Patents by Inventor Edwin G. Butler

Edwin G. Butler has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 8313598
    Abstract: A method of manufacturing a ceramic matrix composite article comprising the steps of: — a) forming a slurry consisting of water, polyvinyl alcohol, nitric acid, polyethylene glycol and alumina particles only, b) providing a length of fabric, the fabric comprising a plurality of ceramic fibres, c) applying slurry to at least one of the sides of the length of fabric such that the slurry adheres and impregnates the length of fabric, d) drying the slurry impregnated length of fabric, e) cutting the slurry impregnated length of fabric into a plurality of pieces of slurry impregnated laminates of fabric, f) applying water to each of the pieces of slurry impregnated laminates of fabric to reactivate the slurry, g) stacking the plurality of pieces of slurry impregnated laminates of fabric on a first mould part, h) consolidating the plurality of pieces of slurry impregnated laminates of fabric on the mould part, and i) sintering the stack of the plurality of pieces of slurry impregnated laminates of fabric to form an
    Type: Grant
    Filed: March 9, 2011
    Date of Patent: November 20, 2012
    Assignee: Rolls-Royce PLC
    Inventor: Edwin G. Butler
  • Publication number: 20110259506
    Abstract: A method of manufacturing a ceramic matrix composite article comprising the steps of: — a) forming a slurry consisting of water, polyvinyl alcohol, nitric acid, polyethylene glycol and alumina particles only, b) providing a length of fabric, the fabric comprising a plurality of ceramic fibres, c) applying slurry to at least one of the sides of the length of fabric such that the slurry adheres and impregnates the length of fabric, d) drying the slurry impregnated length of fabric, e) cutting the slurry impregnated length of fabric into a plurality of pieces of slurry impregnated laminates of fabric, f) applying water to each of the pieces of slurry impregnated laminates of fabric to reactivate the slurry, g) stacking the plurality of pieces of slurry impregnated laminates of fabric on a first mould part, h) consolidating the plurality of pieces of slurry impregnated laminates of fabric on the mould part, and i) sintering the stack of the plurality of pieces of slurry impregnated laminates of fabric to form an
    Type: Application
    Filed: March 9, 2011
    Publication date: October 27, 2011
    Applicant: ROLLS-ROYCE PLC
    Inventor: Edwin G. BUTLER
  • Patent number: 6660115
    Abstract: A method of manufacturing a ceramic matrix composite comprises forming a slurry comprising a ceramic sol, filler particles and a solvent and forming laminates of fibers (12). The laminates of fibers (12) are impregnated with the slurry and are stacked (14) on a mold (10). The stack (14) of laminates of fibers (12) is covered by a porous membrane (16), a breather fabric (18) and a vacuum bag (20). The vacuum bag (20) is evacuated and is heated to a temperature of 60° C. for 10 hours to produce a ceramic matrix composite. The ceramic matrix composite is then heated to a temperature of 1200° C. at atmospheric pressure to sinter the ceramic matrix composite.
    Type: Grant
    Filed: September 18, 2002
    Date of Patent: December 9, 2003
    Assignee: Rolls-Royce plc
    Inventors: Edwin G Butler, Anthony G Razzell, John Dominy, Paul A Doleman, Ihsan A H Al-Dawery
  • Publication number: 20030034113
    Abstract: A method of manufacturing a ceramic matrix composite comprises forming a slurry comprising a ceramic sol, filler particles and a solvent and forming laminates of fibers (12). The laminates of fibers (12) are impregnated with the slurry and are stacked (14) on a mold (10). The stack (14) of laminates of fibers (12) is covered by a porous membrane (16), a breather fabric (18) and a vacuum bag (20). The vacuum bag (20) is evacuated and is heated to a temperature of 60° C. for 10 hours to produce a ceramic matrix composite. The ceramic matrix composite is then heated to a temperature of 1200° C. at atmospheric pressure to sinter the ceramic matrix composite.
    Type: Application
    Filed: September 18, 2002
    Publication date: February 20, 2003
    Inventors: Edwin G. Butler, Anthony G. Razzell, John Dominy, Paul A. Doleman, Ihsan A.H. Al-Dawery
  • Patent number: 6497776
    Abstract: A method of manufacturing a ceramic matrix composite comprises forming a slurry comprising a ceramic sol, filler particles and a solvent and forming laminates of fibres (12). The laminates of fibres (12) are impregnated with the slurry and are stacked (14) on a mould (10). The stack (14) of laminates of fibres (12) is covered by a porous membrane (16), a breather fabric (18) and a vacuum bag (20). The vacuum bag (20) is evacuated and is heated to a temperature of 60° C. for 10 hours to produce a ceramic matrix composite. The ceramic matrix composite is then heated to a temperature of 1200° C. at atmospheric pressure to sinter the ceramic matrix composite.
    Type: Grant
    Filed: December 15, 1999
    Date of Patent: December 24, 2002
    Assignee: Rolls-Royce plc
    Inventors: Edwin G. Butler, Anthony G. Razzell, John Dominy, Paul A. Doleman, Ihsan AI-I Al-Dawery
  • Patent number: 5609741
    Abstract: A method of manufacturing a composite material in which a fibre matt is placed adjacent a plate electrode in ceramic sol. The application of an electric field to the sol via the electrode results in the deposition of sol particles on the electrode which subsequently permeate the fibre matt. The permeated fibre matt is then removed from the sol, dried out and heated to sinter the sol particles.
    Type: Grant
    Filed: October 20, 1994
    Date of Patent: March 11, 1997
    Assignee: Rolls-Royce plc
    Inventors: Trevor J. Illston, Paul A. Doleman, Edwin G. Butler, Peter M. Marquis, Clive B. Ponton, Reza Piramoon, Mark J. Gilbert
  • Patent number: 5554271
    Abstract: A method of manufacturing a composite material which comprises ceramic fibers in a matrix of a ceramic material. A woven mat of ceramic fibers having an electrically conductive coating thereon is immersed in a sol. The sol comprises surface-charged ceramic particles. A potential difference is applied between the fibers and a second electrode placed in the sol. The applied potential difference is continued until the mat is permeated by the ceramic particles in the sol. The mat is removed from the sol and is then heated to sinter the permeated ceramic particles.
    Type: Grant
    Filed: March 8, 1995
    Date of Patent: September 10, 1996
    Assignee: Rolls-Royce plc
    Inventors: Trevor J. Illston, Paul A. Doleman, Edwin G. Butler, Peter M. Marquis, Clive B. Ponton, Reza Piramoon, Mark J. Gilbert
  • Patent number: 4506020
    Abstract: A method of producing a dense ceramic product comprises the steps of mixing a ceramic powder containing a major proportion of an alpha-phase substituted silicon nitride obeying the formula M.sub.x (Si,Al).sub.12 (O,N).sub.16, where x is not greater than 2 and M is a modifying cation (e.g. yttrium, calcium, lithium, magnesium, cerium) with at least one nitride of silicon and/or alumina wherein the alumina represents not more than 10% by weight of the mixture; and sintering the mixture in a non-oxidizing atmosphere at a temperature of 1700.degree. C. to 1900.degree. C. so as to produce (1) a dense ceramic product consisting essentially of beta-phase substituted silicon nitride having the general formula Si.sub.6-z Al.sub.z N.sub.8-z O.sub.z, where z is greater than zero and not greater than 1.5, and 0.05% wt to 20% wt of a further phase containing said modifying cation M, or (2) a dense ceramic product consisting essentially of said beta-phase substituted silicon nitride a 0.
    Type: Grant
    Filed: February 23, 1983
    Date of Patent: March 19, 1985
    Assignee: Lucas Industries
    Inventors: Edwin G. Butler, Andrew Szweda