Producing Microporous Article (e.g., Filter, Etc.) Patents (Class 264/628)
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Patent number: 7488367Abstract: A honeycomb filter includes partition walls forming a plurality of cells extending in one direction, and plugging sections alternately plugging the cells at the ends of the honeycomb filter, the partition walls being formed of a porous base material having a porosity of 45 to 70%. When the average pore size of the base material measured by mercury porosimetry is (A) ?m and the average pore size of the base material measured by a bubble point method is (B) ?m, the average pore size differential rate expressed by “{(A?B)/B}*100” is 35% or less, and the maximum pore size of the base material measured by the bubble point method is 150 ?m or less.Type: GrantFiled: September 21, 2005Date of Patent: February 10, 2009Assignee: NGK Insulators, Ltd.Inventors: Yoshiyuki Kasai, Toshihiro Hirakawa
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Publication number: 20090033005Abstract: Disclosed are compositions for applying to honeycomb bodies. The compositions can be used as plugging mixtures for forming a ceramic wall flow filter. Alternatively, the compositions can be used to form skin coatings on exterior portions of a honeycomb body. The disclosed compositions include an inorganic powder batch composition, an organic binder, a liquid vehicle, and a rheology modifier. The compositions exhibit improved rheological properties, including an increased yield strength and reduced viscosity under shear, which, among various embodiments, can enable the manufacture of sintered phase end plugs having reduced levels of dimple and pinhole formations in the final dried and fired end plugs as well as end plugs having relatively uniform and desired depths. Also disclosed are methods for forming end plugged ceramic wall flow filters from the plugging mixtures disclosed herein.Type: ApplicationFiled: July 25, 2008Publication date: February 5, 2009Inventors: Dana Craig Bookbinder, James Arthur Griffin, JR., David Lambie Tennent, Lung-Ming Wu
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Publication number: 20090031855Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.Type: ApplicationFiled: July 31, 2008Publication date: February 5, 2009Inventors: Charles E. Ramberg, Stephen A. Dynan, Jack A. Shindle
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Patent number: 7485170Abstract: Disclosed are ceramic honeycomb articles, which are composed predominately of a crystalline phase cordierite composition. The ceramic honeycomb articles possess a microstructure characterized by a unique combination of relatively high porosity between 42% and 56%, and relatively narrow pore size distribution wherein less than 15% of the total porosity has a pore diameter less than 10 ?m, less than 20% of the total porosity has a pore diameter greater than 30 ?m, and dbreadth?1.50 wherein dbreadth=(d90?d10)/d50. The articles exhibits high thermal durability and high filtration efficiency coupled with low pressure drop across the filter. Such ceramic articles are particularly well suited for filtration applications, such as diesel exhaust filters or DPFs. Also disclosed is a method for manufacturing the ceramic article wherein the pore former is preferably potato starch having a median particle diameter greater than 40 ?m.Type: GrantFiled: November 30, 2005Date of Patent: February 3, 2009Assignee: Corning IncorporatedInventors: Douglas Munroe Beall, Thomas Richard Chapman, Weiguo Miao, Jianguo Wang
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Patent number: 7482390Abstract: A method of producing an open, porous structure having an outer surface defining a shape having a bulk volume and having interconnecting openings extending throughout said volume and opening through said surface, and products resulting from the method. The method comprises preparing a viscous mixture comprising a sinterable powder dispersed in a sol of a polymer in a primary solvent, replacing the primary solvent with a secondary liquid in which the polymer is insoluble to produce a gel comprising an open polymeric network having the sinterable powder arranged therein, removing the secondary liquid from the gel; removing the polymer network, and sintering the sinterable powder to form the open, porous structure. Also disclosed are shaped, porous products resulting from methods of the invention.Type: GrantFiled: June 30, 2005Date of Patent: January 27, 2009Assignee: Phillips Plastics CorporationInventors: James R. Johnson, Michael Edward Frencl
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Publication number: 20090000473Abstract: Disclosed are processes for preparing conductive glass-ceramic membranes.Type: ApplicationFiled: June 11, 2008Publication date: January 1, 2009Inventors: Mark J. DAVIS, Samuel David Conzone
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Patent number: 7470302Abstract: There is provided a honeycomb structure 1 including porous partition walls 2 disposed so as to form a plurality of through holes 3a, 3b extending from one end portion to the other end portion in A-axis direction, and containing cordierite as a main component. When porosity is P (%), compressive strength in the A-axis direction is C(MPa), and open frontal area is A (%); a relation of C?(600e ?0.0014AP)+0.5 is satisfied. The honeycomb structure has small pressure loss, is hardly damaged, and has excellent trapping efficiency.Type: GrantFiled: March 4, 2004Date of Patent: December 30, 2008Assignee: NGK Insulators, Ltd.Inventors: Kyoko Suzuki, Keiji Matsumoto, Hiroyuki Suenobu
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Patent number: 7468156Abstract: There is provided a method for manufacturing a porous ceramic structure, including: firing a formed body containing ceramic particles and a combustible powder functioning as a pore former, and burning off the combustible powder to obtain the porous ceramic structure. The combustible powder has an exothermic rate of 0 to 35 ?V·min./mg, which is obtained from a differential thermal analysis. The method for manufacturing a porous ceramic structure can inhibit a crack from being generated during firing even without slowing down the temperature rise rate at the combustion range of the pore former or without lowering an oxygen content in the firing atmosphere.Type: GrantFiled: July 31, 2006Date of Patent: December 23, 2008Assignee: NGK Insulators, Ltd.Inventors: Yasushi Noguchi, Hiroyuki Suenobu, Takehiko Watanabe
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Patent number: 7455798Abstract: 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: GrantFiled: February 25, 2004Date of Patent: November 25, 2008Assignee: James Hardie International Finance B.V.Inventors: Amlan Datta, Hamid Hojaji, Shannon Marie Labernik, David Leslie Melmeth, Thinh Pham, Huagang Zhang
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Publication number: 20080286524Abstract: A sintering aid for promoting sintering of ceramic particles and fine particles that are the same materials as ceramic particles and have smaller average particle diameter are mixed to obtain a puddle. The average particle diameter of ceramic particles is preferably about in a range of 5 to 100 ?m; the average particle diameter of the fine particles is preferably about in a range of 0.1 to 1.0 ?m, and the average particle diameter of the sintering aid is preferably about in a range of 0.1 to 10 ?m. As the sintering aid, for example, alumina is used. This puddle is extrusion molded into a honeycomb shape and the molded object is fired at a firing temperature lower than a temperature for sintering without mixing a sintering aid. The thermal conductivity of the obtained honeycomb structure 10 shows about 60% or more of the thermal conductivity of a fired body fired without adding a sintering aid to ceramic particles and shows about 12 W/m·K or more at 20° C.Type: ApplicationFiled: May 14, 2008Publication date: November 20, 2008Inventors: Kazushige Ohno, Kazutake Ogyu, Masayuki Hayashi
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Patent number: 7438739Abstract: An improved catalyzed soot filter is comprised of a porous ceramic having, on at least a portion of the porous ceramic, an amorphous catalytic phase comprised of an alkali containing oxide glass having therein Si, Al or combination thereof. The improved catalyzed soot filter may be formed by contacting a porous ceramic such as mullite, silcon carbide or cordierite with an alkali containing compound that is a silicate, aluminate or alumino-siliicate and heating to a temperature sufficient to form an amorphous catalytic phase fused to at least a portion of the porous ceramic.Type: GrantFiled: July 26, 2005Date of Patent: October 21, 2008Assignee: Dow Global Technologies Inc.Inventors: Robin Paul Ziebarth, Robert Thomas Nilsson
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Patent number: 7431880Abstract: There is provided a method for manufacturing a porous ceramic structure, including: firing a formed body containing ceramic particles and a combustible powder functioning as a pore former, and burning off the combustible powder to obtain the porous ceramic structure. As the combustible powder, porous resin particles having an average particle diameter of 10 to 50 ?m and a porosity of 50 to 90% are used. The method for manufacturing a porous ceramic structure can inhibit the combustible powder functioning as a pore former from being smashed upon mixing/kneading a forming raw material and suppressing an excess heat generation upon firing and can manufacture a porous ceramic structure having a stable porosity with a good yield.Type: GrantFiled: July 31, 2006Date of Patent: October 7, 2008Assignee: NGK Insulators, Ltd.Inventors: Takehiko Watanabe, Hiroyuki Suenobu, Yasushi Noguchi
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Publication number: 20080236123Abstract: A honeycomb ceramic filtration substrate, a filter made of the said substrate and a filter system made of the said filter and their production methods are published in the present invention. The said substrates are extruded with a paste comprising (by portion): SiC: 1; Clay: 0.05-0.5; Flour: 0.1-0.35; grease: 0.025-0.05; Water: 0.2-0.35. The said sintered substrate has a honeycomb structure with cells density ranging from 4˜62 cells/cm2; The cell wall thickness is: 0.2-1.2 mm; The porosity of the cell wall: 40-70%. The cell wall through pore rate is more than 30%; The average diameter distribution of the cell wall micro-pores is in the ranging of 1-50 ?m. The said substrate can be designed in different cylinders whose cross section are in form of square, one border curved square and one border curved triangle etc., After adhering the substrates, the filter can be used as vehicle particulates filter. After the canning of the filter, the filter system is produced.Type: ApplicationFiled: August 17, 2006Publication date: October 2, 2008Applicant: Yunnan Filter Environment Protection S.&T. Co., LtInventors: Qinghua Chen, Dianyi Li, Yi Li
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Patent number: 7429351Abstract: A method for manufacturing a porous ceramic structure which can produce a high porosity ceramic structure as well as a low porosity ceramic structure without causing cracks at the time of firing. A method for manufacturing a porous ceramic structure comprising molding a raw material which contains a ceramic material as a main component and a pore-forming agent and then drying and firing the obtained molded article. When the molded article is fired, the temperature of a firing environment is raised substantially in synchronization with the temperature of the central portion of the molded article within a temperature range in which at least a portion of the molded article is shrunk by firing.Type: GrantFiled: July 23, 2004Date of Patent: September 30, 2008Assignee: NGK Insulators, Ltd.Inventors: Yumi Toda, Yukihisa Wada, Yasushi Noguchi
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Patent number: 7427309Abstract: A ceramic filter assembly having improved exhaust gas processing efficiency. The ceramic filter assembly (9) is produced by adhering with a ceramic seal layer (15) outer surfaces of a plurality of filters (F1), each of which is formed from a sintered porous ceramic body. The seal layer (15) has a thickness of 0.3 mm to 3 mm and a thermal conductance of 0.1 W/mK to 10 W/mk.Type: GrantFiled: September 21, 2005Date of Patent: September 23, 2008Assignee: Ibiden Co., Ltd.Inventors: Kazushige Ohno, Koji Shimato, Masahiro Tsuji
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Patent number: 7419772Abstract: Mesoporous articles and methods for making mesoporous articles are disclosed.Type: GrantFiled: November 21, 2002Date of Patent: September 2, 2008Assignee: University of MassachusettsInventors: James J. Watkins, Rajaram Pai
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Patent number: 7404840Abstract: A method for rigidifying a fiber-based paper substrate for use in the exhaust system of a combustion device. In the method, a green ceramic fiber-based paper substrate is impregnated with an impregnating dispersion. The impregnated substrate is then dried, calcined and fired to form a rigidified substrate that is suitable for use in the exhaust system of a combustion device. This rigidification process is performed at least once and, preferably, two or more times. The green paper substrate comprises two or more sheets of green ceramic fiber-based paper, with at least one creased sheet and another sheet being a laminated together to form a plurality of tubular channels. The rigidified substrate comprises refractory ceramic fibers in the form of a ceramic fiber-based paper and agglomerates of ceramic particles.Type: GrantFiled: July 3, 2002Date of Patent: July 29, 2008Assignee: 3M Innovative Properties CompanyInventors: Thomas E. Wood, Zhongshu Tan
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Patent number: 7399333Abstract: The present invention provides a filter element and a method for producing the same, which do not generate pollution during waste disposal, can be easily produced, improve the pressure loss and reduce the production cost. The filter element and the method for producing the same are characterized in that ultrahigh molecular weight polyethylene fine powders, which have an average molecular weight of 3,000,000 to 11,000,000 and a bulk specific gravity of 0.15 to 0.29, are the aggregate of primary particles, and are shaped to have voids of 1 to 5 ?m in a part where the primary particles are connected, are filled into the pores on the surface of a filter element base made of an open-cell porous molded body prepared by heating and sintering synthetic resin powders, a non-woven fabric or a felt.Type: GrantFiled: October 21, 2003Date of Patent: July 15, 2008Assignee: Nittetsu Mining Co., Ltd.Inventors: Setsuo Agawa, Koji Nakanishi, Yoshinori Ichihara
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Publication number: 20080148700Abstract: An improved ceramic honeycomb filter has at least one porous partition wall defining a channel that is (1) microstructurally different along the length of the channel, (2) microstructurally different than at least a portion of a partition wall defining another channel or (3) combination thereof. The improved filter may be used for filtering Diesel exhaust and may have reduced back pressure and equivalent soot capture efficiency compared to a filter without having said microstructural differences.Type: ApplicationFiled: December 12, 2007Publication date: June 26, 2008Applicant: Dow Global Technologies Inc.Inventor: Robin Ziebarth
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Publication number: 20080150200Abstract: A jig for firing a silicon carbide based material of the present invention is a jig for firing a silicon carbide based material, which is used for placing a silicon carbide based molded body thereon upon firing of the silicon carbide based molded body, wherein a SiO source layer is formed on at least a part of the surface of the jig for firing a silicon carbide based material.Type: ApplicationFiled: June 19, 2007Publication date: June 26, 2008Applicant: IBIDEN CO., LTD.Inventor: Kosei Tajima
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Patent number: 7384442Abstract: A ceramic wall-flow filter for filtering particulate matter from gases and methods for manufacturing such wall-flow filters are disclosed. The filter includes an array of porous ceramic walls defining a pattern of end-plugged inlet and outlet cells, and heat absorbing elements disposed within at least some of the outlet cells such that a bulk heat capacity of the outlet cells is greater than a bulk capacity of the inlet cells. The heat absorbing elements increase a bulk heat capacity of the filter without substantially interfering with a flow of gas through the porous ceramic walls by allowing thinner walls. According to the method, during the step of extruding or thereafter, heat absorbing elements are formed within at least some of the outlet cells such that a heat capacity of the outlet cells is greater than the inlet cells.Type: GrantFiled: February 28, 2005Date of Patent: June 10, 2008Assignee: Corning IncorporatedInventors: Pronob Bardhan, Douglas Munroe Beall, Kenneth Richard Miller, John Forrest Wight, Jr.
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Patent number: 7381362Abstract: 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: GrantFiled: January 21, 2005Date of Patent: June 3, 2008Assignee: Covalent Materials CorporationInventors: Hideo Uemoto, Kazuhide Kawai, Shunzo Shimai, Takashi Matsuyama
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Patent number: 7368076Abstract: A method for producing a silicon nitride filter, which comprises heat-treating in nitrogen a green body comprising from 60 to 95 mass % of metal silicon particles having an average particle diameter of from 10 to 75 ?m, wherein particles having particle diameters of from 5 to 100 ?m are at least 70 mass % in the entire metal silicon particles, and from 5 to 40 mass % of a pore-forming agent, to convert metal silicon substantially to silicon nitride. More preferably, the green body contains at least one member selected from the group consisting of an inorganic acid salt, an organic acid salt and a hydroxide containing at least one metal element selected from the group consisting of Mg, Ca, Fe and Cu.Type: GrantFiled: July 16, 2004Date of Patent: May 6, 2008Assignee: Asahi Glass Company, LimitedInventors: Naomichi Miyakawa, Nobuhiro Shinohara, Toshinari Watanabe
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Patent number: 7354542Abstract: This invention relates to a process of a lightweight, heat insulating, high compressive strength, water insoluble material by heat treatment at temperatures between 650-950° C., possessing a low bulk density (from 300 to 800 kg/m3) and improved heat insulating capacity (?=0.07 to 0.25 W/m·deg.) when it has been used to form an article having a compressive strength of from 0.49 to 5.59 Mpa. The starting chemical composition comprising more than 90% by weight of either perlite, pumice or pumice related group of materials or mixture of them and an additive in quantities less than 10% by weight containing Na2O and B2O3.Type: GrantFiled: November 3, 2000Date of Patent: April 8, 2008Assignee: Nesteks Nevsehir Tekstil Sanayi Ve Ticaret A.S.Inventor: Ismail Girgin
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Patent number: 7329300Abstract: A honeycomb structure includes partition walls arranged so as to form a plurality of cells extending to an other-end portion from a one-end portion through an axial direction. There are provided a honeycomb structure including a partition wall having a different height in the axial direction in the one-end portion, and a manufacturing method suitable for the structure. There is provided a honeycomb structure comprising: a plurality of partition walls arranged so as to form a plurality of cells extending through an axial direction; and a plugging portion in an open end portion of a predetermined cell. The honeycomb structure includes convex and concave plugging portions, and intersecting portions of surrounding partition walls of one cell which does not any plugging portion contact one or more cells including the convex plugging portions and one or more cells including the concave plugging portions for each intersecting portion. A manufacturing method suitable for this honeycomb structure is also provided.Type: GrantFiled: April 2, 2004Date of Patent: February 12, 2008Assignee: NGK Insulators LtdInventor: Yukihito Ichikawa
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Patent number: 7329311Abstract: The present invention is directed to porous composite materials comprised of a porous base material and a powdered nanoparticle material. The porous base material has the powdered nanoparticle material penetrating a portion of the porous base material; the powdered nanoparticle material within the porous base material may be sintered or interbonded by interfusion to form a porous sintered nanoparticle material within the pores and or on the surfaces of the porous base material. Preferably this porous composite material comprises nanometer sized pores throughout the sintered nanoparticle material. The present invention is also directed to methods of making such composite materials and using them for high surface area catalysts, sensors, in packed bed contaminant removal devices, and as contamination removal membranes for fluids.Type: GrantFiled: August 10, 2006Date of Patent: February 12, 2008Assignee: Entegris, In.Inventors: Robert Zeller, Christopher Vroman
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Patent number: 7326271Abstract: A honeycomb filter 1 includes a cylindrical honeycomb structure 2 having a plurality of cells 4, and plugging members 7 disposed to alternately plug openings 5 of predetermined cells 4a on the side of one end face 6a and the openings 5 of the remaining cells 4b on the side of the other end face 6b of the structure 2 in checkered flag form, and further having second plugging members 8 disposed to plug openings 5 of cells 4 which are not plugged by the first plugging member 7 on either side of two end faces 6a and 6b of the structure 2 corresponding to 0.2 to 2.5% of the area of the cross section perpendicular to the center axis of the structure 2 in a center section occupying at least ? of the area from the center axis of the structure 2 to an outer circumferential surface 11.Type: GrantFiled: December 8, 2004Date of Patent: February 5, 2008Assignee: NGK Insulators, Ltd.Inventors: Yoshiyuki Kasai, Tatsuyuki Kuki
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Patent number: 7311750Abstract: Ceramic particles, fine particles having smaller average particle diameter smaller than that of the ceramic particles and a reduction-resistant material are mixed to obtain a puddle. The reduction-resistant material is a material that is reduced by carbon at a higher temperature as compared with a temperature at which an oxide (for example, silica) of an element contained in the ceramic particles is reduced. The average particle diameter of the ceramic particles is preferably about in a range of 5 to 100 ?m and the average particle diameter of the fine particles is preferably about in a range of 0.1 to 10 ?m. The reduction-resistant material is, for example, alumina. This puddle is extrusion molded into a honeycomb filter and the molded object is sintered at about 1600 to 2200° C.Type: GrantFiled: January 20, 2006Date of Patent: December 25, 2007Assignee: Ibeden Co., Ltd.Inventors: Kazushige Ohno, Kazutake Ogyu, Masayuki Hayashi
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Patent number: 7306642Abstract: A porous ceramic support for a gas separation membrane formed by sintering a green body containing grains of a refractory ceramic oxide with a high coefficient of thermal expansion and grains of a reactive binder precursor. Upon sintering, the reactive binder precursor reacts with at least one gaseous, liquid or solid reactant to create a reaction bond that binds the refractory ceramic oxide grains. The support configuration can be a tubular, flat plate, hollow fiber, or multiple-passageway monolith structure.Type: GrantFiled: February 20, 2004Date of Patent: December 11, 2007Assignee: CeraMem CorporationInventors: Peter J. Hayward, Richard Higgins, Robert L. Goldsmith, Bruce A. Bishop
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Patent number: 7294164Abstract: This invention relates to an aluminum titanate body having a narrow pore size distribution as characterized by the relation (d50?d10)/d50 being less than 0.50 corresponding to a high degree of interconnected porosity. The body also preferably exhibits a low coefficient of thermal expansion of less than 15×10?7 C?1, high porosity of at least 38% by volume, and at least 0.10% by weight metal oxide, the metal being either yttrium, calcium, bismuth, a lanthanide metal or combinations of thereof. MOR is preferably at least 450 psi. Median pore diameter is preferably at least 8 microns. The inventive ceramic body is particularly useful as a wall-flow filter for a diesel exhaust. A method of fabrication is provided where the sintering temperature is preferably between 1375°-1550° C.Type: GrantFiled: July 28, 2005Date of Patent: November 13, 2007Assignee: Corning IncorporatedInventor: Gregory A. Merkel
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Patent number: 7285214Abstract: There are disclosed a honeycomb structure which is preferably usable as a filter, for example, for trapping particulates in an exhaust gas of an internal combustion engine, boiler or the like or for filtering liquids such as city water and sewage and in which an increase of a pressure loss at a use time is inhibited. A honeycomb structure 1 comprises: two end surfaces 5 consisting of first and second end surfaces; a porous body 2 in which a plurality of fluid channels 3 extending to a second end surface 5b from a first end surface 5a are formed; and plugging members 4 for plugging end portions 6 on end surfaces 5 side of the fluid channels 3.Type: GrantFiled: April 7, 2004Date of Patent: October 23, 2007Assignee: NGK Insulators, Ltd.Inventor: Yukihito Ichikawa
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Patent number: 7264652Abstract: The collecting filter can capture and collect various chlorinated organic compounds in both particulate form and gaseous form contained in a fluid at the same time, and is easy to extract the collected chlorinated organic compounds therefrom. This collecting filter 7 is provided with a fluid-permeable molded body containing fibers and an inorganic binder for binding the fibers to one another, and a hydrophobic material having higher hydrophobicity than that of the fibers and the inorganic binder, which is retained in the molded body. Various chlorinated organic compounds such as dioxins in both particulate form and gaseous form contained in the sample gas are captured and collected upon passage through the collecting filter 7.Type: GrantFiled: June 17, 2003Date of Patent: September 4, 2007Assignees: Miura Co., Ltd., Osaka Gas Co., Ltd.Inventors: Katsuhisa Honda, Noriaki Hamada, Hirofumi Nakamura, Hisaji Matsui, Kiyotaka Kobayashi
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Patent number: 7255553Abstract: A light guide plate mold core (1) includes a main body (13) having a molding surface (12) and a plurality of concavities (13a) formed at the molding surface. The main body is made of a material whose thermal conductivity is limited in the range from 0.002 cal/cm.s.K. (calories/centimeter.second.Kelvin) to 0.009 cal/cm.s.K. The thermal conductivity of the material for the light guide plate mold core is less than that of stainless steel. Therefore the rate of spreading of heat in the light guide plate mold core is lower than that of a conventional light guide plate mold core, so that stresses within a formed light guide plate can be released more. Thus by using the light guide plate mold core, a light guide plate having a highly even bottom surface can be manufactured. A method for manufacturing the light guide plate mold core is also provided.Type: GrantFiled: July 26, 2004Date of Patent: August 14, 2007Assignee: Hon Hai Precision Ind. Co., Ltd.Inventors: Charles Leu, Tai-Cherng Yu, Ga-Lane Chen
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Patent number: 7223356Abstract: The invention concerns a method for preparing a thin ceramic material with controlled surface porosity gradient, including (A) infiltrating a porous pore-forming substrate of controlled thickness, with a ceramic material suspension; (B) evaporating the solvent; (C) a step which includes eliminating the pore-forming agents and the various organic additives, and (D) a sintering step. The invention also concerns the use of the ceramic material in the method for preparing a solid electrolyte and a mixed ionic-electronic conductor, in methods for preparing ultra-pure oxygen, for eliminating oxygen from a gaseous atmosphere, for producing heat energy, for preparing gas or liquid filtering membranes, for ceramic/metal joints, for biomaterials and sensors.Type: GrantFiled: November 26, 2001Date of Patent: May 29, 2007Assignee: L'Air Liquide, Société Anonyme à Directoire et Conseil deSurveillance pour l'Étude et l'Exploitation des Procédés Georges ClaudeInventors: Thierry Chartier, François Guillotin
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Patent number: 7208108Abstract: A method for producing a porous ceramic article involves a step of kneading raw materials including a raw material for a ceramic and a processing aid, to prepare a body, a step of forming the body, to prepare a ceramic formed product, a step of drying the formed product, to prepare a ceramic dried article, and a step of firing the ceramic dried article, to preparing a porous ceramic article, characterized in that the processing aid is a starch having been subjected to a crosslinking treatment or a material comprising a starch having been subjected to a crosslinking treatment and a foamed resin. The method allows the production of a porous ceramic article which is suppressed in the deformation during drying and is excellent in dimensional accuracy.Type: GrantFiled: December 6, 2002Date of Patent: April 24, 2007Assignee: NGK Insulators, Ltd.Inventors: Aiko Otsuka, Shuichi Ichikawa, Takashi Harada
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Patent number: 7189274Abstract: An exhaust gas filter for cleaning an exhaust gas of an internal combustion engine includes at least one strip-shaped filter layer made of a material through which a fluid can at least partly flow. The filter layer has a length in a longitudinal direction and a width in a transverse direction. The filter layer has a metallic reinforcing region at least in a partial region. The metallic reinforcing region has a width and a length. The width of the reinforcing region is less than the width of the filter layer and/or the length of the reinforcing region is less than the length of the filter layer. A method for producing a filter layer for an exhaust gas filter is also provided.Type: GrantFiled: February 2, 2005Date of Patent: March 13, 2007Assignee: Emitec Gesellschaft für Emissionstechnologie mbHInventors: Rolf Brück, Jan Hodgson, Markus Mengelberg
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Patent number: 7168266Abstract: Techniques for producing a glass structure having interconnected macroscopic pores, employing steps of filling polymerizable glass precursors into pores in a polymeric structure having interconnected macroscopic pores; polymerizing the precursors; and decomposing the polymers to produce a glass oxide structure having interconnected macroscopic pores. Further techniques employ steps of exposing portions of a photosensitive medium including glass precursors to an optical interference pattern; polymerizing or photodeprotecting the exposed portions and removing unpolymerized or deprotected portions; and decomposing the polymerized or deprotected portions to produce a glass structure having interconnected macroscopic pores. Techniques for filling pores of such glass structure with a material having a high refractive index, and for then removing the glass structure.Type: GrantFiled: March 6, 2003Date of Patent: January 30, 2007Assignee: Lucent Technologies Inc.Inventors: Gang Chen, Ronen Rapaport, Elsa Reichmanis, Shu Yang
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Patent number: 7153336Abstract: This invention relates to an exhaust gas purifying apparatus having a particulate filter for collecting particulates in exhaust gas. This particulate filter (22) contains partition walls defining paths (50, 51) in which exhaust gas flows. This partition wall is formed of porous material. This particulate filter (22) is created by gathering tips of the partition walls and then baking with the adjacent partition walls being in contact with each other. The adjacent partition walls are bonded together at a predetermined bonding strength if the partition walls are baked such that they are in contact. According to this invention, the end portion of the particulate filter (22) has a higher strength than the predetermined bonding strength.Type: GrantFiled: August 7, 2002Date of Patent: December 26, 2006Assignee: Toyota Jidosha Kabushiki KaishaInventors: Kazuhiro Itoh, Shinya Hirota, Koichiro Nakatani
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Patent number: 7141089Abstract: A ceramic filter for trapping and combusting diesel exhaust particulates composed of an end-plugged cordierite honeycomb structure exhibiting a pore size distribution as determined by mercury porosimetry in which the quantity d50/(d50+d90) as related to pore size distribution is less than 0.70, a soot loaded permeability factor Sf, as defined by the equation [d50/(d50+d90)]/[% porosity/100], of less than 1.55, and, a coefficient of thermal expansion (25–800° C.) of no greater than 17×10?7/° C. The ceramic filter further exhibits a median pore diameter, d50, of at least 4 micrometers and up to 40 micrometers. A method of making the filter is provided.Type: GrantFiled: June 26, 2003Date of Patent: November 28, 2006Assignee: Corning IncorporatedInventors: Douglas M. Beall, Gregory A. Merkel, Martin J. Murtagh
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Patent number: 7138002Abstract: There is provided a honeycomb structure in which the structure is not segmented, or a smaller number of segments are integrated to suppress a local temperature rise and to reduce breakage by thermal stress at the time of use, and a method of manufacturing the structure. There is disclosed a honeycomb structure 1 comprising: a large number of cells 3 partitioned by cell walls 2 and extending through an axial direction. A flow channel separator 6 is formed in the honeycomb structure 1. There is disclosed a method of manufacturing the honeycomb structure 1 in which the flow channel separator 6 is formed by extrusion. There is disclosed a method of manufacturing the honeycomb structure 1 in which the flow channel separator 6 is formed by clogging.Type: GrantFiled: July 17, 2002Date of Patent: November 21, 2006Assignee: NGK Insulators, Ltd.Inventors: Toshiyuki Hamanaka, Tadato Ito
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Patent number: 7083757Abstract: Semiconductor wire bonding tools used in the assembly and interconnection of integrated circuits (ICs) are micromolded from a mixture of ultrafine particulate materials mixed with an organic binder. Following extraction of the binder the green bonding tools are sintered during which they undergo isotropic, constant and accurately predetermined shrinkage. Hence semiconductor wire bonding tools can be produced with virtually no limit to miniaturization, thus allowing the fabrication of higher integrated semiconductor products.Type: GrantFiled: February 18, 2002Date of Patent: August 1, 2006Inventors: Romain L. Billiet, Hanh T. Nguyen
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Patent number: 7070728Abstract: A method for plugging a subset of cells of a honeycomb structure having a plurality of open-end cells extending therethrough including providing at least one cylindrically-shaped first roller including an engagement surface having a plurality of outwardly-extending teeth spaced along a length and about a circumference of the at least one first roller, wherein the teeth are spaced so as to engage a first subset of a total number of cells exposed on a first end of the honeycomb structure. The method also includes rolling the engagement surface of the at least one first roller across the first end of the honeycomb structure with the teeth extending into the first subset of cells, thereby deforming the first end of the honeycomb structure and plugging a second subset of the total number of cells substantially different from the first subset of cells.Type: GrantFiled: April 7, 2005Date of Patent: July 4, 2006Assignee: Corning IncorporatedInventors: Thierry Luc Alain Dannoux, Jean-Pierre Henri René Lereboullet, Grégory Emmanuel Guillaume Rossignol, Claude Jacques Julien Vanotti
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Patent number: 7008461Abstract: There is disclosed a honeycomb structure usable as a filter for trapping/collecting particulates included in an exhaust gas; and the structure can remove ashes deposited inside without requiring any special mechanism or apparatus or without being detached from the exhaust system. The structure includes: a plurality of through channels 9 extending to the axial direction of the honeycomb structure, porous partition walls 7 separating through channels one another, and plugging portions 11 plugging predetermined through channels 9a at one end and the rest of through channels 9b at other end opposite to the plugged end of the predetermined through channels, wherein a through-hole is formed in at least a part of the plugging portion, and its diameter is 0.2 mm or more, but not more than a value which is smaller between 1 mm and 75% of a diameter of an inscribed circle of the through channel.Type: GrantFiled: September 24, 2003Date of Patent: March 7, 2006Assignee: NGK Insulators, Ltd.Inventors: Tatsuyuki Kuki, Toshio Yamada
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Patent number: 7008576Abstract: Microporous ceramic materials used in structural materials, high-temperature filters, electrode materials or preform materials for infiltration by homogeneously mixing and molding a ceramic precursor powder polymer. The powder is saturated by introducing fluid to a pressure vessel. The fluid is super saturated by adjusting pressure in the vessel. Micropores are formed in the molded bodies by evolving the fluid from the molded bodies by heating and hardening the molded bodies. The hardened molded bodies are heated to pyrolysis. Pore characteristics (e.g., pore size and pore size distribution) suitable to target materials are controlled by adjusting pressure at a non-critical state without requiring additional processes or devices.Type: GrantFiled: June 17, 2003Date of Patent: March 7, 2006Assignee: Korea Institute of Machinery and MaterialsInventors: Hai-Doo Kim, Young-Wook Kim, Chul Bum Park
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Patent number: 7001442Abstract: There is provided a particulate filter for trapping particulates contained in an exhaust gas discharged from a combustion chamber of an engine, comprising a plurality of exhaust gas flow passages each formed by three porous partitions extending substantially parallel with each other, each of the exhaust gas flow passages having a triangular cross section, wherein the partitions defining one of the adjacent exhaust gas flow passages are deformed at one end area of the filter so that the partitions at one end area of the filter approach each other toward one of the ends of the filter, the deformed portions of the partitions are connected to each other at their ends, thereby an opening of one of the adjacent exhaust gas flow passages is at least partially closed, the partitions defining the other exhaust gas flow passage are deformed at the other end area of the filter so that the partitions at the other end area of the filter approach each other toward the other end of the filter, and the deformed portions of tType: GrantFiled: June 16, 2003Date of Patent: February 21, 2006Assignee: Toyota Jidosha Kabushiki KaishaInventors: Koichiro Nakatani, Haruo Ooishi, Shuji Watanabe, Shinya Hirota
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Patent number: 7001528Abstract: The use of an aqueous polymer dispersion comprising dispersed particles of at least one polymer A1 obtainable by free-radical emulsion polymerization in the presence of a polymer A2 synthesized from from 50 to 99.5% by weight of at least one ethylenically unsaturated monocarboxylic and/or dicarboxylic acid, from 0.5 to 50% by weight of at least one ethylenically unsaturated compound selected from the esters of ethylenically unsaturated monocarboxylic acids and the monoesters and diesters of ethylenically unsaturated dicarboxylic acids with an amine containing at least one hydroxyl group, up to 20% by weight of at least one further monomer as a binder for producing filter materials.Type: GrantFiled: February 10, 2004Date of Patent: February 21, 2006Assignee: BASF AktiengesellschaftInventors: Matthias Laubender, Matthias Gerst
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Patent number: 6998064Abstract: A thermochemically stable oxidic thermal insulating material presenting phase stability, which can be used advantageously as a thermal insulating layer on parts subjected to high thermal stress, such as turbine blades or such like. The thermal insulating material can be processed by plasma spraying and consists preferably of a magnetoplumbite phase whose preferred composition is MMeAl11O19, where M is La or Nd and where Me is chosen from among zinc, the alkaline earth metals, transition metals, and rare earths, preferably from magnesium, zinc, cobalt, manganese, iron, nickel and chromium.Type: GrantFiled: July 14, 2003Date of Patent: February 14, 2006Assignee: MTU Aero Engines GmbHInventors: Rainer Gadow, Guenter Schaefer
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Patent number: 6986429Abstract: The invention concerns an anti-microbial porous part based on a polymeric material grafted at the surface and in its volume with ammonium motifs with anti-microbial and/or bactericidal and/or fungicide activity, preferably benzalkonium. The invention is characterized in that it has a porosity sufficiently high to enable a liquid with compatible viscosity to pass through its structure and sufficiently low to trap contaminating germs within said structure.Type: GrantFiled: April 26, 2001Date of Patent: January 17, 2006Assignee: Laboratoire Chauvin S.A.Inventors: Mohammad Naji, Bernard Pages, Jacques Lacombes
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Patent number: 6984671Abstract: A method of producing an open, porous structure having an outer surface defining a shape having a bulk volume and having interconnecting openings extending throughout said volume and opening through said surface, and products resulting from the method. The method comprises preparing a viscous mixture comprising a sinterable powder dispersed in a sol of a polymer in a primary solvent, replacing the primary solvent with a secondary liquid in which the polymer is insoluble to produce a gel comprising an open polymeric network having the sinterable powder arranged therein, removing the secondary liquid from the gel; removing the polymer network, and sintering the sinterable powder to form the open, porous structure. Also disclosed are shaped, porous products resulting from methods of the invention.Type: GrantFiled: June 10, 2003Date of Patent: January 10, 2006Assignee: Phillips Plastics CorporationInventors: James R. Johnson, Michael Edward Frencl
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Patent number: 6972045Abstract: A method of fabricating a substrate used for purifying an exhaust gas is provided. This method comprises the step of transforming a pre-mold having a first end, a second end, a plurality of partition walls extending between the first end and the second end, the first transforming step for transforming the end portions of the partition walls at the first end in such a manner that the ends of the partition walls defining one of two adjacent passages at the first end of the pre-mold are collected toward the center of a corresponding passage and connected to each other, and the second transforming step for transforming the ends of the partition walls at the first end in such a manner that the end surfaces of the partition walls at the first end are depressed toward the center of each of the end surfaces.Type: GrantFiled: September 8, 2003Date of Patent: December 6, 2005Assignee: Toyota Jidosha Kabushiki KaishaInventor: Kazuhiro Itoh