Abstract: A process for preparing a silicon carbide foam by impregnating a polyurethane foam with a suspension of silicon powder in an organic resin, heating progressively to polymerize the resin, heating further to carbonize the polyurethane foam and resin, and finally further heating to carburize the silicon contained in the resin suspension by means of carbon obtained from the carbonization of the foam and resin. The foam obtained is characterized by high macroporosity and a mesoporosity which is variable according to the carburizing temperature.

Abstract: Porous monolithic ceramic bodies containing reticulated macropores are produced by:a) forming a mixture of ceramic material particles, a first organic material and a second organic material,b) dissolving the first and second organic materials in each other to form a homogeneous solution, whereby the ceramic particles form a dispersion in the homogenous solution,c) forming the dispersion into a shape,d) cooling the shape at a rate sufficient to induce the non-equilibrium phase separation, thereby forming a first phase rich in the first organic material and a second phase rich in the second organic material, wherein at least a portion of the ceramic particles are segregated in the first phase,e) removing the second phase from the phase separated shape to form a porous shape,f) firing the porous shape to remove the any of the organic materials contained in the first phase and to sinter the segregated ceramic particles to form the porous monolithic ceramic body.

Abstract: A heat treatment method is disclosed for improving the strength and the toughness of particle reinforced alumina composite. A densified alumina composite is heated to a temperature of higher than 600.degree. C., maintained at that temperature for about 0.5-150 hours, and then the temperature is lowered to room temperature. As a result, the flexure strength and the fracture tougnness of the particle reinforced alumina composite are substantially increased after the heat treatment in comparison to those without heat treatment.

Abstract: A microencapsulation process in which a solid or liquid core material is dispersed in a protein slurry, is heated to create a protein melt and then denatured to bring about encapsulation of the core material and the product of that process.

Abstract: A method of forming a substrate for electronic devices by forming a mixture of a liquid vehicle, crystalline glass powder and carbon powder into a slurry. The slurry is then formed into a desired shape and heated in an oxidizing atmosphere at a temperature less than 900.degree. C. for a time sufficient to oxidize the carbon powder and partially sinter the crystalline glass to form the porous substrate having closed porosity.

Abstract: Silicon carbide sintered bodies having controlled porosity in the range of about 2 to 12 vol %. in which the pores are generally spherical and about 50 to 500 microns in diameter, are prepared from raw batches containing a polymer fugitive. Sintered bodies in the form of mechanical seal members exhibit lower power consumption at low PV and, in addition, lower wear rates at high PV in comparison to commercially available silicon carbide seal members.

Abstract: A process for making a structural member wherein bead members are mixed with a selected material and the mixture is compressed and molded into a shape. The compressed mixture is then heated and the bead members removed by melting. The remaining structure, having been thus formed with a plurality of cells therein where the bead members had been removed, can in some embodiments be further heated to a point sufficient to form a strong, lightweight useful structural member, retaining such plurality of cells therein and creating a substantially solid, structural foam member.

Abstract: A process is described for manufacturing a carbon particle filter having a plurality of channels which extend in the exhaust gas flow direction and which are alternatingly sealed at the upstream and downstream end of a porous ceramic material. To minimize the time required for producing the channels, a slip-like ceramic starting material is applied to a fabric having longitudinal threads corresponding to the size location and position of the channels and extending at least in the longitudinal direction of the filter. The carbon filter body is then formed by layering the coated fabric and thereafter in the course of the ceramic firing of the carbon filter body, its inlet and outlet channels are formed by burning away the longitudinal threads.

Abstract: A bio-injectable drug composition which provides long term drug release. The drug composition is made up of a pharmaceutically active agent in a biodegradable polymer matrix, where the polymer matrix is a solid at temperatures in the range 20.degree. to 37.degree. C. and is flowable at temperatures in the range 38.degree. to 52.degree. C.

Abstract: Ceramic beads having a bimodal pore distribution are prepared by a process involving a) formation of a ceramic particle slurry, b) adding a foamable prepolymer to the slurry to form a mixture, c) dispersing the mixture as beads in a second liquid, d) polymerizing and foaming the prepolymer, e) recovering the beads and firing them to remove the polymer and bond the ceramic particles. The beads can optionally be joined by sintering. Beads with a monodal pore distribution can be made by using a non-foaming prepolymer.

Abstract: A process for manufacturing a porous Si.sub.3 N.sub.4 ceramic filter, wherein silicon powder, the raw material, methyl cellulose, the binding agent, and water, the solvent, are well-mixed together to obtain a slurry. A sponge is then dipped into the slurry to adsorb the slurry. After drying the sponge in an oven, it is biscuit fired at 350.degree. C. for 2 hours, and then sintered at 1200-1400.degree. C. for 15 hours.

Abstract: Improved fiber reinforced composites having near zero coefficients of thermal expansion are described. The improved composites include reinforcing fibers and matrix material in which gap structures which exist within the composite are filled with a bonding agent. The reinforcing fibers can be unidirectionally, bidirectionally or multidirectionally oriented within the matrix material and articles fabricated from the improved composite have reduced coefficients of thermal expansion in directions transverse to the orientations of the fibers. This improvement makes these improved composites useful for fabricating high energy laser mirror substrates.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Specifically, in a particularly preferred embodiment for making metal matrix composite bodies by a spontaneous infiltration technique, an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are in communication with a rigidized filler material or a rigidized preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the rigidized filler material or riigidized preform. A structural refractory material which holds the preform is made by forming a first precursor to the supportive structural refractory material and subsequently causing the precursor to become a rigid supportive structural member. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.

Abstract: The present invention relates to a novel process for removal of at least a portion of at least one metallic component of a metallic constituent from a multi-phase composite body. Particularly, by providing at least one of an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere to be in communication with a permeable mass, which contacts at least a portion of a composite body, said metallic component of the composite body, when made molten, is caused to spontaneously infiltrate the permeable mass. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. The metallic constituent is essentially leached or removed from the multi-phase body by spontaneous infiltration.

Abstract: A fiber-organic composition includes from about 5% to 50% by volume of uniformly dispersed, non-planar or three dimensionally random oriented inorganic fibers or whiskers, and a thermoplastic material such as paraffin wax. The composition also includes surfactants to promote wetting and dispersion of the inorganic fibers or whiskers. These materials are subjected to high shear mixing to form a uniform randomly oriented three-dimensional dispersion of the inorganic fibers or whiskers. After molding the mixture in such a manner so as not to disrupt the uniform, three-dimensional orientation of the fibers or whiskers, a majority of the thermoplastic material is removed leaving a shaped body or preform having sufficient strength for handling. The shaped body or preform can then be infiltrated with molten metal or the like to form a metal matrix composite.

Abstract: A seamless capsule comprising a content and a film for coating said content is disclosed. The content is a hydrophilic substance. A viscous liquid having a viscosity of not more than 1000 cp at 100.degree. C. which is scarcely miscible with water is present between the content and the film. There is also disclosed a process for producing a seamless capsule which comprises simultaneously extruding a film solution for the seamless capsule, a hydrophilic substance solution and a viscous liquid which is scarcely miscible with water into a cooling solution from a concentrically arranged multiple nozzle composed of at least three nozzles, an outermost nozzle, an innermost nozzle and at least one intermediate nozzle placed in the middle position between the above nozzles, respectively, the diameter of said nozzle gradually increasing in that order.

Abstract: A ceramic filter is prepared by mixing together a ceramic powder, a pore forming agent, and any sintering aids required in the sintering of the ceramic powder, forming a tape from the mixture, and molding filter plates from the tape. Two types of annular disk filter plates are formed. A first plate type has an opening on the external annular surface, and a second plate type has an opening on the internal annular surface. The two types of filter plates are stacked in an alternating fashion, and end pieces are added to form a filter assembly. The assembly is sintered to form a filter. The pore forming agent is preferably polystyrene microspheres that are decomposed during the sintering process, leaving porosity that effectively captures particulate impurities when a fluid is passed through the filter in service.

Abstract: Composites of ceramic and metal exhibiting high fracture strength and toughness are formed from layers of the ceramic that have unequal concentrations and unequal porosity. The composites are made by a process that involves arranging layers of the ceramic in a predetermined pattern to provide a body that can be fully infiltrated by the metal.

Abstract: A process for preparing a porous ceramic material, is disclosed. The process uses an organic sponge material, and a ceramic slurry. The ceramic slurry contains liquid, gluten, and ceramic material.In the first step of the process, the ceramic slurry is applied to the sponge in order to substantially saturate it with slurry. Thereafter, the saturated sponge is dehydrated until it contains less than about 5.0 weight percent of liquid. The dehydrated sponge is then fired at a temperature of from about 1,100 to about 3,500 degrees Fahrenheit.

Abstract: A process for preparing a hollow, porous ceramic material is provided. In the first step of the process, a substrate which will burn out (vaporize) at a temperature of 1,100 degrees Fahrenheit (and which, preferably, is carbonaceous) is provided. This substrate is coated with a mixture of gluten, ceramic material, and water. The coated substrate is then dried to a moisture content of less than about 0.5 weight percent and, thereafter, heated to a temperature of from about 1,100 to about 3,200 degrees Fahrenheit to cause the substrate to burn out and the coating to sinter.

Abstract: The preparation of porous ceramic bodies by sintering certain curable organopolysiloxanes filled with silicon carbide powders. This process is advantageous in that the green bodies have relative high strengths and thus can be easily handled and, if desired, machined before sintering.

Abstract: Techniques are described for treatment of ash and paper to eliminate them from the environment and to produce ceramic particles useful as light-weight aggregate (e.g., for use in concrete products). The ash may be that resulting from incineration of rubbish or sewage sludge or it may be fly ash from power plants. The ash and waste paper are mixed with clay and water, shaped into desired shapes and sizes, after which the particles are fired to produce ceramic particles which are lighter in weight than natural aggregates.

Abstract: The invention relates to a method of preparing sintered shapes, comprising the steps of forming a green body from a mixture comprising (A) a major amount of at least one inorganic powder with (B) at least one reaction product of an amine other than an alkanolamine with a hydrocarbyl-substituted carboxylic acylating agent or alkylalkyleneglycolacetic acylating agent; provided the reaction product is other than an alkylene oxide treated fatty monocarboxylic amide and provided that when the hydrocarbyl-substituted carboxylic acylating agent is a nonaromatic acylating agent, then the hydrocarbyl group is other than hydrocarbyl groups having an average of about 55 to about 110 carbon atoms; and sintering the body. Sintered shapes made from the methods of the present invention have relatively high fired densities and small uniform grain sizes; and low porosity. The reaction products of the present invention help disperse the inorganic powder.

Abstract: A method of producing a self-supporting air electrode for a solid electrolyte fuel cell, including the steps of mixing lanthanum or a lanthanum compound, manganese or a manganese compound, and metal A or a compound thereof into a mixture, wherein A is selected from the group consisting of Sr, Ca, Mg, Y, Ce, Yb, Zn and Ba and pre-firing the mixture at a temperature of at least 1400.degree. C. to yield a synthesized product of La.sub.1-x A.sub.x MnO.sub.3 wherein 0<x .ltoreq.0.5 and forming the synthesized product into a green body and firing the green body to form a self-supporting air electrode body consisting of La.sub.1-x A.sub.x MnO.sub.3.

Abstract: A method of producing a hydroxylapatite base porous beads filler for an organism, including mixing hydroxylapatite powder having particle sizes not larger than 125 .mu.m, in an amount ranging from 40 to 90% by weight, synthetic resin powder having particle sizes not larger than 74 .mu.m, in an amount ranging from 5 to 55% by weight, and resinous binder in an amount ranging from 0.5 to 5% by weight to obtain a mixture, granulating the mixture to form beads each having a diameter ranging from 0.03 to 25 mm, firing the beads at a temperature ranging from 900.degree. C. to 1180.degree. C. to form hydroxylapatite base porous beads, dipping the porous beads in a colloidal solution, removing air from the porous beads under vacuum, and filling the colloidal solution into the pores in the porous beads under pressure.

Abstract: A body is made up of at least about 93% by weight cordierite, having a coefficient of thermal expansion of no greater than about 4.times.10.sup.-7 .degree.C.sup.-1, from about 25.degree. C. to about 800.degree.0 C., and a total porosity of greater than about 42%. A method for producing the body which includes selecting raw materials to form a composition which forms cordierite on firing, the raw materials being composed of: talc having a BET surface area of no greater than about 5 m.sup.

Abstract: Solid lipid microspheres having a diameter lower than one micron and a polydispersion of between 0.06 and 0.90 obtained by adding to a molten lipid substance a mixture consisting of water, a surfactant and possibly a co-surfactant, dispersing in water the obtained microemulsion, washing with water the dispersion microspheres by diafiltration and lyophilizing.

Abstract: This invention relates to an improved thermite coated molten metal filter. According to the invention, a molten metal filter is coated with an aqueous thermite coating slurry containing oleic acid, water-miscible surfactants, water-soluble binders, and water-soluble dispersants.

Abstract: This invention relates generally to a novel method for removing metal from a formed self-supporting body. A self-supporting body is made by reactively infiltrating a molten parent metal into a bed or mass containing a boron source material and a carbon source material (e.g., boron carbide) and/or a boron source material and a nitrogen source material (e.g., boron nitride) and, optionally, one or more inert fillers. Once the self-supporting body is formed, it is then placed, at least partially, into contact with another material which causes metallic constituent contained in the self-supporting body to be at least partially removed.

Abstract: There is provided a thermal shock-resistant silicon nitride sintered material including silicon nitride and rare earth element compounds, which material contains at least 10 pore groups per mm.sup.2, each pore group consisting of pores of 10 or less in diameter and which material has a thermal shock resistance .DELTA.Tc (.degree.C.) of 1,000.degree. C. or more. The thermal shock-resistant silicon nitride sintered material can be produced by mixing and shaping starting materials consisting of silicon nitride powders of rare earth element oxides and carbide powder, and then firing the shaped material in a nitrogen atmosphere to decompose the carbide powders.

Abstract: A local anesthetic microsuspension system is disclosed that includes lipospheres, that are solid, water-insoluble microparticles that have a layer of a phospholipid embedded on their surface. The core of the liposphere is a solid anesthetic such as lidocaine or marcaine, or an anesthetic dispersed in an inert solid vehicle, such as a wax. Anesthetic lipospheres provide a controlled delivery of local anesthetics to achieve extended, effective relief from pain by slowly releasing the anesthetic from the solid hydrophobic core. This is highly preferred over the situation in which an aqueous solution of local anesthetic must be frequently administered because it is quickly systemically absorbed.

Abstract: A method of manufacturing a conductive porous ceramic tube including the steps of mixing a powder of La or a La compound, Mn or a Mn compound and Sr or a Sr compound; firing the resulting mixture at a temperature of 1000.degree.-1400.degree. C. and synthesizing the compound of La.sub.1-x Sr.sub.x MnO.sub.3 (where 0<x.ltoreq.0.5); grinding the compound of La.sub.1-x Sr.sub.x MnO.sub.3 to form a powder of 2 to 10 .mu.m in a mean particle diameter; kneading 100 parts by weight of the powder with the addition of an organic binder, water and 1 to 8 parts by weight of a pore-forming agent; forming the kneaded material into a molded tube; drying the molded tube and thereafter firing the molded tube; at a temperature of 1300.degree.-1600.degree. C.

Abstract: A grinding tool is described which comprises self-bonded particles of a ceramic abrasive and has a voids volume of from 5 to 65%.

Abstract: A method of forming an activated carbon or graphite structure is provided by (1) forming, such as extrusion, of a plasticized mixture of: binder selected from cellulose ether and derivative thereof, starch, and mixture thereof; furfuryl alcohol and/or polyfurfuryl alcohol; and carbon, graphite, or a carbon-containing material; and (2) subjecting the formed mixture to a carbon-forming pyrolysis step. The use of furfuryl alcohol allows extrusion at ambient temperatures and provides a "reactive" solvent that provides carbon upon pyrolysis.

Abstract: A soft capsule composed of a plurality of cells coalesced to each other and filling substances encapsulated in the individual cells, the wall of at least one of the cells being formed of a material different from a material forming the wall of at least one of the other cells, and said capsule being seamless.

Abstract: Microcapsules having a solid, fusible shell and a multiplicity of liquid cores. The microcapsules can be made by spray-cooling a water-in-oil type emulsion. The microcapsules, in aggregate, are a dry, free-flowing powder, and can be heated or otherwise processed to release their contents. The microcapsules can be used in food and non-food applications. The core can be any liquid, preferably aqueous, which does not readily dissolve or disperse the shell.

Abstract: After softgels are encapsulated and dried in a drying tunnel, the resulting softgels are subjected to a further stress relieving step. During the stress relieving step, the temperature and humidity conditions in the drying tunnel are heightened. By utilizing the stress relieving step, the volume and number of dimples and bubbles in the softgels are reduced, and dimensional uniformity is maximized.

Abstract: A gas-permeable form tool for manufacturing casting and core moulds from hardenable moulding sand includes a heteroporous, open-pore material. The wall of the tool contains a first fine-pore layer region adjacent to the moulding sand with a thickness of about 0.2-2 mm and a material density of about 75% to 95% of theoretical specific density and a pore diameter of about 50 .mu.m. The first fine-pore layer comes in contact with a second, large-pore supporting skeleton having a theoretical material density of less than 80% of theoretical specific density and a median pore diameter of more than 100 .mu.m.

Abstract: A method of producing a porous ceramic filter, using a cordierite precursor or starting composition including a talc powder component and a silica powder component, such that particles of the talc powder component and the silica powder component whose size is not less than 150 .mu.m constitute not more than 3% by weight of the starting composition, while particles of the talc and silica powder components whose size is not more than 45 .mu.m constitute not more than 25% by weight of the starting composition. A green body for the porous ceramic honeycomb filter formed of this starting composition is fired to react the starting composition to form cordierite and produce the desired porous ceramic honeycomb filter.

Abstract: Porous ceramic articles are made by a method that allows the formed green body to be dried in a dielectric oven without arcing or shorting occurring while maintaining favorable physical properties. The method includes adding water insoluble cellulose and graphite to the ceramic-forming precursors as a burnout material. The method is particularly useful in forming porous cordierite articles that are extruded to form a honeycomb structure conventionally used as a particulate filter for the exhaust fluids of diesel engines. Such articles have a matrix of thin walls forming a multiplicity of open-ended cells extending from one end to another end of the honeycomb. The thin walls have a substantially smaller coefficient of thermal expansion in the direction parallel to the axes of the open-ended cells than in the direction transverse to the thin walls.

Abstract: A process of producing a honeycomb-structural body capable of preventing abrupt heat generation of molding aids and a pore-forming agent by increasing or decreasing the oxygen concentration in the firing atmosphere for the temperature region wherein the pore-forming agent and the molding aids hardly thermally decompose or easily thermally decompose, respectively; or promoting the firing by controlling the oxygen content in the firing atmosphere to be increased for the temperature region wherein the pore-forming agent and the molding aids are hardly burning, so as to reduce the temperature difference existing between the interior or exterior of honeycomb-structural body during firing, thereby to perform an optimal firing in a good condition to attain an uniformity of the specific properties in the interior and the exterior of such a honeycomb structural body by reducing the temperature difference of the same.

Abstract: A porous low density inorganic oxide fibre of improved strength and flexibility has at least 25% of the porosity provided by axially aligned pores. The fibres are produced by spinning into fibres a spinning solution in which is incorporated a non-ionic surface active agent having a cloud point in the solution above the fibre spinning temperature and less than 20.degree. C. above the fibre spinning temperature, preferably within the range of 5.degree.-15.degree. C. above the fibre spinning temperature. The fibre may be an alumina fibre which can be free from silica and is useful as reinforcement in MMCs.

Abstract: In the method of forming a ceramic body, such as for use as a packing body, a dried array of corrugated layers containing ceramic material is first obtained in a green state. Thereafter, the array is cut, for example using a saw, into a desired shape and, thereafter, fired at a firing temperature sufficient to form the array into a one piece ceramic body. The body may initially be cast in a mold which can be cut to shape prior to the final firing step. Alternatively, individual layers of glass fiber material may be coated with ceramic material and dried into the green state prior to cutting and firing.

Abstract: The present invention relates to processes to produce ceramic reinforced and ceramic-metal matrix composite articles. More specifically, the invention concerns the use of pressure filtration to infiltrate a reinforcing organic or inorganic network with ceramic particles. Centrifugation is also used to separate the liquid form the slurry. After heating the reinforced ceramic article is produced. Pressure filtration is also used to infiltrate an organic polymer or organic fiber network with ceramic particles. The solvent is removed carefully followed by intermediate heating to remove the organic network without deforming the preform shape. After densification, the preform is heated and contacted with molten metal (optionally) with pressure to infiltrate the open channel network. Upon cooling the ceramic metal matrix composite is obtained. The reinforced matrix articles are useful in high temperature and high stress applications, e.g.

Abstract: A method is described for manufacturing foamable metal bodies in which a ture (17) of a metal powder (15) and a gas-splitting propellent powder (16) is hot-compacted to a semifinished product (19) at a temperature at which the joining of the metal powder particles takes place primarily by diffusion and at a pressure which is sufficiently high to hinder the decomposition of the propellent in such fashion that the metal particles form a solid bond with one another and constitute a gas-tight seal for the gas particles of the propellant. The foamable metal body can also be produced by rolling. In addition, a use of the foamable metal body (19) thus produced for manufacturing a porous metal body (21) is proposed.

Abstract: A method is described for the production of a porous ceramic body and the subsequent infiltration of the body with a molten metal to produce an article having a reinforced metallic matrix. The article may be further worked by known techniques such as extrusion or forging, for example.

Abstract: A high temperature ceramic filter is produced from a composition containing efractory cement, aggregate, pore forming additives, and sintering agents. The pore forming additives are synthetic or organic powders or fibers which sublimate, melt, or otherwise disintegrate to produce in situ pores in the cement during the refractory treatment of a cast filter. The filters produced are permeable to high temperature gases commonly found in a coal furnace and can be used to collect particulate matter present in those gases.

Abstract: A process of producing a porous ceramic by mixing a ceramic powder, a polymerizable unsaturated compund, an emulsifying agent, and water with stirring to provide an inverted emulsion, radical-polymerizing or redox-polymerizing the polymerizable unsaturated compound in the inverted emulsion to cure the inverted emulsion, and, then, drying and firing the cured product thus obtained. The porous ceramics obtained by this invention are useful as filters, adsorbents, catalyst carriers, refractory heat insulating materials, sound absorbers and building materials.

Abstract: A porous ceramic honeycomb filter having a chemical composition consisting of, as main components, 42-56 wt % SiO.sub.2, 30-45 wt % Al.sub.2 O.sub.3, and 12-16 wt % MgO and containing cordierite as a main component of a crystalline phase. The porous ceramic honeycomb filter has a porosity of at least 40% and not greater than 55%. The volume of pores having a diameter not larger than 2 .mu.m in the filter is not larger than 0.015 cc/g to thereby improve the collecting time with low pressure loss and high collecting efficiency.

Abstract: The process for manufacturing an open pore foam body with three dimensional ceramic network, in particular as a filter for the treatment of hot gases or as a catalyst substrate, has as its starting material a block of open pore plastic foam. This is impregnated at least once with a ceramic suspension, freed of excess ceramic suspension and heated to a temperature below the melting point of the plastic, then finally burnt off at a temperature at which the ceramic sinters together. The plastic foam block of the prescribed outer dimensions is cooled down and machined to produce a Z-flow filter with high precision longitudinal channels.