Carbonizing To Form Article Patents (Class 264/29.1)
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Patent number: 6878337Abstract: A process for producing a honeycomb structure, which comprises adding water to a mixed raw material of a raw material powder and a binder, kneading the mixture to obtain a plastic mixture, molding the plastic mixture into a honeycomb shape to obtain a green honeycomb structure, drying the structure by a step including hot-air drying, and firing the resulting dried honeycomb structure, wherein the binder contains hydroxypropyl methyl cellulose as a major component. The process can produce a crack-free high-quality honeycomb structure rapidly at a low cost.Type: GrantFiled: May 25, 2001Date of Patent: April 12, 2005Assignee: NGK Insulators, Ltd.Inventors: Yasushi Noguchi, Kyoko Makino
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Patent number: 6878173Abstract: A battery electrode plate (19) is produced via an active material impregnation step for impregnating an entire porous core substrate shaped like a thin plate (1) with an active material (3), a pressing step for performing press working on the core substrate to form a plurality of rail shaped protrusions (8), an active material removal step for removing the active material to form core substrate exposed sections (13) by applying ultrasonic vibrations to the rail shaped protrusions, a flattening step for compressing the core substrate exposed sections down to an identical level with the other sections, and a cutting step for cutting predetermined sections including the core substrate exposed sections.Type: GrantFiled: August 29, 2001Date of Patent: April 12, 2005Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Masaharu Miyahisa, Hideyuki Kumakiri, Takehiko Matsunaga, Koichi Kojima
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Patent number: 6875263Abstract: This invention relates to the use of a filler derived from cereal husk, more particularly rice husk, in composite materials to enhance the flame retardant, antistatic, accelerator, plasticiser and blowing characteristics in various composite materials.Type: GrantFiled: January 17, 2000Date of Patent: April 5, 2005Assignees: Contract Research and DevelopmentInventors: Mailvaganam Thavalingam Sivasithambaram Pillai, Khalid Haji Ahmad, Arulgnanam Vettivaloo Arunasalam
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Patent number: 6866801Abstract: A process for preparing a patterned layer of aligned carbon nanotubes on a substrate including: applying a pattern of polymeric material to the surface of a substrate capable of supporting nanotube growth using a soft-lithographic technique; subjecting said polymeric material to carbonization to form a patterned layer of carbonized polymer on the surface of the substrate; synthesising a layer of aligned carbon nanotubes on regions of said substrate to which carbonized polymer is not attached to provide a patterned layer of aligned carbon nanotubes on said substrate.Type: GrantFiled: September 22, 2000Date of Patent: March 15, 2005Assignee: Commonwealth Scientific and Industrial Research OrganisationInventors: Albert Mau, Li-ming Dai, Shaoming Huang
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Patent number: 6858192Abstract: An activated carbon-metal oxide matrix is disclosed. The activated carbon-metal oxide matrix may by obtained by a method including the steps of: preoxidizing a carbon material, grinding the preoxidized carbon material; mixing the ground preoxidized material with a metal oxide to form a carbon mixture; extruding the carbon mixture; carbonizing and activating the extrudate. The activated carbon-metal oxide matrix may be used to remove odorous compounds, acidic gases, and volatile organic compounds from a gas.Type: GrantFiled: December 11, 2001Date of Patent: February 22, 2005Assignee: USFilter CorporationInventors: James Richard Graham, Cheng Jian Yuan
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Patent number: 6855279Abstract: The invention provides a weather-resistant exterior building material which has been unavailable in the past with respect to characteristics of keeping harmful insects such as white ants, and so forth away therefrom, light weight, a long service life, insusceptibility to variation in temperature, hygroscopicity, and easiness in fabrication, and an exterior article made up of the same. The weather-resistant exterior building material according to the invention makes use of a compact formed of RB ceramic, CRB ceramic, or fire-resistant CRB ceramic.Type: GrantFiled: April 18, 2002Date of Patent: February 15, 2005Assignee: Minebea Co., Ltd.Inventors: Kazuo Hokkirigawa, Rikuro Obara
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Patent number: 6846766Abstract: A batch, in particular for the production of a refractory shaped body, includes at least one refractory metal oxide component and a synthetic resin component as a binder, and a graphitizing auxiliary for producing crystalline graphite carbon from the resin. The graphitizing auxiliary originates from a group consisting of reducible organic compounds of transition elements and/or a group of active organic or inorganic metal compounds or metals, such as resin-soluble metal salts, chemically precipitated or micronized metal oxides or metals. The graphitizing auxiliary is available in molecular form over the time and/or temperature range of conversion of the synthetic resin into carbon (carbonization).Type: GrantFiled: November 13, 2000Date of Patent: January 25, 2005Assignee: Refratechnik Holding GmbHInventors: Peter Bartha, Helge Jansen, Heinrich Grosse Daldrup
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Patent number: 6838024Abstract: The invention relates to a simplified production process with which it is possible to obtain carbon blocks, in particular anodes intended for aluminium production using the Hall-Héroult electrolysis process, which have high thermal shock resistance. This process comprises a grain size distribution adjustment operation of a carbon aggregate which includes: a) separating an initial ungraded carbon aggregate AC into a first fraction F1 made up of grains whose sizes are smaller than X, and into a second fraction F2 made up of grains whose sizes are X or greater, X lying between 0.2 and 2 mm; b) crushing B1 the first fraction F1 and part P1 of the second fraction F2 such as to obtain a powder F comprising a controlled proportion of ultra-fine grains; c) mixing the remaining part P2 of fraction F2 and said powder F in proportions with which it is possible to obtain crude carbon blocks whose so-called “Gr/S” ratio between the proportion PGr of grains larger than 0.Type: GrantFiled: November 21, 2000Date of Patent: January 4, 2005Assignees: Aluminium Pechiney, FCB AluminiumInventors: Christian Dreyer, Bernard Samanos
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Patent number: 6838175Abstract: A carbon microrod that holds a fine object by chemically adsorbing the object on the surface to make a dynamic measurement possible. An organic substance that leaves, after firing, glassy carbon that hardly becomes graphite, such as a chlorinated vinyl chloride resin, is mixed with a fine graphite powder having an average particle size of 1 ?m, and the mixture is extrusion molded with a die having a diameter of 50 ?m; the molded article is fired to give a carbon microrod comprising glassy carbon and crystalline carbon.Type: GrantFiled: January 30, 2002Date of Patent: January 4, 2005Assignees: National Institute of Advanced Industrial Science and Technology, Tsukuba Materials Information Laboratory, Ltd., Mitsubishi Pencil Co., Ltd.Inventors: Kaoru Katoh, Masahiro Yamada, Hiroko Kaneko, Yoshihisa Suda
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Publication number: 20040265591Abstract: Connecting pieces for carbon material electrodes include carbon fibers. The fibers are oxidatively activated carbon fibers which additionally have a carbonized coating. The carbonized coating is a carbonization product of a coating material selected from wax, pitch, natural resins, thermoplastic and thermosetting polymers.Type: ApplicationFiled: March 22, 2004Publication date: December 30, 2004Inventors: Wilhelm Frohs, Klaus-Peter Brehler, Michael Heine
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Publication number: 20040253445Abstract: The present invention relates to a carbon fiber nonwoven band-shaped article obtained by cutting a needle-punch nonwoven fabric of carbon fiber, wherein the carbon fiber is primarily oriented in a direction substantially perpendicular to a cut face of the band-shaped article. The band-shaped article can be manufactured by needle-punching a laminate web in which staples of fire-resistant fibers are oriented in substantially one direction, carbonizing an obtained nonwoven fabric by sintering and then cutting a carbonized nonwoven fabric in a direction substantially perpendicular to the direction of an orientation of the staples.Type: ApplicationFiled: April 12, 2004Publication date: December 16, 2004Inventors: Tadao Samejima, Susumu Seki
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Publication number: 20040241447Abstract: A composite material having a high thermal conductivity and a small thermal expansion coefficient, which is obtained by impregnating a porous graphitized extrudate with a metal; the composite material having such anisotropy that the thermal conductivity and the thermal expansion coefficient are 250 W/mK or more and less than 4×10−6/K, respectively, in an extrusion direction; and that the thermal conductivity and the thermal expansion coefficient are 150 W/mK or more and 10×10−6/K or less, respectively, in a direction perpendicular to the extrusion direction.Type: ApplicationFiled: May 14, 2004Publication date: December 2, 2004Applicant: HITACHI METALS, LTD.Inventor: Hideko Fukushima
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Publication number: 20040227265Abstract: An object of the present invention is to provide an apparatus and a method for manufacturing a windable carbonaceous material sheet, which is obtained by continuously curing a long uncured fiber sheet which is obtained by using short fibers to make paper and which contains uncured resin to produce a resin-impregnated cured sheet, and then continuously carbonizing it, and its production process.Type: ApplicationFiled: June 22, 2004Publication date: November 18, 2004Applicant: Mitsubishi Rayon Co., Ltd.Inventors: Toshihiko Nishida, Hidehiko Ohashi, Makoto Nakamura, Mitsuo Hamada, Kazushige Mihara
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Publication number: 20040227264Abstract: This invention relates to a method for the fabrication of improved graphite granules from unimproved graphite granules, where a polymer solution is uniformly sprayed onto a fluidized bed of unimproved graphite granules that are being stirred three dimensionally in high speed. The granules are then heat to dry to obtain coated graphite granules. To further improve the electrochemical properties of the final improved graphite granules, the coated graphite granules are immersed in a surface modifier, filtered, heat to dry and sifted. Then, they are solidified and carbonized in an inert environment to obtain final improved graphite granules. This invention is simple, easy to implement, and easy to implement for industrial production. The improved graphite granules made using embodiments of this invention, when used as the material for the negative electrode of a rechargeable battery produces a battery that has high initial charge/discharge efficiency, high reversible specific capacity and good cycle ability.Type: ApplicationFiled: March 4, 2004Publication date: November 18, 2004Inventors: Caisong Zou, Chuanfu Wang, Junqing Dong
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Patent number: 6814130Abstract: The present invention provides diamond tools, and a method for the formation thereof, using CVD techniques. In one aspect, a mold is provided which has an interface surface configured to inversely match a configuration intended for the working surface of a diamond layer in a tool. After the mold is provided, various CVD techniques may be used to deposit diamond layers upon the diamond interface surface of the mold. Following diamond deposition upon the diamond interface surface, the mold may be removed by various means, such as chemical etching, or the mold may be left intact for certain applications, such as SAW filters. Thus, the working surface of the diamond receives a shape which inversely corresponds to the configuration of the mold's diamond interface surface. The diamond layer may then be incorporated into a tool, if such incorporation has not yet taken place.Type: GrantFiled: October 19, 2001Date of Patent: November 9, 2004Inventor: Chien-Min Sung
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Patent number: 6812171Abstract: A process for producing a carbon fiber sheet, which comprises allowing, as necessary, an oxidized polyacrylonitrile fiber sheet to contain 0.2 to 5% by mass of a resin, then subjecting the resin-containing oxidized polyacrylonitrile fiber sheet to a compression treatment in the thickness direction under the conditions of 150 to 300° C. and 5 to 100 MPa (10 to 100 MPa when no resin treatment is made) to obtain a compressed, oxidized fiber sheet having a bulk density of 0.40 to 0.80 g/cm3 and a compression ratio of 40 to 75%, and thereafter subjecting the compressed, oxidized fiber sheet to a carbonizing treatment, which carbon fiber sheet has a thickness of 0.15 to 1.0 mm, a bulk density of 0.15 to 0.45 g/cm3, a carbon fiber content of 95% by mass or more, a compression deformation ratio of 10 to 35%, an electric resistance of 6 m&OHgr; or less and a feeling of 5 to 70 g.Type: GrantFiled: July 24, 2002Date of Patent: November 2, 2004Assignee: Toho Tenax Co., Ltd.Inventors: Kenji Shimazaki, Shintaro Tanaka
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Publication number: 20040202896Abstract: Carbon-silicon carbide brake preforms are manufactured by carbonizing a blend of carbon (e.g., polyacrylonitrile) fibers and thermosetting pitch resin, optionally along with a lubricant such as graphite,.to provide an intermediate product having open porosity and subsequently filling the pores of the intermediate product with silicon by a melt infiltration process. Molded articles that consist principally of carbon, that have relatively high strength and resistance to decomposition by frictional heat, and that are suitable for melt infiltration with silicon, are produced by, e.g.Type: ApplicationFiled: April 27, 2004Publication date: October 14, 2004Inventor: Paul E. Gray
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Publication number: 20040195712Abstract: Resin or pitch is melted in a melt blender apparatus (11) and then loaded, into a heated jacketed holding tank (12). A pair of feed lines (14, 16) receives resin from the holding tank (12) and feeds an upper gear pump (15) and a lower gear pump (17). A mixing enhancement such as a static mixer (18, 19) is located in each of the feed lines (14, 16) between the gear pumps (15, 17) and the resin delivery ends (25, 26) of the feed lines. The resin-melt feed lines may be equipped with pressure indicators (27, 28, 32, 34) and pressure relief valves (23, 24). The resin-melt feed lines may also be equipped with pump accumulators (31, 33). Resin melt pressure created by the gear pumps (15, 17) forces a piston inside the accumulator back to the desired position. The accumulators (31, 33) can also be used to maintain constant pressure in the feed stock. Resin can be recycled from the accumulators (31, 33) into the melt blender (11).Type: ApplicationFiled: April 4, 2003Publication date: October 7, 2004Inventors: Mark L. La Forest, Christopher S. Wahlers, Roger W. Holloway
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Patent number: 6797202Abstract: The present invention can provide particles for electro-rheological fluid for providing a high electro-rheological effect over a wide temperature range at low electric power consumption, and having high strength and excellent durability, not being susceptible to break-up due to the load of stress. Particles for an electro-rheological fluid of the present invention comprise spherical carbonaceous particles, obtained substantially from a solvent and a condensation product of a methylene type bond of aromatic sulfonic acid or a salt thereof.Type: GrantFiled: March 5, 2002Date of Patent: September 28, 2004Assignees: Bridgestone Corporaton, Mitsui Mining Company, LimitedInventors: Shigeki Endo, Howard See, Tasuku Saito, Koji Sakata, Kenji Fukuda, Youichiro Hara, Tatsuo Umeno
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Patent number: 6794035Abstract: Graphitized carbon powder are produced by carbonizing and expanding a pitch by heating to form carbonaceous foam and by graphitizing before pulverizing or graphitizing after pulverizing the carbonaceous foam. The resultant graphitized carbon powders have an interplanar spacing (d002) of graphite planes of less than 0.3370 nm. The powders preferably have an average particle size of from 2 to 200 &mgr;m. A thermally conductive composition includes the graphitized carbon powders in a matrix. The content of the powders is preferably 1 to 800 parts by weight relative to 100 parts by weight of the matrix. Thus, the graphitized carbon powders that have excellent thermal conductivity and a thermally conductive composition including such powders are provided.Type: GrantFiled: September 26, 2002Date of Patent: September 21, 2004Assignee: Polymatech Co., Ltd.Inventors: Masayuki Tobita, Naoyuki Shimoyama, Shinya Tateda
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Patent number: 6790390Abstract: The invention concerns a composite material comprising activated carbon and expanded graphite. The material is a block wherein the activated carbon is homogeneously and uniformly distributed in the form of microporous particles. The texture of said particles is characterised by a microporous volume W0 ranging between 0.1 cm3g−1 and 1.5 cm3g−1 and a mean pore dimension L0 ranging between 2 Å and 30 Å, the activated carbon particles have substantially the same texture wherever they are located in the composite material, the thermal conductivity levels of the material range between 1 and 100 Wm−1K−1. Said material is obtained by heat treatment of a mixture of expanded graphite and an activated carbon precursor in the presence of an activating agent at a temperature and for a time interval sufficient to obtain a wear rate of the activated carbon precursor ranging between 5 and 70% by mass.Type: GrantFiled: July 26, 2002Date of Patent: September 14, 2004Assignee: Centre National de la Recherche ScientifiqueInventors: Xavier Py, Emmanuel Daguerre, Vincent Goetz, Bernard Spinner
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Patent number: 6787494Abstract: An molded product of activated carbon produced by molding a kneaded mixture containing an activated carbon, a solvent, and a phenol-aldehyde type resin being solid in a normal temperature and containing 50 to 95% by weight of components soluble in the solvent used, drying and curing the molding, and then carbonizing the molding in an inert gas has a high adsorption capability and a high mechanical strength, e.g., a compressive strength, especially the strength after being contacted with an acid or water.Type: GrantFiled: January 16, 2002Date of Patent: September 7, 2004Assignee: Japan EnviroChemicals, Ltd.Inventors: Masanori Tsuji, Masaaki Kameno, Keizo Furukawa
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Patent number: 6776936Abstract: A process for producing solid, porous graphites which provides a more uniform density gradient throughout the ultimate product. The process utilizes a pressure drop during processing in order to induce boiling and varies the processing pressure between an initial pressure which exceeds 1000 psig and a final processing pressure which generally exceeds the initial pressure. The particular processing techniques employed allow additional viscosity manipulation as well as improved density gradient characteristics in the ultimate product. The final products have bulk thermal conductivities in the range from 90-300 W/mK with apparent densities ranging from about 0.678 g/cc-1.Type: GrantFiled: August 9, 2001Date of Patent: August 17, 2004Assignee: Poco Graphite, Inc.Inventors: Leland A. Hardcastle, Rex G. Sheppard, David F. Dingus
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Patent number: 6777360Abstract: A ceramic material suitable for use in production of paving tiles, construction tiles, flooring in offices, flooring in machinery plants and so forth is obtained by a method comprising steps of mixing defatted bran derived from rice bran with a thermosetting resin before kneading, subjecting a kneaded mixture thus obtained to a primary firing in an inert gas at a temperature in a range of 700 to 1000° C., pulverizing the kneaded mixture after the primary firing into carbonized powders, kneading the carbonized powders with which ceramic powders, a solvent, and a binder as desired are mixed into a plastic workpiece (kneaded mass), pressure-forming the plastic workpiece at pressure in a range of 10 to 100 MPa, and subjecting a formed plastic workpiece thus obtained again to firing in an inert gas atmosphere at a temperature in a range of 100 to 1400° C.Type: GrantFiled: February 11, 2002Date of Patent: August 17, 2004Assignee: Minebea Co., Ltd.Inventors: Kazuo Hokkirigawa, Rikuro Obara, Motoharu Akiyama
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Publication number: 20040155382Abstract: A mixture of carbon-containing fibers, a suitable matrix material, such as a milled pitch, and a friction additive is compressed while resistively heating the mixture to form a carbonized composite material. Preferably, the carbonized material has a density of at least about 1.3 g/cm3. Preferably, the composite material is formed in less than ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. Consequently, carbon/carbon composite materials having final densities of about 1.6-1.8 g/cm3 or higher are readily achieved with one or two impregnation cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking. In a second embodiment, the additive is impregnated into the compressed mixture with or without the mixture including the additive.Type: ApplicationFiled: November 24, 2003Publication date: August 12, 2004Inventors: Dai Huang, Richard T. Lewis, Irwin C. Lewis
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Patent number: 6773528Abstract: A process produces a fiber-reinforced silicon carbide composite. The resulting composite has a high toughness where bundles of a reinforcing fiber are densely covered with glassy carbon derived from a resin to avoid deterioration of the strength, and it can easily be produced even in complicated shapes. Specifically, a fiber-reinforced silicon carbide composite is produced by preparing a fiber prepreg containing a powdered silicon and a resin and molding the prepreg to yield a green body having a desired shape, or laminating a fiber prepreg containing a resin and a woven fabric prepreg containing a powdered silicon and a resin in alternate order, and molding the laminate to yield a green body having a desired shape; carbonizing the green body at 900° C. to 1350° C. in an inert atmosphere; impregnating the carbonized body with a resin; firing the impregnated body again at 900° C. to 1350° C.Type: GrantFiled: December 19, 2002Date of Patent: August 10, 2004Assignee: Agency of Industrial Science and TechnologyInventor: Eiji Tani
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Patent number: 6764620Abstract: A method for reaction forming refractory metal carbides. The method involves the fabrication of a glassy carbon preform by casting an organic, resin-based liquid mixture into a mold and subsequently heat treating it in two steps, which cures and pyrolizes the resin resulting in a porous carbon preform. By varying the amounts of the constituents in the organic, resin-based liquid mixture, control over the density of the carbon preform is obtained. Control of the density and microstructure of the carbon preform allows for determination of the microstructure and properties of the refractory metal carbide material produced. The glassy carbon preform is placed on a bed of refractory metal or refractory metal—silicon alloy. The pieces are heated above the melting point of the metal or alloy. The molten metal wicks inside the porous carbon preform and reacts, forming the refractory metal carbide or refractory metal carbide plus a minor secondary phase.Type: GrantFiled: November 28, 2001Date of Patent: July 20, 2004Assignee: The United States of America as represented by the United States Department of EnergyInventors: Marc N. Palmisiano, Kevin J. Jakubenas, Rita Baranwal
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Publication number: 20040131533Abstract: A method of forming graphitic bodies comprises the steps of:—Type: ApplicationFiled: October 22, 2003Publication date: July 8, 2004Inventors: Christopher John Spacie, Anthony Berian Davies, Simon Butler Cannon, Robin Stuart Hopker, Iain Campbell Alexander, Alan Robert Begg, James Charles Boff, Philip Beaton Brown, Laurence Miller Bryce, Mark Christopher Turpin
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Publication number: 20040126535Abstract: A process for producing hollow bodies comprising fiber-reinforced ceramic materials, in which a green body comprising compressible cores and a press moulding composition comprising binder and fiber material which is pressed with compression of the core is produced, the green body is cured and carbonized and pyrolyzed by heating in a nonoxidizing atmosphere and, if desired, is silicized, hollow bodies produced in this way and their use, in particular as brake and clutch discsType: ApplicationFiled: July 22, 2003Publication date: July 1, 2004Inventors: Arno Sommer, Dieter Huber, Dunja Straub, Vahid Shafi
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Publication number: 20040113302Abstract: Molding apparatus for rapid transfer of molten resin or pitch in an infiltration molding process. The apparatus includes e.g. an extruder (4) for melting and conveying a resin or pitch and a mold (10) arranged so that resin or pitch is conveyed to a mold insert cavity (19) within the mold. The mold insert contains an internal protrusion such as an outside diameter ring (20) for effecting a pressure gradient and flow of the resin or pitch from one side (ID) of the mold insert cavity toward an opposite side (OD) of the mold insert cavity. The mold insert also contains an internal protrusion such as a locating ring (25) for positioning a porous body (1, 18) within the mold insert cavity in a position that brings about unidirectional flow of the molten resin or pitch through the porous body.Type: ApplicationFiled: December 11, 2002Publication date: June 17, 2004Inventors: Mark L. La Forest, Christopher S. Wahlers, Barry P. Soos
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Publication number: 20040104497Abstract: A process for preparing graphite articles is presented. In particular, the process includes employing a particulate fraction comprising at least about 35 weight percent coke, coal or combinations thereof having a diameter such that a major fraction of it passes through a 0.25 mm to 25 mm mesh screen. The particulate fraction is mixed with a liquid or solid pitch binder, to form a stock blend; the stock blend is extruded to form a green stock; the green stock is baked to form a carbonized stock; and the carbonized stock is graphitized. The stock blend further comprises one or both of carbon fibers (advantageously added after mixing of the particulate fraction and pitch has begun) and small particle size filler (advantageously added as part of the particulate fraction).Type: ApplicationFiled: August 27, 2003Publication date: June 3, 2004Inventors: James William Kortovich, Richard Liichang Shao, Dai Huang, Irwin Charles Lewis, Richard Thomas Lewis
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Patent number: 6737445Abstract: A polymer is prepared by polymerizing a polymerizable component from a mixture containing the polymerizable component and a surfactant, the surfactant and the polymerizable component being present in the mixture in a molar ratio of at least 0.2:1, having an average pore size greater than 4 nm and a density greater than 0.1 g/cc. The polymerizable component can comprise a resorcinol/formaldehyde system and the mixture can comprise an aqueous solution or the polymerizable component can comprise a divinylbenzene/styrene system and the mixture can comprise an organic solution. Alternatively, the polymerizable component can comprise vinylidene chloride or a vinylidene chloride/divinylbenzene system. The polymer may be monolithic, have a BET surface area of at least about 50 m2/g., include a quantity of at least one metal powder, or have an electrical conductivity greater than 10 Scm−1.Type: GrantFiled: August 20, 2001Date of Patent: May 18, 2004Assignee: TDA Research, Inc.Inventors: William Bell, Steven Dietz
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Patent number: 6733737Abstract: An enhanced method for the post processing, i.e. oxidation or stabilization, of carbon materials including, but not limited to, carbon foams, carbon fibers, dense carbon-carbon composites, carbon/ceramic and carbon/metal composites, which method requires relatively very short and more effective such processing steps. The introduction of an “oxygen spill over catalyst” into the carbon precursor by blending with the carbon starting material or exposure of the carbon precursor to such a material supplies required oxygen at the atomic level and permits oxidation/stabilization of carbon materials in a fraction of the time and with a fraction of the energy normally required to accomplish such carbon processing steps. Carbon based foams, solids, composites and fiber products made utilizing this method are also described.Type: GrantFiled: August 29, 2001Date of Patent: May 11, 2004Assignee: Wright Materials Research Corp.Inventors: Seng Tan, Cher-Dip Tan
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Publication number: 20040084793Abstract: Method of forming a (CFX)n containing adsorbent composition by combining a fine particle (CFX)n starting material with a non-fluorinated carbonaceous material prior to the formation of a solid body and intermediate materials employed in conducting the method.Type: ApplicationFiled: October 31, 2002Publication date: May 6, 2004Inventors: Martin Bulow, Donald P. Satchell, Edward F. Ezell, Jan-Thomas Kuhnert, Wolfgang Schops
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Publication number: 20040076810Abstract: A composite high temperature insulator (A) includes a planar layer (10) having anisotropic thermal conductivity properties. A second planar layer (12) is formed from a rigid insulation material, such as a carbonized mixture of carbon fibers and a binder. The second layer is coextensive with the first layer and is preferably bonded thereto by a carbonaceous cement (44). When used to insulate a heat source, such as a furnace (50), convective heat is directed back to the source by the reflective surface (16) of the inner, anisotropic layer (10). Heat which enters the anisotropic layer is dissipated evenly through the plane of the layer along a plurality of heat paths defined by a plurality of layers (14) of flexible graphite. Accordingly, heat which reaches the outer, second layer (12) results in fewer hot spots than occur with a conventional rigid insulation material, thereby reducing the total amount of insulation material required to achieve a desired level of thermal insulation.Type: ApplicationFiled: October 17, 2002Publication date: April 22, 2004Applicant: UCAR Carbon Company Inc.Inventors: David P. Blain, Robert E. Smith
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Patent number: 6719147Abstract: A novel supported mesoporous carbon ultrafiltration membrane and process for producing the same. The membranes comprise a mesoporous carbon layer that exists both within and external to the porous support. A liquid polymer precursor composition comprising both carbonizing and noncarbonizing templating polymers is deposited on the porous metal support. The coated support is then heated in an inert-gas atmosphere to pyrolyze the polymeric precursor and form a mesoporous carbon layer on and within the support. The pore-size of the membranes is dependent on the molecular weight of the noncarbonizing templating polymer precursor. The mesoporous carbon layer is stable and can withstand high temperatures and exposure to organic chemicals. Additionally, the porous metal support provides excellent strength properties. The composite structure of the membrane provides novel structural properties and allows for increased operating pressures allowing for greater membrane flow rates.Type: GrantFiled: April 27, 2001Date of Patent: April 13, 2004Assignee: The University of DelawareInventors: Michael Strano, Henry C. Foley, Hans Agarwal
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Publication number: 20040065970Abstract: The present invention describes compositions formed from polyanaline and carbon nanotubes, which exhibit enhanced conductivity and which provide uses in electronic circuit applications.Type: ApplicationFiled: July 9, 2003Publication date: April 8, 2004Inventor: Graciela Beatriz Blanchet-Fincher
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Patent number: 6716800Abstract: A composite body of silicon carbide having binderless, allotropic carbon granules distributed throughout is produced. The nominal size of the binderless allotropic carbon granules can range from 5 to 500 micrometers. The concentration of the binderless allotropic carbon particles can vary from 1.0 to 35.0 weight percent. The process to produce such a composite body is to sinter silicon carbide with binderless, carbon-yielding precursor granules. The composite body is utilized in tribological applications. The dense, impervious silicon carbide-binderless carbon composite exhibits excellent physical and tribological characteristics when used as a mechanical face seal, a sliding bearing arrangement, or some other rubbing component.Type: GrantFiled: April 12, 2002Date of Patent: April 6, 2004Assignee: John Crane Inc.Inventors: Joseph F. Demendi, Xin Chen, William R. Clemens
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Patent number: 6716376Abstract: The invention relates to a process for producing a fiber composite material containing fibers with a high hot strength, in particular based on carbon, silicon, boron and/or nitrogen, a pressing compound being produced from fibers, a binder and, if appropriate, fillers and/or additives, which is then pressed in a press mold to form a green body. Various pressing compounds are produced, which contain fibers of different qualities and/or in different proportions, and the press mold is filled with the various pressing compounds in a number of successive steps. The invention also relates to a fiber composite material of this nature.Type: GrantFiled: November 1, 2000Date of Patent: April 6, 2004Assignee: DaimlerChrysler AGInventors: Tilmann Haug, Kolja Rebstock, Christian Schwarz
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Patent number: 6706658Abstract: One aspect of the invention relates to a catalyst composite containing an extruded catalyst support containing an extruded activated carbonaceous material having specifically a defined pore structure. For example, the extruded activated carbonaceous material may have pores wherein at least about 40% of total Hg porosity occurs in pores having a diameter of about 200 Å and larger. Alternatively the extruded activated carbonaceous material may have a first set of pores having a pore diameter of at least about 40 Å and at most about 100 Å with a porosity of at least about 0.15 cc/g, and a second set of pores having a pore diameter of at least about 5,000 Å and at most about 20,000 Å with a porosity of at least about 0.3 cc/g.Type: GrantFiled: December 21, 2001Date of Patent: March 16, 2004Assignee: Engelhard CorporationInventor: James Ferguson White
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Patent number: 6699410Abstract: In order to impregnate a porous workpiece with a liquid impregnating agent, the pre-manufactured workpiece is arranged in an injection mould or diecasting mould and the liquid impregnating agent is introduced into the mould with the aid of a commercially available injection moulding or diecast moulding apparatus. To limit the need for post impregnation cleaning and/or shaping, the mould cavity is configured to closely fit the shape of the pre-manufactured workpiece. The impregnating agent may be a natural or synthetic lubricant, a plastic or, more commonly, a molten metal or metal alloy.Type: GrantFiled: May 31, 2001Date of Patent: March 2, 2004Assignee: Hoffman & Co Elektrokohle AktiengesellschaftInventor: Klaus Reiser
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Patent number: 6699411Abstract: It is an object of the present invention to provide a method for simply producing a high purity silicon carbide sintered body having no remaining metal silicon and excellent heat resistance. A method for producing a silicon carbide sintered body of the present invention comprises the steps of: preparing a slurry by dispersing silicon carbide powder in a solvent; forming a molded body by pouring the slurry into a mold and effecting calcination for the slurry in a vacuum atmosphere or in an inert gas atmosphere; and sealing pores within the calcined molded body by impregnating the pores with high purity metal silicon molten by heating, and allowing the high purity metal silicon and carbon contained in the molded body to react on each other in the pores so as to produce silicon carbide.Type: GrantFiled: August 30, 2001Date of Patent: March 2, 2004Assignee: Bridgestone CorporationInventors: Fumio Odaka, Kazuhiro Ushita, Yoshitomo Takahashi
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Patent number: 6695992Abstract: An apparatus for forming a non-woven mat of nanofibers by using a pressurized gas stream includes paralell, spaced apart, first, second, and third members, each having a supply end and an opposing exit end. The second member is located apart from and adjacent to the first member. The exit end of the second member extends beyond the exit end of the first member. The first and second members define a first supply slit. The third member is located apart from and adjacent to the first member on the opposite side of the first member from the second member. The first and third members define a first gas slit, and the exit ends of the first, second and third members define a gas jet space. A method for forming a non-woven mat of nanofibers utilizes this nozzle.Type: GrantFiled: January 22, 2002Date of Patent: February 24, 2004Assignee: The University of AkronInventor: Darrell H. Reneker
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Publication number: 20040033361Abstract: Disclosed herein is an inner tube of glass-like carbon for CVD apparatus and a process for production thereof. The inner tube has its surface roughened without increase in metal impurities which cause particles. It has improved adhesion to CVD deposit film and also has a high degree of roundness. The surface roughness (on both the inner and outer surfaces) is 0.1-10 &mgr;m measured according to JIS B0601. The concentration of metal impurities (iron, copper, chromium, sodium, potassium, calcium, magnesium, and aluminum) in the surface is less than 50×1010 atoms/cm2.Type: ApplicationFiled: August 1, 2003Publication date: February 19, 2004Applicant: Kabushiki Kaisha Kobe Seiko Sho(Kobe Steel, Ltd.)Inventor: Maki Hamaguchi
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Patent number: 6689295Abstract: The present invention provides a method of manufacturing an exfoliated graphite/phenol resin composite foam of a porosity of 50-95%, a density of 0.1-0.8 g/cm3, by forming under contact pressure or reduced pressure at a temperature of 140-200° C. a mixture comprising 100 parts by weight of powdered and/or crushed exfoliated graphite and 40-240 parts by weight of phenol resin; an exfoliated graphite/phenol resin composite foam obtained by the method; and a method of obtaining an exfoliated graphite/glassy carbon composite foam of a porosity of 50-95%, a density 0.1-0.8 g/cm3 with volumetric baking shrinkage of 10% or less by baking the exfoliated graphite/phenol resin composite foam.Type: GrantFiled: March 21, 2001Date of Patent: February 10, 2004Assignees: Osaka Prefectural Government, E. Tec Co., Ltd.Inventors: Takeshi Hirohata, Shinya Kawakami
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Publication number: 20040007791Abstract: A method for preparing a carbon fiber fabric impregnated with a thermoplastic plastic including providing a fabric which substantially consists of carbon fibers with a coating of an epoxy material without curing agent; bringing the fabric to a temperature in the range of 330° C. to 430° C.; and holding the fabric at the temperature for 120 to 240 minutes such that the carbon fibers remain unaffected and the epoxy material is aged or neutralized and loses its tacky character. Alternatively, the heat treatment may be carried out by bringing the fabric to a temperature of 450±70° C. for 15±5 minutes and subsequently to a temperature of 220±30° C. for 240±60 minutes. Fabrics prepared as described may be used in preparing laminates, which include a plurality of layers consisting alternately of the above-described fabric and a layer of thermoplastic plastic.Type: ApplicationFiled: March 19, 2003Publication date: January 15, 2004Inventors: Robert Gerardus Lenferink, Wilhelmus Hendrikus Maria Van Dreumel
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Publication number: 20040005446Abstract: Insulation materials suited to high temperature applications, such as the insulation of furnaces, are formed from a mixture of pitch carbon fibers, such as isotropic pitch carbon fibers, and a binder comprising a solution of sugar in water. The sugar solution is preferably at a concentration of from 20-60% sucrose to yield a low density material having high flexural strength and low thermal conductivity when carbonized to a temperature of about 1800° C.Type: ApplicationFiled: June 28, 2002Publication date: January 8, 2004Applicant: UCAR Carbon Company Inc.Inventors: Charles C. Chiu, Irwin Charles Lewis, Ching-Feng Chang
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Publication number: 20040000734Abstract: Cylindrical castings (174), suited to thermal insulation applications at high temperatures, are formed by a centrifugal casting process. A mixture of carbon-containing fibers, such as isotropic pitch fibers, and a suitable aqueous binder, such as a sugar solution, is supplied to a rotating drum (12). The mixture is supplied via a feed pipe (18) concentrically aligned with a screen (66) of the drum. The fibers and binder collect on a filter cloth (102) supported by an inner surface of the screen. Excess binder flows through the filter cloth and passes through adjacent apertures (100) in the screen. When a cylindrical preform of sufficient thickness has built up, the drum is disassembled. The preform is dried, to drive off excess water, and heated to a temperature of about 900° C.-2000° C. to form the casting.Type: ApplicationFiled: June 28, 2002Publication date: January 1, 2004Applicant: UCAR Carbon Company Inc.Inventors: William Kapphan, Allen E. Hill, Robert Lowther
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Patent number: 6668985Abstract: A friction element for use in a safety braking device for braking elevators co-operating with at least one elevator guide rail. The friction element has at least one friction surface that can be pressed against the guide rail to decelerate the elevator. The friction element is formed of a fiber-reinforced, ceramic composite material, containing silicon carbide and carbon with carbon fibers as reinforcing components. Preferably, the composite material is formed by a matrix of silicon carbide and carbon and the reinforcing component are exclusively carbon fibers with a minimum length of 10 mm and the volume content of carbon fibers in the friction element being between 30% and 70%.Type: GrantFiled: September 6, 2001Date of Patent: December 30, 2003Assignee: Inventio AGInventors: Walter Krenkel, Ralph Renz
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Patent number: 6667099Abstract: The invention relates to mesotubes and nanotubes (hollow fibers) having an inner diameter of 10 nm-50 &mgr;m and to a method for the production thereof. The hollow fibers can be produced by coating degradable materials with non-degradable materials, whereby the degradable materials are destroyed by thermal methods, for instance. The hollow fibers are used in separation technology, catalysis, micro-electronics, medical technology, material technology or in the clothing industry.Type: GrantFiled: January 29, 2002Date of Patent: December 23, 2003Assignee: Creavis Gesellschaft fuer Technologie und Innovation mbHInventors: Andreas Greiner, Joachim Wendorff, Johannes Averdung, Michael Dröscher