And Carbonaceous Material Patents (Class 501/90)
  • Patent number: 5179050
    Abstract: An SiC-based pressureless sintered product contains a sintered product main component containing grains of at least one additive selected from the group consisting of Tac, NbB.sub.2, VB.sub.2 and WB and the balance of SiC sintered grains constituting a SiC matrix, and a sintering assistant component. The additive grains have a maximum grain size not greater than an average grain size of the SiC sintered grains.
    Type: Grant
    Filed: August 15, 1990
    Date of Patent: January 12, 1993
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Toshiaki Mizutani, Akihiko Tsuge
  • Patent number: 5171722
    Abstract: A method of preparing preceramic SiC fibers having a very low oxygen content by forming fibers from a solution of a polycarbosilane and a vinylic SiC precursor in a mutual volatile solvent, heating fibers in an oxygen-free inert atmosphere to effect a cross-linking reaction therebetween. Also disclosed is a method of preparing SiC fibers having superior high temperature properties and a very low oxygen content comprising heating the above-described cross-linked preceramic fibers in an inert atmosphere substantially free of oxygen for a time and at a temperature sufficient to pyrolyze the cross-linked fibers to SiC fibers. The disclosure also describes the novel fibers produced by the above-described methods.
    Type: Grant
    Filed: October 9, 1991
    Date of Patent: December 15, 1992
    Assignee: University of Florida
    Inventors: William Toreki, Christopher D. Batich
  • Patent number: 5164345
    Abstract: The processes of the invention involve the formation of an initial reactant mixture by combining sources of SiO.sub.2, B.sub.2 O.sub.3, aluminum, and carbon. The mixture may then optionally be shaped or compacted. The reactant mixture is then heated to start a reaction which is described by the formula:4 C+3 SiO.sub.2 +2 B.sub.2 O.sub.3 +8 Al.fwdarw.4 Al.sub.2 O.sub.3 +B.sub.4 C+3 SiC.Depending on the actual reactant mixture compositions and reaction conditions, other reactions may also occur.
    Type: Grant
    Filed: March 21, 1991
    Date of Patent: November 17, 1992
    Assignee: W.R. Grace & Co.-Conn.
    Inventors: Roy W. Rice, Leonard E. Dolhert, Jack H. Enloe
  • Patent number: 5164344
    Abstract: This invention relates to the preparation of highly densified ceramic bodies by the pyrolysis of a mixture comprising a preceramic borosilazane, silicon carbide powder, and, optionally, a curing agent for the borosilazane. Such highly densified ceramic bodies can be prepared by sintering under pressure or by a pressureless sintering process.
    Type: Grant
    Filed: June 26, 1991
    Date of Patent: November 17, 1992
    Assignee: Dow Corning Corporation
    Inventor: Gregg A. Zank
  • Patent number: 5147834
    Abstract: An improved gunning composition for use in the steel industry includes between 60-75% by weight of a refractory base material, 10-20% by weight of silicon carbide, 7-15% by weight of ball clay, 4-8% by weight of a silica binder material, and, optionally, 5-10% by weight of a graphite material. The silica binder replaces binders composed of petroleum pitch or clay. The silica binder causes the composition to have (1) better adhesion, (2) less cracking, (3) improved strength, and (4) increased resistance to oxidation, corrosion and erosion.
    Type: Grant
    Filed: August 19, 1991
    Date of Patent: September 15, 1992
    Assignee: Magneco/Metrel, Inc.
    Inventor: Subrata Banerjee
  • Patent number: 5143540
    Abstract: Substantially dense, void-free ceramic-metal composites are prepared from components characterized by chemical incompatibility and non-wetting behavior. The composites have a final chemistry similar to the starting chemistry and microstructures characterized by ceamic grains similar in size to the starting powder and the presence of metal phase. A method for producing the composites requires forming a homogeneous mixture of ceramic-metal, heating the mixture to a temperature that approximates but is below the temperature at which the metal begins to flow and pressing the mixture at such pressure that compaction and densification of the mixture occurs and an induced temperature spike occurs that exceeds the flowing temperature of the metal such that the mixture is further compacted and densified. The temperature spike and duration thereof remains below that at which significant reaction between metal and ceramic occurs. The method requires pressures of 60-250 kpsi employed at a rate of 5-250 kpsi/second.
    Type: Grant
    Filed: September 18, 1990
    Date of Patent: September 1, 1992
    Assignee: The Dow Chemical Company
    Inventors: Aleksander J. Pyzik, Irving G. Snyder, Jr., Robert R. McDonald, Alexander Pecnenik
  • Patent number: 5137398
    Abstract: A drill bit of a diamond-coated sintered body has a substrate mainly composed of Si.sub.3 N.sub.4 or SiC. At least a wear portion of the bit is coated with a diamond layer. If the bit is of the throw-away kind, an insert is removably secured to a shank. At least the insert or a wear portion thereof is coated with a diamond layer. The sintered body contains a prescribed amount of a sintering assistant or aid selected from MgO, Y.sub.2 O.sub.3 and the like. The diamond coating layer has a thickness of at least 0.1 .mu.m.
    Type: Grant
    Filed: April 25, 1991
    Date of Patent: August 11, 1992
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Naoya Omori, Hideki Moriguchi, Toshio Nomura
  • Patent number: 5135893
    Abstract: This invention provides a carbon-containing ceramic composite for molten non-ferrous metal, the composite being a sintered ceramic body to be used in contact with molten non-ferrous metal, the sintered body containing an aggregate of silicon carbide and/or silicone nitride, the sintered body being characterized in that it comprises,(a) 100 parts by weight of the aggregate,(b) 5 to 45 parts by weight of flake graphite, and(c) boron carbide in an amount of 10 to 40% by weight based on the flake graphite.
    Type: Grant
    Filed: November 30, 1990
    Date of Patent: August 4, 1992
    Assignee: Osaka Gas Company Limited
    Inventors: Shoji Dohi, Akio Nakashiba, Kengo Hamada, Shigenobu Yurugi, Hiroshi Sano, Yoshitaka Hayashi, Akira Nishihira, Hirokazu Asada, Mineyoshi Nishinou, Mamoru Imajo
  • Patent number: 5112779
    Abstract: This invention relates to the preparation of highly densified ceramic bodies by the pyrolysis of a mixture comprising a preceramic borosiloxane, silicon carbide powder, a curing agent for the borosiloxane, a crosslinking agent for the borosiloxane and, optionally, additional components to facilitate sintering. Such highly densified ceramic bodies can be prepared by sintering under pressure or by a pressureless sintering process.
    Type: Grant
    Filed: March 25, 1991
    Date of Patent: May 12, 1992
    Assignee: Dow Corning Corporation
    Inventors: Gary T. Burns, Gregg A. Zank
  • Patent number: 5094985
    Abstract: Disclosed is a sintered silicon carbide body with a high thermal conductivity which has a thermal conductivity of not less than 150 W/m.multidot.K, which is produced by(a) mixing(1) a first silicon carbide powder having a mean grain size of from 0.1 to 10 .mu.m with(2) a second silicon carbide powder having a mean grain size of not greater than 0.1 .mu.m prepared by(2-1) introducing a starting gas composed of a silane compound or silicon halide and a hydrocarbon into a plasma of a non-oxidative atmosphere, and(2-2) conducting gas phase reaction between the silane compound or silicon halide and the hydrocarbon while controlling the pressure of the reaction system within the range of from less than 1 atom to 0.1 torr, and(3) optionally, a carbon powder which is required for reducing oxides contained in both the first and second silicon carbide powders,(b) optioanlly reducing the oxides with the carbon, and(c) heating the resulting mixture for sintering. Also, processes of producing the same are disclosed.
    Type: Grant
    Filed: November 6, 1989
    Date of Patent: March 10, 1992
    Assignees: Kazunori Kijima Kyoto, Sumitomo Cement Co., Ltd.
    Inventors: Kazunori Kijima, Eiki Arai, Youichi Miyazawa, Mikio Konishi, Ken Kato
  • Patent number: 5093039
    Abstract: Disclosed is an electrically conductive sintered silicon carbide body having an electric resistivity of not higher than 1 .OMEGA..multidot.cm, which is produced by(a) mixing(1) a first silicon carbide powder having a mean grain size of from 0.1 to 10 .mu.m with(2) a second silicon carbide powder having a mean grain size of not greater than 0.1 .mu.m prepared by(2-1) introducing a starting gas composed of a silane compound of silicon halide and a hydrocarbon into a plasma of a non-oxidative atmosphere, and(2-2) conducting gas phase reaction between the silane compound or silicon halide and the hydrocarbon while controlling the pressure of the reaction system within the range of from less than 1 atom to 0.1 torr, and(3) optionally, a carbon powder which is required for reducing oxides contained in both the first and second silicon carbide powders,(b) optionally reducing the oxides with the carbon, and(c) heating the resulting mixture for sintering. Also, processes of producing the same are disclosed.
    Type: Grant
    Filed: November 6, 1989
    Date of Patent: March 3, 1992
    Assignees: Kazunori Kijima, Sumitomo Cement Co., Ltd.
    Inventors: Kazunori Kijima, Eiki Arai, Youichi Miyazawa, Mikio Konishi, Ken Kato
  • Patent number: 5075264
    Abstract: Disclosed herein is a slider of which sliding performance, i.e., sealing performance is improved, without decline of combination strength of grain boundaries and abrasion resistance, by including 2-10%, more preferably 3-8% by weight of free carbon in a slider composed of a high density silicon carbide sintered compact of which relative density is not less than 95%.
    Type: Grant
    Filed: March 28, 1991
    Date of Patent: December 24, 1991
    Assignee: Nippon Pillar Packing Co., Ltd.
    Inventors: Hisashi Kinugasa, Nobuto Mukae
  • Patent number: 5071679
    Abstract: The process comprises the steps of forming a fibrous reinforcement with silicium carbide fibers, forming on the fibers an intermediate coating designed to constitute an interface between the fibers and a matrix, and forming a matrix in ceramic material within the residual porosity of the fibrous reinforcement. In a step prior to the formation of the intermediate coating, a treatment is carried out by the chemical route for the elimination of the silica present on the surface of the silicium carbide fibers.
    Type: Grant
    Filed: April 27, 1989
    Date of Patent: December 10, 1991
    Assignee: Societe Europeenne de Propulsion
    Inventors: Louis Heraud, Joelle Lalande
  • Patent number: 5070049
    Abstract: In the production of silicon carbide, a starting composition comprising silicon dioxide powder and a carbonaceous substance and having a bulk density of 0.2 to 2.0 g/cm.sup.3 is used, wherein the silicon dioxide is covered with the carbonaceous substance and uniformly dispersed therein. The starting composition is produced by forming a kneaded mixture of silicon dioxide and high molecular weight organic compound, heating the kneaded mixture to conduct carbonization and thereby form a composite body and then granulating the composite body into 3 to 25 mm sized granules.
    Type: Grant
    Filed: December 19, 1988
    Date of Patent: December 3, 1991
    Assignee: Ibiden, Co. Ltd.
    Inventors: Toshikazu Amino, Satoshi Takenaka
  • Patent number: 5064787
    Abstract: An improved ramming composition for use in the iron and steel industry includes between 65-80% by weight mullite, 5-15% by weight silicon carbide, 2-5% by weight graphite, 2-6% by weight ball clay, and 5-10% by weight of a binder formed from a dispersion of 15-70% by weight silica in water. The silica binder replaces binders composed of petroleum pitch, clay, or other organic materials. The silica binder causes the ramming composition to have a longer use life, increased strength, and reduced tendency to crack, oxidize or smoke.
    Type: Grant
    Filed: November 20, 1989
    Date of Patent: November 12, 1991
    Assignee: Magneco/Metrel, Inc.
    Inventor: Subrata Banerjee
  • Patent number: 5057465
    Abstract: The present invention provides fiber-reinforced ceramics containing at least one member of fibers and whiskers as distributed in a sintering ceramic matrix, which comprises the ceramic matrix being composed mainly of SiC, Si.sub.3 N.sub.4 and Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z, where 0<z.ltoreq.4, the fibers and the whiskers being composed of at least one of SiC, Si.sub.3 N.sub.4 and Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z, where 0<z.ltoreq.4, and a coating film of C, B or BN being provided on the surfaces of the fibers and the whiskers. The fiber-reinforced ceramics have a high fracture toughness, K.sub.1c, and a high bending strength, particularly K.sub.1c of at least 10 MN/m.sup.3/2 and a bending strength of at least 50 kg/mm.sup.2.
    Type: Grant
    Filed: December 20, 1989
    Date of Patent: October 15, 1991
    Assignee: Hitachi, Ltd.
    Inventors: Hiroshi Sakamoto, Tadahiko Miyoshi
  • Patent number: 5055430
    Abstract: The present invention provides fiber-reinforced ceramics containing at least one member of fibers and whiskers as distributed in a sintering ceramic matrix, which comprises the ceramic matrix being composed mainly of SiC, Si.sub.3 N.sub.4 and Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z, where 0<z.ltoreq.4, the fibers and the whiskers being composed of at least one of SiC, Si.sub.3 N.sub.4 and Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z, where 0<z.ltoreq.4, and a coating film of C, B or BN being provided on the surfaces of the fibers and the whiskers. The fiber-reinforced ceramics have a high fracture toughness, K.sub.lc, and a high bending strength, particularly k.sub.lc of at least 10 MN/m.sup.3/2 and a bending strength of at least 50 kg/mm.sup.2.
    Type: Grant
    Filed: December 20, 1989
    Date of Patent: October 8, 1991
    Assignee: Hitachi, Ltd.
    Inventors: Hiroshi Sakamoto, Tadahiko Miyoshi
  • Patent number: 5045269
    Abstract: A method for producing sintered shapes of refractory powders with improved strength and toughness using a grain growth inhibiting powder to inhibit grain growth.
    Type: Grant
    Filed: February 1, 1991
    Date of Patent: September 3, 1991
    Assignee: Union Carbide Coatings Service Technology Corporation
    Inventor: Raymond V. Sara
  • Patent number: 5043303
    Abstract: Boron nitride is coated on filaments of elemental carbon and/or silicon carbide, the coated filaments are contacted with an infiltration-promoting material containing elemental carbon to produce a preform wherein the filaments are substantially parallel and each filament is enveloped with infiltration-promoting material, and the preform is infiltrated with a molten solution of boron and silicon producing a composite containing boron nitride coated filaments.
    Type: Grant
    Filed: July 8, 1988
    Date of Patent: August 27, 1991
    Assignee: General Electric Company
    Inventors: Raj N. Singh, William A. Morrison
  • Patent number: 5034355
    Abstract: A composite material comprises silicon carbide and a boride of at least one element of Groups IVa to VIa of the Periodic Table, at least a portion of the boride being in the form of fiber having an aspect ratio of 3 or above. The composite material has high toughness owing to the fibrous boride.The composite material is produced by molding a raw material mixture composed of silicon carbide, a substance containing at least one element of Groups IVa to VIa of the Periodic Table, at least a portion thereof being in the form of fiber having an aspect ratio of 3 or above, and a substance containing boron, and sintering the molded body.
    Type: Grant
    Filed: October 25, 1988
    Date of Patent: July 23, 1991
    Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho
    Inventors: Toshihiko Tani, Shigetaka Wada
  • Patent number: 5030596
    Abstract: A sintered article of diamond is obtained by coating the surface of diamond particles with 30 to 0.1% by volume, based on the total volume of the diamond particles and aids, of at least one member selected from the group consisting of the transition metals of Groups 4a, 5a, and 6a in the Periodic Table of Elements and boron and silicon, and sintering the coated diamond particles under conditions of high pressure and high temperature, which sintered article consists of 70 to 99.8% by volume of diamond and 30 to 0.2% by volume of the carbide of the coating substance. A method for the production of the sintered article of diamond is also disclosed.
    Type: Grant
    Filed: December 1, 1989
    Date of Patent: July 9, 1991
    Assignees: Agency of Industrial Science and Technology, Ministry of International Trade and Industry
    Inventors: Shoichi Kume, Haruo Yoshida, Kazutaka Suzuki, Yoshio Tasaki, Shiro Ikuta, Masamitu Ishikawa, Michihide Machida
  • Patent number: 5021367
    Abstract: Fibrous material is coated with boron nitride and a silicon-wettable material, the coated fibrous material is admixed with an infiltration-promoting material which is at least partly elemental carbon and the mixture is formed into a preform which is infiltrated with a molten solution of boron and silicon producing a composite containing boron nitride coated fibrous material.
    Type: Grant
    Filed: October 10, 1989
    Date of Patent: June 4, 1991
    Assignee: General Electric Company
    Inventors: Raj N. Singh, William A. Morrison
  • Patent number: 5019537
    Abstract: A forming aid to be mixed in a ceramic material for forming the ceramic material into a formed ceramic body of a desired shape, including at least one of a thermoplastic resin and a wax, and a mineral oil in an amount of 30-95% by volume with respect to an entire volume of the aid. Also disclosed is a process of producing a ceramic article from the formed ceramic body containing the aid.
    Type: Grant
    Filed: April 21, 1988
    Date of Patent: May 28, 1991
    Assignee: NGK Insulators, Ltd.
    Inventors: Kiminari Kato, Masahiro Shirai
  • Patent number: 5017522
    Abstract: 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: Grant
    Filed: July 7, 1989
    Date of Patent: May 21, 1991
    Assignee: Hexcel Corporation
    Inventor: Andreas G. Hegedus
  • Patent number: 5017527
    Abstract: A siliconized graphite for use in mechanical seals is provided. This material is prepared by reacting graphite at an elevated temperature ranging from 1800.degree. to 2100.degree. C. with silicon monoxide. Silicon monoxide is generated in rate-controlled fashion by reacting either silicon carbide and silica or silicon nitride and silica at an elevated temperature ranging from 1500.degree. to 1800.degree. C.Although the optimum temperature range for the SiO generation and the siliconization of graphite is different by 300.degree. C., size-controlled raw materials (silicon carbide, silicon nitride, and silica) and a unique sample loading method make the whole process occurred in situ and make the production of mechanical seals efficient. Size-controlling of the raw materials is essential for a constant supply of silicon monoxide in controlled fashion, and a unique sample loading method is essential to put the SiO generation and the siliconization of graphite within their optimum temperature ranges.
    Type: Grant
    Filed: April 3, 1989
    Date of Patent: May 21, 1991
    Assignee: Korea Advanced Institute of Science & Technology
    Inventors: Lee June-Gunn, Kim Chang-Sam, Choi Heon-Jin, Park Seong-Hoon
  • Patent number: 5010043
    Abstract: A process for producing a diamond compact comprised of diamond crystals bonded mainly by silicon carbide. The diamond crystals are intimately mixed with silicon in the proportions 97 to 65 percent by weight of diamond to 3 to 35 percent by weight of silicon. The thus-mixed diamond crystals and silicon are placed immediately adjacent to one or more bodies of silicon within a container and subjected to high pressure and temperature so as to cause melting of the premixed silicon and of the external silicon which infiltrates into the interstitial spaces between the diamond crystals to cause most of the silicon between the diamond crystals to react with diamond to produce silicon carbide. The elevated temperature is in the range 1,100.degree. to 18,000.degree. C., and the elevated pressure is in the range 10 to 40 kilobars. The resulting compact contains between 50 and 85 volume percent of diamond with a density of at least 3.35 g/cm.sup.3 and a compressive strength of at least 10 kilobars.
    Type: Grant
    Filed: November 15, 1988
    Date of Patent: April 23, 1991
    Assignee: The Australian National University
    Inventor: Alfred E. Ringwood
  • Patent number: 5006423
    Abstract: A method of bonding metallic wires, such as strain gages, thermocouples, etc., directly onto ceramic components, such as silicon nitride or silicon carbide turbine parts, by means of a refractory cement formed from a mixture of water, sodium silicate, and a ceramic powder, preferably of a composition similar to the underlying ceramic component. Several thin layers of the mixture are applied and cured so as to provide a strong bond having good thermal shock resistance for testing at typical gas turbine operating temperatures, such as 2500.degree. F. or above.
    Type: Grant
    Filed: April 26, 1988
    Date of Patent: April 9, 1991
    Assignee: Allied-Signal Inc.
    Inventor: Barry S. Draskovich
  • Patent number: 5001088
    Abstract: A porous form body is produced of sinterable SiC-powder by forming a suitable suspension of said SiC-powder and then treating the suspension to convert it into droplets and the droplets into a granular material in which the granules are substantially larger than the particles of SiC-powder. The granular material is then formed into a green body, e.g. by spraying the granules onto a negative mold of the form body or slip-casting or the like. The green body is then sintered whereby the resulting porosity in the final form body provides the form body with low drag.
    Type: Grant
    Filed: October 25, 1988
    Date of Patent: March 19, 1991
    Assignee: MTU Motoren- und Turbinen-Union
    Inventors: Holger Hauptmann, Gerhard Andrees
  • Patent number: 4994417
    Abstract: The invention relates to a method for producing a sintered silicon carbide article having a sintered density of at least 90% of the theoretical density and a mechanical flexural strength of 50 kg/mm.sup.2 or higher. This is achieved by adding to a finely divided .alpha.-type silicon carbide powder, a tar pitch in such amounts as to provide 4.2-6 parts by weight of carbon after carbonization and a boron compound such as to correspond to a boron content of 0.005-0.15 parts by weight as densification aids, mixing and shaping the resulting mixture, and then sintering the thus-shaped article in an inert atmosphere at a temperature of from 1950 .degree. to 2300.degree. C.
    Type: Grant
    Filed: February 7, 1990
    Date of Patent: February 19, 1991
    Assignee: Sumitomo Aluminum Smelting Company, Limited
    Inventors: Koichi Yamada, Masahide Mouri, Yoshisaburo Nomura
  • Patent number: 4988647
    Abstract: A process of forming a coherent refractory mass on a surface comprises projecting against that surface, together with oxygen, a mixture of refractory particles and fuel which reacts in an exothermic manner with the projected oxygen to release sufficient heat to melt at least the surfaces of the refractory particles and thus form the refractory mass. The projected mixture contains, as fuel, finely divided particles of at least one element which is oxidizable to form a refractory oxide and it also contains carbonaceous particles which are of such a size or composition that carbon particles become occluded in the formed refractory mass. The mixture may contain, as said fuel, finely divided particles having a mean grain size of less than 50 .mu.m of silicon, aluminum and/or magnesium. The carbonaceous particles may comprise a carbonaceous core which is covered by a mantle inhibiting oxidation of the core.
    Type: Grant
    Filed: October 4, 1988
    Date of Patent: January 29, 1991
    Assignee: Glaverbel
    Inventors: Leon-Philippe Mottet, Pierre Robyn, Pierre Laroche
  • Patent number: 4987103
    Abstract: A slider, the sliding performance, i.e., sealing performance of which is improved, without a decline in the combination strength of the grain boundaries and the abrasion resistance, by including 2-10%, more preferably 3-8%, by weight of free carbon in a slider composed of a high density silicon carbide sintered compact the relative density of which is not less than 95%.
    Type: Grant
    Filed: March 21, 1986
    Date of Patent: January 22, 1991
    Assignee: Nippon Pillar Packing Co., Ltd.
    Inventors: Hisashi Kinugasa, Nobuto Mukae
  • Patent number: 4985378
    Abstract: A carbon-containing refractory is formed by mixing 1-10 weight % of silicon nitride, 1-35 weight % of carbon, and a remainder of a refractory raw material, molding the mixture into a molded body, and burning the molded body such that fine whiskers of silicon carbide are uniformly distributed within the matrix.
    Type: Grant
    Filed: September 6, 1988
    Date of Patent: January 15, 1991
    Assignee: Shinagawa Refractories Co., Ltd.
    Inventors: Kenji Ichikawa, Noboru Tsukamoto, Eishi Iida, Yuji Yoshimura, Junichi Inoue
  • Patent number: 4980104
    Abstract: A high density SiC sintered body can be obtained by molding a mixture of two kinds of high temperature-type and low temperature-type silicon carbides together with sintering aids into a shaped article, primarily firing the shaped article, and subjecting the primarily sintered body to an HIP treatment.
    Type: Grant
    Filed: January 10, 1989
    Date of Patent: December 25, 1990
    Assignee: NGK Insulators, Ltd.
    Inventor: Shinji Kawasaki
  • Patent number: 4975396
    Abstract: A process for producing reinforced cementitious compositions in which the following constituents are mixed in the aqueous phase in the following order: about 35-55 parts by weight of water mixed with about 3-12 parts of a polymer, by weight of dry polymer; up to about 5 parts of a water-reducing auxiliary agent and/or a liquifying agent; from about 15-30 parts of metakaolin; from about 50-120 parts of silica sand; and about 100 parts of cement. Continuous mixing is maintained until a homogeneous, thixotropic paste is obtained. Then between 2 and 15% by weight of alkaline-resistant glass fibers, relative to the weight of the paste, is introduced into the paste. The product produced by this method is particularly suitable for use as a mortar or paste which may be easily sprayed upon vertical surfaces and as hydraulic concretes, resistant to the effects of weather and aging.
    Type: Grant
    Filed: March 16, 1989
    Date of Patent: December 4, 1990
    Assignee: Vetrotex Saint-Gobain
    Inventor: Jacques Thiery
  • Patent number: 4963516
    Abstract: A silicon carbide complex sintered body including 20 to 99 wt % of SiC, 80 to 0.5 wt % of at least one compound selected from the group consisting of W.sub.2 B.sub.5 and/or MoB.sub.2, and 0.5 to 5 wt % of at least one material selected from the group consisting of boron, carbon, and boron carbide. A process for producing the sintered body by preparing a mixed powder is also disclosed, wherein the mixed powder includes 20 to 99 wt % of SiC powder having an average particle diameter of not greater than 5 microns, 80 to 0.5 wt % of at least one compound selected from the group consisting of W.sub.2 B.sub.5 and MoB.sub.2, and 0.1 to 5 wt %, when calculated as boron, of boron or a compound containing boron, and 0.1 to 5 wt %, when calculated as carbon, molding the mixture, and firing the molding in a temperature range from 1,900.degree. to 2,500.degree. C. in vacuum or in an inert atmosphere.
    Type: Grant
    Filed: July 21, 1988
    Date of Patent: October 16, 1990
    Assignee: NGK Insulators, Ltd.
    Inventor: Shinji Kawasaki
  • Patent number: 4962069
    Abstract: The preparation of highly densified ceramic bodies by the sintering of certain preceramic polysilazanes filled with silicon carbide powders, metal-containing sintering aids, and, optionally, polysilazane curing agents is described. Such highly densified ceramic bodies can be prepared by either a pressureless sintering process or a hot press sintering process. The compositions of this invention can be formed into desired shapes and then sintered to form ceramic, shaped bodies with high densities. One advantage of the present invention is that the green bodies have relative high strengths and thus can be easily handled and, if desired, machined before sintering. The preceramic polysilazanes useful in this invention must yield ceramic chars which contains free or excess carbon in addition to carbon in the form of silicon carbide upon pyrolysis to elevated temperatures.
    Type: Grant
    Filed: November 7, 1988
    Date of Patent: October 9, 1990
    Assignee: Dow Corning Corporation
    Inventors: Gary T. Burns, Chandan K. Saha, Ronald J. Keller
  • Patent number: 4952533
    Abstract: A bonding composition for silicon carbide ceramics, comprising: silicon carbide powder having a particle size of 1 to 50 .mu.m, powder carbon having a particle size of up to 15 .mu.m, silicon powder having a particle size of up to 10 .mu.m, a thermosetting resin, and a catalytically curable resin and a curing agent therefor. The composition is effective in bonding sintered silicon carbide ceramic pieces.
    Type: Grant
    Filed: February 2, 1990
    Date of Patent: August 28, 1990
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventor: Tatsuhiko Hongu
  • Patent number: 4942145
    Abstract: Preceramic molding compositions capable of forming low density ceramics having acceptable strength and improved wear resistance are compositions having a particle size not larger than about 105 micrometers and comprising an intimate mixture of (A) about 50-90 parts by weight of powder ingredients comprising about 2-50% by weight of graphite powder and about 98-50% by weight of a second powder selected from silicon carbide, silicon nitride, and mixtures thereof and (B) correspondingly, about 50-10 parts by weight of a preceramic polysilazane binder.
    Type: Grant
    Filed: May 26, 1989
    Date of Patent: July 17, 1990
    Assignee: Ethyl Corporation
    Inventors: William E. Moehle, John J. Rogers, John Semen
  • Patent number: 4929573
    Abstract: The preparation of highly densified ceramic bodies by the sintering of certain organopolysiloxanes filled with silicon carbide powders, and metal-containing sintering aids is described. Such highly densified ceramic bodies can be prepared by either a pressureless sintering process or a hot press sintering process. The compositions of this invention can be formed into desired shapes and then sintered to form ceramic, shaped bodies with high densities. One advantage of the present invention is that the green bodies have relative high strengths and thus can be easily handles and, if desired, machined before sintered. The organopolysiloxanes useful in this invention must yield a ceramic char which contains free or excess carbon in addition to carbon in the form of silicon carbide upon pyrolysis to elevated temperatures.
    Type: Grant
    Filed: September 26, 1988
    Date of Patent: May 29, 1990
    Assignee: Dow Corning Corporation
    Inventors: William H. Atwell, Gary T. Burns, Chandan K. Saha
  • Patent number: 4925815
    Abstract: A high-toughness silicon carbide composite ceramic comprising silicon carbide, 5 to 50 vol % of graphite whiskers, and sintering aid, and a method for producing the composite ceramic. The composite ceramic has high-temperature strength and fracture toughness value, and also has electrical conductivity.
    Type: Grant
    Filed: February 15, 1989
    Date of Patent: May 15, 1990
    Assignee: Kabushiki Kaisha Toyota Chuo Kenkyusho
    Inventors: Toshihiko Tani, Shigetaka Wada
  • Patent number: 4920084
    Abstract: In processes of forming a refractory mass on a surface, a mixture of refractory particles and oxidizable particles which react exothermically with oxygen to generate sufficient heat to soften or melt at least the surfaces of the refractory particles are sprayed against that surface to bring about formation of said refractory mass. To promote the reliable and consistent formation of a durable refractory mass, the granulometry of the particles which are sprayed in the mixture is such that the 80% and 20% grain sizes of the refractory particles (that is, the screen mesh sizes G.sub.80 and G.sub.20 through which respectively 80% and 20% by weight of the particles will pass) have a mean greater than the mean of the 80% and 20% grain sizes of the oxidizable particles and the size range spread factor f(G) of the refractory particles is at least 1.
    Type: Grant
    Filed: October 6, 1988
    Date of Patent: April 24, 1990
    Assignee: Glaverbel
    Inventors: Pierre Robyn, Leon-Philippe Mottet, Pierre Deschepper
  • Patent number: 4904424
    Abstract: 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: Grant
    Filed: May 29, 1987
    Date of Patent: February 27, 1990
    Assignee: Hoechst Celanese Corporation
    Inventor: Robert E. Johnson
  • Patent number: 4902652
    Abstract: A sintered article of diamond is obtained by coating the surface of diamond particles with 30 to 0.1% by volume, based on the total volume of the diamond particles and aids, of at least one member selected from the group consisting of the transition metals of Groups 4a, 5a, and 6a in the Periodic Table of Elements and boron and silicon, and sintering the coated diamond particles under conditions of high pressure and high temperature, which sintered article consists of 70 to 99.8% by volume of diamond and 30 to 0.2% by volume of the carbide of the coating substance. A method for the production of the sintered article of diamond is also disclosed.
    Type: Grant
    Filed: July 8, 1988
    Date of Patent: February 20, 1990
    Assignee: Agency of Industrial Science & Technology, Ministry of International Trade & Industry
    Inventors: Shoichi Kume, Haruo Yoshida, Kazutaka Suzuki, Yoshio Tasaki, Shiro Ikuta, Masamitu Ishikawa, Michihide Machida
  • Patent number: 4891340
    Abstract: Low density SiC ceramics having improved bending and specific strengths are prepared by (A) intimately mixing about 50-85% by weight of SiC powder with about 15-50% by weight of a preceramic polysilazane binder, (B) pulverizing the mixture to form particles having a particle size smaller than 105 micrometers, (C) separating from those particles any particles having a particle size larger than about 105 micrometers, (D) molding the resultant composition having a particle size not larger than about 105 micrometers, and (E) pyrolyzing the molded composition in an inert atmosphere to a temperature of about 1200.degree.-1450.degree. C.In a preferred embodiment of the invention, the preceramic binder is at least one polysilazane prepared by reacting an organodihalosilane with ammonia, treating the ammonolysis product with a basic catalyst which is capable of deprotonating an NH group that is adjacent to an SiH group, and quenching the resultant product with an electrophilic quenching reagent.
    Type: Grant
    Filed: August 18, 1988
    Date of Patent: January 2, 1990
    Assignee: Ethyl Corporation
    Inventors: John Semen, John J. Rogers
  • Patent number: 4879334
    Abstract: The invention relates to an organopolyarylsilane which comprises aromatic ring segments having a skelton mainly comprising an aromatic condensed ring structure derived from an organic solvent soluble pitch and organosilane segments randomly bonded thereto with an Si--C linkage intervening therebetween and is soluble in an organic solvent, and further relates to an SiC--C based continuous inorganic fiber exhibiting excellent heat resistant strength, oxidation resistance and electro-conductivity, which is obtained by spinning the above organopolyarylsilane into fiber, and after infusibilizing, heat-treating said fiber under a nonreactive atmosphere at a high temperature. The above organopolyarylsilane can be efficiently obtained in extremely high yields, by a process wherein low boiling substances produced by pyrolysis of the starting material, i.e.
    Type: Grant
    Filed: November 6, 1987
    Date of Patent: November 7, 1989
    Assignee: The Foundation: The Research Institute for Special Inorganic Materials
    Inventors: Yoshio Hasegawa, Kiyohito Okamura
  • Patent number: 4876226
    Abstract: A pressureless liquid phase sintering method for increasing the density of silicon carbide using a sintering composition that includes silicon carbide, calcia, and alumina.
    Type: Grant
    Filed: January 12, 1987
    Date of Patent: October 24, 1989
    Inventor: Ricardo I. Fuentes
  • Patent number: 4872333
    Abstract: A wire drawing die is provided which is characterized by containing a particular thermally stable diamond compact through which a hole is formed for receiving the wire to be drawn therethrough. The thermally stable diamond compact, which preferably has a hexagonal or circular shape in plan, comprises a mass of diamond particles present in an amount of 80 to 90 percent by volume of the compact and a second phase present in an amount of 10 to 20 percent by volume of the compact, the mass of diamond particles containing substantial diamond-to-diamond bonding to form a coherent, skeletal mass and a second phase consisting essentially of silicon, the silicon being in the form of silicon and/or silicon carbide.
    Type: Grant
    Filed: April 8, 1986
    Date of Patent: October 10, 1989
    Inventor: Richard P. Burnand
  • Patent number: 4866012
    Abstract: A method of forming a carbothermally reduced powder of nitrides or carbides is disclosed. The product powder consists principally of unagglomerated particles and is formed by providing a collection of precursor particles in colloidal dispersion, adding to the dispersion a polymerizable monomer, polymerizing the monomer to matrix the precursor particles in discrete, well dispersed positions and carbothermally reducing the particles followed by removing excess carbon by burning. The polymer matrix acts an an agglomerate-inhibiting carbon source during carbothermal reduction.
    Type: Grant
    Filed: February 3, 1988
    Date of Patent: September 12, 1989
    Assignee: Engelhard Corporation
    Inventor: Lance D. Silverman
  • Patent number: 4859638
    Abstract: A sintered material for recording/reading (particularly magnetic) head slider is produced by:preparing a powdery mixture which comprises 0.5 to 6.0% by weight of at least one component selected from the component group A consisting of the following elements and compounds thereof, a garnet type compound consisting essentially of erbium oxide and aluminum oxide in amounts of 2 to 12% by weight and 0 (exclusive) to 2 (inclusive) % by weight based on the total composition, respectively, and expressed by the formula Er.sub.3 (Al,Er).sub.2 (AlO.sub.4).sub.3 through (Er,Al).sub.3 Al.sub.2 (AlO.sub.4).sub.3, and the balance being silicon carbide powder:the elements for the component group A being Ti, V, Cr, Mn, Mg, Y, Zr, Nb, Mo, Ba, La, Ce, Gd, Hf, Ta, W, Th, and Cs; andsintering the resultant mass under the application of a high pressure.Further sintering aids of Be, BeO, B and B.sub.4 C may be present. For the garnet type compound, erbium oxide may be used, preferably in combination with alumina.
    Type: Grant
    Filed: February 16, 1988
    Date of Patent: August 22, 1989
    Assignees: Sumitomo Special Metals Co., Ltd., Nippon Tungsten Co., Ltd.
    Inventors: Toshiaki Wada, Yoshiaki Katsuyama, Mitsuhiko Furukawa, Takashi Kitahira, Michito Miyahara, Kiyohito Misumi, Masaharu Shiroyama
  • Patent number: 4857488
    Abstract: A method for making a casting nozzle, includes mixing a main casting nozzle material 70-95% by weight and electrofused aggregates 5-30% by weight, the electrofused aggregates consisting essentially of ZrO.sub.2 30-60% by weight, Al.sub.2 O.sub.3 20-50% by weight, SiO.sub.2 10-20% by weight and SiC 5-40% by weight together with a binder, thereby to make a mixture, forming the mixture in the shape of a casting nozzle thereby to make a formed body, and sintering the formed body.
    Type: Grant
    Filed: February 28, 1987
    Date of Patent: August 15, 1989
    Assignee: Toshiba Ceramics Co., Ltd.
    Inventors: Yoshiro Aiba, Kazumi Arakawa, Takashi Watanabe, Kazuhide Kawai