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1
CERAMIC FIBERS AND COMPOSITES
COMPRISING SAME
This application is a continuation of U.S. Ser. No. 10/211, 684, filed Aug. 2, 2002, the disclosure of which is incorporated by reference in its entirety herein.
The Government has rights in this invention pursuant to AL-WFO-2002-01.
FIELD OF THE INVENTION
The present invention relates methods of melt spinning to make amorphous and ceramic materials.
DESCRIPTION OF RELATED ART
The use of melt spinning to make amorphous and ceramic materials is known in the art. In general, melt-spinning involves forcing a melt through an orifice (e.g., by the application of gas or mechanical pressure) and then contacting the melt with a moving substrate (e.g., a rotating wheel, commonly a chilled wheel) such that the melt rapidly cools to provide a solid elongated shape (e.g., ribbon or fiber). The shape of the solid elongated shape may depend, for example, on factors such as the viscosity of the melt, surface tension, wetting characteristics, heat transfer rate between the melt and the substrate, capillary and mechanical forces. Furthermore, the shape of the (cooling) substrate at the contact point tends to play a role in determining the shape and the thickness of the solidified material. Forms of solidified materials that have been made include wires, filaments, thin, thick, wide, multi-layered films and sheets.
Although a large number of metal oxides have been obtained in an amorphous (including glass) state by melting and rapidly quenching, most, because of the need for very high quench rates to provide amorphous material, rather than crystalline material, can not be formed into bulk or complex shapes. Generally, such systems are very unstable against crystallization during subsequent reheating and therefore tend not to exhibit properties such as viscous flow. On the other hand, glasses based on the known network forming oxides (e.g., silica and boria) are generally relatively stable against crystallization during reheating and, hence tend to have a "working" range where viscous flow occurs
Formation of large articles made of known glass (e.g., silica and boria) via viscous sintering at temperatures above glass transition temperature is well known. For example, in the abrasive industry, grinding wheels are made using vitrified bond to secure abrasive grains together.
Although there are a number of compositions known to be useful for making amorphous materials, there is a continuing desire for new materials made by melt spinning.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a method for making ceramic comprising glass, the method comprising
contacting a melt with a surface of a rotating substrate such that the melt cools to provide a ceramic comprising glass, the melt comprising at least 35 (in some embodiments, preferably at least 40, 45, 50, 55, 60, 65, or even at least 70) percent by weight A1203, based on the total weight of the melt, a first metal oxide other than A1203, and a second, different metal oxide other than A1203 (e.g., Y203, REO, MgO, Ti02, Cr203, CuO, NiO, Fe203, and complex metal oxides thereof), wherein the melt contains not more than 10 (in some embodiments, preferably not more than 5, 4, 3,2, 1, or zero) percent
2
by weight collectively As203, B203, Ge02, P2Os, Si02, Te02, andV2Os,based on the total weight of the melt; and the ceramic comprising glass, the glass comprising at least 35 (in some embodiments, preferably at least 40, 45, 50, 55, 60, 65,
5 or even at least 70) percent by weight A1203, based on the total weight of the glass, the first metal oxide other than A1203, and the second, different metal oxide other than A1203, wherein the glass contains not more than 10 (in some embodiments, preferably not more than 5, 4, 3, 2, 1, or zero) percent by
10 weight collectively As203, B203, Ge02, P2Os, Si02, Te02, and V2Os, based on the total weight of the glass. In some embodiments, the ceramic comprising glass is a fiber. In some embodiments, the fibers are substantially continuous (i.e., have a length to diameter of at least 1000:1). In some embodi
15 ments, a plurality the shapes (including particles, whiskers, discontinuous fibers, and ribbons (i.e., a planar, elongated shape)) is provided.
For example, in some embodiments, this method comprises contacting a melt with a surface of a rotating substrate
20 such that the melt cools to provide a plurality of fibers comprising glass, the melt comprising at least 35 (in some embodiments, preferably at least 40, 45, 50, 55, 60, 65, or even at least 70) percent by weight A1203, based on the total weight of the melt, and a first metal oxide other than A1203
25 and a second, different metal oxide other than A1203 (e.g., Y203, REO, MgO, Ti02, Cr203, CuO, NiO, Fe203, a complex metal oxides thereof), wherein the melt contains not more than 10 (in some embodiments, preferably not more than 5, 4, 3, 2, 1, or zero) percent by weight collectively
30 As203, B203, Ge02, P2Os, Si02, Te02, and V2Os, based on the total weight of the melt; and the glass comprising at least 35 (in some embodiments, preferably at least 40, 45, 50, 55, 60, 65, or even at least 70) percent by weight A1203, based on the total weight of the glass, the first metal oxide other than
35 A1203, and the second, different metal oxide other than A1203, wherein the glass contains not more than 10 (in some embodiments, preferably not more than 5, 4, 3,2, 1, or zero) percent by weight collectively As203, B203, Ge02, P2Os, Si02, Te02, and V2Os, based on the total weight of the glass.
40 In some embodiments, the fibers are glass fibers. In some embodiments, the fibers are substantially continuous (i.e., have a length to diameter of at least 1000:1).
In another aspect, the present invention provides a method for making ceramic comprising glass, the method comprising
45 contacting a melt with a surface of a rotating substrate such that the melt cools to provide a ceramic comprising glass, the melt comprising at least 35 (in some embodiments, preferably at least 40, 45, 50, 55, 60, 65, or even at least 70) percent by weight A1203, based on the total weight of the melt, a first
50 metal oxide other than A1203, and a second, different metal oxide other than A1203 (e.g., Y203, REO, MgO, Ti02, Cr203, CuO, NiO, Fe203, and complex metal oxides thereof), wherein the A1203, first metal oxide, and second metal oxide collectively comprise at least 70 (in some embodiments, pref
55 erably at least 75, 80, 85, 90, 95, or 100) percent by weight of the melt, and wherein the melt contains not more than 30 (in some embodiments, preferably not more than 25, 20, 15, 10, 5, 4, 3, 2, 1, or zero) percent by weight collectively As203, B203, Ge02, P2Os, Si02, Te02, and V2Os, based on the total
60 weight of the melt; and the glass comprising at least 35 (in some embodiments, preferably at least 40, 45, 50, 55, 60, 65, or even at least 70) percent by weight A1203, based on the total weight of the glass, the first metal oxide other than A1203, and the second, different metal oxide other than A1203, wherein
65 the A1203, first metal oxide, and second metal oxide collectively comprise at least 70 (in some embodiments, preferably at least 75, 80, 85, 90, 95, or 100) percent by weight of the
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