Abstract: A paste-like ink is prepared by dissolving camphor in an alcoholic solvent and dispersing fine carbon particles with a catalyst carried thereon in the solvent (step S100). A sheet-like electrode-forming member is formed on an electrolyte membrane by screen printing the paste-like ink thus obtained (step S102). The electrode-forming member is dried at 80° C. for one hour, in order to deposit camphor included in the electrode-forming member as a pore-forming agent (step S104). The electrode-forming member and the electrolyte membrane are joined with each other by hot pressing (step S106). The joint body of the electrode-forming member and the electrolyte membrane is dried under vacuum at 80° C. for three hours, in order to sublimate and remove camphor depositing in the electrode-forming member (step S108). This gives an electricity-generating layer that is a joint body of an electrode having a plurality of pores and the electrolyte membrane.

Abstract: What is disclosed herein are physically cross-linked, cellular hydrogels and methods for their preparation. The cellular materials are highly resilient, hydrophilic materials having broad uses. The cellular materials are prepared by the physical crosslinking of frothed polymers and providing materials that have cellular pores provided by the use of removable materials during the formation of the cellular materials.

Abstract: A process for producing molded pitch based foam is shown which provides a more uniform density gradient throughout the ultimate product. The process utilizes a pressure drop during processing in order to induce foaming. By inducing foaming through process depressurization, additional viscosity manipulation can be achieved as well as improved density gradient characteristics in the ultimate product.

Abstract: A process to make particles by anaerobic reaction of a water-insoluble solution of organic compounds comprising (a) a monomer selected from C2-4 alkylene glycol esters of a C3-6 acrylic acid and a divinyl benzene; (b) a polyfluorinated vinyl monomer; (c) a monomer selected from acrylic acid, methacrylic acid and esters thereof; (d) a free radical initiator; and (e) a water-insoluble, organic solvent-soluble porogenic material, the weight ratio of comonomers (a) plus (b) plus (c) to the porogenic material being from 0.5:1 to 2:1. The adsorbent particles produced by the process are useful in carrying out chromatographic separations, or in the production of medical devices.

Abstract: Petroleum or coal tar pitch-based cellular or porous products having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 are produced by the controlled heating of mesophase carbon materials derived from coal tar or petroleum pitch having a softening point in excess of about 300° C. and preferably between about 300 and about 400° C. in a “mold” and under a non-oxidizing atmosphere. The porous product thereby produced, preferably as a net shape or near net shape, can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products.

Abstract: A method for making aerated concrete blocks includes dispensing materials for making aerated concrete into a mold and allowing the materials to rise and stiffen into a body. The body may be divided into an array of blocks which are then cured. At least one passageway may be formed in each block, such as by drilling. The drilling may include drilling a plurality of spaced apart passageways through each block, and each passageway may have a circular cylindrical shape. The passageways permit easier grasping by the mason, reduce the weight without significantly compromising strength, and facilitate positioning of blocks during construction of a wall to facilitate the placement of vertical reinforcing members in aligned passageways. The positioning of the passageways in each of the blocks may assist alignment of adjacent passageways, especially at wall corners.

Abstract: An improved proton exchange membrane fuel cell assembly and fuel cell stack assembly are provided for the economical and efficient production of electricity. The present invention comprises improved flow fields and reactant supply systems, which provide improved and more efficient mass transport of the reactants in the fuel cell and the fuel cell stack assembly. The improved flow fields comprise three-dimensional open-cell foamed metals that are preferably plated with gold. The improved reactant supply system comprises an improved distribution frame to house fuel cells wherein the reactants are directly connected to the improved flow fields.

Abstract: The present invention provides a silicon nitride filter which is a filter excellent in heat resistance, thermal shock resistance, corrosion resistance, acid resistance and mechanical strength and suitable for dust arresting or dust removing, and which is particularly useful as a filer for particulates, and a method for its production.

Abstract: A low-cost, efficient method of preparing hierarchically ordered structures by combining, concurrently or sequentially, micromolding, latex templating, and cooperative self-assembly of hydrolyzed inorganic species and amphiphilic block copolymers.

Abstract: A process for producing molded pitch based foam is shown which provides a more uniform density gradient throughout the ultimate product. The process utilizes a pressure drop during processing in order to induce foaming. By inducing foaming through process depressurization, additional viscosity manipulation can be achieved as well as improved density gradient characteristics in the ultimate product.

Abstract: A method of forming foamed articles suitable for refractory, thermal insulation and construction application in a form such as bricks, blocks, slabs and discs includes the preparation of homogeneous mixture of at least one oxygen-containing, water-insoluble raw material having a particle size <200 microns and at least one gas forming reagent having a particle size <130 microns. The mixture is humidified and shaped and then heated to a formation temperature sufficient to melt the raw material to develop an oxygen-containing molten liquid phase. This phase reacts at the formation temperature with the gas-forming reagent to induce a foamed structure which is then cooled to a solid state. The raw materials preferably make up 99-99.95 wt % of the mixture, and the gas forming reagent makes up the balance.

Abstract: In a process for drying microporous, fluid-containing particles, the heat required for increasing the temperature is supplied by convection by reducing the interfacial tension of the fluid, preferably to 0 to 1/10, in particular to 0 to 1/20, of the interfacial tension of the fluid at room temperature, by appropriately increasing the temperature at from close to the critical pressure to supercritical pressure of the fluid. Furthermore, microporous, three-dimensionally networked particles are prepared by a process in which the drying process is used. In addition, an apparatus is used for carrying out the drying process, the apparatus comprising a pressure container having an inner container and pressure-withstanding outer container and suitable measuring and control apparatuses and pump apparatuses and heat exchangers, the inner container being provided for holding the particles to be dried and a gap being provided between the inner container and the outer container.

Abstract: A flexible graphite sheet exhibiting enhanced isotropy is provided. In addition, an apparatus, system and method for continuously producing a resin-impregnated flexible graphite sheet is also provided.

Abstract: A system for making wallboard or backerboard sheets may include a mixer for mixing materials for making aerated concrete, at least one face layer supply, and a former downstream from the mixer. The former is for forming core material having opposing first and second major surfaces and comprising aerated concrete, and for securing at least one face layer from the at least one face layer supply onto at least one of the first and second major surfaces of the core material. The system may also include a cutter downstream from the former for cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example.

Abstract: A method for making wallboard or backerboard sheets which are relatively lightweight, strong, and which have good fire resistance, thermal insulation, and sound absorbing properties includes forming core material having opposing first and second major surfaces and comprising aerated concrete, securing at least one face layer on at least one of the first and second major surfaces of the core material, and cutting the core material and at least one face layer secured thereto into a plurality of wallboard or backerboard sheets. The provision of aerated concrete for the core provides many key advantages over conventional gypsum wallboard sheets, and/or conventional backerboard sheets, such as gypsum greenboard or cementitious backerboard, for example. In one class of embodiments, the method may further include curing the core material prior to securing the at least one face layer thereto. In another class, the method may further include curing the core material after securing the at least one face layer thereto.

Abstract: Disclosed is a rigid fine-celled light-weight foam composition and a method of producing it which has improved retention of liquids by absorption/adsorption which improves the thermal insulation and fire retardant properties of the fine-celled foam particularly suited for use in double walled tanks and hollow canopies, building panels, profiles, and the like.

Abstract: A process for producing molded pitch based foam is disclosed which minimizes cracking. The process includes forming a viscous pitch foam in a container, and then transferring the viscous pitch foam from the container into a mold. The viscous pitch foam in the mold is hardened to provide a carbon foam having a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts.

Abstract: A method for manufacturing an aerated autoclaved concrete material. A quick-stiffening mixture is prepared by combining a silica containing material, quicklime, a rising agent, gypsum, cement and water. The mixture is deposited into a mold and is allowed to form a stiffened body. The stiffened body is removed from the mold and placed in an autoclave station in which it is steam cured at elevated temperature and pressure. The quicklime which is used to form the quick-stiffening mixture is modified with a chemical modifier to provide a desired degree of chemical reactivity in the quick-stiffening mixture.

Abstract: A process is proposed for producing non-combustible moulded articles from blown vermiculite, the blown vermiculite granules being mixed with an inorganic binder and then pressed. The blown vermiculite granules are mixed with a solution of an inorganic binder, the vermiculite granules once mixed are pre-pressed, cut to the shape required and the cut blanks are pressed non-continuously at at least room temperature and preferably at temperatures of at least 100° C. and pressures of at least 0.3 N/mm2 to ensure that all solvent residues are removed from the finished non-combustible moulded article.

Abstract: An active log 20 includes a body made of porous ceramic material. A channel is defined within the active log, within which is carried a gas tube 40. A gas supply line 60 provides gas to the gas tube 40. Gas exhausted from holes defined in the gas tube moves through the porous material from which the active log is constructed, cooling the active log by convection. Due to the slightly greater gas pressure within the active log, gas moves outwardly through the porous material, until it is exhausted from pores on the surface of the active log. Contact with the ambient atmosphere results in combustion. Because the combustion is generally uniformly distributed about the external surface of the active log, and because there is no unsightly external burner from which gas is exhausted, the appearance of the active log is a realistic approximation of the burning surface of a real log.

Abstract: The invention relates to a hydrophobic permeable composite, to a method for producing a hydrophobic permeable composite and to the use of said composite in various processes. Hydrophobic, permeable materials have been known for some time. Plastic materials especially, for example Gore-Tex®, but also materials consisting of other organic polymers are used whenever a material is required to be gas- and steam-permeable but not liquid-permeable. These materials have the disadvantage that they can only be used within a certain temperature range. The inventive composite is characterised by a higher temperature resistance since it consists mainly of inorganic materials. It is also relatively easy to produce since it can be obtained using the sol-gel technique. The inventive composite can be used as a membrane in the oxidation of aromatics, for example in the direct oxidation of benzene to phenol.

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: A process for making articles from perlite material includes grinding raw perlite to a particle size <200 &mgr;m. The ground perlite is mixed with ground silicon carbide powder and moisture added in an amount to achieve a homogeneous mixture having the property of being thixotropic. The mixture is introduced to a mold and agitated to assume the shape of the mold. The agitation is then halted and the material permitted to stiffen to a solidified green molded structure. The molded structure is then removed from the mold and heated at a temperature and time to react the silicon carbide reacts forming carbon dioxide, which induces a foamed structure to the material, and amorphous silicon oxide which fuses with the perlite. The structure is then cooled to yield a resultant fused, foamed perlite article, which may take the form of a building brick, block or panel structure.

Abstract: A method of forming foamed articles suitable for refractory, thermal insulation and construction application in a form such as bricks, blocks, slabs and discs includes the preparation of homogeneous mixture of at least one oxygen-containing, water-insoluble raw material having a particle size <200 microns and at least one gas forming reagent having a particle size <130 microns. The mixture is humidified and shaped and then heated to a formation temperature sufficient to melt the raw material to develop an oxygen-containing molten liquid phase. This phase reacts at the formation temperature with the gas-forming reagent to induce a foamed structure which is then cooled to a solid state. The raw materials preferably make up 99-99.95 wt % of the mixture, and the gas forming reagent makes up the balance.

Abstract: The invention relates to a process for preparing a porous ceramic body, which process is based on a negative replica method. The invention further relates to a ceramic body obtainable by said method and to its use as a scaffold for tissue engineering.

Abstract: A method of producing artificial fossil coral which is an artistic replica of a natural coral reef formed from a slurry of cement, sand, ground PVC chips, colorant and water admixed with artistic rigid lightweight sponge or Styrofoam. Fiber glass strands are used to provide a plant like look to the artificial fossil coral and coloring of the artificial fossil coral duplicates the colors found in natural coral reefs.

Abstract: A method of making carbon foam is described which involves pyrolizing a mixture containing at least one pyrolizable substance and at least one unpyrolizable material and then removing the unpyrolizable material to obtain the carbon foam. Carbon foam made by this process is also described. Incorporating the carbon foam in a variety of end use applications including electrodes, thermal insulation material, polymers, and the like is also described.

Abstract: A moving bed filtration process for the production of sphere based crystals is disclosed. Sphere based crystals having an opal-like structure or an inverse opal-like structure can be produced in accordance with the invention.

Abstract: A method and apparatus for extruding pitch based foam is disclosed. The method includes the steps of: forming a viscous pitch foam; passing the precursor through an extrusion tube; and subjecting the precursor in said extrusion tube to a temperature gradient which varies along the length of the extrusion tube to form an extruded carbon foam. The apparatus includes an extrusion tube having a passageway communicatively connected to a chamber in which a viscous pitch foam formed in the chamber passes through the extrusion tube, and a heating mechanism in thermal communication with the tube for heating the viscous pitch foam along the length of the tube in accordance with a predetermined temperature gradient.

Abstract: A method and apparatus for extruding pitch based foam is disclosed. The method includes the steps of: forming a viscous pitch foam; passing the precursor through an extrusion tube; and subjecting the precursor in said extrusion tube to a temperature gradient which varies along the length of the extrusion tube to form an extruded carbon foam. The apparatus includes an extrusion tube having a passageway communicatively connected to a chamber in which a viscous pitch foam formed in the chamber paring through the extrusion tube, and a heating mechanism in thermal communication with the tube for heating the viscous pitch foam along the length of the tube in accordance with a predetermined temperature gradient.

Abstract: A carbon-carbon composite material is made by providing an open-celled carbon foam preform, and densifying the preform with carbonaceous material. The open-celled carbon foam preform may be oxygen stabilized prior to carbonization, and the foam preform densified by CVD, HIP, PIC, VPI, pitch and resin injection, or any combination thereof. The carbon carbon composite material can be heat treated to provide thermal management materials, structural materials, or a friction material for use in a brake or clutch mechanism.

Abstract: A process for producing carbon foam or a composite is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

Abstract: A process for producing hydrophilic growing media, preferably plugs, providing growing media having improved properties and a minimal amount of binding agent. The method forms a resilient, integral, dimensionally stable cohesive, homogeneous mass by contacting an aggregate with a hydrophilic urethane prepolymer and water. Upon curing, the prepolymer binds the aggregate material together. The mixing of the aggregate, prepolymer and water is conducted under specific, carefully controlled conditions, which enables the use of less prepolymer than would otherwise be necessary to obtain a given strength and stable air space. As result, trays can be filled without necessity of retooling.

Abstract: A plasticizable raw material mixture for use in preparing a substrate having cordierite as its primary phase with the mixture comprised of a chemical composition, percent by weight, of 11 to 17% MgO, 33 to 41% Al2O3 and, 46 to 53% SiO2. The raw material mixture specifically comprises the following: (1) one source of Al2O3 and SiO2 comprising a clay mixture having less than about 22%, by weight based on the total raw materials in the plasticizable mixture, of calcined clay; (2) an alumina yielding precursor comprising alumina having an average particle diameter of about 1 &mgr;m or less; and, (3) at least one source of magnesia having an average particle diameter of between about 3 to 15 microns.

Abstract: A heat-insulating constructional material based on an alkalized and flooded siliceous raw material fabricated by comminuting solid ingredients and mixing all the raw ingredients, steaming a raw mixture and thermally bloating intermediate products obtained from the steamed raw mixture is designed for utilisation as warmth-keeping fills and light-weight concrete aggregates (in a particulate form) and as structural elements for buildings and constructions (in the form of slabs or blocks). For the purpose of controlling the desired products in a wide range of dimensions and to achieve a greater stability in its mechanical strength and water adsorption the material is obtained by cooling the steamed raw mixture prior to its transition in a brittle condition and crushing the brittle mixture prior to bloating for obtaining the intermediate products.

Abstract: In one embodiment a porous partition having predetermined porosity and predetermined photocatalytic properties is formed by mixing particles of photocatalytic material with particles of structural material, forming the particle mixture into a predetermined shape, applying pressure to the formed particle mixture, and heating the formed particle mixture to a predetermined temperature in a predetermined atmosphere. In another embodiment, the particles of structural material and the particles of photocatalytic material are separately formed, pressurized and heated, after which the sintered photocatalytic article is joined to the sintered structural article. In yet another embodiment a sol-gel comprising a metal oxide semiconductor and an organic component is drawn into the pores of a porous stainless steel layer and is thereafter heated to oxidize the organic component leaving the semiconductor in the pores of the stainless steel.

Abstract: A process for producing carbon foam or a composite is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

Abstract: A method of producing foamed clay with optimum characteristics of porosity, mechanical resistance, high coefficients of reduced weight, and thermal and acoustic insulation, wherein a fluid mass consisting of clay is formed, into which compostions reacting therebetween are put so as to cause the homogenous foaming of the whole clay mass.

Abstract: A novel construction board composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a construction board composition comprising primarily gypsum, and in a construction board composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum construction board formulations, thus reducing the weight while maintaining the strength of the construction board structure. In a preferred embodiment, the lightweight, strengthened gypsum construction board of the present invention also comprises an optional covering veneer that is applied to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

Abstract: A material is disclosed which produced by a process in which a mold is filled of deformable shaped bodies, after which the mold is filled with a base material. The bodies are removed and the solidified base material forms a material of shell-like structures and an interconnecting pore system between the skeleton structures. The material produced by the process can be used as bone replacement materials, implants, filters and drug delivery systems.

Abstract: A method of producing a silicon aluminum sputtering target is provided. The target is formed from a powder base of between about 80% to about 95% by weight silicon and about 5% to about 20% by weight aluminum which is placed in a containment unit, heated under vacuum and then sealed. The base is then subjected to a pressure greater than about 3000 psi and heated to a temperature between about 1076° F. and about 1652° F. such that some, but not more than 30%, of the resulting target is formed from liquid phase silicon-aluminum.

Abstract: An alumina-based porous support with uniform physical properties is obtained in a rapid sintering process. An alumina raw material including a raw alumina powder and an inorganic binder is molded into an article, and the article is then sintered for 5 to 8 hours at 1520 to 1560.degree. C. using a roller hearth kiln.

Abstract: Method for filling cavities in workpieces or semi-finished products is provided, in which thermally foamable powdered carbon is added in fixed locations into the cavity to be filled and is heated together with the workpiece or semi-finished product in such fashion that the powdered carbon swells and fills the cavity as carbon foam, with the particles of powdered carbon in the delivered state being smaller than after foaming. A structural component is formed, especially a workpiece or semi-finished product for mounting on or in a motor vehicle body, having an enclosed chamber in which thermally foamable powdered carbon is added in a fixed location, with the powdered carbon being heated together with the structural element to swell the powdered carbon and form carbon foam.

Abstract: Flexible graphite sheet is made by compressing a mixture of fine particle of intercalated, exfoliated, expanded natural graphite with fine particles of intercalated, unexpanded, expandable particles of natural graphite, the unexpanded particles being more finely sized than the expanded particles. The resulting sheet of flexible graphite exhibits improved fire retardant and sealability properties.

Abstract: The present invention provides an inexpensive, open cell, mechanically robust and graphitizable foam preform. The graphitizable foam is produced via a modified standard flower foam formulation. The invention provides a modified formula for such flower foams wherein a mesophase material is incorporated along with a corresponding reduction in the resole component. The mesophase material replaces 30-70% by weight (a target of 50% by weight) of the resole component of the formulation. The formulation is heated to effect foaming of the mixture, and then carbonized to produce an open cell, graphitizable foam preform.

Abstract: A component, particularly for land vehicles, preferably a car body component for motor vehicles, consists of a metallic foam material with a foamed porous layer comprising a metal powder and a blowing agent and possibly at least one solid metal sheet, there being metallic bonds between the solid metal sheet and the foamed porous layer. The component has at least one stamped contour which is raised from its surface, the angles, occurring in the region of the transitions between the three-dimensionally molded contour and the surface region being of the order of 100.degree. to 180.degree.. To produce the component, an essentially flat, metallic foam material, which is provided with solid metal sheets as covering layers, is initially shaped into a semi-finished molded product, which is end-contoured on one side, and the semi-finished molded product, so formed, is placed into a foaming mold, one wall of which is adapted to the end-contoured side of the semi-finished molded product, and foamed therein.

Abstract: A component, particularly for land vehicles, preferably a car body component for motor vehicles, consists of a metallic foam material with a foamed porous layer comprising a metal powder and a blowing agent and possibly at least one solid metal sheet, there being metallic bonds between the solid metal sheet and the foamed porous layer. The component has at least one stamped contour which is raised from its surface, the angles, occurring in the region of the transitions between the three-dimensionally molded contour and the surface region being of the order of 100.degree. to 180.degree.. To produce the component, an essentially flat, metallic foam material, which is provided with solid metal sheets as covering layers, is initially shaped into a semi-finished molded product, which is end-contoured on one side, and the semi-finished molded product, so formed, is placed into a foaming mold, one wall of which is adapted to the end-contoured side of the semi-finished molded product, and foamed therein.

Abstract: The present invention is based, in part, on a method for combining a mixture of hydroxide and hydride functional siloxanes to form a polysiloxane polymer foam, that leaves no residue (zero char yield) upon thermal decomposition, with ceramic and/or metal powders and appropriate catalysts to produce porous foam structures having compositions, densities, porosities and structures not previously attainable. The siloxanes are mixed with the ceramic and/or metal powder, wherein the powder has a particle size of about 400 .mu.m or less, a catalyst is added causing the siloxanes to foam and crosslink, thereby forming a polysiloxane polymer foam having the metal or ceramic powder dispersed therein. The polymer foam is heated to thermally decompose the polymer foam and sinter the powder particles together. Because the system is completely nonaqueous, this method further provides for incorporating reactive metals such as magnesium and aluminum, which can be further processed, into the foam structure.

Abstract: Flexible graphite sheet having embedded ceramic fibers extending from its surfaces into the sheet to increase the permeability of the sheet to resin.

Abstract: A fire resistant, acoustic and thermally insulative product consists essentially of a silica-containing refractory solid in finely divided or powdered particulate form, present in an amount sufficient to intumesce to a predetermined volume when exposed to a predetermined amount of heat. The product further consists essentially of an aqueous sodium silicate solution present in an amount sufficient to act as an agent in producing a foaming process whereby the finely divided solid is so bonded as to form a cellular structure. The product produces substantially no toxic fumes or gases upon exposure to excessive heat or fire.