Abstract: The present invention discloses a method for making a porous calcium phosphate article including i) preparing a shaped article from a paste containing a calcium phosphate cement, a pore-forming powder and a setting liquid; ii) immersing the shaped article in an immersing liquid for a period of time so that the pore-forming powder is dissolved in the immersing liquid, creating pores in said shaped article; and iii) removing the resulting porous shaped article from the immersing liquid, wherein the resulting porous shaped article has an improved compressive strength. The porous shaped calcium phosphate article of the present invention may be used as a tissue-engineered scaffold, medical implant or a reinforcing constituent of a composite.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: A process for the production of a shaped article from a lightweight-aggregate granulate and an inorganic binder has the following process steps: provision of a viscous binder that has been prepared on the basis of diatomite and caustic soda or caustic potash solution, mixing of the binder with lightweight-aggregate granulate, shaping of the lightweight-aggregate granulate binder mixture, and thermal exposure of the lightweight-aggregate granulate binder mixture under foaming and bonding of the lightweight-aggregate granulate particles in a foamed binder matrix to create the shaped article.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: An improved two-step replication process for fabrication of porous metallic membranes is provided. A negative of a porous non-metallic template is made by infiltration of a liquid precursor into the template, curing the precursor to form a solid negative, and removing the template to expose the negative. Metal is deposited to surround the exposed negative. Removal of the negative provides a porous metallic membrane having pores which replicate the pores of the original template membrane. The negative is kept immersed in a liquid at all times between removing the template and depositing the metal. This immersion eliminates damage to the negative that would be incurred in drying the negative out between these processing steps. Another aspect of the invention is metallic membranes prepared according to the preceding method. For example, metallic membranes having pores smaller on one side than on the other side of the membrane are provided.

Abstract: The invention relates to expanded graphite and methods of making the graphite and products that can be made from the graphite made from the inventive process. The invention includes the step of introducing a fluid into at least one of a plurality of interstices of graphite flake, wherein the fluid comprises at least one of a sub-critical point fluid, a near critical point fluid, or a supercritical fluid. The graphite flake is also intercalated with an intercalant and optionally an oxidizing agent. The invention may further include novel techniques of exfoliating the graphite. The invention may be practiced to make nano-sized graphite particles and also graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a method for making a porous calcium phosphate article including i) preparing a shaped article from a paste containing a calcium phosphate cement, a pore-forming powder and a setting liquid; ii) immersing the shaped article in an immersing liquid for a period of time so that the pore-forming powder is dissolved in the immersing liquid, creating pores in said shaped article; and iii) removing the resulting porous shaped article from the immersing liquid, wherein the resulting porous shaped article has an improved compressive strength. The porous shaped calcium phosphate article of the present invention may be used as a tissue-engineered scaffold, medical implant or a reinforcing constituent of a composite.

Abstract: A process for preparing artificial bone is described which comprises: (i) preparing a mixture of a finely divided bio-compatible ceramic powder, an organic binder and a pore-forming agent in an inert liquid to form a body and causing at least some of the pore-forming agent to align along a common axis; (ii) optionally shaping the resulting body; (iii) allowing the pore-forming agent to form a porous structure in the body; (iv) heating the shaped body to a temperature sufficient to fix the porous structure and; (v) further heating the body to eliminate residues of organic binder and pore-forming agent and to fuse it.

Abstract: An electrode device for high pressure applications. These electrodes, designed to withstand pressure of greater than 10,000 psi, are adapted for use in microfluidic devices that employ electrokinetic or electrophoretic flow. The electrode is composed, generally, of an outer electrically insulating tubular body having a porous ceramic frit material disposed in one end of the outer body. The pores of the porous ceramic material are filled with an ion conductive polymer resin. A conductive material situated on the upper surface of the porous ceramic frit material and, thus isolated from direct contact with the electrolyte, forms a gas diffusion electrode. A metal current collector, in contact with the gas diffusion electrode, provides connection to a voltage source.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: The present invention discloses a method for making a porous calcium phosphate article including i) preparing a shaped article from a paste containing a calcium phosphate cement, a pore-forming powder and a setting liquid; ii) immersing the shaped article in an immersing liquid for a period of time so that the pore-forming powder is dissolved in the immersing liquid, creating pores in said shaped article; and iii) removing the resulting porous shaped article from the immersing liquid, wherein the resulting porous shaped article has an improved compressive strength. The porous shaped calcium phosphate article of the present invention may be used as a tissue-engineered scaffold, medical implant or a reinforcing constituent of a composite.

Abstract: The present invention includes a coating. The coating includes flyash in a concentration of 25 to 70 percent by weight; Portland cement; silica; and a curing agent. The coating optionally includes one or more of chopped nylon fiber; styrene; and, rubber.

Abstract: The invention relates to a process for forming a laminate comprising a core of a compressed metal powder mixed with a foaming agent between two metal layers, comprising the successive steps of providing two metal strips and a stock of powder comprising a metal powder mixed with a foaming agent; applying a layer of the powder between the two metal strips; feeding the metal strips, with the powder between them, to a rolling mill; rolling the two strips with the powder between them to form a laminate of compressed powder between two metal layers. The invention also relates to an associated device and to the product formed using the process.

Abstract: Microporous ceramic materials used in structural materials, high-temperature filters, electrode materials or preform materials for infiltration by homogeneously mixing and molding a ceramic precursor powder polymer. The powder is saturated by introducing fluid to a pressure vessel. The fluid is super saturated by adjusting pressure in the vessel. Micropores are formed in the molded bodies by evolving the fluid from the molded bodies by heating and hardening the molded bodies. The hardened molded bodies are heated to pyrolysis. Pore characteristics (e.g., pore size and pore size distribution) suitable to target materials are controlled by adjusting pressure at a non-critical state without requiring additional processes or devices.

Abstract: A thermochemically stable oxidic thermal insulating material presenting phase stability, which can be used advantageously as a thermal insulating layer on parts subjected to high thermal stress, such as turbine blades or such like. The thermal insulating material can be processed by plasma spraying and consists preferably of a magnetoplumbite phase whose preferred composition is MMeAl11O19, where M is La or Nd and where Me is chosen from among zinc, the alkaline earth metals, transition metals, and rare earths, preferably from magnesium, zinc, cobalt, manganese, iron, nickel and chromium.

Abstract: The present invention discloses a prosthetic bone implant made of a hardened calcium phosphate cement having an apatitic phase as a major phase, which includes a dense cortical portion bearing the majority of load and a porous cancellous portion allowing a rapid blood/body fluid penetration and tissue ingrowth.

Abstract: One aspect of the present invention pertains to an apparatus for forming a rigid foamed cementitious core within a plurality of article shells. In general, the apparatus can be comprised of a shell bank for retaining a plurality of article shells and comprising a sled and a plurality of reinforcement shells, a filing station for delivering a gas-entrained cementitious material, and a pump. The gas-entrained cementitious material cures to form a rigid foamed cementitious core within each article shell in the plurality of article shells.

Abstract: Ordered, monodisperse macroporous polymers, their corresponding ordered, monodisperse colloids, and methods of preparing them are disclosed. The methods use an ordered, monodisperse colloidal template to define the polymer pore morphology, which in turn acts as a mold for the growth of a new ordered, monodisperse colloid. The macroporous polymer may be prepared with either spherical or ellipsoidal pores from a wide variety of polymeric systems. The new ordered, monodisperse colloid may be grown from a wide variety of materials including ceramics, semiconductors, metals and polymers. These materials are potentially useful in optical, micro-filtering and drug delivery applications.

Abstract: The present invention provides a dispersant and foaming agent combination that is useful in the production of gypsum wallboard and other aqueous cementitious products, a method of forming a gypsum wallboard and a gypsum wallboard. The dispersant in the combination according to the invention is a naphthalene sulfonate-aldehyde condensate alkali salt polymer having a weight average molecular weight of from about 17,000 to about 47,000. The alkali is preferably an alkali metal and/or an alkaline earth metal. The aldehyde is preferably formaldehyde. The foaming agent used in the combination according to the invention is a soap, preferably an alkali salt of an alkyl ether sulfate and/or an alkyl sulfate. The combination of a high molecular weight dispersant and a foaming agent produces a gypsum wallboard core effect that more efficiently entrains air (i.e., creates void space), thereby lowering overall board weight without detrimentally affecting strength.

Abstract: A cell plate structure for a solid oxide electrolyte type fuel cell is provided with a lower electrode layer, an upper electrode layer provided in opposition to the lower electrode layer, a solid electrolyte layer provided between the lower electrode layer and the upper electrode layer, and an area provided in at least one of the lower electrode layer and the upper electrode layer. The area has a portion which is formed by removing a substance, contained in the at least one of the lower electrode layer and the upper electrode layer during formation thereof, after the at least one of the lower electrode layer and the upper electrode layer has been formed. Such a fuel cell plate structure can be applied to a solid electrolyte fuel cell representatively by being disposed between a pair of separators that have gas flow passages supplying the lower electrode layer and the upper electrode layer with gasses, respectively.

Abstract: Coal based carbon foams that are produced by the controlled beating of coal particulate in a mold and under a non-oxidizing atmosphere and subsequently graphitized have been found to provide excellent electrode materials for electrochemical cell applications.

Abstract: The present invention relates to a molding material for the precision casting and dead-mold casting of metals or metal alloys comprising plastic and/or carbon aerogels, and a process for the preparation of such molding materials. The molding material comprises highly porous open-cell plastic and/or carbon aerogels, obtainable by the sol-gel polymerization of organic plastic materials, optionally followed by partial or complete pyrolysis of the plastic aerogel obtained.

Abstract: A slip casting mold includes a water absorption layer having self water absorption capability and substantial water resistance. With the water saturation percentage of the water absorption layer being controlled, a slurry layer is deposited in the slip casting mold mainly under capillary attractive forces of the slip casting mold. The water absorption layer comprises an open porous body which is manufactured by stirring a mixture of an epoxy compound having at least one epoxy ring in one molecule, a hardener for reacting with the epoxy compound to harden the epoxy compound, a filler for developing self water absorption capability and mold releasability, and water into an O/W-type emulsion slurry, and casting the emulsion slurry into a mold impermeable to water, hardening the emulsion slurry in the mold while containing water.

Abstract: Reinforced, laminated, impregnated, and materials with composite properties as cross linked polyvinyl alcohol hydrogel structures in bulk or cellular matrix forms that can take essentially any physical shape, or can have essentially any size, degree of porosity and surface texture. They have a wide range of physical properties, unusual and unique combinations of physical properties and unique responses to stress fields, which allows for their use in many end use applications.

Abstract: A method for producing a silicon nitride filter by heat-treating in nitrogen green body of from 35 to 90 mass % of silicon nitride particles having an average particle diameter of from 1 to 30 ?m, from 5 to 60 mass % of a pore-forming agent and from 0.1 to 5 mass % of metal oxide particles, provided that the total amount of the silicon nitride particle , the pore-forming agent and the metal oxide particles is at least 90 mass %, to form a porous product.

Abstract: A method for stabilizing gravel, sand, crushed stone, rock and concrete structures which have cracks by injecting a pumpable, low viscous aqueous aerated concrete with a pore volume of at least 20% by volume into the cracks at a low pressure and then increasing the pressure so that the entrained air bubbles escape and sedimentation and hydration occur.

Abstract: A particulate sealant for forming plugs in selected cells of honeycomb structures and consisting essentially, by weight, of about 70 to 90% ceramic blend, the ceramic blend being raw ceramic materials selected to form a composition consisting essentially of in percent by weight about 12 to 16% MgO, about 33 to 38% Al2O3, and about 49 to 54% SiO2, which will form cordierite (2MgO.2Al2O3.5SiO2) on firing, and about 10 to 30% binder system comprising a thermoplastic polymer capable of forming a gel or a thermosetting resin.

Abstract: Microporous hydrophobic inorganic membrane having an average pore size of less than 2 nm and a hydrophobicity index octane/water of at least 2 can be obtained by a process comprising hydrolyzing a metal alkoxide in the presence of a hydrocarbyl metal alkoxide having at least one non-hydrolyzable group in an organic solvent to produce a metal (hydr)oxide sol, and precipitating metal (hydr)oxide from said sol and drying the precipitate. In this process, at least 50% of the amount of hydrocarbyl metal alkoxide is introduced into the solvent after 20% of the hydrolysis period has lapsed.

Abstract: A process and apparatus for creating an acoustically absorbent porous panel comprises the steps of dispensing cement and fibers with a dry mixer to create a dry mix and aqueous mixing water, surfactant and air with an aqueous mixer to create a foam. The process and apparatus provides for combining and mixing the foam and dry mix in a combining mixer to form a foamed cementitious material comprising on a wet basis about 53% to about 68% by weight cement, about 17% to about 48% by weight water, about 0.05% to about 5% by weight fibers, and about 0.01% to about 10% by weight surfactant. The foamed cementitious material is then dried or cured in a drying chamber. The dried foamed cementitious material may then textured with an embossing roller. The cementitious material provides good acoustical performance with enhanced durability and moisture resistance.

Abstract: 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.

Abstract: A method and system of forming a fire door core. Hydraulic binder and resin are supplied from raw material bins and mixed to provide a submixture. Exfoliated vermiculite is then mixed with the submixture to provide a mixture that is deposited into a plurality of compression molds. Each of the filled molds are pressed in a press at a predetermined temperature at a predetermined pressure for a predetermined period of time sufficient to harden the mixture into a hardened slab. The hardened slabs are then removed from the molds, impregnated with water or steam in a water impregnation assembly and dried in a drying assembly.

Abstract: Fiber reinforced aerated concrete compositions and methods of forming structural units such as blocks, panels, etc., from such compositions are disclosed. The compositions comprise a fly ash/cement slurry with a coated Al paste serving as the activator to generate the desired cellular structure. The composition can be self cured at ambient temperature and pressure without the need for ovens or autoclaves. The cured compositions can be easily cut into the desired shape by a band saw or the like.

Abstract: The present disclosure describes improved compositions comprising an agitating agent, the compositions being particularly useful for powder injection molding. The disclosed method includes protocols for extracting binder materials from a powder injection molding prior to sintering. One embodiment of the disclosure includes compositions comprising a sinterable powder, a binder and a gas-forming agent. When induced to release a gas, the gas-forming agent provides internal agitation, which facilitates solvent-based binder extraction, resulting in a higher yield of extracted binder in reduced time. In one embodiment, the compositions include a carbonate, such as sodium carbonate, as the gas-forming agent. In this embodiment, the gas-forming agent is induced to form a gas during binder extraction by including an acid, such as citric acid, in the extraction solvent.

Abstract: A method of manufacturing hollow ceramics fibers with the pores of the micron-scale hollow structure unidirectionally oriented, the method of manufacturing is characterized in the steps of dispersing organic fibers in a dielectric liquid and applying high voltage to the dielectric liquid containing the dispersed organic fibers to electrostatically align them to produce a fiber accumulation in which the organic fibers are unidirectionally oriented, using the fiber accumulation as a mold and dipping the fiber accumulation in a ceramics base solution, and then removing the mold by treatment with heat or organic solvents.

Abstract: A process for the preparation of bulk foams which comprises contacting ceramic foam particles with a hydrophobic material to form impregnated and/or coated ceramic foam particles with hydrophobic properties. The impregnated and/or coated ceramic foam particulate material is mixed with a ceramic binding material with or without an organic binder in an aqueous composition solution to form a castable and pressable mixture. The castable and pressable mixture is cast, and optionally pressed, in a mold to form a wet green body, which is in turn dried to form a dried green body, and is then fired and sintered to form a bulk shape foam article.

Abstract: A low-cost, efficient method of preparing hierarchically ordered structures by filling a mold with a self-assembling mixture of hydrolyzed inorganic species and amphiphilic block copolymers and applying pressure to the mixture. Polymerization of the inorganic species within the mixture results in a mesoscopically structured material having molded features. A mesoporous material can be produced by subsequent thermal removal of the copolymers.

Abstract: A method for preparing precursors for producing high density monolithic aerogels. The method enables fabrication of transparent porous glass monoliths, with the porosity or density controlled by adjusting the ratio of water to monomer. By this adjustment, syneresis is increased or minimized. The method involves either a single step precursor or a two step precursor where a base is added to the single step precursor after hydrolysis has occurred. Monolithic metal oxide aerogels with densities between 0.3 g/cc to 1.5 g/cc have been produced using this method.

Abstract: A sacrificial ceramic fixture precursor is furnished with a shaped portion thereof shaped to receive a supported article. The sacrificial ceramic fixture precursor is immersed into a molten reactive metal for a period of time sufficient to permit the sacrificial ceramic fixture precursor and the reactive metal to react together. The result is a reacted ceramic fixture comprising an open-cell solid foam of ceramic cell walls having an interconnected intracellular volume therebetween. The reacted ceramic fixture is contacted to a supported article to produce a process assembly. The process assembly is processed as required for the supported article, which typically includes heating to an elevated temperature.

Abstract: The invention provides a method of providing void spaces in gypsum wallboard and in a gypsum core composition such that the weight of the gypsum product is reduced without deleteriously affecting its mechanical properties. More specifically, the invention provides a method of providing void spaces in a gypsum wallboard comprising the step of adding air bubbles having different relative stabilities to a gypsum slurry, wherein the less stable air bubbles are sufficiently unstable such that they coalesce on contact with each other in the slurry to form larger air bubbles, and the weight ratio of the less stable air bubbles to the more stable air bubbles initially added to the slurry is such that there are a sufficient number of more stable air bubbles to prevent a majority of the less stable air bubbles from becoming large enough to rupture before the slurry sets sufficiently to prevent the slurry from filling void spaces left by ruptured bubbles.

Abstract: The present invention relates to microporous ceramic materials, and the production method thereof, which can be suitably used in various structural materials, high-temperature filters, electrode materials, preform materials for infiltration, etc., wherein said method comprises the steps of: producing molded bodies by homogeneously mixing a starting material of polymer ceramic precursor powder, and then forming the same; saturating the same by introducing fluid of a non-critical state to said molded bodies in a pressure vessel; super-saturating the fluid of a non-critical state saturated to molded bodies by adjusting pressure in said pressure vessel; forming micropores in said molded bodies by evolving said fluid of a non-critical state from said molded bodies by heating said molded bodies; hardening said molded bodies having micropores; and carrying out pyrolysis by heating said hardened molded bodies. Accordingly, the present invention allows easy control of pore characteristics (e.g.

Abstract: A method of producing a green form for use in manufacturing a composite, ceramic ion transport membrane is provided in which first and second ceramic powder mixtures are used to produce first and second layers of the green form. The first and second ceramic powder mixtures have ceramic particles and a pore former. After formation of each of the first and second layers or after formation of the second layer, heat is applied to burn out the binder and form pores. This heating is completed prior to application of a dense layer to prevent production of defects within the dense layer. The dense layer contains an ion transport material. Defects are also prevented by grading particle size from the first layer to the dense layer. This allows the second intermediate layer to fill in larger pores of the first layer and to present a smooth surface to the dense layer. Additionally, the second ceramic powder mixture contains in part material used in forming the dense layer for thermal expansion compatibility purposes.

Abstract: A process for foaming ceramic foams, in which the ceramic foams are produced from a precursor or a mixture of precursors which contain at least one ceramic-forming element and liberates at least one volatile reaction product during an inorganic gelation process. In one embodiment, foaming is based on a precursor containing crystals of the AICI3(Pri2O) complex. The decomposition of the initial precursor produces polymerizing species dissolved in liquid isopropyl chloride. The solvent and growing AIOxCIy(OPri)z species are mixed homogeneously so that the boiling point of the solution is raised above the boiling point of the pure isopropyl chloride. Polymerization takes place in the liquid until a critical polymer size is attained, whereupon a phase separation into polymer rich and solvent rich regions occurs. Since the expelled solvent is suddenly above its boiling point, bubbles start forming instantly.

Abstract: A method and apparatus for efficiently forming individual building units is provided, generally includes providing a plurality of molds, each capable of simultaneously forming a plurality of building units. Batches of cementitious slurry are individually mixed in order to control the density of each building unit formed. The ingredients are individually measured and combined into the mixing device. The cementitious slurry is then conveyed or transported and poured into one of the molds. The method provides the ability to control the amount of cementitious slurry in each batch in order to control to the extent possible the quantity of cementitious slurry poured into each mold and the ability to precisely control the dimensions of each building unit produced.

Abstract: There is provided an improved ceramic foam filter for use in filtering molten metals, metal prepared from a ceramic slurry containing silicon carbide, a colloidal silica binder and at least 10 percent of fumed silica. The filter has enhanced strength properties.

Abstract: Truss systems and components thereof for use in connection with supporting rock formations in underground mines, caverns, storage vaults, and so forth. Multiple types of truss brackets of unique design are incorporated in the various systems which also include tensioning tie rods and anchor bolts. The truss bracket components are designed so that a minimum or no force couples are exhibited when the tie rods employed are tightened down in their interconnection between associated truss brackets. Various truss systems accommodate mine entries, two-way, three-way, and four-way passageway configurements, and so forth. Additionally, provision is made for intercoupling trusses together.