And Carbonaceous Material Patents (Class 501/90)
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Patent number: 7875211Abstract: A high performance multifunctional cementitious nanocomposite material is made by adding a nano admixture to the water used in a conventional cementitious material manufacturing process. The nano admixture is made by dispersing nanomaterials in a solvent and sonicating the mixture, adding a hydrophilic emulsifier, thickener, additive or cellulose derived compound to hot water, where it separates and expands, cooling the water, causing the compound to dissolve, and then adding the solvent and nanomaterial mixture to the water and mechanically mixing. The contact between the nanomaterials and the surrounding matrix changes with applied stress, affecting the volume electrical response of the finished nanocomposite material. By measuring the electrical resistance of the material, its structural health, as well as the stress applied to it, can be monitored. A bridge made with the material is monitored for structural integrity and for the weight, speed, and location of traffic over the bridge.Type: GrantFiled: February 19, 2010Date of Patent: January 25, 2011Assignee: Oceanit Laboratories, Inc.Inventor: Vinod P. Veedu
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Publication number: 20100331166Abstract: An object of the present invention is to produce a heat-resistant carbon/silicon carbide system composite material having a high density without deteriorating the mechanical properties such as toughness of carbon fiber. The present invention is a carbon/silicon carbide system composite material comprising a matrix containing a silicon carbide phase; a carbon fiber dispersed in the matrix; and a eutectic alloy phase containing silicon and an element for lowering a melting point of the silicon, wherein the carbon fiber is covered with a cover layer formed of a composite carbide of the silicon and the element.Type: ApplicationFiled: June 29, 2010Publication date: December 30, 2010Inventors: Kishio HIDAKA, Kazuya Baba, Makoto Ebihara
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Publication number: 20100292069Abstract: This invention provides carbon composite materials, which comprise metal carbide particles, at least the particle surfaces or the entirety of which are metal carbides, synthesized in situ from a metal source, i.e., at least one member selected from the group comprising metal particles, metal oxide particles, and composite metal oxide particles, and a carbon source, i.e., a thermosetting resin, dispersed in a carbon, carbon fiber, or carbon/carbon fiber matrix, and contain no free metal particles. This invention also provides a method for producing such composite carbon materials, which enables the production of carbon composite materials having a high coefficient of friction, high thermostability, and abrasion resistance.Type: ApplicationFiled: July 23, 2010Publication date: November 18, 2010Inventors: Shigeru Ichikawa, Sumio Kamiya, Koji Yamada, Hironori Sasaki
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Publication number: 20100279845Abstract: A process for producing a silicon-containing CMC article that exhibits improved physical, mechanical, and microstructural properties at elevated temperatures exceeding the melting point of silicon. The process entails producing a body containing a ceramic reinforcement material in a solid matrix that comprises solid elemental silicon and/or silicon alloy and a ceramic matrix material. The ceramic matrix composite article is produced by at least partially removing the solid elemental silicon and/or silicon alloy from the solid matrix and optionally reacting at least part of the solid elemental silicon and/or silicon alloy in the solid matrix to form one or more refractory materials. The solid elemental silicon and/or silicon alloy is sufficiently removed from the body to enable the ceramic matrix composite article to structurally and chemically withstand temperatures above 1405° C.Type: ApplicationFiled: April 30, 2009Publication date: November 4, 2010Applicant: GENERAL ELECTRIC COMPANYInventors: Anteneh Kebbede, Krishan Luthra, Gregory Corman
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Publication number: 20100260972Abstract: This invention provides a protective member comprising a ceramic body comprising a plurality of first phases (2) composed mainly of silicon carbide and a plurality of second phases (3) having a composition different from the composition of the first phase (2) and containing at least boron, silicon and carbon. A part of the second phase is present in the first phase as a whole, and at least a part of the remaining part of the second phase is present between a plurality of the first phases.Type: ApplicationFiled: March 28, 2008Publication date: October 14, 2010Applicant: KYOCERA CORPORATIONInventors: Takehiro Oda, Teppei Kayama, Masahito Nakanishi
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Patent number: 7776773Abstract: A boron carbide sintered body having a plurality of pores, comprises a boron carbide as a main component and a plurality of graphite particles dispersed in the sinter. The graphite particles is exposed to the pores or is in the vicinity of the pores.Type: GrantFiled: November 28, 2007Date of Patent: August 17, 2010Assignee: Kyocera CorporationInventors: Nobuyuki Horiuchi, Teppei Kayama, Masahito Nakanishi, Takehiro Oda
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Publication number: 20100179049Abstract: A silicon carbide-silicon carbide fiber composite consists of silicon carbide particles and silicon carbide fibers. The composite has excellent oxidation resistance and finds a wide range of application as heat resistant material. The silicon carbide conversion method is simple and consistent enough to ensure production of silicon carbide-silicon carbide fiber composites with minimized variation in quality.Type: ApplicationFiled: March 17, 2010Publication date: July 15, 2010Inventors: Hirofumi FUKUOKA, Susumu Ueno, Toshio Okada, Meguru Kashida
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Publication number: 20100179045Abstract: A composite material having a fibrous structure and a coating is disclosed. More specifically, a composite material may be comprised of a fibrous structure having a surface and impregnated with a interface material, a first ceramic material, a ceramic mixture, and a third ceramic material or alloy material or combination thereof, a coating disposed on the surface of the fibrous structure, wherein the coating comprises a first ceramic coating material and a ceramic coating mixture.Type: ApplicationFiled: January 12, 2009Publication date: July 15, 2010Applicant: GOODRICH CORPORATIONInventors: Vincent Fry, Ron Kestler, Andy Lazur
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Patent number: 7749931Abstract: A ceramic material for an optical member which shows black, wherein the ceramic material comprises a reaction-sintered sintered ceramic body prepared by synthesizing a formed body of a mixture comprising a ceramic raw material and a component that accelerates blackening, making use of a reaction sintering; and wherein the ceramic material is a porous body.Type: GrantFiled: February 13, 2007Date of Patent: July 6, 2010Assignees: FUJIFILM Corporation, Fujinon CorporationInventors: Hideki Hyuga, Hideki Kita, Tetsuya Yamazaki, Yasunori Tanaka
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Publication number: 20100152016Abstract: [Problems] To provide a method for industrially producing carbon-containing silicon carbide ceramics having excellent structural and other various physical properties after sintering, especially density and strength. [Solving Means] A method for producing carbon-containing silicon carbide ceramics including the step of burning a mixture X of raw materials containing silicon carbide, a carbon raw material, and a sintering aid, wherein the particles constituting the mixture X have an average particle size of from 0.05 to 3 ?m.Type: ApplicationFiled: January 24, 2007Publication date: June 17, 2010Inventors: Mikio Sakaguchi, Keisaku Inoue, Hiroki Hoshida
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Patent number: 7713448Abstract: Carbon nanomaterials are stabilized and uniformly dispersed in a liquid such as water using a simple procedure. Methylcellulose is added to hot water where it separates and expands with a temperature of about 80-90 degree Celsius. Methylcellulose swiftly dissolves when the water cools down. Carbon nanomaterials are dispersed in a solvent and sonicated. This nanomaterial dispersed solvent is then added to the methylcellulose dispersed water and mechanically stirred. The resulting uniform mixture is up to 90% by weight nanomaterials and is stable for months.Type: GrantFiled: September 25, 2007Date of Patent: May 11, 2010Assignee: Oceanit Laboratories, Inc.Inventor: Vinod P. Veedu
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Publication number: 20100044584Abstract: Disclosed herein is a material for altering electromagnetic radiation incident on the material. The material disclosed herein comprises carbon nanotubes having a length (L) that meets the following formula (1): L?½ ???(1) where ? is the wavelength of the electromagnetic radiation incident on the material. Also disclosed herein are methods of altering electromagnetic radiation, including mitigating, intensifying, or absorbing and re-transmitting electromagnetic radiation using the disclosed material.Type: ApplicationFiled: January 7, 2009Publication date: February 25, 2010Inventors: Christopher H. Cooper, William K. Cooper, Alan G. Cummings
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Patent number: 7666327Abstract: A high performance multifunctional cementitious nanocomposite material is made by adding a nano admixture to the water used in a conventional cementitious material manufacturing process. The nano admixture is made by dispersing nanomaterials in a solvent and sonicating the mixture, adding a hydrophilic emulsifier, thickener, additive or cellulose derived compound to hot water, where it separates and expands, cooling the water, causing the compound to dissolve, and then adding the solvent and nanomaterial mixture to the water and mechanically mixing. The contact between the nanomaterials and the surrounding matrix changes with applied stress, affecting the volume electrical response of the finished nanocomposite material. By measuring the electrical resistance of the material, its structural health, as well as the stress applied to it, can be monitored. A bridge made with the material is monitored for structural integrity and for the weight, speed, and location of traffic over the bridge.Type: GrantFiled: May 22, 2008Date of Patent: February 23, 2010Assignee: Oceanit Laboratories, Inc.Inventor: Vinod P. Veedu
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Patent number: 7648932Abstract: The invention relates to a process for the production of a molded porous ceramic article containing ?-SiC, which process comprises the following steps: the preparation of a molded article containing silicon and carbon and the subsequent pyrolysis and siliconization of the article containing silicon and carbon to form SiC. The invention further relates to a molded porous ceramic article containing SiC which has been produced from a molded article containing silicon and carbon.Type: GrantFiled: July 5, 2006Date of Patent: January 19, 2010Assignee: Mann+Hummel Innenraumfilter GmbH & Co. KGInventors: Lars Weisensel, Thomas Wolff, Heino Sieber, Peter Greil
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Publication number: 20100004115Abstract: A sliding member having a sliding surface comprising a silicon carbide sintered body having a primary phase comprising mainly silicon carbide, and a subphase having a different composition from the primary phase and containing at least boron, silicon and carbon. The ratio of pores having a roundness of 6 ?m or less and a pore diameter of 10 to 60 ?m with respect to all pores having a pore diameter of 10 ?m or more in the sliding surface is 60% or more. This enables retention of good seal properties even in a long-term continuous use. The subphase in the silicon carbide sintered body is preferably granular crystal phases dotted among a plurality of the primary phases. This provides excellent lubricating liquid holding performance as well as excellent thermal conductivity and excellent thermal shock resistance properties.Type: ApplicationFiled: October 30, 2007Publication date: January 7, 2010Applicant: KYOCERA CORPORATIONInventors: Yuusaku Ishimine, Kazuaki Takigawa
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Publication number: 20090305867Abstract: A method for the production of a ceramic substrate for a semiconductor component, includes the steps of producing paper containing at least cellulose fibers, as well as a filler to be carbonized and/or SiC, pyrolizing the produced paper, and siliconizing the pyrolyzed paper.Type: ApplicationFiled: July 13, 2007Publication date: December 10, 2009Applicant: SCHUNK KOHLENSTOFFTECHNIK GMBHInventors: Marco Ebert, Martin Henrich, Andreas Lauer, Gotthard Nauditt, Thorsten Scheibel, Roland Weiss
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Patent number: 7557054Abstract: The compressive strength of a boron carbide sintered compact is improved by controlling crystals of the boron carbide to a polycrystalline structure having a grain size distribution in which coarse crystals with a grain size of 20 ?m or more and fine crystals with a grain size of 10 ?m or less are mixed in an appropriate ratio. Furthermore, a protective member having an improved compressive strength can be provided using the boron carbide sintered compact having a polycrystalline structure in which coarse crystals and fine crystals are mixed in an appropriate ratio or a boron carbide sintered compact containing graphite and silicon carbide.Type: GrantFiled: February 27, 2007Date of Patent: July 7, 2009Assignee: Kyocera CorporationInventors: Takehiro Oda, Masahito Nakanishi, Teppei Kayama
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Publication number: 20090156385Abstract: Carbides and nitrides are provided containing a controlled amount of pre-determined diluents and methods for their manufacture and use are disclosed. The pre-determined diluents include at least one of the silica, silicon metal, carbon, alumina, boron oxide, alkaline earth oxides such as calcium oxide, magnesium oxide, alkali oxides such as sodium oxide, potassium oxide, iron oxide, titanium oxide, and other components typically present in glass, ceramics, or metals. The carbides and nitrides with pre-determined diluents are formed by optionally pyrolyzing a precursor material to form a carboneous mixture and heat treating the carboneous mixture for a pre-determined time and at an elevated temperature during which carbon and/or nitrogen reacts with silica in the mixture to form carbides and/or nitrides and controlled amounts of pre-determined diluents.Type: ApplicationFiled: October 29, 2004Publication date: June 18, 2009Inventors: Giang Biscan, Hamid Hojaji, David Leslie Melmeth, Thinh Pham, Mark G. Stevens, Huagang Zhang
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Publication number: 20090149309Abstract: It is an object of the invention to provide a ceramic sintered body that has a dense structure and minimal cracking and that exhibits excellent sliding properties even in a non-lubricated state, as well as a process for its production and sliding parts that employ the same. According to a preferred mode, the sintered body of the invention comprises silicon carbide as the parent material and further contains a solid lubricant A with a mean particle size of no greater than 5 ?m and a solid lubricant B with a mean particle size of 10-70 ?m.Type: ApplicationFiled: February 22, 2007Publication date: June 11, 2009Applicant: HITACHI CHEMICAL COMPANY, LTD.Inventors: Kazuyuki Akasaka, Kiyoshi Kawai
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Publication number: 20080227619Abstract: A method of sintering a ZrB2—SiC composite body at ambient pressures, including blending a first predetermined amount of ZrB2 powder with a second predetermined amount of SiC powder, wherein both powders are characterized by the presence of surface oxide impurities. Next the blended powders are mixed to yield a substantially homogeneous powder mixture and a portion of the substantially homogeneous powder mixture is formed into a green body. The body is fired to a first temperature, wherein substantially all surface oxide impurities are reduced and/or volatilized to substantially eliminate oxides from the green body, and the body is heated to a second temperature and sintered to yield a composite body of at least about 99 percent theoretical density and characterized by SiC whisker-like inclusions distributed substantially evenly in a ZrB2 matrix.Type: ApplicationFiled: May 12, 2008Publication date: September 18, 2008Inventors: Shi C. Zhang, Gregory E. Hilmas, William G. Fahrenholtz
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Publication number: 20080227618Abstract: A boron carbide sintered body having a plurality of pores, comprises a boron carbide as a main component and a plurality of graphite particles dispersed in the sinter. The graphite particles is exposed to the pores or is in the vicinity of the pores.Type: ApplicationFiled: November 28, 2007Publication date: September 18, 2008Applicant: KYOCERA CORPORATIONInventors: Nobuyuki HORIUCHI, Teppei Kayama, Masahito Nakanishi, Takehiro Oda
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Publication number: 20080146433Abstract: A method for producing a ceramic material product. A filler material is provided. The filler material is divided into filler granules collectively having a median diameter approximately 10 microns or less. A pre-selected amount of carbon is provided. The carbon is divided into carbon dust and the carbon dust is allowed to coat the filler granules. The mixture of carbon-coated filler granules is formed into a selected shape. The formed mixture is placed in a substantial vacuum. The mixture is introduced to a pre-selected amount of fluid silicon and the mixture of carbon-coated filler granules and silicon is heated to a temperature at or above the melting point of the silicon.Type: ApplicationFiled: December 18, 2006Publication date: June 19, 2008Applicant: Dynamic Defense Materials, LLCInventors: John Carberry, George D. Forsythe, Katherine T. Leighton
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Publication number: 20080125306Abstract: Ceramic materials with a matrix which contains at least one carbide, at least one carbide-forming element and carbon, and which furthermore contain a dispersed phase of carbon particles with spherical shape and an average diameter of 0.2 ?m to 800 ?m, a process for their production and their use for thermal insulation, as a protective layer in ceramic armoring against mechanical action, or as a friction layer in brake disks or clutch disks.Type: ApplicationFiled: June 7, 2007Publication date: May 29, 2008Applicant: Audi AGInventors: Andreas Kienzle, Ingrid Kratschmer
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Patent number: 7378362Abstract: The present invention is a composite material, a process and a product formed by the process. The composite is formed by a process that includes forming a fibrous structure comprising fibers into a preform, coating the fibers of the fibrous structure preform with elemental carbon to impregnate that preform, infiltrating the preform with boron carbide to form an impregnated green body. The impregnated green body is infiltrated with liquid naphthalene or other carbon precursor, which is thereafter pyrolyzed to form a carbon char. Then, the char infiltrated green body is infiltrated with molten silicon to form a continuous matrix throughout the composite. The silicon in the continuous matrix is reacted with the carbon char to form silicon carbide.Type: GrantFiled: October 24, 2003Date of Patent: May 27, 2008Assignee: Goodrich CorporationInventors: Thomas Dwayne Nixon, Sai-Kwing Lau, Edward R. Stover, Salvatore J. Calandra, Vijay V. Pujar, Lanny Ritz, Gary L. Clark, Steve T. Keller
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Patent number: 7368405Abstract: The present invention relates to a process of making silicon-silicon carbide ceramic using biopreform derived from monocotyledonous caudex plant stem. The present invention also provides a silicon-silicon carbide ceramic made using a biopreform derived from monocotyledonous caudex plant stem.Type: GrantFiled: December 30, 2002Date of Patent: May 6, 2008Assignee: Council of Scientific and Industrial ResearchInventors: Omprakash Chakrabarti, Himadri Sekhar Maiti, Rabindranath Mazumdar
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Patent number: 7348286Abstract: Ceramic composite material that has excellent mechanical properties within a range from room temperature to high temperature and high die release with respect to glass, resins, ceramics, and similar substances. The ceramic composite material is composed of a ceramic phase and a phase containing 2 to 98 wt. % carbon and/or boron nitride as the main component, and that has a mean particle size of 100 nm or less, wherein the thermal expansion coefficient is within a range of 2.0-9.0×10?6/° C. and the surface roughness after surface polishing is 0.05 ?m or less. The sintered body of the material is obtained by sintering a mixture of powdered starting materials at a sintering temperature of 800-1500° C. and a sintering pressure of 200 MPa or higher.Type: GrantFiled: October 28, 2004Date of Patent: March 25, 2008Assignee: Sumitomo Electric Industries, Ltd.Inventors: Masashi Yoshimura, Tomoyuki Ueno
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Patent number: 7345849Abstract: The magnetic head slider material of the present invention is constituted by a sintered body containing 100 parts by weight of alumina, 20 to 150 parts by weight of titanium carbide and silicon carbide in total, and 0.2 to 9 parts by weight of carbon.Type: GrantFiled: June 27, 2005Date of Patent: March 18, 2008Assignees: TDK Corporation, SAE Magnetics (H.K.) Ltd.Inventors: Yukio Kawaguchi, Kei Sugiura, Masahiro Itoh, Minoru Sakurabayashi, Atsushi Hitomi, Cheng Yih Liu
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Patent number: 7332221Abstract: A composite body produced by a reactive infiltration process that possesses high mechanical strength, high hardness and high stiffness has applications in such diverse industries as precision equipment and ballistic armor. Specifically, the composite material features a boron carbide filler or reinforcement phase, and a silicon component with a porous mass having a carbonaceous component. Potential deleterious reaction of the boron carbide with silicon during infiltration is suppressed by alloying or dissolving boron into the silicon prior to contact of the silicon infiltrant with the boron carbide. In a preferred embodiment of the invention related specifically to armor, good ballistic performance can be advanced by loading the porous mass or preform to be infiltrated to a high degree with one or more hard fillers such as boron carbide, and by limiting the size of the largest particles making up the mass.Type: GrantFiled: November 20, 2001Date of Patent: February 19, 2008Assignee: M Cubed Technologies, Inc.Inventors: Michael K. Aghajanian, Allyn L. McCormick, Bradley N. Morgan, Anthony F. Liszkiewicz, Jr.
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Patent number: 7235506Abstract: Silicon carbide matrix composite material (1) comprises silicon carbide matrix (2) as a host. The silicon carbide matrix (2) comprises first silicon carbide phase (3) of 0.1 to 10 ?m average crystal grain diameter and second silicon carbide phase (4) of 0.01 to 2 ?m average crystal grain diameter. In interstices of silicon carbide crystal grains constituting the silicon carbide matrix (2), liberated silicon phase (5) amounting to, for example, 5 to 50 mass % based on the composite material (1) is present continuously in network form. This fine structure enables realizing high strength and high toughness of the silicon carbide composite material (1).Type: GrantFiled: June 18, 2003Date of Patent: June 26, 2007Assignee: Kabushiki Kaisha ToshibaInventors: Shoko Suyama, Tsuneji Kameda, Yoshiyasu Itoh
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Patent number: 7204878Abstract: This invention relates to refractory mixes produced by mixing a refractory material with an organic binder and heating to a temperature of typically from about 50° C. to about 100° C. to form a stable composite granulate. The refractor mixes comprise a major amount of a refractory material and a minor amount of a binder composition comprising (a) condensed tannin and (b) furfuryl alcohol. The refractory mixes are used to prepare shaped (e.g. bricks) and unshaped (e.g. blast furnace tap holes, troughs, and tundish liners) refractory products. The invention also relates to a process for preparing the refractory products using the refractory mixes.Type: GrantFiled: October 11, 2005Date of Patent: April 17, 2007Assignee: Ashland Licensing and Intellectual Property LLCInventor: Mark R. Stancliffe
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Patent number: 7195722Abstract: Ceramic igniter compositions are provided that contain components of conductive material and insulating material, where the insulating material component includes a relatively high concentration of metal oxide. Ceramic igniters of the invention are particularly effective for high voltage use, including throughout the range of from about 187 to 264 volts.Type: GrantFiled: March 19, 2003Date of Patent: March 27, 2007Assignee: Saint-Gobain Ceramics and Plastics, Inc.Inventors: Roger J. Lin, Craig A. Willkens, Kevin C. Solofra, Thomas J. Sheridan
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Patent number: 7166550Abstract: A ceramic composite body comprising sintered silicon carbide as major phase, dispersed boron nitride/carbon granules as minor phase, and the boron nitride/carbon granules comprise hexagonal phase boron nitride powders bonded together by glassy carbon. The composite body contains at least 3 weight percent of boron nitride, the average size of the boron nitride granules is greater than 10 micrometers, and the shape of majority of the granules is irregular. The composite body of high boron nitride loading can be further processed to improve mechanical and thermal properties by filling the porosity with glassy carbon, obtained from carbonizing glassy carbon precursor. The composite material exhibits superior thermal and tribological characteristics than monolithic silicon carbide.Type: GrantFiled: January 7, 2005Date of Patent: January 23, 2007Inventor: Xin Chen
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Patent number: 7112549Abstract: A low-thermal-expansion, rigid and wear-resistant ceramic is provided. The low-thermal-expansion ceramic of the invention includes 60 vol % to 99.9 vol % of at least one selected from the group consisting of cordierite, spodumene and eucryptite and 0.1 vol % to 40 vol % of at least one selected from the group consisting of carbides, nitrides, borides and silicides of group IVa elements, group Va elements and group VIa elements, and boron carbide. The ceramic has a porosity of 0.5% or less and a thermal expansion coefficient, at 10° C. to 40° C., of 1.5×10?6/° C. or less.Type: GrantFiled: September 20, 2001Date of Patent: September 26, 2006Assignee: Sumitomo Metal Industries, Ltd.Inventors: Yasuki Yoshitomi, Tadahisa Arahori
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Patent number: 7060641Abstract: Fully dense, diamond-silicon carbide composites are prepared from ball-milled microcrystalline diamond/amorphous silicon powder mixture. The ball-milled powder is sintered (P=5–8 GPa, T=1400K–2300K) to form composites having high fracture toughness. A composite made at 5 GPa/1673K had a measured fracture toughness of 12 MPa·m1/2. By contrast, liquid infiltration of silicon into diamond powder at 5 GPa/1673K produces a composite with higher hardness but lower fracture toughness. X-ray diffraction patterns and Raman spectra indicate that amorphous silicon is partially transformed into nanocrystalline silicon at 5 GPa/873K, and nanocrystalline silicon carbide forms at higher temperatures.Type: GrantFiled: April 19, 2005Date of Patent: June 13, 2006Assignee: The Regents of the University of CaliforniaInventors: Jiang Qian, Yusheng Zhao
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Patent number: 7022175Abstract: An initial solids mixture for a later organic coating, such as pigmented coatings, films, priming coats, etc., e.g., for a coil coating method in which an initial solids mixture is applied to a substrate, e.g., broad strip, and this is thereby pre-coated, wherein the initial solids mixture includes, as additive particles, boron carbide and/or silicon carbide and/or compounds of transition elements or lanthanides, the electrical conductivity of which is selected to be in the metallic range (?>102 1/?cm and ?<107 1/?cm), during the later coating, the additive particles have a continuous physical connection in at least one spatial direction.Type: GrantFiled: November 21, 2001Date of Patent: April 4, 2006Assignee: DaimlerChrysler AGInventor: Anita Marten
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Patent number: 7015165Abstract: The invention provides exemplary silicon carbide ceramic bodies and processes for making such ceramic bodies. In one embodiment, a raw batch for producing a ceramic body includes a silicon carbide slurry and agglomerates of particles defining a dry lubricant mixture. The mixture includes a binder and a dry lubricant such as graphite, with a majority of the agglomerates having a shape that is generally spherical.Type: GrantFiled: April 22, 2004Date of Patent: March 21, 2006Assignee: CoorsTek, Inc.Inventor: Eric G. Wilkins
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Patent number: 7012035Abstract: Material from a fibre composite ceramic, constructed from a) a dense fabric or cluster of three-dimensional oriented fibres with a high thermal conductivity, b) a crystalline matrix of ?-silicon carbide, that is produced in a CVI process on the fibres, c) a matrix component of ?-silicon carbide that in a polymer infiltration and pyrolysis process is generated in pores of the fabric structure, starting from a suspension of silicon carbide powder in a polymer, and d) a further matrix component of ?-silicon carbide that is created in a CVI process in cracks and pores of the material, caused by the preceding pyrolysis process.Type: GrantFiled: February 6, 2003Date of Patent: March 14, 2006Assignee: MT Aerospace AGInventor: August Mühlratzer
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Patent number: 6953760Abstract: A ceramic component is disclosed, including a sintered ceramic body from a composition comprising a first ceramic material, and a plurality of inclusions in the ceramic body, each inclusion comprising graphite and a second ceramic material.Type: GrantFiled: June 4, 2003Date of Patent: October 11, 2005Assignee: Saint-Gobain Ceramics & Plastics, Inc.Inventors: Vimal K. Pujari, Jeffrey J. Kutsch
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Patent number: 6939506Abstract: Fully dense, diamond-silicon carbide composites are prepared from ball-milled microcrystalline diamond/amorphous silicon powder mixture. The ball-milled powder is sintered (P=5-8 GPa, T=1400K-2300K) to form composites having high fracture toughness. A composite made at 5 GPa/1673K had a measured fracture toughness of 12 MPa·m1/2. By contrast, liquid infiltration of silicon into diamond powder at 5 GPa/1673K produces a composite with higher hardness but lower fracture toughness. X-ray diffraction patterns and Raman spectra indicate that amorphous silicon is partially transformed into nanocrystalline silicon at 5 GPa/873K, and nanocrystalline silicon carbide forms at higher temperatures.Type: GrantFiled: May 30, 2003Date of Patent: September 6, 2005Assignee: The Regents of the University of CaliforniaInventors: Jiang Qian, Yusheng Zhao
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Patent number: 6914025Abstract: This invention relates to diamond-containing composite materials that have high thermal conductivity and thermal diffusivity, and to the use of such materials in heat sinks, heat spreading and other heat conductive applications. The material comprises diamond particles silicone carbide and silicon and has a thermal conductivity of at least 400 W/mK and a thermal diffusivity of at least 2.1 cm2/s.Type: GrantFiled: September 10, 2001Date of Patent: July 5, 2005Assignee: Skeleton Technologies AGInventors: Thommy Ekstrom, Jie Zheng, Kauthar Kloub, Sergey K. Gordeev, Liya V. Danchukova
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Patent number: 6908667Abstract: A method is provided for producing a fiber-reinforced material which is composed, at least in a region of a surface layer, of a ceramic composite and has carbon-containing fibers reaction-bonded to a matrix containing the elements Si and C. In particular a method of producing fiber-reinforced silicon carbide is provided in which a structure of a matrix contains cracks and/or pores, at least at ambient temperature, because of a high thermal expansion coefficient compared with that of the fibers. Metals are selectively electrodeposited in the open pores and cracks of the matrix and, in particular, in a region of the electrically conductive reinforcing fibers. As a result, the open pores and cracks are filled and, in addition, metallic top layers are optionally formed that are firmly keyed to the ceramic composite and that may serve as an interlayer for glass top layers or ceramic top layers.Type: GrantFiled: June 25, 2002Date of Patent: June 21, 2005Assignee: SGL Carbon AGInventors: Martin Christ, Michael Heine, Andreas Kienzle, Rainer Zimmermann-Chopin
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Patent number: 6887809Abstract: The invention relates to the field of ceramics and open-celled silicon carbide foam ceramics, which can find application, for example, as high temperature- and thermal shock-resistant silicon carbide foam. The aim of the invention is to disclose an open-celled silicon carbide foam ceramic with improved thermal shock resistance, which may be produced by a simple method. Said aim is achieved with an open-celled silicon carbide foam ceramic, the structure of which is made up of sintered silicon carbide with a 5 to 30% pore volume of closed pores with an average diameter of <20 ?m. The invention further relates to a method for the production of an open-celled silicon carbide foam ceramic, whereby coarse and fine silicon carbide powder in the ratio 20:80 to 80:20 parts are mixed and a suspension produced therefrom. An open-celled foam or open-celled network is then coated with said suspension, the foam or network material removed and sintering carried out at a temperature of >1800° C.Type: GrantFiled: August 3, 2001Date of Patent: May 3, 2005Assignee: Fraunhofer-Gesellschaft zur Foerderung der Angewandten Forschung E.V.Inventor: Jörg Adler
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Patent number: 6844282Abstract: The present invention provides a silicon nitride based sintered body having excellent mechanical properties from room temperature to a medium low temperature range, a low friction coefficient and excellent wear resistance. The sintered body comprises silicon nitride, titanium compounds and boron nitride or silicon nitride, titanium based nitride and/or carbide, silicon carbide and graphite and/or carbon; and has a mean particle diameter of 100 nm or less and a friction coefficient under lubricant free conditions of 0.3 or less.Type: GrantFiled: April 18, 2002Date of Patent: January 18, 2005Assignee: Sumitomo Electric Industries, Ltd.Inventor: Masashi Yoshimura
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Patent number: 6844281Abstract: A preform for use in a metal matrix composite, particularly for a magnesium metal composite. In the preform the reinforcing material typically is silicon carbide, boron nitride, titanium nitride, carbon or graphite. The binder used in the preform is sintered magnesium fluoride, which avoids the known problems which result from the high reactivity of molten magnesium metal with other binders, such as silica and alumina, which results in the formation of magnesium oxide in the reinforced composite. The presence of magnesium oxide crystals in the metal matrix adversely affects the properties of the composite. The preform generally has a void volume of from about 50% to about 95%.Type: GrantFiled: November 18, 2002Date of Patent: January 18, 2005Assignee: Her Majesty the Queen in right of Canada, as represented by the Minister of Natural ResourcesInventors: Jason S. H. Lo, Areekattuthazhayil K. Kuriakose, Raul Santos
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Patent number: 6839639Abstract: Shaped composite structures which are strong, stiff and hard and, at the same time, having high toughness, comprise a matrix, for example a cement or ceramics based matrix and embedded therein a plurality of plate shaped or at lest 60 mm thick elongated reinforcement components, the reinforcing component having at least 1.5 times higher tensile strength that the matrix, the minimum volume per cent concentration of the reinforcement components being related in the manner described in the specification to their tensile strength and (in case of elongated reinforcement components) also their thickness and to the compressive strength and modulus of elasticity and modulus of elasticity of the matrix. Methods for modeling and designing such structures are also disclosed, as are methods for establishing the structure for smaller matrix building blocks which may be pre-fabricated and which are arranged around pre-arranged reinforcement bodies and then fixed to each other and to the reinforcement.Type: GrantFiled: May 12, 2003Date of Patent: January 4, 2005Assignee: Giantcode A/SInventor: Hans Henrik Bache
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Publication number: 20040259717Abstract: The present invention provides a sintered silicon carbide jig production method capable of simply increasing the purity of a sintered silicon carbide jig. A method of producing a sintered silicon carbide jig comprising a process in which a second sintered body is heated at a temperature rising rate of 3 to 5° C./min up to heating treatment temperature selected in the range of 2200 to 2300° C. under an argon atmosphere, kept at the same heating treatment temperature for 3 hours, and cooled at a temperature lowering rate of 2 to 3° C./min down to 1000° C.Type: ApplicationFiled: May 4, 2004Publication date: December 23, 2004Inventor: Fumio Odaka
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Publication number: 20040248723Abstract: A ceramic component is disclosed, including a sintered ceramic body from a composition comprising a first ceramic material, and a plurality of inclusions in the ceramic body, each inclusion comprising graphite and a second ceramic material.Type: ApplicationFiled: June 4, 2003Publication date: December 9, 2004Applicant: Saint-Gobain Ceramics & Plastics, Inc.Inventors: Vimal Pujari, Jeffrey J. Kutsch
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Publication number: 20040242399Abstract: Fully dense, diamond-silicon carbide composites are prepared from ball-milled microcrystalline diamond/amorphous silicon powder mixture. The ball-milled powder is sintered (P=5-8 GPa, T=1400K-2300K) to form composites having high fracture toughness. A composite made at 5 GPa/1673K had a measured fracture toughness of 12 MPa·m1/2. By contrast, liquid infiltration of silicon into diamond powder at 5 GPa/1673K produces a composite with higher hardness but lower fracture toughness. X-ray diffraction patterns and Raman spectra indicate that amorphous silicon is partially transformed into nanocrystalline silicon at 5 GPa/873K, and nanocrystalline silicon carbide forms at higher temperatures.Type: ApplicationFiled: May 30, 2003Publication date: December 2, 2004Inventors: Jiang Qian, Yusheng Zhao
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Patent number: 6824862Abstract: Fiber-reinforced ceramic composites contain bundles, tows or hanks of long fibers, wherein the long fiber bundles, tows or hanks are completely surrounded by a short fiber-reinforced matrix, with the long and short fibers having, independently of one another, a mean diameter of from 4 to 12 &mgr;m and the long fibers having a mean length of at least 50 mm and the short fibers having a mean length of not more than 40 mm, a process for producing them and their use for producing clutch disks or brake disks.Type: GrantFiled: December 23, 2002Date of Patent: November 30, 2004Assignee: SGL Carbon AGInventors: Moritz Bauer, Georg Burkhart, Martin Christ, Ronald Huener, Andreas Kienzle, Peter Winkelmann, Rainer Zimmermann-Chopin
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Publication number: 20040207133Abstract: A carbon fiber-carbon matrix reinforced ceramic composite comprises a carbon fiber-carbon matrix reinforcement embedded within a ceramic matrix. The ceramic matrix does not penetrate into the carbon fiber-carbon matrix reinforcement to any significant degree. The carbide matrix is a formed in situ solid carbide of at least one metal having a melting point above about 1850 degrees centigrade. At least when the composite is intended to operate between approximately 1500 and 2000 degrees centigrade for extended periods of time the solid carbide with the embedded reinforcement is formed first by reaction infiltration. Molten silicon is then diffused into the carbide. The molten silicon diffuses preferentially into the carbide matrix but not to any significant degree into the carbon-carbon reinforcement.Type: ApplicationFiled: April 15, 2004Publication date: October 21, 2004Inventors: Brian Williams, Robert Benander