US 12,133,465 B2
Multilayer functional fiber and method of making
Joseph Pegna, Saratoga Springs, NY (US); Erik G. Vaaler, Redwood City, CA (US); John L. Schneiter, Cohoes, NY (US); and Shay L. Harrison, East Schodack, NY (US)
Assigned to Free Form Fibers, LLC, Saratoga Springs, NY (US)
Filed by FREE FORM FIBERS, LLC, Saratoga Springs, NY (US)
Filed on May 11, 2017, as Appl. No. 15/592,726.
Claims priority of provisional application 62/334,607, filed on May 11, 2016.
Claims priority of provisional application 62/334,622, filed on May 11, 2016.
Prior Publication US 2017/0331022 A1, Nov. 16, 2017
Int. Cl. C23C 16/48 (2006.01); H10N 10/01 (2023.01); H10N 10/81 (2023.01); H10N 30/00 (2023.01); H10N 30/06 (2023.01); H10N 30/87 (2023.01); H10N 10/10 (2023.01)
CPC H10N 10/81 (2023.02) [C23C 16/483 (2013.01); H10N 10/01 (2023.02); H10N 30/06 (2023.02); H10N 30/702 (2024.05); H10N 30/87 (2023.02); H10N 10/10 (2023.02)] 16 Claims
OG exemplary drawing
 
1. A method comprising:
using laser induced chemical vapor deposition and 1½-D printing to fabricate a functional fiber, the using comprising:
growing, using the laser induced chemical vapor deposition, a ceramic scaffold fiber, the ceramic scaffold fiber being a single fiber grown using laser induced chemical vapor deposition to provide structural reinforcement to a ceramic material matrix; and
forming, by 1½-D laser printing, a functional pattern, providing one or more specific functions, on the ceramic scaffold fiber, the forming comprising:
forming multiple building blocks of the functional pattern along the ceramic scaffold fiber, the forming comprising for each building block:
selectively laser-printing an axisymmetric first electrode layer along a respective length section of the ceramic scaffold fiber;
selectively laser-printing an axisymmetric functional layer over the first electrode layer along the length section of the ceramic scaffold fiber by controlling the laser to control heat generated by a focused laser beam to break down precursor gases locally, to locally adjust a functional characteristic of the functional layer within the length section, the functional characteristic varying as a function of longitudinal position along the length section of the ceramic scaffold fiber;
laser-printing an axisymmetric second electrode layer over the functional layer;
laser-printing an axisymmetric cladding layer above the second electrode layer; and
embedding the functional fiber in the ceramic material matrix to form a functional ceramic matrix composite structure.