Fusing Or Melting Inorganic Material Patents (Class 264/332)
  • Patent number: 5368791
    Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a cell form having a plurality of cells arranged in a contiguous manner, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into prescribed cells of the cell form, charging a base-course material for forming the base course of the shaped article into the remaining space of the main form not filled with the pattern-course material, removing the cell form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.
    Type: Grant
    Filed: September 30, 1991
    Date of Patent: November 29, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5336454
    Abstract: A ceramic composition and method for making ceramic composites having superior erosion and corrosion resistance to molten metal. The composite includes mullite, aluminum nitride and boron nitride in combination. The composite may be hot pressed or cold formed and pressureless sintered into a desired shape.
    Type: Grant
    Filed: March 26, 1993
    Date of Patent: August 9, 1994
    Assignee: Advanced Ceramics Corporation
    Inventor: Lionel C. Montgomery
  • Patent number: 5328890
    Abstract: To produce more complex molded bodies from precursors of high-temperature superconductors based on the oxides of bismuth, strontium, calcium and copper, the homogeneous melt of these oxides is cast in molds at temperatures of 870.degree. to 1000.degree. C. In this process, the geometrically appropriately shaped molds are composed of a material having a melting point of at least 1000.degree. C. Finally, the molds containing solidified melt of the oxides of bismuth, strontium, calcium and copper are treated with dilute hydrofluoric acid at temperatures of 20.degree. to 90.degree. C. until the molds are dissolved.
    Type: Grant
    Filed: December 18, 1992
    Date of Patent: July 12, 1994
    Assignee: Hoechst Aktiengesellschaft
    Inventors: Eberhard Preisler, Joachim Bock
  • Patent number: 5302328
    Abstract: A method is disclosed of fully densifying a plurality of preformed ceramic plates by axial compression of the billets along a wall defining a cylinder and cavity. A series of the plates are stacked along the wall with the smallest dimension of the billets aligned with the axis of the cavity. The billets have a ratio of the smallest dimension to the largest dimension in the range of 1:3 to 1:40. The largest dimension of each of the plates is less than the lateral dimension of the cavity to leave an annular space; the space is filled with a pseudo isostatic pressing medium. The assembly is hot pressed under sufficient pressure and heat to convert the plates to billets of substantially full density.
    Type: Grant
    Filed: July 19, 1983
    Date of Patent: April 12, 1994
    Assignee: Ceradyne, Inc.
    Inventor: Andre Ezis
  • Patent number: 5294387
    Abstract: A fiber-reinforced ceramic composite material reinforced by particle dispersion with improved fracture toughness comprised of a mullite matrix, and fibers and same or different kind of ceramic fine particles both dispersed within the mullite matrix is produced by a method comprising: dispersing mullite particles forming a matrix in a solution dissolving an organometallic macromolecular substance to prepare an impregnating solution, continuously passing fibers through said impregnating solution to uniformly impregnate the fibers with said impregnating solution, laminating said fibers to provide a laminated body, converting the organometallic macromolecular substance within said laminated body into a nonmeltable state, and performing sintering (or press sintering) of said laminated body in an inert gas and/or nitrogen gas. By press sintering K.sub.Ic of 10 MN/m.sup.3/2 or more is achieved.
    Type: Grant
    Filed: September 18, 1991
    Date of Patent: March 15, 1994
    Assignee: Noritake Co., Limited
    Inventors: Kikuo Nakano, Kenji Oshima, Misao Iwata, Takao Yamada
  • Patent number: 5288679
    Abstract: A superconducting copper oxide based wire exhibiting improved critical current density and method. A superconductor powder and a binder melt are mixed at a solids loading of at least 90% by weight. The binder is an ester wax with no more than about 0.25 weight percent extrusion-aiding additives. The ester wax has the general formula RCOOR' with R and R' being hydrocarbon chains of at least 6 carbons. The ester wax melting point is 40.degree.-100.degree. C.; its melt viscosity is 94-2000 centipoise. The mixture is shaped and heated in an oxidizing atmosphere at up to 120.degree. C./hr to 500.degree.-600.degree. C., and held at that temperature for a time sufficient to remove the binder and achieve a wire density of at least 50% of theoretical. The green wire is heated at 50.degree.-130.degree. C./hr to at least 920.degree. C., and held at 920.degree.-990.degree. C. to achieve 90% of theoretical density, then annealed in oxygen. The wire may be textured during the heating process or by seeding.
    Type: Grant
    Filed: November 26, 1991
    Date of Patent: February 22, 1994
    Assignee: GTE Laboratories Incorporated
    Inventor: Sophia R. Su
  • Patent number: 5284712
    Abstract: The occurrence of efflorescence has been reduced or eliminated in ceramic articles formed from a novel vitreously bonded cement-containing composition. The articles also exhibit improved strength, reduced firing shrinkage and increased frost resistance. The articles are produced by combining hydraulic cement containing calcium silicate and/or calcium aluminate components, vitrifiable inorganic powders forming molten liquid-flowing substances, and reactive or sinterable mineral powders selected from the group consisting of magnesium silicates, aluminum silicates and mixtures thereof; combining the ingredients with water to form a mixture; molding the mixture into an article; hardening the article by hydration; and firing the molded article to a maximum temperature of between about 1000.degree. C. to 1400.degree. C.
    Type: Grant
    Filed: September 25, 1992
    Date of Patent: February 8, 1994
    Inventors: Kazuyuki Kawai, Kazumasa Goto, Takayuki Shirai
  • Patent number: 5276011
    Abstract: A method of manufacturing a component of the tape or filament kind out of a material based on a superconducting oxide having a high critical temperature, wherein said material is formed while it is in the vitreous state,the method being characterized by the fact that the material is subsequently crystallized:in a first step under a magnetic field and at a temperature T.sub.l lying between the vitreous transition temperature T.sub.g and the crystallization temperature T.sub.x, during which step isolated microcrystallites of submicroscopic size develop and their c axes orient themselves parallel to one another because of said applied magnetic field; andin a second step at a temperature T.sub.2 close to the crystallization temperature, in which the existing nuclei grow while retaining the texture imparted to them during said first step.
    Type: Grant
    Filed: January 3, 1992
    Date of Patent: January 4, 1994
    Assignee: Alcatel Alsthom Compagnie Generale d'Electricite
    Inventor: Christian Belouet
  • Patent number: 5275770
    Abstract: Aluminum nitride powder (28), possibly powdered glass (29) and aluminum oxide powder (23) are introduced into the molding cavity of a pressure matrix (26) for fabrication of a carrier body from aluminum nitride, whose surface is at least partially covered with aluminum oxide. Subsequently a pressure stamp (22) of the pressure tool (20) is introduced into the molded cavity of the pressure matrix (26). The powdered layers (28, 29, 30) are compressed and subsequently sintered, for instance for two hours at 1600.degree. C. in a neutral atmosphere.
    Type: Grant
    Filed: April 12, 1990
    Date of Patent: January 4, 1994
    Inventor: Altan Akyurek
  • Patent number: 5273941
    Abstract: It relates to fiber reinforced silicon carbide ceramics in which heat-resistant inorganic short fibers such as flawless SiC or Si.sub.3 N.sub.4 are three-dimensionally dispersed in a matrix composed of silicon carbide and entangled with each other to form a high strength shaped body as well as a method of producing the same. Further, it relates to high density silicon carbide ceramica in which metallic silicon is filled in pores of the shaped body, so that these fiber reinforced silicon carbide ceramics possesses both high strength and high toughness and are composite ceramics suitable as a heat-resistant structural material or a material with bio hard texture.
    Type: Grant
    Filed: September 27, 1989
    Date of Patent: December 28, 1993
    Assignee: Ibiden Co., Ltd.
    Inventors: Ryo Enomoto, Yoshimi Matsuno, Masato Yokoi
  • Patent number: 5266557
    Abstract: A method of fabricating a superconducting ceramic pipe including the steps of: melting a ceramic powder having a predetermined composition to form a melt; filling a supporting tube with the melt by a suction caused by a vacuum pressure; partially solidifying an outer part of the melt near the tube to form a shell (i.e., a ceramic pipe); discharging an inner unsolidified part at the center of the tube from the tube by gravity, to form a solidified ceramic pipe on the inside surface of the tube; and heat treating the ceramic pipe to convert it into a superconducting pipe. When a supporting tube with a bottom plate is used, the melt is poured into the tube, and the tube is turned over to remove an unsolidified melt, whereby a superconducting ceramic pipe with a bottom is fabricated.
    Type: Grant
    Filed: November 26, 1991
    Date of Patent: November 30, 1993
    Assignees: Fujitsu Limited, Yoshihiro Abe
    Inventors: Yoshihiro Abe, Hideo Hosono, Takeshi Akamatsu
  • Patent number: 5258337
    Abstract: Ceramics containing AlN and B.sub.4 C are produced from relatively low cost starting materials. The starting materials are combined and heated whereby they react to form AlN and B.sub.4 C. The reacted mixture can optionally be densified thereafter. The starting materials generally include aluminum metal, boron nitride and carbon.
    Type: Grant
    Filed: June 18, 1992
    Date of Patent: November 2, 1993
    Assignee: W. R. Grace & Co.-Conn.
    Inventors: Craig P. Cameron, John W. Lau
  • Patent number: 5254300
    Abstract: By means of the process and by means of the apparatus, fused silicon is produced continuously, or in phases, and zonally cast into a mold in which it is caused to solidify zonally. The temperature conditions in the solidification zone are controlled with the aid of a movable heating zone, by means of which the crystallization front is adjusted to the rising level that fills up the mold, this level being in turn controlled by the fusion rate of the silicon. Polycrystalline silicon blocks can be obtained in which, because of the flat shape of the crystallization front, the columnar single-crystal domains within the blocks extend almost vertically and which represent an excellent solar cell base material having high diffusion lengths and lifetimes of the minority charge carriers, from which solar cells of correspondingly high efficiencies can be produced.
    Type: Grant
    Filed: June 7, 1991
    Date of Patent: October 19, 1993
    Assignee: Wacker-Chemitronic Gesellschaft fur Elektronik-Grundstoffe mbH
    Inventors: Georg Priewasser, Lothar Huber, Gerhard Spatzier
  • Patent number: 5248656
    Abstract: A method for producing superconductor wire characterized by forming a solid superconductor preform, suspending the preform within an oven such that a portion of it is heated to approximately its melting point, and drawing on the melted portion of the preform to form a superconductor wire. If the preform is solid, so is the drawn wire, and if the preform is hollow, the drawn wire becomes a capillary. Superconductor wires can be intertwined, or can be intertwined with ordinary conductive wires or non-conductive tubing to form superconductor cables. A superconductor transmission line is made by coating a copper tube with subsequent superconductor, insulating, and protective layers.
    Type: Grant
    Filed: October 9, 1990
    Date of Patent: September 28, 1993
    Assignee: Hewlett-Packard Company
    Inventors: V. K. Nagesh, John P. Scalia
  • Patent number: 5244876
    Abstract: Method for joining parts of ceramic high-temperature superconductor material of the composition Bi.sub.(2+a-b) (Sr.sub.1-c) Ca.sub.c) .sub.(3-a) Pb.sub.b Cu.sub.(2+d) O.sub.x, where a is 0 to 0.3, b is 0 to 0.5, c is 0.1 to 0.9 and d is 0 to 2 and x has a value depending on the state of oxidation of the metals present, the end faces of the parts located at a gap spacing apart from one another are heated by means of a fuel gas/oxygen flame to temperatures from 750.degree. to 875.degree. C. Simultaneously, a rod of the same material above the spacing gap is heated until the melt thereof drips off into the gap between the end faces of the two parts, completely filling the gap. At least the joint region between the two parts is then heat-treated for 7 to 100 hours at temperatures between 780.degree. and 850.degree. C.
    Type: Grant
    Filed: October 26, 1992
    Date of Patent: September 14, 1993
    Assignee: Hoechst Aktiengesellschaft
    Inventors: Eberhard Preisler, Joachim Bock, Johannes Holzem, Werner Horst
  • Patent number: 5244621
    Abstract: There are disclosed in process for shaping ceramic composites which comprises shaping a sintered silicon nitride-silicon carbide composite material having a microstructure formed predominantly of equiaxed grains with an average grain size of 2 .mu.m or below and a silicon carbide content of 10-50% by volume, obtained by liquid-phase sintering, at least 40% by volume of the silicon nitride in the material being in the .beta.-phase, by superplastically deforming said material at a strain rate of 10.sup.-6 sec.sup.-1 to 10.sup.-1 sec.sup.-1 under application of tensile stress or compressive stress in a superplastic temperature region of 1400.degree.-1700.degree. C., and a process for shaping ceramic composites which comprises shaping said sintered composite material by superplastic deformation as described above and then heat-treating the shaped article obtained in a non-oxidizing atmosphere under normal or applied pressure at 1000.degree.-2300.degree. C.
    Type: Grant
    Filed: April 8, 1992
    Date of Patent: September 14, 1993
    Assignees: Mitsubishi Gas Chemical Company, Inc., Director-General of the Agency of Industrial Science and Technology
    Inventors: Fumihiro Wakai, Yasuharu Kodama, Kansei Izaki, Takamasa Kawakami
  • Patent number: 5234653
    Abstract: A method for moulding a two-colored material includes moulding a gasket such that it has a profile which is approximately the same as a profile of one of a plurality of possible corresponding regions of the inner surface of a mould. In addition, a rigid material is embedded in the gasket and the gasket is fixed to a separation wall. The gasket and the separation wall are then inserted into the mould with the gasket being aligned along the one of the plurality of possible corresponding regions of the inner surface of the mould, such that a seal between the inner surface of the mould and the separation wall is formed and first and second half-spaces are defined within the mould. The gasket is compressed against the inner surface of the mould to improve the sealing therewith and slush moulding of a layer of a first colored material within the first half-space is performed. The layer of the first colored material is consolidated and the gasket and the separation wall are removed from the mould.
    Type: Grant
    Filed: September 12, 1991
    Date of Patent: August 10, 1993
    Assignee: Industrie ILPEA S.p.A.
    Inventors: Giancarlo Buzzoni, Paolo Cittadini
  • Patent number: 5232908
    Abstract: A method of manufacturing an oxide superconductor including (a) alternately laminating at least one first layer including an oxide superconductor or a precursor thereof with at least one second layer including a metal material to form a laminated body, (b) forming an outermost metal coating layer of the metal material on the laminated body to form a laminated structure, and (c) heating and cooling the laminated structure or elongating the laminated structure into a desired shape and then carrying out heating and cooling.
    Type: Grant
    Filed: January 9, 1992
    Date of Patent: August 3, 1993
    Assignee: The Furukawa Electric Co., Ltd.
    Inventors: Shoji Shiga, Naoki Uno, Noritsugu Enomoto, Hiroyuki Kikuchi
  • Patent number: 5227106
    Abstract: A reconstruction of a heating wall of a coking oven. The reconstruction includes utilization of a novel large size cast refractory repair module which may be utilized to replace existing silica bricks within a coke oven heating wall. The novel large size cast refractory module are monolithic structures formed from a castable refractory material having very high dimensional stability over a wide range of temperatures. Each repair module is a rectangular parallelepiped having one or more vertically extending flues formed therein, one end of a module being adapted to conform to the end shape of the damaged heating wall, the other end of the module being adapted to interfit with existing brickwork. The modules are assembled by initially removing damaged brickwork from the heating wall and then placing in the new modules which are mortared in place.
    Type: Grant
    Filed: August 1, 1991
    Date of Patent: July 13, 1993
    Assignee: Tonawanda Coke Corporation
    Inventor: Robert E. Kolvek
  • Patent number: 5215565
    Abstract: A method of the production of the ceramic superconductor filament comprisesa step including mixing raw materials of ceramic superconductor, subsequently shaping the mixed ceramic superconductor into a ceramic superconductor body of a predetermined shape and preliminarily sintering thereof and further subsequently crushing the sintered ceramic superconductor body into ceramic superconductor powder;a step of filling the ceramic superconductor powder in a glass tube;a step of heating the glass tube including ceramic superconductor powder so that the ceramic superconductor powder is molten; anda step of spinning the glass tube including the ceramic superconductor materialwhereby a ceramic super conductor covered with the glass material can be obtained.
    Type: Grant
    Filed: January 8, 1992
    Date of Patent: June 1, 1993
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Akira Urano, Kenichi Takahashi, Kazuya Ohmatsu, Masashi Onishi
  • Patent number: 5194298
    Abstract: Method of manufacture of ceramic materials which require stability in severely-corrosive environment having high alkali-metal activity, high sulfur/sulfide activity and/or molten halides at temperatures of 200.degree.-550.degree. C. or organic salt (including SO.sub.2 and SO.sub.2 Cl.sub.2) at temperatures of 25.degree.-200.degree. C. These surfide ceramics form stoichiometric (single-phase) compounds with sulfides of Ca, Li, Na, K, Al, Mg, Si, Y, La, Ce, Ga, Ba, Zr and Sr and show melting-points that are sufficiently low and have excellent wettability with many metals (Fe, Ni, Mo) to easily form metal/ceramic seals. Ceramic compositions are also formulated to adequately match thermal expansion coefficient of adjacent metal components.
    Type: Grant
    Filed: September 14, 1990
    Date of Patent: March 16, 1993
    Inventor: Thomas D. Kaun
  • Patent number: 5187128
    Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron nitride material typically resulting in a body comprising a boron-containing compound, a nitrogen-containing compound and metal. The mass to be infiltrated may contain one or more inert fillers admixed with the boron nitride, to produce a composite by reactive infiltration, which composite comprises a matrix which embeds the filler material. The matrix, in a composite body containing filler material, comprises one or more of metal, a boron-containing compound and a nitrogen-containing compound. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal and/or porosity. The mass to be infiltrated can be contained within a refractory vessel having a venting means included therein.
    Type: Grant
    Filed: July 12, 1990
    Date of Patent: February 16, 1993
    Assignee: Lanxide Technology Company, LP
    Inventors: Danny R. White, Terry D. Claar
  • Patent number: 5178808
    Abstract: An end plug for an arc tube for a high pressure discharge lamp is made by pressing alumina powder in a tapered cylindrical die so that the diameter of the as-pressed plug is greatest at that part of the plug that has the lowest as-pressed density. The variation in diameter of the as-pressed plug compensates for the variation in density so that upon high temperature sintering, the plug shrinks to a substantially uniform diameter.
    Type: Grant
    Filed: October 5, 1988
    Date of Patent: January 12, 1993
    Inventors: Frank B. Makar, George A. Fryburg
  • Patent number: 5171491
    Abstract: A method of producing near net shape fusion cast refractories. The method includes the steps of continuously introducing refractory particles into a melting furnace, rapidly heating the particles, depositing the heated particles into a melt pool, continuously introducing the molten material into a mold, and continuously withdrawing a solidified body from the mold as the molten material continually solidifies. The above stated method produces a fusion cast refractory having a generally random, fine, uniform microstructure; uniform chemistry; and generally evenly distributed closed pores.
    Type: Grant
    Filed: February 8, 1991
    Date of Patent: December 15, 1992
    Assignee: The Carborundum Company
    Inventors: Jonathan J. Kim, Thomas A. Myles, Bruce J. Dover, Alan LeBold
  • Patent number: 5167886
    Abstract: A boron compound, capable of forming boron oxide on hot pressing in an oxygen-containing atmosphere, is used as a densification aid for hot pressing of alumina-containing ceramics in oxygen-containing atmospheres. The boron compound may be incorporated into the material to be hot pressed or may be applied to the surface of that material. Air may be used as the hot pressing atmosphere. The alumina-containing ceramic to be hot pressed may be formed by reaction processing techniques. Boron nitride is a preferred boron compound.
    Type: Grant
    Filed: August 29, 1991
    Date of Patent: December 1, 1992
    Assignee: W. R. Grace & Co. Conn.
    Inventors: Craig P. Cameron, Roy W. Rice
  • Patent number: 5167915
    Abstract: A process for producing a rare earth-iron-boron magnet, which includes the steps of: (1) charging a melt spun powder of a rare earth-iron-boron magnet into at least one cavity, which is confined by a pair of electrodes inserted into a hole of an electrically non-conductive ceramic die; (2) subjecting the melt spun powder to a non-equilibrium plasma treatment, under a reduced atmosphere of 10.sup.-1 to 10.sup.-3 Torr, while applying a uniaxial pressure of 200 to 500 kgf/cm.sup.2 to the melt spun powder in the direction connecting the electrodes interposed between a pair of thermally insulating members, thereby fusing the melt spun powder; and (3) heating the fused melt spun powder to a temperature higher than or equal to its crystallization temperature by transferring a Joule's heat generated in the thermally insulating members by passing a current through the members to the melt spun powder thereby causing the plastic deformation of the melt spun powder to form a rare earth-iron-boron magnet.
    Type: Grant
    Filed: March 27, 1991
    Date of Patent: December 1, 1992
    Assignee: Matsushita Electric Industrial Co. Ltd.
    Inventors: Fumitoshi Yamashita, Masami Wada, Takeichi Ota
  • Patent number: 5157017
    Abstract: Articles comprising a quantity of superconductive oxide material can be fabricated by a process that comprises melting of part of an oxide precursor material, with resultant directional resolidification. Exemplary embodiments comprise zone melting and movement of the hot zone through the precursor material. The method can result in superconductive material having improved properties, e.g., higher critical current, as compared to prior art oxide superconductors.
    Type: Grant
    Filed: May 12, 1988
    Date of Patent: October 20, 1992
    Assignee: AT&T Bell Laboratories
    Inventors: Sungho Jin, Richard C. Sherwood, Thomas H. Tiefel
  • Patent number: 5154882
    Abstract: The invention includes an apparatus and method for hot isostatic compaction of compactible material in a heated and pressurized environment within a pressure vessel, having a compaction container which can be hermetically sealed over a load, and which can transmit pressure from the pressure vessel to the load sealed in the container, a compaction die which can be hermetically sealed within the container, the die having an interior wall area which defines within the die an internal cavity having a width measured along a first axis, the die interior wall area extending along a second axis transverse to the first axis to generally define the height of the die cavity, the die having a wall thickness measured along the first axis, and a punch arrangement for applying compacting force to the compactible material and having a width essentially equal to the die cavity width such that when the punch arrangement is loaded oriented along the first axis within the die cavity, respective ends of the punch arrangement cont
    Type: Grant
    Filed: August 13, 1991
    Date of Patent: October 13, 1992
    Assignee: Industrial Materials Technology
    Inventor: Daniel H. Zick
  • Patent number: 5145833
    Abstract: This invention provides a process for producing a ceramic body by heating a ceramic material, such as particulate zirconium oxide, to a temperature greater than about 30 percent of the material's melting temperature, but less than said melting temperature, and thereafter applying sufficient isostatic pressure to consolidate the ceramic material into a body having a density of at least 85 percent of the theoretical density of the material.This invention also provides a process for producing superconducting ceramic articles such as those represented by the general formula YBa.sub.2 Cu.sub.3 O.sub.7-x where 0<x<0.6. Starting materials for such articles include sources of yttria, cupric oxide and barium monoxide. The general process parameters for the ceramic body process are modified to accomodate the starting materials.
    Type: Grant
    Filed: March 14, 1990
    Date of Patent: September 8, 1992
    Assignee: The Dow Chemical Company
    Inventors: Arthur R. Prunier, Jr., Stanley F. Spangenberg, Sunil Wijeyesekera
  • Patent number: 5140004
    Abstract: A method of preparing a high Tc superconducting fiber is disclosed, which comprises drawing into fiber form a core filament of a crystalline oxide, continuously depositing on the heated core filament a high Tc superconducting thin film and then depositing a protective layer on the outer surface of the high Tc superconducting thin film.
    Type: Grant
    Filed: June 18, 1991
    Date of Patent: August 18, 1992
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Saburo Tanaka, Hideo Itozaki, Takeshi Yamaguchi, Shuji Yazu, Tetsuji Jodai
  • Patent number: 5127158
    Abstract: A process for producing a printed circuit board includes steps, sequentially conducted of dispersing in water or organic solvent:(A) 95 to 20% by weight of a styrene polymer having a syndiotactic structure, (B) 5 to 80% by weight of a fibrous filler having a fiber length of 1 to 50 mm, and (C) 0.1 to 30 parts by weight of at least one of a binder and a binding fiber in proportion to 100 parts by weight of the total amount of the components (A) and (B), to make a slurry having a concentration of 0.5 to 100 g/l; separating the solids from the slurry and drying and molding them. Thereafter the solids are either subjected to melting with heating and pressure forming into the molded article, or they are impregnated with a thermoplastic resin which is then cured. Finally, a metal layer is provided on the molded article.
    Type: Grant
    Filed: August 30, 1990
    Date of Patent: July 7, 1992
    Assignee: Idemitsu Kosan Co., Ltd.
    Inventor: Akikazu Nakano
  • Patent number: 5122317
    Abstract: A method for deforming a ceramic compound by doping a zirconia ceramic material with an effective amount of a transition metal and superplastically deforming the material.
    Type: Grant
    Filed: October 16, 1991
    Date of Patent: June 16, 1992
    Assignee: The Regents of the University of Michigan
    Inventors: I-Wei Chen, Chinmau J. Hwang
  • Patent number: 5120483
    Abstract: The invention encompasses unsintered and sintered compositions comprising boride and alumina. A sintered material containing boride and alumina may be produced by a method comprising:a) combining sources of borate glass frit and aluminum to form a mixture;b) compacting the mixture to form a shape;c) heating the shape, whereby the sources react to form boride and alumina; andd) densifying the reacted shape.Specific embodiments of the invention include the use of rare earth borate glasses such as La.sub.2 O.sub.3. 6 B.sub.2 O.sub.3 glass to form compositions containing rare earth boride.
    Type: Grant
    Filed: April 3, 1991
    Date of Patent: June 9, 1992
    Assignee: W. R. Grace & Co.-Conn.
    Inventors: Craig P. Cameron, Roy W. Rice
  • Patent number: 5114641
    Abstract: Method for producing an elongated sintered article, characterized by the steps including filling powder material in a pipe, carrying out plastic deformation of the pipe filled with the powder material, and heating the pipe filled with the powder material to burn and/or sinter the powder material.The method of the present invention is advantageously applicable to production of wire or rod of ceramics, particularly so called new ceramics or fine ceramics, sintered alloys or their combination, which are difficult of shaping or moulding by conventional process such as wire-drawings, rolling or extrusion of powder material and are difficult of machining or processing after the powder material is sintered.
    Type: Grant
    Filed: October 31, 1990
    Date of Patent: May 19, 1992
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Susumu Yamamoto, Teruyuki Murai, Nozomu Kawabe, Masaaki Tobioka
  • Patent number: 5098631
    Abstract: Use a material which has a coefficient of thermal expansion greater than silicon nitride and does not react with silicon nitride under hot pressing conditions either to fabricate or to coat hot-pressing die plates suitable for densification of silicon nitride. The die plates separate cleanly from the silicon nitride thereby allowing preparation of near-net shapes having complex geometries, but without post densification grinding or machining.
    Type: Grant
    Filed: September 13, 1990
    Date of Patent: March 24, 1992
    Assignee: The Dow Chemical Company
    Inventors: Aleksander J. Pyzik, Timothy L. Allen
  • Patent number: 5089196
    Abstract: A non-magnetic substrate used for a magnetic head comprising a pair of non-magnetic substrates, and a magnetic layer structure sandwiched between the pair of non-magnetic substrates. The magnetic layer structure is comprised, of alternately laminated magnetic layers and intermediate insulating layers. The invention discloses for the substrate material a composition expressed by Zn.sub.x M.sub.y Co.sub.2-x-y O.sub.2, with the proviso that M is Mn or Ni, 0.ltoreq.x.ltoreq.0.4, 0.4.ltoreq.y.ltoreq.1.0, 0.8.ltoreq.x+y.ltoreq.1.0, or Co.sub.x Ni.sub.2-x O.sub.2, with the proviso that 0.2.ltoreq.x.ltoreq.1.8, and having a rock-salt structure.
    Type: Grant
    Filed: April 12, 1991
    Date of Patent: February 18, 1992
    Assignee: Nippon Mining Co., Ltd.
    Inventors: Eiji Itoh, Ryuichi Nagase, Kazuhiro Saito, Hiroshi Hosaka, Hihumi Nagai
  • Patent number: 5089468
    Abstract: The present process for producing a Bi-based superconducting oxide includes the steps of molding a material powder and subjecting the molded article to partial melting and then to crystallization in the presence of oxygen. In that case, the molded article is annealed, after the partial melting, to the crystallization temperature and subjected to crystallization at that temperature. Also, the article after the crystallization is cooled and the cooled article is heat-treated in an inert gas atmosphere. According to the above process, there can be obtained a Bi-based superconducting oxide having excellent superconducting properties.
    Type: Grant
    Filed: March 28, 1990
    Date of Patent: February 18, 1992
    Assignee: NGK Insulators, Ltd.
    Inventors: Hitoshi Yoshida, Hitoshi Sakai, Shuichiro Oki, Keiichiro Watanabe, Manabu Yoshida, Toshio Oda
  • Patent number: 5080959
    Abstract: A multilayer tile, wherein the tile-materials of the first and third layers are substantially equal to each other in shrinkage during drying and firing and in thermal expansion coefficient after firing.
    Type: Grant
    Filed: December 19, 1988
    Date of Patent: January 14, 1992
    Assignee: Inax Corporation
    Inventors: Hideo Tanaka, Itaru Takeda, Hiroyuki Tada
  • Patent number: 5069841
    Abstract: Compositions of matter consisting of matrix materials having silicon carbide dispersed throughout them and methods of making the compositions. A matrix material is an alloy of an intermetallic compound, molybdenum disilicide, and at least one secondary component which is a refractory silicide. The silicon carbide dispersant may be in the form of VLS whiskers, VS whiskers, or submicron powder or a mixture of these forms.
    Type: Grant
    Filed: August 9, 1990
    Date of Patent: December 3, 1991
    Assignee: University of California
    Inventors: John J. Petrovic, Richard E. Honnell, W. Scott Gibbs
  • Patent number: 5064589
    Abstract: A method for producing a high density boron nitride sintered body includes mixing high purity hexagonal boron nitride powder with 0.1 to 20% by weight of at least one alkaline earth metal, then shaping the resultant mixture and firing the resultant shaped body in a non-oxidizing atmosphere containing nitrogen.
    Type: Grant
    Filed: February 26, 1991
    Date of Patent: November 12, 1991
    Assignee: Showa Denko K.K.
    Inventors: Kagetaka Ichikawa, Takao Noda
  • Patent number: 5063022
    Abstract: The invention includes an apparatus and method for hot isostatic compaction of compactible material in a heated and pressurized environment within a pressure vessel, having a compaction container which can be hermetically sealed over a load, and which can transmit pressure from the pressure vessel to the load sealed in the container, a compaction die which can be hermetically sealed within the container, the die having an interior wall area which defines within the die an internal cavity having a width measured along a first axis, the die interior wall area extending along a second axis transverse to the first axis to generally define the height of the die cavity, the die having a wall thickness measured along the first axis, and a punch arrangement for applying compacting force to the compactible material and having a width essentially equal to the die cavity width such that when the punch arrangement is loaded oriented along the first axis within the die cavity, respective ends of the punch arrangement cont
    Type: Grant
    Filed: December 19, 1990
    Date of Patent: November 5, 1991
    Assignee: Industrial Materials Technology, Inc.
    Inventor: Daniel H. Zick
  • Patent number: 5051218
    Abstract: A method for consolidating or densifying material selected from metal, ceramic or mixtures thereof to form a densified compact article, which process includes (a) arranging the sample to be consolidated or densified in a general configuration within a temperature controlled high pressure chamber completely surrounded by a pre-glass material which forms a glass at elevated temperature in close proximity and surrounded by a heating element within the pre-glass material and having at least one temperature measuring device in close proximity to the sample all located within a shell; (b) externally heating the arrangement produced in step (a) at an elevated temperature for a time effective to remove moisture, volatiles, impurities, volatile oxides or mixtures thereof; (c) heating the sample produced in step (c) to produce fusion of the pre-glass at between about 500.degree. to 1600.degree. C.
    Type: Grant
    Filed: February 10, 1989
    Date of Patent: September 24, 1991
    Assignee: The Regents of the University of California
    Inventor: M. Dean Matthews
  • Patent number: 5049329
    Abstract: In the method for making a ceramic matrix composite article comprising the steps of providing a porous preform for the article formed of a combination of a fibrous reinforcing material and a ceramic matrix material, and thereafter consolidating the preform by the application of heat and consolidation pressure thereto, improved consolidation of preforms of curved or other complex configuration is achieved by applying consolidation pressure to the preforms through the medium of a softened glass.
    Type: Grant
    Filed: October 30, 1989
    Date of Patent: September 17, 1991
    Assignee: Corning Incorporated
    Inventors: Roger A. Allaire, Frank Coppola
  • Patent number: 5047186
    Abstract: A process for producing a silicon nitride-based article of improved fracture toughness and strength. The process involves densifying to at least 98% of theoretical density a mixture including (a) a bimodal silicon nitride powder blend consisting essentially of about 10-30% by weight of a first silicon nitride powder of an average particle size of about 0.2 .mu.m and a surface area of about 8-12 m.sup.2 /g, and about 70-90% by weight of a second silicon nitride powder of an average particle size of about 0.4-0.6 .mu.m and a surface area of about 2-4 m.sup.2 /g, (b) about 10-50 percent by volume, based on the volume of the densified article, of refractory whiskers or fibers having an aspect ratio of about 3-150 and having an equivalent diameter selected to produce in the densified article an equivalent diameter ratio of the whiskers or fibers to grains of silicon nitride of greater than 1.0, and (c) an effective amount of a suitable oxide densification aid.
    Type: Grant
    Filed: December 28, 1989
    Date of Patent: September 10, 1991
    Assignee: GTE Laboratories Incorporated
    Inventors: Marvin Huckabee, Sergej-Tomislav Buljan, Jeffrey T. Neil
  • Patent number: 5045137
    Abstract: For reliably improving the strength of the composite body formed by hot-pressing together the silicon nitride surfaces at which parts of the composite body are joined, one of the silicon nitride surfaces to be joined is covered by a set of three thin layers applied by sputtering, the first a nitrogen-deficient layer of SiN.sub.x where 1.3>x and .gtoreq.0, a second layer of SiN.sub.y in which y>1.33 and a third layer like the first. The first and third layers have the same thickness and the second layer has twice that thickness. The three layers together have a thickness not exceeding 3 .mu.m and the overall composition of the set of three layers is Si.sub.3 N.sub.4. With such a set of layers, the wetting of the surfaces of the bodies to be joined during hot-pressing is substantially improved, resulting in better bonding of the parts across the joint seam.
    Type: Grant
    Filed: December 8, 1989
    Date of Patent: September 3, 1991
    Assignee: Forschungzentrum Julich GmbH
    Inventor: Erno Gyarmati
  • Patent number: 5045269
    Abstract: A method for producing sintered shapes of refractory powders with improved strength and toughness using a grain growth inhibiting powder to inhibit grain growth.
    Type: Grant
    Filed: February 1, 1991
    Date of Patent: September 3, 1991
    Assignee: Union Carbide Coatings Service Technology Corporation
    Inventor: Raymond V. Sara
  • Patent number: 5039658
    Abstract: Bi.sub.2 Sr.sub.2 Ca,Cu.sub.2 2212 superconductive oxide fiber having enhanced current carrying capacity is prepared by forming an intimate mixture of the Bi.sub.2 Sr.sub.2 Ca.sub.1 Cu.sub.2 superconductive oxide precursors or their functional equivalents, firing the mixture at a temperature of at least 400.degree. C. but below the melting point of the superconductive oxide, dispersing the fired mixture in an organic binder, extruding the dispersion as fiber extrudate, firing the fiber at a temperature sufficient to cause the organic binder to burn off and to cause melting of the superconductive oxide while substantially retaining the filamentary shape, and then cooling the fiber.
    Type: Grant
    Filed: December 27, 1989
    Date of Patent: August 13, 1991
    Assignee: E. I. Du Pont de Nemours and Company
    Inventor: Che-Hsiung Hsu
  • Patent number: 5019306
    Abstract: A high-frequency dielectric ceramic compound having a perovskite-type crystal structure comprising a chemical composition substantially represented by the formula (Sr.sub.x Ca.sub.y Mn.sub.z)TiO.sub.3 in which 0.98<x+y+z<1.02, 0.34<y<0.4, and 0.0075<z<0.0015, and possessing a non-linear temperature coefficient is set forth. A method is presented for utilizing the compound to formulate a high-frequency dielectric material, the formulated material being particularly suitable for providing filters and related applications with a relatively low resonant frequency temperature coefficient.
    Type: Grant
    Filed: November 14, 1990
    Date of Patent: May 28, 1991
    Assignee: Motorola, Inc.
    Inventors: Rong-Fong Huang, Dean Anderson
  • Patent number: 5015540
    Abstract: Fibrous material is coated with boron nitride and a silicon-wettable material, the coated fibrous material is admixed with an infiltration-promoting material which is at least partly elemental carbon and the mixture is formed into a preform which is infiltrated with molten silicon producing a composite containing boron nitride coated fibrous material.
    Type: Grant
    Filed: June 1, 1987
    Date of Patent: May 14, 1991
    Assignee: General Electric Company
    Inventors: Marcus P. Borom, William B. Hillig, Raj N. Singh, William A. Morrison, Leonard V. Interrante
  • Patent number: 5000896
    Abstract: A composition consisting of an intermetallic compound, molybdenum disilicide, which is reinforced with VS silicon carbide whiskers dispersed throughout it and a method of making the reinforced composition. Use of the reinforcing material increases fracture toughness at low temperatures and strength at high temperatures, as compared to pure molybdenum disilicide.
    Type: Grant
    Filed: March 15, 1990
    Date of Patent: March 19, 1991
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventors: John J. Petrovic, David H. Carter, Frank D. Gac