Burning Out Components To Form Pores Patents (Class 264/44)
  • Patent number: 6858192
    Abstract: An activated carbon-metal oxide matrix is disclosed. The activated carbon-metal oxide matrix may by obtained by a method including the steps of: preoxidizing a carbon material, grinding the preoxidized carbon material; mixing the ground preoxidized material with a metal oxide to form a carbon mixture; extruding the carbon mixture; carbonizing and activating the extrudate. The activated carbon-metal oxide matrix may be used to remove odorous compounds, acidic gases, and volatile organic compounds from a gas.
    Type: Grant
    Filed: December 11, 2001
    Date of Patent: February 22, 2005
    Assignee: USFilter Corporation
    Inventors: James Richard Graham, Cheng Jian Yuan
  • Patent number: 6852272
    Abstract: The present invention relates to the fabrication of low cost, in situ, porous metallic, ceramic and cermet foam structures having improved mechanical properties such as energy absorption and specific stiffness. Methods of fabricating the structures from compositions including ceramic and/or metallic powders are provided. The flowable compositions also include an immiscible phase that results in pores within the final structure. Furthermore, the structures may be shaped to have external porosity, such as with mesh-like structures.
    Type: Grant
    Filed: January 27, 2003
    Date of Patent: February 8, 2005
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: Gregory Artz, K. Ranji Vaidyanathan, Michael L. Fulcher, Mark J. Rigali, John L. Lombardi, Joseph Walish, Ronald A. Cipriani
  • Patent number: 6849213
    Abstract: A method for producing a silicon nitride filter including heat-treating in nitrogen a green body containing from 40 to 90% of metal silicon particles having an average particle diameter of from 1 to 200 ?m and from 10 to 60% of a pore-forming agent, where the total amount of the metal silicon particles and the pore-forming agent is at least 90%, forms a porous product made substantially of silicon nitride.
    Type: Grant
    Filed: August 13, 2002
    Date of Patent: February 1, 2005
    Assignee: Asahi Glass Company, Limited
    Inventors: Naomichi Miyakawa, Nobuhiro Shinohara, Kanji Arai, Hideo Takahashi
  • Patent number: 6838026
    Abstract: A method for producing a silicon nitride filter by heat-treating in nitrogen green body of from 35 to 90 mass % of silicon nitride particles having an average particle diameter of from 1 to 30 ?m, from 5 to 60 mass % of a pore-forming agent and from 0.1 to 5 mass % of metal oxide particles, provided that the total amount of the silicon nitride particle , the pore-forming agent and the metal oxide particles is at least 90 mass %, to form a porous product.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: January 4, 2005
    Assignee: Asahi Glass Company, Limited
    Inventor: Naomichi Miyakawa
  • Publication number: 20040262801
    Abstract: A method of preparing a low-density material and precursor for forming a low-density material is provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. Control of the blowing agent can be accomplished via a variety of means including appropriate distribution throughout the precursor, addition of a control agent into the precursor, or modification of the firing conditions such as oxygen deficient or fuel rich environment, plasma heating etc.
    Type: Application
    Filed: February 25, 2004
    Publication date: December 30, 2004
    Inventors: Hamid Hojaji, Shannon Marie Labernik, Thinh Pham, Huagang Zhang
  • Publication number: 20040253279
    Abstract: An aqueous dispersion of ceramic particles and containing a polymerisable monomer was foamed before polymerisation, e.g., using a catalyst and initiator, was started.
    Type: Application
    Filed: April 8, 2004
    Publication date: December 16, 2004
    Applicant: Dytech Corporation Limited
    Inventors: Robert Terence Smith, Rodney Martin Sambrook
  • Publication number: 20040239011
    Abstract: Method of manufacturing an exhaust gas purifying filter capable of purifying an exhaust gas.
    Type: Application
    Filed: April 23, 2004
    Publication date: December 2, 2004
    Applicant: DENSO CORPORATION
    Inventor: Mikio Ishihara
  • Patent number: 6818580
    Abstract: A ceramics structure body having chemical composition of 42 to 56 wt % of SiO2, 30 to 45 wt % of Al2O3 and 12 to 16 wt % of MgO, crystalline phase mainly composed of cordierite, a porosity of 55 to 65%, an average pore size of 15 to 30 &mgr;m; and the total area of pores exposed on surfaces of partition walls constituting the honeycomb ceramics structure body being 35% or more of the total area of partition wall surfaces. Fifteen to 25 wt % of graphite and 5 to 15 wt % of a synthetic resin are added as a pore forming agent to a cordierite-forming raw material; the resultant is kneaded and molded into a honeycomb shape; and the resultant is dried and fired to produce above-mentioned honeycomb ceramics structure body. According to this honeycomb ceramics structure body, a low pressure loss and a high collection efficiency can be attained.
    Type: Grant
    Filed: December 23, 2002
    Date of Patent: November 16, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Kazuhiko Kumazawa, Yasushi Noguchi, Hideaki Nishi, Hiroyuki Suenobu
  • Patent number: 6811602
    Abstract: A process for preparing a silicate porous product, which comprises a step of forming a clay mineral into a dispersion by means of a dispersant, a step of removing gases dissolved in the dispersion, a step of freezing the dispersion and drying it in its frozen state under reduced pressure, and a step of firing the dried product obtained by the drying.
    Type: Grant
    Filed: March 27, 2002
    Date of Patent: November 2, 2004
    Assignee: Asahi Glass Company, Limited
    Inventors: Yoshihisa Beppu, Shinji Kondoh
  • Patent number: 6808663
    Abstract: There is a method of manufacturing a ceramic structure in which a ceramics raw material, a prefoamed resin foam, and a forming aid if needed are mixed together to prepare a mixture, then the mixture is formed into a formed body, and subsequently the formed body is fired to obtain a porous ceramic structure. According to the manufacturing method, a ceramic structure having a high porosity can be obtained, without using a large amount of flammable powder.
    Type: Grant
    Filed: October 16, 2002
    Date of Patent: October 26, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Noguchi, Hideaki Nishi, Hiroyuki Suenobu
  • Patent number: 6809139
    Abstract: A particulate sealant for forming plugs in selected cells of honeycomb structures and consisting essentially, by weight, of about 70 to 90% ceramic blend, the ceramic blend being raw ceramic materials selected to form a composition consisting essentially of in percent by weight about 12 to 16% MgO, about 33 to 38% Al2O3, and about 49 to 54% SiO2, which will form cordierite (2MgO.2Al2O3.5SiO2) on firing, and about 10 to 30% binder system comprising a thermoplastic polymer capable of forming a gel or a thermosetting resin.
    Type: Grant
    Filed: February 28, 2002
    Date of Patent: October 26, 2004
    Assignee: Corning Incorporated
    Inventors: Michelle D. Fabian, Shahid G. Lakhwani, Mia K. Roberts
  • Patent number: 6808656
    Abstract: A nuclear fuel sintered body is produced from a powder which contains at least one fissile heavy metal oxide. During the further treatment of the powder over the course of the process preceding the sintering operation, a dopant that contains at least 100 ppm of an iron oxide compound is added to the powder. The powder is a UO2-containing powder obtained from a dry-chemical conversion process, and if appropriate, a powder which contains further fissile heavy metal oxide (U3O8, PuO2, inter alia). As a result, the sintered body is provided with high plasticity combined, at the same time, with a large grain size. This advantageously reduces an interaction between the nuclear fuel sintered body and a fuel rod cladding tube during an operation of the reactor.
    Type: Grant
    Filed: March 27, 2002
    Date of Patent: October 26, 2004
    Assignee: Framatome ANP GmbH
    Inventors: Gerhard Gradel, Wolfgang Dörr
  • Publication number: 20040201119
    Abstract: 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 &mgr;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: Application
    Filed: March 18, 2004
    Publication date: October 14, 2004
    Inventors: Andreas Kuhstoss, Thomas Rothig, Peter Neumann
  • Patent number: 6803086
    Abstract: There are provided a porous honeycomb structure body capable of satisfying a pressure loss and isostatic strength which are mutually contradictory properties simultaneously and a method for manufacturing the same. In a porous honeycomb structure body having partition walls which contain cordierite as a primary crystal phase and have a porosity of 40 to 75% and an average pore diameter of 10 to 50 &mgr;m, porosity and an average pore diameter in a center portion of the structure body are made larger than porosity and an average pore diameter in a peripheral portion of the structure body.
    Type: Grant
    Filed: December 23, 2002
    Date of Patent: October 12, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Noguchi, Yukihisa Wada, Yumi Muroi
  • Patent number: 6797138
    Abstract: A gas sensor comprises a first electrode and a reference electrode with an electrolyte disposed therebetween, wherein the first electrode and said reference electrode are in ionic conmmunication, wherein the reference electrode has a surface on a side of the reference electrode opposite the electrolyte and the surface has a surface area. The gas sensor also comprises a reference gas channel in fluid communication with the reference electrode, wherein at least a portion of the surface of the reference electrode physically contacts at least a portion of the reference gas channel, and wherein the portion of the reference electrode in physical contact with the reference gas channel is less than about 90% of the surface area.
    Type: Grant
    Filed: August 14, 2002
    Date of Patent: September 28, 2004
    Assignee: Delphi Technologies, Inc.
    Inventors: Eric J. Detwiler, Jeffrey T. Coha, Da Yu Wang
  • Patent number: 6797206
    Abstract: Microporous hydrophobic inorganic membrane having an average pore size of less than 2 nm and a hydrophobicity index octane/water of at least 2 can be obtained by a process comprising hydrolyzing a metal alkoxide in the presence of a hydrocarbyl metal alkoxide having at least one non-hydrolyzable group in an organic solvent to produce a metal (hydr)oxide sol, and precipitating metal (hydr)oxide from said sol and drying the precipitate. In this process, at least 50% of the amount of hydrocarbyl metal alkoxide is introduced into the solvent after 20% of the hydrolysis period has lapsed.
    Type: Grant
    Filed: February 7, 2001
    Date of Patent: September 28, 2004
    Assignee: Stichting Energieonderzoek Centrum Nederland
    Inventors: Renate Marina De Vos, Hendrik Verweij, Benedictus Clemens Bonekamp, Petrus Paulus Antonius Catharina Pex
  • Patent number: 6783894
    Abstract: A process for producing a porous sintered positive electrode for a secondary battery. The steps include: (a) calcining a raw material containing a lithium compound under an oxidizing atmosphere to form calcined powders; (b) mixing the calcined powders with organic fibers or organic polymer particles to form a raw mixture; (c) forming the raw mixture into a raw electrode; and (d) heating the raw electrode to remove any organic fibers or any organic polymer particles.
    Type: Grant
    Filed: April 2, 2001
    Date of Patent: August 31, 2004
    Assignee: Kao Corporation
    Inventors: Yoshio Kajiura, Tetsuya Kusakabe, Nobuyuki Isshiki
  • Patent number: 6777114
    Abstract: It is directed to a silicon carbide-based porous body, wherein said body is a porous one which contains silicon carbide particles as an aggregate and metallic silicon, and has an oxygen-containing phase at the surfaces of silicon carbide particles and/or metallic silicon or in the vicinity of the surfaces thereof. The silicon carbide-based porous body contains refractory particles such as silicon carbide particles or the like and yet can be produced at a relatively low firing temperature at a low cost, has a high thermal conductivity, and is superior in oxidation resistance, acid resistance, chemical resistance to ash and particulates.
    Type: Grant
    Filed: August 13, 2002
    Date of Patent: August 17, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Takahiro Tomita, Shuichi Ichikawa, Shinji Kawasaki, Hiroaki Sakai
  • Patent number: 6773479
    Abstract: A particulate filter for diesel engines comprises a metal shell or casing inside which is set a filtering body made of ceramic foam. The filtering body is made up of a plurality of separate elements made of ceramic foam and having a substantially plane and elongated shape, which are set about a longitudinal axis of the shell in such a way as to define, inside the shell, an inner chamber (B) set inside the array of filtering elements and at least one outer chamber (A) set outside the array. The said chambers respectively communicate with the intake pipe and with the outlet pipe, or vice versa, in such a way that, during use, the flow of the engine exhaust gases that traverses the shell passing from the intake pipe to the outlet pipe (or vice versa) is forced to traverse the aforesaid filtering elements, thus assuming a component of radial velocity with respect to the longitudinal axis of the shell.
    Type: Grant
    Filed: January 18, 2002
    Date of Patent: August 10, 2004
    Assignee: C.R.F. Societa Consortile per Azioni
    Inventors: Massimo Debenedetti, Gianmarco Boretto
  • Patent number: 6773481
    Abstract: A porous honeycomb filter made from a material containing cordierite, of which pore distribution is controlled, as the primary crystalline phase. The pore distribution is such that the volume of a pore with a diameter of below 10 &mgr;m is 15% or less of the total pore volume, the volume of a pore with a diameter of 10 to 50 &mgr;m is 75% or more of the total pore volume, and the volume of a pore with a diameter of above 50 &mgr;m is 10% or less of the total pore volume. This porous honeycomb filter has a high collection efficiency for fine particles (particulates), or the like, and can prevent increase in pressure loss due to the plugging of pores, and particularly can exploit the characteristics thereof for diesel engines that use recent high-pressure fuel injection, common rails, etc.
    Type: Grant
    Filed: July 17, 2002
    Date of Patent: August 10, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasushi Noguchi, Hideaki Nishi, Hiroyuki Suenobu
  • Publication number: 20040148916
    Abstract: A cordierite ceramic body having (i) a pore size distribution and a porosity which satisfy the relationship 10.2474/[(d50)2(pore fraction)]+0.0366183(d90)−0.00040119(d90)2+0.468815(1/pore fraction)2+0.0297715(d50)+1.61 639(d50−d10)/d50≦3.65, and (ii) a CTE (25°-800° C.) of ≦15×10−7/° C., wherein the cordierite ceramic body is produced from a moldable mixture comprising cordierite-forming raw materials including (a) a fine talc having a median particle diameter, as measured by laser diffraction, of less than 10 micrometers, and a B.E.T. specific surface area of greater than 5 m2/g, and (b) a pore former. The cordierite ceramic body is suitable in the fabrication of cellular, wall-flow diesel particulate filters having a low pressure drop, high filtration efficiency and improved strength.
    Type: Application
    Filed: January 30, 2003
    Publication date: August 5, 2004
    Inventor: Gregory A. Merkel
  • Patent number: 6770111
    Abstract: A ceramic structure which is pollucite-based and has high refractoriness and high resistance to thermal shock. The inventive structure is suitable in high temperature applications such as a filtering particulates from diesel engine exhaust.
    Type: Grant
    Filed: October 25, 2001
    Date of Patent: August 3, 2004
    Assignee: Corning Incorporated
    Inventors: Robert Morena, Dell J. St. Julien, Bryan R. Wheaton, John F. Wight, Jr.
  • Publication number: 20040129371
    Abstract: 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: Application
    Filed: January 7, 2003
    Publication date: July 8, 2004
    Applicant: INTERNATIONAL BUSINESS MACHINES CORPORATION
    Inventors: Govindarajan Natarajan, Umar Ahmad, Raschid J. Bezama, James N. Humenik, John U. Knickerbocker, Rao V. Vallabhaneni
  • Patent number: 6759117
    Abstract: A multilayer ceramic composite is described which contains at least one supporting zone having oxidation-sensitive reinforcing fibers as well as a matrix. The matrix optionally contains oxidation-sensitive components. The composite further contains at least one surface layer, as well as at least one additional protective layer disposed between the supporting zone and surface layer, and whose matrix is composed substantially of at least one component of the matrix of the supporting zone or cover layer. The protective layer further contains additives that form self-healing layers.
    Type: Grant
    Filed: July 8, 2002
    Date of Patent: July 6, 2004
    Assignee: SGL Carbon AG
    Inventors: Moritz Bauer, Martin Christ, Udo Gruber, Michael Heine, Andreas Kienzle, Jens Rosenlöcher, Rainer Zimmermann-Chopin
  • Patent number: 6749656
    Abstract: The invention concerns a heating, ventilating and/or air conditioning device comprising at least an air distribution channel having a downstream end, and at least an air diffusing element arranged at said one downstream end. The invention is characterized in that the air diffusing element (1) comprises a support (11) provided with through orifices (17) and covered over at least one of its faces with a material (12, 16), having air resistance ranged between 10 N.s.m−3 and 180 N.s.m−3.
    Type: Grant
    Filed: February 10, 2003
    Date of Patent: June 15, 2004
    Assignees: Valeo Climatisation, Rieter Technologies A.G.
    Inventors: Carine Paumier, Pascale Petitjean, Didier Loup, Jean Casulli, Emmanuel Reymond, Marc Saget, Jean Philippe Thome
  • Patent number: 6746748
    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.
    Type: Grant
    Filed: August 12, 2002
    Date of Patent: June 8, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
  • Patent number: 6723425
    Abstract: A thermally conductive molded article is produced by molding a conductive composition into a predetermined shape. The composition includes a polymer matrix and carbon powders. The carbon powders are obtained by graphitizing a polymeric material that has an aromatic ring on its main chain by heating. The carbon powders are aligned in a certain direction in the polymer matrix. Thus, the molded article can be produced easily and effectively that has excellent thermal conductivity in a given direction and that is suitable for use as a heat radiator, heat transfer member, or a component thereof in electronic hardware.
    Type: Grant
    Filed: June 4, 2002
    Date of Patent: April 20, 2004
    Assignee: Polymatech Co., Ltd.
    Inventors: Masayuki Tobita, Naoyuki Shimoyama, Shinya Tateda
  • Patent number: 6716378
    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.
    Type: Grant
    Filed: May 14, 2002
    Date of Patent: April 6, 2004
    Assignee: The Regents of the University of California
    Inventors: Peidong Yang, Tao Deng, George M. Whitesides, Galen Stucky, Dongyaun Zhao, Bradley Chmelka, David Pine, Pingyun Feng
  • Patent number: 6716512
    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.
    Type: Grant
    Filed: September 14, 2001
    Date of Patent: April 6, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Yoshinori Yamamoto, Naomi Noda, Takashi Harada
  • Publication number: 20040021240
    Abstract: A method of producing a green form for use in manufacturing a composite, ceramic ion transport membrane is provided in which first and second ceramic powder mixtures are used to produce first and second layers of the green form. The first and second ceramic powder mixtures have ceramic particles and a pore former. After formation of each of the first and second layers or after formation of the second layer, heat is applied to burn out the binder and form pores. This heating is completed prior to application of a dense layer to prevent production of defects within the dense layer. The dense layer contains an ion transport material. Defects are also prevented by grading particle size from the first layer to the dense layer. This allows the second intermediate layer to fill in larger pores of the first layer and to present a smooth surface to the dense layer. Additionally, the second ceramic powder mixture contains in part material used in forming the dense layer for thermal expansion compatibility purposes.
    Type: Application
    Filed: July 31, 2002
    Publication date: February 5, 2004
    Inventors: Hancun Chen, Jack C. Chen, Weitung Wang
  • Patent number: 6680013
    Abstract: The present application discloses a method of forming an inorganic macroporous material. In some embodiments, the method includes: providing a sample of organic polymer particles having a particle size distribution of no greater than about 10%; forming a colloidal crystal template of the sample of organic polymer particles, the colloidal crystal template including a plurality of organic polymer particles and interstitial spaces therebetween; adding an inorganic precursor composition including a noncolloidal inorganic precursor to the colloidal crystal template such that the precursor composition permeates the interstitial spaces between the organic polymer particles; converting the noncolloidal inorganic precursor to a hardened inorganic framework; and removing the colloidal crystal template from the hardened inorganic framework to form a macroporous material. Inorganic macroporous materials are also disclosed.
    Type: Grant
    Filed: April 15, 2000
    Date of Patent: January 20, 2004
    Assignee: Regents of the University of Minnesota
    Inventors: Andreas Stein, Brian T. Holland, Christopher F. Blanford, Hongwei Yan
  • Patent number: 6663776
    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.
    Type: Grant
    Filed: September 27, 2002
    Date of Patent: December 16, 2003
    Assignee: Selee Corporation
    Inventors: William Isaac Hoffman, Rudolph A. Olson, III
  • Patent number: 6632849
    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.
    Type: Grant
    Filed: May 25, 2000
    Date of Patent: October 14, 2003
    Assignee: UBE Industries, Ltd.
    Inventors: Shigeru Yao, Shyusei Ohya, Yukihiko Asano
  • Publication number: 20030171822
    Abstract: A process for preparing artificial bone is described which comprises: (i) preparing a mixture of a finely divided bio-compatible ceramic powder, an organic binder and a pore-forming agent in an inert liquid to form a body and causing at least some of the pore-forming agent to align along a common axis; (ii) optionally shaping the resulting body; (iii) allowing the pore-forming agent to form a porous structure in the body; (iv) heating the shaped body to a temperature sufficient to fix the porous structure and; (v) further heating the body to eliminate residues of organic binder and pore-forming agent and to fuse it.
    Type: Application
    Filed: May 9, 2003
    Publication date: September 11, 2003
    Inventor: Wei Jen Lo
  • Patent number: 6616873
    Abstract: Process for making thermally stable macro porous spheres with or without central core cavity includes steps of homogenizing dry pulverized selective constituents with or without burnable core particles and with <25% combustibles; sprinkling over pan pelletizer wetted with PVA aqua sol binder and rolling to form spheres having <25% moisture and dry compacting in pelletizer before oven drying at 90-100° C. until moisture and core particles are partially destroyed and sintering under rotary motion of the spheres for 45-60 minutes at 1350-1380° C. before being rapidly cooled down to ambient temperature and sieving and recovering therefrom low-to-high temperatures >90% loose fill macro porous spheres for catalyst and moulded bricks/monoliths forming refractory insulation applications.
    Type: Grant
    Filed: August 1, 2001
    Date of Patent: September 9, 2003
    Assignee: Associated Cement Companies Ltd.
    Inventors: Venkateswaran Duraiswami, Vajifdar Parvez, Cursetji Rustom Minocher, Chatterjee Anjan Kumar
  • Patent number: 6613255
    Abstract: A method of making a permeable fiber-reinforced ceramic body comprising mixing an organic particulate with silica fiber, alumina fiber, alumina borosilicate fiber, a dispersant, and water to produce a slurry of fibrous ceramic material. The slurry is then placed within a mold and vaccuum pressure is applied thereto to substantially remove the water to form a fibrous ceramic body. The fibrous ceramic body is then dried and sintered to a temperature sufficient to bond the ceramic material together to form a porous ceramic article. Simultaneously, the fibrous ceramic body is heated to a temperature sufficient to generally burn off the organic particulate to create voids interconnecting the pores to form a permeable fiber reinforced porous ceramic article.
    Type: Grant
    Filed: April 13, 2001
    Date of Patent: September 2, 2003
    Assignee: The Boeing Company
    Inventor: Robert A. DiChiara, Jr.
  • Publication number: 20030151155
    Abstract: There is here disclosed 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.
    Type: Application
    Filed: December 30, 2002
    Publication date: August 14, 2003
    Applicant: NGK Insulators, Ltd.
    Inventors: Yumi Muroi, Yukihisa Wada, Yasushi Noguchi
  • Patent number: 6605648
    Abstract: 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: Grant
    Filed: April 6, 1999
    Date of Patent: August 12, 2003
    Assignee: Phillips Plastics Corporation
    Inventors: James R. Johnson, Michael Edward Frencl
  • Publication number: 20030137071
    Abstract: There is a method of manufacturing a ceramic structure in which a ceramics raw material, a prefoamed resin foam, and a forming aid if needed are mixed together to prepare a mixture, then the mixture is formed into a formed body, and subsequently the formed body is fired to obtain a porous ceramic structure. According to the manufacturing method, a ceramic structure having a high porosity can be obtained, without using a large amount of flammable powder.
    Type: Application
    Filed: October 16, 2002
    Publication date: July 24, 2003
    Inventors: Yasushi Noguchi, Hideaki Nishi, Hiroyuki Suenobu
  • Publication number: 20030134735
    Abstract: The invention relates to a method for producing porous inorganic solids on the basis of an aqueous dispersion of particles that are composed of a polymer and finely divided inorganic solids.
    Type: Application
    Filed: November 8, 2002
    Publication date: July 17, 2003
    Inventors: Zhijian Xue, Harm Wiese
  • Patent number: 6592787
    Abstract: An improved porous article and a method for forming such porous article are provided. A mixture of ceramic or metal particles and pliable organic hollow spheres is prepared in a liquid, typically as a suspension. The article is formed by pressing, slip casting, extruding or injection molding the mixture. The article is dried to remove the liquid, and then is fired so that the particles are bonded such as by sintering, and the organic spheres are eliminated, resulting in a strong porous article having uniformly spaced interconnected voids.
    Type: Grant
    Filed: March 7, 2001
    Date of Patent: July 15, 2003
    Assignee: Porvair Corporation
    Inventors: Gary R. Pickrell, Kenneth R. Butcher, Chi Li Lin
  • Patent number: 6589457
    Abstract: An organic solvent-free process for deposition of metal oxide thin films is presented. The process includes aqueous solutions of necessary metal precursors and an aqueous solution of a water-soluble polymer. After a coating operation, the resultant coating is fired at high temperatures to yield optical quality metal oxide thin films.
    Type: Grant
    Filed: July 31, 2000
    Date of Patent: July 8, 2003
    Assignee: The Regents of the University of California
    Inventors: DeQuan Li, Quanxi Jia
  • Patent number: 6576173
    Abstract: An improved method for manufacturing a porcelain object in a desired shape, from a mixture of at least clay, feldspar and quartz. According to the method, an aqueous dispersion of vinyl acetate and ethylene based copolymer is added to the mixture, and the mixture transformed into an aqueous mass in the shape of a foil with a thickness of 50 &mgr;m to 3 mm and dried. The dried foil is then formed into a desired object shape, and permanently hardened by a ceramic firing process. The dried foil may be brought into the desired object shape by known processes such as rolling, laminating, calendering, cutting, punching, paper folding methods and deep drawing. Once brought into the desired object shape, no drying is required before ceramic firing.
    Type: Grant
    Filed: August 22, 2000
    Date of Patent: June 10, 2003
    Inventors: Franz Koppe, Gerald Weber
  • Patent number: 6569797
    Abstract: An improved method for preparing low density ceramics is described wherein the process incorporates paper residuals which are a by-product of the paper recycling process. The method for making a low density-ceramic comprises the steps of: a) providing a paper residual comprising from about 0.5 to about 99 percent, by weight, of at least one filler, from about 0 to about 20 percent, by weight, of a dye, from about 0 to about 10 percent, by weight, of an ink, from about 0.5 to about 99.5 percent, by weight, of paper fiber, and from about 0 to about 30 percent, by weight, of other components, based on a dry weight of the residual; b) admixing a ceramic material with the paper residual, the ceramic material comprising up to about 90%, by weight, of the admixture, based on a dry weight of the admixture; c) forming the admixture into a desired shape; and d) firing the admixture to a temperature ranging from about 1850° F. to about 2900° F.
    Type: Grant
    Filed: November 17, 2000
    Date of Patent: May 27, 2003
    Assignee: Clemson University
    Inventor: Denis A. Brosnan
  • Publication number: 20030094716
    Abstract: A process for forming a silicon carbide structure includes molding by compression a mixture of a silicon precursor powder and a cross-linking thermoset resin to form a rigid structure, carbonizing the rigid structure, and forming a silicon carbide structure by heating the carbonized rigid structure at a temperature sufficient to allow carbon and silicon in the structure to react to form silicon carbide.
    Type: Application
    Filed: November 20, 2001
    Publication date: May 22, 2003
    Inventors: Kishor P. Gadkaree, Joseph F. Mach
  • Patent number: 6555032
    Abstract: A process for forming a porous silicon nitride-silicon carbide body, the process comprising (a) forming a plasticizable batch mixture comprising (1) powdered silicon metal; (2) a silicon-containing source selected from the group consisting of silicon carbide, silicon nitride and mixtures thereof; (3) a water soluble crosslinking thermoset resin having a viscosity of about 50-300 centipoise; and, (4) a water soluble thermoplastic temporary binder; (b) shaping the plasticizable batch mixture to form a green body; (c) drying the green body; (d) firing the green body in nitrogen at a temperature of 1400° C. to 1600° C. for a time sufficient to obtain a silicon nitride-silicon carbide structure.
    Type: Grant
    Filed: July 2, 2002
    Date of Patent: April 29, 2003
    Assignee: Corning Incorporated
    Inventor: Kishor P. Gadkaree
  • Patent number: 6547967
    Abstract: The present invention relates to the field of ceramics and to a ceramic network which can, for example, be applied as a deep-bed filter and a method for the production and utilization thereof. The present invention provides a ceramic network in which the mechanical stability is improved and/or an application-dependent structure can be specifically adjusted. To this end, a ceramic network is provided which comprises two or three dimensional ceramic struts that are connected to one another. The cavities in the ceramic struts have a cross-sectional area with a circular or approximately circular or extensively circular or a convex or multiply convex contour. In addition, a method is provided in which a fiber network is produced. The fiber network comprises polymer fibers and/or natural fibers and/or other fibers, with the fibers each having cross-sectional area with a circular or approximately circular or extensively circular or a convex or multiply convex contour.
    Type: Grant
    Filed: May 31, 2000
    Date of Patent: April 15, 2003
    Assignee: Franhofer-Gesellschaft zur Forderung der Angewandten Forschung E.V.
    Inventors: Jörg Adler, Heike Heymer, Gisela Standke
  • Patent number: 6549340
    Abstract: The invention relates to a focusing device comprising a Luneberg lens comprising a homogeneous volume of dielectric. It is characterized in that the dielectric comprises a granular agglomerate defined by a homogeneous granule size distribution of thermoplastic granules, at least one plurality of these granules being welded together by granule boundaries in order to keep said volume consolidated. Particular application to lenses for the tracking of nongeostationary satellites, of at least one geostationary satellite, or for use in an MMDS system.
    Type: Grant
    Filed: August 22, 2001
    Date of Patent: April 15, 2003
    Assignee: Thomson Licensing S.A.
    Inventors: Patrice Hirtzlin, Christian Yves Allaire, Ali Louzir, Luc Pagnier
  • Patent number: 6540972
    Abstract: A graphite having geometrically shaped holes limited to the top atomic layer such as circles, polygons and combinations thereof, and a method of preparing a graphite having geometrically shaped holes such as circles, polygons and combinations thereof where the geometrically shaped holes are limited to the top atomic layer.
    Type: Grant
    Filed: November 3, 1999
    Date of Patent: April 1, 2003
    Assignee: NEC Corporation
    Inventor: Hidefumi Hiura
  • Publication number: 20030052428
    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.
    Type: Application
    Filed: July 1, 2002
    Publication date: March 20, 2003
    Applicant: Toshiba Ceramics Co., Ltd.
    Inventors: Hideo Uemoto, Kazuhide Kawai, Shunzo Shimai, Takashi Matsuyama
  • Patent number: 4776729
    Abstract: Truss systems and components thereof for use in connection with supporting rock formations in underground mines, caverns, storage vaults, and so forth. Multiple types of truss brackets of unique design are incorporated in the various systems which also include tensioning tie rods and anchor bolts. The truss bracket components are designed so that a minimum or no force couples are exhibited when the tie rods employed are tightened down in their interconnection between associated truss brackets. Various truss systems accommodate mine entries, two-way, three-way, and four-way passageway configurements, and so forth. Additionally, provision is made for intercoupling trusses together.
    Type: Grant
    Filed: February 27, 1987
    Date of Patent: October 11, 1988
    Inventor: Ben L. Seegmiller