Abstract: Methods for limiting bleed-through of aqueous catalyst solutions in ceramic articles are described herein. The methods include applying a hydrophobic cellulose derivative, such as ethylcellulose, to an exterior surface of a fired porous ceramic article. The aqueous catalyst solution is applied to the fired porous ceramic article, such that the hydrophobic cellulose derivative limits bleed-through of the aqueous catalyst solution through at least a portion of the ceramic article. Ceramic articles with skins that limit bleed-through of aqueous catalyst solutions are also described herein.

Abstract: The present invention relates to an additive for use in the molding of a ceramic material, which exhibits satisfactory water absorption performance in a ceramic green ceramic clay, can highly achieve both high fluidability and low loading performance during extrusion molding and high shape-retaining performance after extrusion at the same time, and comprises polymer microparticles. This additive for use in the molding of a ceramic material comprises polymer microparticles, is characterized in that the polymer microparticles have an average particle size between 10 and 150 ?m when the polymer microparticles are swollen with ion exchange water until the swollen polymer microparticles reach a saturated state and can absorb 10-60 mL/g of ion exchange water under ordinary pressure, and is also characterized in that an aqueous dispersion prepared by dispersing 1 part by mass of the polymer microparticles in 110 parts by mass of ion exchange water has an electrical conductivity of 1500 ?S/cm or less at 25° C.

Abstract: The invention illustrates a material for friction components of disc brakes comprising between 1% and 8% by weight of at least one preceramic resin and between 2% and 10% by weight of at least one organic resin. It also illustrates a friction component for a disc brake, a disc brake, and a process for producing such a material.

Abstract: According to the invention, by setting the linear thermal expansion amount when a mold made of a molding sand is heated from a room temperature to 1000° C. to be not more than 0.9%, and the ratio (D/d) between the diameter of a slump (D) and the diameter of a slump cone (d) in a slump test of the molding sand having a hardening agent kneaded to be not less than 1.65, a molding sand preferable for use in a mold produced using the self-hardening type of three dimensional laminate molding sand mold, having low thermal expansibility preventing occurrence of a veining defect, and capable of forming a large and complicated shape can be obtained.

Abstract: A reactive liquid ceramic binder suitable for the production of ceramic products from ceramic powders is provided. The reactive liquid ceramic binder contains organo-modified siloxane compounds, wherein the liquid organo-modified siloxane compounds contain organoalkoxysiloxane units according to general formula (I) wherein R1=alkyl radical and/or aryl radical, R2=H and/or alkyl radical with 1 to 4 carbon atoms, a?0 and ?2, and b>0 and ?3, with the proviso that a+b?1 and ?4.

Abstract: The invention relates to binders for pulverulent metals, metal alloys or ceramics based on polyacetals, polyethers and polyesters, to thermoplastic compositions comprising these binders for the production of metallic or ceramic moldings, to the use thereof and to processes for production of moldings therefrom.

Abstract: A method for manufacturing an aluminum nitride particle includes the steps of wet-milling an aluminum nitride material to form a solution containing aluminum nitride powders; blending a binding agent and a dispersing agent with the solution to gain a slurry; and granulating the slurry to obtain the aluminum nitride particle.

Abstract: A silica structure includes mesoporous silica spheres; and connection portions each of which includes metal oxide, and each of which connects the mesoporous silica spheres to each other.

Abstract: A composition for injection molding includes: an inorganic powder composed of at least one of a metal material and a ceramic material; and a binder containing a polyacetal-based resin, an unsaturated glycidyl group-containing polymer, and a lubricant. In the composition, the unsaturated glycidyl group-containing polymer is contained in an amount of 1% by mass or more and 30% by mass or less with respect to the amount of the polyacetal-based resin.

Abstract: Embodiments of the present invention disclosed herein include a sintering aid composition that has a material useful for sintering, an amine, and optionally a carboxylic acid.

Abstract: A process for the preparation of a ceramic molded part from a suspension/dispersion with a solids content and a fluid content by depositing solids content at the periphery of a porous self-supporting support that is at least partially immersed in the suspension/dispersion and has the same shape as the molded part to be prepared, but with a reduced size, wherein: the solids content contains oxide-ceramic particles; the porous self-supporting support is detachably connected with a discharge in a zone that is not immersed in the suspension/dispersion; the suspension/dispersion is moved towards the porous self-supporting support by means of a positive pressure difference between a pressure prevailing in the suspension/dispersion and a pressure prevailing in the discharge; wherein the fluid content of the suspension/dispersion enters in the porous self-supporting support with depositing solids content at the periphery of the porous self-supporting support.

Abstract: Slip for use in a hot-melt inkjet printing process which contains (A) ceramic particles, (B) wax and (C) at least one radically polymerizable monomer, and use of the slip to prepare dental restorations. Furthermore, a process for the preparation of a green compact is described, in which the slip is molded in layers to the geometrical shape of the green compact and subjected to a radical polymerization in order to obtain a cured green compact.

Abstract: The invention relates to a process for obtaining a porous material made of recrystallized SiC, especially in the form of a structure for filtering a particulate-laden gas, starting from at least two powders of fine and coarse SiC particles, blended with an organic material comprising an organic pore former and/or a binder, in suitable proportions and in the presence of a sufficient amount of a solvent, such as water, so as to allow forming of said blend and firing thereof between 1600° C. and 2400° C., said process being characterized in that the difference between the percentile d90 of the coarse particle powder and the percentile d10 of the fine particle powder multiplied by the volume of organic material in the initial blend, expressed as a percentage relative to the total volume of the SiC particles, is between 250 and 1500. The invention also relates to the porous material made of recrystallized SiC that can be obtained by said process.

Abstract: Slip for use in a hot-melt inkjet printing process which contains (A) ceramic particles, (B) wax and (C) at least one radically polymerizable monomer, and use of the slip to prepare dental restorations. Furthermore, a process for the preparation of a green compact is described, in which the slip is moulded in layers to the geometrical shape of the green compact and subjected to a radical polymerization in order to obtain a cured green compact.

Abstract: A coating material, green sheet and the method capable of producing a green sheet without a pin hole, having enough strength to be peeled from a support body and excellent surface smoothness even when the green sheet is extremely thin, and being suitable to make an electronic device thin and multilayered, are provided. The present invention provides a green sheet coating material comprising a ceramic powder, a binder resin including a butyral based resin as a main component thereof, and a solvent. The solvent includes a first solvent having an SP value as a solubility parameter of 10 or larger and a second solvent having the SP value of 8 or larger but smaller than 10. The second solvent is included by 20 to 60 wt % and, preferably, 25 to 60 wt % with respect to 100 wt % of the solvent as the entire weight.

Abstract: A carbon heating element having an arbitrary specific resistance and an arbitrary shape which are arbitrary necessary as a heating element, and a method of producing the same. The carbon heating element is obtained by uniformly dispersing one or at least two metal or metalloid compounds into a composition having shapability and showing a high yield of a carbon residue after firing, shaping the dispersed material-containing mixture thus obtained, and firing the shaped material under a nonoxidizing atmosphere.

Abstract: A green product for use in fabricating a ceramic article comprises a ceramic powder immobilized within a silicone matrix, wherein the silicone matrix comprises one or more cross linked or polymerized silicone monomers and/or oligomers, wherein the one or more cross linked or polymerized silicone monomers and/or oligomers have a alkenyl reactive functional group and a hydride reactive functional group. Processes for forming a green product and a ceramic core with the silicone monomers and/or oligomers are also disclosed.

Abstract: A novel process for manufacturing of injection molded metal, ceramic, and CERMET parts, in a manner amenable to high-volume, low-cost manufacturing, comprising the steps of forming a mechanical mixture of metal and/or ceramic powders at room temperature, a binder and a liquid carrier, said carrier being a solvent for the binder at elevated temperature; supplying the as-mixed components to the inlet hopper of an injection molding machine or extruder; molding or extruding green parts; and then drying and sintering the green parts to obtain net or near-net-shape finished metal, ceramic or CERMET parts.

Abstract: The invention relates to a method for the production of a sintered, microcrystalline ?-Al2O3-based shaped body, which are used, for example, as abrasive bodies, wherein an ?-Al2O3 powder is used as starting material, said powder having an average particle diameter of <2 ?m, and processed with at least one binder and a solvent with the purpose of obtaining an extrudable material that is subsequently extruded. The extrudate is then further processed into a shaped body that is sintered at a temperature range of between 1300° C. and 1750° C.

Abstract: The present invention relates to a method of fabricating a micro device, comprising the steps of pressing an upper mold formed with a plurality of recesses for molding a plurality of rods and a lower mold formed with a seat recess for molding a plate supporting the plurality of rods against each other; injecting ceramic material mixed with a polymer into the mold; releasing a resultant ceramic molding mixed with the polymer from the molds; removing the polymer from the ceramic molding by burning out or melting away the polymer; sintering the ceramic molding; filling a polymer into spaces between the plurality of rods of the sintered ceramic molding so that the top surfaces of the plurality of rods are exposed to the outside; and removing the plate through a polishing process so that bottom surfaces of the plurality of rods are exposed to the outside.

Abstract: A ceramic material containing organic binder is formed by extrusion, dried and cut off so as to make the honeycomb body 100 having the bulkheads 11 and a plurality of cells 12 partitioned by the bulkheads 11 and penetrating between both end faces of the honeycomb body 100. The tapered jig 3 having a tapered forward end portion 31 is inserted into the opening 13 of the cell 12 of the honeycomb body 100. Then, the bulkheads 11 are heated and softened and deformed by a pushing force given by the tapered jig 3 so that the opening 13 of the cell 12 is expanded to form the large opening 131, and the opening 13 of the adjoining cell 12 is reduced at the same time so as to form the small opening 132. After that, the honeycomb body 100 is fired. In this way, the exhaust gas purifying filter for collecting particulates is manufactured.

Abstract: A method for compounding gel-free injection molding feed stock for injection molding net-shape ceramic parts, including the steps of: mixing inorganic particles with non-gel forming water soluble organic binders having molecular weight between 1000 and 1,000,000 and that are between 0.5 weight % and 10 weight % based upon the inorganic particles, along with plasticizers, water and processing aids in a mixer to form a mixture, wherein the non-gel forming water soluble organic binders are composed of high and low molecular weight organic binders; compounding the mixed inorganic particles and the non-gel forming water soluble organic binders at a high temperature in the range of between 70° and 98° Centigrade, under shear force, to form a homogenous viscous slurry in the range of 5×103 and 7×104 Pa.sec at a shear rate of 10 sec?1; cooling the homogenous viscous slurry to room temperature to form a compounded solid mass.

Abstract: A novel process for manufacturing of injection molded metal, ceramic, and CERMET parts, in a manner amenable to high-volume, low-cost manufacturing, comprising the steps of forming a mechanical mixture of metal and/or ceramic powders at room temperature, a binder and a liquid carrier, said carrier being a solvent for the binder at elevated temperature; supplying the as-mixed components to the inlet hopper of an injection molding machine or extruder; molding or extruding green parts; and then drying and sintering the green parts to obtain net or near-net-shape finished metal, ceramic or CERMET parts

Abstract: A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer rendering of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216).

Abstract: A process for making an alkaline resistant material comprises the steps of grinding together 0-40% light magnesia, 0-80% roasted magnesia, 10-54% ceramic clay, 0-9% limestone, 1-4% water glass, 0-1.5% carboxymethyl cellusolve, 0-27% talc, 0-3% calcium or barium carbonate to a particle size of less than 50 microns, mixing the ground mixture with water to produce a paste containing <23% wt. water, shaping the paste to a desired shape, drying the shaped product at a temperature of 110 degrees Centigrade, and firing the dried shaped product in a kiln at 1350 degrees Centigrade. The resulting alkali resistant ceramic contains 25-76 wt % MgO, 13-47% SiO2, 5-20 wt % Al2O3, and 1-10 wt % Fe2O3, CaO, K2O, and/or Na2O, with forsterite and spinel being the dominant crystalline phases.

Abstract: The core/jacket catalyst molding with a core made from an inorganic support material and with a jacket made from a catalytically active material can be prepared by coextruding an aqueous molding composition which comprises the support material or a precursor thereof, with an aqueous molding composition which comprises the catalytically active material or a precursor thereof, then drying the coextrudate, and then calcining the dried coextrudate.

Abstract: A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.

Abstract: A dielectric ceramic article precursor and a process for preparing a dielectric ceramic article are presented. The ceramic article precursor comprises a crystalline aluminosilicate zeolite or an amorphous aluminosilicate, a zinc oxide additive and a glass phase. The ceramic article precursor can optionally contain at least one forming aid selected from binders, plasticizers and surfactants. The process for preparing a dielectric ceramic article involves forming a mixture from the above components into a shaped article such as a tape and then calcining the shaped article at a temperature of about 700° C. to about 1000° C. for a time of about 0.5 to about 24 hours.

Abstract: It is directed to a silicon carbide-based porous body, wherein said body is a porous one which contains silicon carbide particles as an aggregate and metallic silicon, and has an oxygen-containing phase at the surfaces of silicon carbide particles and/or metallic silicon or in the vicinity of the surfaces thereof. The silicon carbide-based porous body contains refractory particles such as silicon carbide particles or the like and yet can be produced at a relatively low firing temperature at a low cost, has a high thermal conductivity, and is superior in oxidation resistance, acid resistance, chemical resistance to ash and particulates.

Abstract: A honeycomb structure body which has a number of passages partitioned with partition walls and penetrating along the axial direction. A porous honeycomb structure body which contains refractory grains as filler, one or more elements selected from the group consisting of the rare earth elements, alkaline earth elements, Al, and Si, and the crystal containing one or more kinds of these elements. The present honeycomb structure body contains refractory grains such as silicon carbide grains and the like, but it can be produced at a relatively low firing temperature at a low price, it is sufficiently porous and high in specific surface area, and it can be used as a filter for purifying automobile exhaust gas, a catalyst carrier, and the like under the high SV conditions.

Abstract: A method of fabricating nanostructure bodies by integrating the steps of attriting precursor nanometer-sized particulate materials, desorbing the exposed surfaces of the attrited nanoparticulates, adsorbing a surfactant on at most 50% of the desorbed surfaces and dispersing the surfactant-coated nanoparticulates in an organic matrix to form a homogeneous thermoplastic compound from which green bodies are shaped, dewaxed and sintered.

Abstract: A ceramic-molding binder includes a vinyl alcohol polymer having an ethylene unit content of 2 to 19 mole %, a polymerization degree of 200 to 2,000, a degree of saponification of 80 to 99.99 mole %, and a carboxylic acid and lactone ring content of 0.02 to 0.4 mole %. The use of the ceramic-molding binder provides green moldings with better formability and handling properties during the formation of smaller green moldings of more complex shape, and also provides ceramic products of good quality, higher yields, and fewer ceramic cracks when obtained by sintering such green moldings.

Abstract: A method for manufacturing containers for growing plants, comprising an initial step of reducing plastics and fired clay to granules and a final step of releasing the containers from molds. The method includes, in order of sequence, the intermediate steps of preparing a mixture of the granules, introducing the mixture into the molds, heating the mixture until the melting temperature of the material is approximately reached, holding the mixture at that temperature, and cooling the mixture. A container produced with the method includes uniformly distributed fired clay granules and reticular formations of plastics that mutually bind the granules. The invention overcomes the drawbacks of the prior art, by providing containers that combine the best characteristics of earthenware and plastic containers, respectively.

Abstract: A molded honeycomb material is obtained by subjecting a mixture of a raw material powder and a binder to extrusion molding. In the honeycomb material, no open pores are present, and the binder includes a thermoplastic material which is molten at the molding temperature. A process for producing the above molded honeycomb material includes heating a mixture of a raw material powder and a binder to a molding temperature to melt the binder, subjecting the mixture to extrusion molding, and cooling and solidifying the extrudate. The honeycomb material has a small partition wall thickness and can be mass-produced without impairing the product quality.

Abstract: A method for producing agglomerated boron carbide, including the steps of providing a boron carbide powder precursor having particle sizes smaller than about 1 micron in diameter, mixing the boron carbide powder precursor with binder solution to form a slurry, drying the slurry to yield a solid residue, crushing the solid residue to yield green boron carbide particles, and firing the green boron carbide particles. The resultant agglomerated boron carbide particles have diameters generally ranging from about 5 to about 20 microns. The agglomerated boron carbide particles are characterized as boron carbide grains of about 1-2 microns in diameter suspended in a vitreous boron oxide matrix.

Abstract: The present invention provides a carbon heating element having an arbitrary specific resistance and an arbitrary shape which are arbitrary necessary as a heating element, and a method of producing the same. The carbon heating element is obtained by uniformly dispersing one or at least two metal or metalloid compounds into a composition having shapability and showing a high yield of a carbon residue after firing, shaping the dispersed material-containing mixture thus obtained, and firing the shaped material under a nonoxidizing atmosphere.

Abstract: The present invention related to a method for producing agglomerated boron carbide. One form of the present invention includes the steps of providing a boron carbide powder precursor having particle sizes smaller than about 1 micron in diameter, mixing the boron carbide powder precursor with binder solution to form a slurry, drying the slurry to yield a solid residue, crushing the solid residue to yield green boron carbide particles, and firing the green boron carbide particles. The resultant agglomerated boron carbide particles have diameters generally ranging from about 5 to about 20 microns. The agglomerated boron carbide particles are characterized as boron carbide grains of about 1-2 microns in diameter suspended in a vitreous boron oxide matrix.

Abstract: A refractory material comprising a strontium aluminate refractory fibre and an inorganic binder comprises when fired greater than 35 wt % strontium oxide and/or Al2O3=aluminium oxide content of strontium aluminate fibre ±65 wt %, SiO2=silicon oxide content of strontium aluminate fibre ±20 wt %

Abstract: Exemplary silicon carbide ceramic bodies are produced according to the invention. An exemplary ceramic body includes silicon carbide in major amounts and an organic gelation agent in a minor amount. An exemplary ceramic body exhibits sufficient density and hardness to function as body armor.

Abstract: A process for producing a monolithic ceramic electronic component, which includes: providing a ceramic slurry, a conductive paste, and a ceramic paste; forming a plurality of composite structures each comprising a ceramic green sheet produced by shaping the ceramic slurry, internal circuit element films formed by applying the conductive paste partially onto a main surface of the ceramic green sheet so as to provide step-like sections, and a ceramic green layer which compensates for spaces defined by the step-like sections, the ceramic green layer being formed by applying the ceramic paste onto the region on the main surface of the sheet on which the element films are not formed, so as to substantially compensate for the spaces; forming a green laminate by laminating the composite structures; and firing the green laminate, wherein the ceramic paste contains ceramic powder, an organic solvent, and an organic binder.

Abstract: A binder system for forming a ceramic body, such as a translucent arc tube for a metal halide lamp, comprises a hydrocarbon, such as a paraffin wax, a copolymer, such as poly (ethylene-co-vinyl acetate), and optionally a surfactant. The binder system is mixed with a ceramic powder and heated to above the melting point of the binder. The heated mixture is formed into a compact having the general shape of the finished ceramic body and then cooled or allowed to cool. The hydrocarbon and copolymer have overlapping freezing points so that when the shaped compact cools, crystalline segments of the copolymer (such as ethylene segments) co-crystallize with the hydrocarbon, while amorphous segments (such as vinyl acetate) form bridges between the crystalline regions. As a result, the cooled compact has improved green strength over conventional binder systems.

Abstract: An improved submerged entry nozzle is provided which is useful in the casting of aluminum killed molten steel. The nozzle has an improved slagline sleeve or collar which surrounds the outer portion of the nozzle to protect it from corrosion during the casting process. The slagline sleeve is made from resin bonded zirconia/graphite which has been formulated so that upon curing of the resin to form resite, there is a reduction in the contractile tendency which results in a reduction in stress fracturing. The reduction of the contractile tendency and the resulting resistance to stress fracturing is achieved by adding an effective amount of calcium oxide to the resin-zirconia-graphite mixture which is used to form the sleeve.

Abstract: A method of producing ceramic slurry capable of producing uniformly dispersed ceramic slurry without excessively damaging a ceramic powder, and a method of producing a ceramic slurry composition used for producing a multilayer ceramic electronic part, from which an undissolved binder is precisely removed. Also provided is a method of producing a ceramic green sheet, and a method of producing a multilayer ceramic electronic part. A ceramic powder having an average particle diameter of about 0.01 to 1 &mgr;m is mixed with a dispersion solvent (solvent) and disintegrated by a medium-type dispersion method using a dispersion medium such as balls, beads, or the like to obtain mixed and disintegrated slurry, followed by high-pressure dispersion under a pressure of about 100 kg/cm2 or more.

Abstract: A process for the removal of binder material from powder injected molded parts that employs a low pressure plasma reactor to generate reactive species which react with the binder material in the injected molded part is presented. The reactive species cause the binder material to break down into smaller molecules and thereby be removed from the injected molded part.

Abstract: A process for forming a silicon carbide structure includes molding by compression a mixture of a silicon precursor powder and a cross-linking thermoset resin to form a rigid structure, carbonizing the rigid structure, and forming a silicon carbide structure by heating the carbonized rigid structure at a temperature sufficient to allow carbon and silicon in the structure to react to form silicon carbide.

Abstract: A polymeric binder system and method of making, and a method for extruding thin-walled articles such as thin-walled tubes is provided. The extrusion method comprises providing a polymeric binder system comprising a substantially homogeneous solution of a polymeric binder and an organic solvent, adding a ceramic or metal powder to form a mixture, and evaporating the solvent from the mixture. The remaining mixture is then extruded from a die and heated to burn-off the binder and sinter the article.

Abstract: A method of making a water-based ceramic that contains carrageenan and various average-molecular-weight preparations of poly(ethylene oxide). Various other materials can be added to yield mixtures appropriate for specialized applications.

Abstract: A method for producing ceramic bodies, particularly ceramic foils, from a castable slip made of a dispersion of a ceramic powder in a solvent. A dispersion of an aqueous vinyl-acetate homopolymer or an aqueous vinyl-acetate/ethene copolymer being used as the solvent.

Abstract: The well known slip casting process for the production of ceramic green parts, in which hardening is achieved by water removal with porous molds, is characterized by disadvantages in terms of strength, shrinkage during drying and problems with cracking during drying. The present invention avoids these disadvantages and produces ceramic green parts by changing the surface potential of powder particles in the slip instead of by removing water. Further more the coagulation strength is increased by adding polymers or extremely fine divided colloidal particles.

Abstract: The present invention relates to a method of fabricating a micro device and a method for manufacturing a mold for molding the micro device.