Ceramic Containing Electrode, Or Coil, Electrode, Or Coil Having Ceramic Portion, Or Shaped Electrolyte Body Patents (Class 264/618)
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Patent number: 6527937Abstract: Methods to at least partially reduce a niobium oxide are described wherein the process includes heat treating the niobium oxide in the presence of a getter material and in an atmosphere which permits the transfer of oxygen atoms from the niobium oxide to the getter material, and for a sufficient time and at a sufficient temperature to form an oxygen reduced niobium oxide. Niobium oxides and/or suboxides are also described as well as capacitors containing anodes made from the niobium oxides and suboxides.Type: GrantFiled: February 19, 2002Date of Patent: March 4, 2003Assignee: Cabot CorporationInventor: James A. Fife
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Publication number: 20030030192Abstract: A BaTiO3-type semiconducting ceramic material which has undergone firing in a reducing atmosphere and re-oxidation, wherein the relative density of the ceramic material after sintering is about 85-90%. A process for producing the semiconducting ceramic material of the present invention and a thermistor containing the semiconducting ceramic material are also disclosed.Type: ApplicationFiled: September 18, 2002Publication date: February 13, 2003Applicant: Murata Manufacturing Co., Ltd.Inventors: Hideaki Niimi, Akira Ando, Mitsutoshi Kawamoto, Masahiro Kodama
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Publication number: 20030027027Abstract: The present invention relates to compositions of matter represented by the general formulaType: ApplicationFiled: April 27, 2001Publication date: February 6, 2003Inventors: Raymond Ashton Cutler, Robin Edward Richards
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Publication number: 20030027033Abstract: A method of making ceramic electrode materials comprising intimate mixtures of two or more components, including at least one nanoscale ionically conducting ceramic electrolyte material (e.g., yttrium-stabilized zirconia, gadolinium-doped ceria, samarium-doped ceria, etc.) and at least one powder of an electrode material, which may be an electrically conducting ceramic electrode material (e.g., lanthanum strontium manganite, praseodymium strontium manganese iron oxide, lanthanum strontium ferrite, lanthanum strontium cobalt ferrite, etc.) or a precursor of a metallic electrode material (e.g., nickel oxide, copper oxide, etc.). The invention also includes anode and cathode coatings and substrates for solid oxide fuel cells prepared by this method.Type: ApplicationFiled: June 28, 2002Publication date: February 6, 2003Inventors: Matthew M. Seabaugh, Scott L. Swartz
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Patent number: 6514453Abstract: This invention describes a method of rapidly monitoring the temperature of a medium and a method of preparing a quantum confined device that can enable such measurements. The monitoring principle uses changes in impedance of nanostructured devices, i.e. devices in which one or more materials have the domain size precision engineered to less than 500 nanometers, preferably to dimensions less than the domain sizes where quantum confinement effects become significant and modify the electrical or thermal properties of the materials. The invention can be used to monitor absolute values of and changes in temperature of gases, inorganic and organic liquids, solids, suspensions, and mixtures of one or more of the said phases. The invention can be used to monitor radiation, power, heat and mass flow, charge and momentum flow, and phase transformation.Type: GrantFiled: February 17, 1998Date of Patent: February 4, 2003Assignee: NanoProducts CorporationInventors: Anthony Vigliotti, Tapesh Yadav, Clayton Kostelecky, Carrie Wyse
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Patent number: 6508964Abstract: Ceramic sintered bodies having a different thickness along a predetermined axial direction are manufactured in the following manner. At first, a ceramic formed body to be sintered having different thickness along the predetermined axial direction is accommodated in a hot press apparatus. An upper forming mold and a lower forming mold each having a forming surface corresponding to an upper surface and a lower surface of the ceramic formed body to be sintered are set. A pressure along the predetermined axial direction is applied to the ceramic formed body to be sintered via the upper forming mold and the lower forming mold while heating the ceramic formed body to be sintered to perform a hot press sintering thereof. A thickness of a ceramic sintered body is controlled in such a manner that a maximum thickness in the predetermined direction is not more than two times a minimum thickness in the predetermined direction.Type: GrantFiled: September 4, 2001Date of Patent: January 21, 2003Assignee: NGK Insulators, LtdInventors: Hiromichi Kobayashi, Satoru Yamada, Tetsuhisa Abe
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Publication number: 20020185376Abstract: A hydrocarbon sensor is formed with an electrolyte body having a first electrolyte surface with a reference electrode depending therefrom and a metal oxide electrode body contained within the electrolyte body and having a first electrode surface coplanar with the first electrolyte surface. The sensor was formed by forming a sintered metal-oxide electrode body and placing the metal-oxide electrode body within an electrolyte powder. The electrolyte powder with the metal-oxide electrode body was pressed to form a pressed electrolyte body containing the metal-oxide electrode body. The electrolyte was removed from an electrolyte surface above the metal-oxide electrode body to expose a metal-oxide electrode surface that is coplanar with the electrolyte surface. The electrolyte body and the metal-oxide electrode body were then sintered to form the hydrocarbon sensor.Type: ApplicationFiled: May 30, 2002Publication date: December 12, 2002Inventors: Rangachary Mukundan, Eric L. Brosha, Fernando Garzon
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Publication number: 20020175076Abstract: A laminated assembly having a first layer, a second layer, and at least one sintered insulating film for electrical insulation of the first layer from the second layer. The first layer is one of a first solid electrolyte layer that conducts oxygen ions and a first electrically conducting layer. The second layer is one of a second solid electrolyte layer that conducts oxygen ions and a second electrically conducting layer. The insulating film is formed on a substrate using a paste or a suspension produced from at least one of a ceramic powder and a glass powder. One of the first layer and the second layer serves at least partly as the substrate. The sintered insulting film has a thickness ≦10 &mgr;m, and the powder is a nanoscale powder with a BET specific surface >50 m2/g and a maximum particle size of 100 nm.Type: ApplicationFiled: April 24, 2002Publication date: November 28, 2002Inventors: Frieder Gora, Stefan Malkmus, Christina Modes, Annette Kipka
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Publication number: 20020146611Abstract: An electrochemical cell including at least one dense solid electrolyte body, at least two dense interconnectors for collecting current flowing the cell, cathodes and anodes, wherein the at least one dense solid electrolyte body and at least two dense interconnectors constitute a structural body, a plurality of first gas flow channels and a plurality of second gas flow channels both extend in a given direction, and are each defined and surrounded by a part of the at least one solid electrolyte body and a part of the at least two interconnectors, the anodes are formed on respective walls defined by a part of at least one solid electrolyte body and a part of at least two interconnectors and constituting the respective first gas flow channels, the cathodes are formed on respective walls defined by a part of at least one solid electrolyte body and a part of at least two interconnectors and constituting the respective second gas flow channels, every anode is opposed to an adjacent cathode or adjacent cathodes via aType: ApplicationFiled: May 31, 2002Publication date: October 10, 2002Applicant: NGK Insulators, Ltd.Inventors: Shinji Kawasaki, Kiyoshi Okumura
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Publication number: 20020140135Abstract: A green sheet stack having a cavity is produced, and a shrinkage-reducing sheet containing inorganic powder material, which is not fired in a step of firing the green sheet stack, is prepared. The shrinkage-reducing sheet is placed so as to close an aperture of the cavity and to cover an end face in the sheet-stacking direction of the green sheet stack. The green sheet stack is pressed via an elastic member in the sheet-stacking direction so that the shrinkage-reducing sheet is cut and a shrinkage-reducing sheet piece formed of a cut portion of the shrinkage-reducing sheet is placed on a bottom surface of the cavity. The green sheet stack is fired in such a state in which the shrinkage-reducing sheet piece is placed on the bottom surface of the cavity.Type: ApplicationFiled: March 8, 2002Publication date: October 3, 2002Inventor: Hideyuki Harada
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Publication number: 20020125618Abstract: A ceramic green sheet is manufactured by preparing a support which includes a releasing layer formed on its top surface and has a smoothness that at least a region of the top surface of the support to be coated with a ceramic slurry has substantially no projections having a height of equal to or more than about 1 &mgr;m, and applying a ceramic slurry to the releasing layer of the support, which ceramic slurry contains a ceramic powder dispersed in a medium. This ceramic green sheet has a small thickness of, for example, about 0.3 to 3 &mgr;m, has no depressions or through holes caused by a filler in the support and is excellent in smoothness.Type: ApplicationFiled: October 5, 2001Publication date: September 12, 2002Applicant: Murata Manufacturing Co., Ltd.Inventors: Toshiya Anahara, Ichiro Nakamura
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Publication number: 20020113344Abstract: There is provided a method for producing a beta-alumina solid electrolyte without calcination of starting materials, according to which the step of synthesizing a magnesium-aluminum spinel starting material is not needed and a beta-alumina solid electrolyte of low resistance can be produced at lower cost. According to this method, the beta-alumina solid electrolyte is produced without carrying out calcination of the starting materials by granulating a slurry obtained by milling and mixing starting materials of an aluminum source, a magnesium source and a sodium source in water, molding the granulated product and then firing the molded product. In this method, magnesium hydroxide is used as the magnesium source and an active spinel high in reactivity is synthesized in the course of firing, and citric acid is added to the slurry as a dispersing agent.Type: ApplicationFiled: November 26, 2001Publication date: August 22, 2002Applicant: NGK Insulators, Ltd.Inventors: Toshiji Kitagawa, Masaharu Kajita
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Publication number: 20020113343Abstract: A method of manufacturing a ceramic body and a gas sensor is disclosed. The method comprises mixing a ceramic material and an organometallic material with a solvent to form a mixture. The organometallic material comprises both a metallic component and an organic ligand. The mixture is disposed onto a surface, dried, and removed to form the ceramic body. The sensor is made by disposing the ceramic body adjacent to an unfired electrolyte body having an electrode disposed on each side thereof to form a green sensor. The green sensor is co-fired to form the sensor.Type: ApplicationFiled: December 18, 2000Publication date: August 22, 2002Inventors: Walter T. Symons, Kaius K. Polikarpus, Kerry J. Gross
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Patent number: 6419875Abstract: There is provided a method for producing a beta-alumina solid electrolyte without calcination of starting materials, according to which the step of synthesizing a magnesium-aluminum spinel starting material is not needed and a beta-alumina solid electrolyte of low resistance can be produced at lower cost. According to this method, the beta-alumina solid electrolyte is produced without carrying out calcination of the starting materials by granulating a slurry obtained by milling and mixing starting materials of an aluminum source, a magnesium source and a sodium source in water, molding the granulated product and then firing the molded product. In this method, magnesium hydroxide is used as the magnesium source and an active spinel high in reactivity is synthesized in the course of firing, and citric acid is added to the slurry as a dispersing agent.Type: GrantFiled: November 26, 2001Date of Patent: July 16, 2002Assignee: NGK Insulators, Ltd.Inventors: Toshiji Kitagawa, Masaharu Kajita
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Publication number: 20020079622Abstract: There are provided methods and compositions for co-fired multilayer piezoelectric ceramic materials with base metal electrodes. The method of the invention is performed at low firing temperatures and without the oxidation of base metal or reduction of ceramic components. A variety of ceramic materials may be used and copper is the preferred base metal in the multi-layer piezoelectric devices of the invention.Type: ApplicationFiled: November 16, 2001Publication date: June 27, 2002Applicant: The Penn State Research FoundationInventors: Clive A. Randall, Amanda L. Baker, Yi Fang, Thomas Shrout
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Publication number: 20020076593Abstract: Flexible ceramic sheets with enhanced strain tolerance for electrochemical applications such as solid oxide fuel cell electrolytes incorporate a surface indentation pattern providing a strain tolerance of not less than 0.5% in any direction in the sheet plane, being made from flexible green ceramic sheet comprising a ceramic powder and a thermoplastic organic binder by heating and reshaping the green sheet to form a multidirectional surface corrugation pattern therein, followed by firing to sinter the ceramic powder to a flexible ceramic sheet having a multi-directional surface corrugation pattern.Type: ApplicationFiled: December 15, 2000Publication date: June 20, 2002Inventors: John D. Helfinstine, Thomas D. Ketcham, Eric J. Maher, Dell J. St. Julien
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Publication number: 20020063365Abstract: Methods for lowering processing and raw material costs are disclosed. Specifically, the use of nanostructured powders is disclosed for faster and lower sintering temperatures whereby electrodes currently employing platinum can be substituted with lower melting point metals and alloys.Type: ApplicationFiled: December 3, 2001Publication date: May 30, 2002Inventors: Anthony Vigliotti, Tapesh Yadav, Clayton Kostelecky, Carrie Wyse
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Patent number: 6348160Abstract: The present invention relates to the preparation of compositions and/or ferroelectric ceramic materials having niobate anions in combination with lead, barium, lanthanum, and bismuth cations. In preferred embodiments, the compositions comprised the formula Pb(x−3y/2−3z/2)Ba(1−x)LayBizNb2O6, wherein x is from about 0.4 to about 0.6, y is from about 0.01 to about 0.03, and z is from about 0.01 to about 0.03. The compositions may be easily poled, and have unexpectedly high piezoelectric charge coefficients and unexpectedly high dielectric constants. The invention also provides processes for preparing the compositions, ferroelectric ceramic materials, and articles comprising the ferroelectric ceramic materials.Type: GrantFiled: June 2, 2000Date of Patent: February 19, 2002Assignee: Department of Science & TechnologyInventors: Akella Bhanumathi, Vakkalanka Venkata Narasimhacharya, Kodidasu Umakantham
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Patent number: 6346161Abstract: The process for the production of a laminated electronic part containing a major component as represented by general formula: X(MgaZn(1−a))xSiOx+2—YAl2O3—ZSrTiO3 (where symbol a is defined by: 0.1≦a≦0.8; and symbol x is defined by: ≦x≦1.5); and an additive component comprised of a compound containing one or more elements selected from Nb, Ta and W; wherein a mole percent ratio of magnesium zinc silicate, (MgaZn(1−a))xSiOx+2, (X), to alumina, Al2O3, (Y), and strontium titanate, SrTiO3, (Z), each of which constitutes said major component, is set to be located in a region enclosed by a polygon having apexes at points A, B, C and D, as defined below, in a three-component composition map: A (94.9, 0.1, 5.0) B (85.0, 10.0, 5.0) C (65.0, 10.0, 25.0) D (65.0, 0.1, 34.9); and the additive component is contained at a rate of 0.01 to 0.Type: GrantFiled: September 6, 2000Date of Patent: February 12, 2002Assignee: Taiyo Yuden Co., Ltd.Inventors: Youichi Mizuno, Yasuyuki Inomata, Toshikazu Toba, Hirokazu Chazono
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Publication number: 20020013994Abstract: In a method for fabricating a surface mountable chip inductor, a spiral coil pattern is formed on a surface of a cylindrical body fabricated by mixing ferrite or ceramic powder with thermoplastic organic binder, the cylindrical body is transformed into a square-shaped body by being inserted into a square-shaped mold and being applied pressure at a certain temperature. An electric characteristic lowering problem can be prevented by forming the coil on the cylindrical body, and transforming the cylindrical body into a square-shaped body is advantageous to surface mounting.Type: ApplicationFiled: July 26, 2001Publication date: February 7, 2002Applicant: Ceratech CorporationInventor: Byeung-Joon Ahn
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Publication number: 20010041278Abstract: A solid oxide fuel cell and method of making same is disclosed. An electrolyte layer of an oxide ion conductor material that may be specified by La1—aAaGa1—(b+c)BbCocO3 and an air electrode layer of an electron conductor material that may be specified by La1—dAdCoO3 are laminated, preferably with an intermediate layer of an electron and ion mixed conductor material that may be specified by La1—eAeGa1—(f+g)BfCogO3 interposed therebetween. The laminate may be sintered to integrate the layers, and may then subjected to a heat treatment to cause elements to diffuse through an interface between adjoining layers. The composition in each interface is thus continuously changed. Here, A may be at least one element selected from the group consisting of Sr and Ca, B may be at least one element selected from the group consisting of Mg, Al, and In, and 0.05≦a≦0.3, 0≦b, e≦0.3, 0≦c≦0.15, b+c≦0.3, 0≦d≦d≦0.5, 0≦f≦0.15, 0.15<g≦0.Type: ApplicationFiled: July 5, 2001Publication date: November 15, 2001Applicant: Mitsubishi Materials CorporationInventors: Ikiko Hashimoto, Norikazu Komada, Kazunori Adachi
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Patent number: 6309589Abstract: A method is proposed for manufacturing a pin heater that has a substantially internal insulating layer and an external conductive layer, the two layers composed of a ceramic composite structure, wherein before the pin heater is sintered, its shaping is accomplished by way of the ceramic injection molding technique or by cold combined axial/isostatic pressing.Type: GrantFiled: October 12, 2000Date of Patent: October 30, 2001Assignee: Robert Bosch GmbHInventors: Guenter Knoll, Gert Lindemann, Wilfried Aichele, Friederike Lindner, Harry Schlachta
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Patent number: 6294128Abstract: The present invention is a method for the manufature of a membrane structure for use in electrochemical conversions.Type: GrantFiled: October 13, 2000Date of Patent: September 25, 2001Assignee: Ford Global Technologies, Inc.Inventor: Gary Mark Crosbie
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Publication number: 20010022416Abstract: A method of manufacturing a multilayer ceramic device includes forming first and second glass-ceramic green sheets from a ceramic material containing glass by laminating the material to form a green sheet laminate having a cavity with an open surface at one surface thereof. Then, shrinkage-suppressing layers which are formed with shrinkage-suppressing inorganic material having a higher sintering temperature than the ceramic material are applied over the surfaces of the green sheet laminate. Thus, a composite laminate is obtained. Then, the composite laminate is pressed in the laminating direction such that the bottom portion of the cavity receives the same amount of pressure as the surrounding region of the cavity via an opening. Then, the composite laminate is fired, and the shrinkage-suppressing layers are removed.Type: ApplicationFiled: December 28, 2000Publication date: September 20, 2001Applicant: Murata Manufacturing Co., Ltd.Inventors: Hideyuki Harada, Hideaki Nakai, Hirofumi Sunahara, Hiroshi Takagi
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Patent number: 6274079Abstract: A ceramic pin heating element having exterior heating conductors and integrated electrical connection surfaces, and method for making same. A first body is injection molded from a first injection-moldable ceramic composite compound having a first electrical resistance, and a second body is injection-molded from a second injection-moldable ceramic composite compound having a second electrical resistance about the first body so as to form a compound body. The compound body is then sintered. The resulting ceramic pin heating element is directly formed without additional steps for protecting (insulating) the element so as to prevent the exterior, complementary heating conductors from contacting the housing and/or terminal bolts. The danger of breakage of the pins at the mounting location and/or at the seal seat through variations in the thickness of contact and/or insulation coatings is minimized.Type: GrantFiled: June 23, 1999Date of Patent: August 14, 2001Assignee: Robert Bosch GmbHInventors: Gert Lindemann, Wilfried Aichele, Friederike Lindner
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Publication number: 20010010617Abstract: A process for producing a monolithic ceramic electronic component, which includes: providing a ceramic slurry, a conductive paste and a ceramic paste; forming a plurality of composite structures each comprising a ceramic green sheet produced by shaping the ceramic slurry, internal circuit element films formed by applying the conductive paste partially onto a main surface of the ceramic green sheet so as to provide step-like sections, and a ceramic green layer which compensates for spaces defined by the step-like sections, the ceramic green layer being formed by applying the ceramic paste onto the region on the main surface of the sheet on which the element films are not formed so as to substantially compensate for the spaces; forming a green laminate by laminating the composite structures; and firing the green laminate. A monolithic ceramic electronic component which is produced through the process; a ceramic paste; and a production process for the paste are also disclosed.Type: ApplicationFiled: December 13, 2000Publication date: August 2, 2001Applicant: Murata Manufacturing Co., Ltd.Inventors: Makoto Miyazaki, Satoru Tanaka
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Publication number: 20010009314Abstract: This invention describes a method of rapidly monitoring the temperature of a medium and a method of preparing a quantum confined device that can enable such measurements. The monitoring principle uses changes in impedance of nanostructured devices, i.e. devices in which one or more materials have the domain size precision engineered to less than 500 nanometers, preferably to dimensions less than the domain sizes where quantum confinement effects become significant and modify the electrical or thermal properties of the materials. The invention can be used to monitor absolute values of and changes in temperature of gases, inorganic and organic liquids, solids, suspensions, and mixtures of one or more of the said phases. The invention can be used to monitor radiation, power, heat and mass flow, charge and momentum flow, and phase transformation.Type: ApplicationFiled: February 17, 1998Publication date: July 26, 2001Inventors: ANTHONY VIGLIOTTI, TAPESH YADAV, CLAYTON KOSTELECKY, CARRIE WYSE
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Publication number: 20010006451Abstract: A process for producing a monolithic ceramic electronic component, which includes: providing a ceramic slurry, a conductive paste, and a ceramic paste; forming a plurality of composite structures each comprising a ceramic green sheet produced by shaping the ceramic slurry, internal circuit element films formed by applying the conductive paste partially onto a main surface of the ceramic green sheet so as to provide step-like sections, and a ceramic green layer which compensates for spaces defined by the step-like sections, the ceramic green layer being formed by applying the ceramic paste onto the region on the main surface of the sheet on which the element films are not formed, so as to substantially compensate for the spaces; forming a green laminate by laminating the composite structures; and firing the green laminate, wherein the ceramic paste contains ceramic powder, an organic solvent, and an organic binder.Type: ApplicationFiled: December 13, 2000Publication date: July 5, 2001Applicant: Murata Manufacturing Co., Ltd.Inventors: Makoto Miyazaki, Satoru Tanaka, Koji Kimura, Koji Hato, Koji Suzuki
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Patent number: 6200516Abstract: A process is disclosed for producing a corrosion-resistant ceramic member, which process includes the steps of preparing a sintered body made of a ceramic material containing at least aluminum, immersing the ceramic sintered body in hydrofluoric acid, and forming a film of aluminum fluoride at a surface layer portion of the ceramic sintered body by heating the ceramic sintered body.Type: GrantFiled: February 8, 1999Date of Patent: March 13, 2001Assignee: NGK Insulators, Ltd.Inventors: Yasufumi Aihara, Akira Narukawa, Keiichiro Watanabe, Shinji Kawasaki
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Patent number: 6197246Abstract: A plasma generating electrode device including a substrate 31 made of a dense ceramic, and an electrode 55 buried in said substrate 31, wherein said electrode 55 is isolated from a setting face of said substrate 31, and plasma is generated over said substrate. It is preferable that the minimum thickness of an electromagnetic wave permeation layer 37 is not less than 0.1 mm, the average thickness of the electromagnetic wave permeation layer is not less than 0.5 mm, the electrode 55 is a planar electrode made of a metal bulk, and the electrode is a monolithic sinter free from a joint face. This structure can be applied to an electric dust collector, an electromagnetic shield device or an electrostatic chuck. These can be preferably installed inside a semiconductor production unit using a halogen-based corrosive gas.Type: GrantFiled: March 2, 2000Date of Patent: March 6, 2001Assignee: NGK Insulators, Ltd.Inventors: Yusuke Niori, Koichi Umemoto, Ryusuke Ushikoshi
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Patent number: 6174489Abstract: A method for manufacturing an oxygen sensor unit of the type which includes at least a shaped body of a solid electrolyte, an inner electrode provided on an inside surface of the shaped body and exposed to a reference gas, an outer electrode provided on an outside surface of the shaped body and exposed to a gas to be measured, and a porous protective layer covering the outer electrode and a portion of the shaped body adjoining to said outer electrode wherein the solid electrolyte is made of a mixture of zirconia and a stabilizer therefor and is constituted of a sintered product of partially stabilized zirconia. The method is characterized in that the partially stabilized, sintered zirconia is obtained according to a high temperature sintering process which includes at least the step of sintering the mixture at a temperature of 1200° C.Type: GrantFiled: August 26, 1998Date of Patent: January 16, 2001Assignee: Denso CorporationInventors: Kiyomi Kobayashi, Naoto Miwa, Toshitaka Saito, Hiromi Sano, Namitsugu Fujii
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Patent number: 6168746Abstract: A method for injection molding fine particulate ceramic ferroelectric materials to form an article such as ink jet printhead includes the steps of spray drying fine particulate ceramic ferroelectric material to form agglomerate material; mixing the spray dried fine particulate ceramic ferroelectric agglomerate material with a binder system including materials selected from the group consisting of wax having wax components of different molecular weight, magnesium-X silicate, agaroid gel forming material, and agaroid gel forming material mixed with magnesium-X silicate to form a compounded material; injecting the compounded material at a selected pressure into a mold to form a green article; debinding or drying the green article; sintering the debinded or dried green article to form the final molded article; poling the final molded article to align the electrical dipoles within the piezoelectric material; forming a coating of conductive material over the top and bottom surfaces of the final molded article and tType: GrantFiled: February 22, 1999Date of Patent: January 2, 2001Assignee: Eastman Kodak CompanyInventors: Dilip K. Chatterjee, Syamal K. Ghosh, James K. Lee
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Patent number: 6156175Abstract: A method for producing a NOx sensor comprises the steps of forming electrodes on ceramic green sheets, and stacking and integrating the ceramic green sheets into one unit followed by sintering to prepare a substrate, wherein an oxygen concentration is controlled to be not more than 0.5% in a sintering atmosphere after removal of a binder in the step of sintering the substrate. Specifically, the sintering is performed in an atmospheric atmosphere in Interval 1 in which the temperature in a furnace is changed from room temperature to about 1000.degree. C., and the sintering is performed in a nitrogen atmosphere (oxygen concentration in the atmosphere in the furnace is controlled to be about 400 ppm) in Interval 2 in which the temperature is changed from 1000.degree. C. to a maximum temperature followed by spontaneous radiational cooling.Type: GrantFiled: November 13, 1998Date of Patent: December 5, 2000Assignee: NGK Insulators, Ltd.Inventors: Nobuhide Kato, Kunihiko Nakagaki
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Patent number: 6146581Abstract: A method of manufacturing a ceramic component including at least one cermet body, especially a cermet electrode, in which the costs are reduced and the ceramic component can be produced in accordance with requirements with an integrated cermet body in a reproducible manner. The cermet body initially is produced as a green compact; the cermet body then is inserted into the ceramic composition; the ceramic composition subsequently is consolidated together with the green compact cermet body, e.g. by pressing, and the resulting assembly is finally sintered.Type: GrantFiled: August 23, 1999Date of Patent: November 14, 2000Assignees: Friatec Aktiengesellschaft, Krohne Messtechnik GmbH & Co. KGInventors: Guenther Bitz, Helmut Mayer, Hans-Joachim Graf
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Patent number: 6143238Abstract: Ceramic raw powder containing conductive ceramic powder is mixed with a prescribed quantity of a molding assistant containing carbon component. This mixture is molded into a prescribed shape of a resistive heating element to thereby produce a heating element mold. A composite mold is prepared by embedding the heating element mold into molds of a ceramic substrate. The composite mold is sintered at a sintering temperature of 1700.degree. C. or higher. During a process of rising temperature to the sintering temperature, the composite mold is kept in an oxygen containing atmosphere having an oxygen partial pressure of 2.times.10.sup.-4 to 1.0 Torr for 7 minutes or longer at a temperature of 1200.degree. C. or higher.Type: GrantFiled: January 29, 1999Date of Patent: November 7, 2000Assignee: NGK Spark Plug Co., Ltd.Inventors: Masahiro Konishi, Shindo Watanabe
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Patent number: 6129886Abstract: The object of the present invention is to realize the piezoelectric ceramics which, even when used as high frequency elements utilizing third harmonics wave of thickness longitudinal vibration, are small in temperature coefficient of resonant frequency and high in mechanical Q value and easy to correspond to the trend toward miniaturization and low voltage driving. When the piezoelectric ceramics with lead titanate as its main component are manufactured in order to achieve this object, it was decided that the piezoelectric ceramics be manufactured by the manufacturing method, wherein a heat treatment is performed between a firing process and a polarization process in the atmosphere of oxygen partial pressure less than the oxygen partial pressure of the atmospheric pressure at temperatures more than 500.degree. C. and not more than the firing temperatures.Type: GrantFiled: March 27, 1998Date of Patent: October 10, 2000Assignee: TDK CorporationInventors: Kazushi Tachimoto, Mahoko Takada, Kenji Horino, Kazuo Miyabe, Hitoshi Oka
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Patent number: 6051330Abstract: One aspect of the invention relates to an interconnect for an SOFC wherein the interconnect is made from a cermet including partially stabilized tetragonal zirconia and a superalloy that is resistant to oxidizing and reducing conditions. Another aspect of the invention relates to an SOFC having vias for carrying fuel and an oxidant and at least one patterned feature in the anode, electrolyte, cathode and/or interconnect for laterally distributing the fuel or oxidant.Type: GrantFiled: January 15, 1998Date of Patent: April 18, 2000Assignee: International Business Machines CorporationInventors: Benjamin V. Fasano, Kevin M. Prettyman
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Patent number: 6051173Abstract: Disclosed is a method of making a solid oxide fuel cell with controlled porosity by varying the size of the ceramic particles, the type of organics, the sintering cycle and the amount of catalyst.Type: GrantFiled: January 15, 1998Date of Patent: April 18, 2000Assignee: International Business Machines CorporationInventors: Benjamin V. Fasano, Kevin M. Prettyman
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Patent number: 6045747Abstract: A method is provided of producing an LC-circuit in form of a single component, in which the inductor and capacitor elements are arranged atop one another, and where the inductor elements are formed by ferromagnetic zones made of layers (6,8) of ferrite of a high permeability, and between which electrode layers (7) are provided, and where the capacitor elements are formed by dielectric zones made of layers (9) of dielectric with electrode layers (4,5) on both sides, said inductor and capacitor elements being produced by way of tape- or thick-film technology. According to the invention, the capacitor elements are initially provided and being subjected to a sintering at a relatively high temperature, whereafter the inductor elements (6,7,8) are applied and a sintering is performed at a considerably low temperature. In this manner undesired reactions are avoided between the two zones.Type: GrantFiled: September 21, 1998Date of Patent: April 4, 2000Assignee: The Whitaker CorporationInventor: Jens Peter Holm
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Patent number: 6040055Abstract: Disclosed is an improved surface discharge element comprising a dielectric substrate having a discharge electrode on one surface and an inductive electrode on the other surface of the substrate, at least said discharge electrode being of a thick film conductor including conductive powder and lead-free glass as main constituents. The lead-free discharge electrode is physically resistive to erosion by electric discharge, and accordingly it can have an elongated life in use.Type: GrantFiled: June 4, 1997Date of Patent: March 21, 2000Assignee: Densoken Co., Ltd. & Shoei Chemical Inc.Inventors: Seiji Baba, Takashi Endo
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Patent number: 6017485Abstract: A controlled dielectric loss, sintered aluminum nitride body having a density of greater than about 95% theoretical, a thermal conductivity of greater than about 100 W/m-K, and a dissipation factor measured at room temperature at about 1 KHz selected from:(a) less than or equal to about 0.001; and(b) greater than or equal to about 0.01.A process for producing a controlled dielectric loss, sintered aluminum nitride body, comprising heat treating an aluminum nitride body at sintering temperatures, including providing a heat treatment atmosphere which effects a selected nitrogen vacancy population in the aluminum nitride body at the sintering temperatures, and cooling the aluminum nitride body from sintering temperatures at a controlled rate and in a cooling atmosphere effective to control the selected nitrogen vacancy population.Type: GrantFiled: March 28, 1996Date of Patent: January 25, 2000Assignee: Carborundum CorporationInventors: Rudolph C. Enck, Jonathan H. Harris, Robert A. Youngman, Thomas S. Nemecek
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Patent number: 6015322Abstract: A spark ignition electrode assembly includes an electrode wire and an electrically insulative support member receiving and positioning the electrode wire proximate to the gas burner. The electrically insulative support member includes an upper body portion covering the electrode wire. The upper body portion contains a spark ignition passageway for communicating spark ignition discharge between the electrode wire and the gas burner. A ceramic material is formed to define the electrically insulative support member having an electrode wire receiving opening for receiving and positioning an electrode wire proximate to the gas burner and a spark ignition passageway for communicating spark ignition discharge between the electrode wire and the gas burner. The electrode wire is inserted in the electrode wire receiving opening and then the formed ceramic material including the inserted electrode wire is fired.Type: GrantFiled: November 3, 1998Date of Patent: January 18, 2000Assignee: Harper-Wyman CompanyInventors: David Baker White, Darryl Williams
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Patent number: 6004644Abstract: A zirconia diaphragm structure, and a method of producing such structure in which the zirconia diaphragm structure includes a zirconia substrate having at least one window, and a zirconia diaphragm plate formed integrally with the zirconia substrate so as to close each window, the zirconia substrate comprising a zirconia material as a major component, and containing 0.1-3.0% by weight of alumina, 0.1-3.0% by weight of silica, 0.1-5.0% by weight of alumina and silica, 0.1-5.0% by weight of alumina and magnesia, or 0.1-5.0% by weight of alumina, silica and magnesia.Type: GrantFiled: August 16, 1996Date of Patent: December 21, 1999Assignee: NGK Insulators, Ltd.Inventors: Yukihisa Takeuchi, Hideo Masumori, Katsuyuki Takeuchi, Tsutomu Nanataki
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Patent number: 6001761Abstract: Disclosed are a ceramics sheet which has an area of 400 cm.sup.2 or more, thickness of 0.4 mm or less, maximum waviness height of 100 .mu.m or less, and warp of 0.1% or less and in which frequency of generated cracking and breakage is 10% or less when a load-applying test and a deflection-loading test each described in the text are carried out in succession, and a flat and large ceramics sheet having an area of 600 cm.sup.2 or more and thickness of 1 mm or less.Type: GrantFiled: May 19, 1997Date of Patent: December 14, 1999Assignee: Nippon Shokubai Co., Ltd.Inventors: Kazuo Hata, Norikazu Aikawa, Hideki Imai, Tetuya Yasaka
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Patent number: 5997800Abstract: A method of manufacturing a ceramic multilayer component, comprising electrically conductive and electrically insulating layers which are stacked in alternate arrangement in a multilayer structure, which method comprises the following steps:providing three extrudable polymeric mixtures, each mixture comprising a binder and a particulate filler, whereby:(a) a first mixture comprises a ceramic filler;(b) a second mixture comprises a metallic filler and a first binder;(c) the third mixture comprises a metallic filler and a second binder;with the aid of an extrusion device having an extrusion channel which is provided with a layer-multiplication element, manufacturing an extruded multilayer stack comprising a plurality of the basic units abac, in which layers a,b,c correspond respectively to the first, second and third mixtures, the stack having two oppositely situated side walls along which part of each layer is exposed;with the aid of a first solvent, dissolving away part of each layer b exposed along a first sType: GrantFiled: October 26, 1998Date of Patent: December 7, 1999Assignee: U.S. Philips CorporationInventors: Reinhold Wimberger Friedl, Peter P. Koets, Johan G. De Bruin
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Patent number: 5993985Abstract: A method of manufacturing porous ceramic tubes for fuel cells with improved properties and higher manufacturing yield is disclosed. The method involves extruding a closed end fuel cell tube, such as an air electrode of a solid oxide fuel cell, in which the closed end also functions as the sintering support. The resultant fuel cell tube has a superior porosity distribution which allows improved diffusion of oxygen at the closed end of the tube during operation of the fuel cell. Because this region has the highest current density, performance enhancement and improved reliability of the fuel cell tube result. Furthermore, the higher manufacturing yield associated with the present method decreases the overall fuel cell cost.Type: GrantFiled: April 9, 1998Date of Patent: November 30, 1999Assignee: Siemens Westinghouse Power CorporationInventor: Brian P. Borglum
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Patent number: 5989484Abstract: A multilayer glass ceramic substrate having a plurality of conductor layers each laminated through a glass ceramic layer. The glass ceramic layer has a composition comprising of alumina, borosilicate magnesium glass and cordierite crystal produced by chemical reaction between alumina and borosilicate magnesium glass. The content of alumina is 12 to 59.6 wt %, the content of borosilicate magnesium glass is 18 to 69.6 wt %, the content of the cordierite crystal is 1 to 50 wt % and the sum of components is 100 wt %. The multilayer glass ceramic substrate shows improved mechanical strength.Type: GrantFiled: December 24, 1997Date of Patent: November 23, 1999Assignee: NEC CorporationInventors: Kazuhiro Ikuina, Yuzo Shimada
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Patent number: 5985068Abstract: A method of manufacturing a monolithic ceramic electronic device includes the following steps: forming a first metal film on a PET film; forming a multilayered metal film by forming a second metal film on a part of the first metal film, the second metal film being thicker than the first metal film; forming a monolithic ceramic structure including the multilayered metal film; forming the first metal film, which is partially overlain by the second metal film in the monolithic ceramic structure, into an insulating structure in such a manner that metal components forming the first metal film are diffused into the ceramics; and firing the ceramics. Disclosed also is a monolithic ceramic electronic device manufactured by the method.Type: GrantFiled: February 28, 1997Date of Patent: November 16, 1999Assignee: Murata Manufacturing Co., Ltd.Inventors: Hiroyuki Kawakami, Yoshiaki Kohno, Noriyuki Kubodera
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Patent number: 5942348Abstract: A high-temperature fuel cell has a solid electrolyte between metal plates. The surfaces of the metal plates are at least partly coated with stabilized zirconium oxide or a similar firmly adhering gas-tight ceramic with crystal structure. The coating reduces the gap between the plates at the edge of the fuel cell and makes it possible to fill the reduced gap with a glass solder green foil or a similar solder material which forms a gas-tight lateral seal for the fuel cell during the assembly of the fuel cell. The plates are also insulated from one another. The gas conduits formed in the plates for the aggressive reaction gases may also be protected against attack by the reaction gases with a thin coating of the same material.Type: GrantFiled: June 2, 1997Date of Patent: August 24, 1999Assignee: Siemens AktiengesellschaftInventors: Thomas Jansing, Thomas Martens
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Patent number: 5935358Abstract: The method of producing a ceramic sheet for laminated ceramic electronic devices according to the present invention comprises printing an electrically conductive composition imagewise on one side of a carrier film F either directly or indirectly through a green ceramic layer G' by the screen printing technique to form electrodes E and then printing a green ceramic composition in solid on top of the printed surface by the screen printing technique to form a green ceramic layer G.Type: GrantFiled: April 17, 1998Date of Patent: August 10, 1999Assignee: New Create CorporationInventor: Akio Yamasaki