Producing Fiber Containing Article Or Fiber Patents (Class 264/640)
  • Patent number: 10607125
    Abstract: A transaction card includes a card body that may comprise a ceramic material, the card body including a primary surface and a secondary surface, a laser marked feature disposed on the card body and a laser etched feature disposed on the card body. A method of making a transaction card may comprise forming a ceramic material slurry comprising a ceramic material and a binder, forming a green body from the ceramic material slurry, firing the green body at a firing temperature to create a fired ceramic body, grinding the fired ceramic body into a card body, and polishing a primary surface of the card body.
    Type: Grant
    Filed: March 15, 2016
    Date of Patent: March 31, 2020
    Assignee: AMERICAN EXPRESS TRAVEL RELATED SERVICES COMPANY, INC.
    Inventors: Troy Patrick Williams, Peter Bates
  • Patent number: 10087111
    Abstract: A method of creating a tackified prepreg includes steps of providing a fiber weave that have unidirectional fibers and woven sections spaced apart from one another to provide unidirectional fiber sections, applying a tackifier to the fiber weave, and separating the unidirectional fiber section from the woven sections.
    Type: Grant
    Filed: September 11, 2014
    Date of Patent: October 2, 2018
    Assignee: United Technologies Corporation
    Inventors: Erica L. Prevost, Alex J. Sember
  • Patent number: 9564643
    Abstract: A seal for a solid oxide fuel cell includes a glass matrix having glass percolation therethrough and having a glass transition temperature below 650° C. A deformable second phase material is dispersed in the glass matrix. The second phase material can be a compliant material. The second phase material can be a crushable material. A solid oxide fuel cell, a precursor for forming a seal for a solid oxide fuel cell, and a method of making a seal for a solid oxide fuel cell are also disclosed.
    Type: Grant
    Filed: July 24, 2013
    Date of Patent: February 7, 2017
    Assignees: UT-BATTELLE, LLC, BATTELLE MEMORIAL INSTITUTE
    Inventors: Wayne Surdoval, Edgar Lara-Curzio, Jeffry Stevenson, Joseph Thomas Muth, Beth L. Armstrong, Amit Shyam, Rosa M. Trejo, Yanli Wang, Yeong Shyung Chou, Travis Ray Shultz
  • Patent number: 9365233
    Abstract: The invention relates to a steering column for a motor vehicle, comprising a steering spindle mounted rotatably in a steering spindle bearing unit, and comprising a guide bracket for connecting the steering spindle bearing unit to a body of the motor vehicle, wherein at least one component of the steering column is formed at least in part from a fiber-reinforced composite material, wherein a component has a thin-walled braided core which corresponds to the shape of the subsequent component, is formed from a thermoplastic material, and is braided with a fiber material, wherein the braided core is produced in an injection molding method and contains functional elements molded therein.
    Type: Grant
    Filed: March 11, 2013
    Date of Patent: June 14, 2016
    Assignee: THYSSENKRUPP PRESTA AG
    Inventors: Thomas Heitz, Sebastian Regner, Arne Schacht
  • Patent number: 9039955
    Abstract: When a molded fabric body (X) is impregnated with a powder (K) of a predetermined material, there are performed a first step of dispersing the powder (K) in a liquid to prepare a slurry, and a second step of burying the molded fabric body (X) made of fiber bundles in the slurry and vibrating the slurry by use of a predetermined vibrator (M). Furthermore, in the second step, the vibrator (M) is moved along a surface of the molded fabric body (X). As a result, it is possible to improve the rate of impregnation of the powder (K) more than that in the conventional cases, irrespective of the shape of the molded fabric body (X).
    Type: Grant
    Filed: March 29, 2011
    Date of Patent: May 26, 2015
    Assignee: IHI CORPORATION
    Inventors: Hiroshige Murata, Yasutomo Tanaka, Yuuki Nonaka, Takeshi Nakamura
  • Patent number: 8986599
    Abstract: Methods are provided for making ceramic preforms having two-dimensional interconnected channels therein. The methods include (i) positioning a sacrificial material having a selected profile within a bed of ceramic powder; (ii) compacting the bed of ceramic powder to form a compacted mass; (iii) heating the compacted mass to thermally transform the sacrificial materials into a fluid without cracking the compacted mass; and (iv) removing the fluid from the compacted mass, thereby leaving a two-dimensional network of interconnected channels having the selected profile of the sacrificial material within the compacted mass. Ceramic preforms are also provided which include a compacted mass of ceramic powder and two-dimensional interconnected channels therein.
    Type: Grant
    Filed: August 25, 2011
    Date of Patent: March 24, 2015
    Assignee: Florida State University Research Foundation, Inc.
    Inventors: Okenwa O. I. Okoli, Ben Wang, Osayande Lord-Rufus Ighodaro
  • Patent number: 8956480
    Abstract: The carbon-carbon composite material is obtained by densification with a pyrolytic carbon matrix originating from a precursor in gaseous state at least in a main external phase of the matrix, and, at the end of the densification, final heat treatment is performed at a temperature lying in the range 1400° C. to 1800° C.
    Type: Grant
    Filed: December 15, 2010
    Date of Patent: February 17, 2015
    Assignee: Messier-Bugatti-Dowty
    Inventors: Jean-Marie Jouin, Eric Lherm, Philippe Turgis
  • Patent number: 8940132
    Abstract: The present invention relates to a process for the manufacture of structural hybrid thermoplastic composites where organic and inorganic fibers are well dispersed in a thermoplastic matrix. The process comprises defibrillating the organic fibers with or without the presence of surface active agents using a mixer at a high shear and at a temperature lower than the decomposition temperature of organic fibers and melting point of the surface active agents to separate the hydrogen bonded fibers and generate microfibers, followed by blending and dispersion of the organic fibers in the thermoplastic matrix to produce a fiber composite, followed by further blending and dispersion of the fiber composite with inorganic fibers at a low shear to get the moldable hybrid composite, followed by extrusion, injection or compression-injection molding. Low shear mixing maintains the inorganic fiber length.
    Type: Grant
    Filed: September 21, 2007
    Date of Patent: January 27, 2015
    Inventors: Mohini M. Sain, Suhara Panthapulakkal, Shiang F. Law
  • Patent number: 8936748
    Abstract: Artificial turf has a base layer, a multiplicity of blades fixed in and projecting upward from the base layer, and a mass of damping material on the base layer and through which the blades project. Each of the blades is at least partially formed of a polyester of terephthalic acid made from waste. The polyester is polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), both from waste. The base layer is a flat primary layer, preferably a textile and preferably consists of plastic, a polyolefin and/or a polyester of terephthalic acid, preferably a polyester of terephthalic acid from waste.
    Type: Grant
    Filed: August 16, 2012
    Date of Patent: January 20, 2015
    Assignee: Reifenhaeuser GmbH & Co. KG Maschinenfabrik
    Inventor: Juergen Morton-Finger
  • Patent number: 8932501
    Abstract: The present invention concerns processes for reducing water in never-dried fiber comprising copolymer derived from the copolymerization of para-phenylenediamine, 5(6) -amino-2-(p-aminophenyl)benzimidazole; and terephthaloyl dichloride, the process comprising the steps of: (a) heating the never-dried fiber to a temperature of at least 20° C. but less than 100 ° C. until the moisture content of the fiber is 20 weight percent or less of the fiber; and (b) further heating the fiber to a temperature of at least 350° C.
    Type: Grant
    Filed: January 13, 2012
    Date of Patent: January 13, 2015
    Assignee: E I du Pont de Nemours and Company
    Inventors: Steven R. Allen, Christopher William Newton
  • Patent number: 8906288
    Abstract: Provided is a process for producing dense SiC fiber-bonded ceramics excellent in heat resistance and having a shape hard to form by hot pressing such as an elongated shape. The process for producing SiC fiber-bonded ceramics composed of: inorganic fiber made of SiC; and interfacial layers mainly made of carbon includes vacuum-sealing a preform, prepared by forming specific silicon carbide-based inorganic fiber into a certain shape, into a capsule and hot-isostatic-pressing the preform. The process is characterized in that the ratio of the number of carbon atoms to the number of silicon atoms in the preform is 1.02 to 1.20, and before the hot isostatic pressing, the preform is heated in an inert gas atmosphere or a reducing gas atmosphere at a temperature of 1200° C. to 1800° C. to adjust the oxygen content in the inorganic fiber to 6.0% by weight or lower, and then the hot isostatic pressing is carried out.
    Type: Grant
    Filed: September 17, 2009
    Date of Patent: December 9, 2014
    Assignee: Ube Industries, Ltd.
    Inventors: Kenji Matsunaga, Shinji Kajii, Tsutomu Kodama
  • Patent number: 8894918
    Abstract: Methods are disclosed for producing architectural preforms and high-temperature composite structures containing high-strength ceramic fibers with reduced preforming stresses within each fiber, with an in-situ grown coating on each fiber surface, with reduced boron within the bulk of each fiber, and with improved tensile creep and rupture resistance properties tier each fiber. The methods include the steps of preparing an original sample of a preform formed from a pre-selected high-strength silicon carbide ceramic fiber type, placing the original sample in a processing furnace under a pre-selected preforming stress state and thermally treating the sample in the processing furnace at a pre-selected processing temperature and hold time in a processing gas having a pre-selected composition, pressure, and flow rate.
    Type: Grant
    Filed: February 19, 2010
    Date of Patent: November 25, 2014
    Assignee: The United States of America as Represented by the Administrator of National Aeronautics and Space Administration
    Inventors: James A. DiCarlo, Hee-Mann Yun
  • Patent number: 8887863
    Abstract: A mat member includes inorganic fibers, a first surface and a second surface opposite to the first surface. The first surface has a plurality of needle penetration marks and/or a plurality of needle protrusion marks. The second surface has a plurality of needle protrusion marks and/or a plurality of needle penetration marks. A plurality of needle marks are formed in the mat member by needle punching and extend from the needle penetration mark to the needle protrusion mark. An inorganic fiber bundle which includes a plurality of the inorganic fibers oriented in a closed loop configuration is formed at the needle protrusion mark.
    Type: Grant
    Filed: October 6, 2008
    Date of Patent: November 18, 2014
    Assignee: Ibiden Co., Ltd.
    Inventors: Takahiko Okabe, Daisuke Suzuki
  • Patent number: 8865031
    Abstract: A method and apparatus for applying a mid-IR graded microstructure to the end of an As2S3 optical fiber are presented herein. The method and apparatus transfer a microstructure from a negative imprint on a nickel shim to an As2S3 fiber tip with minimal shape distortion and minimal damage-threshold impact resulting in large gains in anti-reflective properties.
    Type: Grant
    Filed: April 27, 2011
    Date of Patent: October 21, 2014
    Assignee: BAE Systems Information and Electronic Systems Integration Inc.
    Inventors: Joseph M. Owen, David P. Kelly, Michael E. Chadwick
  • Patent number: 8865040
    Abstract: This invention provides a fuel cell flow field plate or bipolar plate having flow channels on faces of the plate, comprising an electrically conductive polymer composite. The composite is composed of (A) at least 50% by weight of a conductive filler, comprising at least 5% by weight reinforcement fibers, expanded graphite platelets, graphitic nano-fibers, and/or carbon nano-tubes; (B) polymer matrix material at 1 to 49.9% by weight; and (C) a polymer binder at 0.1 to 10% by weight; wherein the sum of the conductive filler weight %, polymer matrix weight % and polymer binder weight % equals 100% and the bulk electrical conductivity of the flow field or bipolar plate is at least 100 S/cm. The invention also provides a continuous process for cost-effective mass production of the conductive composite-based flow field or bipolar plate.
    Type: Grant
    Filed: February 4, 2011
    Date of Patent: October 21, 2014
    Assignee: Nanotek Instruments, Inc.
    Inventors: Bor Z. Jang, Aruna Zhamu, Lulu Song
  • Publication number: 20140273703
    Abstract: Fibrous materials and methods of manufacturing fibrous materials are disclosed. In particular, this application discloses methods of making and processing serially deposited fibrous structures, such as serially deposited fibrous mats. Serially deposited fibrous mats may be used in implantable medical devices with various characteristics and features. Serially deposited fibrous mats of various mat thickness, fiber size, porosity, pore size, and fiber density are disclosed. Additionally, serially deposited fibrous mats having various amounts of fiber structures (such as intersections, branches, and bundles) per unit area are also disclosed.
    Type: Application
    Filed: March 12, 2014
    Publication date: September 18, 2014
    Applicant: Merit Medical Systems, Inc.
    Inventors: Wayne L. Mower, John William Hall, Rachel L. Simmons, Bart Dolmatch, F. Mark Ferguson
  • Publication number: 20140186599
    Abstract: The inorganic fiber molded body of the present invention is characterized in that the molded body has an extremely light weight, and is free from problems such as scattering of fibers and particulate matters from a surface thereof and environmental pollution such as generation of harmful gases. In addition, the present invention provides an inorganic fiber molded body that is excellent in not only thermal shock resistance and mechanical shock resistance but also a high-speed wind erosion resistance, well-balanced in properties and can be used in the applications of various heat-insulating materials. The present invention relates to an inorganic fiber molded body comprising inorganic fibers and inorganic binder particles and having at least one set of a high-fiber density region and a low-fiber density region, in which a ratio of a content of the binder particles in the high-fiber density region to a content of the binder particles in the low-fiber density region as measured by a predetermined method is 0.
    Type: Application
    Filed: March 6, 2014
    Publication date: July 3, 2014
    Applicant: MITSUBISHI PLASTICS, INC.
    Inventors: Tsuyoshi FUKUI, Toshio Ito, Yusaku Hata, Hisashi Aoyagi, Hidetaka Ito
  • Publication number: 20140179188
    Abstract: A ceramic composite material is comprised of a fabric of fibers of an inorganic substance; and a matrix for combining the fibers. The matrix consists essentially of a ceramic. The matrix is formed by burying the fabric in a mixture of a powder of carbon, a powder of silicon and a medium including an organic solvent, producing an oscillation in the mixture to impregnate the fabric with the mixture, and calcining the fabric impregnated with the mixture.
    Type: Application
    Filed: February 27, 2014
    Publication date: June 26, 2014
    Applicants: THE SOCIETY OF JAPANESE AEROSPACE COMPANIES, INC., ISHIKAWAJIMA-HARIMA HEAVY INDUSTRIES CO., LTD.
    Inventors: Hiroshige MURATA, Takeshi Nakamura, Yasutomo Tanaka
  • Patent number: 8747730
    Abstract: A method of forming a woven fiber structure for a molding process to produce a ceramic matrix composite, includes depositing a tackifier composition having a carrier solvent, a resin material, and an inorganic filler onto at least a portion of a woven fiber structure; drying the tackifier composition on woven fiber structure to remove at least a portion of the carrier solvent from the tackifier composition; and forming the dried woven fiber structure into a preform.
    Type: Grant
    Filed: June 14, 2012
    Date of Patent: June 10, 2014
    Assignee: United Technologies Corporation
    Inventor: John Riehl
  • Patent number: 8728383
    Abstract: A ceramic composite material is comprised of a fabric of fibers of an inorganic substance; and a matrix for combining the fibers. The matrix consists essentially of a ceramic. The matrix is formed by burying the fabric in a mixture of a powder of carbon, a powder of silicon and a medium including an organic solvent, producing an oscillation in the mixture to impregnate the fabric with the mixture, and calcining the fabric impregnated with the mixture.
    Type: Grant
    Filed: March 29, 2007
    Date of Patent: May 20, 2014
    Assignees: Ishikawajima-Harima Heavy Industries Co., Ltd., The Society of Japanese Aerospace Companies, Inc.
    Inventors: Hiroshige Murata, Takeshi Nakamura, Yasutomo Tanaka
  • Publication number: 20140084521
    Abstract: A method for producing a part made of ceramic matrix and ceramic fibres composite material. It comprises: the formation of a fibrous preform by intertwining threads constituted of ceramic material fibres on a contact surface of a support element reproducing the internal and/or external shape of the part to be produced; the partial densification of the fibrous preform at a temperature below the melting temperature of the material of the support element and below the melting temperature of the material of the fibres of the preform, said partial densification resulting in a consolidated fibrous preform comprising a matrix volume fraction above 5% and at the most equal to 40% of the matrix volume of the part to be produced; the removal of the support element from the consolidated fibrous preform by chemical attack of the contact surface of the material of the support element; the densification of the consolidated preform, carried out at a temperature below the melting temperature of the fibres of said preform.
    Type: Application
    Filed: January 23, 2012
    Publication date: March 27, 2014
    Inventors: Cédric Sauder, Christophe Lorrette
  • Patent number: 8679378
    Abstract: A method and system for generating an optical fiber is provided. The method includes creating a green fiber consisting primarily of a ceramic material and sintering the green fiber with a laser by moving the green fiber through a beam of the laser to increase the density of the fiber after sintering. The system for creating a continuous optical fiber includes an extruder, a processing chamber and a laser. The extruder is configured to extrude a ceramic slurry as a green fiber. The processing chamber is configured to receive and process the green fiber. And, the laser is configured to direct a laser spot on the green fiber exiting the processing chamber to sinter the green fiber.
    Type: Grant
    Filed: August 18, 2011
    Date of Patent: March 25, 2014
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Jonathan Goldstein, Geoff Fair, Heedong Lee, HyunJun Kim
  • Patent number: 8652648
    Abstract: A method for manufacturing indium tin oxide nanowires by preparing a solution that includes an indium-containing species, a tin-containing species and a polymeric material, wherein the solution has a molar ratio of tin to indium in a range from about 5 to about 15 percent, electrospinning fibers using the solution, and heating the fibers to a calcination temperature and maintaining the fibers at the calcination temperature for a predetermined calcination time.
    Type: Grant
    Filed: June 13, 2013
    Date of Patent: February 18, 2014
    Assignee: The Boeing Company
    Inventors: Chaoyin Zhou, Amanda Phelps, Richard W. Burns, Wen Li
  • Patent number: 8628713
    Abstract: An inorganic board contains, in a solid content ratio, 30 to 70 mass % of hydraulic material, 5 to 15 mass % of reinforcing fiber, and 1 to 30 mass % of wollastonite having a wet volume (after being allowed to stand for 30 minutes) of 15 to 45 ml. Also, a method includes: step of producing a slurry containing hydraulic material, reinforcing fiber, and wollastonite; step of producing a sheet by dehydrating the slurry; and step of pressing and curing the sheet; wherein, in the step of producing a slurry, a composition of the slurry is set so as to contain, in a solid content ratio, 30 to 70 mass % of hydraulic material, 5 to 15 mass % of reinforcing fiber, and 1 to 30 mass % of wollastonite having a wet volume (after being allowed to stand for 30 minutes) of 15 to 45 ml.
    Type: Grant
    Filed: March 5, 2013
    Date of Patent: January 14, 2014
    Assignee: Nichiha Corporation
    Inventors: Satoshi Ikeda, Yusuke Omori
  • Patent number: 8623263
    Abstract: A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic materials applied to the plurality of glass fibers is disclosed herein. The process includes the step of enclosing the muffler preform in a chamber. The process also includes the step of surrounding the muffler preform with steam. The process also includes the step of causing steam to enter the muffler preform from multiple directions.
    Type: Grant
    Filed: September 21, 2009
    Date of Patent: January 7, 2014
    Assignee: OCV Intellectual Capital, LLC
    Inventors: Norman T. Huff, Janakikodandaram Karra
  • Patent number: 8585947
    Abstract: A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on fibers and on a crosslinkable resin, by continuous winding and superposition of several layers of a tape of reinforcement fibers embedded in a matrix based on a composition comprising a crosslinkable resin. The process comprises from upstream to downstream, the following steps: producing a rectilinear arrangement (12) of reinforcement fibers (11) and conveying this arrangement in a feed direction (F); degassing the arrangement (12) of fibers by the action of a vacuum (13); after degassing, impregnating said arrangement (12) of fibers under vacuum with said resin composition in the liquid state (17); passing the pre-preg thus obtained through a die (20) to make said pre-preg into the form of a tape (21) composed of reinforcement fibers (11) in their liquid resin (17) matrix, the thickness of said tape being less than 0.
    Type: Grant
    Filed: January 23, 2007
    Date of Patent: November 19, 2013
    Assignee: Michelin Recherche et Technique S.A.
    Inventors: Jean-Paul Meraldi, Antonio Delfino
  • Patent number: 8562901
    Abstract: The current invention provides a method to fabricate a crack-free continuous fiber-reinforced ceramic matrix composite by eliminating shrinkage stresses through a unique combination of freeze forming and a non-shrinking matrix composition. Cracks related to drying shrinkage are eliminated through freeze forming and cracks related to sintering shrinkage are eliminated by using a matrix that does not shrink at the given sintering temperature. After sintering, a crack-free ceramic composite is obtained.
    Type: Grant
    Filed: August 24, 2009
    Date of Patent: October 22, 2013
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Tai-Il Mah, Kristin A. Keller, Michael K. Cinibulk
  • Patent number: 8491835
    Abstract: A refractory ceramic composite for an armor shell, comprising a ceramic core that is formable to replicate a portion of a three dimensional surface, e.g., of an aircraft, to provide ballistic protection. A method of making a shell of refractory ceramic armor capable of conforming to the geometry is provided. The shell is formed by forming a mold to replicate the surface area; arranging a ceramic core on the mold; and removing the mold to leave said ceramic core, and heat treating the ceramic core to a desired hardness. The ceramic core is in the shape of the surface area.
    Type: Grant
    Filed: December 15, 2011
    Date of Patent: July 23, 2013
    Assignee: United Technology Corporation
    Inventor: Wayde R. Schmidt
  • Patent number: 8465691
    Abstract: A method for manufacturing indium tin oxide nanowires by preparing a solution that includes an indium-containing species, a tin-containing species and a polymeric material, wherein the solution has a molar ratio of tin to indium in a range from about 5 to about 15 percent, electrospinning fibers using the solution, and heating the fibers to a calcination temperature and maintaining the fibers at the calcination temperature for a predetermined calcination time.
    Type: Grant
    Filed: May 26, 2010
    Date of Patent: June 18, 2013
    Assignee: The Boeing Company
    Inventors: Chaoyin Zhou, Amanda Phelps, Richard W. Burns, Wen Li
  • Patent number: 8398906
    Abstract: The invention pertains to a method for making a polymer-additive composite particle from a dope by jet spinning the dope to obtain a pulp, fibril or fibrid, wherein the solvent of the dope is selected from N-methyl-2-pyrrolidone, N,N?-dimethylformamide, N,N?-dimethylacetamide, tetramethylurea, and 4 to 75 wt % of a composition consisting of 2 to 95 wt % of a para-aramid polymer and 5-98 wt % of a solid additive material, to a total of 100 wt %, and wherein the aramid polymer is dissolved in the solvent; or coagulating the dope by means of a rotor-stator apparatus in which the polymer solution is applied through the stator on the rotor so that the precipitating polymer-additive composite particle is subjected to shear forces while they are in a plastic deformable stage.
    Type: Grant
    Filed: March 28, 2008
    Date of Patent: March 19, 2013
    Assignee: Teijin Aramid B.V.
    Inventors: Anton Johannes Josef Hendriks, Mirjam Ellen Oldenzeel, Johannus Maria Bergmans, Tetsuya Akamatsu
  • Patent number: 8357323
    Abstract: A stitching geometry and method for selective interlaminar reinforcement of a CMC wall (20A). The CMC wall is formed of ceramic fiber layers (22) individually infused with a ceramic matrix, stacked, and at least partially cured. A row of holes is formed in the wall, and a ceramic fiber thread (25) is infused with a wet ceramic matrix and passed through the holes to form stitches (28, 30, 31). The stitches are then cured, causing them to shrink more than any remaining wall shrinkage, thus tensioning the stitches and compressing the wall laminae together. The stitches may have through-wall portions (30, 31) that are angled differently in different wall areas as a function of interlaminar shear over interlaminar tension, optimizing wall reinforcement locally depending on magnitude and direction of shear. Alternate rows of stitches (54, 56) may have offsets in a stitch direction (34) and/or different through-wall angles (A1, A2).
    Type: Grant
    Filed: July 16, 2008
    Date of Patent: January 22, 2013
    Assignee: Siemens Energy, Inc.
    Inventors: Jay A. Morrison, Jay E. Lane
  • Patent number: 8309013
    Abstract: A method for the production of components made of ceramic-matrix composite material, in the fields of aerospace engines and turbines and turbine systems and plants; according to the method, a preform of ceramic fibers is shaped and set in a draining mold, for example made of plaster; the fibers of the preform are impregnated with a suspension of ceramic powders, the liquid of which is drained by capillarity from the draining mold; simultaneously to draining, a suspension of ceramic powders is infiltrated between the fibers of the preform so as to fill the empty space left by the drained liquid; at the end of the steps of draining/infiltration a body is obtained with a solidified or compacted porous matrix, which is removed from the draining mold and is sintered.
    Type: Grant
    Filed: October 23, 2009
    Date of Patent: November 13, 2012
    Assignee: Avio S.p.A.
    Inventors: Giuseppe Pasquero, Giovanni Paolo Zanon, Maria Rita Petrachi, Antonio Licciulli, Antonio Chiechi, Maurizio Fersini
  • Publication number: 20120267833
    Abstract: A method of forming a woven fiber structure for a molding process to produce a ceramic matrix composite, includes depositing a tackifier composition having a carrier solvent, a resin material, and an inorganic filler onto at least a portion of a woven fiber structure; drying the tackifier composition on woven fiber structure to remove at least a portion of the carrier solvent from the tackifier composition; and forming the dried woven fiber structure into a preform.
    Type: Application
    Filed: June 14, 2012
    Publication date: October 25, 2012
    Inventor: John Riehl
  • Publication number: 20120153216
    Abstract: High thermal conductivity sintered metallic networks are provided for enhancing the transverse thermal conductivity of fiber reinforced polymeric materials. The approach establishes sintered metallic networks in both the intratow and interlaminar regions of a FRP part after appropriate thermal processing Dispersing metallic nanoparticles into a fluxing polymeric resin, and optionally mixing in low and high melting point metallic particles, can establish continuous metallurgical networks through the thickness of a FRP laminate. The fluxing polymeric resin has the dual benefit of reducing native oxides on the metallic fillers to aid the sintering reactions, and also to tailor the rheological properties to yield usable material embodiments with limited impact on material density. The high intrinsic thermal conductivity of the metallic networks yields a FRP part with enhanced transverse thermal conductivity.
    Type: Application
    Filed: December 20, 2011
    Publication date: June 21, 2012
    Inventor: Matthew Wrosch
  • Publication number: 20120157358
    Abstract: Methods are described to make strong, tough, and lightweight whisker-reinforced glass-ceramic composites through a self-toughening structure generated by viscous reaction sintering of a complex mixture of oxides. The present invention further relates to strong, tough, and lightweight glass-ceramic composites that can be used as proppants and for other uses.
    Type: Application
    Filed: January 20, 2011
    Publication date: June 21, 2012
    Applicant: OXANE MATERIALS, INC.
    Inventors: Christopher Y. Fang, Yuming Xie, Dilip K. Chatterjee, Christopher E. Coker
  • Publication number: 20120124952
    Abstract: A mat includes inorganic fibrous substances, first and second main faces, first and second side faces and intertwined portions. The intertwined portions respectively extend from needle piercing points of the first main face to needle piercing points of the second main face. A first virtual straight line and each of second virtual straight lines intersect with each other at a first angle of less than about 90° when viewed from the first side face to the second side face. The first virtual straight line and each of third virtual straight lines intersect with each other at a second angle of more than about 90° when viewed from the first side face to the second side face. The second virtual straight lines and the third virtual straight lines intersect with each other at a third angle when viewed from the first side face to the second side face.
    Type: Application
    Filed: September 28, 2011
    Publication date: May 24, 2012
    Applicant: IBIDEN CO., LTD.
    Inventor: Ryoji Uno
  • Patent number: 8182738
    Abstract: Process for producing bodies from ceramic materials using silicon carbide, comprising the steps: configuration of fiber-reinforced porous bodies (1, 5) that consist of carbon on a base (2) that is inert relative to liquid silicon, the bodies having cavities (3) that are accessible from the exterior or surface recesses (3?), and the cavities (3) being closed at the bottom in the porous bodies or the surface recesses (3?) together with the base (2) forming a reservoir that is sealed at the bottom; heating the configuration by introduction of energy to melt the silicon (6) that is present in the reservoir; and infiltrating the melted silicon in the bodies (1, 5) and reaction of the silicon with the carbon to form silicon carbide; and use of the thus produced bodies as brake disks and as clutch driving disks.
    Type: Grant
    Filed: September 16, 2010
    Date of Patent: May 22, 2012
    Assignee: Audi, AG
    Inventors: Andreas Kienzle, Johann Daimer
  • Patent number: 8109734
    Abstract: An article such as a fan blade of a turbofan engine comprises a core made up of components at least some of which comprise packs of rods embedded in a resin matrix material. The rods extend in the span-wise direction of the blade to resist centrifugal forces imposed on the blade during operation. The core is encased in a skin formed from preforms which may comprise fabric reinforcements.
    Type: Grant
    Filed: February 24, 2009
    Date of Patent: February 7, 2012
    Assignee: Rolls-Royce PLC
    Inventor: Robert C Backhouse
  • Patent number: 8101106
    Abstract: Molding material that includes a layer of fibrous reinforcing material having one surface on which a first layer of a resin partially impregnates the fibrous material and a further resin layer located on the opposite surface which retains in position surface fibers of the fibrous material. The further resin layer is of lower weight than the first layer and is formed as an openwork structure with a solid part and spaces through which the fibrous material is exposed.
    Type: Grant
    Filed: July 16, 2007
    Date of Patent: January 24, 2012
    Assignee: Hexcel Composites, Ltd.
    Inventor: John Ellis
  • Publication number: 20110101575
    Abstract: A preform for a composite material which has high strength and excellent air permeability and hence is applicable to a high-speed die casting method and which is capable of forming a metal composite material having excellent mechanical properties by a high-speed die casting method. Also provided is a process for producing such a preform. Ceramic fibers or/and ceramic particles are mixed with a silica sol and calcium carbonate and sintered at a predetermined temperature to form a calcium/silicon sinter obtained from the silica sol and calcium carbonate. The calcium/silicon sinter coats the ceramic fibers or/and ceramic particles so that a preform having the fibers or/and the particles bound to each other by the calcium/silicon sinter is obtained. The preform for a composite material has high strength and excellent air permeability and is applicable to the high-speed die casting method capable of attaining high productivity.
    Type: Application
    Filed: December 23, 2010
    Publication date: May 5, 2011
    Applicants: Central Motor Wheel Co., Ltd., TOYOTA JIDOSHA KABUSHIKI KAISHA, GE TECHNO CO., LTD.
    Inventors: Makoto Fujita, Kunio Kumagai, Masaoki Hashimoto, Kazuko Hashimoto, Hidenori Uebayashi, Hiroshi Kawai, Mitsuyoshi Sato, Masaru Kato
  • Patent number: 7919418
    Abstract: A composite material which has excellent ballistic performance and has improved flexibility. Surprisingly, it has been found that a combination of poly(alpha-olefin) fiber and matrix resin provides these desirable product features. The resin matrix is a block copolymer of a conjugated diene and a vinyl aromatic monomer, preferably a styrene-isoprene-styrene block copolymer, that is applied as an aqueous composition. The fiber has a tenacity of at least about 35 g/d and a tensile modulus of at least about 1200 g/d. The composite has a total density equal to or less than about 100 g/m2 and a stiffness of less than about 2.5 pounds (1.14 kg) for a two layer structure of the composite, and a total areal density equal to or less than about 190 g/m2 and a stiffness of less than about 3.0 pounds (1.36 kg) for a four layer structure of the composite. The Peel Strength for a two layer structure of less than about 1.0 pounds (0.45 kg) for a two layer structure of the composite, and less than about 0.7 pounds (0.
    Type: Grant
    Filed: June 28, 2007
    Date of Patent: April 5, 2011
    Assignee: Honeywell International Inc.
    Inventors: Ashok Bhatnagar, Brian D. Arvidson, David A. Hurst, Danelle F. Powers, David A. Steenkamer
  • Patent number: 7919039
    Abstract: The invention relates to a particularly low-cost and flexible process for the preparation of a sintered ceramic fiber composite material consisting of oxide-ceramic continuous fibers and an oxide-ceramic matrix, and to a fiber composite material prepared by such process.
    Type: Grant
    Filed: June 13, 2006
    Date of Patent: April 5, 2011
    Assignee: Deutsches Zentrum fur Luft und Raumfahrt e.V.
    Inventor: Bernhard Kanka
  • Patent number: 7893000
    Abstract: Boron carbide ceramics produced by spark sintering methods have more desirable mechanical properties than conventionally produced carbides. The boron carbide ceramics include amorphous boron, amorphous carbon, and Al2O3 powder as a sintering aid. The boron carbides may also contain a carbon nano fiber in a nearly homogeneously dispersed state. The sintered compact has a relative density of a boron carbide ceramic of approximately not less than 99%. The boron carbide ceramics are prepared preferably by subjecting a mixed powder of the starting raw materials and the carbon nano fiber to simultaneous synthesis and sintering using the spark plasma sintering method.
    Type: Grant
    Filed: August 16, 2010
    Date of Patent: February 22, 2011
    Assignee: The Doshisha
    Inventors: Ken Hirota, Yoshihiro Nakayama, Shingo Nakane
  • Patent number: 7850892
    Abstract: A test blade and a method for fabricating the test blade are presented for use in calibrating a tomography system configured to inspect turbomachine blades for defects. The test blade may include a three-dimensional fiber blank and a polymerized resin. The blank may be created by weaving synthetic material fibers. The resin may be configured to be injected into a mold as a liquid where the resin may polymerize around the fiber blank. The test blade may be configured to be modified to include particular defects such as cut fibers and/or cavity defects which are perceived by the tomography system. The dimensions of the cavity defects may be substantially created by pulling two or more fibers apart at a specific distance with a spreading tool.
    Type: Grant
    Filed: October 22, 2007
    Date of Patent: December 14, 2010
    Assignee: SNECMA
    Inventors: Jean-Louis Romero, Myriam Wozniak
  • Patent number: 7807092
    Abstract: The invention relates to methods for fabricating ceramic nanocomposite powders, comprising a ceramic matrix and carbon nanotubes homogeneously dispersed in the ceramic matrix. The ceramic nanocomposite powders of the invention can prevent property deterioration due to agglomeration of carbon nanotubes.
    Type: Grant
    Filed: February 19, 2004
    Date of Patent: October 5, 2010
    Assignee: Korea Advanced Institute of Science and Technology
    Inventors: Soon Hyung Hong, Seung Il Cha, Kyung Tae Kim, Kyong Ho Lee, Chan Bin Mo
  • Patent number: 7799715
    Abstract: Boron carbide ceramics produced by spark sintering methods have more desirable mechanical properties than conventionally produced carbides. The boron carbide ceramics include amorphous boron, amorphous carbon, and Al2O3 powder as a sintering aid. The boron carbides may also contain a carbon nano fiber in a nearly homogeneously dispersed state. The sintered compact has a relative density of a boron carbide ceramic of approximately not less than 99%. The boron carbide ceramics are prepared preferably by subjecting a mixed powder of the starting raw materials and the carbon nano fiber to simultaneous synthesis and sintering using the spark plasma sintering method.
    Type: Grant
    Filed: September 12, 2008
    Date of Patent: September 21, 2010
    Assignee: The Doshisha
    Inventors: Ken Hirota, Yoshihiro Nakayama, Shingo Nakane
  • Publication number: 20100179052
    Abstract: A clay-pulp mixture is prepared by blending a predetermined ratio of clay and wood pulp derived from alpha virgin cellulose in dry form, moistening the mixture homogeneously by adding water and continuing to blend until a malleable consistency is achieved. Air is extracted from the moist mixture, and solid blocks formed for storage and delivery to end-users.
    Type: Application
    Filed: January 15, 2009
    Publication date: July 15, 2010
    Inventor: Jonathan Brooks
  • Patent number: 7744807
    Abstract: A coherent nonwoven fibrous web comprises directly formed elastic fibers that have a molecular orientation sufficient to provide a birefringence number of at least 1×10?5 and preferably at least 1×10?2. The web can be made by a method that comprises a) extruding filaments of elastic-fiber-forming material; b) directing the filaments through a processing chamber in which gaseous currents apply a longitudinal stress to the filaments that attenuates and draws the filaments; c) maintaining the filaments at their orienting temperature while the filaments are under attenuating and drawing stress for a sufficient time for molecules within the filaments to become oriented along the length of the filaments; d) cooling the filaments to their orientation-locking temperature while the filaments are under attenuating and drawing stress and further cooling the filaments to a solidified fiber form; and e) collecting the solidified fibers as a fibrous nonwoven web.
    Type: Grant
    Filed: August 7, 2006
    Date of Patent: June 29, 2010
    Assignee: 3M Innovative Properties Company
    Inventors: Michael R. Berrigan, Anne N. De Rovere, Bradley W. Eaton, Brandy S. Nolan, Troy K. Ista, Timothy J. Lindquist
  • Publication number: 20100109209
    Abstract: A method for the production of components made of ceramic-matrix composite material, in the fields of aerospace engines and turbines and turbine systems and plants; according to the method, a preform of ceramic fibres is shaped and set in a draining mould, for example made of plaster; the fibres of the preform are impregnated with a suspension of ceramic powders, the liquid of which is drained by capillarity from the draining mould; simultaneously to draining, a suspension of ceramic powders is infiltrated between the fibres of the preform so as to fill the empty space left by the drained liquid; at the end of the steps of draining/infiltration a body is obtained with a solidified or compacted porous matrix, which is removed from the draining mould and is sintered.
    Type: Application
    Filed: October 23, 2009
    Publication date: May 6, 2010
    Applicant: AVIO S.p.A.
    Inventors: Giuseppe Pasquero, Giovanni Paolo Zanon, Maria Rita Petrachi, Antonio Licciulli, Antonio Chiechi, Maurizio Fersini
  • Patent number: RE45450
    Abstract: A method for producing a glass wool molded product includes the steps of processing a glass material into fibers so as to obtain a glass wool, gathering such glass wools to form a glass wool mat, and subjecting the glass wool mat to press molding, wherein the above described press molding is carried out, while supplying water so that the water content of the above described glass wool mat becomes 0.1% to 7.0% by mass, and while maintaining a temperature between 250° C. and 450° C.
    Type: Grant
    Filed: March 18, 2013
    Date of Patent: April 7, 2015
    Assignees: Mag-Isover K.K., Panasonic Corporation
    Inventor: Toru Murakami