Abstract: A hermetic glass-to-metal seal between a conductive pin and an outer body, wherein a corrosion-resistant noble metal (e.g., gold) coating is applied to the conductive pin before the hermetic seal is formed. The noble metal-coated conductive pin is located in glass having a softening point less than about 650° C. and disposed in a cavity of the outer body. This is accomplished by inserting the coated conductive pin into a bore in a glass preform, heating the assembly to a temperature in excess of the softening point of the glass but less than about 700° C., and cooling the assembly. The coefficients of thermal expansion of the components of the assembly are preferably selected such that the resulting assembly is a hermetic compression seal.

Abstract: The present invention is directed to a process for fabricating ceramic-metal composites having continuous ceramic and metal phases. The process includes the steps of contacting a porous ceramic matrix material with a molten metal whereby capillary action pulls the metal into the ceramic matrix to substantially fill the void space. The present invention also provides a ceramic-metal composite having continuous metal and ceramic phases.

Abstract: A process for forming a hermetic glass-to-metal seal between a conductive pin and an outer body, wherein a corrosion-resistant noble metal (e.g., gold) coating is applied to the conductive pin before the hermetic seal is formed. The process generally includes providing a noble metal-coated conductive pin, placing glass having a softening point less than about 650.degree. C. into a cavity of the outer body, inserting the coated conductive pin into a bore in the glass preform, heating the assembly to a temperature in excess of the softening point of the glass but less than about 700.degree. C., and cooling the assembly. The coefficients of thermal expansion of the components of the assembly are preferably selected such that the resulting assembly is a hermetic compression seal.

Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal.

Abstract: A process for fabricating ceramic-metal composites having continuous ceramic and metallic phases. The process includes the steps of contacting a porous ceramic matrix material having the general shape of an article of manufacture with molten metal whereby capillary action pulls the metal into the open porosity of the ceramic matrix to substantially fill the open void space. The present invention also provides a ceramic-metal composite having continuous metal and ceramic phases.

Abstract: A method for fabricating ceramic-metal composites having continuous ceramic and metallic phases. In one embodiment, the metal phase includes copper metal. The method can include the steps of contacting a porous ceramic matrix material with molten metal whereby capillary action pulls the metal into the ceramic matrix to substantially fill the open void space. The present invention also provides a ceramic-metal composite having continuous metal and ceramic phases.

Abstract: The present invention relates to electronic components and in particular relates to ceramic-based electronic components wherein a portion of the component comprises a metal-infiltrated ceramic. In a preferred embodiment, the metal-infiltrated ceramic comprises copper metal.

Abstract: The present invention relates to a process for fabricating a hermetic coaxial feedthrough device wherein a pin is substantially centered within the device. The pin can be electrically connected to the outer portion of the device via a bridge wire to form a header that is particularly useful for igniting a gas-generating composition in an air bag device. The invention also provides an eyelet useful in the process and an improved header device having a substantially smooth surface.

Abstract: A method and apparatus for the manufacture of hollow ceramic beams are described using a plurality of substantially parallel spaced mandrels mounted within a flexible mold bag which is filled with ceramic forming powder and compressed within an isostatic press to produce a compressed body of powder. A sliding spacer shoe slides along the mandrels during filling as the powder is vibrated for compaction to maintain the mandrels in a predetermined spaced relationship. The mandrels are removed from the compressed body and it is machined to the proper dimensions before firing in a kiln to sinter the body into a hollow ceramic beam. The ceramic beam includes internal support partitions formed integral with the outer walls of the beam by web portions of the body produced between the mandrels.

Abstract: A porous cordierite ceramic and a process for making the same are provided by the present invention. Preferably, the ceramic material includes at least about 95 percent cordierite in the crystal phase, a porosity of at least about 30 volume percent, a crush load strength of at least about 6 pounds, and a thermal conductivity of less than about 5 watts/meter-.degree.K. The method of producing a porous cordierite ceramic includes (a) combining alumina, clay, talc, a pore-forming material and preferably free silica; (b) adding binder, water and other additives; and (c) shaping the mixture to form a green body. The green body is thereafter fired to form a sintered ceramic body. The porous cordierite is useful in a heat source retainer.