Abstract: A honeycomb structure made of a silicon carbide-based porous body and having a number of through-holes extending in the axial direction, separated by partition walls. The strength and Young's modulus of the silicon carbide-based porous body satisfy the following relation: Strength (MPa)/Young's modulus (GPa)≧1.1. The honeycomb structure contains refractory particles such as silicon carbide particles and the like and yet can be produced at a relatively low firing temperature at a low cost, has a high strength and a high thermal shock resistance, and can be suitably used, for example, as a filter for purification of automobile exhaust gas by a treatment such as plugging of through-channel at its inlet or outlet, or as a catalyst carrier, even under a high SV condition.

Abstract: A composite material with a porous inorganic-nonmetallic matrix and a second material, characterized in that

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 honeycomb structure having, in the axial direction, a number of through-channels separated by partition walls, which honeycomb structure contains refractory particles and a vitreous component and is porous. Although the honeycomb structure contains refractory particles such as silicon carbide particles or the like, it can be produced at a relatively low firing temperature; therefore, the honeycomb structure has a low production cost and a high yield and can be provided at a low price.

Abstract: The aim of the invention is to provide filters with a graduated structure, which are simple to produce and exhibit excellent properties in terms of their permeability to liquids and/or gases. To achieve this, the filters are produced from sinterable material consisting of at least two layers of differing pore size, a first layer having a minimum pore size of 0.005 &mgr;m and consisting of metal oxide or mixtures of metal oxide and the additional layer that is connected to the first layer consisting of a material other than metal oxide. The invention also relates to a method for producing the inventive filters and to the use thereof.

Abstract: A sintering schedule to allow the reliable formation of inorganic or ceramic materials, exemplified using porous calcium polyphosphate samples to be used for forming novel implants for bone interfacing applications. The key to the successful definition of the process was the determination of the factors affecting the crystallization temperature of the powders that are gravity sintered to form porous samples of desired density and with a pore size range suitable for the particular application.

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: An open-cell glass crystalline porous material made from hollow microspheres which are cenospheres obtained from fly ash, having an open-cell porosity of up to 90 vol. % is produced. The cenospheres are separated into fractions based on one or more of grain size, density, magnetic or non-magnetic, and perforated or non-perforated. Selected fractions are molded and agglomerated by sintering with a binder at a temperature below the softening temperature, or without a binder at a temperature about, or above, the softening temperature but below the temperature of liquidity. The porous material produced has an apparent density of 0.3-0.6 g/cm3, a compressive strength in the range of 1.2-3.5 MPa, and two types of openings: through-flow wall pores in the cenospheres of 0.1-30 micrometers, and interglobular voids between the cenospheres of 20-100 micrometers.

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: A porous carbonized film with fine continuous pores, obtained by carbonization of a highly heat-resistant resin porous film in an anaerobic atmosphere, and a process for its production.

Abstract: A production method of a large-size or intricately shaped lightweight ceramic molding having a bulk density of about 0.3 g/cm3 or less and having high heat resistance is accomplished by the following method.

Abstract: Disclosed is an anode-supported tubular solid oxide fuel cell stack, in which a thin and dense electrolyte layer and an air electrode are coated in good order on the surface of a porous anode-supported tube extruded by use of a slurry dipping process useful in mass production of a fuel cell, thereby the stable fuel cell stack with high mechanical strength is formed, and method of fabricating the anode-supported tubular solid oxide fuel cell stack. After a plurality of unit cells for anode-supported tubular solid oxide fuel cell stacks with excellent electric conductivity and a smooth current flow are inexpensively produced, the unit cells are stacked and combined with a plurality of metal connector plates having semicircular grooves for mounting unit cells thereon to fabricate a desired fuel cell stack.

Abstract: A method of producing ceramic foam wherein a precursor including an AlCl3 (Pri2O) complex is decomposed to form a mixture of a polymerizing species and liquid isopropyl chloride and the mixture is foamed. The foamed mixture is sintered and/or calcined to produce a ceramic foam.

Abstract: To provide a method for producing a ceramic porous material which has a high strength, though it has a high porosity, and which is excellent in permeability without dust generation. In a ceramic porous material having a three-dimensional mesh-like skeleton structure with a large number of substantially spherical adjacent cells communicating with each other via communication holes, the crystal particle size at the rim of each communication hole in the skeleton structure is provided substantially equal to the crystal particle size in the other parts.

Abstract: The decorative vitreous beads of the present invention have a hard, solid, substantially vitreous, unitary body comprised primarily of silica and having a generally spherical form, with the largest dimension being in the range between ⅛ inch to 2 inches. The body by weight comprising 35% to 70% of silica and the remaining ingredients by weight are from 65% to 30% for a total of 100% taken from the group comprising potash, soda, calcia, strontia, alumina, zinc oxide, boric oxide, zirconia, magnesia and potassium. Methods are further disclosed for making the decorative beads comprising mixing together a batch of minerals in powder state comprising by weight 35% to 70% of silica and the remaining oxides by weight from 65% to 30% for a total of 100% taken from a group comprising the oxides mentioned previously. The mixed batch is placed in the container which is inserted into a kiln.

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 method for making a boron carbide containing ceramic involves pyrolyzing a precursor having one or more monosubstituted decaboranyl groups and at least one substituting group containing carbon. The precursor may be molecular, for example comprising two decaboranyl groups linked by a single substituting group, or polymeric, in which case the decaboranyl groups are part of the pendant group of the polymer while a portion of the substituting group makes up the polymer backbone. In either case, the substituting group may be a hydrocarbon, in which case boron carbide may be formed. Alternatively, the substituting group may contain carbon and another ceramic forming element (i.e., other than boron or carbon), such as silicon, nitrogen, or phosphorous, in which case a composite including boron carbide is formed.

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: A thermally conductive carbon foam is provided, normally having a thermal conductivity of at least 40 W/m·K. The carbon foam usually has a specific thermal conductivity, defined as the thermal conductivity divided by the density, of at least about 75 W·cm3/m·° K·gm. The foam also has a high specific surface area, typically at least about 6,000 m2/m3. The foam is characterized by an x-ray diffraction pattern having “doublet” 100 and 101 peaks characterized by a relative peak split factor no greater than about 0.470. The foam is graphitic and exhibits substantially isotropic thermal conductivity. The foam comprises substantially ellipsoidal pores and the mean pore diameter of such pores is preferably no greater than about 340 microns. Other materials, such as phase change materials, can be impregnated in the pores in order to impart beneficial thermal properties to the foam.

Abstract: An open-cell glass crystalline porous material made from hollow microspheres which are cenospheres obtained from fly ash, having an open-cell porosity of up to 90 vol. % is produced. The cenospheres are separated into fractions based on one or more of grain size, density, magnetic or non-magnetic, and perforated or non-perforated. Selected fractions are molded and agglomerated by sintering with a binder at a temperature below the softening temperature, or without a binder at a temperature about, or above, the softening temperature but below the temperature of liquidity. The porous material produced has an apparent density of 0.3-0.6 g/cm3, a compressive strength in the range of 1.2-3.5 MPa, and two types of openings: through-flow wall pores in the cenospheres of 0.1-30 micrometers, and interglobular voids between the cenospheres of 20-100 micrometers.

Abstract: A ceramic molded body obtained by molding a raw material powder having a mean grain size of about 1 &mgr;m or less and a BET specific surface area of about 5 m2/g or more is fired in an atmosphere of about 95% or higher oxygen concentration at a temperature higher than an ordinary firing temperature for a time shorter than an ordinary time, whereby the sintering can be completed in a short time.

Abstract: Ceramic oxide pre-forms comprising substantially continuous, alpha alumina fibers, and methods for making the same. The ceramic oxide pre-forms are useful, for example, as in making metal matrix composites reinforced with substantially continuous, alpha alumina fibers.

Abstract: A filter media structure, which is capable of operating in the micro- and nanofiltration regime, offers: low cost, durability, high temperature and chemical resistance, high permeability, high flow rate, low pressure drop across the filter media, high mechanical strength, separation efficiency, and biocompatibility. The filter media structure is comprised of mixture of carbon or ceramic fibers and inorganic fiber whiskers generally having a diameter of from about 0.03 to about 5 microns. The present invention further provides a method of preparing a filter media structure comprising mixing together a) inorganic fibers; b) inorganic fiber whiskers; c) a water soluble binder, and optionally depositing a thin layer of pyrolytic carbon on the surface of the inorganic fibers and inorganic fiber whiskers comprising the filter media structure. The filter media structure is selected from the group consisting of a paper, felt and fabric.

Abstract: The present invention relates to a porous aluminum oxide structure comprising Al2O3 and Zr, the structure having an open porosity greater than about 30% and an average pore size from about 20 nm to about 1000 nm, wherein the Zr, expressed as ZrO2, has a concentration less than about 5 weight % of the weight of the Al2O3.

Abstract: A method for producing a silicon nitride filter, which comprises heat-treating in nitrogen a green body comprising from 35 to 90 mass % of silicon nitride particles having an average particle diameter of from 1 to 30 &mgr;m, from 5 to 60 mass % of a pore-forming agent and from 0.

Abstract: This invention relates to a method of producing an alumina porous material using a mixed powder of alumina powder and aluminum hydroxide represented by the chemical formula Al(OH)3 at different percentages as the starting material, comprising the steps of heating this mixed powder to decompose the aluminum hydroxide and further heat treating it within a temperature range of 1,000 to 1,600° C., and to the alumina porous material produced by the above-mentioned method with a porosity exceeding 40 volume % and its specific surface area of 8 to 40 m2/g, and further to a filter and catalyst carrier that are obtained using this alumina porous material.

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: 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 mullite composition is comprised substantially of mullite grains that are essentially chemically bound wherein the composition has at least two adjoining regions that have substantially different microstructures. The composition may be produced by forming a mixture of one or more precursor compounds having the elements present in mullite; shaping the mixture into a porous green shape applying a nucleation control agent to a portion of the porous green shape and then heating the porous green shape under an atmosphere and to a temperature sufficient to form the mullite composition.

Abstract: The ceramic porous membrane comprises ceramic particles and ceramic sol particles (with the exception of TiO2 sol particles). The ceramic particles and the ceramic sol particles are kneaded to obtain a kneaded product or a slurry, and the kneaded product or the slurry are sintered at a lower temperature. The ceramic sol particles have an average particle diameter of ⅕ or less of an average particle diameter of the ceramic particles, and the ceramic sol has a solid content of 1 to 30% by weight based on the weight of solid content of the ceramic particles.

Abstract: A method of forming a monolithic, fired ceramic gas diffuser for injecting gas into a molten metal bath includes the steps of: preparing first and second batch materials, depositing the batch materials into a mold to form different portions of the diffuser, and firing the casting to obtain the monolithic diffuser. Various embodiments of the method include vibrating the mold at least while the second batch material is deposited therein, partially freezing a first portion of the casting, and freezing the entire casting prior to firing.

Abstract: The invention concerns a method for preparing macro-porous synthetic ceramics designed in particular for bone substitution. The invention also concerns macro-porous synthetic ceramics comprising pores of controlled dimensions, distributed in number and in surface in a predetermined manner, the interconnection between the pores thereof being controlled.

Abstract: A mullite composition is comprised substantially of mullite grains that are essentially chemically bound wherein the composition has at least two adjoining regions that have substantially different microstructures. The composition may be produced by forming a mixture of one or more precursor compounds having the elements present in mullite; shaping the mixture into a porous green shape applying a nucleation control agent to a portion of the porous green shape and then heating the porous green shape under an atmosphere and to a temperature sufficient to form the mullite composition.

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 ceramic composition is provided to insulate ceramic matrix composites under high temperature, high heat flux environments. The composition comprises a plurality of hollow oxide-based spheres of various dimensions, a phosphate binder, and at least one oxide filler powder, whereby the phosphate binder partially fills gaps between the spheres and the filler powders. The spheres are situated in the phosphate binder and the filler powders such that each sphere is in contact with at least one other sphere. The spheres may be any combination of Mullite spheres, Alumina spheres, or stabilized Zirconia spheres. The filler powder may be any combination of Alumina, Mullite, Ceria, or Hafnia. Preferably, the phosphate binder is Aluminum Ortho-Phosphate. A method of manufacturing the ceramic insulating composition and its application to CMC substrates are also provided.

Abstract: The invention concerns a process for the preparation of an insulated soft magnetic powder comprising the steps of mixing particles of a soft magnetic iron base powder with an acidic, aqueous insulating-layer forming solution, in which MgO has been dissolved; and drying the obtained mixture to obtain an electrically insulating Mg containing layer on the particle surfaces. The invention also concerns the powder per se as well as compressed soft magnetic powder cores prepared from the powder.

Abstract: A process for producing a biocompatible implant material which can be suitably shaped into a variety of forms. A binder is added to a mixture of hydroxylapatite powder and calcium phosphate glass frit (5 wt. %), to thereby prepare a slurry, and the resultant slurry is granulated, to prepare spherical raw material granules. Separately, spherical polyisobutyl methacrylate particles are prepared, and the particles are dry-mixed with the above-prepared granules, to thereby obtain a powder mixture. The powder mixture is compacted using a mold press, to thereby form a cuboid sample. The resultant compact is heated in a drier at 170° C. for three hours, to thereby melt spherical polyisobutyl methacrylate particles. Thereafter, the compact is allowed to cool, to thereby bind the raw material granules together via the polyisobutyl methacrylate that solidifies after melting. After the compact is allowed to cool, the compact is subjected to shaping by use of a copy machining machine and also to drilling.

Abstract: A method for rapidly manufacturing “green-state” ceramic matrix composite components, components made from this method, and a resin/catalyst precursor mixture used in the method. The method includes manufacturing a component by preparing the precursor mixture by mixing a requisite quantity of a polymer-derived ceramic precursor resin, a catalyst, a discontinuous reinforcing fiber and filler material, and then loading this precursor mixture in a preheated mold. The precursor mixture then is cured in the mold to form the component which is porous. Thereafter, the component is reinfilitrated with a resin to at least partially fill the pores of the component. This method yields a ceramic matrix composite component that is cured in approximately one minute as well as a resin/catalyst precursor mixture that can be stored in excess of four weeks.

Abstract: A porous composite product comprised of a network of fibers is produced by forming an unsintered preformed network of fibers and a gasifiable structure forming agent, followed by gasification of the structure forming agent prior to sintering of the fibers at appropriate junction points. The preferred structure forming agent is a cellulosic material.

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: A process for making a low volume fraction preform for a metal matrix composite including the steps of: mixing a reinforcement with a binder and sacrificial fillers to provide a castable slurry; placing the slurry in a mold to provide a green cast preform; drying the green casting to remove any water and/or solvent; firing the green preform at a relatively low temperature to burn off the sacrificial fillers; firing the green preform at an elevated temperature to sinter the binder to bond the reinforcement together. The firing steps include particular combinations of temperature and time to ensure decomposition of the sacrificial filler and sintering without destruction or cracking of the green preform.

Abstract: In a process for stabilizing a foamed starting slip material, the starting slip material which is foamed comprises the following constituents: a. inorganic sinterable material, b. a source of blowing gas, c. a framework former which forms a framework when the pH of the starting slip material is changed, d. pH control material, e. liquid, f. if desired, one or more of the following materials: dispersant binder viscosity modifier, and the pH of the starting slip material is changed to initiate or accelerate the formation of the framework from the framework former.

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: Liposomal bupivacaine compositions are prepared using an ammonium sulfate gradient loading procedure, at a pH which prevents precipitation of the drug from the loading solution. Also described are liposome suspensions comprising `GMV` (giant multivesicular) liposomes and methods for their preparation. The liposomal compositions are characterized by high drug-to-lipid ratios and provide long term analgesia.

Abstract: A method for loading liposomes with biopolymeric substances functional in humans involves combining a physiologically compatible solution of the biopolymeric substances with one or more dry, liposome-forming lipids, effecting a lipid-containing fraction, combining the lipid-containing fraction with an organic solvent, effecting an organic solvent fraction, and drying the organic solvent fraction, which effects a dry fraction of liposomes loaded with the biopolymeric substances.

Abstract: A ceramic contact sheet and setter tile with controlled porosity is introduced, along with the method for making the same. The amount of porosity is controlled by the volume percentage, particle size, and particle shape of a fugitive phase which can be added to the original refractory material slurry used to fabricate setter tiles and contact sheets. The fugitive phase can be used independently to introduce porosity in setter tiles and contact sheets or in conjunction with partial densification. Since porosity is not solely dependent upon partial sintering, higher porosity levels can be achieved with less impact on subsequent mechanical properties of the resultant refractory material.

Abstract: A process for the entrapment of amphiphilic compounds as uncharged or ionic with different mole ratios of phospholipid to the amphiphilic compound. Preparations of ionic species of amphiphilic compounds in the absence of crystals can be prepared, while preparations of uncharged amphiphilic compounds can be prepared with the compound exclusively entrapped inside the liposomes, or partly entrapped inside the liposomes with extraliposomal crystals.

Abstract: Compositions comprising an aqueous dispersion of lipid vesicles having an aqueous core, wherein the dispersion comprises at least one uncoated pigment dispersed in the aqueous phase and wherein the lipid vesicles with an aqueous core and a lipid membrane formed from at least one fatty acid ester, these compositions being stable, of homogeneous color and containing no or virtually no lumps of pigment, and a process for dispersing a filler in an oil-in-water dispersion of lipid vesicles by means of a high-pressure homogenizer.

Abstract: Novel amidinium derivatives of formula (I), wherein R1 is a cholesterol derivative or an alkylamino-NR'R" grouping, and each of R2 and R3 is independently a hydrogen atom or a grouping of formula (II), wherein each of R4 and R5 is independently a hydrogen atom or a grouping of formula (III), are disclosed. The corresponding pharmaceutical compositions, which are particularly useful in gene therapy for transferring therapeutic genes into cells, are also disclosed.