Particular Or Specific Manner Of Positioning, Arranging, Or Conveying Of Single Article Or Preform (e.g., Utilizing Spacer, Etc.) During Sintering, Vitrifying, Or Drying Patents (Class 264/671)
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Patent number: 11952285Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.Type: GrantFiled: July 25, 2023Date of Patent: April 9, 2024Assignee: Corning IncorporatedInventors: Micheal Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
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Patent number: 10265881Abstract: The manufacturing method of the honeycomb structure includes a mounting step of mounting an extruded honeycomb formed body on a firing setter disposed on a shelf plate, and a firing step of firing the honeycomb formed body mounted on the firing setter to form the honeycomb structure, and in the mounting step, the firing setter is used in which a value obtained by dividing an area of a formed body end face of the honeycomb formed body by an area of a honeycomb mounting surface of the firing setter which faces the formed body end face and at least a part of which comes in contact with the formed body end face is in a range of 2.5 to 20.0.Type: GrantFiled: February 16, 2017Date of Patent: April 23, 2019Assignee: NGK Insulators, Ltd.Inventors: Daniel Yukichi Kitaguchi, Toshihiro Fukui
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Patent number: 10211295Abstract: The present invention provides a substrate for a semiconductor device and a semiconductor device using the same. The substrate for a semiconductor device comprises a ceramic supporting base plate formed by a polycrystalline aluminum nitride (AlN) sintered body; at least one silicon oxide layer formed on the base plate by a sol-gel method wherein the at least one silicon oxide layer has an average roughness less than the base plate to block polycrystalline orientation of the base plate and has a total thickness in a range of 10˜5000 nm, the silicon oxide layer is only formed from the sol-gel method and is not single crystalline; a first buffer layer comprising aluminum nitride (AlN) on the at least one silicon oxide layer with a thickness of 0.1˜10 ?m; and a gallium nitride layer formed on the first buffer layer and having a single-crystal crystalline structure.Type: GrantFiled: June 6, 2017Date of Patent: February 19, 2019Assignee: National Chi Nan UniversityInventors: Jiann-Heng Chen, Puru Lin, Sun-Zen Chen
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Publication number: 20150145385Abstract: A method for forming a monolithic seal frame and lid for use with a substrate and electronic circuitry comprises the steps of forming a mandrel from a ceramic and glass based material, forming a seal frame and lid block from a ceramic and glass based material, creating a seal frame and lid by forming a compartment and a plurality of sidewalls in the seal frame and lid block, placing the seal frame and lid on the mandrel such that the mandrel fits within the compartment, and cofiring the seal frame and lid block.Type: ApplicationFiled: November 27, 2013Publication date: May 28, 2015Applicants: Sandia Corporation, Honeywell Federal Manufacturing & Technologies, LLCInventors: Daniel S. Krueger, Kenneth A. Peterson, Dave Stockdale, James Brent Duncan, Bristen Riggs
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Publication number: 20150111164Abstract: Disclosed herein are a ceramic substrate, a firing setter, and a manufacturing method of a ceramic substrate using the same. According to the present invention, there is provided a ceramic substrate including: a first substrate concave-convex part formed on a lower surface thereof and having a first substrate roughness; and a second substrate concave-convex part formed on an upper surface thereof and having a second substrate roughness.Type: ApplicationFiled: March 6, 2014Publication date: April 23, 2015Applicant: Samsung Electro-Mechanics Co., Ltd.Inventors: Seung Wook Park, Jang Su Kim, No Il Park, Doo Sung Jung
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Patent number: 8865614Abstract: A process for producing a ringlike oxidic shaped body by mechanically compacting a pulverulent aggregate introduced into the fill chamber of a die, wherein the outer face of the resulting compact corresponds to that of a frustocone.Type: GrantFiled: February 28, 2013Date of Patent: October 21, 2014Assignee: BASF SEInventors: Knut Eger, Jens Uwe Faust, Holger Borchert, Ralf Streibert, Klaus Joachim Mueller-Engel, Andreas Raichle
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Publication number: 20140183800Abstract: An apparatus for forming a cutting insert may include a compression device having a sleeve with a bore. The sleeve may receive a substantially hollow can. Solid particulates may be positioned within the can, and a substrate material or other punch may also be positioned in the can. A forming device adjacent an end of the can in which the solid particulates are located may include at least one protrusion extending into the bore. The protrusion may be adapted to deform the can while also forming the plurality of solid particulates into a solid mass having one or more reliefs and/or lobes. A method may include pressing the solid particulates while within a can to form a solid mass having one or more reliefs or lobes. An HPHT process may be performed to bond the solid mass to a substrate material.Type: ApplicationFiled: December 27, 2013Publication date: July 3, 2014Applicant: Smith International, Inc.Inventors: Michael Stewart, Yi Fang, Scott L. Horman, Jeremy Peterson
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Publication number: 20140137603Abstract: Feeder channel for molten glass including an infrastructure including a block self-cast and sintered in situ. Furthermore, a method for manufacturing a block of such an infrastructure and a supply channel for a glassmaking furnace are claimed.Type: ApplicationFiled: June 12, 2012Publication date: May 22, 2014Applicant: SAINT-GOBAIN CENTRE DE RECHERCHES ET D'ETUDES EUROPEENInventors: Cyril Linnot, Michel Bobo
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Patent number: 8652378Abstract: The present invention relates to rapid dissolve thin film drug delivery compositions for the oral administration of active components. The active components are provided as taste-masked or controlled-release coated particles uniformly distributed throughout the film composition. The compositions may be formed by wet casting methods, where the film is cast and controllably dried, or alternatively by an extrusion method.Type: GrantFiled: March 29, 2013Date of Patent: February 18, 2014Assignee: MonoSol Rx LLCInventors: Robert K. Yang, Richard C. Fuisz, Garry L. Myers, Joseph M. Fuisz
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Patent number: 8580184Abstract: A method of forming hollow fiber bundles includes the step of providing a mat having a plurality of hollow fibers forming a weft and a plurality of soluble fibers forming a warp. Each hollow fiber extends between a first side and an opposed second side of the mat. The mat is bundled so as to form a bundle with the first side of the mat defining a first end of the bundle and the second side of the mat defining a second end of the bundle. At least a portion of the bundle is potted so as to substantially fix a position of the hollow fibers relative to each other. The soluble fibers are at least partially dissolved so as to remove the soluble fibers from the bundle.Type: GrantFiled: June 21, 2011Date of Patent: November 12, 2013Inventor: Jean Patrick Montoya
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Patent number: 8415268Abstract: A process for producing a ringlike oxidic shaped body by mechanically compacting a pulverulent aggregate introduced into the fill chamber of a die, wherein the outer face of the resulting compact corresponds to that of a frustocone.Type: GrantFiled: June 30, 2009Date of Patent: April 9, 2013Assignee: BASF SEInventors: Knut Eger, Jens Uwe Faust, Holger Borchert, Ralf Streibert, Klaus Joachim Mueller-Engel, Andreas Raichle
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Patent number: 8398796Abstract: A method of green joining ceramic components is disclosed, particularly for use in forming a discharge body for a ceramic metal halide lamp. The process includes providing a first green ceramic component having a male joining surface, and providing a second green ceramic component having a female joining surface dimensioned to matingly receive the first component. The first and second green ceramic components are assembled along the joining surfaces, the assembled components are uniformly heated to join the first and second components. The joined components are next cooled in a cooling bath that uniformly cools the joined components. Thereafter, the joined green part may be inserted in the furnace for debindering and sintering.Type: GrantFiled: November 20, 2007Date of Patent: March 19, 2013Assignee: General Electric CompanyInventors: Glenn H. Kuenzler, Thomas J. Boyle, Michael Vincent Yee, Brian Danison
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Patent number: 7780905Abstract: An adjustable mold is used to mold material to form a first support. A first ceramic article is supported by the first support during firing. The adjustable mold may be adjusted and used to mold material to form a second support having a second configuration. The second support is used to support a second ceramic article during firing. The first and second supports may advantageously be formed with projections which engage the ceramic articles during firing. The length of these projections may be varied by adjusting the mold. A second adjustable mold may be used to form a first retainer which limits upward movement of the first ceramic article during firing. The second adjustable mold may be adjusted and used to form a second retainer which limits upward movement of the second ceramic article during firing.Type: GrantFiled: March 4, 2008Date of Patent: August 24, 2010Assignee: PCC Airfoils, Inc.Inventor: Gerald C. Dodds
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Patent number: 7716948Abstract: A fused glass crucible includes a collar of doped aluminum silica that defines uppermost and outermost surfaces of the crucible. The melt line that defines the surface of molten silicon in the crucible may be substantially at the lower end of the collar or slightly above it. Crystallization of the collar makes it hard and therefore supports the remaining uncrystallized portion of the crucible above the melt line. The melt line may also be below the lower end of the collar, especially if the melt is drawn down or poured early in the process. Because there is little or no overlap or because the overlap does not last long, the doped aluminum collar is not damaged by the heat of from the melt.Type: GrantFiled: December 18, 2006Date of Patent: May 18, 2010Assignees: Heraeus Shin-Etsu America, Inc., Shin-Etsu Quartz Products Co., Ltd.Inventors: Katsuhiko Kemmochi, Yasuo Ohama
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Publication number: 20100093514Abstract: A high-purity aluminum nitride sintered body is provided by efficiently removing oxides contained in a raw material powder in producing an aluminum nitride sintered body and preventing composite oxide produced by reaction of oxides contained in the raw material powder with a sintering aid from remaining in the aluminum nitride sintered body. The above sintered body is achieved by an aluminum nitride sintered body having a concentration of residual oxygen excluding attached oxygen of 350 ppm or less.Type: ApplicationFiled: February 4, 2008Publication date: April 15, 2010Applicant: TOKUYAMA CORPORATIONInventors: Yukihiro Kanechika, Masanobu Azuma
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Publication number: 20090130459Abstract: A method of green joining ceramic components is disclosed, particularly for use in forming a discharge body for a ceramic metal halide lamp. The process includes providing a first green ceramic component having a male joining surface, and providing a second green ceramic component having a female joining surface dimensioned to matingly receive the first component. The first and second green ceramic components are assembled along the joining surfaces, the assembled components are uniformly heated to join the first and second components. The joined components are next cooled in a cooling bath that uniformly cools the joined components. Thereafter, the joined green part may be inserted in the furnace for debindering and sintering.Type: ApplicationFiled: November 20, 2007Publication date: May 21, 2009Inventors: Glenn H. Kuenzler, Thomas J. Boyle, Michael Vincent Yee, Brian Danison
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Patent number: 7497983Abstract: Methods of forming a colored ceramic body or dental article are described that include: (a) forming a body from a ceramic-containing powder; (b) shaping the body into a desired shape; and (c) firing the shaped body in an atmosphere comprising at least one coloring agent. Methods of forming a fully dense ceramic body that lacks discoloration, are also described which include: (a) forming a body from a ceramic-containing powder; (b) shaping the body into a desired shape; (c) placing the shaped body in a firing atmosphere containing at least one impurity that promote discoloration of the ceramic body; (d) placing the ceramic body in proximity to an atmosphere powder; and (e) firing the shaped body in proximity to an atmosphere powder; wherein the atmosphere powder acts as at least one of a barrier and a getter for the at least one impurity.Type: GrantFiled: August 17, 2007Date of Patent: March 3, 2009Assignee: Pentron Ceramics, Inc.Inventors: Ajmal Khan, Dmitri G. Brodkin
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Patent number: 7442662Abstract: A highly heat-conductive Si-containing material containing a Si phase whose lattice constant at room temperature is controlled at a level of more than 0.54302 nm but 0.54311 nm or less. Firing is conducted using a kiln material containing no B compound. With this highly heat-conductive Si-containing material and the process for production thereof, a reduction in heat conductivity can be prevented and a high heat conductivity can be exhibited stably.Type: GrantFiled: April 28, 2006Date of Patent: October 28, 2008Assignee: NGK Insulators, Ltd.Inventors: Kenji Morimoto, Shinji Kawasaki, Hiroaki Sakai
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Publication number: 20080241457Abstract: An interior trim component includes an aerated skin layer and a glass-reinforced urethane substrate layer. A method for manufacturing an interior trim component is also disclosed. The method includes the steps of aerating a skin layer into a molding tool and depositing a glass-reinforced urethane substrate layer over the aerated skin layer.Type: ApplicationFiled: March 30, 2007Publication date: October 2, 2008Inventors: Dennis L. Arnold, Michael A. West, Robert J. Valcke
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Publication number: 20080215098Abstract: An implant comprising a shaped body having a first region with a mean porosity P2 and a second region with a mean porosity P3<P2; wherein the second region with the lower mean porosity P3 is effective for handling and fixation of the implant.Type: ApplicationFiled: February 7, 2008Publication date: September 4, 2008Inventors: Thomas Imwinkelried, Lukas Giger
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Publication number: 20080197544Abstract: A heating furnace for calcining an object to be heated. The heating furnace includes a wall defining a furnace space and configured to receive the object in the furnace space, and a heating device configured to raise a temperature within the furnace space. The heating furnace also includes an oxygen supply channel configured to introduce gases containing oxygen into the furnace space. The oxygen supply channel is formed as an opening in a part of the wall surrounding the furnace space. The heating furnace further includes a gas discharge channel fluidly connected to the furnace space and configured to discharge gases in the furnace space to an outside of the furnace space, and a measurement device installed in the gas discharge channel and configured to measure properties of the gases passing through the gas discharge channel.Type: ApplicationFiled: December 31, 2007Publication date: August 21, 2008Applicant: IBIDEN CO., LTD.Inventors: Takamitsu Saijo, Koji Higuchi
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Publication number: 20080157445Abstract: A circulating apparatus includes a firing jig assembling apparatus, a firing furnace, a firing jig disassembling apparatus, and a transporting conveyor. The firing jig assembling apparatus includes a lid member attaching mechanism that attaches the lid member to a predetermined position of the firing jig placed on the table or the conveyor; and a jig delivering mechanism that delivers the firing jig which has the ceramic molded body being mounted thereon and the lid member being attached thereto, to the firing furnace. The firing jig disassembling apparatus further includes a jig receiving mechanism that receives the firing jig which has the fired ceramic molded body being mounted thereon and the lid member being attached thereto, from the firing furnace; and a lid member detaching mechanism that detaches the lid member from the firing jig placed on the table or the conveyor with the lid member being attached thereto.Type: ApplicationFiled: October 29, 2007Publication date: July 3, 2008Applicant: IBIDEN CO., LTD.Inventors: Tsuyoshi KAWAI, Takamitsu Saijo, Kenichiro Kasai
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Patent number: 7128870Abstract: A method for manufacturing multilayer ceramic electronic components includes the steps of removing organic materials from multilayer ceramic bodies having internal electrodes and ceramic layers, and then sintering the multilayer ceramic bodies. After finishing the removing step, it is preferable that the amount of the remaining organic materials in the multilayer ceramic body is 0.5 to 8.5 weight %, more preferably 1.0 to 5.0 weight %. The removing process may be performed in a neutral, a reductive or inert atmosphere. It is also preferable that the organic materials removing temperature of the internal electrodes are controlled to be higher than that of the ceramic layer.Type: GrantFiled: June 24, 2003Date of Patent: October 31, 2006Assignee: Taiyo Yuden Co., Ltd.Inventor: Koji Otsuka
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Patent number: 7108827Abstract: The present invention relates to a ceramic sheet having uniform quality over its entire surface with a decreased number of defects such as foreign matters and flaws. When the ceramic sheet was divided into sections of 30 mm square or smaller, each divided section has 5 or less defects detected based on an image obtained with a charge coupled device (CCD) camera. The present invention also relates to a method of producing the ceramic sheet. In this method, a green sheet or a calcined sheet mainly including spherical ceramic particles having an average particle diameter of 0.1 to less than 5 ?m was used as a spacer. By using this spacer, the green sheet for ceramic sheet slides smoothly on the spacer surface when it shrinks in baking, and the friction resistance between the green sheet for ceramic sheet and the spacer is lowered. In this manner, the method of the present invention can mass-produce the above-described high quality ceramic sheets.Type: GrantFiled: April 6, 1999Date of Patent: September 19, 2006Assignee: Nippon Shokubai Co., Ltd.Inventors: Kazuo Hata, Norikazu Aikawa, Keijirou Takasaki
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Patent number: 7094301Abstract: A method of joining at least two sintered bodies to form a composite structure, including providing a first multicomponent metallic oxide having a perovskitic or fluorite crystal structure; providing a second sintered body including a second multicomponent metallic oxide having a crystal structure of the same type as the first; and providing at an interface a joint material containing at least one metal oxide containing at least one metal identically contained in at least one of the first and second multicomponent metallic oxides. The joint material is free of cations of Si, Ge, Sn, Pb, P and Te and has a melting point below the sintering temperatures of both sintered bodies. The joint material is heated to a temperature above the melting point of the metal oxide(s) and below the sintering temperatures of the sintered bodies to form the joint. Structures containing such joints are also disclosed.Type: GrantFiled: March 21, 2003Date of Patent: August 22, 2006Assignee: Air Products and Chemicals, Inc.Inventors: Darryl Paul Butt, Raymond Ashton Cutler, Steven Walton Rynders, Michael Francis Carolan
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Patent number: 6936557Abstract: A novel multipurpose mineral composition capable of emitting a large quantity of far infrared rays, negative ions and oxygen heat is manufactured by setting up an iron railing, an iron rod and an iron plate on a brazier, placing a tinfoil on the iron plate, and layering yellow soil, kaolin, sericite, and biomineral in sequence on the tinfoil, while inserting the tinfoil between the layers, loading a pulverized elvan in the furnace, pulverizing a mixed stone including 40 wt % of germanium, 15 wt % of tourmaline, 30 wt % of zeolite, and 15 wt % of franklinite, to the particle size under about 44 ?m, and loading the pulverized mixed stone in an internal furnace which is made by winding a copper plate with a tinfoil and placed on the plurality of layers of the furnace, heating the pulverized mixed stone at about 1,000° C. for about seven days into a lump, and repulverizing the lump.Type: GrantFiled: May 28, 2002Date of Patent: August 30, 2005Inventor: Yong-Jin Park
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Patent number: 6843821Abstract: The aim of the invention is to provide filtering candles (1) comprising a sintered filtering tube (2) and a collar (3) which is connected thereto, and having an increased shelf life and improved resistance values. To this end, the collar (3) comprises an annular collar wall (4) which oriented towards the filtering tube (2) from the neck. Said wall comprises at least one recess (8) which is arranged in a perpendicular manner and at an angle in relation to a plane which is perpendicular to the axis of the filtering tube.Type: GrantFiled: June 19, 2003Date of Patent: January 18, 2005Assignee: GKN Sinter Metals GmbHInventor: Simon Steigert
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Patent number: 6814903Abstract: A method for producing high-alumina bodies with superior chemical properties at reduced sintering temperatures, including the steps of providing an alumina powder precursor, adding about 4 weight percent magnesia powder precursor, homogenizing the resultant green powder precursor, pressing a green body from the green powder precursor, removing residual moisture and organic material from the green body, and firing the green body to about cone 13, wherein the resulting high-alumina body is substantially non-vitreous, has a substantially uniformly sized grain structure, is very resistant to dissolution in molten aluminum, and has superior resistance to chemical attack over substantially the entire pH range.Type: GrantFiled: March 6, 2002Date of Patent: November 9, 2004Inventor: Gerard E. Parker
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Patent number: 6808676Abstract: A method and device for producing shaped ceramic bodies, particularly ceramic sheets or multilayer hybrids provided with printed circuit traces, switching elements and/or plated-through holes. The shaped ceramic bodies are initially present as green bodies and also contain organic auxiliary agents, for example as a binder. During sintering and/or removal of the binder from the shaped ceramic bodies, they are compressed between porous setter plates in whose pores a catalytically active substance is introduced, so that the gaseous, organic, bake-out products of the green bodies, these products developing during sintering and/or binder removal, are catalytically converted when escaping through the porous setter plates. The setter plates be provided with separating layers that likewise may contain the catalytically active substance. The method should provide a considerable time savings when sintering and/or removing binder from the shaped ceramic bodies.Type: GrantFiled: July 23, 2001Date of Patent: October 26, 2004Assignee: Robert Bosch GmbHInventor: Ulrich Eisele
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Patent number: 6555048Abstract: A silica product, method and apparatus for manufacturing a tube-shaped silica glass product using a molded green body having a hollow rod structure. A molded green body having a hollow rod structure has a uniform outer diameter and has a bore having an inner diameter increasing gradually from one end to the other. When sintered in a vertically movable sintering furnace, a tube-shaped silica glass product having a longitudinal cross section distribution less than a tolerance limit may be obtained. Optical fiber manufactured using the silica glass tube according to the present invention may have a uniform longitudinal geometrical structure, thereby exhibiting superior transmission characteristics.Type: GrantFiled: August 22, 2000Date of Patent: April 29, 2003Assignee: Samsung Electronics Co., Ltd.Inventors: Young-Sik Yoon, Young-Min Baik
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Patent number: 6550280Abstract: The invention involves fabricating a ceramic tube, e.g., a silica overcladding tube, with very little bow, e.g., about 0.3 mm per meter or less. In particular, the invention involves securing the tube by a handle that both allows the tube to hang plumb during treatment, and also is capable of deforming during such heat treatment to maintain the plumb arrangement.Type: GrantFiled: December 13, 1999Date of Patent: April 22, 2003Assignee: Agere Systems Guardian Corp.Inventors: Eric M Monberg, Frederick W. Walz, Jr.
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Patent number: 6511727Abstract: Flat strip lamella for reinforcing weight-carrying or weight-transferring building components. It has a composite structure consisting of a plurality of pliant or loose-flex supporting fibers (26) aligned parallel to each other, and a binding matrix (28) which connects the supporting fibers to each other so that they are shear-resistant, and is fastenable by means of an adhesive (16) by its broad side to the surface of the building component (12) that is to be reinforced. So that the flat strip lamella, to which the binding matrix gives rigid elastic form, can also be bent over corner edges of a building component (12), the invention proposes that the binding matrix (28) be removed, in at least an intermediary area (30), by uncovering the supporting fibers (26), and that the uncovered supporting fibers be subjected to a liquid or pasty thermosetting plastic, in order to stabilize the bent-over condition.Type: GrantFiled: July 16, 1999Date of Patent: January 28, 2003Assignee: Sika AG, vormals Kaspar Winkler & Co.Inventors: Alexander Bleibler, Ernesto Schümperli, Werner Steiner
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Publication number: 20020195752Abstract: The present invention provides a process for producing alumina matrix carbide and boride reinforced ceramic composites wherein for any particular composite, the relative density is about 97% or more of the theoretical density. The composites are prepared in a container wherein the interior surfaces of the container are graphite and have a protective coating consisting of a first layer comprising silicon carbide and boron carbide with a binder and a second layer comprising silicon carbide particles, wherein the protective coating prevents carbon bleed-through and the protective coating maintains a boride-containing equilibrium atmosphere during the process.Type: ApplicationFiled: July 24, 2002Publication date: December 26, 2002Applicant: C-Max Technology, Inc.Inventor: Xi Yang
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Patent number: 6495072Abstract: A method for producing a ceramic material, subsequently including mixing ceramic material, such as oxidic ceramic material, which as a raw material essentially comprises aluminum oxide, zircon oxide and/or titanium oxide, and glass component; melting at least the glass component in the mixture by sintering, where the glass component infiltrates the ceramic material and absorbs raw material of the ceramic material through a reaction at the surface; and bringing the mixture into a shape, such as powder, which is suitable for further processing, such as additional sintering. Also, a basis for the crown, the crown in its entirety having layers of for instance porcelain applied to the basis, and methods for producing the basis and the crown through subsequent processing steps, to which the basis is preferably subjected on the same underground, for instance based on CAD/CAM techniques.Type: GrantFiled: February 3, 2000Date of Patent: December 17, 2002Assignee: Cicero Dental Systems B.V.Inventor: Joseph Maria Van der Zel
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Publication number: 20020163109Abstract: A procedure is provided for bringing an incompletely densified cast radome to a desired final or near final shape through the use of one or more conformal tools during a high temperature firing operation. A conformal firing tool is defined in this case as a mandrel or mold made from a high temperature material, such as a graphite composite, that represents the desired shape of the finished radome. The process consists of firing the cast radome body over a mandrel, or inside a mold, or in combination with the two, such that the tools impart a desired dimensionality to the cast part as it densities and flows at high temperature.Type: ApplicationFiled: March 26, 2002Publication date: November 7, 2002Applicant: RAYTHEON COMPANYInventors: Kevin W. Kirby, Anthony T. Jankiewicz, James M. Lyon, Joseph W. Barber
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Patent number: 6447712Abstract: Flexible setter powder deposition sheets containing setter powders were developed for sintering of ceramic articles including tapes by an economical, fast and simple method. The sheets provide for deposition of a thin and uniform layer of setter powders on a green ceramic article after burnout of a binder in the sheet. Because of high strength and low burnout temperature, hydroxypropyl methylcellulose binder is preferred for production of these sheets. Tape cast sheets with low solids loading can be obtained by optimizing the wetting behavior of aqueous slurries on tape carrier. Setter, powder deposition sheets are of particular benefit in processing of thin ceramic tapes, particularly for processing of piezoelectric ceramic tapes. Tapes can be processed in a sandwich formed by layering setter powder deposition sheets between tapes and cover plates employed to maintain tape flatness and to reduce evaporation of volatile components of the ceramic.Type: GrantFiled: December 28, 1999Date of Patent: September 10, 2002Assignee: University of WashingtonInventors: Fatih Dogan, Jian-Huei Feng, Lucian G. Ferguson
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Patent number: 6403020Abstract: A method for firing a ceramic core includes placing the ceramic core on a setter, placing at least one flexible refractory bag containing refractory particulates on the core to apply a force on the core toward the setter during firing, and then heating the ceramic core on the setter to an elevated superambient firing temperature. Heating of the ceramic core with the flexible weight bag(s) thereon conforms the core to a surface of the setter to reduce distortion of the core and improve yields of cores within preselected dimensional tolerances.Type: GrantFiled: August 7, 2001Date of Patent: June 11, 2002Assignee: Howmet Research CorporationInventors: Mark A. Altoonian, Randall D. Runions
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Publication number: 20020050669Abstract: The present invention provides a production process of a hexagonal honeycomb structure having low deformation of hexagonal cells. This process comprises an extrusion step for obtaining moldings (7) in which partitions (71) are provided in the form of a hexagonal matrix by extrusion molding of a mixed raw material using a horizontal extruder having an extrusion die provided with slits in the form of a hexagonal matrix and in which the direction of extruding is substantially the horizontal direction, a drying step for drying moldings (7), and a baking step for baking moldings (7). The extrusion step is performed such that c axis (700) parallel to two parallel sides (702) and (705) of the six sides (701) through (706) of each hexagon formed by partitions (71) of extruded moldings (7) is substantially vertical relative to the horizontal plane.Type: ApplicationFiled: September 5, 2001Publication date: May 2, 2002Inventors: Takasi Obata, Yosiyasu Andou, Kazuhiko Yasuda
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Patent number: 6352669Abstract: The invention utilizes green support structures during sintering to maintain the shape, reduce sagging and prevent separate part sections from coming into contact and fusing together during the sintering process. In the most preferred embodiment, monolithic green structures are form with integrated support green structures that are released from the parts after sintering. Preferably monolithic green structures are formed by the Mold Shape Deposition Manufacturing (Mold SDM) process. By the method described, complex sintered structures can be made having interlocking and independently movable interlocking parts.Type: GrantFiled: October 22, 1999Date of Patent: March 5, 2002Assignee: The Board of Trustees of the Leland Stanford Junior UniversityInventors: Alexander Cooper, Friedrich Prinz
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Patent number: 6309590Abstract: The present invention provides a production process of a hexagonal honeycomb structure having low deformation of hexagonal cells. This process comprises an extrusion step for obtaining moldings (7) in which partitions (71) are provided in the form of a hexagonal matrix by extrusion molding of a mixed raw material using a horizontal extruder having an extrusion die provided with slits in the form of a hexagonal matrix and in which the direction of extruding is substantially the horizontal direction, a drying step for drying moldings (7), and a baking step for baking moldings (7). The extrusion step is performed such that c axis (700) parallel to two parallel sides (702) and (705) of the six sides (701) through (706) of each hexagon formed by partitions (71) of extruded moldings (7) is substantially vertical relative to the horizontal plane.Type: GrantFiled: August 11, 1999Date of Patent: October 30, 2001Assignee: Denso CorporationInventors: Takasi Obata, Yosiyasu Andou, Kazuhiko Yasuda
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Patent number: 6165936Abstract: An alumina-based porous support with uniform physical properties is obtained in a rapid sintering process. An alumina raw material including a raw alumina powder and an inorganic binder is molded into an article, and the article is then sintered for 5 to 8 hours at 1520 to 1560.degree. C. using a roller hearth kiln.Type: GrantFiled: July 23, 1998Date of Patent: December 26, 2000Assignee: Noritake Co., Ltd.Inventors: Takao Yamada, Kazuhito Tsumuki
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Patent number: 6126887Abstract: A method of manufacturing a ceramic arc chamber (420) comprising providing a sintering tray (412) including a plurality of bores (422). The bores (422) having a first diameter upper section (424) and a second narrower diameter lower section (426). Positioning a plurality of ceramic end caps (212) having a main body portion (216), and a leg portion (219) in the bores (422) such that the leg portion (219) passes downwardly through the narrower diameter lower section (426) and the main body portion (216) is retained within the upper section (424). Moreover, the second diameter lower section (426) acts as a shoulder supporting the end cap (210). Next, a ceramic arc tube (214) is positioned within the first diameter upper section (424) and mated with the ceramic end cap (212). A second end cap (210) is mated to a second upper open end of the ceramic arc tube (214) to form an arc tube preform (420). The arc tube preforms (420) are then sintered to join the components via controlled shrinkage.Type: GrantFiled: July 30, 1999Date of Patent: October 3, 2000Assignee: General Electric CompanyInventors: Lisa Mason Ward, Curtis E. Scott, J. Robert Woodward
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Patent number: 6013224Abstract: A method for producing a long ceramic body with lower shape fluctuations and higher shape accuracy, by controlling the deformation of the long ceramic body, includes firing a long non-sintered ceramic body which has been suspended in a sheath so as not to contact directly the interior surface of the sheath, at a sufficient temperature and for a sufficient time until sintering is completed; inverting the long body; and re-firing the long body at a sufficient temperature for re-sintering the same. A predetermined downward load is applied to the long body in the vicinity of the bottom thereof during re-firing.Type: GrantFiled: December 10, 1997Date of Patent: January 11, 2000Assignee: NGK Insulators, Ltd.Inventor: Mitsuru Hattori
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Patent number: 5980788Abstract: The invention aims at providing highly reliable zinc oxide varistors through simple production steps. The varistor is produced by dispersing a powdery raw material comprising 1-40 molar % (in terms of Fe.sub.2 O.sub.3) iron, 0-20 molar % (in terms of Bi.sub.2 O.sub.3) bismuth, and the balance consisting of SiO.sub.2 in a solution of a water-soluble binder such as polyvinyl alcohol, and applying the formed dispersion to a molded or calcined zinc oxide varistor to form on the lateral face thereof a lateral high-resistance layer (2) containing Zn.sub.2 SiO.sub.4 as the principal ingredient and a solid solution of iron in Zn.sub.7 Sb.sub.2 O.sub.12 as the auxiliary ingredient.Type: GrantFiled: February 20, 1998Date of Patent: November 9, 1999Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Masaaki Katsumata, Osamu Kanaya
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Patent number: 5961917Abstract: A method for producing a long ceramic body, including the steps of pre-firing a non-fired long ceramic body at a first temperature for a sufficient time to achieve a shrinkage ratio in the body of 5% to 95%, thereby forming a pre-fired ceramic body, hanging the pre-fired ceramic body in a substantially vertical direction inside a sheath while maintaining a spacing between the pre-fired ceramic body and the sheath, applying a downward load to the pre-fired ceramic body at a position proximate the bottom end thereof, and firing the pre-fired body at a second temperature for a sufficient time to sinter the pre-fired ceramic body.Type: GrantFiled: February 10, 1998Date of Patent: October 5, 1999Assignee: NGK Insulators, Ltd.Inventor: Mitsuru Hattori
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Patent number: 5935513Abstract: A method for sintering tube pre-forms in an furnace for obtaining ceramic tubes which are extremely straight is provided, in which, during sintering, the tube preforms are placed inside supporting tubes in ceramic material, the support tubes 1 containing the tube preforms being arranged parallel to each other forming stacks 7 of layers 3 supported by support plates 4 in a refractory material, the inside surface of the support tubes being out-of-true by less than 0.1 mm over a length of 90 mm.Type: GrantFiled: January 14, 1998Date of Patent: August 10, 1999Assignee: Societe des Ceramiques TechniquesInventors: Martial Martreuil, Jacques Gillot, Phillippe Henneguez
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Patent number: 5814262Abstract: Thin inorganic sintered structures having strength and flexibility sufficient to permit bending without breakage in at least one direction to a radius of curvature of less than 20 centimeters, methods for making them, and products incorporating them, are described. Preferred sintered ceramic structures according to the invention can comprise zirconias, titanias, aluminas, silicas, rare earth metal oxides, alkaline oxides, alkaline earth metal oxides and first, second, and third transition series metal oxides and combinations thereof and therebetween. Sintered metal structures can also be provided.Type: GrantFiled: October 21, 1992Date of Patent: September 29, 1998Assignee: Corning IncorporatedInventors: Thomas D. Ketcham, Wayne B. Sanderson, deceased, by Stuart R. Sanderson, administrator, Dell J. St. Julien, Kathleen A. Wexell
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Patent number: 5804131Abstract: The present invention is a method of preparing a ceramic article which includes compacting a particulate alloy of a primary oxide and a secondary oxide to form a blank. The primary oxide is zirconium oxide and the secondary oxide is selected from MgO, CaO, Y.sub.2 O.sub.3, Sc.sub.2 O.sub.3,CeO.sub.2 and rare earth oxides and combinations thereof. The blank is sintered in contact with a smectite containing sol.Type: GrantFiled: October 7, 1997Date of Patent: September 8, 1998Assignee: Eastman Kodak CompanyInventors: Debasis Majumdar, Dilip K. Chatterjee, Syamal K. Ghosh
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Patent number: 5804132Abstract: A method for firing a green ceramic compact including: placing a casing containing a green ceramic compact into a firing tube made of a highly heat-conductive material provided in a furnace so as to substantially close the casing; firing the green ceramic compact; cooling the fired ceramic compact by directly exposing the outer surface of the firing tube; and removing the casing from the firing tube, is described. Also described is a firing apparatus for a green ceramic compact including: a furnace; and a firing tube provided in the furnace with a given space from the side wall of the furnace. The bottom end of the firing tube can be placed on a first stage loaded with a casing containing the green ceramic compact so as to substantially close the casing, the firing tube having a space for firing the green ceramic compact therein and being formed from a highly heat-conductive material.Type: GrantFiled: March 20, 1997Date of Patent: September 8, 1998Assignee: Murata Manufacturing Co., Ltd.Inventor: Toshinori Kawahara
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Patent number: 5725826Abstract: The ceramic cooking container fabricating method of the invention includes the steps of: (a) material preparation to prepare material from clay; (b) shape pressing to prepare a green cooking container and a green annular supporting cushion from the material thus obtained and to cover the green cooking container with a layer of glaze; and (c) firing to make an annular groove on the bottom side of the green cooking container, then to put the green annular supporting cushion and the green cooking container on the silicon carbide plate in a kiln, permitting the annular groove of the green cooking container to be supported on the green annular cushion, and then to fire the green cooking container and the green annular supporting cushion at about 135.degree. C. for a predetermined length of time, and then to fasten electrically conductive annular membranes to the bottom side of the cooking container so as to obtain a finished ceramic cooking container.Type: GrantFiled: May 17, 1996Date of Patent: March 10, 1998Inventor: Goh Kim Guan