With Vitrification Or Firing Ceramic Material Patents (Class 156/89.11)
  • Patent number: 7001569
    Abstract: A method of producing a ceramic multilayer substrate involves: producing a green composite laminate 11 containing first and second shrink-suppressing layers formed on the main surfaces of a green multilayer mother substrate 12 containing ceramic powder, the first and second shrink-suppressing layers containing a sintering-difficult powder substantially incapable of being sintered under the sintering conditions for the ceramic powder; forming first grooves 16 extending from the first shrink-suppressing layer 13 side into a part of the multilayer mother substrate 12; firing the composite laminate 11; removing the first and second shrink-suppressing layers 13 and 14; dividing the multilayer mother substrate 12 along the grooves 16 and obtaining a plurality of the ceramic multilayer substrates. Thereby, shrinkage in the plan direction at firing can be suppressed. Thus, a ceramic multilayer substrate having a high dimensional accuracy and a high reliability can be produced with a high production efficiency.
    Type: Grant
    Filed: November 22, 2001
    Date of Patent: February 21, 2006
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Yoshifumi Saitoh, Hiromichi Kawakami
  • Patent number: 6990729
    Abstract: A method for making an embedded toroidal inductor (118) includes forming in a ceramic substrate (100) a first plurality of conductive vias (102) radially spaced a first distance from a central axis (101) so as to define an inner circumference. A second plurality of conductive vias (104) is formed radially spaced a second distance about the central axis so as to define an outer circumference. A first plurality of conductive traces (110) forming an electrical connection between substantially adjacent ones of the first and second plurality of conductive vias is formed on a first surface (106) of the ceramic substrate. Further, a second plurality of conductive traces (110) forming an electrical connection between circumferentially offset ones of the first and second plurality of conductive vias is formed on a second surface of the ceramic substrate opposed from the first surface to define a three dimensional toroidal coil.
    Type: Grant
    Filed: September 5, 2003
    Date of Patent: January 31, 2006
    Assignee: Harris Corporation
    Inventors: Michael D. Pleskach, Andrew J. Thomson
  • Patent number: 6990725
    Abstract: This invention relates to the fabrication of planar inductive components whereby the design in cross-section describes a conductor surrounded by magnetic material along the length of the conductor; an electrical insulator is placed between the conductor and the magnetic material. Cases also apply where more than one independent conductor is used. The planar form allows integration of inductive components with integrated circuits. These inductive components can be embedded in other materials. They can also be fabricated directly onto parts.
    Type: Grant
    Filed: October 4, 2002
    Date of Patent: January 31, 2006
    Inventors: Mark D. Fontanella, Paul Greiff, Donato Cardarelli, Joseph G. Walsh
  • Patent number: 6984277
    Abstract: A composite structure (62) having a bond enhancement member (76) extending across a bond joint (86) between a ceramic matrix composite (CMC) material (80) and a ceramic insulation material (82), and a method of fabricating such a structure. The bond enhancement member may extend completely through the CMC material to be partially embedded in a core material (84) bonded to the CMC material on an opposed side from the insulation material. A mold (26) formed of a fugitive material having particles (18) of a bond enhancement material may be used to form the CMC material. A two-piece mold (38, 46) may be used to drive a bond enhancement member partially into the CMC material. A compressible material (56) containing the bond enhancement member may be compressed between a hard tool (60) and the CMC material to drive a bond enhancement member partially into the CMC material.
    Type: Grant
    Filed: July 31, 2003
    Date of Patent: January 10, 2006
    Assignee: Siemens Westinghouse Power Corporation
    Inventors: Jay Alan Morrison, Gary Brian Merrill, Thomas Barrett Jackson
  • Patent number: 6978901
    Abstract: The invention relates to the area of ceramics and to ceramic multilayer filters, such as used for separating gases. The invention provides ceramic multilayer filters which are more economical to produce. To this end, the inventive ceramic multilayer filters include at least two layers of different particle size, the particle surfaces of all of the ceramic particles being completely or partially perfused with a material and spot and/or surface joints being formed between particles. The invention also provides a method for producing ceramic multilayer filters of this type, according to which slips are produced from at least two ceramic powders of different particle size, the particles of the ceramic powders being perfused with a material or a material in powder form being added to the ceramic slips. One or more layers are formed from the slips and then dried. At least two layers are placed one above the other and/or joined to each other and together are subjected to a temperature increase.
    Type: Grant
    Filed: December 3, 1999
    Date of Patent: December 27, 2005
    Assignee: Fraunhofer-Gesellschaft zur Forderung der Angewandten Forschung e.V.
    Inventors: Jörg Adler, Reinhard Lenk, Hans-Jürgen Richter
  • Patent number: 6974516
    Abstract: A method of fabricating a ceramic tube with electrodes thereon suitable for use as a tubular reaction chamber for a fuel cell. In one embodiment, the method includes wrapping a first electrode material around a mandrel, then wrapping a green ceramic material over the first electrode material, and then wrapping a second electrode material over the green ceramic material. The wrapped layers are laminated together, and then removed from the mandrel and sintered, in either sequence, to produce the laminated ceramic tube having an inner first electrode and an outer second electrode. Alternatively, a first electrode tube is provided in place of the mandrel and around which the green ceramic material is wrapped. The outer second electrode may be produced by wrapping a second electrode material around the green ceramic material, before or after laminating, or by printing the electrode material onto the sintered ceramic tube.
    Type: Grant
    Filed: February 23, 2004
    Date of Patent: December 13, 2005
    Assignee: Presidio Components, Inc.
    Inventors: Alan Devoe, Mary Trinh
  • Patent number: 6974515
    Abstract: A ceramic substrate having a defined curvature and a method of its manufacture are described. For this purpose at least two ceramic layers having different defined temperature coefficients of expansion are positioned on top of one another and are permanently bonded together. A curved ceramic substrate may be advantageously utilized in micro-hybrid technology, in multilayer ceramic technology, or in hybrid technology, e.g., as a membrane element of a piezoresistive pressure sensor element.
    Type: Grant
    Filed: January 27, 2003
    Date of Patent: December 13, 2005
    Assignee: Robert Bosch GmbH
    Inventors: Anja Neubert, Holger Hoefer
  • Patent number: 6942833
    Abstract: To produce a green composite laminate 11, a green multilayer collective substrate 13 containing low-temperature sinterable glass ceramic powder as a main ingredient is disposed between first and second shrinkage-restraining layers 14a and 14b containing alumina powder as a main ingredient. Grooves 16 are formed on one main surface 11a of the green composite laminate 11 such as to pass through the first shrinkage-restraining layer 14a and the green multilayer collective substrate 13 and reach the second shrinkage-restraining layer 14b, but not to reach the other main surface 11b of the green composite laminate 11. The green composite laminate 11 provided with the grooves 16 is sintered under conditions where the low-temperature sinterable glass ceramic powder is sintered and the green first and second shrinkage-restraining layers 14a and 14b are removed to prepare a plurality of ceramic multilayer substrates.
    Type: Grant
    Filed: January 24, 2003
    Date of Patent: September 13, 2005
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Hiromichi Kawakami, Yoshifumi Saito
  • Patent number: 6913815
    Abstract: The present invention provides a plastics-covered metal plate excellent in chipping resistance, corrosion resistance etc. made by covering one surface or both surfaces of a metal plate with at least two kinds of plastics layers whose rates of elongation are different and a process of covering a car body by using said covered metal plate.
    Type: Grant
    Filed: February 9, 2001
    Date of Patent: July 5, 2005
    Assignee: Kansai Paint Co., Ltd.
    Inventors: Tadashi Watanabe, Tadayoshi Hiraki, Akira Tominaga, Takeshi Yawata
  • Patent number: 6911941
    Abstract: A substrate (300) for an RF device includes a plurality of layers (102) of dielectric material cofired in a stack. The plurality of layers (102) is formed from a material having a permittivity. Selected ones of the layers (102) have a pattern of perforations (106) formed in at least one perforated area (104). The perforated areas (104) are generally aligned with one another in the stack to lower one or more of an effective value of a permittivity and a loss tangent in a least one spatially defined region (504) of the substrate (300).
    Type: Grant
    Filed: June 19, 2003
    Date of Patent: June 28, 2005
    Assignee: Harris Corporation
    Inventors: Dennis Tebbe, Thomas Smyth, William Johnson Chappell
  • Patent number: 6899777
    Abstract: A process for continuous composite coextrusion comprising: (a) forming first a material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate in a manner such that the composition has a substantially cylindrical geometry and thus can be used as a substantially cylindrical feed rod; (b) forming a hole down the symmetrical axis of the feed rod; (c) inserting the start of a continuous spool of ceramic fiber, metal fiber or carbon fiber through the hole in the feed rod; (d) extruding the feed rod and spool simultaneously to form a continuous filament consisting of a green matrix material completely surrounding a dense fiber reinforcement and said filament having an average diameter that is less than the average diameter of the feed rod; and (e) depositing the continuous filament into a desired architecture which preferably is determined from specific loading conditions of the desired object and CAD design of the object to provide a green fiber rei
    Type: Grant
    Filed: January 2, 2002
    Date of Patent: May 31, 2005
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: K. Ranji Vaidyanathan, Joseph Walish, Mark Fox, John W. Gillespie, Jr., Shridhar Yarlagadda, Michael R. Effinger, Anthony C. Mulligan, Mark J. Rigali
  • Patent number: 6884486
    Abstract: The invention relates to a structure assembled from elements, the elements forming an entity with topological interlocking.
    Type: Grant
    Filed: May 28, 2003
    Date of Patent: April 26, 2005
    Assignee: Technische Universitat Clausthal
    Inventors: Juri Estrin, Norbert Müller, Detlef Trenke, Arcady Dyskin, Elena Pasternak
  • Patent number: 6871391
    Abstract: In a method of manufacturing a laminated ceramic electronic component, a first transfer sheet in which a composite green sheet having a non-magnetic ceramic area and a magnetic ceramic area is supported by a supporting film, and a second transfer sheet in which a ceramic green sheet is supported by a supporting film are prepared. The method includes the first transfer step of sequentially transferring the ceramic green sheet onto a lamination stage, the second transfer step of transferring the composite green sheet, the third transfer step of transferring the ceramic green sheet of the second transfer sheet, and the step of obtaining a laminate.
    Type: Grant
    Filed: November 9, 2001
    Date of Patent: March 29, 2005
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Hiromichi Tokuda, Takashi Tomohiro
  • Patent number: 6866733
    Abstract: A flexible insulation blanket having a ceramic matrix composite (CMC) outer layer, and a method of producing a flexible insulation blanket having a smooth, aerodynamically suitable, outer surface by infiltrating ceramic material within the outer ceramic fabric layer of the flexible insulation blanket and curing the ceramic material to form a CMC layer. The CMC layer is cured while the blanket is under compression such that the resulting CMC layer has a smooth surface.
    Type: Grant
    Filed: July 1, 2003
    Date of Patent: March 15, 2005
    Assignee: The Boeing Company
    Inventors: Jerry Denham, Robert A. Dichiara, Jr., Vann Heng, Leanne L. Lehman, David Zorger
  • Patent number: 6852271
    Abstract: A flexible insulation blanket having a smoothly surfaced, secondarily bonded, ceramic matrix composite (CMC) outer layer, and a method of producing a flexible insulation blanket having a secondarily bonded CMC layer by forming a CMC prepreg layer comprising a woven ceramic fabric layer impregnated with a pre-ceramic slurry and layering the prepreg layer with a flexible insulation blanket. The blanket and prepreg layer are then compressed such that the prepreg layer abuts a rigid smoothly surfaced plate and the ceramic material is cured by heating while under compression. Pressure is then released and the insulation is fired to sinter the ceramic material of the CMC layer.
    Type: Grant
    Filed: August 11, 2003
    Date of Patent: February 8, 2005
    Assignee: The Boeing Company
    Inventor: Robert A. DiChiara, Jr.
  • Patent number: 6852569
    Abstract: A method of fabricating a multilayer ceramic substrate includes stacking one or a plurality of unfired ceramic greensheets on one or both sides of a previously fired ceramic substrate, thereby forming a stack, each unfired ceramic greensheet having a firing temperature substantially equal to or lower than a firing temperature of the previously fired ceramic substrate, stacking a restricting greensheet on the unfired ceramic greensheet composing an outermost layer of the stack, the restricting greensheet having a higher firing temperature than each unfired ceramic greensheet, firing the stack at the firing temperature of the unfired ceramic green sheets with or without pressure applied via the restricting greensheet while the stack is under restriction by the restricting greensheet, thereby integrating the stack, and eliminating remainders of the restricting greensheet after the firing step.
    Type: Grant
    Filed: October 28, 2002
    Date of Patent: February 8, 2005
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Satoshi Nakano, Yoshio Mizuno, Junzo Fukuta, Katsuhiko Naka
  • Publication number: 20040261932
    Abstract: The non-stick coating of the invention comprises at least one primer layer comprising a fluorocarbon resin and inorganic particles, the primer layer being applied on a support and covered in one or more finishing layers based on fluorocarbon resin. The inorganic particles are ceramic particles having a mean diameter less than 4 &mgr;m. The coating is particularly suitable for cooking utensils.
    Type: Application
    Filed: August 20, 2004
    Publication date: December 30, 2004
    Inventors: Jean-Pierre Buffard, Claudine Gardaz
  • Patent number: 6835260
    Abstract: Methods to create raised pedestal parts in ceramic substrates sintered under a load. The invention uses a patterned, buried, non-sintering layer that provides the needed transfer of load during the sintering process to the raised or pedestal portion of the substrate while maintaining dimensional control of the metallized features on the surface of the pedestal base. The methods involve cutting channels in the ceramic substrate corresponding in position to the perimeter of the opening in the patterned non-sintering contact sheet. The channels may be cut either before or after the sintering of the ceramic substrates.
    Type: Grant
    Filed: October 4, 2002
    Date of Patent: December 28, 2004
    Assignee: International Business Machines Corporation
    Inventors: Benjamin V. Fasano, David H. Gabriels, Richard F. Indyk, Glenn A. Pomerantz, Richard A. Shelleman
  • Publication number: 20040247826
    Abstract: A method for joining glass ceramic surfaces to each other and/or other types of surfaces using a silicate liquid is disclosed. The products are suitable for use as, e.g. mirror blanks or microlithography stages, at low temperatures. Component pieces are polished then joined at low temperature using a silicate-containing joining liquid. Assembly is then performed in such a way that the joining liquid forms an interface between each component. After a period of low or slightly elevated temperature curing, rigid joints are formed throughout and the composite is dimensionally, vibrationally, and temperature stable and can withstand tensile stresses >4000 psi. The room-temperature cured composite can be heat treated using a slow, systematic temperature increase to dehydrate the joints. A sealing coating may optionally be provided to prevent excess dried joining liquid from flaking off the formed joint.
    Type: Application
    Filed: June 23, 2003
    Publication date: December 9, 2004
    Inventors: Samuel David Conzone, Alexander J Marker, Joseph S Hayden, Robert D Simpson
  • Patent number: 6827800
    Abstract: A method to produce a distortion-free asymmetrical low-temperature co-fired ceramic structure comprising at least one layer of glass-containing internal constraining tape and at least one layer of glass-containing primary tape wherein the internal constraining tape and the primary tape are laminated to form an asymmetrical laminate and wherein a release layer is deposited on at least one surface of the laminate forming an assembly, wherein the surface is opposite the position of greatest asymmetry of the laminated layers and wherein the assembly is thermally processed producing a structure exhibiting an interactive suppression of x,y shrinkage.
    Type: Grant
    Filed: May 6, 2003
    Date of Patent: December 7, 2004
    Assignee: E. I. du Pont de Nemours and Company
    Inventors: Carl Baasun Wang, Kenneth Warren Hang, Christopher Roderick Stewart Needes
  • Publication number: 20040238099
    Abstract: This invention is a method of forming features, such as counter-bore holes in a circuit board assembly. A first and second substrate are processed and counter-bore holes are formed in the first substrate. After the holes are formed, sealing glass is deposited on the bottom side of the first substrate and the top side of the second substrate and is sintered on the bottom side of the first substrate and the top side of the second substrate. After sintering, the bottom side of the first substrate is fixtured to the top side of the second substrate and the first and second substrate are refired, causing the sealing glass to reflow and fuse the bottom side of the first substrate to the top side of the second substrate. Finally, the first and second substrate are cooled.
    Type: Application
    Filed: May 29, 2003
    Publication date: December 2, 2004
    Inventors: Vincent J. Milano, Greg Mitchell
  • Publication number: 20040238100
    Abstract: A piezoelectric ceramic composition including three components, Pb(Zn1/3Nb2/3)O3, PbTiO3, and PbZrO3, and having a basic composition formula of Pb(Zn1/3Nb2/3)xZryTizO3, where 0.90<x+y+z<1.0, exhibits excellent piezoelectric characteristics and heat resistance and has a low sintering temperature of about 900° C., a coupling coefficient Kp not less than 0.50, and a Curie temperature not lower than 300° C. A piezoelectric device using this composition may employ inexpensive silver and silver-palladium alloys containing a high percentage of silver as material of an internal electrode, thus being inexpensive and having excellent characteristics.
    Type: Application
    Filed: March 15, 2004
    Publication date: December 2, 2004
    Inventors: Seiichi Minami, Yasushi Goto, Kazuhiro Okuda
  • Patent number: 6824897
    Abstract: A method for producing a bonded article composed of a first substrate, a second substrate, and a bonding layer through which the first and second substrates are bonded to one another includes the steps of interposing a water-based bonding agent between the first and second substrates, and forming the bonding layer by heating the water-based bonding agent. The water-based bonding agent contains an alkali metal element, and has a water-soluble compound dissolved therein. The water-soluble compound produces a composite oxide by heating.
    Type: Grant
    Filed: December 6, 2001
    Date of Patent: November 30, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Ken-ichi Noda, Tatsuo Kawaguchi
  • Publication number: 20040226647
    Abstract: A method for producing a multi-layer ceramic capacitor 10 in which reliability of electrical contact between a via electrode 28 and an internal electrode layer 24 (24a or 24b) provided between ceramic layers 22 is enhanced. A laminated sheet 100 including ceramic layers 22 and internal electrode layers 24, the layers 22 and 24 being alternately laminated and combined together, is formed, through-holes 26 are formed in the laminated sheet 100 by means of laser irradiation, and an electrically conductive material is charged into the through-holes 26 using charging container 110, to thereby form via electrodes 28. The electrically conductive material is charged, under application of pressure, into each of the through-holes 26 via an opening of the through-hole 26.
    Type: Application
    Filed: October 8, 2003
    Publication date: November 18, 2004
    Applicant: NGK SPARK PLUG CO., LTD.
    Inventors: Junichi Ito, Hideo Tange, Jun Otsuka, Manabu Sato, Hisahito Kashima
  • Publication number: 20040211506
    Abstract: The present invention relates to a method to achieve the suppression of planar shrinkage in LTCC ceramic tape laminate structures without externally applied forces or sacrificial constraining tape. The method utilizes a non-sacrificial constraining tape that constrains a tape assembly.
    Type: Application
    Filed: May 24, 2004
    Publication date: October 28, 2004
    Inventors: Carl Baasun Wang, Kenneth Warren Hang, Christopher Roderick Stewart Needes
  • Patent number: 6802921
    Abstract: A novel process for manufacturing fully vitrified flat extruded ceramic glazed, unglazed tiles and profiles includes the following steps: mixing of raw materials in predetermined ratios; wet milling in ball mills; mechanical filter pressing to get cakes; shredding of cake to obtain noodles like structure; using a de-airing pug mill machine to produce proper mixing by removing of air the body; drawing a column of clay body through a die for required shapes; drying in three layer horizontal drier and chamber drier; coloring in a appropriate glazing line; firing in a appropriate roller kiln; sorting line; packing and palletizing machine; and using a sawing and glueing machine for smaller size tiles to make patterns and for border tiles. The invention also includes a system for carrying out the invented process so as to achieve high quality fully vitrified ceramic tiles and profiles.
    Type: Grant
    Filed: February 11, 2003
    Date of Patent: October 12, 2004
    Assignee: Boss Profiles Limited
    Inventors: Rudrapatnakeshavamurthy Venkatesha, Snehasish Ghosh, Kasturi Umapathy Rao
  • Publication number: 20040194870
    Abstract: A ceramic capacitor has at least one dielectric layer and at least two electrodes having the dielectric layers therebetween. The dielectric layer includes a sintered body of ceramic grains containing a primary component of a perovskite crystal structure in a form of ABO3 and a ratio A/B of outer portions of the ceramic grains is greater than that of an inner portions thereof.
    Type: Application
    Filed: April 20, 2004
    Publication date: October 7, 2004
    Applicant: TAIYO YUDEN CO., LTD.
    Inventors: Jun Ogasawara, Youichi Mizuno
  • Publication number: 20040194866
    Abstract: A newly designed “Stained Glass” window-panel process constructed from one piece of glass without the led/zinc or copper foil assembly method. “Stained Glass—The Fusing Way” is created by utilizing a kiln firing method. The results obtained can be compared to “Stained Glass” window-panels but the “Stained Glass—The Fusing Way” delivers superior strength, maintenance free results and a safer and stronger window-panel.
    Type: Application
    Filed: April 1, 2003
    Publication date: October 7, 2004
    Inventor: Monique Feldman
  • Patent number: 6797094
    Abstract: The present invention relates to a process for the production of a braking band for a brake disk with venting passages and to a braking band which can be produced by the process. The process comprises the following steps: molding a core (200) of the braking band in a suitable mold (1), molding two covers (8) onto the core in a further suitable mold (101) so as to form a semi-finished product having a “sandwich” structure, firing the semi-finished product so as to produce a predetermined porosity of the covers, firing the semi-finished product further, in the presence of silicon, at a temperature such as substantially to bring about fusion of the silicon and its infiltration into the covers.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: September 28, 2004
    Assignee: Freni Brembo S.p.A.
    Inventors: Giovanni Paolo Pacchiana, Ralf Siegfried Goller
  • Patent number: 6793873
    Abstract: A melt-infiltrated, fiber-reinforced composite ceramic containing high-temperature-resistant fibers, in particular fibers based on Si/C/B/N, which are reaction-bonded to a matrix based on Si and also a process for producing such a composite ceramic are described. The silicon melt which is used for the melt infiltration contains additions of iron, chromium, titanium, molybdenum, nickel or aluminum, with particular preference being given to a silicon melt containing from about 5 to 50% by weight of iron and from about 1 to 10% by weight of chromium. This gives a simplified production process compared with conventional silicon melt infiltration and improved properties of the composite ceramic (FIG. 1).
    Type: Grant
    Filed: August 23, 2001
    Date of Patent: September 21, 2004
    Assignee: DaimlerChrysler AG
    Inventors: Rainer Gadow, Tilmann Haug, Andreas Kienzle
  • Publication number: 20040173304
    Abstract: A method for joining similar materials to create multi-component assemblies so the joint materials share similar physical, chemical, and electrical characteristics with the base materials. The method includes aligning the materials, applying joining material, focusing a microwave beam on the joint area to initially heat the joint area to allow the joining material to soften and fill physical discontinuities while the surrounding surfaces remains cool, rapidly heating the joint area to the reactive area of the joining material, rapidly cooling the joint area and maintaining the joint area at a recrystallization temperature. The materials can be ceramics such as aluminum oxide.
    Type: Application
    Filed: September 26, 2003
    Publication date: September 9, 2004
    Inventors: Ralph W. Bruce, David Lewis, Manfred Kahn, Arne W. Fliflet, Steven H. Gold
  • Publication number: 20040164269
    Abstract: A low temperature co-fired ferrite-ceramic (FECERA) composite consisting of two different dielectric materials (Ceramic and Ferrite) can be used to make a diversification combination filter component by the process of a multi-layer passive component, so that the combination filter component can prevent the function of electromagnetic interference (EMI) and has an excellent electromagnetic couple effect.
    Type: Application
    Filed: February 25, 2003
    Publication date: August 26, 2004
    Inventor: Chaby Hsu
  • Publication number: 20040159389
    Abstract: This invention provides a stacked ceramic body in which de-lamination (inter-layer peeling) does not easily occur, and a production method thereof. In the invention, a predetermined number of unit layers 151 and 152 each including a ceramic layer 111 112, an internal electrode layer 121, 122, a spacer 131, 132 having substantially the same thickness as the internal electrode layer 121, 122 and adhesive layers 14 stacked on the surface of the internal electrode layer and on the surface of the adhesive layer are stacked. A print portion for the internal electrode layer 121, 122 and a print portion for the spacer 131, 132 are formed on a green sheet for the ceramic layer 111, 112, and print portions for the adhesive layer 14 are formed on both of them to give an unsintered unit. The unsintered units are stacked to give an unsintered stacked body, are press-bonded and are then sintered.
    Type: Application
    Filed: February 20, 2004
    Publication date: August 19, 2004
    Applicant: Denso Corporation
    Inventors: Akio Iwase, Yukihisa Takeuchi, Tetuji Ito
  • Patent number: 6776860
    Abstract: A method of manufacturing a ceramic composite comprises the steps of preparing at least two ceramics bodies to be bonded together, each of the at least two ceramics bodies having a bonding surface; preparing a slurry in which primary particles of a bonding ceramic are dispersed; applying the slurry to the bonding surface of at least one of the ceramic bodies to be bonded; and sintering the ceramic bodies between which the slurry has been interposed to bond them. In this method, the bonding ceramic in the slurry is preferably constituted from the same ceramic starting material as that of the at least one of the ceramic bodies to be bonded. In this way, it becomes possible to manufacture, with a simple technique, a ceramic composite having a required strength and excellent biocompatibility and biosafety.
    Type: Grant
    Filed: November 30, 1999
    Date of Patent: August 17, 2004
    Assignee: PENTAX Corporation
    Inventors: Kaoru Arai, Masahiro Kohketsu, Asako Matsushima, Masanori Nakasu
  • Patent number: 6776861
    Abstract: The present invention relates to a method to achieve the suppression of planar shrinkage in LTCC ceramic tape laminate structures without externally applied forces or sacrificial constraining tape. The method utilizes a non-sacrificial constraining tape that constrains a tape assembly.
    Type: Grant
    Filed: January 2, 2003
    Date of Patent: August 17, 2004
    Assignee: E. I. du Pont de Nemours and Company
    Inventors: Carl Baasun Wang, Kenneth Warren Hang, Christopher Roderick Stewart Needes
  • Publication number: 20040154725
    Abstract: A method for the production of joints between ceramic bodies such as silicon carbide bodies in which a preceramic polymer mixed with a powder, such as bimodal silicon carbide, is applied in slurry form. The mechanical and hermetic properties may be enhanced by the inclusion of additional bodies constraining the polymer slurry in the joint region, such as a collar. The thermal processing of the joint is described which provides a useful joint.
    Type: Application
    Filed: February 5, 2004
    Publication date: August 12, 2004
    Inventors: Frederick M. Mako, Robert L. Bruce
  • Patent number: 6770159
    Abstract: The method includes selecting two or more types of ceramic materials (202, 204), each having a distinct set of electrical properties different from the other of the types of ceramic materials. A substrate pattern can also be selected. The substrate pattern can comprise at least two types of distinct substrate areas having the distinct sets of electrical properties of the ceramic materials. Each distinct area can be selected so as to have dimensions much smaller than a wavelength at a frequency of interest. The ceramic materials (202, 204) can thereafter be fired and then cut into a size and shape consistent with the distinct areas to form dielectric pieces (206, 208). The process continues by selectively arranging the dielectric pieces on a base plate (302) in accordance with the pattern to form the textured ceramic dielectric substrate.
    Type: Grant
    Filed: March 26, 2003
    Date of Patent: August 3, 2004
    Assignee: Harris Corporation
    Inventors: Dennis Tebbe, Thomas Smyth, Terry Provo, Dara Ruggiero, Holly Todd
  • Publication number: 20040144476
    Abstract: After a resistor and/or a capacitor are simultaneously fired on a fired ceramic core substrate to be fired, the fired resistor and/or the fired capacitor is trimmed so that the resistance and the capacitance are adjusted. Thereafter, an after-lamination green sheet is laminated onto the ceramic core substrate and the produced after-lamination substrate is fired at a temperature which is lower than the sintering temperature of the resistor and the dielectric. Thus, the sintered resistor and dielectric can be prevented from being softened and melted when the after-lamination substrate is fired. Moreover, the resistance and the capacitance accurately adjusted by trimming before the after-lamination substrate is fired are not changed by the firing.
    Type: Application
    Filed: January 9, 2004
    Publication date: July 29, 2004
    Inventors: Junzo Fukuta, Satoru Adachi
  • Patent number: 6764565
    Abstract: A method of producing lithium aluminosilicate (LAS) ceramics, which uses a mixing powder of lithium carbonate, aluminum oxide, and silicon oxide as a raw material powder. After being mixed by ball milling and baked dry, the raw material powder is processed with a calcinations process such that the raw material powder becomes a precursor. The precursor is then pressed into the green ceramic. Significantly, the high heat conducting metal sheets are tightly attached above and below the surfaces of the ceramic during sinter and heat-treatment processes. A solid-state sinter process is performed with the green ceramic. Next, the ceramic is treated with a proper heat-treatment process. Since the top and bottom surfaces of the ceramic are capped with the high heat conducting metal, the ceramics are uniformly heated during all the heating processes.
    Type: Grant
    Filed: December 17, 2002
    Date of Patent: July 20, 2004
    Assignee: National Central University
    Inventors: Jyh-Chen Chen, Gwo-Jiun Sheu
  • Publication number: 20040129370
    Abstract: A process for joining at least two substrates together comprises applying between the substrates a composition comprising a liquid pre-ceramic binder and at least one other component selected from a metal powder, a metal oxide powder and mixtures thereof, and pyrolysing the composition, to form a join between the two substrates, the join comprising a mixed metal oxide. The composition is capable of joining together a wide variety of substrates, without failure, after exposure to high temperature.
    Type: Application
    Filed: December 29, 2003
    Publication date: July 8, 2004
    Inventors: Alan Taylor, John Andrew Fernie, Paul Jackson, Caroline Williams
  • Publication number: 20040129371
    Abstract: A plate for use in mixing and testing materials in the pharmaceutical industry is formed by a method in which apertures in a set of greensheets are formed by a material removal process, at least some of the apertures being filled with a fugitive material that escapes during sintering.
    Type: Application
    Filed: January 7, 2003
    Publication date: July 8, 2004
    Applicant: INTERNATIONAL BUSINESS MACHINES CORPORATION
    Inventors: Govindarajan Natarajan, Umar Ahmad, Raschid J. Bezama, James N. Humenik, John U. Knickerbocker, Rao V. Vallabhaneni
  • Patent number: 6758926
    Abstract: A method for fabricating a multilayer ceramic substrate having a cavity with multi-steps therein for mounting an electronic component is provided. A block is inserted into a lower cavity segment of the cavity formed in a green sheet laminate to be the multilayer ceramic substrate, wherein the block has substantially the same three-dimensional shape as that of the cavity segment and has a height equal to or larger than the depth of the cavity segment. Thus, the pressing step is performed in a state such that the cavity has an apparent single step.
    Type: Grant
    Filed: March 14, 2002
    Date of Patent: July 6, 2004
    Assignee: Murata Manufacturing Co. Ltd.
    Inventors: Hideyuki Harada, Hirofumi Sunahara
  • Publication number: 20040112503
    Abstract: A method of producing lithium aluminosilicate (LAS) ceramics, which uses a mixing powder of lithium carbonate, aluminum oxide, and silicon oxide as a raw material powder. After being mixed by ball milling and baked dry, the raw material powder is processed with a calcinations process such that the raw material powder becomes a precursor. The precursor is then pressed into the green ceramic. Significantly, the high heat conducting metal sheets are tightly attached above and below the surfaces of the ceramic during sinter and heat-treatment processes. A solid-state sinter process is performed with the green ceramic. Next, the ceramic is treated with a proper heat-treatment process. Since the top and bottom surfaces of the ceramic are capped with the high heat conducting metal, the ceramics are uniformly heated during all the heating processes.
    Type: Application
    Filed: December 17, 2002
    Publication date: June 17, 2004
    Inventors: Jyh-Chen Chen, Gwo-Jiun Sheu
  • Publication number: 20040108041
    Abstract: A ceramic multilayer component with a monolithic component body is proposed that features alternating ceramic and electrode layers in the component body. The electrode layers are alternately connected to two collector electrodes laterally attached to the component, wherein the material of the internally disposed electrodes comprises tungsten and, therefore, contains at least tungsten or a tungsten compound.
    Type: Application
    Filed: October 8, 2003
    Publication date: June 10, 2004
    Inventor: Lutz Kirsten
  • Patent number: 6743316
    Abstract: In a ceramic green-sheet stack to be fired to form a multilayered ceramic substrate having a cavity, a shrinkage-reducing pad is formed along a boundary interface between first ceramic green sheets having an opening for defining a cavity, and second ceramic green sheets having no opening. The shrinkage-reducing pad is exposed on the entire periphery of the inner peripheral surface of the cavity at the bottom end of the inner peripheral surface. The shrinkage-reducing pad contains a glass component, and serves to reduce shrinkage stress produced at the boundary interface between the first and second ceramic green sheets during the firing process.
    Type: Grant
    Filed: November 1, 2001
    Date of Patent: June 1, 2004
    Assignee: Murata Manufacturing Co. Ltd
    Inventors: Hideyuki Harada, Hirofumi Sunahara
  • Publication number: 20040099364
    Abstract: A method of producing a composite sheet in which a through hole formed in a predetermined portion of the first ceramic sheet is buried with a different kind of sheet having substantially the same thickness as the first ceramic sheet, such as a resin sheet a metal sheet or a ceramic sheet of a material different from that of the first ceramic sheet. A first method comprises a step of preparing a first ceramic sheet from a ceramic powder, and a different kind of sheet; a step of forming a through hole in a predetermined portion of the first ceramic sheet; a step of laminating the different kind of sheet on the ceramic sheet in which the through hole is formed; and a step of preparing a composite sheet by pressing the portion of the first ceramic sheet where the through hole is formed from the side of the different kind of sheet, such that the first ceramic sheet and the different kind of sheet are integrated together.
    Type: Application
    Filed: August 28, 2003
    Publication date: May 27, 2004
    Applicant: KYOCERA CORPORATION
    Inventors: Shinichi Suzuki, Koichi Nagata, Takayuki Ikeuchi, Yuji Tanaka, Yasuhiro Sasaki, Shigeki Yamada, Yasuhiko Yoshihara, Masamitsu Onitani
  • Patent number: 6740183
    Abstract: A method for manufacturing a multi-layered ceramic substrate which enables to remove a shrinkage suppression sheet without damaging the multi-layered substrate. The shrinkage suppression sheets are formed on both faces of unfired laminated green sheets, and then the laminated green sheets are fired. For removing the shrinkage suppression sheets on both faces of the multi-layered ceramic substrate 2 after sintering, water, ceramic powder, or water and ceramic powder mixture is sprayed together with compressed air.
    Type: Grant
    Filed: April 24, 2000
    Date of Patent: May 25, 2004
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Shigetoshi Segawa, Hiroshi Ochi, Yasuyuki Baba, Osamu Shiraishi, Masao Konishi
  • Patent number: 6733871
    Abstract: A process for producing a ceramic member for bonding, which comprises: a first step of preparing a lower layer paste with the use of a first mixture comprising nickel, tungsten and molybdenum, applying the lower layer paste to a surface of a ceramic base which is a sintered ceramic, and drying the resultant coating layer to form a lower layer after the applying; a second step of preparing an upper layer paste with the use of a second mixture comprising one of nickel and nickel oxide and at least one of copper, copper oxide, manganese and manganese oxide, applying the upper layer paste to the lower layer, and drying the resultant coating layer to form an upper layer after the applying; and a third step of heating the lower layer and the upper layer to bake the lower layer and the upper layer.
    Type: Grant
    Filed: October 7, 2002
    Date of Patent: May 11, 2004
    Assignee: NGK Spark Plug Co., Ltd.
    Inventor: Yusuke Makino
  • Patent number: 6733607
    Abstract: A method for forming a low temperature cofired ceramic (LTCC) device includes forming a channel in a first LTCC tape layer. A wax is inserted in the channel. The wax is of a type that burns out at a temperature below a sintering temperature of the first LTCC tape layer. At least a second LTCC tape layer is stacked on the first LTCC tape layer to form a stack. The stack is pressed sufficiently for the first and second layers to bond into a laminate. The laminate is fired at the sintering temperature to form a sintered ceramic structure from the first and second LTCC tape layers, so that all or substantially all of the wax is burned out from the channel.
    Type: Grant
    Filed: April 15, 2002
    Date of Patent: May 11, 2004
    Assignee: Harris Corporation
    Inventors: Brian R. Smith, Randy T. Pike, C. Michael Newton
  • Publication number: 20040084131
    Abstract: [Object] To produce a laminated electronic part which has a superior surge-proofing property, a sufficient resistance to a flux, and good electrical properties, without occurring of structural effects such as cracking, delamination, or the like.
    Type: Application
    Filed: May 30, 2003
    Publication date: May 6, 2004
    Inventors: Masahuru Konoue, Kimiharu Anao