Sintering Or Heat Fusing Particles Patents (Class 264/125)
  • Patent number: 6673280
    Abstract: The present invention relates to a method of making a board product with fiber scrap materials, including the steps of adding a binder powder to the fiber scrap materials, processing the scrap fiber into pieces and mixing the fiber scrap materials with the binder powder, distributing the fiber and binder combination across the width of a forming conveyor, and melting the combination to fix the fiber with the binder.
    Type: Grant
    Filed: June 20, 2002
    Date of Patent: January 6, 2004
    Assignee: CertainTeed Corporation
    Inventors: Alain Yang, Gary Tripp, Mark Trabbold
  • Patent number: 6670021
    Abstract: 12A high temperature gas turbine component includes an inner core made of a monolithic ceramic material embedded within an outer CMC shell. The inner core may be formed with a through hole, blind hole, wear pads and the like. A method of making the bushing includes the steps of a) forming an inner core of silicon nitride or silicon carbide; and b) applying a ceramic matrix composite material over substantially all of the inner core.
    Type: Grant
    Filed: November 14, 2001
    Date of Patent: December 30, 2003
    Assignee: General Electric Company
    Inventors: Mark Stewart Schroder, Paul Stephen DiMascio, Randall Richard Good
  • Patent number: 6667261
    Abstract: An open-cell glass crystalline porous material made from hollow microspheres which are cenospheres obtained from fly ash, having an open-cell porosity of up to 90 vol. % is produced. The cenospheres are separated into fractions based on one or more of grain size, density, magnetic or non-magnetic, and perforated or non-perforated. Selected fractions are molded and agglomerated by sintering with a binder at a temperature below the softening temperature, or without a binder at a temperature about, or above, the softening temperature but below the temperature of liquidity. The porous material produced has an apparent density of 0.3-0.6 g/cm3, a compressive strength in the range of 1.2-3.5 MPa, and two types of openings: through-flow wall pores in the cenospheres of 0.1-30 micrometers, and interglobular voids between the cenospheres of 20-100 micrometers.
    Type: Grant
    Filed: May 15, 2002
    Date of Patent: December 23, 2003
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventors: Alexander G. Anshits, Olga M. Sharonova, Tatiana A. Vereshchagina, Irina D. Zykova, Yurii A. Revenko, Alexander A. Tretyakov, Albert S. Aloy, Rem I. Lubtsev, Dieter A. Knecht, Troy J. Tranter, Yevgeny Macheret
  • Patent number: 6666958
    Abstract: A method for making a dry plating built-up film comprises providing silicon carbide as a starting source and subjecting to dry plating while changing a concentration of a reactive gas continuously or intermittently to deposit and form, on a substrate, a thin film having different refractive indices along its thickness. A method for making a sputter built-up film is also described, which comprising providing silicon carbide as a target and subjecting to sputtering while changing making electric power against the target continuously or intermittently to deposit and form a thin film having different refractive indices along its thickness.
    Type: Grant
    Filed: September 28, 1999
    Date of Patent: December 23, 2003
    Assignee: Bridgestone Corporation
    Inventors: Masato Yoshikawa, Shingo Ohno, Sho Kumagai
  • Publication number: 20030218268
    Abstract: A method of synthesizing negative-thermal-expansion ceramics of synthesizing Zr(1−x)XxW2O8 in which X represents a substituent element for zirconium Zr, and 0≦x <<1, having a negative thermal expansion coefficient, the method comprising mixing two mols of tungsten trioxide WO3 and one mol of the sum of zirconium oxide ZrO2 and a substituent element X in accordance with substitution amount x at a stoichiometrical ratio, further mixing the thus obtained starting material in a powdery form having a particle size distribution including two groups of particles comprising smaller diameter particles with a particle size of 0.
    Type: Application
    Filed: May 22, 2003
    Publication date: November 27, 2003
    Applicant: Moritex Corporation
    Inventors: Yuhkoh Morito, Kouji Takahashi, Takuya Hashimoto
  • Patent number: 6641759
    Abstract: Powder of a polymer active material 1 exhibiting an electro-chemical oxidation-reduction reaction is mixed with powder of a conductivity assisting agent 2 to obtain a mixture. The mixture is molded by a thermal press into a unitary block. Thus, a cell electrode having a large film thickness is produced without causing cracks or breakage. The electrode having a large film thickness improves the energy density of the polymer secondary cell.
    Type: Grant
    Filed: September 22, 2000
    Date of Patent: November 4, 2003
    Assignee: NEC Tokin Corporation
    Inventors: Gaku Harada, Toshihiko Nishiyama, Masaki Fujiwara, Shinako Kaneko, Masato Kurosaki, Yuuji Nakagawa
  • Patent number: 6638572
    Abstract: A particulate silicone based material and method for forming a heat resistant composite is provided. The particulate silicone based material is heated to a temperature between about 200° F. and about 400° F. The particulate silicone based material is cooled until a solid composite is formed. The solid composite is resistant to melting and thermal decomposition when heated to temperatures of at least 3000° F. The particulate silicone based material may be formed by mixing liquid silicone resin with a catalyst and powdered silicone molding compound.
    Type: Grant
    Filed: June 27, 2001
    Date of Patent: October 28, 2003
    Inventor: Charles F. Inglefield
  • Patent number: 6638459
    Abstract: A method for preparing compression molded or pressed lignocellulosic articles is disclosed. The method involves forming a binder resin by combining a polyisocyanate component with a parting agent and preferably a synergist. The parting agent is the reaction product of an isocyanate compound and an isocyanate-reactive compound of the general structure R—(ao)n—Y where: R is a hydrophobic group containing alkyl, alkaryl, polyaryl, or siloxane moieties; (ao) is an alkylene oxide or mixture of alkylene oxides; n is from 1 to 25; and Y represents a monofunctional isocyanate-reactive group. A resinated lignocellulosic mixture is formed by combining the binder resin with lignocellulosic particles. Then a compression molded or pressed lignocellulosic article is formed by compressing the resinated lignocellulosic mixture at an elevated temperature and under pressure.
    Type: Grant
    Filed: August 20, 2002
    Date of Patent: October 28, 2003
    Assignee: BASF Corporation
    Inventors: Donald C. Mente, Li-Mei Lu, David D. Peters, Joe C. Wilson, Anthony G. Schaefer
  • Patent number: 6630084
    Abstract: A method of making a magnetoplumbite-type ferrite material powder includes the step of preparing the ferrite material powder by spraying a mixed chloride solution, in which a chloride of iron and a chloride of strontium are dissolved, into a heated atmosphere. The solution of the mixed chloride contains 25% through 35% of the chloride of iron and 2.4% through 4.9% of the chloride of strontium.
    Type: Grant
    Filed: October 6, 2000
    Date of Patent: October 7, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventor: Etsushi Oda
  • Patent number: 6627131
    Abstract: A method of forming a composite panel includes the steps of supplying a material to a forming station, supplying a dry additive to the material at the forming station, producing a mat comprising the material and the additive at the forming station, and applying heat and pressure to the mat to produce a composite panel.
    Type: Grant
    Filed: February 9, 2001
    Date of Patent: September 30, 2003
    Assignee: Georgia-Pacific Resins, Inc.
    Inventor: Christopher W. Huber
  • Patent number: 6620287
    Abstract: A method of manufacturing a fiber assembly, the method comprising: (a) providing a plurality of layers, each layer comprising sintered fibers of piezoelectric material aligned substantially parallel; (b) laminating the plurality of layers; and (c) applying a matrix material to the laminated layers to affix the layers and form a fiber assembly.
    Type: Grant
    Filed: April 12, 2001
    Date of Patent: September 16, 2003
    Inventor: Richard B. Cass
  • Patent number: 6602561
    Abstract: A discharge surface treatment method with which discharge is caused to occur between an electrode and a workpiece to generate energy to form a coating on a surface of the workpiece, and method therefore. An electrode is made by combining a hard material, such as WC, and a soft material, such as Co. The hard and soft materials are mixed and compressed into a green compact. The green compact is baked in a vacuum furnace at a temperature which is below the sintering temperature but high enough to melt the soft material. The melted soft material fills the gaps between the particles of the hard material, resulting in an electrode having a texture similar to chalk called incomplete-sintering. The electrode is then used in discharge surface treatment.
    Type: Grant
    Filed: June 20, 2000
    Date of Patent: August 5, 2003
    Assignee: Mitsubishi Denki Kabushiki Kaisha
    Inventors: Toshio Moro, Akihiro Goto
  • Patent number: 6599457
    Abstract: In the production of a silicon nitride sintered body through a hot press method, a sintering aid protecting agent is added to the raw material. The employable protecting agents are metallic elements such as Ta, W and Mo and compounds of the metallic elements such as nitrides and silicides. Conversion of these elements and compounds to carbides occurs preferentially to reduction of the sintering aid. Thus, it becomes possible to suppress reduction of the sintering aid in a reducing atmosphere formed, for example, of carbon monoxide, which is generated particularly when a graphite pressing die is employed.
    Type: Grant
    Filed: December 7, 2001
    Date of Patent: July 29, 2003
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Shindo Watanabe, Masahiro Konishi
  • Patent number: 6592983
    Abstract: A cut-resistant and shred-resistant absorbent sheet material including an absorbent substrate and cut-resistant particles distributed through the substrate. Preferably, the absorbent substrate comprises cellulosic material and the particles comprise polymeric materials having an average size of at least about 100 micrometers, and most preferably between 100 and 1000 micrometers. It is also preferred that the absorbent substrate is provided in an amount of at least 50 percent by weight and is substantially free of inorganic free filler particulate. In addition, it is preferred that the sheet material has a basis weight of at least 100 pounds per 3000 ft2, and that the particles are provided in an amount of between about 10 percent and about 50 percent by weight of the sheet. The sheet material can be made using typical paper making processes. Preferably, heat and/or pressure are applied to the sheet material to cause the particles to at least partially flow, so as to bond to the absorbent substrate.
    Type: Grant
    Filed: April 27, 2000
    Date of Patent: July 15, 2003
    Assignee: The Procter & Gamble Company
    Inventors: John Kit Carson, Steven Michael Schennum
  • Patent number: 6589462
    Abstract: For forming a preform of composite material, such as aluminum-based composite material (MMC) by using friction during the forming thereof, ceramic reinforcement, such as Al2O3 and binder are prepared, and the prepared reinforcement and the silanor group binder are put into a die for press forming. During the forming, polycondensation occurs due to frictional heat generated between the fibrous or grain-like particles of the reinforcement and the silanor group binder to harden it, thereby obtaining a preform in which the particles of the reinforcement are fixedly connected to one another.
    Type: Grant
    Filed: December 11, 2000
    Date of Patent: July 8, 2003
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Yasuhiro Nakao, Kunitoshi Sugaya, Hiroto Shoji
  • Patent number: 6589448
    Abstract: A ceramic bearing ball in which at least a portion of a constituent ceramic is formed of an electrically conductive inorganic compound phase, whereby a proper electrical conductivity is imparted to the ceramic. Thus, electrifying of a bearing ball is prevented or effectively suppressed. This prevents the problem involved in production of balls of small diameter wherein such balls adhere to an apparatus (e.g., a container) during production thereof, thus hindering smooth progress of the production process. In addition, when ceramic balls are used in precision electronic equipment, such as a hard disk drive of a computer, which is operated at high rotational speed, adhesion of foreign substance due to electrification of the balls, and resultant generation of abnormal noise or vibration can be prevented or effectively suppressed.
    Type: Grant
    Filed: April 10, 2001
    Date of Patent: July 8, 2003
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Tomonori Niwa, Tetsuji Yogo
  • Patent number: 6582641
    Abstract: An apparatus and process for making metal oxide sputtering targets from volatile and thermally unstable metal oxide powder by hot-pressing the metal oxide powder in a graphite die assembly having a ceramic barrier sleeve disposed therein to isolate the metal oxide powder from the graphite die assembly components.
    Type: Grant
    Filed: August 25, 1994
    Date of Patent: June 24, 2003
    Assignee: Praxair S.T. Technology, Inc.
    Inventors: Chi-Fung Lo, John Turn
  • Patent number: 6579483
    Abstract: A consolidated cellulosic article of increased thickness and target face density, as well as an apparatus and method of manufacturing same, are disclosed. The apparatus includes first and second dies adapted to move toward on e another with a mat of cellulosic material and a binding agent therebetween. When the dies move together, the mat is compressed under pressure and heat with forms on one of the dies forming identations in the mat. Compression zones of increased density form between the indentations and a first face of the mat. By spacing the forms appropriately, the compression zones overlap, and the face of the resulting consolidated board is provided with substantially uniform density. Since the entire board is not compressed to the same degree, its overall thickness is enchanced while the density of the first face of the mat is increased, and relatively little material is used.
    Type: Grant
    Filed: May 19, 2000
    Date of Patent: June 17, 2003
    Assignee: Masonite Corporation
    Inventor: Dennis H. Vaders
  • Publication number: 20030080315
    Abstract: A garnet ferrite used for a non-reciprocal circuit device contains Fe in an amount lower than the value derived from stoichiometry by 0.5% to 5%, and more preferably by 1% to 3%. The garnet ferrite can exhibit a low insertion loss in a high-frequency band of more than 5 MHz.
    Type: Application
    Filed: October 23, 2002
    Publication date: May 1, 2003
    Applicant: Alps Electric Co., Ltd.
    Inventors: Yutaka Yamamoto, Tomoo Kato, Toshio Takahashi, Hitoshi Onishi
  • Patent number: 6554984
    Abstract: A method of manufacturing a gas sensor, including a substrate electrode layer forming step, and a surface electrode layer forming step. The gas sensor includes first and second processing spaces, an oxygen concentration detection element, an oxygen pumping element, an oxidation catalyst and a combustible gas component concentration detection element.
    Type: Grant
    Filed: June 20, 2001
    Date of Patent: April 29, 2003
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Ryuji Inoue, Shoji Kitanoya, Kenji Kato, Tomohiro Fuma, Takafumi Oshima
  • Patent number: 6536097
    Abstract: In order to obtain a superconducting wire containing an oxide superconductor, whose critical current density is not much reduced upon application of bending, a plurality of strands 3, comprising oxide superconductors 1 covered with first metal sheaths 2, are filled into a second metal sheath 4, and deformation processing is performed to sectionally apply a compressive load to the second metal sheath, so that the thickness of the oxide superconductor 1 contained in each strand 3 is not more than 5% of the overall thickness of the superconducting wire 6.
    Type: Grant
    Filed: November 27, 2000
    Date of Patent: March 25, 2003
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Kenichi Sato, Hidehito Mukai, Nobuhiro Shibuta
  • Patent number: 6531086
    Abstract: A method for producing three-dimensional bodies of a large number of mutually connected layers of a particle-shaped material such as a powder, and where the information of the appearance of each layer is achieved from a computer's CAD-unit or similar. An essentially even particle layer (7) of building material is applied on a support base (6) and on a masking device (9) is arranged a masking pattern in accordance with the information from the CAD-unit, which masking device is led over said particle layer and close to it. A radiation producer (8) is arranged or is led over the masking device (9), whereby the particles which are not covered by the masking pattern are exposed for radiation and thereby are attached to each other. The masking pattern is removed from the masking device and new sequences in accordance with the above are carried through until the three-dimensional body (19) is produced.
    Type: Grant
    Filed: October 27, 1999
    Date of Patent: March 11, 2003
    Assignee: Speed Part RP AB
    Inventor: Ralf Larsson
  • Publication number: 20030044483
    Abstract: Protective containers are provided for transporting moldable preform charges used in precision molding operations, in which the moldable material includes a conductive filler in a thermosetting resin matrix. The granular moldable material is loaded into the containers and compacted. Next, the loaded containers are transported to a molding station, where each preform of the moldable material is ejected from its container. The containers are sufficiently rigid to hold their shapes under high compaction pressures, thus to determine preform shapes with greater precision. By surrounding the preforms, the containers minimize evaporative loss of monomer, maintaining the preforms in a condition more suitable for molding, and reducing the impact of monomer loss on the surrounding environment. Each such container can take the form of a sleeve, or may have an end wall incorporating a flexure at one end.
    Type: Application
    Filed: September 5, 2001
    Publication date: March 6, 2003
    Inventor: James E. Cabak
  • Patent number: 6524414
    Abstract: A method for producing ceramic composite bodies, in particular, cylindrical ceramic bodies for sheathed-element glow plugs, in which a plurality of shaping sleeves, which accommodate piece parts premolded by cold pressing, are inserted into corresponding bore holes of a vertically standing supporting plate that is heated via additional bore holes with the aid of cartridge heaters or a heat transfer liquid. The vertically standing supporting plate with the shaping sleeves is then clamped between two press plates of a press, and the piece parts located inside are subsequently pressed by press pins which, on both sides, pass through the press plates and into the shaping sleeves. Upon completion of the necessary pressure keeping period, the pressed compound, after retraction of the press pins and opening the press, can be hardened in a non-pressurized manner in the shaping sleeves located in the withdrawn supporting plate that is subjected to further heating.
    Type: Grant
    Filed: July 25, 2001
    Date of Patent: February 25, 2003
    Assignee: Robert Bosch GmbH
    Inventors: Wilfried Aichele, Wolfgang Dressler
  • Patent number: 6508964
    Abstract: Ceramic sintered bodies having a different thickness along a predetermined axial direction are manufactured in the following manner. At first, a ceramic formed body to be sintered having different thickness along the predetermined axial direction is accommodated in a hot press apparatus. An upper forming mold and a lower forming mold each having a forming surface corresponding to an upper surface and a lower surface of the ceramic formed body to be sintered are set. A pressure along the predetermined axial direction is applied to the ceramic formed body to be sintered via the upper forming mold and the lower forming mold while heating the ceramic formed body to be sintered to perform a hot press sintering thereof. A thickness of a ceramic sintered body is controlled in such a manner that a maximum thickness in the predetermined direction is not more than two times a minimum thickness in the predetermined direction.
    Type: Grant
    Filed: September 4, 2001
    Date of Patent: January 21, 2003
    Assignee: NGK Insulators, Ltd
    Inventors: Hiromichi Kobayashi, Satoru Yamada, Tetsuhisa Abe
  • Patent number: 6507077
    Abstract: A voltage nonlinear resistor is composed of an aggregate of silicon carbide particles doped with impurities, in which oxygen and at least one of aluminum and boron are diffused in the vicinity of the surfaces of the silicon carbide particles, the diffusion length of the oxygen is about 100 nm or less from the surfaces of the silicon carbide particles, and the diffusion length of at least one of the aluminum and the boron is in the range of about 5 to 100 nm from the surfaces of the silicon carbide particles. A method for fabricating a voltage nonlinear resistor and a varistor using a voltage nonlinear resistor are also disclosed.
    Type: Grant
    Filed: March 7, 2001
    Date of Patent: January 14, 2003
    Assignee: Murata Manufacturing Co. Ltd
    Inventors: Kazutaka Nakamura, Yukihiro Kamoshida
  • Patent number: 6495072
    Abstract: A method for producing a ceramic material, subsequently including mixing ceramic material, such as oxidic ceramic material, which as a raw material essentially comprises aluminum oxide, zircon oxide and/or titanium oxide, and glass component; melting at least the glass component in the mixture by sintering, where the glass component infiltrates the ceramic material and absorbs raw material of the ceramic material through a reaction at the surface; and bringing the mixture into a shape, such as powder, which is suitable for further processing, such as additional sintering. Also, a basis for the crown, the crown in its entirety having layers of for instance porcelain applied to the basis, and methods for producing the basis and the crown through subsequent processing steps, to which the basis is preferably subjected on the same underground, for instance based on CAD/CAM techniques.
    Type: Grant
    Filed: February 3, 2000
    Date of Patent: December 17, 2002
    Assignee: Cicero Dental Systems B.V.
    Inventor: Joseph Maria Van der Zel
  • Publication number: 20020185376
    Abstract: A hydrocarbon sensor is formed with an electrolyte body having a first electrolyte surface with a reference electrode depending therefrom and a metal oxide electrode body contained within the electrolyte body and having a first electrode surface coplanar with the first electrolyte surface. The sensor was formed by forming a sintered metal-oxide electrode body and placing the metal-oxide electrode body within an electrolyte powder. The electrolyte powder with the metal-oxide electrode body was pressed to form a pressed electrolyte body containing the metal-oxide electrode body. The electrolyte was removed from an electrolyte surface above the metal-oxide electrode body to expose a metal-oxide electrode surface that is coplanar with the electrolyte surface. The electrolyte body and the metal-oxide electrode body were then sintered to form the hydrocarbon sensor.
    Type: Application
    Filed: May 30, 2002
    Publication date: December 12, 2002
    Inventors: Rangachary Mukundan, Eric L. Brosha, Fernando Garzon
  • Patent number: 6482343
    Abstract: An improved process for producing a consolidated polymeric monolith from an assembly of thermoplastic polymer. The assembly is placed under pressure to fill a majority of the voids thereof by mechanical deformation of the fibers, and heated to a temperature too low to melt the fibers at the deformation pressure but sufficiently high to at least partly melt the fibers at a lower transition pressure. While maintaining the assembly at this temperature, the pressure is reduced to the transition pressure long enough for partial melting of the fibers to fill the rest of the voids, and then is increased to a consolidation pressure at least as high as the deformation pressure. The assembly is cooled slowly to ambient temperature at the consolidation pressure. The process allows accurate control of thermal expansion coefficients of the product. Further, products of manufacture produced by the process exhibit improved strength, thermal stability, infrared transparency and unique intrinsic physical characteristics.
    Type: Grant
    Filed: November 26, 1999
    Date of Patent: November 19, 2002
    Assignee: Polyeitan Composites Ltd.
    Inventors: Yachin Cohen, Dmitry M. Rein, Lev Vaykhansky
  • Patent number: 6451416
    Abstract: The present invention is a low density hybrid airfoil comprising a temperature resistant exterior layer and a tough, high impact resistant interior layer. Specifically, the airfoil comprises a monolithic ceramic exterior layer and a fiber reinforced ceramic matrix composite interior layer. Both the monolithic ceramic and fiber reinforced ceramic matrix composite are low density materials. Additionally, the monolithic ceramic is a high temperature resistant material, and the fiber reinforced ceramic matrix composite is a relatively high impact resistant structure. Encapsulating the airfoil with a temperature resistant exterior layer protects the airfoil in a high temperature environment, and supporting the airfoil with a high impact resistant, fiber reinforced ceramic matrix composite improves the overall impact resistance of the airfoil thereby resulting in a tough, high temperature resistant, low density airfoil.
    Type: Grant
    Filed: November 19, 1999
    Date of Patent: September 17, 2002
    Assignee: United Technologies Corporation
    Inventors: John E. Holowczak, Karl M. Prewo, Jayant S. Sabnis, William K. Tredway
  • Patent number: 6444162
    Abstract: An open-cell glass crystalline porous material made from hollow microspheres which are cenospheres obtained from fly ash, having an open-cell porosity of up to 90 vol. % is produced. The cenospheres are separated into fractions based on one or more of grain size, density, magnetic or non-magnetic, and perforated or non-perforated. Selected fractions are molded and agglomerated by sintering with a binder at a temperature below the softening temperature, or without a binder at a temperature about, or above, the softening temperature but below the temperature of liquidity. The porous material produced has an apparent density of 0.3-0.6 g/cm3, a compressive strength in the range of 1.2-3.5 MPa, and two types of openings: through-flow wall pores in the cenospheres of 0.1-30 micrometers, and interglobular voids between the cenospheres of 20-100 micrometers.
    Type: Grant
    Filed: November 27, 2000
    Date of Patent: September 3, 2002
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventors: Alexander G. Anshits, Olga M. Sharonova, Tatiana A. Vereshchagina, Irina D. Zykova, Yurii A. Revenko, Alexander A. Tretyakov, Albert S. Aloy, Rem I. Lubtsev, Dieter A. Knecht, Troy J. Tranter, Yevgeny Macheret
  • Patent number: 6440343
    Abstract: A process for controlling and thus predicting the microstructural bias of multi-phase composites to obtain preferential positioning of the component compounds in their morphology and position in the resulting microstructure to cause the grains of a first phase either to locate at the grain boundaries of a second phase, or to be homogeneously distributed in the second phase using both conventional manually mixing and advanced self-propagating high-temperature processing technologies. A process whereby a lower cost composite material performs comparably to a more expensive monolithic nature of higher performance material by causing the higher performance first phase grains to preferentially locate at the grain boundaries of the second phase during densification/fusing. A process to optimize the performance properties by preferentially biasing the microstructure to cause the phase which intrinsically has the preferred properties to influence and enhance the desired properties of the bulk composite material.
    Type: Grant
    Filed: April 14, 2000
    Date of Patent: August 27, 2002
    Assignee: Georgia Tech Research Corporation
    Inventor: Kathryn V. Logan
  • Publication number: 20020084548
    Abstract: An improvement to existing board manufacturing process which utilize lignocellulose particles is described wherein the adhesive to be applied as a binder is at least partly applied before the particles are dried. Using the invention improvement in resin application rates without increase in the water content of the particles fed to a press is achieved. Reduction in edge thickness swelling has been achieved.
    Type: Application
    Filed: September 27, 2001
    Publication date: July 4, 2002
    Inventors: James Randall, Harden Christopher Wren, Earl K. Phillips
  • Patent number: 6399001
    Abstract: Procedure for the fabrication of a blank for a structural product, such as a blank for a structural board, from material (1) comprising longer (L) and shorter (S) particles and possibly also particles (F) smaller than these. The particles are mixed with a binding agent and possible additives and then passed into at least one blank former, from where the particles are brought onto a base (10). Longer particles (L) are brought onto the base (10) to form a first surface layer, onto which is brought at least one layer of smaller particles (F, S), and onto this layer is again brought a layer of longer particles (L) to form a second surface layer, the smallest particles (F) being so brought onto the base that they mainly end up in at least one middle layer in the cross-section of the blank while the amount of the smallest particles (F) diminishes towards the surface layers as seen in the cross-section of the blank.
    Type: Grant
    Filed: February 5, 1998
    Date of Patent: June 4, 2002
    Assignee: Sunds Defibrator Loviisa Oy
    Inventors: Aarne Laatikainen, Jarmo Laitinen
  • Publication number: 20020062740
    Abstract: A method and apparatus for making filter elements in which a mixture of activated carbon granules and fibers are processed with meltable polymer fibers to form a porous element. The density of the porous structure increases in a direction from the periphery thereof to its center. Also, the article formed by the method using the apparatus.
    Type: Application
    Filed: September 27, 2001
    Publication date: May 30, 2002
    Inventors: Nikolay V. Brukov, Joseph L. Schmidt
  • Patent number: 6395214
    Abstract: A hot pressing method involves the simultaneous application of high pressure (1.5-8 GPa) at a relatively low temperature (0.2-0.6 Tm) High compaction pressure causes particle deformation, such that the green density increases with pressure up to a maximum at about 8 GPa. Low sintering temperature mitigates grain growth during the consolidation process. Another factor that promotes densification is the occurrence of a pressure-induced phase transformation (typically from a metastable structure to a more stable structure), accompanied by a significant reduction in free volume for example greater than about 1 to about 2 vol. %. Such transformation-assisted consolidation has been successfully applied to produce sintered oxide and non-oxide bulk nanocrystalline ceramics having a grain size less than 100 nm, starting with even finer-scale ceramic nanopowders. Under appropriate high pressure conditions, a sintered grain size can be realized that is actually smaller than the original powder particle size.
    Type: Grant
    Filed: November 19, 1999
    Date of Patent: May 28, 2002
    Assignee: Rutgers, The State University of New Jersey
    Inventors: Bernard H. Kear, Shih-Chieh Liao, William E. Mayo
  • Patent number: 6368993
    Abstract: The present invention relates to a sintered ceramic composite implant material and a fabrication method thereof. A sintered ceramic composite implant material includes an apatite matrix phase, a ceramic secondary phase located in the apatite matrix phase, a barrier layer coating the ceramic secondary phase. The secondary phase compensates for and improves the mechanical properties of the apatite matrix phase and the barrier layer restrains an interfacial reaction between the apatite matrix phase and the secondary phase.
    Type: Grant
    Filed: December 21, 1999
    Date of Patent: April 9, 2002
    Inventors: Hyoun Ee Kim, Young Min Kong, In Seop Lee
  • Publication number: 20020037233
    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.
    Type: Application
    Filed: October 8, 2001
    Publication date: March 28, 2002
    Inventors: Romain L. Billiet, Hanh T. Nguyen
  • Publication number: 20020037232
    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.
    Type: Application
    Filed: September 20, 2001
    Publication date: March 28, 2002
    Inventors: Romain L. Billiet, Hanh Thi Nguyen
  • Patent number: 6342573
    Abstract: Process for the preparation of end-products based on vinylaromatic polymers with a predominantly syndiotactic structure which comprises: a) compressing the polymer in powder form in a mould at a pressure ranging from 0.1 to 500 Mpa; b) sintering the compressed powder, under pressure, at a temperature ranging from the glass transition temperature of the polymer (Tg) to 150° C.; c) slowly cooling the end-product to room temperature.
    Type: Grant
    Filed: April 16, 1999
    Date of Patent: January 29, 2002
    Assignee: Enichem S.p.A.
    Inventors: Gennaro Antonio, Giannotta Giorgio
  • Publication number: 20020003318
    Abstract: Ceramic sintered bodies having a different thickness along a predetermined axial direction are manufactured in the following manner. At first, a ceramic formed body to be sintered having different thickness along the predetermined axial direction is accommodated in a hot press apparatus. An upper forming mold and a lower forming mold each having a forming surface corresponding to an upper surface and a lower surface of the ceramic formed body to be sintered are set. A pressure along the predetermined axial direction is applied to the ceramic formed body to be sintered via the upper forming mold and the lower forming mold while heating the ceramic formed body to be sintered to perform a hot press sintering thereof. A thickness of a ceramic sintered body in such a manner that a maximum thickness in the predetermined direction is not two times larger or more than a minimum thickness in the predetermined direction.
    Type: Application
    Filed: September 4, 2001
    Publication date: January 10, 2002
    Applicant: NGK Insulators, Ltd
    Inventors: Hiromichi Kobayashi, Satoru Yamada, Tetsuhisa Abe
  • Publication number: 20020000682
    Abstract: A process for controlling and thus predicting the microstructural bias of multi-phase composites to obtain preferential positioning of the component compounds in their morphology and position in the resulting microstructure to cause the grains of a first phase either to locate at the grain boundaries of a second phase, or to be homogeneously distributed in the second phase using both conventional manually mixing and advanced self-propagating high-temperature processing technologies. A process whereby a lower cost composite material performs comparably to a more expensive monolithic nature of higher performance material by causing the higher performance first phase grains to preferentially locate at the grain boundaries of the second phase during densification/fusing. A process to optimize the performance properties by preferentially biasing the microstructure to cause the phase which intrinsically has the preferred properties to influence and enhance the desired properties of the bulk composite material.
    Type: Application
    Filed: April 14, 2000
    Publication date: January 3, 2002
    Inventor: Kathryn V. Logan
  • Patent number: 6331267
    Abstract: A mold for molding a core for use in casting hollow parts includes, a lower mold portion and an upper mold portion defining therein a cavity corresponding to the outer surface of the core. The lower mold portion includes a cutout disposed along a parting line defined between the lower mold portion and the upper mold portion and opening onto the cavity. After introduction of a ceramic slurry mixture into the mold the upper mold portion is removable, to expose a first side of the core and a protective flash formed in the cutout. Desirably, a heat shield is positioned over the protective flash and the exposed portion of the parting line of the lower mold portion so that the lower mold portion is not exposed directly to a flame during a preliminary firing to impart sufficient strength to the ceramic core so that the ceramic core may be handled.
    Type: Grant
    Filed: November 16, 1999
    Date of Patent: December 18, 2001
    Assignee: General Electric Company
    Inventors: Martin Kin-Fei Lee, George Gerald Gunn, James Michael Placko
  • Patent number: 6312633
    Abstract: A method of producing dashboards, door or side trim panels for motor vehicles with a predetermined breaking line for an airbag flap is described. To accomplish this, slush material is introduced into a mold which can be heated to a molding temperature and determines the shape of the slush membrane, where the slush material is distributed and deposited on the heated mold surface by rotating the mold and is then sintered and gelled. After cooling the mold, the slush membrane is removed from the mold by unmolding. To create a predetermined breaking line, a mold having a divider on its mold surface at the location of the predetermined breaking line to be created is used. By controlled rotation and/or positioning of the mold while applying the powder and/or gelling the slush material, a reduction in the layer thickness of the slush material to an extent that establishes a predetermined breaking line is achieved.
    Type: Grant
    Filed: July 22, 1998
    Date of Patent: November 6, 2001
    Assignee: Benecke Kaliko AG
    Inventors: Gerd Henning Kiesel, Walter André
  • Patent number: 6312632
    Abstract: The process relates to the production of boards of wood-based material, in particular, oriented strand board, chipboard or fiberboard comprising lignocellulose- and/or cellulose-containing particles. The particles, in the form of chips, fibers, chippings or the like, are mixed with a binder and scattered in a scattering station onto a moving molding belt to form a mat of pressed stock. The mat of pressed stock is pressed and cured by the application of pressure and heat in a platen press or a continuously operating press. To accomplish surface structuring during the production cycle, the finished board of wood-based material just released from the pressing operation is subjected to a structuring operation on one or both sides.
    Type: Grant
    Filed: May 4, 1998
    Date of Patent: November 6, 2001
    Assignee: Maschinenfabrik J. Dieffenbacher GmbH & Co.
    Inventor: Matthias Graf
  • Patent number: 6309583
    Abstract: This invention relates to processes for the formation of composite layers containing insoluble particles in metal matrices onto bodies to achieve enhanced thermal properties.
    Type: Grant
    Filed: August 2, 1999
    Date of Patent: October 30, 2001
    Assignee: Surface Technology, Inc.
    Inventor: Michael David Feldstein
  • Patent number: 6305920
    Abstract: An apparatus for forming a nonwoven fibrous web wherein the web contains at least one binder fiber and at least one support fiber. The apparatus comprises a mixer for creating a homogeneous mixture of the fibers, a conveyor for transporting the resulting fiber mixture to a shaker chute, an oscillating mechanism which acts on the fiber mixture, a depositing mechanism for depositing the fiber mixture onto a horizontal planar surface, a heater for heating the mixture to a temperature to fuse the binder and support fibers, and a cooling mechanism to cool the mixture after heating.
    Type: Grant
    Filed: August 3, 1999
    Date of Patent: October 23, 2001
    Assignee: Boricel Corporation
    Inventors: James H. Kean, Tod M. Kean, Kenneth R. Williams
  • Patent number: 6306997
    Abstract: The present invention relates to a soybean-based adhesive resin including a soybean flour and a cross-linking agent. The cross-linking agent is reacted with the functional groups in the soybean flour to form an adhesive resin. The present invention also relates to a method of making a soybean-based adhesive resin. This method involves providing an aqueous solution of soybean flour and adding a cross-linking agent to the solution under conditions effective to cross-link the soybean flour so that an adhesive resin is formed. Also disclosed is a composite product which includes particulate plant material and the soybean-based adhesive resin. The adhesive is prepared by reacting the cross-linking agent with the functional groups in the soybean flour. The present invention also relates to a method of making a composite product by providing particulate plant material and applying the soybean-based adhesive resin to the particulate plant material.
    Type: Grant
    Filed: July 29, 1999
    Date of Patent: October 23, 2001
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Monlin Kuo, Deland J. Myers, Howard Heemstra, Daniel Curry, Daniel O. Adams, Douglas D. Stokke
  • Patent number: 6306325
    Abstract: Ceramic sintered bodies having a different thickness along a predetermined axial direction are manufactured in the following manner. At first, a ceramic formed body to be sintered having different thickness along the predetermined axial direction is accommodated in a hot press apparatus. An upper forming mold and a lower forming mold each having a forming surface corresponding to an upper surface and a lower surface of the ceramic formed body to be sintered are set. A pressure along the predetermined axial direction is applied to the ceramic formed body to be sintered via the upper forming mold and the lower forming mold while heating the ceramic formed body to be sintered to perform a hot press sintering thereof. A thickness of a ceramic sintered body in such a manner that a maximum thickness in the predetermined direction is not two times larger or more than a minimum thickness in the predetermined direction.
    Type: Grant
    Filed: November 5, 1999
    Date of Patent: October 23, 2001
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiromichi Kobayashi, Satoru Yamada, Tetsuhisa Abe
  • Patent number: 6296793
    Abstract: Composition for preparing water-repellent coatings on optical substrates, comprising a porous, electrically conductive molding and an organosilicon compound, obtainable by mixing an electrically conductive or semiconductive support material with a binder and subjecting the mixture to compression molding to form a compression molding, sintering the compression molding at preferably 1100 to 1500° C. in air to form a porous molding, impregnating the molding with the organosilicon compound, and ageing the impregnated molding by storage in air for at least 3 days.
    Type: Grant
    Filed: June 4, 1999
    Date of Patent: October 2, 2001
    Assignee: Merck Patent Gesellschaft mit
    Inventors: Uwe Anthes, Reiner Dombrowski