Manufacture and use of engineered carbide and nitride composites

Abstract

Carbides and nitrides are provided containing a controlled amount of pre-determined diluents and methods for their manufacture and use are disclosed. The pre-determined diluents include at least one of the silica, silicon metal, carbon, alumina, boron oxide, alkaline earth oxides such as calcium oxide, magnesium oxide, alkali oxides such as sodium oxide, potassium oxide, iron oxide, titanium oxide, and other components typically present in glass, ceramics, or metals. The carbides and nitrides with pre-determined diluents are formed by optionally pyrolyzing a precursor material to form a carboneous mixture and heat treating the carboneous mixture for a pre-determined time and at an elevated temperature during which carbon and/or nitrogen reacts with silica in the mixture to form carbides and/or nitrides and controlled amounts of pre-determined diluents. The carbides and nitrides disclosed herein may be used as blowing agents in a glass, ceramic, or metal forming processes or for promoting dispersion of the carbides and nitrides throughout a glass, ceramic, or metal composite.

1 - 55 . (canceled) 
   
   
       56 . A composite, comprising:
 silicon carbide making up less than 3 wt. % of the formed composite, and   a diluent that makes up at least about 10% by weight of the silicon carbide composite, and wherein the diluent comprises at least a silica compound and another element at an amount greater than 0.1 wt %.   
   
   
       57 . The composite of  claim 56 , wherein said diluent is selected from the group consisting of silica fume, silica gel, glass sand, a silane and mixtures thereof. 
   
   
       58 . The composite of  claim 56 , wherein said silica compound acts as the diluent. 
   
   
       59 . The composite of  claim 56 , wherein said diluent acts as a flux or binder. 
   
   
       60 . The composite of  claim 56 , wherein said silicon carbide composite is formed from a carbonaceous mixture that has undergone pyrolysis, wherein the carbonaceous mixture includes of the silica compound and at least one carbon containing material. 
   
   
       61 . The composite of  claim 56 , wherein said silica compound is a glass forming material. 
   
   
       62 . The composite of  claim 57 , wherein said diluent comprises between about 20% and 99 wt. % of the composite. 
   
   
       63 . A silicon carbide composite, comprising:
 at least one silicate material; and   at least one carbon bearing material in a mixture forming a carbonaceous mixture,   wherein the carbonaceous mixture includes another element at an amount greater than 0.1 wt %, wherein the mixture is heated to form the silicon carbide composite, wherein heating is in the presence of a diluent, wherein the diluent makes up at least about 10% by weight of the silicon carbide composite, wherein silicon carbide makes up less than 3 wt. % of the formed composite.   
   
   
       64 . The composite of  claim 63 , wherein the diluent is one or more components selected from the group consisting of silica, carbon, alumina, boron oxide, calcium oxide, magnesium oxide, alkali metal oxides, iron oxide, titanium oxide, zirconium oxide, and combinations thereof. 
   
   
       65 . The composite of  claim 63 , further including a binder. 
   
   
       66 . The composite of  claim 65 , wherein the binder is an alkali metal containing binder and comprises greater than about 3 wt. % of the formed composite. 
   
   
       67 . The composite of  claim 65 , wherein the binder is an alkali metal. 
   
   
       68 . The composite of  claim 65 , wherein the binder is selected from one or more of the group consisting of alkali metal silicate, alkali metal borate, alkali metal phosphate, polymer emulsion, polyvinyl alcohol emulsion, cellulose ether, methylcellulose, and sugar. 
   
   
       69 . The composite of  claim 63 , wherein the carbon bearing material is a material selected from the group consisting of carbon black, coke, graphite, a hydrocarbon with straight or branch chain containing up to 1000 carbon atoms, a cyclic or heterocyclic hydrocarbon compound, a carbohydrate, a resin and combinations thereof. 
   
   
       70 . The composite of  claim 69 , wherein the carbohydrate is selected from the group consisting of one or more sugars, starches, corn syrup, fructose, sucrose, natural fibers and combinations thereof. 
   
   
       71 . The composite of  claim 69 , wherein the resin is selected from the group consisting of phenol resin, furan resin, epoxy resin, phenoxy resin, oil, grease, glycerin, glycol, paraffin and combinations thereof. 
   
   
       72 . The composite of  claim 63 , wherein the silicate material is selected from the group consisting of silica fume, silica mineral, ash, diatomaceous earth, silica gel, glass, sand, a silane and combinations thereof. 
   
   
       73 . The composite of  claim 72 , wherein the silane is selected from the group consisting of disilane, chlorosilane, silane tetrachloride, chloroalkylsilane, aminosilane, and derivations and combinations thereof.