US 12,134,582 B2
Methods for producing metal carbide materials
John E. Garnier, Idaho Falls, ID (US); and George W. Griffith, Idaho Falls, ID (US)
Assigned to ADVANCED CERAMIC FIBERS, LLC, Idaho Falls, ID (US)
Filed by Advanced Ceramic Fibers, LLC, Idaho falls, ID (US)
Filed on Feb. 19, 2021, as Appl. No. 17/179,642.
Application 17/179,642 is a division of application No. 16/261,246, filed on Jan. 29, 2019, granted, now 10,954,167.
Application 14/570,927 is a division of application No. 12/901,309, filed on Oct. 8, 2010, granted, now 8,940,391, issued on Jan. 27, 2015.
Application 16/261,246 is a continuation in part of application No. 14/954,518, filed on Nov. 30, 2015, granted, now 10,208,238, issued on Feb. 19, 2019.
Application 14/954,518 is a continuation in part of application No. 14/615,685, filed on Feb. 6, 2015, granted, now 9,803,296, issued on Oct. 31, 2017.
Application 14/954,518 is a continuation in part of application No. 14/570,927, filed on Dec. 15, 2014, granted, now 9,272,913, issued on Mar. 1, 2016.
Application 14/954,518 is a continuation in part of application No. 13/215,967, filed on Aug. 23, 2011, granted, now 9,199,227, issued on Dec. 1, 2015.
Application 14/954,518 is a continuation in part of application No. 12/901,326, filed on Oct. 8, 2010, granted, now 9,275,762, issued on Mar. 1, 2016.
Claims priority of provisional application 61/941,001, filed on Feb. 18, 2014.
Prior Publication US 2021/0269366 A1, Sep. 2, 2021
Int. Cl. C04B 35/622 (2006.01); B82Y 30/00 (2011.01); C01B 32/956 (2017.01); C04B 35/565 (2006.01); C04B 35/571 (2006.01); C04B 35/573 (2006.01)
CPC C04B 35/62281 (2013.01) [B82Y 30/00 (2013.01); C01B 32/956 (2017.08); C04B 35/565 (2013.01); C04B 35/571 (2013.01); C04B 35/573 (2013.01); C04B 2235/428 (2013.01); C04B 2235/46 (2013.01); C04B 2235/48 (2013.01); C04B 2235/5244 (2013.01); C04B 2235/5248 (2013.01); C04B 2235/526 (2013.01); C04B 2235/5264 (2013.01); C04B 2235/5284 (2013.01); C04B 2235/5445 (2013.01); C04B 2235/616 (2013.01); C04B 2235/72 (2013.01); C04B 2235/767 (2013.01); Y10T 428/249924 (2015.04); Y10T 428/249928 (2015.04); Y10T 428/24993 (2015.04); Y10T 428/249974 (2015.04); Y10T 428/2918 (2015.01); Y10T 428/292 (2015.01); Y10T 428/2933 (2015.01); Y10T 428/2958 (2015.01); Y10T 428/2964 (2015.01); Y10T 428/2967 (2015.01); Y10T 428/2975 (2015.01)] 20 Claims
 
1. A method of forming metal carbide material, the method comprising:
reacting a carbon material with at least one of a metal or metal oxide source material in a reaction zone of a continuous throughput tube furnace having one and only one reaction zone, the metal or metal oxide source material being in a form of a gaseous vapor, the metal or metal oxide source material comprising aluminum, beryllium, boron, calcium, cerium, chromium, dysprosium, erbium, europium, gadolinium, hafnium, holmium, iron, lanthanum, lithium, magnesium, manganese, molybdenum, niobium, neodymium, praseodymium, samarium, scandium, silicon, tantalum, terbium, thorium, titanium, tungsten, uranium, vanadium, ytterbium, yttrium, zirconium, aluminum oxide, beryllium oxide, boron oxide, calcium oxide, cerium oxide, chromium oxide, dysprosium oxide, erbium oxide, europium oxide, gadolinium oxide, hafnium oxide, holmium oxide, iron oxide, lanthanum oxide, lithium oxide, magnesium oxide, manganese oxide, molybdenum oxide, niobium oxide, neodymium oxide, praseodymium oxide, samarium oxide, scandium oxide, silicon oxide, tantalum oxide, terbium oxide, thorium oxide, titanium oxide, tungsten oxide, uranium oxide, vanadium oxide, ytterbium oxide, yttriumn oxide, zirconium oxide or a combination thereof, wherein the carbon material is continuously drawn through the continuous tube furnace so that only a portion of the carbon material being reacted is disposed within the reaction zone at any given time and the reaction zone is maintained at a temperature greater than:
the melting temperature of the metal or metal oxide source material; or
the vaporization temperature of the metal or metal oxide source material;
so as to produce a metal carbide material as the carbon material is converted to metal carbide by reaction with the at least one of a metal or metal oxide;
wherein the metal or metal oxide source material is converted to be in the form of a gaseous vapor in the same one and only one reaction zone in which the carbon material is reacted with the at least one of a metal or metal oxide source material.