repulsion refers to the barrier imposed by the adsorption of a species onto the surface of a particle that serves to prohibit overlap of particles.
  • the steric mechanism of repulsion is typically surfactant/em ulsifier concentration dependent and in some embodiments may be highly highly highly highly highly highly highly
  • one of the additional mechanisms is Ostwald Ripening, or diffusive species transfer.
  • the fundamental driving force of energy minimization due to surface area minimization is still the active motivation for mass transfer. This can be intuitively understood by recognizing that the larger percentage of the volume of a system present in larger diameter particles, the lower the overall surface area. Thus, the growth of a larger particle at the expense of a smaller particle is typically
  • thermodynamically favored and diffusion is allowed to proceed by concentration gradients induced by the curvature of the particles. Diffusive transfer phenomena will tend to occur on longer time scales then collisional coalescence until very small diameters are present in the system. The rate of mass transfer stays roughly constant, and thus the rate of diameter change varies dramatically as a function of diameter.
  • the dispersed phase is typically the precursor formulation and the continuous phase is typically aqueous.
  • an initiator e.g., the catalyst, heat, or both
  • the initiator is preferably soluble in the continuous phase.
  • the surfaces of the precursor formulation polymers serve as nucleation sites, but particle polymerization or growth occurs in the continuous phase.
  • the initial emulsion of the precursor formulation polymers serves as both nucleation sites and a reservoir for particle growth. In general, this can have implications for growth kinetics and particle size distribution of the PDC, e.g., polysilocarb, preform particle.
  • nucleation can be initiated simultaneously for nearly all particles resulting in relatively mono-dispersed final particles.
  • the growth rate of the particles is diffusively limited, and depending upon the specific embodiment of the system and precursors, the complete formation of the emulsion may take a long time (e.g., greater than 30 minutes, greater than 1 hour, greater than 12 hours, and more than 24 hours).
  • the initiator e.g., the catalyst
  • the PDC precursor e.g., the polysilocarb precursor, itself
  • typically is added to, e.g., is already present in, the dispersed phase, prior to emulsification.
  • curing occurs in-situ for the dispersed phase.
  • the initiator may be the catalyst, heat, and preferably both. Consequently, it is theorized that the particle size distribution is controlled directly by the dispersed phase distribution in the emulsion - these generally should become the final particles. It is further theorized that because there is no diffusive rate-limiting kinetics in this process, polymerization/cure can occur more rapidly than in emulsion polymerization.
  • the final particle size is typically primarily determined by nucleation and growth kinetics and not by the initial emulsion droplet distribution.
  • An aspect, in some embodiments of emulsion polymerization growth is the simultaneous nucleation of particles.
  • the achievement of a stable steady state emulsion for the long period of time required for emulsion polymerization to proceed in some embodiments may be challenging.
  • the particle size distribution can be approximately normal, e.g., a Gaussian distribution.
  • the droplet size and distribution of the emulsion will directly correspond to the particle size of the system.
  • the droplet size distribution is in general process dependent, and relates, among other things, to the statistics of energy partition across length scales in a flowing system.
  • the presence of surfactants/emulsifying agents in the system can have an affect on, and in some embodiments critically alters, both droplet break-up and droplet coalescence phenomena.
  • the most common mechanism by which this reduction occurs is a surfactant having a lipophilic and a hydrophilic end.
  • the lipohilic end associates with the precursor polymer and the hydrophilic end with the continuum or the continuous phase, e.g., the aqueous phase.
  • the percentage of the surface of a particle adsorbed with surfactant depends on the activity of the surfactant (which is in turn dependent on the concentration) in the continuum. The larger the concentration of surfactant, the more a particle surface will be covered, and the lower the surface tension. Typically this is a nonlinear process with diminishing returns because of the thermodynamics of activity. Further, as will be discussed below, the addition of surfactants can modify the viscosity of the continuous phase further impacting break-up phenomena.
  • solid nanoparticles can be used in lieu of chemical surfactants due to their ability to provide coalescence disruption, though they can be less effective at reducing surface tension.
  • the appropriate surfactant for a given process is highly dependent upon the material systems in use, the temperature range of the process (described below), the desired particle size distribution, and further steps in the process (i.e.
  • the surfactant with the greatest surface tension reduction is chosen, as this is a factor, and in some embodiments may be a critical parameter, affecting droplet size and required energy input.
  • High concentrations of emulsifiers can change the diffusivity of the continuum to the precursor formulation. This affects, and in some embodiments strongly affects, emulsion polymerization process kinetics, but typically does not impact, in some embodiments, the kinetics of suspension polymerization.
  • thermodynamic driving force for diffusion is too large to allow the particle to remain metastable.
  • This is influenced by and in some embodiments strongly influenced by the emulsifier concentration, because of the reduction of Free Energy differences between the bulk state and the dispersed state.
  • certain classes of surfactants can make drying the particles more difficult, and thus can make powder formation processes more complex. It is a factor to choose emulsifying agents with a view toward subsequent process and end use requirements.
  • Viscosity can be a factor, and in some embodiments a critical parameter, in determining the final particle size distribution.
  • the dispersed phase viscosity, the continuous phase viscosity, and the relative viscosities of the two phases in turn are considered.
  • the viscosity of the dispersed phase can have a direct correlation to particle size. It is noted that the Weber Number did not account for the viscosity of the dispersed phase. Rheological dissipation can occur when the viscosity of the dispersed phase is high. Consequently, additional energy is required to achieve the same droplet diameter as a lower viscosity dispersed phase.
  • Particle Interactions For high dispersed-phase concentrations particles tend to interact. Steric repulsion and coulombic interactions lead to modified viscosity. Specifically, viewing this as two spheres in a liquid making contact, it can be theorized that they 'bump into' each other, leading to rheological dissipation and momentum transfer increasing the viscosity of the system. If two charged particles pass each other the additional force causes momentum transfer and adds to the viscosity of the system as well.
  • Emulsifier Concentration The addition of emulsifier can, impact, and in some embodiments directly impact, the homogenous viscosity of the continuous medium. However, due to electroviscous and steric repulsion, the viscosity can be dependent on emulsifier concentration in different manners.
  • the primary independent impact of the viscosity of the continuous phase is in the viscous dissipation of energy input.
  • the viscosity of the continuous phase can have a strong impact on the hydrodynamic conditions of the system, and can lead to modified turbulence and eddy length scales.
  • this impact will typically be highly device specific, as convergent flow vs. turbulent mixing technologies have different geometries and flow conditions.
  • Temperature can have an impact, and in some embodiments a significant impact impact on the kinetics of coalescing and break-up phenomena, and consequently the particle size distribution can depend on temperature, and it is theorized can be temperature depending in several ways.
  • temperature can have an effect on cure rate, and the degree of cure, for polysilocarb precursor formulations.
  • Viscosity is typically a function of temperature, and different materials can have different magnitudes of change in viscosity associated with a given
  • the temperature reflects an average kinetic energy of the system. Most especially, in some embodiments, e.g. , for small particles, this can directly impact Brownian motion of the particles leading to enhanced coalescence rate due to higher average kinetic energies to overcome kinetic barriers established by surfactants.
  • Diffusion is also temperature dependent (for thermally activated diffusion mechanisms) and consequently Ostwald Ripening can generally be enhanced with higher temperatures.
  • Nucleation rate varies with temperature.
  • the nucleation of particles can be greatly enhanced at higher temperatures, thus reducing average particle size.
  • an increase in temperature leads to larger average particle sizes.
  • this variation as a function of time can result in a less monodisperse batch of particles.
  • temperature effects should be balanced against the effect temperature may have on cure rate, and in particular the cure rate of polysilocarb precursor formulations.
  • a variety of factors can influence the temperature of a system. For example, some typical factors are the energetic dissipation from the homogenizer and exothermic polymerization reactions. It should be noted that the effect of exothermic reaction generally becomes a greater factor as the concentration of dispersed phase increases.
  • volume fraction of the dispersed phase can impact the system, variations of the following can lead to a reverse emulation, in which case the disperse phase and continuous phase are reversed.
  • large volume fractions can, among other things, induce non-Newtonian viscous effects, enhance viscosity, lead to temperature variation for exothermic systems, increase coalescence probability, reduce the ultimate efficacy of surfactants, and combinations and variations of these.
  • the impact of volume fraction on particle size tends to be negative - the larger the volume fraction the larger the average particle size.
  • droplets form a skin and are recalculated through the mechanical emulsification mixer they may beak-up and form smaller non uniform particles.
  • the adsorption characteristics of a surfactant on the surface of a dispersed phase may vary between the polymerized solid and the monomer liquid. Consequently, the steric or electrostatic repulsive properties of the surfactant may be modified as a function of the degree of cure. This could potentially result in post— cure agglomeration. Surfactants that function both for the monomer liquid and polymer solid are thus preferred.
  • Another example, of these effects relates to the factor that typically solids aggregate by different mechanism than liquids coalesce. Specifically, they adhere without a necessary reduction in surface area. This means that aggregation kinetics can vary, and in some embodiments vary strongly, from the liquid phase.
  • a liquid-liquid emulsion may be stable yet the solid-liquid emulsion may naturally aggregate. Or may aggregate depending on the rate, and degree of cure, e.g., the cohesion of the initially cured solids, or skins on the solids.
  • coalescence are kinetic in nature, and thus, have rates associated with them. As such, the impact that time-dependency has on emulsion systems is a factor that generally should be evaluated, utilized and considered.
  • the evolution of particle size to the steady state can be, or behave as a time constant.
  • Surfactant adsorption can also be time dependent. "Quickly Adsorbing" surfactants adsorb readily due to, for example, thermodynamic or kinetic reasons. The impact of having quickly or slowly adsorbing species is a factor in determining the final particle size distribution. This can be understood by recognizing that once adsorbed, surfactant molecules, generally, do not permanently adhere to the surface of the droplet. Rather, they are continuously exchanged with the continuum. This typically occurs during events where the geometry is altered, such as collision or break-up. If the surfactant is not readily readsorbed, coalescence may occur.
  • these systems require only minimal components, provide the ability to make large amounts of particles, beads, and proppants having, and if desired having very high uniformity, e.g., size distribution, for example, at least about 70% or more of the particles size distribution is within 5% size range, at least about 80% or more of the particles size distribution is within a 5% size range, at least about 90% or more of the particle size distribution is within a 5% size range.
  • size distribution for example, at least about 70% or more of the particles size distribution is within 5% size range, at least about 80% or more of the particles size distribution is within a 5% size range, at least about 90% or more of the particle size distribution is within a 5% size range.
  • distributions can be obtained unfiltered, or unsieved, i.e., without the need for filtering, sieving or post processing.
  • these systems have a vessel, which preferably is temperature controlled.
  • the vessel can be, for example a tank, vat, trough, channel, and other shapes and types of structures, having a capacity of about 1 gallon or less, to 100 gallons or more, to 1 ,000 gallons, and larger.
  • the vessels hold a liquid in which the precursor batch is formed into a volumetric shape and then cured.
  • the liquid in the vessel can be any liquid, (this liquid has been referred to as the continuum, continuous phase, and may also be referred to as the forming liquid, unless specified otherwise all such terms are interchangeable) that permits the formation of discrete volumetric shapes of the precursor in the forming liquid.
  • the forming liquid is preferably water, distilled water, deionized water, but could also be polar liquids, non-polar liquids, alcohols, and combinations and variations of these.
  • an embodiment of the forming liquid is deionized water with reduced oxygen content (e.g., dissolved O2), for example, preferably less than about O2, less than about 10 ppm O2, less than about 5 ppm O2 , less than about 1 ppm O2, and less than about 0.1 ppm O2.
  • reduced oxygen content e.g., dissolved O2
  • higher 02 content may be used, such as for example 20 ppm, 50 ppm, 100 ppm, and 300 ppm and more.
  • the forming liquid can also have, and preferably does have, a surfactant.
  • surfactants in conjunction with, or independent, from surfactants, other techniques or methodologies can be utilized, such as variations in pH, ionic strength and/or conductivity of the water.
  • additives to the continuous phase such as rheology modifiers, thinning agents, defoamers, inhibitors, additional catalysts, reactive diluents, etc.
  • the surfactant can be any type of surfactant that has polar and non-polar functionalities.
  • the surfactants can be Mono and diglycerides (e.g.
  • Sorbitan Fatty Acid Esters e.g. SPAN 20, Span 80
  • Polyoxyethylene sorbitan fatty acid esters e.g. Tween 80, Tween 61
  • Polyoxyethylene sorbitol esters ARLATONE T, ATLAS GN-1441
  • Polyoxyethylene Acids
  • surfactants can be used in concentrations from about 0.1 % surfactant to forming liquid (e.g., water) and more, 0.5% and more, 1 % and more, 5% and more and 7.5% and more.
  • the surfactant may also be added into the precursor formulation, be in the forming liquid and both.
  • the same or different surfactants may be used in the precursor and forming liquid.
  • Surfactant may be added to the continuous phase in a continuous or batch process.
  • the surfactant-continuous phase mixture may be recirculated and as particles or beads cure and are removed, additional surfactant is added to the
  • the forming liquid temperature is controlled, for example, by heating and cooling devices associated with the vessel.
  • the temperature of the liquid should be controlled to address, among other things, any exotherms, and to enhance bead formation, and uniformity.
  • the forming liquid is, at atmospheric pressure (and more preferably with the surface being under an inert atmosphere), with its temperature being maintained from about 80° C, to about 90° C, to less than 100° C.
  • the volumetric shapes, e.g., beads are formed and cured to a greater or lessor degree in the forming liquid.
  • beads will be used as the volumetric shape, it being understood that this is without limitation to the forming of other types of volumetric shapes, and that the following is applicable to such other shapes.
  • the beads may only be partially cured in the forming liquid, and later or subsequent curing prior to pyrolysis may take place, or as a preliminary step in pyrolysis.
  • storage of the partially cured, and cured beads should preferably be under reduced oxygen and held at cooler
  • Mixing preferably is provided to agitate the forming liquid, provide shear to the precursor, and control among other things, particle size, coalescence, temperature uniformity, and size distribution.
  • the precursor can be added to the liquid in various manners, from simple pouring through air, to injection nozzles located under the surface of the atmosphere, sparges, screens, distribution headers, droplets generated in a gas (e.g., the atmosphere) and then falling on to the surface of the continuous phase and combinations and variations of these and other apparatus and methods to introduce the precursor into the forming liquid.
  • each precursor introduction device may have multiple introduction ports or openings, depending upon, among other things, the size of the system, the desired rate of production, rate of cure, intended particle size, intended size distribution, and other factors.
  • FIG. 9 there is shown a schematic of an embodiment of a type of solution formation system and process.
  • This system may be used for batch and continuous production of cured beads.
  • the solution formation system 1401 has a vessel 1403 that contains a forming liquid 1402.
  • the forming liquid 1402 has a surface 1407, which as an atmosphere above it.
  • the forming liquid for example can be deionized water, with at about 1 % surfactant, and preferably less than about 15 ppm O2, less than about 10 ppm O2, less than about 5 ppm O2 , less than about 1 ppm O2, and less than about 0.1 ppm O2.
  • the vessel 1403 has a temperature control apparatus 1404 having control and power cable 1405. It being understood that the temperature control apparatus can be in the vessel, as shown, located anywhere within the vessel, in the walls of the vessel, external to the vessel, on fluid inlet lines, on storage tanks, and combinations and variations of these.
  • the vessel has an agitator 1406 located within the vessel 1403, the agitator has a drive member 1412, e.g., a drive shaft, and an impeller 1413.
  • the agitator impeller 1413 is located below the surface 1407 of the liquid 1402 and near to the opening 141 1 for the nozzle 1410 for the in-feed line 1408, e.g., the precursor introduction device 1415.
  • the precursor introduction device 1415 can have for example, an in feed line 1408, a nozzle 1410, that forms an opening 141 1 for introduction of the precursor into the forming liquid 1402 below the surface 1407.
  • the introduction device can have multiple in feed lines, these lines can be within the walls of the vessel, and thus, in essence form an opening in the walls of the vessel for introduction into the liquid.
  • the vessel wall introduction openings can be on the sidewalls, bottom and both, of the vessel.
  • a single in feed line may have one, two, three or more openings associated with it.
  • the in feed lines are connected to the make up, holding or other handling facilities for the polymer. It should be noted that in general, when the precursor is in the in feed line it has been catalyzed. Although in some embodiments the addition of the catalysis could take place in other locations, such as for example in an inline mixer located in the in feed line.
  • the agitator can be located in other positions relative to the forming liquid surface, the vessel, and the precursor introduction device. There also can be one, two, three or more agitators associated with a vessel.
  • the agitators may be located entirely below the surface of the liquid, and preferably are so located, to minimize the entrainment of gas at the drive shaft surface interface.
  • the agitators may be located at different levels, and when multiple agitators are used, for example, one may positioned adjacent to the precursor introduction device, and others may be removed from that device.
  • the agitators may be operated at different speeds, for different periods of time and combinations and variations of these during a forming process, to facility particle formation, particle size distribution and curing, to name a few parameters and affects.
  • the solution formation system 1500 has a vessel 1501 that contains a forming liquid 1502.
  • the forming liquid 1502 has a surface 1508, which as a media above it. (Note that while the media is preferably a gas, it can be a liquid phase, a reduced pressure gas, a high pressure gas, a gas at ambient pressure, and a vacuum.)
  • the forming liquid 1502, for example, can be deionized water, with a surfactant.
  • the vessel 1501 has a temperature control apparatus 1503 that wraps the wall 1516 of the vessel 1501. It being understood that the temperature control apparatus can be external and on the vessel, as shown, located anywhere within the vessel, in the walls of the vessel, on the forming liquid inlet line, in a storage tank, and combinations and variations of these.
  • the vessel has an agitator assembly 1504 located within the vessel 1501 , the agitator assembly 1504 has a drive member 1512, e.g., a drive shaft, and an impeller 1513.
  • the entirety of the agitator assembly 1504 is located below the surface 1508 of the forming liquid 1502. It being understood that the agitator can be located in other positions relative to the forming liquid surface, the vessel, and the precursor introduction device.
  • the precursor introduction device 1515 has an in-feed line 1505 and a distribution assembly 1530.
  • the distribution assembly 1530 has a screen 1506 that has a large number of openings, e.g., 1507, through which the precursor is feed, e.g., pumped, flowed, gravity feed, etc.
  • the diameters of the openings can be used to size the particles, as well as contribute to, and determine the shape of the particles. For example, circular openings, among others, can be used to from spheres.
  • the screen 1506 and the screen openings, e.g., 1507 are located below the surface 1508 of the forming liquid 1502.
  • the introduction device can have multiple in feed lines, these lines can be within the walls of the vessel, and thus, feed into a screen in the wall of the vessel for introduction into the forming liquid.
  • the vessel wall introduction openings can be on the sidewalls, bottom and both, of the vessel. There can be one, two, three, four or more of these screen openings in the vessel walls.
  • FIG. 1 1 there is shown a perspective view of an
  • the formation system 1600 has a vessel 1601 , which in this case is a rectangular bath.
  • the vessel 1601 has four zones 1601 a, 1601 b, 1601 c, 1601 d.
  • the four zones can have the same conditions or different conditions.
  • the four zones can have different temperatures, surfactant levels, degree of agitation, depth, temperature, flow rate and combinations and variations of these.
  • the first zone 1601 a can be set up to have the best conditions for particle formation, and for a predetermined size of particle.
  • the second zone 1601 b can have the best conditions for initial curing.
  • the third zone 1601 c can have the best conditions to prevent agglomeration during final cure, and the fourth zone 1601 d can be a removal or harvesting zone for the cured particles.
  • the vessel 1601 contains a forming fluid 1603 that is flowing in the direction of arrow 1604. The fluid is agitated to a greater or lesser extent depending upon the zone, and the predetermined purpose or function of that zone, as well as other factors.
  • the precursor is added to the forming fluid 1603 via distribution header 1602, which could be a screen, several screens, nozzles, slits, and combinations and variations of these and other devices to introduce precursors.
  • the cured particles are removed from the system by particle removal device 1605, which could be a fine mesh collection system or a screen.
  • a return line 1606 provides for the forming fluid to be returned and feed into the vessel by the inlet line 1607.
  • the particles e.g., proppant are formed, at or near the distribution header 1602 and are carried by the flowing forming fluid 1603 in the direction of arrow 1604.
  • the various zones of the system 1600 provide the requisite conditions for creating the cured particles, e.g., cured proppant.
  • the cured material is to be pyrolized and transitioned into a ceramic, preferably the excess water is removed; and more preferably the material is dry before pyrolysis takes place.
  • the cured material should be stored at less than 150° C, at less than 140° C, and at less than 100° C, preferably it should also be stored in a reduce O2 atmosphere. Additional curing may also take place after the cured particles are removed from the forming fluid and prior to pyrolysis. This final, or further curing and pyrolysis can take place together, e.g., serially in the same furnace, or can be separate procedures, e.g., different furnaces, storage time between procedures.
  • Embodiments of the methods that can be practiced using systems like the embodiment of FIGS. 9, 10 and 1 1 can be used to to produce spherical or non- spherical particles from precursors.
  • the temperatures will generally be at, or below the boiling point for water, e.g., 100° C (at standard temperature and pressure).
  • higher temperatures can be used.
  • these systems can be used with any type precursor that is in liquid form, as long as the precursor does not react with the forming fluid at the processing temperatures, e.g., does not react water at or below 100° C.
  • embodiments of aqueous systems using polysilocarb precursors can produce particles from about 5 mm diameter down to about 1 micron, although smaller and larger sizes are contemplated.
  • the particles made by these embodiments can have different shapes and would include for example teardrop, spherical, dodecahedral, faceted, as well as other volumetric shapes.
  • polysilocarb precursor formulations that can be used in these systems, and in particular aqueous systems, are: 100% MHF; 95% MHF - 5% TV; 46% MHF - 34% TV - 20% VT; 70% MHF - 20 % TV - 10% VT; 75% MHF - 15% TV - 10% VT; 85/15 MHF/DCPD reaction blend; 70/30 MHF/DCPD reaction blend; and 65/35 MHF/DCPD reaction blend; 60/40 MHF/DCPD reaction blend; and 82/18
  • Catalysis may include, for example 1 -20 ppm platinum, dilute base, dilute acid, an amine catalyst, as well as other types of catalysts.
  • -Pour the catalyzed polymer into the water/surfactant mixture and stir with a mechanical stirrer at 100-500 rpm in order to break up the polymer into droplets of the desired size (typically 2-3 minutes of stirring)
  • -Pour the polymer/water/surfactant mixture from above into 1 liter of de- ionized water that has been heated to 63-68°C and agitate using a low shear agitation method for 45 minutes to 1 hour while keeping the entire batch of material in the range of 45°C to 50°C
  • the beads After the beads have become hard and not sticky, pour off the liquid into a pan or through a set of sieves to separate out the beads and solidified siloxane from the water/surfactant mix -The beads should then be dried and further cured by heating to 50°C - 60°C for 1 -2 hours followed by 80-85°C for 1 -2 hours and a subsequent 1 - 2 hours at 1 15°C to complete the curing.
  • the beads can then be pyrolized into ceramic.
  • HLB is the Hydrophile-Lipophile Balance.
  • an HLB number can be assigned to the group of ingredients that are going to be used to form an emulsion, and then a surfactant or blend of surfactants can be selected to match that number.
  • the HLB of an emulsifier is an expression of its Hydrophile- Lipophile Balance, e.g., the balance of the size and strength of the hydrophilic (water- loving or polarj and the lipophilic (oil- loving or non-polarj groups of the emulsifier.
  • emulsifiers consist of a molecule that combines both hydrophilic and lipophilic groups.
  • An emulsifier that is lipophilic in character is assigned a low HLB number (below 9.0), and one that is hydrophilic in character is assigned a high HLB number (above 1 1 .0). Those in the range of 9-1 1 are intermediates.
  • HLB numbers typically range from 0 to 20 for non-ionic surfactants and can exceed 50 for ionic surfactants.
  • surfactants and surfactant combinations or blends can have HLB values from about 2 to about 18, about 5 to about 15, and preferably about 8 to about 12. Other HLP values outside these ranges can be utilized and may be preferred for certain types of precursors.
  • FIG. 12 there is shown a process flow diagram 1701 for an embodiment of a solution formulation system and process.
  • the catalyzed precursor 1701 is formed into a bead 1702 the beads are cured 1703 (with slow mixing and a temperature of about 45-55° C).
  • the beads, water and surfactant are transferred 1705 and the cured beads 1708 are removed 1707.
  • the removed water is transferred 1709, where the siloxane 1719 is removed 1710 from the water, which is returned 1716 to surfactant and water mixing station 1717.
  • the beads are dried and further cured 1712, at about 50-1 15° C, after which non-bead scrap 1715 (which can be used as or further processed into pigments, abrasives, etc.) is removed 1713, from the use beads 1714.
  • Station 1717 mixes water and surfactant, and has return deionized water 1704 as a water source.
  • Surfactant for example, HLD 9.1 , 1718 is added to the water at station 1717.
  • the water and surfactant are used for bead forming 1702.
  • a polysicocarb batch having 50% by volume fly ash is added to a polysilocarb batch having 70% MH, 20% TV, 10% VT and 1 % catalyst (10 ppm platinum and 0.5% Luprox 231 peroxide).
  • EXAMPLE 5 A polysilocarb batch having 70% of the MH precursor (molecular weight of about 800) and 30% of the TV precursor are mixed together in a vessel and put in storage for later use.
  • a polysilocarb batch having 70% of the MH precursor (molecular weight of about 800) and 30% of the TV precursor are mixed together in a vessel and put in storage for later use.
  • the polysilocarb batch has good shelf life and room temperature and the precursors have not, and do not react with each other.
  • the polysilocarb batch has a viscosity of about 15 cps.
  • 21 % of a silica fume (about 325 mesh) are added to the batch to make a filled polysilocarb batch, which can be kept for later use.
  • 10 ppm of a platinum catalyst is added to the polysilocarb batch
  • VT molecular weight of about 6000
  • 1 % of the OH terminated precursor 1 %
  • a polysilocarb batch has 75% MH, 15% TV, 10% VT and a viscosity of about 65 cps. 10 ppm of a platinum and peroxide catalyst mixture is added to this batch prior to forming into preforms. [00272] EXAMPLE 12
  • a polysilocarb batch having 70% of the MH and 30% of the VT having a molecular weight of about 500 and about 42% of a submicron and a 325 mesh silica are mixed together.
  • the polysilocarb batch has a viscosity of about 300 cps.
  • a polysilocarb reaction blend batch having 85/15 MHF/DCPD with 1 % P01 catalyst and 1 % peroxide catalyst.
  • a polysilocarb batch having 50 - 65% MHF; 5 - 10% Tetravinyl; and 25 - 40% Diene (Dene Dicyclopentadiene or Isoprene or Butadiene), preferably catalyzed with P01 or other Platinum catalyst.
  • EXAMPLE 23 A polysilocarb reaction blend batch having 85/15 MHF/DCPD, and preferably using P01 and Luperox® 231 catalysts.
  • Methyltriethoxysilane 0.00 0.0% 178.30 - 0.00% - -
  • Methyldiethoxysilane 182 23.2% 134.25 1.36 63.57% 1.36 2.71
  • a polysilocarb formulation has 95% MHF and 5% TV.
  • a polysilocarb formulation has 90% MHF, 5% TV, and 5% VT.
  • a polysilocarb formulation has 0-20% MHF, 0-30% TV, 50-100% H62 C and 0-5% a hydroxy terminated dimethyl polysiloxane.
  • a polysilocarb formulation has 40% MHF, 40% TV, and 20% VT and has a hydride to vinyl molar ratio of 1 .12:1 , and may be used as to form strong ceramic beads, e.g., proppants for use in hydraulically fracturing hydrocarbon producing
  • a polysilocarb formulation has 42% MHF, 38% TV, and 20% VT and has a hydride to vinyl molar ratio of 1 .26:1 , and may be used as to form strong ceramic beads, e.g., proppants for use in hydraulically fracturing hydrocarbon producing
  • EXAMPLE 38 [00325] A polysilocarb formulation has 55% MHF, 25% TV, and 20% VT and has a hydride to vinyl molar ratio of 2.36:1 , and may be used as to form strong ceramic beads, e.g., proppants for use in hydraulically fracturing hydrocarbon producing formations.
  • FIG. 5 illustrates an underwater pelletizer structure with the self- aligning hub.
  • the pelletizer includes an inlet housing 510 including an inlet passageway 512 for receiving liquid PDC precursor from upstream equipment.
  • the liquid PDC precursor is diverted outwardly by a nose cone 514 and enters into a plurality of extrusion orifices 516 in a die plate 518.
  • the die plate 518 is secured to the inlet housing by fastening bolts or the like 520 and is provided with heating elements 522 located in cavities 524 in the die plate.
  • the die plate includes a die face 526 of wear resistant material, which is mounted on the die plate along with heat transfer plates 528.
  • a cutter chamber generally designated by reference numeral 530 which includes a water circulating inlet passageway 532 and a discharge passageway 534 for water and pellets.
  • the cutting chamber includes a flange 536 attached to the die plate and housing and a flange 538 at the opposite end thereof having an inclined surface 540 for association with a similar flange on an adapter connected to a drive unit.
  • a drive shaft 542 extends through the cutter chamber 530 and supports and drives a cutter assembly 544, which includes a hub 546 and a plurality of cutter knives 548 having their cutting edge associated with the die face 526 and the discharge point of the orifices 516.
  • the hub 546 and the manner in which it is attached to the drive shaft 542 and supported therefrom for self-alignment of the hub and thus the cutting elements 548 with the die face 526 is illustrated in the figures.
  • the cutter assembly 544 includes a plurality of arms 550 having notches 552 which receive the cutter blades that are secured by the use of conventional fasteners threaded into threaded bores 554 as is well known in the art.
  • the arms 550 are integral with the central hub 546 which is connected to a reduced externally threaded end portion 556 on the drive shaft 542.
  • the hub 546 is provided with an axial bore 558 extending therethrough and which has an inner face that is partially spherical as indicated by reference numeral 560 and as illustrated in FIGS. 5B and 5D.
  • an adapter 562 Positioned in the bore 558 is an adapter 562 having an internally threaded bore 564 extending therethrough for threading onto the threaded reduced end 556 of the shaft 542.
  • the exterior surface of the adapter 562 is partially spherical as indicated by reference numeral 566 and as shown in FIGS. 5B to 5D with the curvature of the partially spherical surfaces 560 and 566 matching or corresponding and closely associated as illustrated in FIG. 5B with the diameter of the partially spherical surfaces at the end edges thereof being less than the diameter at the central portions of the partially spherical surfaces.
  • the partially spherical exterior surface 566 of the adapter 562 is provided with a pair of diametrically opposed generally semispherical recesses 568 oriented equally distant from the end edges of the partially spherical surface 566 as illustrated in FIGS. 5C and 5D. Received in each of the semispherical recesses 568 is a spherical ball 570.
  • the hub bore 558 includes a pair of diametrically opposed axial, semicylindrical recesses 572 which terminate at their inner ends in adjacent but spaced relation to the opposite end of the bore 558 and terminate in a partially spherical inner end 574.
  • the recesses 572 receive the balls 570 which provide for torque transfer from the shaft 542 and adapter 562 to the hub 546.
  • the bore 558 includes an axial recess 576, which extends
  • the recesses 576 are provided to enable the partially spherical surface 566 of the adapter 562 to be inserted into the bore when the adapter 562 is oriented in perpendicular relation to the bore as illustrated in FIG, 5D.
  • the balls 570 being placed and retained in the cavities 568 in a suitable manner by the application of grease or the like are inserted into the recesses 572 when the assembled adapter 562 is moved into the bore 558 until the balls 570 reach a central point between the two ends of the bore 58.
  • the adapter 62 can be rotated 90° into the bore 558 with the partially spherical surfaces 560 and 566 being in close registry as illustrated in FIG. 5B with the curvature of the surfaces 560 and 566 serving to retain the adapter 562 within the bore 558 and retain the balls 570 in the recesses 568 and 572.
  • the balls 570 transmit driving torque and the surfaces 560 and 566 enable the hub 546 to pivot in a universal direction with respect to the drive shaft thereby enabling the cutter hub and cutter knives 548 to be oriented in parallel closely spaced relation to the die face for efficient cutting of the extruded PDC into pellets.
  • the cutter hub and adapter can be mounted on the drive shaft 542 by engaging the internal threads 564 with the external threads 556 until the axial recess 580 formed in one end of the adapter 562 receives the shoulder 582 on the end of the shaft with the matching spherical surfaces 560 and 566 being oriented slightly outwardly of the periphery of the drive shaft in view of the distance between the periphery of the internal recess 580 and the periphery of the surfaces 566 and 560 radially outwardly thereof.
  • This enables the cutter hub to pivot universally on the adapter 562.
  • the assembled hub and adapter may be manually screw threaded onto the shaft threads 556 to attach or detach the adapter and hub. If necessary, a wooden hammer may be used to lightly tap the hub to tighten or loosen the hub. Further teachings for the embodiment of this example can be found in US Patent No. 5,264,688, the entire disclosure of which is incorporated herein by reference.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 39 to make volumetric shapes. Preferably spherical beads are made.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 39 to make the polysilocarb proppants taught and disclosed in US Patent Publication No. 2014/0326453.
  • PDC formulation into the form of discrete pellets or granules can be accomplished with the aid of the hybrid iiquid-mechanicai cutter apparatus of the embodiment shown in FIGS, 6 to 6C.
  • this embodiment there is provided continuous extrusion of strands of the PDC formulation through one or more orifices, formed in a planar die face, directly into a curing liquid, and cutting the extruded strand(s) within the curing liquid into pellets or granules as the latter are undergoing solidification.
  • This embodiment of a rotary hybrid iiquid-mechanicai cutter apparatus can be used for producing pellets from a strand or strands of a partly liquid PDC formulation in cooperation with an extrusion die, having a planar die surface intersected by one or more extrusion orifices.
  • FIGS. 6-6C there is shown therein a portion of the rotating drive shaft 610 which is provided with a reduced portion
  • a connecting key 613 which is positioned in a keyway formed by axialiy aligned, corresponding slots 614 and 615 in the reduced portion of the drive shaft 61 1 and in the inner cap member 612,
  • One alternate structure is to make members 610, 61 1 , and 612 into one integral piece thereby eliminating key 613 and slots 614 and 615.
  • the rotational movement of the inner cap member 612 is in turn transmitted to an outer sleeve member 616 by means of a relatively loose fitting of a plurality of circumferential!y spaced and axiaily extended splines 617 located on the interior periphery of the outer sleeve member 616 with a corresponding plurality of circumferentiaily spaced and axiaily extended splines 618 located on the exterior periphery of the inner cap member
  • a stud bolt 623 which is threadably received into a recess 824 formed in the reduced part of the drive shaft 61 1 , is provided with two hexagonal nuts 625 and 626.
  • a jam nut 625 holds the inner cap member 612 tightly against the reduced portion of the drive shaft 61 1.
  • An outer stop nut 626 is positioned against the outer face 627 of the knife holder assembly 618 and can be adjustably positioned to pre-load the helical spring 628.
  • the helical spring 628 is positioned between the flat face of the inner cap member 629 and that of the washer 630.
  • the washer 631 is provided with a convex spherical face 632, which engages with the concave inner face
  • the knife holder assembly 620 which is held firmly against the stop nut 626 by virtue of spring tension transmitted by the washer 630 and the outer sleeve member 616, is mounted around the stud bolt 623 and possesses a number of circumferentiaily spaced and radially extending knife elements 634, The knife elements 634 are secured in place by any suitable means, e.g. by threaded bolts 635, in the ends 636 of the knife holder assembly 620.
  • FIG, 6 shows the entire hybrid liquid-mechanical cutter assembly submerged in a curing liquid 640 with ports 841 provided in the outer sleeve member for ready flow-through of the curing liquid 640.
  • the helical spring is pre-loaded by tightening the stop nut 626. The drive shaft is then moved toward the die face until knife element-to-die face contact occurs.
  • EXAMPLE 40A The polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 40 to make volumetric shapes. Preferably spherical beads are made.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 40 to make the polysilocarb proppants taught and disclosed in US Patent Publication No. 2014/0326453.
  • the underwater pelletizer is generally designated by reference numeral 710 and includes a transition device 712 including a die plate 714 associated with a cutting blade assembly 716 supported and driven by a shaft assembly 718 drivingiy connected to a motor 720 through a coupling 722 with the position of the cutting blade assembly being adjusted by an adjustment mechanism 724 and a support structure 726 is provided for supporting the motor, shaft assembly and cutting blade assembly.
  • a water circulating passageway assembly 728 is provided for supplying water to a water box or container 729 enclosing the cutter blade assembly 16 and the die face on the die plate 714.
  • the shaft assembly 718 includes a generally cylindrical elongated rigid shaft member 730 oriented axially within the hollow interior 732 of a housing 734 with the shaft member 730 being rotatably supported by a pair of longitudinally spaced ball bearing assemblies 736 each of which includes an inner race 738 secured to the shaft member 730 in an immovable manner such as by retaining rings 740 securing the bearing assembly 736 remote from the motor 720 and a retaining ring 740 and shoulder 742 on the shaft member 730 securing the outer bearing assembly 736 to the shaft member 730.
  • the retaining rings 740 and shoulder 742 secure the inner races 738 of the ball bearing assemblies 736 longitudinally on the shaft member 730.
  • outer races 744 of the bail bearing assemblies 736 are axially slidabiy or movably disposed in the hollow interior 732 of the housing 734 so that the drive shaft assembly including the cutter blade assembly 716 may be adjusted axially of the housing 734 and the die plate 714 to adjust the position of the cutting blade assembly and compensate for wear.
  • the adjustment assembly 724 for axially adjusting the shaft assembly 718 includes an internally threaded cup-shaped member 746 which is in screw threaded engagement at 747 with an externally threaded reduced end portion 748 on the housing 734.
  • the cup-shaped member 746 encircles the shaft member 730 and a thrust bearing 750 interconnects the cup-shaped member 746 and the shaft member 730 with the inner race of the thrust bearing 750 engaging a shoulder 752 on the shaft member 730 and being retained against the shoulder 752 by a threaded nut 754 threaded onto a threaded portion 756 of the shaft member 730 to prevent axial movement of the thrust bearing 750 on the shaft member 730.
  • a retaining plate 758 is mounted against the end of the cup-shaped member 746 remote from the threaded engagement with the housing by suitable bolts, cap screws 759 or the like with the retaining plate 758 having an inner opening which overlaps and engages the outer race of the thrust bearing 50 so that the outer race of the thrust bearing 750 is precluded from axial movement in relation to the cup-shaped member 746 by engagement with the retaining plate 758 and a forward shoulder 760 formed in the interior surface of the cup shaped member 746.
  • the outer race of the thrust bearing 750 is provided with radial clearance 762 between the outer circumference of the outer race of the thrust bearing 750 and the interior of the recess in the cup-shaped member 746 which receives the outer race of the thrust bearing 750. This permits lateral movement of the thrust bearing so that it will not preload the alignment bearings 736 for the shaft assembly 718.
  • the periphery of the cup-shaped member 746 is provided with a plurality of radially extending knobs or handles 764 having a screw threaded connection 766 with internally threaded sockets or recesses formed in the periphery of the cup-shaped member 746 thereby enabling the cup-shaped member to be rotated about the axis of the shaft member 730.
  • cup-shaped member 746 is an adjustment nut that retains the thrust bearing 750 captive axially so that axial thrust can be exerted on the shaft assembly 718 in either direction with the radial clearance 762 enabling lateral movement of the thrust bearing 750 so that it will not introduce a preload into the alignment ball bearings 736 which permanently align the shaft member 730 in relation to the die plate and housing.
  • the coupling 722 includes a hub 768, secured to the reduced end 770 of shaft member 730 by a suitable key-and-set screw arrangement 772.
  • a similar hub 774 is secured to the output shaft 775 of the motor 720 in a similar manner with the reduced end 770 of the shaft member 730 being generally in alignment with the motor output shaft 775 and spaced therefrom with the hubs 788 and 774 also being in spaced aligned relation as illustrated in FIG. 7.
  • the external surface of each of the hubs 788 and 774 has gear teeth 776 thereon for axial sliding engagement with internal gear teeth 778 on coupling members 780 each of which includes an outwardly extending flange 782 with the flanges being secured by fastening bolts 784.
  • This structure permits relative axial movement between the hubs 768 and 774 and the reduced end 770 of shaft member 730 and the output shaft 775 from motor 720 while maintaining a driving connection there between.
  • Each of the sleeve-like coupling members 780 is provided with an inwardly extending flange 786 engaged with a shoulder 788 on the respective hub to limit the outward movement of the hubs in relation to retain the coupling members 780 and an O-ring seal 790 is provided between the inner edge of the flange 786 and the exterior surface of the respective hubs to the coupling lubricant therein.
  • This structure enables limited relative movement between the output shaft 775 of the motor 720 and the shaft member 730 thereby eliminating axial and radial forces from being transmitted to the shaft member 730 from the motor output shaft 775.
  • the structure of the coupling 722 per se is known and is commercially available. However, the concept of employing a coupling which compensates for both parallel and angular misalignment as well as end float is unique in driving the shaft assembly 718 in a pelletizer.
  • the support assembly 726 includes a support plate 792 which has the motor 720 attached thereto through a base plate 794 on the motor 720, a resilient pad 796 and fastening bolts 798. Also attached to the support plate 792 is a protective housing or enclosure 7100 for the coupling 722 to prevent accidental contact with the rotating components.
  • the protective enclosure or housing 7100 is secured to the support plate 792 by bolts 7102.
  • the housing 734 is secured to the support plate 792 by fastening bolts 7104 with the resilient pad 7106 interposed between the support piate 792 and the housing 734.
  • a support platform or base 7108 Positioned videow the support plate 792 and supporting the support piate 792 is a support platform or base 7108 supported in any suitable manner such as from a pedestal 71 10.
  • the support piate 792 is adjustably supported from the base 7108 by a plurality of externally threaded bolts 71 12 having a nut 71 14 on each end with one nut being above the piate 792 and the other nut being below the platform or base 7108.
  • a compression coil spring 71 16 is positioned on the bolt 71 12 with the upper end thereof engaging the under surface of the support plate 92 and the lower end engaged with an adjustment nut 71 18 on the bolt 71 12.
  • bolts 71 12 are provided between the support piate 792 and the platform or base 7108 so that by adjustment of the nuts 71 18, the pelletizer can be supported in a manner that it floats in relation to the end of the extruder barrel to prevent stresses and misalignment due to thermal growth of the extruder barrel supports.
  • the individual adjustment of the springs 71 16 by the adjustment nuts 71 18 enables proper tensioning of springs 71 16.
  • Accurate resilient positioning of the pelletizer components in relation to the die plate 714 and transition 712 is accomplished by adjusting bolts 71 12.
  • FIG. 7C illustrates another feature of the underwater pelletizer of the present embodiment in which the die piate 714 includes passageways 7120 for flow of liquid PDC formulation 7122 in the form of a strand or ribbon.
  • the die plate 714 includes a die face member 7124 having an outwardly tapering exit passageway or hole 7126 from which the PDC formulation 7122 exits and solidifies to form a pellet 7128 which is cut off by the cutting blade assembly.
  • exit hole is cylindrical, there may be, depending upon the formulation and cure conditions, a solidification of the PDC formulation on the interior thereof which causes a constriction in the flow path of the PDC formulation with the constriction being at the exit of the die hole which reduces the cross-sectional area of the passageway and forms a constriction at the exit which is believed to cause non-uniform pellets and premature solidification.
  • the outwardly tapered exit hole 7126 of the present embodiment does not prevent the curing of the PDC formulation but the layer 7130, under some conditions can form an insulated die hole so that the final shape of the die hole will be cylindrical as designated by numeral 7132.
  • the solidified PDC formulation 7130 forms an insulating layer of very low thermal conductivity and provides an excellent thermal barrier so that only the tapered portion of the exit hole 7126 will be filled with solidified PDC formulation so that the residual hole 7132 will be substantially cylindrical and will remain substantially cylindrical due to the insulation characteristics of the cured PDC formulation 7130. Thus, the final cylindrical shape hole will produce more uniform pellets and prevent premature curing. Further teachings for the embodiment of this example can be found in US Patent No. 4,728,276 the entire disclosure of which is incorporated herein by reference.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 41 to make volumetric shapes. Preferably spherical beads are made.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 41 to make the polysilocarb proppants taught and disclosed in US Patent Publication No. 2014/0326453.
  • the polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 41 to make one or more of the following volumetric shaped preforms: spheres, pellets, rings, lenses, disks, panels, cones, frustoconical shapes, squares, rectangles, trusses, angles, ribbons, channels, hollow sealed chambers, hollow spheres, blocks, sheets, coatings, balls, squares, prolate spheroids, ellipsoids, spheroids, eggs, cones, multifaceted structures, films, skins, particulates, beams, rods, angles, columns, fibers, staple fibers, tubes, cups, pipes, and polyhedrons (e.g. , octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism).
  • volumetric shaped preforms spheres, pellets, rings, lenses, disks, panels, cones, frustoconical shapes
  • the present embodiment relates generally to an improved underwater peiletizer in which a liquid PDC formulation is extruded through die orifices in a die plate in the form of continuous strands that are cut into pellets by a rotating knife holder with knives that engage the die plate.
  • the die plate and the knife assembly are housed within a fluid, e.g. , water, housing so that the pelletizing takes place under water.
  • This embodiment of the peiletizer provides a series of heat transfer tubes to transfer heat from the inlet of a transition piece where the liquid PDC formulation enters the extruder die so that heat is transferred more efficiently from the extruder forwardiy to the die face and the die plate to thereby facilitate extrusion and controlled predetermined curing of the PDC through the die and die orifices.
  • liquid PDC formulation leaving the die orifices at a predetermined temperature so as to provide uniform viscosity, uniform cure, and both, of PDC formulation at the orifice to provide uniform strands and, in turn, uniform pellets.
  • the warmer the PDC the less chance there is of having die plugging when the water contacts the PDC.
  • the underwater pelietizer of the present embodiment also provides for water to be conducted to the cutter through a hollow shaft that supports the cutter and turns it so that the cutting blades abut the die orifice. Water from the hollow shaft is expelled from the cutter blade holder in advance of each cutter blade through water nozzles formed in the cutter blade holder. This arrangement can prevent cavitation of the water in front of the cutter blades as the cutter blade holder turns to cut the extruded PDC.
  • FIGS. 8 and 8A there is shown an underwater pelietizer indicated generally at 810.
  • An extruder die 812 receives liquid PDC formulation that is forced through orifices in the extruder die where the strands of PDC are cut by a cutter assembly indicated generally at 814.
  • the cutter assembly is housed within a water housing indicated generally at 818.
  • a breaker plate 818 allows the liquid PDC formulation to pass into the extruder die 812.
  • a plurality of passages 820 conduct the liquid PDC formulation to the die face where a hardened steel die face plate 822 is fixed to the die face.
  • the hardened steel face plate 822 is shown in greater detail in FIG. 8D.
  • the hardened steel face plate 822 has a plurality of small holes 824 formed at the end of each passage 820 (FIG. 8 ) that feeds liquid PDC formulation to the die face plate 822.
  • the present embodiment is being described for use in peiletizing small size pellets.
  • the holes 824 in the die face plate 822 are about 300 to 900 ⁇ , 100 to 200 and about 0.020 to 0.050 inches in diameter so that the liquid PDC formulation strands are fine. While the present embodiment can be utilized to form thicker strands of PDC and is useful for that purpose, it is particularly suited for forming fine and very fine PDC strands that are peiletized under water.
  • Within the transition piece core 829 (FIGS. 8A, 8B and 8C) a large heat tube 826 and eight smaller heat tubes 828 are positioned as shown in FIGS. 8B and 8C.
  • the large heat tube 826 extends the entire length of extruder die 812 while the smaller heat tubes 828 are parallel axially to the large heat tube 826 and surround it as best seen in FIG. 8C.
  • the heat tubes of the present embodiment are sealed stainless steel tubes that contain a thermal transfer fluid.
  • the tubes are permanently sealed and they serve to efficiently transfer heat from the inlet end of extruder die 812 to the die face plate 822 where the liquid PDC formulation leaves through the small hole orifices 824 in the die face plate 822.
  • the transfer of heat from the entering liquid PDC formulation to the die face plate 822 is greatly facilitated by the heat tubes 826 and 828.
  • the cutter assembly 814 which is housed within the water housing 816 includes a hollow shaft 840 which has a water passage 842 formed longitudinally through the center of the shaft 840.
  • a blade holder 844 (FIG. 8E) has blades 846 secured to spokes 848 that extend from the blade holder 844.
  • a plurality of water nozzles 850 extend between each of the spokes 848. Water is fed through the water passage 842 in shaft 844 into the blade holder 844 from which it is ejected through the nozzles 850.
  • the nozzles 850 help to insure that there is water around the blades at all times as they rotate to cut the PDC extrudate as it leaves the die face plate 822.
  • the blades 846 bear against the die face plate 822 and cut the strands of liquid PDC formulation as they leave the die face plate 822 and enter the water bath within the water housing body 852.
  • the water within housing body 852 enters through water inlet 854 that is positioned at approximately a 45° angle to the horizontal and enters the housing at the level of the cutter shaft 840.
  • the water outlet 856 from housing body 852 is vertical as shown in FIGS. 8A and 8E.
  • the water and entrained pellets leave through outlet 856.
  • cavitation within the water is eliminated when the arrangement of inlet 854 and outlet 856 is combined with the water nozzles 850 that emit water that enters through the water passage 842 in shaft 840.
  • FIG. 8F shows an alternative die face plate 860 which has a double concentric row of small orifices 824 formed in a fashion similar to the die face plate 822 shown in FIG. 8D.
  • the die face plate 860 of FIG. 8F is also formed of hardened steel and may be substituted into the structure shown in FIGS. 8 and 8A.
  • the blade holder 844 has elongated spokes 862 that each carry two blades 864. The two blades on each spoke 862 register with the double row of small orifices 824 so that they cut ail of the strands being emitted from the die 812 when the die face plate 860 is utilized.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 42 to make volumetric shapes. Preferably spherical beads are made.
  • polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 42 to make the polysilocarb proppants taught and disclosed in US Patent Publication No. 2014/0326453.
  • the polysilocarb precursors of Examples 1 to 38 are used in the equipment of Example 42 to make one or more of the following volumetric shaped preforms: spheres, pellets, rings, lenses, ribbons, disks, panels, cones, frustoconical shapes, squares, rectangles, trusses, angles, channels, hollow sealed chambers, hollow spheres, blocks, sheets, coatings, balls, squares, prolate spheroids, ellipsoids, spheroids, eggs, cones, multifaceted structures, films, skins, particulates, beams, rods, angles, columns, fibers, staple fibers, tubes, cups, pipes, and polyhedrons (e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism).
  • volumetric shaped preforms spheres, pellets, rings, lenses, ribbons, disks, panels, cones, frustocon
  • FIG. 1 The embodiment of FIG. 1 is used to make the polysilocarb proppants taught and disclosed in US Patent Publication No. 2014/0326453, the entire disclosure of which is incorporated herein by reference.
  • FIG. 1 The embodiment of FIG. 1 is used to make make one or more of the following volumetric shaped polysilocarb preforms: spheres, pellets, rings, lenses, disks, panels, cones, frustoconical shapes, squares, ribbons, rectangles, trusses, angles, channels, hollow sealed chambers, hollow spheres, blocks, sheets, coatings, balls, squares, prolate spheroids, ellipsoids, spheroids, eggs, cones, multifaceted structures, films, skins, particulates, beams, rods, angles, columns, fibers, staple fibers, tubes, cups, pipes, and polyhedrons (e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism).
  • volumetric shaped polysilocarb preforms spheres, pellets, rings, lenses, disks, panels, cones, frustoconical
  • FIG. 4 The embodiment of FIG. 4 is used to make one or more of the following volumetric shaped polysilocarb preforms: fibers, tubes, ribbons, sheets, films, skins, beams, rods, columns, staple fibers, cups, pipes, and elongate polyhedrons (e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism).
  • polyhedrons e.g., octahedron, dodecahedron, icosidodecahedron, rhombic triacontahedron, and prism.
  • polymer derived ceramic precursor formulations can generally be made by three types of processes, although other processes, and variations and combinations of these processes may be utilized. These processes generally involve combining precursors to form a precursor formulation.
  • One type of process generally involves the mixing together of precursor materials in preferably a solvent free process with essentially no chemical reactions taking place, e.g., "the mixing process.”
  • the other type of process generally involves chemical reactions, e.g., "the reaction type process,” to form specific, e.g., custom, precursor formulations, which could be monomers, dimers, trimers and polymers.
  • a third type of process has a chemical reaction of two or more components in a solvent free environment, e.g., "the reaction blending type process.”
  • the reaction blending type process essentially all, and preferably all, of the chemical reactions take place during subsequent processing, such as during curing, pyrolysis and both.
  • reaction type process reaction blending type process
  • mixing type process mixing type process
  • reaction process can be used to create a precursor material that is then used in the mixing process with another precursor material.
  • a formulation from the mixing type process may be used as a precursor, or component in the reaction type process, or the reaction blending type process.
  • a formulation from the reaction type process may be used in the mixing type process and the reaction blending process.
  • a formulation from the reaction blending type process may be used in the mixing type process and the reaction type process.
  • the precursors may be made by way of an alkoxylation type process, e.g., an ethoxylation process.
  • chlorosilanes are reacted with ethanol in the presences of a catalysis, e.g., HCI, to provide the precursor materials, which materials may further be reacted to provide longer chain precursors.
  • a catalysis e.g., HCI
  • Other alcohols e.g., methanol may also be used.
  • SiCI 4 , SiCI 3 H, SiCI 2 (CH 3 )2, SiCI 2 (CH 3 )H, Si(CH 3 )3CI, Si(CH 3 )CIH are reacted with ethanol CH 3 CH 2 OH to form precursors.
  • phenols may be the source of the phenoxy group, which is substituted for a hydride group that has been placed on the silicon.
  • One, two or more step reactions may need to take place.
  • Precursor materials may also be obtained by way of an acetylene reaction route.
  • acetylene reaction route there are several known paths for adding acetylene to Si-H.
  • tetramethylcyclotetrasiloxane can be reacted with acetylene in the presence of a catalyst to produce tetramethyltetravinylcyclotetrasiloxane.
  • This product can then be ring opened and polymerized in order to form linear vinyl, methylsiloxanes.
  • typical vinyl silanes can be produced by reacting methyl, dichlorosilane (obtained from the direct process or Rochow process) with acetylene.
  • the vinyl monomers can then be purified (because there may be some scrambling) to form vinyl, methyl, dichlorosilane. Then the vinyl monomer can be polymerized via hydrolysis to form many cyclic, and linear siloxanes, having various chain lengths, including for example various cyclotetrasiloxanes (e.g., D 4 ') and various cyclopentasiloxanes (e.g., D 5 ').
  • various cyclotetrasiloxanes e.g., D 4 '
  • various cyclopentasiloxanes e.g., D 5 '.
  • Precursor materials may be methyl hydrogen, and substituted and modified methyl hydrogens, siloxane backbone additives, reactive monomers, reaction products of a siloxane backbone additive with a silane modifier or an organic modifier, and other similar types of materials, such as silane based materials, silazane based materials, carbosilane based materials, phenol/formaldehyde based materials, and combinations and variations of these.
  • the precursors are preferably liquids at room temperature, although they may be solids that are melted, or that are soluble in one of the other precursors.
  • the precursors are mixed together in a vessel, preferably at room temperature.
  • little, and more preferably no solvents e.g., water, organic solvents, polar solvents, non-polar solvents, hexane, THF, toluene, are added to this mixture of precursor materials.
  • each precursor material is miscible with the others, e.g., they can be mixed at any relative amounts, or in any proportions, and will not separate or precipitate.
  • the "precursor mixture” or "polysilocarb precursor formulation” is compete (noting that if only a single precursor is used the material would simply be a "polysilocarb precursor” or a “polysilocarb precursor formulation” or a “formulation”).
  • fillers and reinforcers may be added to the formulation.
  • essentially no, and more preferably no chemical reactions, e.g., crosslinking or polymerization takes place within the formulation, when the formulation is mixed, or when the formulation is being held in a vessel, on a prepreg, or over a time period, prior to being cured.
  • the precursors can be mixed under numerous types of atmospheres and conditions, e.g., air, inert, N 2 , Argon, flowing gas, static gas, reduced pressure, elevated pressure, ambient pressure, and combinations and variations of these.
  • atmospheres and conditions e.g., air, inert, N 2 , Argon, flowing gas, static gas, reduced pressure, elevated pressure, ambient pressure, and combinations and variations of these.
  • inhibitors such as cyclohexane, 1 -Ethynyl-1 -cyclohexanol (which may be obtained from ALDRICH), Octamethylcyclotetrasiloxane, and
  • tetramethyltetravinylcyclotetrasiloxane may be added to the polysilocarb precursor formulation, e.g., an inhibited polysilocarb precursor formulation. It should be noted that tetramethyltetravinylcyclotetrasiloxane may act as both a reactant and a reaction retardant (e.g., an inhibitor), depending upon the amount present and temperature, e.g., at room temperature it is a retardant and at elevated temperatures it is a reactant.
  • a reaction retardant e.g., an inhibitor
  • polysilocarb precursor formulation e.g., a filled polysilocarb precursor formulation
  • fillers such as SiC powder, carbon black, sand, polymer derived ceramic particles, pigments, particles, nano-tubes, whiskers, or other materials, discussed in this specification or otherwise known to the arts.
  • a formulation with both inhibitors and fillers would be considered an inhibited, filled polysilocarb precursor formulation.
  • a catalyst or initiator may be used, and can be added at the time of, prior to, shortly before, or at an earlier time before the precursor formulation is formed or made into a structure, prior to curing.
  • the catalysis assists in, advances, and promotes the curing of the precursor formulation to form a preform.
  • the catalyst can be any platinum (Pt) based catalyst, which can, for example, be diluted to a ranges of: about 0.01 parts per million (ppm) Pt to about 250 ppm Pt, about 0.03 ppm Pt, about 0.1 ppm Pt, about 0.2 ppm Pt, about 0.5 ppm Pt, about 0.02 to 0.5 ppm Pt, about 1 ppm to 200 ppm Pt and preferably, for some applications and embodiments, about 5 ppm to 50 ppm Pt.
  • the catalyst can be a peroxide based catalyst with, for example, a 10 hour half life above 90 C at a
  • catalysts can be any organometallic catalyst capable of reacting with Si-H bonds, Si-OH bonds, or unsaturated carbon bonds, these catalysts may include: dibutyltin dilaurate, zinc octoate, peroxides, organometallic compounds of for example titanium, zirconium, rhodium, iridium, palladium, cobalt or nickel. Catalysts may also be any other rhodium, rhenium, iridium, palladium, nickel, and ruthenium type or based catalysts. Combinations and variations of these and other catalysts may be used.
  • Catalysts may be obtained from ARKEMA under the trade name LUPEROX, e.g., LUPEROX 231 ; and from Johnson Matthey under the trade names: Karstedt's catalyst, Ashby's catalyst, Speier's catalyst.
  • custom and specific combinations of these and other catalysts may be used, such that they are matched to specific formulations, and in this way selectively and specifically catalyze the reaction of specific constituents.
  • the use of these types of matched catalyst-formulations systems may be used to provide predetermined product features, such as for example, pore structures, porosity, densities, density profiles, high purity, ultra high purity, and other morphologies or features of cured structures and ceramics.
  • predetermined product features such as for example, pore structures, porosity, densities, density profiles, high purity, ultra high purity, and other morphologies or features of cured structures and ceramics.
  • Chemical reactions e.g., polymerizations, reductions, condensations, substitutions, take place or are utilized in the making of a starting material or precursor.
  • a polysilocarb precursor formulation by the mixing type process, preferably no and essentially no, chemical reactions and molecular rearrangements take place.
  • These embodiments of the present mixing type process which avoid the need to, and do not, utilize a polymerization or other reaction during the making of a precursor formulation, provides significant advantages over prior methods of making polymer derived ceramics.
  • polymerization, crosslinking or other chemical reactions take place primarily, preferably essentially, and more preferably solely during the curing process.
  • the precursor may be a siloxane backbone additive, such as, methyl hydrogen (MH), which formula is shown below.
  • MH methyl hydrogen
  • the MH may have a molecular weight ("mw” which can be measured as weight averaged molecular weight in amu or as g/mol) from about 400 mw to about 10,000 mw, from about 600 mw to about 3,000 mw, and may have a viscosity preferably from about 20 cps to about 60 cps.
  • the percentage of methylsiloxane units "X" may be from 1 % to 100%.
  • the percentage of the dimethylsiloxane units ⁇ " may be from 0% to 99%.
  • This precursor may be used to provide the backbone of the cross-linked structures, as well as, other features and characteristics to the cured preform and ceramic material. This precursor may also, among other things, be modified by reacting with unsaturated carbon compounds to produce new, or additional, precursors.
  • methyl hydrogen fluid (MHF) has minimal amounts of ⁇ ", and more preferably ⁇ " is for all practical purposes zero.
  • the precursor may be a siloxane backbone additive, such as vinyl substituted polydimethyl siloxane, which formula is shown below.
  • This precursor may have a molecular weight (mw) from about 400 mw to about 10,000 mw, and may have a viscosity preferably from about 50 cps to about 2,000 cps.
  • the percentage of methylvinylsiloxane units "X" may be from 1 % to 100%.
  • the percentage of the dimethylsiloxane units ⁇ " may be from 0% to 99%.
  • X is about 100%.
  • This precursor may be used to decrease cross-link density and improve toughness, as well as, other features and characteristics to the cured preform and ceramic material.
  • the precursor may be a siloxane backbone additive, such as vinyl substituted and vinyl terminated polydimethyl siloxane, which formula is shown below.
  • This precursor may have a molecular weight (mw) from about 500 mw to about 15,000 mw, and may preferably have a molecular weight from about 500 mw to 1 ,000 mw, and may have a viscosity preferably from about 10 cps to about 200 cps.
  • the percentage of methylvinylsiloxane units "X" may be from 1 % to 100%.
  • the percentage of the dimethylsiloxane units ⁇ " may be from 0% to 99%.
  • This precursor may be used to provide branching and decrease the cure temperature, as well as, other features and characteristics to the cured preform and ceramic material.
  • the precursor may be a siloxane backbone additive, such as one or more of the following: vinyl substituted and hydrogen terminated polydimethyl siloxane; allyl terminated polydimethyl siloxane; vinyl terminated polydimethyl siloxane; silanol (hydroxy) terminated polydimethyl siloxane; silanol (hydroxy) terminated vinyl substituted dimethyl siloxane; hydrogen (hydride) terminated polydimethyl siloxane; di- phenyl terminated siloxane; mono-phenyl terminated siloxane; diphenyl dimethyl polysiloxane; vinyl terminated diphenyl dimethyl polysiloxane; hydroxy terminated diphenyl dimethyl polysiloxane;
  • a siloxane backbone additive such as one or more of the following: vinyl substituted and hydrogen terminated polydimethyl siloxane; allyl terminated polydimethyl siloxane; vinyl terminated polydimethyl siloxane; silano
  • the precursor batch may also contain non-silicon based cross-linking agents, be the reaction product of a non-silicon based cross linking agent and a siloxane backbone additive, and combinations and variation of these.
  • the non-silicon based cross-linking agents are intended to, and provide, the capability to cross-link during curing.
  • non-silicon based cross-linking agents that can be used include: cyclopentadiene (CP), methylcyclopentadiene (MeCP), dicyclopentadiene
  • DCPD methyldicyclopentadiene
  • MeDCPD methyldicyclopentadiene
  • TCPD tricyclopentadiene
  • piperylene divnylbenzene, isoprene, norbornadiene, vinylnorbornene, propenylnorbornene, isopropenylnorbornene, methylvinylnorbornene, bicyclononadiene,
  • cycloheptadiene 1 ,3-butadiene, cyclooctadiene and isomers thereof.
  • Some organic materials containing oxygen, nitrogen, and sulphur may also function as cross-linking moieties.
  • the precursor may be a reactive monomer. These would include molecules, such as tetramethyltetravinylcyclotetrasiloxane ("TV”), which formula is shown below.
  • TV tetramethyltetravinylcyclotetrasiloxane
  • This precursor may be used to provide a branching agent, a three- dimensional cross-linking agent, as well as, other features and characteristics to the cured preform and ceramic material. (It is also noted that in certain formulations, e.g., above 2%, and certain temperatures, e.g., about from about room temperature to about 60° C, this precursor may act as an inhibitor to cross-linking, e.g., in may inhibit the cross-linking of hydride and vinyl groups.)
  • the precursor may be a reactive monomer, for example, such as trivinyl cyclotetrasiloxane; divinyl cyclotetrasiloxane; trivinyl monohydride
  • the precursor may be a silane modifier, such as vinyl phenyl methyl silane, diphenyl silane, diphenyl methyl silane, and phenyl methyl silane (some of which may be used as an end capper or end termination group).
  • silane modifiers can provide chain extenders and branching agents. They also improve toughness, alter refractive index, and improve high temperature cure stability of the cured material, as well as improving the strength of the cured material, among other things.
  • a precursor, such as diphenyl methyl silane may function as an end capping agent, that may also improve toughness, alter refractive index, and improve high temperature cure stability of the cured material, as well as, improving the strength of the cured material, among other things.
  • the precursor may be a reaction product of a silane modifier with a vinyl terminated siloxane backbone additive.
  • the precursor may be a reaction product of a silane modifier with a hydroxy terminated siloxane backbone additive.
  • the precursor may be a reaction product of a silane modifier with a hydride terminated siloxane backbone additive.
  • the precursor may be a reaction product of a silane modifier with TV.
  • the precursor may be a reaction product of a silane.
  • the precursor may be a reaction product of a silane modifier with a cyclosiloxane, taking into
  • the precursor may be a partially hydrolyzed tetraethyl orthosilicate, such as TES 40 or Silbond 40.
  • the precursor may also be a
  • methyisesquisiioxane such as SR-350 available from General Electric Company, Wilton, Conn.
  • the precursor may also be a phenyl methyl siloxane such as 604 from Wacker Chemie AG.
  • the precursor may also be a methylphenylvinylsiloxane, such as H62 C from Wacker Chemie AG.
  • the precursors may also be selected from the following:
  • a precursor may be a compound of the following general formula.
  • R groups R ⁇ R 2 , R 3 , and R 4 may all be different, or one or more may be the same.
  • R 2 is the same as R 3
  • R 3 is the same as R 4
  • Ri and R 2 are different with R 3 and R 4 being the same, etc.
  • embodiments of formulations for polysilocarb formulations may for example have from about 0% to 50% MH, about 20% to about 99% MH, about 0% to about 30% siloxane backbone additives, about 1 % to about 60% reactive monomers, about 30% to about 100% TV, and, about 0% to about 90% reaction products of a siloxane backbone additives with a silane modifier or an organic modifier reaction products.
  • reaction type process in general, a chemical reaction is used to combine one, two or more precursors, typically in the presence of a solvent, to form a precursor formulation that is essentially made up of a single polymer that can then be, catalyzed, cured and pyrolized.
  • This process provides the ability to build custom precursor formulations that when cured can provide plastics having unique and desirable features such as high temperature, flame resistance and retardation, strength and other features.
  • the cured materials can also be pyrolized to form ceramics having unique features.
  • reaction type process allows for the predetermined balancing of different types of functionality in the end product by selecting functional groups for incorporation into the polymer that makes up the precursor formulation, e.g., phenyls which typically are not used for ceramics but have benefits for providing high
  • a custom polymer for use as a precursor formulation is made by reacting precursors in a condensation reaction to form the polymer precursor formulation. This precursor formulation is then cured into a preform through a hydrolysis reaction. The condensation reaction forms a polymer of the type shown below.
  • Ri and R 2 may be the same or different.
  • the custom precursor polymers can have several different polymeric units, e.g., A-i , A 2 , A n , and may include as many as 10, 20 or more units, or it may contain only a single unit, for example, MHF made by the reaction process may have only a single unit.
  • Embodiments may include precursors, which include among others, a triethoxy methyl silane, a diethoxy methyl phenyl silane, a diethoxy methyl hydride silane, a diethoxy methyl vinyl silane, a dimethyl ethoxy vinyl silane, a diethoxy dimethyl silane.
  • the end units, Si End 1 and Si End 2 can come from the precursors of dimethyl ethoxy vinyl silane, ethoxy dimethyl phenyl silane, and trimethyl ethoxy silane. Additionally, if the polymerization process is properly controlled a hydroxy end cap can be obtained from the precursors used to provide the repeating units of the polymer.
  • the precursors are added to a vessel with ethanol (or other material to absorb heat, e.g., to provide thermal mass), an excess of water, and hydrochloric acid (or other proton source).
  • ethanol or other material to absorb heat, e.g., to provide thermal mass
  • hydrochloric acid or other proton source
  • This mixture is heated until it reaches its activation energy, after which the reaction typically is exothermic.
  • the water reacts with an ethoxy group of the silicon of the precursor monomer, forming a hydroxy (with ethanol as the byproduct). Once formed this hydroxy becomes subject to reaction with an ethoxy group on the silicon of another precursor monomer, resulting in a polymerization reaction.
  • This polymerization reaction is continued until the desired chain length(s) is built.
  • the material Upon completion of the polymerization reaction the material is transferred into a separation apparatus, e.g., a separation funnel, which has an amount of deionized water that, for example, is from about 1 .2x to about 1 .5x the mass of the material.
  • This mixture is vigorously stirred for about less than 1 minute and preferably from about 5 to 30 seconds. Once stirred the material is allowed to settle and separate, which may take from about 1 to 2 hours.
  • the polymer is the higher density material and is removed from the vessel. This removed polymer is then dried by either warming in a shallow tray at 90° C for about two hours; or, preferably, is passed through a wiped film distillation apparatus, to remove any residual water and ethanol.
  • sodium bicarbonate sufficient to buffer the aqueous layer to a pH of about 4 to about 7 is added. It is further understood that other, and commercial, manners of mixing, reacting and separating the polymer from the material may be employed.
  • a catalyst is used in the curing process of the polymer precursor formulations from the reaction type process.
  • the same polymers, as used for curing the precursor formulations from the mixing type process can be used. It is noted that, generally unlike the mixing type formulations, a catalyst is not necessarily required to cure a reaction type polymer. Inhibitors may also be used. However, if a catalyst is not used, reaction time and rates will be slower.
  • the curing and the pyrolysis of the cured material from the reaction process is essentially the same as the curing and pyrolysis of the cured material from the mixing process and the reaction blending process.
  • the reaction type process can be conducted under numerous types of atmospheres and conditions, e.g., air, inert, N 2 , Argon, flowing gas, static gas, reduced pressure, ambient pressure, elevated pressure, and combinations and variations of these.
  • atmospheres and conditions e.g., air, inert, N 2 , Argon, flowing gas, static gas, reduced pressure, ambient pressure, elevated pressure, and combinations and variations of these.
  • reaction blending type process precursor are reacted to from a precursor formulation, in the absence of a solvent.
  • a reaction blending type process has a precursor formulation that is prepared from MHF and Dicyclopentadiene ("DCPD").
  • DCPD Dicyclopentadiene
  • a MHF/DCPD polymer is created and this polymer is used as a precursor formulation.
  • MHF of known molecular weight and hydride equivalent mass
  • PO P01 is a 2% Pt(0) tetravinylcyclotetrasiloxane complex
  • a sealable reaction vessel with a mixer, can be used for the reaction. The reaction is conducted in the sealed vessel, in air; although other types of atmosphere can be utilized.
  • the reaction is conducted at atmospheric pressure, but higher and lower pressures can be utilized.
  • the reaction blending type process can be conducted under numerous types of atmospheres and conditions, e.g., air, inert, N 2 , Argon, flowing gas, static gas, reduced pressure, ambient pressure, elevated pressure, and combinations and variations of these.
  • the temperature of the reaction vessel is controlled to, maintain a predetermined temperature profile over time, and to manage the temperature increase that may be accompanied by an exotherm.
  • the temperature of the reaction vessel is regulated, monitored and controlled throughout the process.
  • the temperature profile can be as follows: let temperature reach about 80° C (may take ⁇ 15-40 min, depending upon the amount of materials present); temperature will then increase and peak at ⁇ 104° C, as soon as temperature begins to drop, the heater set temperature is increased to 100° C and the temperature of the reaction mixture is monitored to ensure the polymer temp stays above 80° C for a minimum total of about 2 hours and a maximum total of about 4 hours. After 2-4 hours above 80° C, the heater is turned off, and the polymer is cooled to ambient. It being understood that in larger and smaller batches, continuous, semi-continuous, and other type processes the temperature and time profile may be different.
  • the precursor formulations from the above types of processes, as well as others, can be cured to form a solid, semi-sold, or plastic like material.
  • the precursor formulations are spread, shaped, or otherwise formed into a preform, which would include any volumetric structure, or shape, including thin and thick films.
  • the polysilocarb precursor formulation may be processed through an initial cure, to provide a partially cured material, which may also be referred to, for example, as a preform, green material, or green cure (not implying anything about the material's color). The green material may then be further cured. Thus, one or more curing steps may be used.
  • the material may be "end cured,” i.e., being cured to that point at which the material has the necessary physical strength and other properties for its intended purpose.
  • the amount of curing may be to a final cure (or "hard cure"), i.e., that point at which all, or essentially all, of the chemical reaction has stopped (as measured, for example, by the absence of reactive groups in the material, or the leveling off of the decrease in reactive groups over time).
  • the material may be cured to varying degrees, depending upon its intended use and purpose. For example, in some situations the end cure and the hard cure may be the same. Curing conditions such as atmosphere and temperature may affect the composition of the cured material.
  • the forming step, the curing steps, and the pyrolysis steps may be conducted in batch processes, serially, continuously, with time delays (e.g., material is stored or held between steps), and combinations and variations of these and other types of processing sequences.
  • the precursors can be partially cured, or the cure process can be initiated and on going, prior to the precursor being formed into a volumetric shape.
  • These steps, and their various combinations may be, and in some embodiments preferably are, conducted under controlled and predetermined conditions (e.g., the material is exposed to a predetermined atmosphere, and temperature profile during the entirely of its processing, e.g., reduced oxygen, temperature of cured preform held at about 140° C prior to pyrolysis).
  • system, equipment, or processing steps, for forming, curing and pyrolizing may be the same equipment, continuous equipment, batch and linked equipment, and combinations and variations of these and other types of industrial processes.
  • a spray drying technique could form cured particles that are feed directly into a fluidized bed reactor for pyrolysis.
  • the polysilocarb precursor formulations can be made into neat, non- reinforced, non-filled, composite, reinforced, and filled structures, intermediates, end products, and combinations and variations of these and other compositional types of materials. Further, these structures, intermediates and end products can be cured (e.g., green cured, end cured, or hard cured), uncured, pyrolized to a ceramic, and combinations and variations of these (e.g., a cured material may be filled with pyrolized material derived from the same polysilocarb as the cured material).
  • the precursor formulations may be used to form a "neat” material, (by “neat” material it is meant that all, and essentially all of the structure is made from the precursor material or unfilled formulation; and thus, there are no fillers or
  • the polysilocarb precursor formulations may be used to coat or impregnate a woven or non-woven fabric, made from for example carbon fiber, glass fibers or fibers made from a polysilocarb precursor formulation (the same or different formulation), to from a prepreg material.
  • Sand, or other small particulate like materials may be coated with a precursor material, and then the precursor material cured to a plastic like coating on the sand, or pyrolized to a ceramic coating on the sand.
  • a polysilocarb bead could be similarly coated, or coated with another type of resin to provide various features to the bead.
  • the reinforcing material may also be made from, or derived from the same material as the formulation that has been formed into a fiber and pyrolized into a ceramic, or it may be made from a different precursor formulation material, which has been formed into a fiber and pyrolized into a ceramic.
  • the polysilocarb precursor formulation may be used to form a filled material.
  • a filled material would be any material having other solid, or semi-solid, materials added to the polysilocarb precursor formulation.
  • the filler material may be selected to provide certain features to the cured product, the ceramic product and both. These features may relate to, or be, for example, aesthetic, tactile, thermal, density, radiation, chemical, cost, magnetic, electric, and combinations and variations of these and other features. These features may be in addition to strength. Thus, the filler material may not affect the strength of the cured or ceramic material, it may add strength, or could even reduce strength in some situations.
  • the filler material could impart color, magnetic capabilities, fire resistances, flame retardance, heat resistance, electrical conductivity, anti-static, optical properties (e.g., reflectivity, refractivity and iridescence), aesthetic properties (such as stone like appearance in building products), chemical resistivity, corrosion resistance, wear resistance, reduced cost, abrasions resistance, thermal insulation, UV stability, UV protective, and other features that may be desirable, necessary, and both, in the end product or material.
  • filler materials could include carbon black, copper lead wires, thermal conductive fillers, electrically conductive fillers, lead, optical fibers, ceramic colorants, pigments, oxides, sand, dyes, powders, ceramic fines, polymer derived ceramic particles, pore-formers, carbosilanes, silanes, silazanes, silicon carbide, carbosilazanes, siloxane, powders, ceramic powders, metals, metal complexes, carbon, tow, fibers, staple fibers, boron containing materials, milled fibers, glass, glass fiber, fiber glass, and nanostructures (including
  • nanostructures of the forgoing to name a few.
  • the polysilocarb formulation and products derived or made from that formulation may have metals and metal complexes. Filled materials would include reinforced materials. In many cases, cured, as well as pyrolized polysilocarb filled materials can be viewed as composite materials. Generally, under this view, the polysilocarb would constitute the bulk or matrix phase, (e.g., a continuous, or
  • the filler would constitute the dispersed (e.g., non- continuous), phase.
  • the filler can be evenly distributed in the precursor formulation, unevenly distributed, distributed over a predetermined and controlled distribution gradient (such as from a predetermined rate of settling), and can have different amounts in different formulations, which can then be formed into a product having a predetermined amounts of filler in predetermined areas (e.g., striated layers having different filler concentration).
  • a material as "filled” or “reinforced” it does not imply that the majority (either by weight, volume, or both) of that material is the polysilcocarb.
  • the ratio (either weight or volume) of polysilocarb to filler material could be from about 0.1 :99.9 to 99.9:0.1 .
  • the polysilocarb precursor formulations may be used to form non- reinforced materials, which are materials that are made of primarily, essentially, and preferably only from the precursor materials; but may also include formulations having fillers or additives that do not impart strength.
  • the curing may be done at standard ambient temperature and pressure ("SATP", 1 atmosphere, 25° C), at temperatures above or below that temperature, at pressures above or below that pressure, and over varying time periods.
  • SATP standard ambient temperature and pressure
  • the curing can be conducted over various heatings, rate of heating, and temperature profiles (e.g., hold times and temperatures, continuous temperature change, cycled temperature change, e.g., heating followed by maintaining, cooling, reheating, etc.).
  • the time for the curing can be from a few seconds (e.g., less than about 1 second, less than 5 seconds), to less than a minute, to minutes, to hours, to days (or potentially longer).
  • the curing may also be conducted in any type of surrounding environment, including for example, gas, liquid, air, water, surfactant containing liquid, inert
  • the furnace, containers, handling equipment, atmosphere, and other components of the curing apparatus and process are clean, essentially free from, and do not contribute any elements or materials, that would be considered impurities or contaminants, to the cured material.
  • the curing environment e.g., the furnace, the atmosphere, the container and combinations and variations of these can have materials that contribute to or effect, for example, the composition, catalysis, stoichiometry, features, performance and combinations and variations of these in the preform, the ceramic and the final applications or products.
  • the curing takes place at temperatures in the range of from about 5°C or more, from about 20°C to about 250°C, from about 20°C to about 150°C, from about 75°C to about 125°C, and from about 80°C to 90°C.
  • temperatures in the range of from about 5°C or more, from about 20°C to about 250°C, from about 20°C to about 150°C, from about 75°C to about 125°C, and from about 80°C to 90°C.
  • rate of temperature change over time e.g., ⁇ degrees/time
  • hold times e.g., hold times, and temperatures
  • the cure conditions may be dependent upon, and in some embodiments can be predetermined, in whole or in part, by the formulation to match, for example the size of the preform, the shape of the preform, or the mold holding the preform to prevent stress cracking, off gassing, or other phenomena associated with the curing process.
  • the curing conditions may be such as to take advantage of, preferably in a controlled manner, what may have previously been perceived as problems associated with the curing process.
  • off gassing may be used to create a foam material having either open or closed structure.
  • curing conditions can be used to create or control the microstructure and the nanostructure of the material.
  • the curing conditions can be used to affect, control or modify the kinetics and thermodynamics of the process, which can affect morphology, performance, features and functions, among other things.
  • a cross linking reaction takes place that provides in some embodiments a cross-linked structure having, among other things, an -Ri-Si-C-C-Si-0-Si-C-C-Si-R2- where Ri and R 2 vary depending upon, and are based upon, the precursors used in the formulation.
  • the cured materials may have a cross-linked structure having 3- coordinated silicon centers to another silicon atom, being separated by fewer than 5 atoms between silicons.
  • some formulations may exhibit an exotherm, i.e., a self heating reaction, that can produce a small amount of heat to assist or drive the curing reaction, or that may produce a large amount of heat that may need to be managed and removed in order to avoid problems, such as stress fractures.
  • a self heating reaction i.e., a self heating reaction
  • During the cure off gassing typically occurs and results in a loss of material, which loss is defined generally by the amount of material remaining, e.g., cure yield.
  • Embodiments of the formulations, cure conditions, and polysilocarb precursor formulations of embodiments of the present inventions can have cure yields of at least about 90%, about 92%, about 100%.
  • the materials may have cure yields above 100%, e.g., about 101 -105%, as a result of oxygen being absorbed from the air.
  • this shrinkage may be, depending upon the formulation, cure conditions, and the nature of the preform shape, and whether the preform is reinforced, filled, neat or unreinforced, from about 20%, less than 20%, less than about 15%, less than about 5%, less than about 1 %, less than about 0.5%, less than about 0.25% and smaller.
  • Curing of the preform may be accomplished by any type of heating apparatus, or mechanisms, techniques, or morphologies that has the requisite level of temperature and environmental control, for example, heated water baths, electric furnaces, microwaves, gas furnaces, furnaces, forced heated air, towers, spray drying, falling film reactors, fluidized bed reactors, lasers, indirect heating elements, direct heating, infrared heating, UV irradiation, RF furnace, in-situ during emulsification via high shear mixing, in-situ during emulsification via ultrasonication.
  • heated water baths for example, heated water baths, electric furnaces, microwaves, gas furnaces, furnaces, forced heated air, towers, spray drying, falling film reactors, fluidized bed reactors, lasers, indirect heating elements, direct heating, infrared heating, UV irradiation, RF furnace, in-situ during emulsification via high shear mixing, in-situ during emulsification via ultrasonication.
  • the cured preforms may be used as a stand alone product, an end product, a final product, or a preliminary product for which later machining or processing may be performed on.
  • the preforms may also be subject to pyrolysis, which converts the preform material into a ceramic.
  • the preform, or cured structure, or cured material In pyrolizing the preform, or cured structure, or cured material, it is heated to about 600° C to about 2,300° C; from about 650° C to about 1 ,200° C, from about 800°C to about 1300°C, from about 900°C to about 1200°C and from about 950°C to 1 150°C. At these temperatures typically all organic structures are either removed or combined with the inorganic constituents to form a ceramic. Typically at temperatures in the about 650° C to 1 ,200° C range the resulting material is an amorphous glassy ceramic.
  • the material When heated above about 1 ,200° C the material typically may from nano crystalline structures, or micro crystalline structures, such as SiC, Si3N 4 , SiCN, ⁇ SiC, and above 1 ,900° C an a SiC structure may form, and at and above 2,200° C a SiC is typically formed.
  • the pyrolized, e.g., ceramic materials can be single crystal, polycrystalline, amorphous, and combinations, variations and subgroups of these and other types of morphologies.
  • the pyrolysis may be conducted under many different heating and environmental conditions, which preferably include thermo control, kinetic control and combinations and variations of these, among other things.
  • the pyrolysis may have various heating ramp rates, heating cycles and environmental conditions.
  • the temperature may be raised, and held a predetermined temperature, to assist with known transitions (e.g., gassing, volatilization, molecular rearrangements, etc.) and then elevated to the next hold temperature corresponding to the next known transition.
  • the pyrolysis may take place in reducing atmospheres, oxidative atmospheres, low O2, gas rich (e.g., within or directly adjacent to a flame), inert, N 2 , Argon, air, reduced pressure, ambient pressure, elevated pressure, flowing gas (e.g., sweep gas, having a flow rate for example of from about from about 15.0 GHSV to about 0.1 GHSV, from about 6.3 GHSV to about 3.1 GHSV, and at about 3.9 GHSV), static gas, and combinations and variations of these.
  • gas rich e.g., within or directly adjacent to a flame
  • inert e.g., N 2 , Argon
  • air reduced pressure
  • ambient pressure e.g., elevated pressure
  • flowing gas e.g., sweep gas, having a flow rate for example of from about from about 15.0 GHSV to about 0.1 GHSV, from about 6.3 GHSV to about 3.1 GHSV, and at about 3.9 GHSV
  • static gas e.g.
  • the pyrolysis is conducted over a time period that preferably results in the complete pyrolysis of the preform.
  • the furnace, containers, handling equipment, and other components of the pyrolysis apparatus are clean, essentially free from, free from and do not contribute any elements or materials, that would be considered impurities or contaminants, to the pyrolized material.
  • a constant flow rate of "sweeping" gas can help purge the furnace during volatile generation.
  • the pyrolysis environment e.g., the furnace, the atmosphere, the container and combinations and variations of these, can have materials that contribute to or effect, for example, the composition, stoichiometry, features, performance and combinations and variations of these in the ceramic and the final applications or products.
  • char yield or pyrolysis yield
  • the formulations and polysilocarb precursor formulations of embodiments of the present formulations can have char yields for SiOC formation of at least about 60%, about 70%, about 80%, and at least about 90%, at least about 91 % and greater. In fact, with air pyrolysis the materials may have char yields well above 91 %, which can approach 100%.
  • formulations high in phenyl content at least about 1 1 %, and preferably at least about 20% by weight phenyls
  • formulations high in allyl content at least about 15% to about 60%
  • embodiments and for some uses generally yields a structure that is not very dense, and for example, may not reached the density required for its intended use.
  • the first pyrolysis may be, and is typically sufficient.
  • a reinfiltration process may be performed on the pyrolized material, to add in additional polysilocarb precursor formulation material, to fill in, or fill, the voids and spaces in the structure. This reinfiltrated material may then be cured and repyrolized.
  • the reinfiltrated materials is cured, but not pyrolized.
  • This process of pyrolization, reinfiltration may be repeated, through one, two, three, and up to 10 or more times to obtain the desired density of the final product.
  • Si-O-C ceramic upon pyrolization, graphenic, graphitic, amorphous carbon structures and combinations and variations of these are present in the Si-O-C ceramic.
  • a distribution of silicon species, consisting of SiOxCy structures, which result in SiO4, SiO3C, SiO2C2, SiOC3, and SiC4 are formed in varying ratios, arising from the precursor choice and their processing history.
  • Carbon is generally bound between neighboring carbons and/or to a Silicon atom. In general, in the ceramic state, carbon is largely not coordinated to an oxygen atom, thus oxygen is largely coordinated to silicon
  • the pyrolysis may be conducted in any heating apparatus that maintains the request temperature and environmental controls.
  • pyrolysis may be done with gas fired furnaces, electric furnaces, direct heating, indirect heating, fluidized beds, kilns, tunnel kilns, box kilns, shuttle kilns, coking type apparatus, lasers, microwaves, induction, radiation, electrical dissipation, and combinations and variations of these and other heating apparatus and systems that can obtain the request temperatures for pyrolysis.
  • Custom and predetermined control of when chemical reactions, arrangements and rearrangements, occur in the various stages of the process from raw material to final end product can provide for reduced costs, increased process control, increased reliability, increased efficiency, enhanced product features, increased purity, and combinations and variation of these and other benefits.
  • the sequencing of when these transformations take place can be based upon the processing or making of precursors, and the processing or making of precursor formulations; and may also be based upon cure and pyrolysis conditions. Further, the custom and predetermined selection of these steps, formulations and conditions, can provide enhanced product and processing features through the various transformations, e.g., chemical reactions; molecular arrangements and rearrangements; and microstructure arrangements and rearrangements.
  • the polymer derived ceramic structures e.g., polysilocarb structures, intermediates and end products, and combinations and variations of these, may be machined, milled, molded, shaped, drilled, etched, or otherwise mechanically processed and shaped.

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Abstract

La présente invention concerne des systèmes de formation mécanique immergés hybrides destinés à fabriquer de petites formes volumétriques de céramiques dérivées de polymère. Les formes volumétriques peuvent être des sphères, des perles et des fibres. Les matériaux en céramique dérivée de polymère sont dérivés de précurseurs contenant du silicium, de l'oxygène et du carbone.
PCT/US2016/042347 2015-07-15 2016-07-14 Appareil de formation, systèmes et procédés de fabrication de structures en céramique dérivée de polymère WO2017011696A1 (fr)

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CN112390955A (zh) * 2019-08-15 2021-02-23 山东理工大学 一种含硅碳树脂微球及其制备方法

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