Patents by Inventor Shinji Kajii
Shinji Kajii 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).
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Patent number: 9701587Abstract: Provided is a method for producing an inorganic fiber-bonded ceramic material, which can produce, at a high yield, an inorganic fiber-bonded ceramic material with fewer defects, and with an end part and a central part equivalent to each other in microstructure and mechanical properties, and also makes it possible to increase the ceramic material in size. The method for producing an inorganic fiber-bonded ceramic material is characterized in that it includes: a first pressing step of setting, in a carbon die, a laminate to be surrounded by a ceramic powder, the laminate obtained by stacking a coated inorganic fiber shaped product including an inorganic fiber part of inorganic fibers that have a pyrolysis initiation temperature of 1900° C. or lower, and a surface layer of an inorganic substance for bonding the inorganic fibers to each other, and pressing the laminate at a temperature of 1000 to 1800° C.Type: GrantFiled: March 21, 2013Date of Patent: July 11, 2017Assignee: Ube Industries, Ltd.Inventors: Kenji Matsunaga, Shinji Kajii, Shohei Suizu, Tsutomu Kodama
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Publication number: 20150137411Abstract: Provided is a method for producing an inorganic fiber-bonded ceramic material, which can produce, at a high yield, an inorganic fiber-bonded ceramic material with fewer defects, and with an end part and a central part equivalent to each other in microstructure and mechanical properties, and also makes it possible to increase the ceramic material in size. The method for producing an inorganic fiber-bonded ceramic material is characterized in that it includes: a first pressing step of setting, in a carbon die, a laminate to be surrounded by a ceramic powder, the laminate obtained by stacking a coated inorganic fiber shaped product including an inorganic fiber part of inorganic fibers that have a pyrolysis initiation temperature of 1900° C. or lower, and a surface layer of an inorganic substance for bonding the inorganic fibers to each other, and pressing the laminate at a temperature of 1000 to 1800° C.Type: ApplicationFiled: March 21, 2013Publication date: May 21, 2015Inventors: Kenji Matsunaga, Shinji Kajii, Shohei Suizu, Tsutomu Kodama
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Patent number: 8906288Abstract: Provided is a process for producing dense SiC fiber-bonded ceramics excellent in heat resistance and having a shape hard to form by hot pressing such as an elongated shape. The process for producing SiC fiber-bonded ceramics composed of: inorganic fiber made of SiC; and interfacial layers mainly made of carbon includes vacuum-sealing a preform, prepared by forming specific silicon carbide-based inorganic fiber into a certain shape, into a capsule and hot-isostatic-pressing the preform. The process is characterized in that the ratio of the number of carbon atoms to the number of silicon atoms in the preform is 1.02 to 1.20, and before the hot isostatic pressing, the preform is heated in an inert gas atmosphere or a reducing gas atmosphere at a temperature of 1200° C. to 1800° C. to adjust the oxygen content in the inorganic fiber to 6.0% by weight or lower, and then the hot isostatic pressing is carried out.Type: GrantFiled: September 17, 2009Date of Patent: December 9, 2014Assignee: Ube Industries, Ltd.Inventors: Kenji Matsunaga, Shinji Kajii, Tsutomu Kodama
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Publication number: 20130089705Abstract: Disclosed is to provide a material which can withstand rapid increase in temperature to 1600° C. or more and exhibits little change in properties even in a high-speed combustion gas stream. Specifically disclosed is a SiC fiber-bonded ceramic coated with SiC, which is characterized by being produced by coating the surface of a SiC fiber-bonded ceramic with use of a coating layer including mainly SiC, wherein the SiC fiber-bonded ceramic includes inorganic fibers having a sintered SiC structure, each of which contains 0.01 to 1 wt % of oxygen (O) and at least one or more metal atoms of metal atoms in Groups 2A, 3A, and 3B and a 1-100 nm interfacial layer containing carbon (C) as a main component formed between the fibers.Type: ApplicationFiled: March 2, 2011Publication date: April 11, 2013Applicant: UBE INDUSTRIES, LTD.Inventors: Kenji Matsunaga, Tsutomu Kodama, Hisao Tanaka, Shinji Kajii
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Publication number: 20110187030Abstract: Provided is a process for producing dense SiC fiber-bonded ceramics excellent in heat resistance and having a shape hard to form by hot pressing such as an elongated shape. The process for producing SiC fiber-bonded ceramics composed of: inorganic fiber made of SiC; and interfacial layers mainly made of carbon includes vacuum-sealing a preform, prepared by forming specific silicon carbide-based inorganic fiber into a certain shape, into a capsule and hot-isostatic-pressing the preform. The process is characterized in that the ratio of the number of carbon atoms to the number of silicon atoms in the preform is 1.02 to 1.20, and before the hot isostatic pressing, the preform is heated in an inert gas atmosphere or a reducing gas atmosphere at a temperature of 1200° C. to 1800° C. to adjust the oxygen content in the inorganic fiber to 6.0% by weight or lower, and then the hot isostatic pressing is carried out.Type: ApplicationFiled: September 17, 2009Publication date: August 4, 2011Applicant: UBE INDUSTRIES, LTD.Inventors: Kenji Matsunaga, Shinji Kajii, Tsutomu Kodama
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Patent number: 7951736Abstract: An SiC fiber bonded ceramic constituted of both a base material which comprises both inorganic fibers made mainly of a sintered SiC structure containing 0.01 to 1 wt % of oxygen (O) and at least one of Groups 2A, 3A and 3B metals and a 1 to 100-nm and carbon (C)-base boundary layer formed among the fibers and a surface part which is made mainly of an SiC-base ceramic structure and formed on at least part of the surface of the base material, characterized in that the boundary portion between the surface part and the base material takes such a gradient structure that the structure of the base material changes into the structure of the surface part gradually and continuously.Type: GrantFiled: September 11, 2007Date of Patent: May 31, 2011Assignee: Ube Industries, LtdInventors: Kenji Matsunaga, Shinji Kajii, Toshihiko Hogami
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Publication number: 20100041541Abstract: An SiC fiber bonded ceramic constituted of both a base material which comprises both inorganic fibers made mainly of a sintered SiC structure containing 0.01 to 1 wt % of oxygen (O) and at least one of Groups 2A, 3A and 3B metals and a 1 to 100-nm and carbon (C)-base boundary layer formed among the fibers and a surface part which is made mainly of an SiC-base ceramic structure and formed on at least part of the surface of the base material, characterized in that the boundary portion between the surface part and the base material takes such a gradient structure that the structure of the base material changes into the structure of the surface part gradually and continuously.Type: ApplicationFiled: September 11, 2007Publication date: February 18, 2010Applicant: UBE INDUSTRIES, LTD.Inventors: Kenji Matsunaga, Shinji Kajii, Toshihiko Hogami
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Patent number: 7112547Abstract: Production processes of an inorganic fiber-bonded ceramic component comprising inorganic fibers mainly comprising Si, M, C and O, an inorganic substance mainly comprising Si and O and boundary layers comprising carbon as a main component; and an inorganic fiber-bonded ceramic component comprising inorganic fibers which are composed mainly of a sintered structure of SiC and contain specific metal atoms and boundary layers composed mainly of carbon, wherein a preliminary shaped material is set in a carbon die, covered with a carbon powder and then hot-pressed to load a pseudo-isotropic pressure on the preliminary shaped material; and a highly heat-resistant inorganic fiber-bonded ceramic component almost free from the occurrence of peelings of surface fibers or delamination, wherein fibers are aligned in a surface shape.Type: GrantFiled: August 6, 2003Date of Patent: September 26, 2006Assignee: UBE Industries, Ltd.Inventors: Shinji Kajii, Kenji Matsunaga, Toshihiko Hogami, Mitsuhiko Sato
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Patent number: 6541416Abstract: A silica-group composite oxide fiber formed of a composite oxide phase of an oxide phase (first phase) mainly made of a silica component and a metal oxide phase (second phase) excluding silica, in which the existent ratio of at least one metal element of a metal oxide constituting the second phase upward slopingly increases toward the surface layer of the fiber and a process for the production thereof.Type: GrantFiled: June 6, 2001Date of Patent: April 1, 2003Assignee: Ube Industries, Ltd.Inventors: Toshihiro Ishikawa, Yoshikatu Harada, Hidekuni Hayashi, Shinji Kajii
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Publication number: 20020001702Abstract: A silica-group composite oxide fiber formed of a composite oxide phase of an oxide phase (first phase) mainly made of a silica component and a metal oxide phase (second phase) excluding silica, in which the existent ratio of at least one metal element of a metal oxide constituting the second phase upward slopingly increases toward the surface layer of the fiber and a process for the production thereof.Type: ApplicationFiled: June 6, 2001Publication date: January 3, 2002Inventors: Toshihiro Ishikawa, Yoshikatu Harada, Hidekuni Hayashi, Shinji Kajii
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Patent number: 6132856Abstract: A highly heat-resistant sintered SiC fiber bonded material free of a decrease in strength and less breakable at an ultra-high temperature over 1,400.degree. C., comprising inorganic fibers which are composed mainly of a sintered SiC crystal, contain at least one kind of metal atoms selected from the class consisting of metal atoms of the 2A, 3A and 3B groups of the periodic table and are bonded nearly in the close-packed structure and 1 to 50 nm boundary layers composed mainly of carbon which are present at the interface of fibers, the less breakable highly heat-resistant sintered SiC fiber-bonded material having a density of at least 2.7 g/cm.sup.3 and an elastic modulus of at least 200 GPa, and a process for the production thereof.Type: GrantFiled: July 17, 1998Date of Patent: October 17, 2000Assignee: Ube Industries, Ltd.Inventors: Toshihiro Ishikawa, Shinji Kajii, Kenji Matsunaga, Toshihiko Hogami
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Patent number: 6117534Abstract: A reinforcement for composite materials is disclosed, which comprises a number of filaments of inorganic long fiber and glass and/or glass ceramic present in the gaps among the filaments and having a wire or tape form. Also disclosed is a metallic or ceramic composite material composed of a plurality of the reinforcements and a metal or intermetallic compound or ceramic which is present in the gaps among the individual reinforcements.Type: GrantFiled: October 1, 1999Date of Patent: September 12, 2000Assignee: Research Institute of Advanced Material Gas-Generator, Ltd.Inventors: Takemi Yamamura, Mitsuhiko Sato, Makoto Tamura, Shinji Kajii, Yasuo Matsumori, Yoshikatu Harada
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Patent number: 6004671Abstract: A reinforcement for composite materials is disclosed, which comprises a number of filaments of inorganic long fiber and glass and/or glass ceramic present in the gaps among the filaments and having a wire or tape form. Also disclosed is a metallic or ceramic composite material composed of a plurality of the reinforcements and a metal or intermetallic compound or ceramic which is present in the gaps among the individual reinforcements.Type: GrantFiled: January 13, 1995Date of Patent: December 21, 1999Assignee: Research Institute of Advanced Material Gas-Generator, Ltd.Inventors: Takemi Yamamura, Mitsuhiko Sato, Makoto Tamura, Shinji Kajii, Yasuo Matsumori, Yoshikatu Harada