Abstract: Pressureless sintered high density materials containing hexagonal boron nitride have low coefficients of friction and high wear resistance and are useful for bearings, bushings and other articles subjected to bearing loads.

Abstract: Pressureless sintered high density materials containing hexagonal boron nitride have low coefficients of friction and high wear resistance and are useful for bearings, bushings and other articles subjected to bearing loads.

Abstract: Semiconductor wire bonding tools used in the assembly and interconnection of integrated circuits (ICs) are micromolded from a mixture of ultrafine particulate materials mixed with an organic binder. Following extraction of the binder the green bonding tools are sintered during which they undergo isotropic, constant and accurately predetermined shrinkage. Hence semiconductor wire bonding tools can be produced with virtually no limit to miniaturization, thus allowing the fabrication of higher integrated semiconductor products.

Abstract: The invention overcomes prior art problems associated with mass-production of technology-based commercial products like watch cases, mobile telephone housings, medical appliances, etc. such as high investment in tooling, delays in production, short economic tool life, inconsistence and mismatching between parts made in different geographical locations, etc., through the use of standardized, interchangeable ceramic mold inserts.

Abstract: Ultrasmall, complex-shaped high-precision micromolds are produced by controlled shrinkage upon sintering of green parts molded from mixtures of micrometer- or nanometer-sized particulates dispersed in an organic binder.

Abstract: Permanent magnet for voice coil actuator motors used to actuate head-arm assemblies in small form disk drives are produced from a dispersion of prealloyed rare earth magnetic particles in a thermoplastic binder. Upon shaping of green parts the magnetic axis of the particles is aligned with the field lines of a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better than tolerances and 100% material utilization are claimed.

Abstract: Precise control of the shrinkage upon sintering of bodies made from mixtures of particulate materials and organic binders is achieved through precision pycnometry of the particulate materials and of the resulting sintered bodies, thus allowing a single molding tool to be used to produce parts in different sizes and from different materials and to tight manufacturing tolerances.

Abstract: Rotors for stepping motors used in analog timepieces are produced from a mixture of prealloyed rare earth magnetic particles and a thermoplastic binder. The mixture is either tape cast in a magnetic field following blanking of green rotors or injection molded in a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better tolerances and 100% material utilization are claimed.

Abstract: Permanent magnets for voice coil actuator motors used to actuate head-arm assemblies in small form factor disk drives are produced from a dispersion of prealloyed rare earth magnetic particles in a thermoplastic binder. Upon shaping of green parts the magnetic axis of the particles is aligned with the field lines of a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better tolerances and 100% material utilization are claimed.

Abstract: Rotors for stepping motors used in analog timepieces are produced from a mixture of prealloyed rare earth magnetic particles and a thermoplastic binder. The mixture is either tape cast in a magnetic field following blanking of green rotors or injection molded in a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better tolerances and 100% material utilization are claimed.

Abstract: Semiconductor wire bonding tools used in the assembly and interconnection of integrated circuits (ICs) are micromolded from a mixture of ultrafine particulate materials mixed with an organic binder. Following extraction of the binder the green bonding tools are sintered during which they undergo isotropic, constant and accurately predetermined shrinkage. Hence semiconductor wire bonding tools can be produced with virtually no limit to miniaturization, thus allowing the fabrication of higher integrated semiconductor products.

Abstract: A method to produce polycrystalline sapphire or ruby watch jewels is disclosed. Green watch jewels are formed from a mixture of fine ceramic powders with a thermoplastic binder. Following extraction of the binder the parts are sintered to net shape and full density. The method obviates the inefficient and labor intensive technique of monocrystalline watch jewel manufacturing. The purity of the raw materials and processing conditions result in sintered polycrystalline rubies or sapphires with homogeneous microstructures, small grain size and hardness similar to that of their synthetic monocrystalline counterparts.

Abstract: A method is disclosed to form micromolds and micromold components from mixtures of micrometer or nanometer-sized particulates dispersed in an organic binder. Following extraction of the organic binder the green micromolds or micromold components are sintered to full density, upon which they shrink by accurately predetermined amounts. The method allows to achieve complex-shaped micrometer and nanometer-sized precision parts such as MEMS devices and MEMS packages.

Abstract: A method is disclosed to accurately determine the volumetric composition of thermoplastic compounds made from sinterable materials mixed with an organic binder so that parts produced from such compounds will have a precisely controlled shrinkage upon sintering. The invention allows the use of a single molding tool to fabricate parts to very tight manufacturing tolerances in a range of different sizes and from different materials such as stainless steels, carbides, advanced ceramics, metal and ceramic matrix composites, etc. The invention also allows the miniaturization of metal and ceramic injection molded components.

Abstract: The invention overcomes prior art problems associated with mass-production of technology-based commercial products like watch cases, mobile telephone housings, medical appliances, etc. such as high investment in tooling, delays in production, short economic tool life, inconsistence and mismatching between parts made in different geographical locations, etc., through the use of standardized, interchangeable ceramic mold inserts.

Abstract: A method of binder removal from a green body before sintering or the like wherein the binder is constituted of a polymeric material or mixture which is degradable by thermo-oxidation and the green body is initially heated to a temperature where the binder reaches an energy level above the activation energy of the binder, as a result of which exothermic degradation reactions are initiated at the binder-atmosphere interface. The rate of the exothermic reaction is controlled by the rate of supply of thermal energy and oxygen to the reaction site as well as the rate of evacuation of the heat of reaction generated during the thermal oxidation. Substantially all of the binder is thus removed from the green body which can then be sintered in accordance with the practices of the prior art.