And Aluminum Compound (e.g., Clay, Aluminum Oxide, Etc.) Patents (Class 501/107)
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Patent number: 11192825Abstract: Disclosed is a refractory product for casting of steel, which is capable of forming a dense surface layer which is high in terms of a slag infiltration suppressing ability and strong, in a surface region thereof efficiently or sufficiently or in an optimum state. The refractory product contains 1 mass % or more of free carbon, and 2 mass % to 15 mass % of an aluminum component as metal, with the remainder comprising a refractory material as a main composition, wherein the refractory product has a permeability of 1×10?16 m2 to 15×10?16m2.Type: GrantFiled: January 19, 2018Date of Patent: December 7, 2021Assignee: KROSAKIHARIMA CORPORATIONInventors: Tarou Makino, Shuuji Noai, Keiichirou Akamine
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Patent number: 10328484Abstract: A foundry sand comprises a blend that includes a silica sand and a zircon aggregate. The zircon aggregate exhibiting a sharp rise in linear thermal expansion coefficient in a temperature band above 1200° C. A method of casting an article in molten metal at a temperature above 1200° C. includes forming a single or multi-part mold for the article from the above-described foundry sand, admitting molten metal to the mold at a temperature such that at least one or more regions of the foundry sand in contact with the admitted metal are heated to a temperature within the temperature band, and cooling the mold and metal to obtain a cast article.Type: GrantFiled: April 7, 2016Date of Patent: June 25, 2019Assignees: Iluka Resources Limited, University of Northern Iowa Research FoundationInventors: Gerard Thiel, Sairam Ravi
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Patent number: 8859445Abstract: The present invention relates to a molten, fluid refractory product comprising, in weight percentages on the basis of the oxides and for a total of 100% of the oxides: ZrO2+Hf2O: remainder to 100% 4.5%<SiO2<6.0% Al2O3<0.80% 0.3%<B2O3<1.0% Ta2O5+Nb2O5<0.15% Na2O+K2O<0.1% K2O<0.04% CaO+SrO+MgO+ZnO+BaO<0.4% P2O6<0.05% Fe2O3+TiO2<0.55% other oxide species, optionally including Y2O3: <1.5%, where Y2O3<0.3%, the “A/B” ratio of Al2O3/B2O3 content by weight being 0.5 to 2.0. The invention can be used in glass melting furnaces.Type: GrantFiled: January 28, 2011Date of Patent: October 14, 2014Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Isabelle Cabodi, Michel Gaubil
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Patent number: 8822362Abstract: The present invention relates to a molten, fluid refractory product comprising, in weight percentages on the basis of the oxides and for a total of 100% of the oxides: ZrO2+Hf2O: remainder to 100% 4.0%<SiO2<6.5% Al2O3?0.75% 0.2%<B2O3<1.5% 0.3%<Ta2O5 Nb2O5+Ta2O5<1.4% Na2O+K2O<0.2% BaO<0.2% P2O5<0.15% Fe2O3+TiO2<0.55% other oxide species: <1.5% the “A/B” ratio of Al2O3/B2O3 content by weight being no higher than 1.50. The invention can be used in glass melting furnaces.Type: GrantFiled: January 28, 2011Date of Patent: September 2, 2014Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Isabelle Cabodi, Michel Gaubil
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Patent number: 8796167Abstract: The invention relates to a molten cast refractory product comprising, in weight percentages on the basis of the oxides and relative to a total of 100% of the oxides: ZrO2+Hf2O is the remainder making up 100%, 4.5%<SiO2<6.0%, 0.80%?Al2O3<1.10%, 0.3%<B2O3<1.5%, Ta2O5+Nb2O5<0.15%, Na2O+K2O<0.1%, K2O<0.04%, CaO+SrO+MgO+ZnO+BaO<0.4%, P2O5<0.05%, Fe2O3+TiO2<0.55%, and other oxide species <1.5%, the “A/B” ratio of the Al2O3/B2O3 contents by weight being between 0.75 and 1.6. The invention can be applied to glass melting furnaces.Type: GrantFiled: January 28, 2011Date of Patent: August 5, 2014Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Isabelle Cabodi, Michel Gaubil
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Patent number: 8765620Abstract: A fused and cast refractory product containing, in weight percentages on the basis of the oxides and for a total of 100%: ZrO2: remainder up to 100% Hf2O: <5% SiO2: 2% to 10% 0.9%<Y2O3+CeO2+CaO+MgO?4.0% B2O3: ?4.5% B2O3: ?0.09×(Y2O3+?(CeO2+CaO+MgO))×SiO2 Al2O3: 0.3% to 2.0% Na2O+K2O: ?0.5% P2O5: <0.05% Fe2O3+TiO2: <0.55% other species: <1.0%, as long as the Y2O3 content is no lower than 0.5% and the CeO2+CaO+MgO content is no lower than 2%.Type: GrantFiled: December 16, 2010Date of Patent: July 1, 2014Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Michel Gaubil, Ludovic Massard, Isabelle Cabodi
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Patent number: 8642492Abstract: To provide a high zirconia fused cast refractory having high durability, which hardly has cracks during the heating, by temperature changes during use and during the cooling at the time of suspension of operation. A high zirconia fused cast refractory which has a chemical composition comprising from 86 to 96 mass % of ZrO2, from 2.5 to 8.5 mass % of SiO2, from 0.4 to 3 mass % of Al2O3, from 0.4 to 1.8 mass % of K2O, at most 0.04 mass % of B2O3, at most 0.04 mass % of P2O5 and at most 3.8 mass % of Cs2O and containing substantially no Na2O.Type: GrantFiled: March 15, 2013Date of Patent: February 4, 2014Assignee: Asahi Glass Company, LimitedInventor: Nobuo Tomura
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Patent number: 8563454Abstract: A fused and cast refractory product including, in mass percentages on the basis of the oxides and for a total of 100% of the oxides: ZrO2 + Hf2O: balance to 100%; SiO2: ?7.0% to 11.0%; Al2O3: 0.2% to 0.7%; Na2O + K2O: <0.10%; B2O3: 0.3% to 1.5%; CaO + SrO + MgO + ZnO + BaO: ?<0.4%; P2O5: <0.15%; Fe2O3 + TiO2: <0.55%; Other oxide species: ?<1.5%; the mass content of a dopant selected from Nb2O5, Ta2O5 and mixtures thereof being of less or equal to 1.0%, and the A/B ratio of the Al2O3/B2O3 mass contents being less than or equal to 2.0.Type: GrantFiled: February 24, 2010Date of Patent: October 22, 2013Assignee: Saint-Gobain Centre de Recherches et D'Etudes EuropeenInventors: Michel Gaubil, Isabelle Cabodi, Sophie Papin
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Patent number: 8497221Abstract: The present invention provides a fused refractory product having the following average chemical composition, as a % by weight based on the oxides and for a total of 100%; ZrO2: 30%-46%; SiO2: 10%-16%; Al2O3: complement to 100%; Y2O3?50/ZrO2 and Y2O3?5%; Na2O+K2O: 0.5%-4%; CaO: ?0.5%; and other species: ?1.5%. Application to a glass-melting furnace.Type: GrantFiled: December 17, 2009Date of Patent: July 30, 2013Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventor: Micaela Alasia
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Patent number: 8383537Abstract: Refractory materials are provided which contain P2O5/R2O3 constituents, where R is Y, Sc, Er, Lu, Yb, Tm, Ho, Dy, Tb, Gd, or a combination thereof, and/or V2O5/R?2O3 constituents where R? is Y, Sc, one or more rare earth elements, or a combination thereof. In certain embodiments, the refractory materials are xenotime-type materials and/or xenotime-stabilized zircon-type materials. The refractory materials can be used in the manufacture of glass and glass-ceramics. For example, the refractory materials, especially those that contain P2O5/R2O3 constituents, can be used as forming structures (“isopipes”) in the fusion process for making flat sheets of glass such as the glass sheets used as substrates in the manufacture of flat panel displays.Type: GrantFiled: October 18, 2011Date of Patent: February 26, 2013Assignee: Corning IncorporatedInventors: Hilary Tony Godard, Cameron Wayne Tanner, Michelle M Wallen, Elizabeth Margaret Wheeler
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Publication number: 20120263929Abstract: A refractory object can include a beta alumina. In an embodiment, the refractory object is capable of being used in a glass fusion process. In another embodiment, the refractory object can have a total Al2O3 content of at least 10% by weight. Additionally, a Mg—Al oxide may not form along a surface of the refractory object when the surface is exposed to a molten glass including an Al—Si—Mg oxide. In a particular embodiment, a refractory object can be in the form of a glass overflow forming block used to form a glass object that includes an Al—Si—Mg oxide. When forming the glass object, the glass material contacts the beta alumina, and during the flowing of the glass material, a Mg—Al oxide does not form along the beta alumina at the surface.Type: ApplicationFiled: April 13, 2012Publication date: October 18, 2012Applicant: SAINT-GOBAIN CERAMIC & PLASTICS, INC.Inventor: Olivier Citti
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Patent number: 8288300Abstract: The invention provides a novel fused cast refractory product with a high zirconia content having improved electrical resistivity. Said refractory product comprises, as a percentage by weight based on the oxides and for a total of more than 98.5%: ZrO2 + Hf2O: >85%; SiO2: >10% to 12%; Al2O3: 0.1% to 2.4%; B2O3: <1.5%; and a dopant selected from the group formed by V2O5, CrO3, Nb2O5, MoO3, Ta2O5, WO3, and mixtures thereof, in a weighted quantity as expressed below: 2.43V2O5+4.42CrO3+1.66Nb2O5+3.07MoO3+Ta2O5+1.91WO3?0.2%.Type: GrantFiled: August 21, 2008Date of Patent: October 16, 2012Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Isabelle Cabodi, Michel Gaubil
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Patent number: 8273673Abstract: The invention provides a fused cast refractory product with a high zirconia content comprising, as. a percentage by weight based on the oxides: ZrO2+Hf2O: >85%; SiO2: 6% to 12%; Al2O3: 0.4% to 1%; Y2O3: 0.2%; a dopant selected from the group formed by Nb2O5, Ta2O5, and mixtures thereof, in a quantity such that the molar ratio ZrO2/(Nb2O5+Ta2O3) is in the range 200 to 350.Type: GrantFiled: August 21, 2008Date of Patent: September 25, 2012Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Isabelle Cabodi, Michel Gaubil
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Patent number: 8258068Abstract: The present invention relates to a sintered product elaborated from a starting charge containing 75-99% of zircon, in mass percentage based on the oxides and having the following average weight chemical composition, in mass percentages based on the oxides 60%?ZrO2?72.8%, 27%?SiO2?36%, 0.1%?B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5, 0.1%?ZnO+PbO+CdO, B2O3+GeO2+P2O5+Sb2O3+Nb2O5+Ta2O5+V2O5+ZnO+PbO+CdO?5%, 0%?Al2O3+TiO2+MgO+Fe2O3+NiO+MnO2+CoO+CuO?5%, other oxides: ?1.5%, for a total of 100%. Notably used in a glass furnace.Type: GrantFiled: April 14, 2009Date of Patent: September 4, 2012Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Olivier Citti, Julien Fourcade
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Patent number: 8236719Abstract: Sintered product produced from a starting charge containing 75 to 99% zircon, and having the following average chemical composition by weight, the percentages by weight being based on the oxides: 60%<ZrO2+HfO2<75%; 27%<SiO2<34%; O<TiO2; O<Y2O3<3.5%; 0.1%<Nb2O5+Ta2O5<=5%; and other oxides: <1.5%; for a total of 100%, The sintered product may be used in a glass furnace.Type: GrantFiled: October 15, 2007Date of Patent: August 7, 2012Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeanInventors: Olivier Citti, Julien Fourcade
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Patent number: 8187990Abstract: A green part, a region of a refractory furnace or a hollow piece for producing a sintered refractory has the following mean mineral chemical composition in weight percent based of mineral oxides: 40%?Al2O3?94%, 0%?ZrO2?41%, 2%?SiO2?22%, 1%<Y2O3+V2O5+TiO2+Sb2O3+Yb2O3+Na2O. The sintered refractory products obtained from this green part give rise to a reduced bubbling effect.Type: GrantFiled: September 8, 2008Date of Patent: May 29, 2012Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Richard Avedikian, Yves Boussant-Roux, Jacques Guigonis
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Patent number: 8067326Abstract: Refractory materials are provided which contain P2O5/R2O3 constituents, where R is Y, Sc, Er, Lu, Yb, Tm, Ho, Dy, Tb, Gd, or a combination thereof, and/or V2O5/R?2O3 constituents where R? is Y, Sc, one or more rare earth elements, or a combination thereof. In certain embodiments, the refractory materials are xenotime-type materials and/or xenotime-stabilized zircon-type materials. The refractory materials can be used in the manufacture of glass and glass-ceramics. For example, the refractory materials, especially those that contain P2O5/R2O3 constituents, can be used as forming structures (“isopipes”) in the fusion process for making flat sheets of glass such as the glass sheets used as substrates in the manufacture of flat panel displays.Type: GrantFiled: December 21, 2005Date of Patent: November 29, 2011Assignee: Corning IncorporatedInventors: Hilary Tony Godard, Cameron Wayne Tanner, Michelle M Wallen, Elizabeth Margaret Wheeler
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Patent number: 8017230Abstract: This invention relates to ceramic powders comprising a zirconia-based component, e.g., yttria-stabilized zirconia, and an (alumina+silica)-based component, e.g., mullite. The ceramic powders are useful for forming thermal shock resistant coatings having the same composition, through deposition by thermal spray devices. This invention also relates to thermal barrier coating systems suitable for protecting components exposed to high temperature environments, such as the thermal environment of a gas turbine engine. This invention further relates to forming free-standing solid ceramic articles.Type: GrantFiled: October 2, 2006Date of Patent: September 13, 2011Assignee: Praxair S.T. Technology, Inc.Inventor: Thomas Alan Taylor
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Patent number: 7943541Abstract: The invention concerns a sintered refractory product having the following average chemical composition, in weight percentages based on oxides: 20%<Al2O3<90%; 6%=SiO2<30%; 3%<ZrO2<50%; 0%=Cr2O3<50%. The inventive product is characterized in that it comprises 17 to 85 wt. % of mullite-zirconium grains.Type: GrantFiled: September 25, 2006Date of Patent: May 17, 2011Assignee: Saint Gobain Centre de Recherches et d'Etudes EuropeenInventors: Richard Avedikian, Michel Bobo, Thibault Champion, Christian His
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Patent number: 7932201Abstract: Disclosed are ceramic articles comprising a sintered phase ceramic composition containing, as expressed on a weight percent oxide basis: a(Al2TiO5)+b(ZrTiO4)+c(Y2O3)+d(YPO4) wherein “a, b, c, and d” represent weight fractions of each component such that (a+b+c+d)=1.00 and wherein 0.5<a?0.95; 0?b?0.5, 0.0?c?0.10, and 0?d?0.5. Also disclosed are precursor batch compositions and methods for manufacturing the ceramic articles disclosed herein.Type: GrantFiled: March 23, 2010Date of Patent: April 26, 2011Assignee: Corning IncorporatedInventors: Steven Bolaji Ogunwumi, Cameron Wayne Tanner
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Patent number: 7842633Abstract: A high-zirconia cast refractory material which contains 85-95 wt % of ZrO2, 4-12 wt % of SiO2, 0.1 to less than 0.8 wt % of Al2O3, less than 0.04 wt % of Na2O, 0.01-0.15 wt % of K2O, 0.1-1.5 wt % of B2O3, 0.01-0.2 wt % of CaO, less than 0.4 wt % of BaO, less than 0.2 wt % of SrO, 0.05-0.4 wt % of Y2O3, and 0.3 wt % or less of Fe2O3 and TiO2 together, but does not substantially contain CuO and P2O5 (less than 0.01 wt %), such that the molar ratio of the glass-forming oxides (such as SiO2 and B2O3) to the glass-modifying oxides (such as Na2O, K2O, CaO, MgO, SrO, and BaO) is 20-100, said refractory material having an electric resistance being 200 ?·cm or higher after standing for 12 hours at 1500° C.Type: GrantFiled: December 16, 2008Date of Patent: November 30, 2010Assignee: Saint-Gobain TM K.K.Inventors: Nobuo Tomura, Shigeo Endo, Yasuo Misu
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Patent number: 7687422Abstract: A novel fused and cast refractory product with a high zirconia content having improved electrical resistivity includes, as a percentage by weight relative to the oxides and for a total of more than 98.5%: ZrO2 + Hf2O: >85% SiO2: 2% to 10% Al2O3: 0.1% to 2.4%, with Al2O3/SiO2 <0.5 Y2O3: ?1%, B2O3: <1.5%; and a dopant selected from the group formed by V2O5, CrO3, Nb2O5, MoO3, Ta2O5, WO3, and mixtures thereof, in a weighted quantity such that: 0.2%?2.43V2O5+8.84CrO3+1.66Nb2O5+6.14MoO3+Ta2O5+3.81WO3.Type: GrantFiled: February 23, 2007Date of Patent: March 30, 2010Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeanInventors: Yves Boussant-Roux, Isabelle Cabodi, Michel Gaubil
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Patent number: 7655587Abstract: The invention provides a novel fused and cast refractory product with a high zirconia content having improved electrical resistivity. Said refractory product comprises, as a percentage by weight relative to the oxides and for a total of more than 98.5%: ZrO2+Hf2O: >85% SiO2: 1% to 12% Al2O3: 0.1% to 2.4%, with Al2O3/SiO2<0.5 Y2O3: ?1%, B2O3: <1.5%; and a dopant selected from the group formed by V2O5, CrO3, Nb2O5, MoO3, Ta2O5, WO3, and mixtures thereof, in a weighted quantity such that: 0.2%?2.43V2O5+8.84CrO3+1.66Nb2O5+6.14MoO3+Ta2O5+3.81WO3.Type: GrantFiled: August 24, 2007Date of Patent: February 2, 2010Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeenInventors: Yves Boussant-Roux, Isabelle Cabodi, Michel Gaubil
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Patent number: 7642211Abstract: An AZS type fused cast refractory product presenting the following chemical composition, as a percentage by weight: ZrO2: 15.5% to 22%; SiO2: 10.5% to 15%; Na2O+K2O+Li2O: 1.0% to 2.5%; impurities: <1%. Application to glass furnaces, in particular to the superstructures and crowns thereof.Type: GrantFiled: September 14, 2005Date of Patent: January 5, 2010Assignee: Saint-Gobain Centre de Recherches et d'Etudes EuropeanInventors: Yves Boussant-Roux, Isabelle Cabodi, Michel Gaubil
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Patent number: 7598195Abstract: A fusion-cast refractory is provided. The refractory comprises 0.8% to 2.5% Al2O3, 4.0% to 10.0% SiO2, 86% to 95% ZrO2, 0.1% to 1.2% B2O3, up to 0.04% Na2O, up to 0.4% CaO, up to 0.1% Fe2O3 and up to 0.25% TiO2.Type: GrantFiled: December 30, 2004Date of Patent: October 6, 2009Assignee: Refractory Intellectual Property GmbH & Co. KGInventors: Amul Gupta, Stephen M. Winder
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Patent number: 7566674Abstract: In dental ceramics containing zirconium dioxide and silicon-dioxide with a Zr/Si ratio of between 0.5 and 1.0, 1 to 12 wt % of aluminum oxide and up to 2 wt % of an alkali- or earth alkali metal oxide, those materials are selectively mixed with yttrium-stabilized zirconium dioxide with a Zr/Si ratio of the mixture being between 0.5 and 1 wt % and also a silicon organic compound as well as a compression aid, and a green body is formed from the mixture by milling, which green body is then sintered.Type: GrantFiled: February 12, 2007Date of Patent: July 28, 2009Assignee: Forschungszentrum Karlsruhe GmbHInventors: Joachim Binder, Jürgen Hausselt, Hans-Joachim Ritzhaupt-Kleissl, Nadja Schlechtriemen, Stefan Stolz
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Patent number: 7282463Abstract: A thermocautery block is formed by mixing alumina, zirconium silicate, feldspar, pottery stone, siliceous limestone, kaolin, Gairome clay (Japan), and black soil with water; evenly stirring the mixture; compressing, dehydrating, and extruding the mixture into polygonal blocks; and drying, kilning, and cooling the blocks. The thermocautery block has a high density and a hardness higher than 6.0, and could store thermal energy after being heated for a short time. The stored thermal energy is progressively released via superficial areas of the block other than corners thereof to produce the effect of progressive temperature rise.Type: GrantFiled: November 18, 2004Date of Patent: October 16, 2007Inventor: Chieh Ming Chang
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Patent number: 7176153Abstract: A refractory system for glass melting furnaces includes alumina, zirconia, and silica mixed with a silica binder. The refractory may be formed as refractory blocks or directly onto the wear portion of a glass melting furnace. The refractory may be formed using casting, pumping, or shotcreting methods.Type: GrantFiled: December 9, 2003Date of Patent: February 13, 2007Assignee: Magneco/Metrel, Inc.Inventor: Michael W. Anderson
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Patent number: 7129192Abstract: The invention concerns a refractory product comprising more than 85% of zirconia (ZrO2), characterized in that it comprises in wt. % with respect to oxides: ZrO2>92%, SiO2: 2 to 8%, Na2O: 0.12 to 1%, Al2O3: 0.2 to 2%, 0.5%?Y2O3+CaO?2.6%, with the proviso that Y2O3: 0.3 to 2% and that CaO: 0.5 to 1.93%.Type: GrantFiled: February 28, 2003Date of Patent: October 31, 2006Assignee: Saint-Gobain Centre de Recherches et D'Etudes EuropeenInventors: Yves Marcel Leon Boussant-Roux, Michel Marc Gaubil
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Publication number: 20040266604Abstract: An unwrought refractory composition, in particular for producing glass furnace hearths, includes a base mixture comprising in wt. %: 1 to 6% of a hydraulic cement, and 94 to 99% of particles of at least a refractory material mainly consisting of alumina (Al2O3), zirconia (ZrO2) and silica (SiO2), the fraction of the particles of the base mixture having a size less than 40 &mgr;m being distributed in wt. % relative to the weight of the base mixture, as follows: fraction<0.5 &mgr;m: ≧4%; fraction<2 &mgr;m: ≧5%; fraction<10 &mgr;m: ≧16%; fraction<40 &mgr;m: 29-45%, the refractory composition further comprising, in wt. % relative to the weight of the base mixture: 0.02 to 0.08% of organic fibers, and 0.075 to 1% of a surfactant.Type: ApplicationFiled: May 19, 2004Publication date: December 30, 2004Inventors: Jacques Marius Louis Guigonis, Thierry Claude Consales
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Publication number: 20040198583Abstract: The present invention relates to a sole-covering agent for use in a carbonization chamber of a coke oven wherein the agent includes a refractory material having an average particle diameter of 10 &mgr;m or less and a melting point higher than a wall surface temperature of a carbonization chamber during operation and an organic binder and the agent has an average particle diameter in the range of from 0.3 to 10 mm, and a method of manufacturing the same. Furthermore, a method of applying the sole-covering agent to a coke oven is also provided. According to the invention, a load generated after coating of a high temperature refractory material for use in a carbonization chamber of an oven wall and applied on a coke pushing machine can be reduced.Type: ApplicationFiled: January 22, 2004Publication date: October 7, 2004Inventors: Takeshi Ando, Tadakatsu Kishi, Ryuzou Wakimoto, Teruo Onozawa, Shigeru Nakai
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Publication number: 20040138048Abstract: A refractory system for glass melting furnaces includes alumina, zirconia, and silica mixed with a silica binder. The refractory may be formed as refractory blocks or directly onto the wear portion of a glass melting furnace. The refractory may be formed using casting, pumping, or shotcreting methods.Type: ApplicationFiled: December 9, 2003Publication date: July 15, 2004Inventor: Michael W. Anderson
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Patent number: 6514892Abstract: Transparent solid, fused microspheres are provided. In one embodiment, the microspheres contain alumina, zirconia, and silica in a total content of at least about 70% by weight, based on the total weight of the solid, fused microspheres, wherein the total content of alumina and zirconia is greater than the content of silica, and further wherein the microspheres have an index of refraction of at least about 1.6 and are useful as lens elements.Type: GrantFiled: May 2, 2000Date of Patent: February 4, 2003Assignee: 3M Innovative Properties CompanyInventors: Toshihiro Kasai, Kenton D. Budd, Stephen L. Lieder, James A. Laird, Chikafumi Yokoyama, Toshinori Naruse, Kenji Matsumoto, Hirohiko Ono
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Patent number: 6458732Abstract: A dry refractory composition having superior insulating value. The dry refractory composition also may have excellent resistance to molten metals and slags. The composition includes filler lightweight material, which may be selected from perlite, vermiculite, expanded shale, expanded fireclay, expanded alumina silica hollow spheres, bubble alumina, sintered porous alumina, alumina spinel insulating aggregate, calcium alumina insulating aggregate, expanded mulllite, cordierite, and anorthite, and matrix material, which may be selected from calcined alumina, fused alumina, sintered magnesia, fused magnesia, silica fume, fused silica, silicon carbide, boron carbide, titanium diboride, zirconium boride, boron nitride, aluminum nitride, silicon nitride, Sialon, titanium oxide, barium sulfate, zircon, a sillimanite group mineral, pyrophyllite, fireclay, carbon, and calcium fluoride.Type: GrantFiled: June 7, 1999Date of Patent: October 1, 2002Assignee: Allied Mineral Products, Inc.Inventors: Douglas K. Doza, John Y. Liu
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Patent number: 6419737Abstract: A cementitious matrix consisting essentially of aluminosilicate polymer containing a liquid component of an aqueous solution of an alkali metal silicate having the formula M2O.RSiO2.XH2O, in which: M is an alkali metal monovalent cation such K+ or Na+; R is the molar ratio of SiO2/M2O, where the range is between 0.5/1 and 9/1; and X is the amount of water, where the amount of water is between 30 and 70 wt %; and a powder component which contains the silico-aluminous reactive raw materials Al6Si2O13 and Al2O3.4SiO2, with a relative proportion between 40 and 60 wt %, where the particle size of both components ranges between 40 and 70 microns. The cementitious matrix has high mechanical strength and is resistant to high temperatures.Type: GrantFiled: January 18, 2000Date of Patent: July 16, 2002Assignee: H.T.B.S. Corporation B.V.Inventor: Anas Haji
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Patent number: 6352951Abstract: The invention concerns a refractory material based on chromium corundum, a chromium corundum brick made of said material as well as the use thereof.Type: GrantFiled: March 12, 2000Date of Patent: March 5, 2002Assignee: Didier-Werke AGInventors: Karl-Heinz Mossal, Selim Yesiltas, Albert Kleinevoss, Thomas Weichert
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Patent number: 6121177Abstract: The invention relates to a novel sintered material, characterized in that it is produced from a batch containing 5 to 40% zircon and in that it has the following chemical composition in % by weight:______________________________________ ZrO.sub.2 + HfO.sub.2 82-96 SiO.sub.2 1.7-14 TiO.sub.2 0.2-3 Y.sub.2 O.sub.3 0.4-5 Al.sub.2 O.sub.3 0.2-2.Type: GrantFiled: April 20, 1999Date of Patent: September 19, 2000Assignee: Societe Europeenne des Produits RefractairesInventors: Jacques Marius Louis Guigonis, Eric Thierry Georges Jorge, Charles Nicholas McGarry
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Water soluble ceramic core for use in die casting, gravity and investment casting of aluminum alloys
Patent number: 6024787Abstract: A water-soluble ceramic core is prepared which can be advantageously used in the die casting, gravity casting, and investment casting of precision aluminum alloy objects. The ceramic core contains: (a) 60 to 70% by weight of alumina (A1.sub.2 O.sub.3) flour; (b) about 15 to 25 by weight of zircon (ZrSiO.sub.4) flour; (c) about 5 to 15 by weight of sodium hydrogen phosphate (Na.sub.2 HPO.sub.4); and (d) about 5 by weight of sugar. In preparing the ceramic core, sodium hydrogen phosphate and sugar are first dissolved in water to form a sodium hydrogen phosphate/sugar solution. Then alumina flour and zircon flour are added into the sodium hydrogen phosphate/sugar solution to form a slurry, which is caused to form a precursory ceramic core using an injection molding or slip casting process. After blow-drying the precursory ceramic core is calcined at temperatures between 70 and 800.degree. C.Type: GrantFiled: June 5, 1998Date of Patent: February 15, 2000Assignee: Industrial Technology Research InstituteInventor: Yuh-Wen Lee -
Patent number: 5958814Abstract: A composite and monolithic refractory structure, particularly adapted for making furnaces for glassmaking or the like, constituted by a block-shaped component made of electro-cast refractory material based on oxides of aluminum, zirconium, silicon, and the like, having shapes and dimensions that are adapted for its uses, inside which at least one protective element is monolithically inserted; the protective element is highly resistant to the attack of molten glass baths or the like and is chosen among metals, noble metals, refractory metals, refractory materials, conventional and non-conventional ceramic materials, such as carbides, nitrides, borides, and the like, or graphite-based materials, alloys and/or compounds and/or composites thereof; the element is provided substantially in the shape of a plate that is shaped and sized so as to have a profile that is similar to the peripheral profile of the refractory block and is arranged, inside the block, so that its surfaces are located at, and proximate to, theType: GrantFiled: December 18, 1996Date of Patent: September 28, 1999Assignee: Refel S.p.A.Inventors: Giancarlo Dinelli, Alessandro Fantinel
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Patent number: 5912201Abstract: A shaped ceramic article capable of being cut manually into selected sizes and process is based on a mixture of high-temperature resistant ceramic fibers and fibers which soften at temperatures below 2000.degree. F., particles of a ceramic material stable to temperatures exceeding 2000.degree. F., particles of a ceramic material which sinter at temperatures below 2000.degree. F., and a binder which provides green strength to shapes formed by vacuum formation from a slurry. The vacuum formed shape is dried at about 400.degree. F., thereby dried to form a shape which is preferably dipped in colloidal alumina or silica and dried again. The shape is sinterable by contact with flowing molten metal or by being sujected to radiant heat to form a hardened shape-stable ceramic form.Type: GrantFiled: July 24, 1997Date of Patent: June 15, 1999Assignee: Fiber Ceramics, Inc.Inventors: Clifford E. Couture, Paul A. Schumacher, Orville C. Clemmons
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Patent number: 5900382Abstract: The present invention relates to a refractory binder that comprises a mixture of aqueous phosphate and silica sol. The silica sol has been found to gel and set in a surprisingly effective and useful way. Preferably, the refractory binder further incorporates a small amount of magnesia as an accelerator. The present invention also provides a method of binding a refractory material such, for example, as alumina, zirconia mullite or aluminium silicate by using a refractory binder according to the invention.Type: GrantFiled: August 12, 1997Date of Patent: May 4, 1999Inventor: Richard Dudley Shaw
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Patent number: 5877105Abstract: An alumina-zirconia sintered body comprising 92 to 35% by weight of aluminum oxide and 8 to 65% by weight of zirconium oxide having mainly tetragonal system, and 0.2 to 5 parts by weight of silicon oxide per 100 parts by weight of the total of aluminum oxide and zirconium oxide, and having a relative density of 95% or more, has improved wear resistance and suitable for use in an impact grinder.Type: GrantFiled: January 28, 1997Date of Patent: March 2, 1999Assignees: Hitachi Chemical Company, Ltd., Kansai Matec Co., Ltd.Inventors: Akihito Iwai, Hiroshi Wada, Katsumi Matsumoto, Sosuke Naito, Yoshihiko Imai, Hideki Nakamura, Hiroaki Tanaka
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Patent number: 5753572Abstract: Mixes suitable for casting or gunning containing a heat-resistant aggregate blend containing at least about 50 wt. % high alumina grain, silicon carbide, and zircon sand, and to the method of utilizing the same to form alkali-resistant linings in high temperature vessels that have improved resistance to build-up.Type: GrantFiled: June 28, 1996Date of Patent: May 19, 1998Assignee: Harbison-Walker Refractories CompanyInventors: Mark C. Langenohl, Christopher L. Macey
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Patent number: 5731250Abstract: Ceramic bodies comprised mainly of zircon and wollastonite, with zircon being the dominant crystalline phase, show improved resistance to alkaline conditions at elevated temperatures than conventional bodies and excellent thermal stability.Type: GrantFiled: June 6, 1997Date of Patent: March 24, 1998Assignee: Norton Chemical Process Products CorporationInventors: John S. Reid, Thomas Szymanski
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Patent number: 5691259Abstract: A shaped ceramic article capable of being cut manually into selected sizes and process is based on a mixture of high-temperature resistant ceramic fibers and fibers which soften at temperatures below 2000.degree. F., particles of a ceramic material stable to temperatures exceeding 2000.degree. F., particles of a ceramic material which sinter at temperatures below 2000.degree. F., and a binder which provides green strength to shapes formed by vacuum formation from a slurry. The vacuum formed shape is dried at about 400.degree. F., thereby dried to form a shape which is preferably dipped in colloidal alumina or silica and dried again. The shape is sinterable by contact with flowing molten metal or by being sujected to radiant heat to form a hardened shape-stable ceramic form.Type: GrantFiled: November 8, 1996Date of Patent: November 25, 1997Assignee: Fiber Ceramics, Inc.Inventors: Clifford E. Couture, Paul A. Schumacher, Orville C. Clemmons
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Patent number: 5567214Abstract: A process is described for the production of alumina/zirconia materials which uses cheap scrap alumina/zirconia/silica material as feedstock along with a reducing agent to lower the final silica content to an acceptable level.Type: GrantFiled: May 3, 1995Date of Patent: October 22, 1996Assignee: Saint-Gobain/Norton Industrial Ceramics CorporationInventor: Peter J. Ashley
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Patent number: 5466643Abstract: High zirconia fused cast refractories which include as chemical components of refractories in weight %, 85 through 91% of ZrO.sub.2, 7.0 through 11.2% of SiO.sub.2, 0.85 through 3.0% of Al.sub.2 O.sub.3, 0.05 through 1.0% of P.sub.2 O.sub.5, 0.05 through 1.0% of B.sub.2 O.sub.3 and 0.01 through 0.12% of a summed amount of K.sub.2 O and Na.sub.2 O, wherein the weight % of K.sub.2 O is not smaller than the weight % of Na.sub.2 O.Type: GrantFiled: February 1, 1994Date of Patent: November 14, 1995Assignee: Asahi Glass Company Ltd.Inventors: Toshihiro Ishino, Otojiro Kida, Yoshihisa Beppu
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Patent number: 5082741Abstract: The present invention relates to a novel thermal spray material in any one of the forms of a particle mixture material, a granule material, and an electric fused material of 2CaO.SiO.sub.2 and CaO.ZrO.sub.2. As 2CaO.SiO.sub.2, .gamma.-2CaO.SiO.sub.2 is used. The ratio of .gamma.-2CaO.SiO.sub.2 to CaO.ZrO.sub.2 is specified by weight %. This invention relates also to a thermal sprayed member formed by thermal spraying this thermal spray material on a thermal resistant substrate.Type: GrantFiled: February 8, 1991Date of Patent: January 21, 1992Assignees: Tocalo Co., Ltd., Onoda Cement Co., Ltd.Inventors: Hatsuo Taira, Masakazu Ikeda, Yoshio Harada, Hiroshi Hagiwara
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Patent number: 5066624Abstract: The invention relates to a refractory thixotropic self-hardening vibration compound on the basis of zirconium silicate having the following chemical composition (in % by mass);______________________________________ 20 to 30% SiO.sub.2 20 to 45% Al.sub.2 O.sub.3 0.7 to 1.4% TiO.sub.2 0.2 to 0.8% P.sub.2 O.sub.5 0 to 1.5% K.sub.2 O + Na.sub.2 O + LiO.sub.2 0 to 1.0% Fe.sub.2 O.sub.3 0 to 0.05% CaO residue ZrO.sub.Type: GrantFiled: April 23, 1987Date of Patent: November 19, 1991Assignee: Martin & Pagenstecher GmbHInventors: Gert Konig, Jurgen Baumann
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Patent number: 5055433Abstract: An alumina-zirconia electrofusing material whose chemical composition consists of about 30-75 wt. % Al.sub.2 O.sub.3 and about 25-70 wt. % ZrO.sub.2 is provided in an amount of about 5-50 wt %, and this electrofusing material is mixed with other materials, and a resultant mixture is press-shaped and fired to produce a slide gate refractory. In order to further improve resistance to corrosion and spalling, particle diameters of the electrofusing material are continuously distributed in a range from about 0.1 mm to about 2.5 mm.Type: GrantFiled: June 1, 1989Date of Patent: October 8, 1991Assignee: Toshiba Ceramics Co., Ltd.Inventors: Shigeki Niwa, Kazuhide Kawai, Takahumi Nishibe, Toshio Kawamura