Burning Out Components To Form Pores Patents (Class 264/44)
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Patent number: 7749425Abstract: A method of forming a nanoscale ceramic composite generally includes modifying a polymeric ceramic precursor, mixing the modified polymeric ceramic precursor with a block copolymer to form a mixture, forming an ordered structure from the mixture, wherein the modified polymeric ceramic precursor selectively associates with a specific type of block of the block copolymer, and heating the ordered structure for a time and at a temperature effective to form the nanoscale ceramic composite.Type: GrantFiled: December 21, 2005Date of Patent: July 6, 2010Assignee: General Electric CompanyInventors: Patrick Roland Lucien Malenfant, Julin Wan, Mohan Manoharan
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Patent number: 7732037Abstract: A conductive porous material includes a matrix having a sintered compact of an oxide, a communicating opening formed in the matrix, having a small diameter and being permeable to gas and impermeable to substance other than gas, and a conductive layer provided on an internal wall of the communicating opening and receiving a current to generate heat. As conductive material is used, an organic substance adheres on the internal wall of communicating opening. To address this, conductive layer is caused to generate heat to decompose and thus remove the organic substance and thus prevent the communicating opening from clogging.Type: GrantFiled: January 25, 2005Date of Patent: June 8, 2010Assignees: Towa Corporation, Japan Fine Chemicals CenterInventors: Takaki Kuno, Keiji Maeda, Yoshinori Noguchi, Satoshi Kitaoka, Naoki Kawashima
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Publication number: 20100052200Abstract: A method for reducing shrinkage variability of ceramic honeycombs formed from batch mixtures including inorganic materials and a pore former. X is a cumulative amount of pore former particles having a diameter less than 37 ?m. There is a maximum value of X (Xmax) and a minimum value of X (Xmin) during a production period, and ?X=Xmax?Xmin. The method fixes an amount of pore former fines such that X ranges from 25%-71% by volume, and ?X is ?23% throughout the production period.Type: ApplicationFiled: February 27, 2009Publication date: March 4, 2010Inventors: Thomas James Deneka, Nancy Ann Golomb, Sandra Lee Gray, Daniel Edward McCauley, Patrick David Tepesch, Christopher John Warren
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Publication number: 20100031822Abstract: A hydrogen permeable membrane is disclosed. The membrane is prepared by forming a mixture of metal oxide powder and ceramic oxide powder and a pore former into an article. The article is dried at elevated temperatures and then sintered in a reducing atmosphere to provide a dense hydrogen permeable portion near the surface of the sintered mixture. The dense hydrogen permeable portion has a higher initial concentration of metal than the remainder of the sintered mixture and is present in the range of from about 20 to about 80 percent by volume of the dense hydrogen permeable portion.Type: ApplicationFiled: September 30, 2009Publication date: February 11, 2010Applicant: UChicago Argonne, LLCInventors: Sun-Ju Song, Tae H. Lee, Ling Chen, Stephen E. Dorris, Uthamalingam Balachandran
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Patent number: 7658863Abstract: A Si—C—O composite powder is obtained by curing a reactive silane or siloxane having crosslinkable groups through heat curing or catalytic reaction into a crosslinked product and sintering the crosslinked product in an inert gas stream at a temperature of 700-1,400° C. into an inorganic state. It exhibits satisfactory cycle performance when used as the negative electrode material for non-aqueous electrolyte secondary cells.Type: GrantFiled: July 21, 2005Date of Patent: February 9, 2010Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Mikio Aramata, Satoru Miyawaki, Hirofumi Fukuoka
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Patent number: 7648548Abstract: Disclosed are ceramic articles, which in one aspect are composed predominately of a cordierite having a composition close to that of Mg2Al4Si5O18. The ceramic articles possess a microstructure characterized by a unique combination of relatively high porosity and relatively narrow pore size distribution, both as measured by mercury porosimetry, that render the ceramic structure useful for ceramic filter applications requiring high thermal durability and high filtration efficiency coupled with low pressure drop along the length of the filter. Such ceramic bodies are particularly well suited for filtration applications, such as diesel exhaust filters or DPFs. Also disclosed are methods for the manufacture of the ceramic articles described herein.Type: GrantFiled: May 10, 2006Date of Patent: January 19, 2010Assignee: Corning IncorporatedInventors: Weiguo Miao, Steven Bolaji Ogunwumi, Paul John Shustack, Jianguo Wang
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Patent number: 7645934Abstract: Nanostructured layers with 10 nm to 50 nm pores spaced 10-50 nm apart, a method for making such nanostructured layers, optoelectronic devices having such nanostructured layers and uses for such nanostructured layers are disclosed. The nanostructured layer can be formed using precursor sol, which generally includes one or more covalent metal complexes, one or more surfactants, a solvent, one or more optional condensation inhibitors, and (optionally) water. Evaporating the solvent from the precursor sol forms a surfactant-templated film. Covalently crosslinking the surfactant-templated film forms a nanostructured porous layer. Pore size is controlled, e.g., by appropriate solvent concentration, choice of surfactant, use of chelating agents, use of swelling agents or combinations of these.Type: GrantFiled: April 29, 2003Date of Patent: January 12, 2010Assignee: Nanosolar, Inc.Inventors: Jacqueline Fidanza, Brian M. Sager, Martin R. Roscheisen, Dong Yu, Gina J. Gerritzen
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Publication number: 20090255402Abstract: A process for producing a regenerable ceramic particulate filter for diesel vehicles is described, wherein a material comprising silicon-containing particles is pyrolyzed in the presence of a polyamide. The resulting particulate filters have a BET surface area of >350 m2/l.Type: ApplicationFiled: April 13, 2009Publication date: October 15, 2009Applicant: EVONIK DEGUSSA GmbHInventors: Martin Risthaus, Hans-Joachim Woenicker
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Patent number: 7575618Abstract: Porous ceramic articles such as ceramic filters are provided from ceramic extrusion batches comprising mixtures of oxides and oxide precursors with a reactive binder system, the binder system comprising a cellulosic temporary binder and two or more reactive binder components such as colloidal alumina, carbohydrate pore formers, reactive high charge density polymers, and chemical cross-linkers, the reactive binder system promoting cross-linking or networking reactions in the batch that enhance the fine pore structures of the porous ceramic products.Type: GrantFiled: March 30, 2006Date of Patent: August 18, 2009Assignee: Corning IncorporatedInventors: Weiguo Miao, Jianguo Wang
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Patent number: 7567817Abstract: A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host.Type: GrantFiled: May 14, 2007Date of Patent: July 28, 2009Assignee: GEO2 Technologies, Inc.Inventors: James Jenq Liu, Bilal Zuberi
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Patent number: 7556755Abstract: A process for producing a ceramic molding having a three-dimensional network structure with a plurality of spherical cells and a plurality of through holes present in dividing walls between the spherical cells, includes: a step of obtaining an aggregate of coated particles in which a plurality of ceramic particles are attached to the surface of spherical synthetic resin particles; a step of arranging the aggregate of coated particles in closest packed form within a mold; a step of filling gaps in the aggregate of coated particles with a ceramic so as to give a shaped product; a step of releasing the shaped product from the mold; a step of thermally decomposing the spherical synthetic resin particles of the shaped product so as to form the spherical cells and form the plurality of through holes in dividing wall-forming sections that are present between adjacent spherical cells; and a step of sintering the ceramic particles and the ceramic so as to form the dividing walls.Type: GrantFiled: November 15, 2004Date of Patent: July 7, 2009Assignee: Honda Motor Co., Ltd.Inventors: Kazuo Shibata, Tadashi Ohya, Tsuyoshi Tanaka
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Publication number: 20090169863Abstract: A method for making a heat dissipating device having an irregular porous structure includes the steps of: (a) blending a low temperature combustible solid material, a solid binder component, and a heat-conducting component to form a mixture; (b) molding the mixture to form a molded article by heating the mixture at a temperature that is higher than a melting temperature of the solid binder component, that is lower than a melting temperature of the heat-conducting component, and that is sufficiently high to burn or melt out the low temperature combustible solid material; and (c) cooling the molded article.Type: ApplicationFiled: March 28, 2008Publication date: July 2, 2009Inventor: CHIN-KUANG LUO
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Publication number: 20090142529Abstract: A volatile liquid loadable porous metal or ceramic container and manufacturing method thereof provided with a structural body formed by metal or ceramic sintering and provided with breathable pores, which extend from an outer surface of the structural body to the interior of the structural body, and the breathable pores form spaces to transport or/and store liquid. The manufacturing method includes: a. taking a low temperature volatile material as the core; b. completely covering the aforementioned core with metal or ceramic powder in the predetermined mold; c. controlling compactness of the metal or ceramic powder; d. sintering of the core at a temperature higher than the vaporization temperature to cause gaseous effusion of the core; e. taking off the predetermined mold after completing sintering.Type: ApplicationFiled: November 29, 2007Publication date: June 4, 2009Applicant: Far East UniversityInventors: Tien-Yin Chan, Chin-Sheng Lee, Chia-Liang Chen, Yu-Che Huang, Zhe-Yong Wu
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Patent number: 7541303Abstract: The present invention provides materials and methods for the manufacture of high porosity ceramic exhaust filters employing relatively low amounts of pore formers, the filters combining efficient diesel particulate filtration with effective support for exhaust emissions control catalysts. Cordierite-forming ceramic batches comprising non-hydrated transition alumina powders of relatively large particle size provide high porosities with well-controlled pore sizes and with low filter thermal expansion coefficients and good mechanical strengths.Type: GrantFiled: December 21, 2005Date of Patent: June 2, 2009Assignee: Corning IncorporatedInventors: William Peter Addiego, Isabelle Marie Melscoet-Chauvel
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Patent number: 7537716Abstract: The present invention relates to a method for producing porous ceramic, the method including molding a mixture containing a water absorbent polymer particle, a ceramic raw material, and water, the water absorbent polymer particle having a water absorption amount in a range of 5 to 30 ml/g at a pressure of 980 Pa, and heating and baking the resulting molded product. The water absorbent polymer particle is preferably composed of a polymer having a 2-acrylamide-2-methylpropanesulfonic acid unit or an acrylamide unit as a constituting monomer unit.Type: GrantFiled: February 5, 2004Date of Patent: May 26, 2009Assignees: Toagosei Co., Ltd., NGK Insulators, Ltd.Inventors: Morikatsu Matsunaga, Koushi Yamamoto, Akira Kuriyama
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Patent number: 7537634Abstract: A method for manufacturing a plugged honeycomb structure includes the steps of: applying a predetermined amount of the plugging slurry on a face of an end face sealing member, one end face of the masked honeycomb structure is pressed against the face to which the plugging slurry was applied of the end face sealing member to fill the plugging slurry in the predetermined cells on the one end face side, and drying at least the plugging slurry at a portion in contact with the face of the end face sealing member in a state that the face of the end face sealing member is pressed against the one end face of the masked honeycomb structure. The method can manufacture simply at a low cost a plugged honeycomb structure with reduced accumulation of deposit on an end face when the honeycomb structure is used as a filter or the like.Type: GrantFiled: March 15, 2006Date of Patent: May 26, 2009Assignee: NGK Insulators, Ltd.Inventors: Tatsuhiko Hatano, Masahiro Masuda, Yukihito Ichikawa
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Publication number: 20090130424Abstract: A composite article includes a substrate and a thermal barrier secured to the substrate. The thermal barrier includes a plurality of closed pores within a ceramic matrix. For example, the closed pores comprise 20 vol % to 80 vol % of the thermal barrier.Type: ApplicationFiled: May 30, 2007Publication date: May 21, 2009Inventors: Susan M. Tholen, Christopher W. Strock
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Patent number: 7520911Abstract: A porous cordierite ceramic honeycomb article with increased mechanical strength and thermal shock resistance. The porous cordierite ceramic honeycomb article has MA<2220, or MT>2660 wherein MA=3645(IA)?106(CTE)+19(d90)+17(% porosity), MT=4711(IT)+116(CTE)?26(d90)?28(% porosity), and a CTE?9×10?7/° C. in at least one direction. A method of manufacturing is also disclosed wherein the inorganic raw material mixture contains talc, an alumina-forming source, a silica-forming source, and 0-18 wt. % of a kaolin or calcined kaolin containing not more than 8 wt. % of a fine kaolin source having a median particle diameter of less than 7 ?m, wherein the fired porous ceramic cordierite honeycomb article has a porosity<54% . Alternatively, if greater than 8 wt. % of the fine kaolin source is used, then a slow ramp rate is utilized from 1200° C. to 1300° C. of not more than 20° C./hr.Type: GrantFiled: November 30, 2005Date of Patent: April 21, 2009Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Gregory Albert Merkel, David John Thompson
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Publication number: 20090098465Abstract: A microporous membrane having excellent properties which is produced by extruding a combination of a diluent or solvent and a polyolefin resin composition comprising (a) from about 40 to about 60% of a first polyethylene resin having a weight average molecular weight of from about 2.5×105 to about 4×105 and a molecular weight distribution of from about 5 to about 100, (b) from about 20 to about 40% of a first polypropylene resin having a weight average molecular weight of from about 0.8×106 to about 1.Type: ApplicationFiled: October 12, 2007Publication date: April 16, 2009Inventors: Shintaro Kikuchi, Kotaro Takita
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Publication number: 20090096121Abstract: The present invention provides a method of producing low-density open-cell inorganic foam. The method includes the steps of providing a dry powder mixture containing at least inorganic particles, soluble space-filler particles, and solid organic binder; shaping the dry powder composition into a preform by pouring it in a mold having a given form; heating the preform to melt the organic binder; solidifying the organic binder to obtain a solid perform; removing at least the space-filler from the solid preform by dissolution in an appropriate solvent; heating and maintaining the material at a temperature sufficient to burn-out the remaining organic binder; and finally sintering the remaining inorganic material to obtain an open-cell inorganic foam.Type: ApplicationFiled: October 16, 2008Publication date: April 16, 2009Inventor: Lhoucine AZZI
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Patent number: 7514024Abstract: A porous sintered body of a calcium phosphate-based ceramic having a porosity of 80% or more. The porous sintered body is produced by a method comprising the steps of: (1) preparing a slurry comprising a calcium phosphate-based ceramic powder, a water-soluble high molecular compound and a nonionic surface active agent; (2) stirring the slurry vigorously to froth the slurry; (3) solidifying the frothed slurry into a gel; and (4) drying and sintering the gel.Type: GrantFiled: February 6, 2004Date of Patent: April 7, 2009Assignee: Hoya CorporationInventor: Toshio Matsumoto
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Patent number: 7494557Abstract: A method of using sacrificial materials for fabricating internal cavities and channels in laminated dielectric structures, which can be used as dielectric substrates and package mounts for microelectronic and microfluidic devices. A sacrificial mandrel is placed in-between two or more sheets of a deformable dielectric material (e.g., unfired LTCC glass/ceramic dielectric), wherein the sacrificial mandrel is not inserted into a cutout made in any of the sheets. The stack of sheets is laminated together, which deforms the sheet or sheets around the sacrificial mandrel. After lamination, the mandrel is removed, (e.g., during LTCC burnout), thereby creating a hollow internal cavity in the monolithic ceramic structure.Type: GrantFiled: January 30, 2004Date of Patent: February 24, 2009Assignee: Sandia CorporationInventor: Kenneth A. Peterson
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Patent number: 7488368Abstract: The ceramic honeycomb structure has a plurality of cells partitioned by porous partition walls and extending through the structure in an axial direction, one end portion of a predetermined cell is plugged with a plugging portion constituted of a plugging material with which the cell is filled, and the other end portion of a remaining cell is plugged with the plugging portion on a side opposite to the end portion of the predetermined cell. In the ceramic honeycomb structure, a sectional numerical aperture of the plugging portion in the vicinity of the partition wall is smaller than that of the plugging portion in the vicinity of a central axis, and a difference between the sectional numerical apertures is 10% or more.Type: GrantFiled: October 19, 2005Date of Patent: February 10, 2009Assignee: NGK Insulators, Ltd.Inventors: Toshio Yamada, Tatsuhiko Hatano
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Patent number: 7481968Abstract: A novel method is disclosed for the preparation of a sintered porous body of a metallic or ceramic powder having a closed cell texture and a porosity as high as 95% or higher. The method comprises the steps of: preparing a foamable aqueous slurried composition containing a powder of the metallic or ceramic material, a blowing agent and a binder resin which is a water-soluble polymer capable of becoming gelled; subjecting the slurried composition to gelation of the binder resin; subjecting the gelled mass of the composition to foaming by gas-evolution from the blowing agent; and heating the thus gelled and foamed body of the composition to effect drying and sintering of the particles of the metallic or ceramic powder.Type: GrantFiled: March 10, 2005Date of Patent: January 27, 2009Assignee: National Institute of Advanced Industrial Science and TechnologyInventors: Toru Shimizu, Kanichi Hatsukano, Kotaro Hanada, Kunio Matsuzaki
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Patent number: 7482390Abstract: A method of producing an open, porous structure having an outer surface defining a shape having a bulk volume and having interconnecting openings extending throughout said volume and opening through said surface, and products resulting from the method. The method comprises preparing a viscous mixture comprising a sinterable powder dispersed in a sol of a polymer in a primary solvent, replacing the primary solvent with a secondary liquid in which the polymer is insoluble to produce a gel comprising an open polymeric network having the sinterable powder arranged therein, removing the secondary liquid from the gel; removing the polymer network, and sintering the sinterable powder to form the open, porous structure. Also disclosed are shaped, porous products resulting from methods of the invention.Type: GrantFiled: June 30, 2005Date of Patent: January 27, 2009Assignee: Phillips Plastics CorporationInventors: James R. Johnson, Michael Edward Frencl
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Publication number: 20080302243Abstract: A filter membrane includes a substrate, a polymer layer provided on the substrate and a plurality of filter openings each having a width of from about 2 nanometers to about 5 nanometers provided in the polymer layer. A method of controlling pore size of a filter membrane and a method of decontaminating a filter membrane are also disclosed.Type: ApplicationFiled: June 6, 2007Publication date: December 11, 2008Inventors: Norman R. Byrd, James P. Huang, Gwen Gross
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Patent number: 7449165Abstract: A carbon monolith includes a robust carbon monolith characterized by a skeleton size of at least 100 nm, and a hierarchical pore structure having macropores and mesopores.Type: GrantFiled: February 3, 2004Date of Patent: November 11, 2008Assignees: UT-Battelle, LLC, UTRFInventors: Sheng Dai, Georges A. Guiochon, Chengdu Liang
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Patent number: 7442425Abstract: A ceramic honeycomb substrate for use in an automotive catalytic converter system which exhibits improved light-off performance by virtue of a high porosity of 45 to 75% while still maintaining a wall thickness of greater than 2.0 mil (0.0020 inch, 0.0508 mm), preferably 2.5 mil (0.0025 in., 0.0635 mm) to 7 mil (0.0070 in., 0.1778 mm), and more preferably 2.5 mil (0.0025 in., 0.0635 mm) to 3 mil (0.0030 in., 0.0762 mm). The median pore size is in the range of 2-10 micrometers, and a coefficient of thermal expansion (CTE) (25-800° C.) of less than 15×10?7/° C.Type: GrantFiled: September 30, 2003Date of Patent: October 28, 2008Assignee: Corning IncorporatedInventors: Xiaodong R. Fu, Jun Hou, John F. Wight, Jr.
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Patent number: 7435376Abstract: A composite of a metal matrix with one or more incorporated secondary phases is referred to as a metal matrix composite (MMC). Secondary phase refers to all the particles or fibers which have a different composition than the metal matrix, and which are incorporated therein. As incorporation phases, elements and compounds are possible which, as a result of their material characteristics, are suited for improving individual properties of the metal matrix. Besides an improvement in individual properties of the pure metal matrix as a result of the incorporated secondary phase, certain properties of the metal are also degraded, in particular by particles having a size of 1 to 50 ?m. For example, the elongation at break decreases, the strength may decrease, or the tribology may become less favorable.Type: GrantFiled: December 15, 2003Date of Patent: October 14, 2008Assignee: CeramTec AGInventors: Dirk Rogowski, Ilka Lenke, Dieter Theil
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Patent number: 7429351Abstract: A method for manufacturing a porous ceramic structure which can produce a high porosity ceramic structure as well as a low porosity ceramic structure without causing cracks at the time of firing. A method for manufacturing a porous ceramic structure comprising molding a raw material which contains a ceramic material as a main component and a pore-forming agent and then drying and firing the obtained molded article. When the molded article is fired, the temperature of a firing environment is raised substantially in synchronization with the temperature of the central portion of the molded article within a temperature range in which at least a portion of the molded article is shrunk by firing.Type: GrantFiled: July 23, 2004Date of Patent: September 30, 2008Assignee: NGK Insulators, Ltd.Inventors: Yumi Toda, Yukihisa Wada, Yasushi Noguchi
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Publication number: 20080213611Abstract: The exemplary embodiment of the present invention are provided which relate to porous implants and methods for manufacture thereof which use powder molding techniques. For example, a suspension can be provided comprising a plurality of first particles of at least one organic polymer, a plurality of second particles of at least one metal-based material, and at least one solvent. The first and second particles can be substantially insoluble in the solvent. The suspension can be molded to form a green body comprising the first particles embedded in a matrix of compressed second particles. The first particles may be removed from the green body by thermally induced decomposition and/or evaporation. The green body can be sintered to form the implant. The removals of the first particles can be performed during sintering.Type: ApplicationFiled: January 18, 2008Publication date: September 4, 2008Applicant: CINVENTION AGInventor: Sohéil Asgari
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Publication number: 20080179771Abstract: The invention describes a high porosity ceramic article and method of manufacturing the same and intermediate dried honeycomb green body articles. The article may have a total porosity of at least about fifty-five percent, above sixty percent, or even above sixty-five percent. The method of manufacture includes mixing a ceramic-forming powder, an organic pore former, water, and a crosslinker. Drying causes a condensation reaction between the pore former and the crosslinker thereby forming a network within the green body that strengthens the green body and reduces cracking. The pore former may include starch or an activated cellulose compounds. Secondary pore forming agents, such as graphite may also be included.Type: ApplicationFiled: January 29, 2007Publication date: July 31, 2008Inventors: Weiguo Miao, Steven Bolaji Ogunwumi, Jianguo Wang
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Patent number: 7357976Abstract: The ceramic molded body of the present invention includes spherical cells of a spherical bubble plurally formed therein: in the ceramic molded body the spherical cells neighboring each other are communicated through communication porosities and form a three-dimensional network structure, and a ratio (Md/MD) of a median (Md) of inner diameters of the communication porosities to a median (MD) of inner diameters of the spherical cells is less than 0.5. In the ceramic molded body used for manufacturing a metal matrix composite, a metal is filled within the spherical cells and the communication porosities.Type: GrantFiled: April 15, 2005Date of Patent: April 15, 2008Assignee: Honda Motor Co., Ltd.Inventors: Satoshi Yamamura, Kazuo Shibata, Tadashi Ohya
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Publication number: 20080050557Abstract: Disclosed are porous ceramic honeycomb articles, such as filters, which are composed predominately of a cordierite composition. The ceramic honeycomb articles possess a porous microstructure characterized by a unique combination of relatively high porosity (>45%), and moderately narrow pore size distribution wherein greater than 15% and less than 38% of the total porosity exhibits a pore diameter less than 10 ?m, and low CTE wherein CTE?6.0×10?7/° C. (from 23° C. to 800° C.). The articles exhibit high thermal durability and high filtration efficiency coupled with low pressure drop. Such ceramic articles are particularly well suited for use in filtration applications, such as in diesel exhaust filters. Also disclosed are methods for manufacturing the porous ceramic honeycomb article.Type: ApplicationFiled: August 23, 2007Publication date: February 28, 2008Inventors: Douglas Munroe Beall, Thomas Richard Chapman, Martin Joseph Murtagh, Balaji Venkatesan Swarnamani
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Patent number: 7306753Abstract: The aim of the invention is to produce a thin porous layer, with a defined porosity and also, a high strength. Said aim is achieved, whereby such a layer with open porosity is produced from a mixture, comprising a sinterable powder with a predetermined powder particle size distribution. The sintered layer is of a thickness, which corresponds to about triple the average diameter of the powder particles employed, has a pore diameter in the range from 0.01 to 50 ?m and a tensile strength of in a range from about 5 to 500 N/mm2. The invention further relates to a method for the production of said thin porous layer with open porosity.Type: GrantFiled: March 18, 2004Date of Patent: December 11, 2007Assignee: GKN Sinter Metals GmbHInventors: Andreas Kuhstoss, Thomas Röthig, Peter Neumann
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Patent number: 7290586Abstract: A ceramic foam having pores in the range of 20 to 800 microns and 10 to 30 % of theoretical density is placed in a preheated mould and molten metal or plastics is drawn in to form a bicomposite structure.Type: GrantFiled: August 22, 2001Date of Patent: November 6, 2007Assignee: Dytech Corporation LimitedInventor: Rodney Martin Sambrook
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Patent number: 7208108Abstract: A method for producing a porous ceramic article involves a step of kneading raw materials including a raw material for a ceramic and a processing aid, to prepare a body, a step of forming the body, to prepare a ceramic formed product, a step of drying the formed product, to prepare a ceramic dried article, and a step of firing the ceramic dried article, to preparing a porous ceramic article, characterized in that the processing aid is a starch having been subjected to a crosslinking treatment or a material comprising a starch having been subjected to a crosslinking treatment and a foamed resin. The method allows the production of a porous ceramic article which is suppressed in the deformation during drying and is excellent in dimensional accuracy.Type: GrantFiled: December 6, 2002Date of Patent: April 24, 2007Assignee: NGK Insulators, Ltd.Inventors: Aiko Otsuka, Shuichi Ichikawa, Takashi Harada
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Patent number: 7199067Abstract: A homogeneous bulky porous ceramic material is provided, the average pore diameter D50 of which is less than 4 ?m and the closed porosity of which is less than 2 ?m, and having a bubble point that matches the pore diameter measured on the material. A hollow fiber based on the material and a module employing such fibers together with a paste constituting a precursor for the material and including a pore-forming agent are also provided.Type: GrantFiled: January 10, 2003Date of Patent: April 3, 2007Assignee: Pall CorporationInventors: Raymond Soria, Jean-Claude Foulon, Jean-Michel Cayrey
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Patent number: 7186360Abstract: Ceramic composite materials have unidirectional alignment of the reinforcing fibers. The ratio of the volume of the fiber strands of the reinforcing fibers to the volume of the matrix is at least 0.5. A process for their production involves initially coating the fiber strands or rovings of the reinforcing fibers with a sacrificial polymer. The coated fiber strands are processed with binder resins into unidirectionally reinforced CFK molded parts. The formed CFK bodies are carbonized to form CFC bodies. The CFC bodies are then silicized with liquid silicon. The liquid silicon diffuses into the pores formed in the CFC body and combines there at least partially with the carbon to form silicon carbide. The sacrificial polymer is pyrolized. The ceramic composite materials also can be used in fiber-reinforced ceramic structural parts.Type: GrantFiled: February 28, 2003Date of Patent: March 6, 2007Assignee: SGL Carbon AGInventor: Bodo Benitsch
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Patent number: 7141089Abstract: A ceramic filter for trapping and combusting diesel exhaust particulates composed of an end-plugged cordierite honeycomb structure exhibiting a pore size distribution as determined by mercury porosimetry in which the quantity d50/(d50+d90) as related to pore size distribution is less than 0.70, a soot loaded permeability factor Sf, as defined by the equation [d50/(d50+d90)]/[% porosity/100], of less than 1.55, and, a coefficient of thermal expansion (25–800° C.) of no greater than 17×10?7/° C. The ceramic filter further exhibits a median pore diameter, d50, of at least 4 micrometers and up to 40 micrometers. A method of making the filter is provided.Type: GrantFiled: June 26, 2003Date of Patent: November 28, 2006Assignee: Corning IncorporatedInventors: Douglas M. Beall, Gregory A. Merkel, Martin J. Murtagh
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Patent number: 7112234Abstract: A composite porous media for either gas or liquid flow is strong and efficient, and can readily be formed in or into a wide range of different shapes and configurations. In particular, the porous media is a composite of a metal, aerogel or ceramic foam (i.e., a reticulated inter-cellular structure in which the interior cells are interconnected to provide a multiplicity of pores passing through the volume of the structure, the walls of the cells themselves being substantially continuous and non-porous, and the volume of the cells relative to that of the material forming the cell walls being such that the overall density of the intercellular structure is less than about 30 percent theoretical density) the through pores of which are impregnated with a sintered powder or aerogel. The thickness, density, porosity and porous characteristics of the final composite porous media can be varied to conform with what is demanded by the intended use.Type: GrantFiled: March 2, 2004Date of Patent: September 26, 2006Assignee: Mott CorporationInventors: Sunil C. Jha, Kenneth L. Rubow, Cathy L. Cowan, Mark R. Eisenmann
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Patent number: 7070879Abstract: An electrode suitable for use in a fuel cell includes a passive support having pores wherein the passive support has an asymmetric pore morphology with respect to at least one dimension of the passive support; and an electrode material positioned in the pores of the passive support. An exemplary electrode includes an electrode material of a metal and/or metal oxide. An exemplary porous electrode includes a deposited electrolyte layer that blocks at least some pores of the porous electrode. An exemplary method includes reducing an electrode material positioned in pores of a passive support to create secondary porosity and/or to limit agglomeration. Other exemplary devices and/or methods are also disclosed.Type: GrantFiled: April 10, 2003Date of Patent: July 4, 2006Assignee: Hewlett-Packard Development Company, L.P.Inventors: Peter Mardilovich, Gregory S Herman, Christopher Beatty, James O'Neil, David Champion
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Patent number: 7033527Abstract: Disclosed herein are a highly porous ceramic having a high porosity of not less than 60% and a pore density of not less than 108 pores/cm3 fabricated from expandable microspheres and a preceramic polymer, and a method for fabricating highly porous ceramic. The method for fabricating highly porous ceramic from expandable microspheres and a preceramic polymer comprises the steps of: homogeneously mixing a preceramic polymer powder and expandable hollow microspheres, if necessary, a ceramic powder, and molding the mixture to form a molded body; heating the molded body to expand it; curing the expanded molded body; and pyrolyzing the cured molded body. Since the highly porous ceramic has a higher porosity and pore density than conventional porous ceramics, it can be suitably used for various high temperature structure materials, kiln furniture, bulletproof materials, shock-absorbing materials, insulating materials, refractory materials, lightweight structure materials, etc.Type: GrantFiled: September 23, 2003Date of Patent: April 25, 2006Assignee: Korea Institute of Machinery and MaterialsInventors: Young-Wook Kim, Hai-Doo Kim, Shin-Han Kim, Chul-B Park
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Patent number: 7014799Abstract: A low-cost, efficient method of preparing hierarchically ordered structures by filling a minimold with a microsphere-containing latex suspension, forming an close-packed array of microspheres within the minimold and filling void space in the array with a self-assembling mixture of hydrolyzed inorganic species and amphiphilic block copolymers. A macroporous and mesoporous material can be produced by subsequent thermal removal of the microspheres and copolymers.Type: GrantFiled: May 14, 2002Date of Patent: March 21, 2006Inventors: Peidong Yang, Tao Deng, George M. Whitesides, Galen Stucky, Dongyaun Zhao, Bradley Chmelka, David Pine, Pingyun Feng
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Patent number: 7005210Abstract: 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, 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.Type: GrantFiled: October 9, 2002Date of Patent: February 28, 2006Assignee: The Texas A&M University SystemInventor: George R. King
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Patent number: 6998064Abstract: 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.Type: GrantFiled: July 14, 2003Date of Patent: February 14, 2006Assignee: MTU Aero Engines GmbHInventors: Rainer Gadow, Guenter Schaefer
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Patent number: 6984671Abstract: A method of producing an open, porous structure having an outer surface defining a shape having a bulk volume and having interconnecting openings extending throughout said volume and opening through said surface, and products resulting from the method. The method comprises preparing a viscous mixture comprising a sinterable powder dispersed in a sol of a polymer in a primary solvent, replacing the primary solvent with a secondary liquid in which the polymer is insoluble to produce a gel comprising an open polymeric network having the sinterable powder arranged therein, removing the secondary liquid from the gel; removing the polymer network, and sintering the sinterable powder to form the open, porous structure. Also disclosed are shaped, porous products resulting from methods of the invention.Type: GrantFiled: June 10, 2003Date of Patent: January 10, 2006Assignee: Phillips Plastics CorporationInventors: James R. Johnson, Michael Edward Frencl
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Patent number: 6955777Abstract: A plate for use in mixing and testing materials in the pharmaceutical industry is formed by a method in which apertures in a set of greensheets are formed by a material removal process, at least some of the apertures being filled with a fugitive material that escapes during sintering.Type: GrantFiled: January 7, 2003Date of Patent: October 18, 2005Assignee: International Business Machines CorporationInventors: Govindarajan Natarajan, Umar Ahmad, Raschid J. Bezama, James N. Humenik, John U. Knickerbocker, Rao V. Vallabhaneni
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Patent number: 6942713Abstract: An aluminum titanate-based ceramic body having a composition a formula comprising a(Al2O3.TiO2)+b(CaO.Al2O3.2SiO2)+c(SrO.Al2O3.2SiO2)+d(BaO.Al2O3.2SiO2)+e(3Al2O3.2SiO2)+f(Al2O3)+g (SiO2)+h(Fe2O3.TiO2)+i(MgO.2TiO2), wherein a, b, c, d, e, f, g, h, and i are weight fractions of each component such that (a+b+c+d+e+f+g+h+i)=1, wherein 0.5<a?0.95; 0?b?0.5; 0?c?0.5; 0?d?0.5; 0<e?0.5; 0?f?0.5; 0?g?0.1; 0?h?0.3; 0?i?0.3; b+d>0.01. A method of forming the ceramic body is provided. The ceramic body is useful in automotive emissions control systems, such as diesel exhaust filtration.Type: GrantFiled: September 30, 2004Date of Patent: September 13, 2005Assignee: Corning IncorporatedInventors: Steven B. Ogunwumi, Patrick D. Tepesch, Raja R. Wusirika
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Patent number: 6926852Abstract: 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.Type: GrantFiled: August 12, 2002Date of Patent: August 9, 2005Assignee: Nissan Motor Co., Ltd.Inventors: Fuminori Satou, Mitsugu Yamanaka, Makoto Uchiyama, Masaharu Hatano, Keiko Kushibiki, Naoki Hara, Tatsuhiro Fukuzawa, Itaru Shibata