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Composite materials and methods for making the same

United States Patent Application

20020058107
A1
View the Complete Application at the US Patent & Trademark Office
The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the composite body such that any undesirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. The getterer material(s) may form at least one compound which acts as a passivation layer, and/or is able to move by bulk transport (e.g., by viscous flow as a glassy material) to a crack, and sealing the crack, thereby further enhancing the oxidation protection of the composite body. One or more ceramic filler materials which serve as reinforcements may have a plurality of super-imposed coatings thereon, at least one of which coatings may function as or contain an oxidation protection mechanism. Specifically, a coating comprising boron nitride which has been engineered or modified to contain some silicon exhibits improved corrosion resistance, specifically to oxygen and moisture. The coated materials may be useful as reinforcing materials in high performance composites to provide improved mechanical properties such as fracture toughness. The present invention also relates to improved composites which incorporate these materials, and to their methods of manufacture.
Fareed, Ali Syed (Newark, DE), Garnier, John Edward (Newark, DE), Schiroky, Gerhard Hans (Newark, DE), Kennedy, Christopher Robin (Newark, DE), Sonuparlak, Birol (Longmont, CO)
09/ 790,118
February 21, 2001
[0002] This invention was made with Government support under Contract No. DE-FC02-92CE40994 awarded by the Department of Energy. The Government has certain rights to this invention.