Hrl Laboratories, LLC

The Boeing Company

Other

Phuong Bui

Tobias A Schaedler

Zak C Eckel

Ashley M Dustin

Andrew Paul Nowak

April Rose Rodriguez

Kayleigh A Porter

Mark O'Masta

Jacob Michael Hundley

Carissa Ann Pajel

Melinda Dae Miller

Stella Fors

Nhan Xuan Bui

John Hunter Martin

Raviv Perahia

Logan D Sorenson

Shanying Cui

Matthew J Pelliccione

Kevin J Drummey

Tony Koung

Gregory Phillip Nowak

Sean M Meenehan

My Bui

Some variations provide a pre-ceramic matrix composite comprising: a precursor pre-ceramic matrix; reinforcing elements disposed within the precursor pre-ceramic matrix; and a compressible material disposed on the surface of the reinforcing elements and interposed between the reinforcing elements and the precursor pre-ceramic matrix. Other variations provide a ceramic matrix composite comprising: a ceramic matrix; reinforcing elements disposed within the ceramic matrix; and a compressed material disposed on the surface of the reinforcing elements and interposed between the reinforcing elements and the matrix. The coating of compressible material prevents cracking during processing because the coating absorbs stresses associated with volumetric shrinkage of the ceramic matrix during densification, thereby reducing the stresses at the interface between the reinforcing elements and the ceramic matrix. Methods of fabricating ceramic matrix composites using the principles of the invention are disclosed. Methods include pyrolysis of pre-ceramic polymers, sintering of pre-ceramic materials, and sol-gel processing.

Compressible coating reinforcements for ceramic matrix composites, and methods of making the same

An adhesion promoter composition is disclosed. The adhesion promoter composition also includes one or more reactive silanes which includes a mercaptopropyltrimethoxysilane, a glycidoxypropyltrimethoxysilane, or combinations thereof. The adhesion promoter composition also includes one or more reactive organometallics. The composition may include one or more organic solvents, an optional one or more gelling agents, and an optional one or more functional additives. A method for applying the adhesion promoter composition is disclosed, including contacting the one or more organic solvents, the one or more reactive silanes, the one or more reactive organometallics, the optional one or more gelling agents, and the one or more functional additives with one another to prepare the adhesion promoter composition, homogenizing the adhesion promoter composition, applying the adhesion promoter composition to a substrate, evaporating the organic solvents from the adhesion promoter composition, and applying a resin or paint layer over the adhesion promoter composition.

Adhesion promoter compositions to eliminate substrate preparation and methods for the same

A ceramic article. In some embodiments, the ceramic article includes a ceramic body composed of a ceramic material; and a first conductive trace, the first conductive trace having a first portion entirely within the ceramic material, the first portion having a length of 0.5 mm and transverse dimensions less than 500 microns, the ceramic material including a plurality of ceramic particles in a ceramic matrix.

Method of manufacturing a ceramic structure with metal traces

Adhesive formulations for forming a fluorinated poly(imide-phthalonitrile) thermoset polymer are provided. Such an adhesive formulation may comprise a fluorinated imide-phthalonitrile oligomer having Formula IV wherein Ris an unsubstituted or substituted aryl group and does not comprise an ether group; Ris an unsubstituted or substituted aryl group and does not comprise an ether group; at least one of Rand Rcomprises a fluorine substituent; and n has a value of from 1 to 30.

Fluorinated poly(imide-phthalonitrile) adhesive formulations and related methods

This disclosure provides resin formulations which may be used for 3D printing and thermally treating to produce a ceramic material. The disclosure provides direct, free-form 3D printing of a preceramic polymer, followed by converting the preceramic polymer to a 3D-printed ceramic composite with potentially complex 3D shapes. A wide variety of chemical compositions is disclosed, and several experimental examples are included to demonstrate reduction to practice. For example, preceramic resin formulations may contain a carbosilane in which there is at least one functional group selected from vinyl, allyl, ethynyl, unsubstituted or substituted alkyl, ester group, amine, hydroxyl, vinyl ether, vinyl ester, glycidyl, glycidyl ether, vinyl glycidyl ether, vinyl amide, vinyl triazine, vinyl isocyanurate, acrylate, methacrylate, alkacrylate, alkyl alkacrylate, phenyl, halide, thiol, cyano, cyanate, or thiocyanate. The resin formulations may contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material.

Preceramic 3D-printing monomer and polymer formulations

A cure promoter composition is disclosed, including an accelerator which may include a thiocarbamate, a hydrated thiocarbamate, a dithiocarbamate, a thiazole, a mercaptothiazole, a sulfenamide, a thiazolesulfenamide, a metal salt of thiocarbamate, sulfur chloride, or combinations thereof. The cure promoter composition also includes a compatibilizing carrier, one or more organic solvents, a catalyst, an optional reducing agent, an optional reactive silane, an optional reactive organometallic, an optional gelling agent, and an optional aqueous component. A method for applying the cure promoter composition is disclosed, including contacting the organic solvents, the accelerator, the carrier, the reactive silanes, the reactive organometallics, the reducing agents, and the catalyst with one another to prepare the cure promoter composition, homogenizing the cure promoter composition, pausing after homogenizing to allow the cure promoter time to react, applying a sealant onto a substrate, and applying the cure promoter composition to a surface of the sealant.

Cure promoter compositions and methods for the same

3D printed ceramic structure with metal traces

The disclosed structure is configured such that it does not support electromagnetic waves having frequencies within a selected band gap; those electromagnetic waves are thus reflected. Some variations provide an omnidirectional infrared reflector comprising a three-dimensional photonic crystal containing: rods of a first material that has a first refractive index, wherein the rods are arranged to form a plurality of lattice periods in three dimensions, and wherein the rods are connected at a plurality of nodes; and a second material that has a refractive index that is lower than the first refractive index, wherein the rods are embedded in the second material. The lattice spacing and the rod radius or width are selected to produce a photonic band gap within a selected band of the infrared spectrum. Methods of making and using the three-dimensional photonic crystal are described. Applications include thermal barrier coatings and blackbody emission signature control.

Omnidirectional and thermally durable infrared reflectors, and methods for making the same

Some variations provide a composition for additive manufacturing (3D printing) of metals, comprising: from 10 vol % to 70 vol % of a photocurable liquid resin; from 10 vol % to 70 vol % of metal or metal alloy particles, optionally configured with a photoreflective surface; and from 0.01 vol % to 10 vol % of a photoinitiator. Other variations provide a composition for additive manufacturing of metals, comprising: from 1 vol % to 70 vol % of a photocurable liquid resin; from 0.1 vol % to 98 vol % of an organometallic compound containing a first metal; from 1 vol % to 70 vol % of metal or metal alloy particles containing a second metal (which may be the same as or different than the first metal); and from 0.01 vol % to 10 vol % of a photoinitiator. Many examples of metals, photocurable resins, organometallic compounds, photoinitiators, and optional additives are disclosed, and methods of making and using the composition are described.

Resin formulations for additive manufacturing of metals, and methods of making and using the same

A stress isolating interposer includes: an outer pad; an inner pad configured to accommodate a positional sensor is mounted; and a stress isolating structure coupling the outer pad and the inner pad to each other. The outer pad, the stress isolating structure, and the inner pad are a monolithic structure.

Stress isolating interposer and sensor package and method of manufacturing the same

A fire retardant (FR) composite composition, including a liquid polymer, wherein the liquid polymer includes a photopolymer including at least two of a first molecule, a second molecule, and a third molecule, a FR thermoset, and a photoinitiator.

FR composite composition for light-based additive manufacturing

Some variations provide a preceramic resin precursor formulation comprising: first molecules comprising at least one Si&#x2014;C bond and/or at least one Si&#x2014;N bond, wherein the first molecules include at least one silyl hydride group (Si&#x2014;H) available for hydrosilylation; and second molecules with at least one unsaturated carbon-carbon bond attached to a UV-active functional group. The first molecules and second molecules may be reacted, via hydrosilylation with a homogeneous or heterogeneous metal-containing catalyst, to produce third molecules comprising a hydrosilylation-modified polysilazane that contains the UV-active functional group. Many possible starting formulations are described, and methods are disclosed for carrying out the chemical reactions to generate the hydrosilylation-modified polysilazanes. The hydrosilylation-modified polysilazanes may then be 3D-printed and thermally treating to fabricate a ceramic material.

Formulations for 3D printing of hydrosilylation-modified polysilazanes

The present invention describes power assisted system (PAS) driving the front wheel of a bicycle, including kits and bicycles containing said PAS.

Power assisted front wheel drive bicycle

Some variations provide a preceramic resin precursor formulation comprising: first molecules comprising at least one Si&#x2014;N bond and/or at least one Si&#x2014;C bond; and second molecules of the formula R&#x2014;N&#x2550;C&#x2550;O or R&#x2014;N&#x2550;C&#x2550;S, wherein Ris a UV-active functional group. In some embodiments, Ris selected from acrylate, methacrylate, vinyl ether, epoxide, oxetane, thiol, or a combination thereof. The first and second molecules are reacted with an isocyanate or isothiocyanate to form third molecules, providing a preceramic radiation-curable resin composition. The resin composition contains at least one Si&#x2014;N bond and/or at least one Si&#x2014;C bond in the main chain of the third molecules. Side chains of the third molecules may be selected from hydrogen, unsubstituted or substituted hydrocarbon groups, halides, esters, amines, hydroxyl, or cyano. The resin composition may be 3D printed and thermally treated to generate a ceramic material.

Growing community of inventors

Thousand Oaks, CA, United States of America

Phuong Bui