US 12,168,632 B2
Aluminum-containing nitride ceramic matrix composite, method of making, and method of use
Mark P. D'Evelyn, Vancouver, WA (US); and David N. Italiano, Washougal, WA (US)
Assigned to SLT Technologies, Inc., Los Angeles, CA (US)
Filed by SLT Technologies, Inc., Los Angeles, CA (US)
Filed on Oct. 11, 2022, as Appl. No. 17/963,910.
Claims priority of provisional application 63/254,937, filed on Oct. 12, 2021.
Prior Publication US 2023/0111390 A1, Apr. 13, 2023
Int. Cl. C04B 35/581 (2006.01); C04B 35/626 (2006.01); C04B 35/645 (2006.01); C04B 35/65 (2006.01); C09K 11/02 (2006.01); C09K 11/77 (2006.01); B28B 1/30 (2006.01); B28B 3/02 (2006.01)
CPC C04B 35/581 (2013.01) [C04B 35/62695 (2013.01); C04B 35/645 (2013.01); C04B 35/65 (2013.01); C09K 11/02 (2013.01); C09K 11/77348 (2021.01); B28B 1/30 (2013.01); B28B 3/02 (2013.01); C04B 2235/3865 (2013.01); C04B 2235/3869 (2013.01); C04B 2235/402 (2013.01); C04B 2235/5427 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/5445 (2013.01); C04B 2235/656 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method for forming an aluminum-containing nitride ceramic matrix composite, comprising:
forming at least one green body comprising a phosphor powder and an aluminum-containing composition, wherein
the at least one green body is characterized by a porosity between about 10% and about 80%, and
the phosphor powder comprises at least one phosphor composition, and phosphor powder particles have a D50 diameter between about 100 nanometers and about 500 micrometers; and
heating a sealable container to a temperature between about 400 degrees Celsius and about 800 degrees Celsius and a pressure between about 10 MPa and about 1000 MPa,
wherein
the at least one green body, ammonia, and a mineralizer composition are disposed within the sealable container before heating and pressurizing the sealable container,
the aluminum-containing composition has a purity, on a metals basis, between about 90% and about 99.9999%,
the fraction of free volume within the sealable container that is filled with liquid ammonia is between about 10% and about 95% before heating and pressurizing the sealable container, and
the heating the sealable container comprises heating the sealable container for a first period of time to form the aluminum-containing nitride ceramic matrix composite characterized by a phosphor-to-aluminum nitride (AlN) ratio, by volume, between about 1% and about 99%, by a porosity between about 1% and about 50%, and by a thermal conductivity between about 1 watt per meter-Kelvin and about 320 watts per meter-Kelvin.