Phillips Petroleum Company

George F Schuette

Bruce W Gerhold

Kenneth E Inkrott

Michael C Carter

A ceramic product comprising both carbon and nitrogen and a method for its production are provided. The product is formed in a reactor having a chamber defined therein which is divided into a combustion zone and a reaction zone. A combustible mixture is injected into the combustion zone in a direction generally toward the reaction zone, and is accordingly combusted in the combustion zone to produce hot combustion products. At least one reactant containing carbon, nitrogen and an additional component (i.e. silicon) is injected at the boundary between the zones into the reactor chamber so as to flow with the hot combustion products into the reaction zone and react to form the ceramic product.

Production of silicon product containing both carbon and nitrogen

A method of producing a composite ceramic powder is provided herein. A precursor product powder is first produced in a reactor from at least one carbide-forming reactant by heating the reactant(s) by means of combustion of a fuel, and the precursor product powder as collected from the reactor is heated in a nitrogen-containing atmosphere to produce a final product comprising a carbide compound as well as a nitride compound.

Method for producing a ceramic product

A method and apparatus are provided for producing a product comprising a nitride compound, such as for example silicon nitride. A reactor is provided which has a chamber defined therein which is divided into a combustion zone and a reaction zone. A combustible mixture is injected into the combustion zone and accordingly combusted to form hot combustion products. At least one reactant (i.e. silane) is injected at the boundary between the zones so as to be carried into the reaction zone by the combustion products and react to form raw product comprising the nitride compound. The raw product can be purified by subsequent processing to remove oxygen and convert by-products to the desired nitride compound. The product of the invention has a low level of impurities and is made up of primarily submicron, highly uniform particles. This makes the product particularly useful for fabrication of sintered ceramic parts.

Silicon nitride products and method for their production

A method and apparatus are provided for producing a product comprising a carbide compound, such as for example silicon carbide. A reactor is provided which has a chamber defined therein which is divided into a combustion zone and a reaction zone. A combustible mixture is injected into the combustion zone and accordingly combusted to form hot combustion products. At least one reactant (i.e. silane) is injected at the boundary between the zones so as to be carried into the reaction zone by the combustion products and react to form raw product comprising the carbide compound. The raw product can be purified by subsequent processing to remove oxygen and convert by-products to the desired carbide compound. The product of the invention has a low level of impurities and is made up of submicron, highly uniform particles. This makes the product particularly useful for fabrication of sintered ceramic parts.

Growing community of inventors

Bartlesville, OK, United States of America

George F Schuette