Inorganic Fiber Patents (Class 264/DIG19)
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Patent number: 6148641Abstract: An apparatus and method for producing dried, chopped strands from a supply of continuous fiber strands by the direct deposition of wet, chopped strands ejected from a chopping assembly into a drying chamber is disclosed. A transition chute is interposed between the chopping assembly and the drying chamber to guide the chopped strands to pass directly into the drying chamber.Type: GrantFiled: December 18, 1998Date of Patent: November 21, 2000Assignee: PPG Industries Ohio, Inc.Inventors: John R. Blough, Jerry B. Noftsger, Ronald L. Hawkins
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Patent number: 6103178Abstract: The present invention relates to a method for the formation of amorphous boron silicon oxycarbide fibers and crystalline boron-doped silicon carbide fibers wherein the method comprises preparing a blend of a siloxane resin and a carborane-siloxane oligomer, forming the blend into green fibers, and then curing and pyrolyzing the fibers.Type: GrantFiled: February 2, 1999Date of Patent: August 15, 2000Assignee: Dow Corning CorporationInventors: Duane Ray Bujalski, Kai Su
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Patent number: 6068803Abstract: A method of making a building block from waste particulate siliceous materials, such as fly ash, bottom ash, and rock mineral fines, includes employing a major amount of such waste particulate materials in combination with a calciferous additive and water to cure and shape the same under the influence of controlled pressure and temperature for a predetermined time to create building block which is characterized by a mineralogical crystalline phase. Preferred ratios of fine waste particulate material and coarser waste particulate materials are disclosed. The product produced by the method is also disclosed.Type: GrantFiled: February 18, 1998Date of Patent: May 30, 2000Assignee: Pittsburgh Mineral and Enviromental Technology, Inc.Inventors: Thomas E. Weyand, Casimir J. Koshinski, Wolfgang Baum
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Patent number: 6043172Abstract: A ceramic fiber insulation material is disclosed. It is prepared from a precursor blend generally comprising a gelled colloid and a ceramic fiber filler. Other filler, e.g., other fiber of refractory material, is contemplated, particularly when mixed with ceramic fiber. The gelled colloid ban be formed such as by mixing a gelling agent with a colloid of inorganic oxide or by blending anionic colloid with cationic colloid. The gelling agent is typically nonionic and water-soluble. The blend is trowelable, pumpable and possesses excellent adhesive characteristics including the ability to stick to most surfaces, including metal surfaces. The blend is also virtually shrink-free during drying and, after drying, can provide the insulation material.Type: GrantFiled: January 14, 1998Date of Patent: March 28, 2000Assignee: Global Consulting, Inc.Inventor: Charles M. Hart
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Patent number: 6022820Abstract: Silicon carbide (SiC) fibers, or SiC bodies such as coatings, thin films, substrates or bulk objects, which have been sintered with boron containing additives to promote densification and pore removal, are further treated to remove a substantial amount of the residual boron from the SiC fibers. The SiC fibers, subsequent to the sintering steps and either before or after cooling, are exposed to a carbon monoxide (CO) containing atmosphere at elevated temperatures from approximately 1600-2200.degree. C., but more preferably from approximately 1700-2000.degree. C., with treatment times ranging from seconds to hours to days depending on the chosen treatment temperature. The resulting SiC fibers show a significant reduction of residual boron content, a reduction of greater than 90% in some cases, while retaining high tensile strength. Fibers with less than 0.1 wt % residual boron have been obtained.Type: GrantFiled: May 21, 1998Date of Patent: February 8, 2000Assignee: University of FloridaInventor: Michael D. Sacks
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Patent number: 5976718Abstract: A premix composition for producing an inorganic solid foamed mass by mixing component (A) an aqueous acidic phosphate solution of mainly polyvalent cations and phosphoric acid wherein between 0.8 and 1.75 protons of the phosphoric acid molecule of said phosphate are neutralized by the cations, which also contains one or more fillers dispersed therein, with (B) an oxide, hydroxide or polyvalent salt of a weak acid as hardener and a carbonate foaming agent. A process of producing an inorganic foamed mass using the premix composition and a solid foamed mass produced by the process are also disclosed. The process produces a relatively elastic cross-linked structure due to mainly the secondary phosphates being neutralized versus the tertiary phosphate groups.Type: GrantFiled: June 29, 1998Date of Patent: November 2, 1999Inventor: Gerhard Melcher
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Patent number: 5958324Abstract: The present invention relates to a method for the formation of amorphous boron silicon oxycarbide fibers and crystalline boron-doped silicon carbide fibers comprising: preparing a blend of a siloxane resin and a boron-containing polymer, forming the blend into green fibers, and then curing and pyrolyzing the fibers.Type: GrantFiled: February 6, 1998Date of Patent: September 28, 1999Assignee: Dow Corning CorporationInventors: Duane Ray Bujalski, Kai Su
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Patent number: 5911944Abstract: A method for the production of a fiber comprises a first step of dispersing a raw material containing at least one of a metal hydrate and a hydrated metal compound in an alcohol-based solvent having a boiling point of not lower than 70.degree. C. thereby preparing a sol solution, a second step of heating the sol solution obtained in the first step at a temperature of not higher than 100.degree. C. thereby polymerizing the raw material and effecting conversion thereof to a complex and subsequently concentrating the complex until it manifests spinnability, a third step of stretching the sol solution obtained at the end of the second step into a fiber precursor thereby effecting gelation thereof, and a fourth step of heating the gelatinized fiber precursor thereby producing a fiber.By this method of production, a fiber of homogeneous and dense metal oxide having a high assay is obtained without inducing such impurities as precipitate in the course of manufacture.Type: GrantFiled: June 30, 1997Date of Patent: June 15, 1999Assignee: Minolta Co., Ltd.Inventor: Kenji Kitaoka
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Patent number: 5851942Abstract: A method of preparing polymer derived silicon fibers comprising the steps of providing a spin dope solution comprising a silicon carbide forming organosilicon polymer, preferably polycarbosilane, a solvent, a soluble boron precursor, preferably solid boron hydride, and a nitrogen containing precursor, preferably polyvinylsilazane; spinning the solution to form high strength green fibers; and heat treating the green fibers to produce high strength, homogeneously doped, boron containing fibers. The fibers produced are high strength, homogeneously boron doped silicon carbide fibers with average tensile strength in the range of from about 2.0 to 4.0 GPa at room temperature.Type: GrantFiled: August 20, 1997Date of Patent: December 22, 1998Assignee: University of FloridaInventors: Michael D. Sacks, William Toreki, Christopher D. Batich, Guang J. Choi
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Patent number: 5783139Abstract: A ceramic fiber is made by spinning a plurality of polymeric materials each including at least one ceramic precursor into a composite fiber, and then pyrolysing the composite fiber to form a composite ceramic fiber of non-homogeneous composition. A preferred ceramic material for use in this method is made by pyrolysing an organo-metallic compound dispersed in an organic polymer carrier. The principal products are tailored matrix-compatible ceramic fibers for reinforcements, and have a core-sheath structure made by coaxial spinning methods. A core of desired mechanical properties, such as silicon carbide, is given a chemically appropriate surface layer. Transition metals compounds are preferred, in a range of organo-metallic ceramic precursors that include carborane derivatives. Allowed additives include metal-silicon compounds, other ceramics, corresponding metal oxides and elementary metals.Type: GrantFiled: January 17, 1995Date of Patent: July 21, 1998Inventor: Dennis John Gerard Curran
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Patent number: 5743932Abstract: A method of making an insulation product of hollow fibers whereby molten insulation material is centrifuged through a plurality of orifices and gas is directed into the molten insulation material through a plurality of gas conduits, wherein each gas conduit directs gas into one of the portions of the molten insulation material being centrifuged through one of the orifices to form a hollow fiber having a hollow bore formed therethrough. The hollow fibers are combined to form the insulation product.Type: GrantFiled: June 7, 1995Date of Patent: April 28, 1998Assignee: Owens-Corning Fiberglas Technology Inc.Inventors: Ronald A. Houpt, Larry J. Huey, David C. K. Lin
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Patent number: 5707584Abstract: In order to produce ceramic hollow fibers, in particular hollow fiber membranes for microfiltration, ultrafiltration and gas separation, a paste is made filling a polymer binder system with a ceramic powder. The paste is processed by extruding through a spinneret to give hollow fibers. The binder system is removed with the aid of thermal diffusion and the powder particles are sintered to each other.Type: GrantFiled: November 29, 1995Date of Patent: January 13, 1998Assignee: Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek TnoInventors: Rinse Alle Terpstra, Joost Petrus Gerardus Maria Van Eijk, Frits Kornelis Feenstra
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Patent number: 5614452Abstract: Asbestos cement may be converted to a harmless product by melting at a melt temperature of 1400.degree. to 1700.degree. C. a blend of 50 to 85% by weight asbestos cement with 15 to 50% by weight of additives that include naturally occurring silicate material such that the total blend has a CaO content of not more than 50%. The melt is discharged from the furnace, cooled and solidified and may be used as aggregate or, generally after solidification as regular units, may be used as part or all of the charge for producing MMV fibre material. It is of particular value for the production of man made vitreous fibre material that has low alumina content and is soluble in lung fluids.Type: GrantFiled: September 8, 1995Date of Patent: March 25, 1997Assignee: Rockwool International A/SInventors: Anders U. Clausen, Vermund R. Christensen, Soren L. Jensen
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Patent number: 5525558Abstract: A process for producing a carbon fiber reinforced carbon composite material, comprising dispersing a short fibrous bundle of carbon fibers which comprises a plurality of single fibers, preparing a sheet in which fibers are in the two-dimensional random orientation, impregnating with a resin or pitch, laminating and molding, and then applying a baking and densifying treatment, a dispersion degree of the bundle of carbon fibers being controlled based on the formula (1) expressing correlation between the dispersion degree of the bundle of carbon fibers and the mechanical strength of the carbon fiber reinforced composite material:Dispersion degree=A-B.times.coefficient of friction (1)wherein A and B are constants determined experimentally, to produce a carbon fiber reinforced carbon composite material having desired mechanical characteristic.Type: GrantFiled: March 17, 1994Date of Patent: June 11, 1996Assignee: Mitsubishi Chemical CorporationInventors: Kazuo Niwa, Toshihiro Fukagawa, Nobuyuki Oonishi, Takeo Matsui, Yutaka Kawamata, Hitoshi Seki
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Patent number: 5501788Abstract: This invention provides a process for preparing a solvated isotropic pitch having a fluid temperature at least 40.degree. C. lower than the same pitch in the non-solvated state. Additionally, the present invention provides a solvated isotropic pitch which may be formed into carbon artifacts which do not require oxidative stabilization prior to carbonization.Type: GrantFiled: June 27, 1994Date of Patent: March 26, 1996Assignee: Conoco Inc.Inventors: H. Ernest Romine, Edward J. Nanni, Mark W. Carel, W. Mark Southard
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Patent number: 5417889Abstract: A method for making a filter aid for tangled short-length ceramic fibers having a bulk density in the range of about 0.02-0.18 g/cm.sup.3 includes cutting long ceramic fibers in water, dehydrating, forming small masses, and then heating to provide constant weight masses.Type: GrantFiled: February 2, 1993Date of Patent: May 23, 1995Assignee: Kabushiki Kaisha Hayashibara Seibutsu Kagaku KenkyujoInventors: Masanori Akiba, Masahiro Kida, Shoichi Hamada
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Patent number: 5407619Abstract: A spinning nozzle for dry spinning a spinning solution containing a metal compound and an organic polymer compound by a blowing method. In the spinning nozzle, an air nozzle 6 is provided having a rectangular-prism-like slit which is formed by opposing inner surfaces, extending in parallel to each other. The opposing inner surfaces each include a projecting portion, which are formed at the front side of a pair of cover plates 1,1, with each of the projecting portions having a knife edge portion at its free end. Spinning solution supplying nozzles are composed of a plurality of linear pipes and are arranged in the air nozzle 6 in such a manner that they are in parallel to the parallel surfaces of the cover plates and project from the edges of the parallel surfaces. Air fed through a gas feeding port 5 and blown out as an air stream from the air nozzle 6, and streams of the spinning solution extruded from the spinning solution supplying nozzles form parallel streams.Type: GrantFiled: October 6, 1993Date of Patent: April 18, 1995Assignee: Mitsubishi Kasei CorporationInventors: Hiroshi Maeda, Mamoru Shoji
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Patent number: 5369064Abstract: This invention relates to a shaped fibrous material for use in the manufacture of fiber-reinforced metals comprising a uniform mixture of ceramic fibers and aluminum borate whiskers. The invention also relates to a method for producing the shaped fibrous material comprising the steps of dispersing ceramic fibers and aluminum borate whiskers in a suitable solvent containing a binder to form a slurry, transferring the slurry into a suction molding, aspirating and dehydrating the slurry to form a shaped dehydrated fibrous material, and drying and firing the shaped dehydrated fibrous material to obtain the shaped fibrous material. The shaped fibrous material can be cast efficiently into a fiber-reinforced metal with a high yield. The thus produced fiber-reinforced metal has a high wear resistance combined with a very mild nature of attacking the mating member.Type: GrantFiled: May 27, 1992Date of Patent: November 29, 1994Assignees: Nichias Corporation, Nissan Motor Co., Ltd.Inventors: Takayuki Ohashi, Kenichi Shibata, Junichi Ogawa, Mitsushi Wadasako
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Patent number: 5358674Abstract: Ceramic SiCO fibers are formed by spinning a mixture of a substantially linear polysiloxane fluid having unsaturated hydrocarbon substituents and a photoinitiator into a fiber, exposing the fiber to radiation, and heating the fiber in an inert environment to a temperature above about 800.degree. C.Type: GrantFiled: March 18, 1993Date of Patent: October 25, 1994Assignee: Dow Corning CorporationInventor: James A. Rabe
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Patent number: 5340515Abstract: A method for preparing polycrystalline lithium metal oxide fibers of the formula Li.sub.x M.sub.y O.sub.z by filling micromold fibers of a desired inner diameter and length with a mixture composed of the desired metal salts or solutions of salts or alkoxides, solvents, binders, plasticizers, and deflocculants, firing the filled micromold fibers at elevated temperatures but below temperatures of lithium oxide volatilization in air for at least one hour to simultaneously burn-out the micromold and yield the polycrystalline lithium metal oxide fiber.Type: GrantFiled: August 10, 1992Date of Patent: August 23, 1994Assignee: FMC CorporationInventors: Charles C. Fain, Gregory M. Lowe, Teresita N. C. Frianeza-Kullberg, Daniel P. McDonald
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Patent number: 5340511Abstract: A method of producing carbon fiber includes the steps of providing a solution of a coal-derived material in a solvent, typically dimethylformamide, adding polyethylene oxide having a molecular weight of at least 3.times.10.sup.6 daltons to the solution to provide a spinning solution, spinning the spinning solution into a fiber and causing the fiber to gel, typically by contacting it with a gelling solvent. The coal-derived material will have a composition, free of solvent, of 70 to 91 percent by mass of carbon, 2 to 6 percent by mass of hydrogen and 3 to 20 percent by mass of oxygen.Type: GrantFiled: August 16, 1993Date of Patent: August 23, 1994Assignee: Enerkom (Proprietary LimitedInventors: David L. Morgan, Vladimir Cukan, Klaus Frielingsdorf
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Patent number: 5320791Abstract: Molded articles of high-purity alumina fibers, which are porous materials in which heat resistance is high, and in particular, deformation and linear shrinkage in heat cycles at a temperature more than 1700.degree. C. are small. The production method comprising spinning a spinning solution containing an alumina fiber precursor as the main component to obtain precursor fibers, prefiring these precursor fibers at 400.degree. to 1000.degree. C. to form prefired fibers, and then molding and calcining these prefired fibers. Sintering between the fibers can be achieved at a relatively low temperature. In particular, even when no inorganic binder component is added, the molded articles of high-purity alumina fibers can be obtained by a simple process.Type: GrantFiled: April 28, 1992Date of Patent: June 14, 1994Assignee: Mitsui Mining Company, LimitedInventors: Yoshiaki Saitou, Shigeyuki Date, Shinpei Nonaka, Takashi Shinbo, Hiroshi Nakamura
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Patent number: 5290502Abstract: A rigidized fiber filter element is produced from a precursor fiber web. The precursor fiber web contains heat-shrinkable fibers or binder fibers or both. The web is exposed to temperatures sufficiently elevated to cause shrinkage of the fibers or melting of the binder. After cooling the web, the filter elements produced are self-supporting, and may have densities up to 500 kg/m.sup.3 to improve filtration while retaining good functional characteristics for operating pressure drop and air permeability. Rigidized fiber filter elements can be constructed of one material, and thus may be suitable for recycling.Type: GrantFiled: September 25, 1992Date of Patent: March 1, 1994Assignee: Albany International Corp.Inventors: Andrew B. Jeffery, George Bakis, John Skelton
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Patent number: 5238742Abstract: The present invention relates to ceramic fibers of the Si-C-N-O series with a diameter less than about 20 micrometers. It has been unexpectedly found that the thermal stability of these fibers can be increased by minimizing the impurity content, primarily the content of metals or metallic compounds. Such fibers with low levels of contaminants retain greater than about 60 percent of their initial tensile strength when subjected to temperatures of 1300.degree.-1400.degree. C. for at least 30 minutes in a non-oxidative environment.Type: GrantFiled: December 16, 1991Date of Patent: August 24, 1993Assignee: Dow Corning CorporationInventors: Harvey A. Freeman, Neal R. Langley, Chi-Tang Li, Jonathan Lipowitz, James A. Rabe
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Patent number: 5223461Abstract: The present invention concerns novel high strength ceramic fibers derived from boron, silicon, and carbon organic precursor polymers. The ceramic fibers are thermally stable at and above 1200.degree. C. in air. The method for preparation of the boron-silicon-carbon fibers from a low oxygen content organosilicon boron precursor polymers of the general formula Si(R.sub.2)BR.sup.1 by melt-spinning, crosslinking and pyrolysis. Specifically, the crosslinked (or cured) precursor organic polymer fibers do not melt or deform during pyrolysis to form the silicon-boron-carbon ceramic fiber. These novel silicon-boron-carbon ceramic fibers are useful in high temperature applications because they retain tensile and other properties up to 1200.degree. C., from 1200.degree. to 1300.degree. C., and in some cases higher than 1300.degree. C.Type: GrantFiled: May 11, 1992Date of Patent: June 29, 1993Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Salvatore R. Riccitiello, Ming-ta S. Hsu, Timothy S. Chen
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Patent number: 5190820Abstract: An oxide barrier coating for a reinforcing fiber is provided with a preselected microstructure and thickness through control of the concentration of metal salt in heat decomposable form as a precursor of metal oxide. In one form, the salt is a metal oxyhalide salt such as zirconium oxyhalide or hafnium oxyhalide. Fibers, such as ones of alumina, aluminasilicate or silicon carbide, having the coating of the invention are especially useful as reinforcing fibers for reinforced ceramic matrix composites.Type: GrantFiled: March 1, 1991Date of Patent: March 2, 1993Assignee: General Electric CompanyInventors: Michael L. Millard, Michael G. Harrison, Andrew Szweda
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Patent number: 5166130Abstract: A superconductive ceramic wire or film comprises 100 parts by weight of superconductive oxide crystal composed of a rare earth element, an alkaline earth metal, copper, and oxygen, and 0.2-5.0 parts by weight of copper oxide, thereof.Type: GrantFiled: June 30, 1988Date of Patent: November 24, 1992Assignee: Ibiden Co. Ltd.Inventors: Ryo Enomoto, Yoshimi Matsuno
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Patent number: 5151390Abstract: Inorganic fibers having a high strength and a high modulus of elasticity at a high temperature are provided. The inorganic fibers are amorphous inorganic silicon nitirde-based fibers composed of silicon and nitrogen, optionally with oxygen, carbon and hydrogen, and having atomic ratio between above respective elements of N/Si=0.3 to 3, O/Si=up to 15, C/Si=up to 7 and H/Si=up to 15, wherein ratios of X-ray scattering intensity thereof to that of air at 1.degree. and 0.5.degree. are from 1 to 20 respectively and the silicon nitride-based fiber is still amorphous after heating in an inactive atmosphere at 1200.degree. C. for 1 hour. Composites of a metal, a ceramics, and a high molecular weight organic compound reinforced with the above fibers are also provided.Type: GrantFiled: July 18, 1991Date of Patent: September 29, 1992Assignee: Toa Nenryo Kogyo Kabushiki KaishaInventors: Hiroyuki Aoki, Tadashi Suzuki, Toshio Katahata, Mutsuo Haino, Genshiro Nishimura, Hiroshi Kaya, Kozaburo Tamura, Takeshi Isoda
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Patent number: 5145625Abstract: Shaped articles are produced from a finely particulate material as aggregate and an aqueous binder preparation containing an acrylate polymer by moistening the aggregate with the binder preparation, making it into the desired shape and then drying it, using a binder preparation whose binder is an acrylate polymer whose glass transition range is relatively high and which is formed from (A) a predominant amount of methyl methacrylate, (B) a minor amount of (meth) acrylic acid, (C) a minor amount of an optional alkyl acrylate and (D) a small optional amount of another specific polymerizable compound.Type: GrantFiled: June 12, 1991Date of Patent: September 8, 1992Assignee: BASF AktiengesellschaftInventors: Bernhard Dotzauer, Wilhelm F. Beckerle, Hans-Juergen Denu, Kurt Wendel, Manfred Schwartz
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Patent number: 5135895Abstract: A high temperature, preferably polycrystalline, ceramic fiber having a selectable diameter of between 1 and 200 microns. The fiber is stable in an inert atmosphere at a temperature above about 1700.degree. C. and is often stable even in air at a temperature above 1500.degree. C. The fiber comprises a sintered ceramic powder having a maximum particle size less than the diameter of the fiber and an average particle size less than 0.2 times the diameter of the fiber. The ceramic powder is also stable in an inert atmosphere at a temperature above about 1700.degree. C. At least 90% of the ceramic is selected from borides, nitrides, carbides, and silicides. The fiber is characterized by a smooth surface and is preferably out of round.The invention further comprises a textilable sinterable filament, comprising a flexible polymer matrix containing high temperature sinterable ceramic powder particles. The ceramic powder particles are selected from ceramic borides, nitrides, carbides, and silicides.Type: GrantFiled: January 23, 1991Date of Patent: August 4, 1992Assignee: The Standard Oil CompanyInventors: Francis J. Frechette, Wolfgang D. G. Boecker, Carl H. McMurtry, Martin R. Kasprzyk
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Patent number: 5114887Abstract: The process of this invention for preparing oxynitride ceramic fibers comprises spinning a viscous sol obtained by the hydrolysis of a feed mainly consisting of metal alkoxides, steam-treating the gel fibers, and firing the steam-treated gel fibers in a stream of ammonia and is commercially useful for the production of oxynitride fibers with excellent hardness, strength, modulus of elasticity, heat resistance, and corrosion resistance.Type: GrantFiled: April 19, 1991Date of Patent: May 19, 1992Assignee: Colloid Research InstituteInventors: Masahiro Sekine, Shingo Katayama
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Patent number: 5112781Abstract: Zirconium based granules are produced by the steps of forming an aqueous solution of a zirconium compound such as zirconium acetate, combining the aqueous solution with a phase stabilizer, and then heating the solution to evaporation thereby forming amorphous zirconium based granules.In an alternate embodiment, an alcohol solution of a zirconium compound such as zirconium propoxide in propanol is acidified and hydrolyzed with water. The partially or fully hydrolyzed zirconium complex is mixed with a phase stabilizer to form a homogeneous solution. The solution is then subjected to evaporation by heat to form amorphous zirconium based granules.Zirconia fibers are produced by making aqueous solutions of the amorphous zirconium based granules containing the phase stabilizer to the desired viscosity, fiberizing the solution, and finally converting the fibers under appropriate conditions.Type: GrantFiled: March 6, 1991Date of Patent: May 12, 1992Assignee: Manville CorporationInventor: Sivananda S. Jada
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Patent number: 5106549Abstract: The invention relates to a process for the preparation of a shapable dough which comprises mixing and kneading a particulate titania with water and an alkanolamine or ammonia or an ammonia- releasing compound to obtain a mixture having a total solids content of from 50 to 85% by weight, the alkanolamine or ammonia being present in an amount of from 0.5 to 20% by weight on the total solids content of the mixture, to a shapable dough obtained by this process, to the preparation of titania extrudates therefrom and to their use as catalyst carriers in hydrocarbon conversion processes, in hydrogenation processes or in hydrocarbon synthesis processes.Type: GrantFiled: February 7, 1990Date of Patent: April 21, 1992Assignee: Shell Oil CompanyInventors: Jacobus T. Daamen, Hennie Schaper, Johannes A. R. Van Veen
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Patent number: 5017522Abstract: A ceramic body of controlled porosity is formed by coating unidirectional fiber carriers with a hardenable liquid resin bearing powdered ceramic material, which resin is subsequently cured, hardened, or cooled to provide a green body which may be assembled with similar layers, in a desired shape, and subsequently sintered, to form a ceramic body having continuous pores corresponding to the position of the fibers.Type: GrantFiled: July 7, 1989Date of Patent: May 21, 1991Assignee: Hexcel CorporationInventor: Andreas G. Hegedus
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Patent number: 4965038Abstract: Laminated composites including method for the preparation thereof comprising forming in combination in a mold at least one layer of a rigid polyurethane modified polyisocyanurate by reacting in said mold, a reaction mixture of an organic di- or polyisocyanate, a cyclic alkylene carbonate and a polyether polyol in the presence of a soluble adduct aminecarbonate catalyst, and at least one layer of material selected from metal, plastic, cellulose, glass and ceramic or combinations thereof. The electrically conductive "metal clad" laminates are especially usefual as printed circuit boards.Type: GrantFiled: September 15, 1989Date of Patent: October 23, 1990Assignee: Arco Chemical Technology, Inc.Inventor: Usama E. Younes
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Patent number: 4961889Abstract: A process for producing an inorganic fiber superior in stretchability, which comprises; heating either a solution of a polymetalloxane in an organic solvent, the polymetalloxane content in the solution being at least 85% by weight and the viscosity of the solution at 25.degree. C. being at least 5000 poises, or a solid state polymetalloxane to prepare a spinning liquid having a viscosity of 1 to 3000 poises; spinning the spinning liquid to form a precursor fiber; and baking the precursor fiber.Type: GrantFiled: July 28, 1989Date of Patent: October 9, 1990Assignee: Sumitomo Chemical Company, LimitedInventors: Hidekimi Kadokura, Masashi Harakawa, Nagatoshi Nogami
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Patent number: 4916093Abstract: A continuous inorganic fiber consisting of Si, N and O has excellent physical, chemical and electrically insulating properties, is superior to carbon fiber in wettability with metal, is low in reactivity with metal, and can be used not only as a reinforcing fiber for fiber-reinforcing type metals and fiber-reinforcing type ceramics, but also in electrical insulating materials and in heat-resistant materials.Type: GrantFiled: February 21, 1989Date of Patent: April 10, 1990Assignee: Nippon Carbon Co., Ltd.Inventors: Kiyohito Okamura, Mitsuhiko Sato, Yoshio Hasegawa
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Patent number: 4911781Abstract: A method for preparing substrates for VLS fiber producing reactions and a method for preparing SiC fibers by the VLS process. The first method includes the steps of forming an alcohol sol containing a fiber growth promoter material precursor, applying the sol to at least one surface of the substrate and drying the sol. More particularly, the steps can include forming a sol of colloidal hydrous metal oxide particles in a liquid, the metal oxide being a fiber growth promoter material precursor and the liquid being capable of dissolving a salt of the metal and of wetting the substrate surface as a sol, applying the sol to at least one surface of the substrate and drying the sol.Type: GrantFiled: February 16, 1989Date of Patent: March 27, 1990Assignee: The Standard Oil CompanyInventors: Joseph R. Fox, Douglas A. White
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Patent number: 4908340Abstract: A high temperature, preferably polycrystalline, ceramic fiber having a selectable diameter of between 1 and 200 microns. The fiber is stable in an inert atmosphere at a temperature above about 1700.degree. C. and is often stable even in air at a temperature above 1500.degree. C. The fiber comprises a sintered ceramic powder having a maximum particle size less than the diameter of the fiber and an average particle size less than 0.2 times the diameter of the fiber. The ceramic powder is also stable in an inert atmosphere at a temperature above about 1700.degree. C. At least 90% of the ceramic is selected from borides, nitrides, carbides, and silicides. The fiber is characterized by a smooth surface and is preferably out of round.The invention further comprises a textilable sinterable filament, comprising a flexible polymer matrix containing high temperature sinterable ceramic powder particles. The ceramic powder particles are selected from ceramic borides, nitrides, carbides, and silicides.Type: GrantFiled: July 16, 1987Date of Patent: March 13, 1990Assignee: The Standard Oil CompanyInventors: Francis J. Frechette, Wolfgang D. G. Boecker, Carl H. McMurtry, Martin R. Kasprzyk
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Patent number: 4904424Abstract: Ceramic alloys or solid solutions are formed by dispersing a powdery metal alloy or intimate mixture of two alloying metals in a precarbonaceous polymer such as polyacrylonitrile, forming the mixture into a molded article such as fibers, and heating the molded articles at a temperature and in a pyrolyzation atmosphere sufficient to carbonize the polymer and cause reaction of the metals with carbon and/or the pyrolyzation gas.Type: GrantFiled: May 29, 1987Date of Patent: February 27, 1990Assignee: Hoechst Celanese CorporationInventor: Robert E. Johnson
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Patent number: 4902442Abstract: A prereaction mixture which is useful in the preparation of porous silica compositions with uniform pore sizes. The porous silica composition comprises a substituted nitrogen-containing siliconate, a colloidal silica and a soluble alkali silicate. By the addition of the substituted nitrogen containing siliconate to either the colloidal silica or soluble silicate, or by combining all three ingredients, a stable solution results, thereby avoiding the premature polymerization of the colloidal silica upon the addition of the soluble silicate. The soluble alkali silicate can have a metal cation which is selected from the group consisting of potassium and sodium.Type: GrantFiled: October 24, 1988Date of Patent: February 20, 1990Assignee: The Dow Chemical CompanyInventor: Juan M. Garces
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Patent number: 4885120Abstract: Ceramic metal oxide fibers are made by intercalating graphitic graphite fibers with a mixture of metal chlorides and then heating the intercalated fibers to oxidize or burn off the carbon leaving a metal oxide fiber having generally the shape and structure of the graphite fiber precursors to make composite fibers, such as binary fibers of aluminum oxide-zirconium oxide and aluminum oxide-ferric oxide.Type: GrantFiled: July 5, 1988Date of Patent: December 5, 1989Assignee: The United States of America as represented by the Secretary of the Air ForceInventors: Barry W. McQuillan, George H. Reynolds
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Patent number: 4885265Abstract: A process for producing a moldable ceramic mass which comprises preparing a suspension of ceramic material in a liquid vehicle, said ceramic material being comprised of a mixture of fibers and particulates of a ceramic selected from the group consisting of aluminum oxide, beryllium oxide, silicon carbide, silicon nitride, titanium carbide, titanium diboride, zirconium carbide and zirconium diboride wherein the volume ratio of fibers to particulates ranges from about 1:5 to about 1:1, said ceramic material being present in an amount greater than about 4% by volume of the suspension, said fibers being present in an amount greater than about 2% by volume of the suspension, and removing a portion of the liquid vehicle in an amount sufficient to produce a moldable mass.Type: GrantFiled: December 22, 1986Date of Patent: December 5, 1989Assignee: General Electric CompanyInventors: William B. Hillig, Henry C. McGuigan
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Patent number: 4838914Abstract: A process for producing silica glass fibers comprising:a step of preparing a silica glass fiber spinning solution by adding a polymerization regulator to a silica sol solution obtained by the hydrolysis and condensation of a silicon alkoxide in the presence of an acid catalyst;a step of spinning the spinning solution into gel fibers by extruding the spinning solution from nozzles;a step of applying an oiling agent containing substantially no water or lower alcohol to the gel fibers;a step of forming a fiber cake by winding the oiled gel fibers on a tube or bobbin;a step of aging the gel fibers constituting the fiber cake;a step of sintering the gel fibers unwound from the fiber cake after the aging step, to form silica glass fibers.Type: GrantFiled: December 15, 1987Date of Patent: June 13, 1989Assignee: Asahi Glass Company Ltd.Inventors: Hironori Ohta, Toshiyasu Kawaguchi, Takashi Mukaiyama, Katsuhiko Matsuzaki, Junichi Ebisawa, Naoki Taneda, Daikichi Arai, Noriyuki Yoshihara, Yoshikazu Yamada, Koushiro Kunii
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Patent number: 4824623Abstract: A continuous, bicomponent, non-vitreous ceramic fiber comprises components existing in a longitudinal side by side relationship wherein each of the components is derived from the different fiber-forming precursor liquid. The precursor liquids are formed into a fiber and gelled or hydrolyzed to provide a bicomponent non-refractory green fiber. Firing the bicomponent green fibers in a reducing atmosphere can provide ceramic/cermet or cermet/cermet fibers wherein each cermet component has a graded composition.Type: GrantFiled: July 20, 1987Date of Patent: April 25, 1989Assignee: Minnesota Mining and Manufacturing CompanyInventor: George M. Rambosek
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Patent number: 4820664Abstract: Special C-shaped carbon fibers, melt spun from mesophase pitch, were used as micro-molds to form nested dual fibers and ceramic fibers. By wetting these carbon fibers in a wet chemical precursor, and subsequently heat treating, ceramic fibers of various compositions were formed. Also, through proper control, carbon-ceramic nested fibers were produced. The ceramic materials were silica, alumina, silicon carbide, hydroxyapatite, and zirconia. The ceramic fibers could be formed with non-circular transverse cross-sectional perimeters.Type: GrantFiled: January 20, 1987Date of Patent: April 11, 1989Assignee: Clemson UniversityInventor: Charles C. Fain
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Patent number: 4812271Abstract: Disclosed is a process for continuously producing highly flexible long .alpha.-alumina fibers of small diameter according to the slurry spinning technique. Also disclosed are a specific spinnable slurry containing an alumina powder having an average particles diameter of 0.1 .mu.m or less, the specific thermophysical conditions under which the slurry is spun into a multifilament yarn, and the well-balanced residence time conditions under which the multifilament yarn running as a single continuous fiber is prefired and fired to form a long .alpha.-alumina fiber.Type: GrantFiled: September 4, 1987Date of Patent: March 14, 1989Assignee: Mitsui Mining Company, LimitedInventors: Keiichiro Koba, Taizo Utsunomiya, Yoshiaki Saitow, Katsusuke Iwanaga, Michihiko Matsue, Noriaki Nishitani
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Patent number: 4801562Abstract: Refractory fibers comprising a homogeneous mixture of 60 to 95 weight percent amorphous alumina and 40 to 5 weight percent amorphous phosphorus pentoxide. The fibers optionally can contain chloride, and up to 20 weight percent carbon derived from the alumina precursor material. Other organic residues can be present. The fibers are useful in the manufacture of fireproof consumer fabrics as well as reinforcement or polymeric composites.Type: GrantFiled: May 7, 1987Date of Patent: January 31, 1989Assignee: Minnesota Mining and Manufacturing CompanyInventors: Harold G. Sowman, Tai T. Tran
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Patent number: 4800180Abstract: A shaped article is described comprising a ceramic matrix and dispersed therein in the range of 5 to 30 weight percent mechanically added silicon carbide, said article having a modulus of elasticity (E) value of at least 10 percent greater than the inherent elastic modulus value of the fully dense host matrix. The articles are useful as high temperature stable reinforcement materials in composites requiring a high modulus of elasticity.Type: GrantFiled: September 26, 1986Date of Patent: January 24, 1989Assignee: Minnesota Mining and Manufacturing CompanyInventors: Jerome W. McAllister, Lien-Huong T. Pham, Harold G. Sowman
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Patent number: 4798815Abstract: Special C-shaped carbon fibers, melt spun from mesophase pitch, were used as micro-molds to form nested dual fibers and ceramic fibers. By wetting these carbon fibers in a wet chemical precursor, and subsequently heat treating, ceramic fibers of various compositions were formed. Also, through proper control, carbon-ceramic nested fibers were produced. The ceramic materials were silica, alumina, silicon carbide, hydroxyapatite, and zirconia. The ceramic fibers could be formed with non-circular transverse cross-sectional perimeters.Type: GrantFiled: September 23, 1987Date of Patent: January 17, 1989Assignee: Clemson UniversityInventor: Charles C. Fain