General Atomics has patented a method for producing silicon carbide ceramic matrix composites from hydrocarbons. The process involves preforming silicon carbide fibers, introducing a silicon and polymer slurry, and utilizing pyrolysis to create a carbon coating, ultimately leading to the formation of silicon carbide through controlled heating and reactions. GlobalData’s report on General Atomics gives a 360-degree view of the company including its patenting strategy. Buy the report here.
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According to GlobalData’s company profile on General Atomics, Welding robots was a key innovation area identified from patents. General Atomics's grant share as of July 2024 was 60%. Grant share is based on the ratio of number of grants to total number of patents.
Method for producing silicon carbide ceramic matrix composites
The patent US12054433B2 outlines a method for producing a silicon carbide (SiC) ceramic matrix composite. The process begins with placing a silicon carbide preform in a vacuum chamber, where a slurry mix of silicon particles and a polymer is introduced. The chamber is then pressurized to allow the slurry to permeate the silicon carbide fibers. Heating the chamber to a first temperature, approximately 1000°C, facilitates the pyrolysis of the polymer, converting it into carbon and hydrogen gas, which densifies the silicon particles. Following this, a hydrocarbon is introduced, which also undergoes pyrolysis, resulting in additional carbon coating on the silicon particles. The hydrocarbon flow is stopped when the molar ratio of silicon to carbon reaches about 1. The chamber is then heated to a second temperature, around 1414°C, where the silicon melts and reacts with the carbon to form the SiC composite.
The method includes several specific parameters, such as maintaining the first temperature for about one hour to ensure proper pyrolysis and densification, and the second temperature for approximately three hours to allow for the complete formation of the SiC ceramic matrix composite. The patent also specifies that the resulting composite should have a high, uniform density of at least 90% and may contain trace quantities of silicon and carbon. Various hydrocarbons, including methane and other common fuels, can be used in the process. Additionally, the method allows for the introduction of inert gases during the heating stages to further optimize the production of the SiC ceramic matrix composite.
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GlobalData Patent Analytics tracks bibliographic data, legal events data, point in time patent ownerships, and backward and forward citations from global patenting offices. Textual analysis and official patent classifications are used to group patents into key thematic areas and link them to specific companies across the world’s largest industries.
