Strategic Technologies
Silicon Nitride Ceramics
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Reference Number: T 04-12
Inventor (s) Edler, James et al. on behalf of Eaton Corporation Incorporated.
Background EATON began research in the late 1980s to develop low cost silicon nitride material. At the time of development, the raw materials and manufacturing process required to make silicon nitride ceramics were inherently expensive, leading to high costs for the manufacturer and a high cost end product. Thus, silicon nitride ceramics have been used in applications for which the users are willing and able to pay high prices for the benefits of ceramics. However, with the introduction of the EATON technology, the cost of producing silicon nitride ceramic material has been greatly reduced, thus allowing for a broader potential market as well as enabling its use in wider applications. EATON has assigned all patent rights to NISTAC, a not-for-profit company affiliated with Kansas State University and the State of Kansas.
Description The EATON technology differs from previous silicon nitride manufacturing processes in the raw materials used and the process used that allows for less time required to produce a material with the same properties. The EATON process uses low-cost silicon powder as its base material, rather than the conventional silicon nitride or aluminum oxide powders. The cost savings from the raw material alone is significant for current manufacturers of silicon nitride. The technology provides for an improved reaction-bonding process that substantially reduces process time and makes the reaction bonding process more economically favorable.
The technology is based on water processing and the use of a low-cost cerium oxide additive. The process was designed to be similar to aluminum oxide processing, as any company making aluminum oxide already has most of the technology needed to manufacture silicon nitride ceramics. The only additional piece of equipment required would be the furnace to handle the nitridation or sintering operations, which is dependent on the required strength of the final product.
Application
Ceramic Insulator
Automotive Ceramics
Ceramic Cutting Tools
Ceramic Hybrid Bearings
Medical Ceramics
Ceramic Body/Vehicle Armor
Wear Parts
Electrical Insulating Applications
Aerospace and Space Applications
Abrasion Resistance Components
Textile Applications
Computer Applications
Advantages
Greatly reduces the cost of producing silicon nitride ceramic material.
Greatly reduces the time required to produce silicon nitride, while producing material which has substantially the same properties.
Silicon nitride ceramic has better high temperature capabilities than most metals.
Combines retention of high strength and creep resistance with oxidation and corrosion resistance.
Low thermal expansion coefficient gives good thermal shock resistance compared with most ceramic materials.
US Patents 12 issued patents
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