Abstract: A ceramic pin heating element having exterior heating conductors and integrated electrical connection surfaces, and method for making same. A first body is injection molded from a first injection-moldable ceramic composite compound having a first electrical resistance, and a second body is injection-molded from a second injection-moldable ceramic composite compound having a second electrical resistance about the first body so as to form a compound body. The compound body is then sintered. The resulting ceramic pin heating element is directly formed without additional steps for protecting (insulating) the element so as to prevent the exterior, complementary heating conductors from contacting the housing and/or terminal bolts. The danger of breakage of the pins at the mounting location and/or at the seal seat through variations in the thickness of contact and/or insulation coatings is minimized.

Abstract: A ceramic pin heating element having exterior heating conductors and integrated electrical connection surfaces, and method for making same. A first body is injection molded from a first injection-moldable ceramic composite compound having a first electrical resistance, and a second body is injection-molded from a second injection-moldable ceramic composite compound having a second electrical resistance about the first body so as to form a compound body. The compound body is then sintered. The resulting ceramic pin heating element is directly formed without additional steps for protecting (insulating) the element so as to prevent the exterior, complementary heating conductors from contacting the housing and/or terminal bolts. The danger of breakage of the pins at the mounting location and/or at the seal seat through variations in the thickness of contact and/or insulation coatings is minimized.

Abstract: To provide a steering wheel which is lightweight, and which has adequate strength and shock resistance, a carbon fiber prepreg 13 is wound on a mandrel 11 or a lightweight foam core 40 so as to obtain a preformer 14. By heating this preformer 14 in a mold 18, a steering wheel is obtained wherein the rim is formed from a fiber-reinforced synthetic resin joined to a metal skeleton 23.

Abstract: An improved materials feeder equipment includes highly efficient, durable, and wear and abrasion resistant sliding contact elements. In particular, the equipment has a feeder box and a ware plate arranged for sliding contact, each having high precision tetragonal zirconia polycrystal (TZP) ceramic or, alternatively, zirconia-alumina composite.

Abstract: A process for producing a body having a porous matrix of at least one recrystallized ceramic material, or for producing a similar fiber-reinforced body, includes shaping a raw material batch which contains a raw material powder and then sintering. A raw material powder is used which has grain size distribution of a fine grain fraction of an average grain size of at most approximately 2 &mgr;m and a coarse grain fraction of an average grain size of approximately 1.5 &mgr;m to approximately 30 &mgr;m, and the sintering process is carried out at a temperature of at most approximately 1,800° C. Because of the selected grain sizes and grain size distributions, the sintering process can be carried out at lower temperatures. In particular, reinforcing fibers can be worked in which can withstand higher sintering temperatures. By defining the grain size of the powder, a porosity can also be set which permits a good impregnating with organic and/or inorganic substances.

Abstract: The toner fuser roll of the present invention, which is characterized by good thermal conductivity and resistance to degradation by release agents in addition to excellent wear properties, is capable of producing toner fused images with desirably high gloss. In accordance with the invention, the fuser roll comprises a cylindrical core and a base cushion layer comprising a condensation-cured poly(dimethylsiloxane) elastomer formed on the core. A barrier layer that comprises a cured fluorocarbon polymer and includes a particulate filler overlies the cushion layer. Overlying the barrier layer is a highly smooth outer surface layer comprising an addition-cured poly(dimethylsiloxane) elastomer and having a roughness value, Ra, no greater than about 10 microinches. Further in accordance with the invention is a process for forming the just described toner fuser roll.

Abstract: A cavity plate of an ink jet printer head is adapted to be attached to a piezoelectric element member and has walls prescribing a plurality of ink storing chambers and a plurality of ink discharge holes. A mold for molding the cavity is provided with: a corniform block member including (i) a plurality of corniform convex portions to mold the ink storing chambers, each having an opening portion on a side of an attachment surface of the cavity plate to be attached to the piezoelectric element member, and (ii) a plurality of corniform concave portions to mold partition walls of the cavity plate for partitioning each of the ink storing chambers; and plurality of pin members to mold the ink discharge holes, which are continuous to the ink storing chambers such that the ink discharge holes have straight tubular portions respectively from the ink storing chambers to ink discharge tip portions at an ink discharge surface of the cavity plate on an opposite side of the attachment surface.

Abstract: A method and composition for combining ceramic powder and binder to form green elements suitable for shaping and firing uses dry blending techniques. The binder includes a particulate wax component that is not melted in order to combine it with the ceramic powder, but rather, the wax component is combined in particulate form with the ceramic powder. The particulate wax is mixed in conventional blender apparatus in a relatively short time period. The binder composition may also include a lubricity enhancer or slip agent and a dispersion or colloidal binder.

Abstract: An improved porous ceramic article and a method for forming such porous ceramic article. A mixture of ceramic particles and pliable organic hollow spheres is prepared in a liquid, typically as a suspension. The article is formed by pressing, slip casting, extruding or injection molding the mixture. The article is dried to remove the liquid, and then is fired so that the ceramic particles are bonded such as by sintering, and the organic spheres are burned off, resulting in a strong porous ceramic article having uniformly spaced interconnected voids.

Abstract: An injection molded ceramic cup, such as a teacup, includes a body and a handle. The body and handle together are an integral, one-piece, unitary construction formed of ceramic and a binder in a single injection molding operation. Additionally, an injection molded article, such as a ceramic cup, has a concealed sprue and includes an injection molded article body having an outer surface defining a recess and a sprue (whether negative or positive) terminating in the recess. A plug is disposed in the recess for concealing the sprue, the plug being molded separate and distinct from the article, having a first surface for concealing the sprue and a sidewall for substantially filling the recess, and being fired in situ with the article to secure the article and plug together.

Abstract: A method for injection molding fine particulate ceramic ferroelectric materials to form an article such as ink jet printhead includes the steps of spray drying fine particulate ceramic ferroelectric material to form agglomerate material; mixing the spray dried fine particulate ceramic ferroelectric agglomerate material with a binder system including materials selected from the group consisting of wax having wax components of different molecular weight, magnesium-X silicate, agaroid gel forming material, and agaroid gel forming material mixed with magnesium-X silicate to form a compounded material; injecting the compounded material at a selected pressure into a mold to form a green article; debinding or drying the green article; sintering the debinded or dried green article to form the final molded article; poling the final molded article to align the electrical dipoles within the piezoelectric material; forming a coating of conductive material over the top and bottom surfaces of the final molded article and t

Abstract: An improved method for injection molding fine particulate inorganic materials that first spray dries a fine particulate inorganic material and then mixes the dried particulate inorganic material with a binder system to form a compounded material. The compounded material is then injected, at a low pressure into a mold to form a green part. The green part is then debinded to remove most of the binder system and the debinded green part is then sintered to form the final molded part.

Abstract: Recycled, reground ceramic powder is mixed with a liquid carrier, a binder and processing additives to form a material useful for molding complex-shaped parts at relatively low pressures in conventional injection molding equipment.

Abstract: A process for producing an alumina material with high strength is disclosed. The process for producing an alumina material includes the steps of (a) providing a solution containing a dispersing agent, (b) mixing a .theta.-alumina powder and an .alpha.-alumina powder with the solution to form a slurry, (c) filtering the slurry to form a green part, (d) drying the green part, and (e) densifying the dried green part to form the alumina material.

Abstract: A method is provided for simulating fluid flow within a three dimensional object having first and second generally opposed surfaces. The method includes: matching each element of the first surface with an element of the second surface between which a reasonable thickness may be defined, wherein matched elements of the first surface constitute a first set of matched elements and matched elements of the second surface constitute a second set of matched elements, specifying a fluid injection point, and performing a flow analysis using each set of the matched elements. In this way, the injection point is linked to all locations on the first and second surfaces from which flow may emanate such that resulting flow fronts along the first and second surfaces are synchronized.

Abstract: The invention relates to the field of ceramics and concerns sintered Al.s2 O.sub.3 compositions produced from corundum powder and also methods for the use of the invented compositions as medical implants or tool material. To produce such materials, an initially unsintered precursor having a relative density of .rho..gtoreq.55% is produced from .alpha.-Al.sub.2 O.sub.3 powder having defined properties using at least two different dispersing methods, this precursor is subsequently subjected to heat treatment and sintering.

Abstract: A process for producing a ceramic product includes mixing and kneading a ceramic powder and a binder to obtain a mixture to be molded, injecting the mixture into the cavity of a mold to obtain a molded material, releasing the molded material and subjecting the released molded material to degreasing and firing. The weight of the molded material is controlled. With this process, it is possible to determine favorable molding conditions prior to the degreasing step, whereby a ceramic product free from molding defect and degreasing defect and having excellent dimensional accuracy can be obtained at high productivity.

Abstract: A filter arrangement with a cellular structure in which a plurality of filter chambers extend in the direction of the medium to be filtered. There is a filter cloth or fabric attached to each of the two sides of a cell frame which closes the filter chambers on both sides. The filter chambers are each provided with a filling of predominantly active charcoal granules. To achieve a simple and advantageous structure of the filter arrangement, the cellular structure is in the form of a rectangular cell frame each with rectangular filter chambers, preferably made of synthetic resin. Appropriate, right-angled partition walls inside the cell frame and the installation of reinforcement members can result in filter chambers of optimum size.

Abstract: A method for manufacturing ceramics with fine hole(s) includes the steps of: forming independently ceramic compacts, said ceramic compacts having their shapes corresponding to the divided parts of one integrated body having at least one fine hole along which the integrated body is divided; joining said compacts into an integrated form by cold isostatic pressing (CIP); and firing the integrated compact. Another method for manufacturing ceramics with fine hole(s) includes the steps of: forming independently ceramic compacts; grooving said compacts to make at least one desired partial hole in given places of each cross section by machining; joining said compacts into an integrated form by cold isostatic pressing (CIP); and firing the integrated compact. According to these methods, there can be obtained a sintered ceramic body with holes, each having a very small diameter and an unrestricted depth, or holes in a complex or curved shape.

Abstract: A process for producing a ceramic-base sinter, comprising sintering coated ceramic particles wherein the particles are prepared for sintering by the steps of: dispersing a powder of ceramic core particles in a gaseous atmosphere to form a mixture of a gas and particles in a powder of highly dispersed core particles; charging a precursor for the coat forming substance that has been formed via the vapor phase and/or a precursor for the coat forming substance in a vapor-phase state and the mixture of the gas and the powder of highly dispersed core particles that have a predetermined dispersity according to the average diameter of the core particles in a coating start region of a coating space; coating the surfaces of the core particles with the coat forming substance by allowing the precursor to contact and/or impinge against the core particles; shaping and sintering the thus coated ceramic core particles or a mixture containing them under appropriate sintering conditions.

Abstract: A powder injection molding composition or feedstock is made of 70% or more by weight of a powdered metal or ceramic and 30% or less by weight of a binder system. The binder system contains a sufficient amount of polypropylene or polyethylene to hold the so-called brown preform of the molded metal or ceramic powder together for the sintering step of the injection molding process and a sufficient amount of partially hydrolyzed cold water soluble polyvinyl alcohol water and plasticizer to facilitate molding of the composition into the so- called green preform of the article to be manufactured. The debinding step of the injection molding process for transforming the green preform into the brown preform consists simply of immersing the green preform in water at ambient temperature to dissolve the polyvinyl alcohol. The binder system is nonhazardous, safe, harmless and fully degradable.

Abstract: A method of manufacturing porous ceramic tubes for fuel cells with improved properties and higher manufacturing yield is disclosed. The method involves extruding a closed end fuel cell tube, such as an air electrode of a solid oxide fuel cell, in which the closed end also functions as the sintering support. The resultant fuel cell tube has a superior porosity distribution which allows improved diffusion of oxygen at the closed end of the tube during operation of the fuel cell. Because this region has the highest current density, performance enhancement and improved reliability of the fuel cell tube result. Furthermore, the higher manufacturing yield associated with the present method decreases the overall fuel cell cost.

Abstract: The purpose of this invention is to manufacture complex shaped Cr.sub.3 C.sub.2 /Al.sub.2 O.sub.3 components efficiently with effective cost. Chromium carbide, which is quite chemically inert at elevated temperature, is added into an alumina matrix for toughening purposes. Chromium carbide and alumina ceramic powders are mixed with binders to form a solidified suspension. The suspension is then crushed, heated, and injected into green products. Controlled solvent and thermal debinding processes are followed before performing pressureless sintering. Samples are sintered in pre-treated argon gas with minimum oxygen partial pressure, or in vacuum for controlling the phase stability and microstructure for tailoring mechanical properties. The processing parameters for injection molding, the composition design of binders and ceramic composites, and the techniques for controlling the phase transformation of chromium carbide are developed.

Abstract: A process for production of a moulded ceramic and/or metallic body from a ductile material comprising one or more ceramic and/or metallic components, which material is fed into the pre-heated mould cavity (1) of a moulding tool. The moulded tool includes at least two mould parts (4, 5) of which at least one wholly or partly consists of a microporous material with communicating micropores. At least one mould cavity (1) comprising at least one mould surface (2, 3) exhibiting closed micropores is arranged in the microporous mould part (4, 5) or in a microporous section (6) thereof. The microporous mould part (4, 5) or the microporous section (6) thereof is pre-heated by supply of warm fluid, such as a heated gas. Said part (4, 5) or section (6) is after terminated moulding cooled by supply of cold fluid, such as a condensed gas. the invention includes in a further aspect a moulded body produced according to the process.

Abstract: A powder injection molding composition or feedstock is made of 70% or more by weight of a powdered metal or ceramic and 30% or less by weight of a binder system. The binder system contains a sufficient amount of polypropylene or polyethylene to hold the so-called brown preform of the molded metal or ceramic powder together for the sintering step of the injection molding process and a sufficient amount of partially hydrolyzed cold water soluble polyvinyl alcohol, water and plasticizer to facilitate molding of the composition into the so-called green preform of the article to be manufactured. The debinding step of the injection molding process for transforming the green preform into the brown preform consists simply of immersing the green preform in water at ambient temperature to dissolve the polyvinyl alcohol. The binder system is nonhazardous, safe, harmless and fully degradable.

Abstract: A method of injection molding ceramic or metal parts having an internal cavity or other complicated shape. A fugitive core is formed of a particulate and a first binder. The core is then suspended in a conventional injection molding cavity. The part is then injection molded by injecting a ceramic or metal powder mixed with a second binder while in a plastic state into the mold cavity and around the suspended core. Once the second different binder hardens or gels, the molded part together with the core are removed from the mold cavity. The molded part and core are then subject to a debinding process to debind the first binder to thereby remove the core. Because two different binders were used for the core and molding, the binder used to form the molded part remains unaffected when removing the core.

Abstract: The invention relates to the field of ceramic and hard metal industries and concerns a process for manufacturing hard metal parts, in particular th having a complex geometry, such as those used for example as machining tools and wear elements. The object of the invention is to create a process which allows the manufacture of hard metal parts with a complex geometry by using a stable dispersed hard metal-binder suspension, wherein the binder is a thermoplastic binder having a viscosity of 3 to 6 mPa s, and without using an organic solvent to eliminate the binder. For that purpose, a process is disclosed wherein a hard metal powder having an average grain size smaller than 2.0 .mu.m is mixed with a liquefied thermoplastic binder, with viscosity of the mixture being set upon a value of at least 100 mPa s and up to 4,000 mPa s during the whole production and treatment process.

Abstract: The present invention is a method of producing a ceramic article. The method includes forming an intercalated or exfoliated solution of smectite clay and a polymer selected from polyvinyl alcohols, polyethylene oxides, polystyrene sulfonates, polyacrylamides, polymers of styrene, alkyl acrylates, alkyl methacrylates, olefins, acrylonitriles, polyurethanes and polyester ionomers. The solution is mixed with zirconia stabilized with at least one rare earth oxide element selected from Mg, Ca, Y, Sc and Ce to form a mixture. The mixture is molded into a green part. The green part is sintered to form the ceramic article.

Abstract: A ceramic spinneret used for producing manufactured fibers and formed from a fine grained, essentially pure structural ceramic such as aluminum oxide, zirconium oxide, composites of aluminum oxide and zirconium oxide known as toughed ceramics, silicon nitride, silicon carbide, or any fine grained essentially pure structural ceramic. Such spinnerets are formed as a single piece and contain non-circular capillaries suitable for forming shaped or void containing fibers.

Abstract: A process of molding inorganic materials into desired shapes comprises mixing the material with a dispersant, milling, molding the mixture, drying the mixture and sintering.

Abstract: A low-cost thermal decomposition degreasing method capable of drastically reducing the time required for a degreasing process which involves heating, vaporization and thermal decomposition, while assuring the shape retention property of an injection molded product during degreasing. The degreasing process comprises: (i) a first step wherein a molded product placed under a reduced pressure less than or equal to atmospheric pressure is heated at a temperature lower than the melting point of a thermoplastic binder so that the thermoplastic binder partially evaporates by 5 wt % or more, and then the molded product is further heated at a temperature lower than higher one of the melting points of a more volatile organic compound and a thermoplastic resin whereby the thermoplastic binder further evaporates by 10 wt % or more, and wherein the final temperature is set to 200.degree. C.

Abstract: A disk drive is disclosed including a substantially monolithic stator. The stator is formed by a metal injected molding (MIM) process in which high silicon iron is sintered to produce a stator made from loss magnetic material. The low loss magnetic material is a low hysteresis loss, high resistivity material. A substantially monolithic stator without multiple laminations is thus achieved. Avoiding stator laminations in this manner permits the fabrication of a disk drive having a significantly reduced vertical profile while still suppressing undesired eddy current and hysteresis losses in the stator. The stator is advantageously directly machined with a central bore to receive a bearing assembly for the spindle of the hub of the drive motor. The disclosed stator geometry is optimized in three dimensions to minimize stator volume and maximize the stator winding volume.

Abstract: A blow molded container is provided which includes a neck portion having locking teeth with features which ensure the proper formation of the teeth. Specifically, the container neck portion includes an annular inclined surface extending from both the upper and lower sides of the teeth, while all edges of the teeth are rounded. The annular inclined surfaces and the rounded edges ensure that the teeth are formed with sufficient material to ensure strong, sturdy teeth devoid of weak areas, holes or cracks. A method of forming the container is also provided which includes rounding all edges of the teeth as a parison abuts molds so as to inhibit undesirable stretching of the material forming the teeth. The method may also include forming the annular inclined surfaces to further inhibit undesirable stretching of the material forming the teeth thus ensuring proper formation of the teeth.

Abstract: A water soluble acrylate is polymerised to bind ceramic particles in a dispersion. The polymer is then burned away.

Abstract: A process for the production of dense silicon nitride materials by the nitriding of moulded bodies of silicon powder, silicon nitride powder and sintering additives under normal pressure and sintering of the moulded bodies at normal nitrogen pressure as well as silicon nitride materials produced correspondingly.

Abstract: Methods of making fiber reinforced ceramic matrix composite (FRCMC) parts by compression and injection molding. The compression molding method generally includes the initial steps of placing a quantity of bulk molding compound into a female die of a mold, and pressing a male die of the mold onto the female die so as to displace the bulk molding compound throughout a cavity formed between the female and male dies, so as to form the part. The injection molding method general includes an initial step of injecting a quantity of bulk molding compound into a cavity of a mold. In both methods, the bulk molding compound is a mixture which includes pre-ceramic resin, fibers, and, if desired, filler materials. Once the part has been formed by either method, the mold is heated at a temperature and for a time associated with the pre-ceramic resin which polymerizes the resin to form a fiber-reinforced polymer composite structure.

Abstract: A silicon nitride reaction-sintered body having a high mechanical strength without surface working can be produced by (1) forming a silicon powder mixture of at least two types of silicon powders having substantially independent particle size distribution ranges into a green body, the silicon powder mixture having an average particle size ranging from 5 .mu.m to 300 .mu.m; (2) heating the green body in a nitrogen-containing atmosphere for nitrogenation; and (3) sintering the nitrogenated green body at a temperature of 1900.degree. C. or higher.

Abstract: The present invention is a method for injection molding fine particulate inorganic materials which includes the steps of, compounding a particulate inorganic material and a magnesium-X silicate, wherein X represents lithium, sodium, potassium or other monovalent ion, containing binder, injecting the compounded material at low pressure and ambient temperature into a mold to form a green part, and sintering the green part to form the final molded part.

Abstract: A method of producing a cylindrical piezoelectric element includes:(a) injecting the molding fluid containing calcined powder of piezoelectric material in a mold having cylindrical cavity and wire-shaped core inserted therein;(b) heating to dry the molding fluid injected in the mold so as to obtain cylindrical member;(d) removing cylindrical member from the mold; and(e) sintering the cylindrical member to obtain a piezoelectric element.

Abstract: A method for forming parts from inorganic particulate materials is diclosed. The method utilizes a two-component binder composition which is removable at a faster rate than conventional binder compositions, thereby reducing the formation of voids and cracks that occur during binder removal. No toxic materials are required and the method does not rely on solvents. The method may be used with ceramics, metals, and cermets.

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 of manufacturing whisker reinforced ceramic bodies with new and improved properties. By replacing the tool pressing with injection molding, surprisingly a more homogeneous structure and more advantageous whisker orientation has been obtained. By choosing the conditions of the molding, it is possible to control the whisker orientation to get optimal material properties. Bodies according to the invention are particularly suitable for chip forming machining of heat resistant materials.