Producing Uniformly Dispersed Particulate Fiber Containing Article Patents (Class 264/641)
  • 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: 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: 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: 20140120355
    Abstract: A method of making a tile, the method comprising: providing a plurality of nano-particles, wherein the plurality of nano-particles comprises a plurality of ceramic nano-particles; and performing a spark plasma sintering (SPS) process on the plurality of nano-particles, thereby forming a tile comprising the plurality of nano-particles, wherein the nano-structure of the nano-particles is present in the formed tile. In some embodiments, the tile is bonded to a ductile backing material.
    Type: Application
    Filed: September 25, 2013
    Publication date: May 1, 2014
    Applicant: SDCmaterials, Inc.
    Inventor: Maximilian A. BIBERGER
  • 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: 8584570
    Abstract: Methods for making armor and armor articles with transformed nanomaterial. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
    Type: Grant
    Filed: July 11, 2012
    Date of Patent: November 19, 2013
    Assignee: NanoRidge Materials, Inc.
    Inventors: Douglas Charles Ogrin, Kyle Ryan Kissell, Kurt Lee Lundberg, John Richard Tidrow
  • Publication number: 20130288880
    Abstract: A SiC ceramic material includes a bundle of SiC continuous fibers in a porous SiC ceramic matrix, has thermal insulation properties, a high level of strength and a high degree of toughness. A SiC ceramic structure is made of the SiC ceramic material. It is produced by preparing a pressure-sintered compact using a slurry prepared by mixing SiC powder and carbon powder in a liquid and by gasifying and releasing the carbon powder. The SiC ceramic structure can be produced by heating a reaction preparation containing a bundle of SiC continuous fibers and Si powder to a temperature equal to or higher than the melting point of silicon causing a reaction of the carbon component and Si powder and thereby obtaining a reaction-sintered compact, and by gasifying and releasing the carbon component from the reaction-sintered compact. The SiC ceramic can be produced by a chemical vapor deposition method.
    Type: Application
    Filed: November 10, 2011
    Publication date: October 31, 2013
    Applicant: KYOTO UNIVERSITY
    Inventors: Tatsuya Hinoki, Yi-Hyun Park
  • 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: 8257637
    Abstract: A method is provided for removing a resin layer of a resin-coated metal tube. The resin layer is removed with a laser beam. More particularly, the resin layer of a desired range is burned out by focusing the laser beam into a pinpoint without defocusing the sectional shape of the laser beam in the axial direction o the resin-coated metal tube.
    Type: Grant
    Filed: January 14, 2005
    Date of Patent: September 4, 2012
    Assignee: Usui Kakusai Sangyo Kaisha Limited
    Inventor: Atsushi Okada
  • Patent number: 8225704
    Abstract: Armor with ceramic material and transformed nanotube material produced during/via process transformation, the transformed material in one aspect being graphene ribbon-like material; in one be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
    Type: Grant
    Filed: January 16, 2010
    Date of Patent: July 24, 2012
    Assignee: Nanoridge Materials, Inc.
    Inventors: Douglas Charles Ogrin, Kyle Ryan Kissell, Kurt Lee Lundberg, John Richard Tidrow
  • 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
  • Patent number: 8058197
    Abstract: This invention provides carbon composite materials, which comprise metal carbide particles, at least the particle surfaces or the entirety of which are metal carbides, synthesized in situ from a metal source, i.e., at least one member selected from the group comprising metal particles, metal oxide particles, and composite metal oxide particles, and a carbon source, i.e., a thermosetting resin, dispersed in a carbon, carbon fiber, or carbon/carbon fiber matrix, and contain no free metal particles. This invention also provides a method for producing such composite carbon materials, which enables the production of carbon composite materials having a high coefficient of friction, high thermostability, and abrasion resistance.
    Type: Grant
    Filed: July 23, 2010
    Date of Patent: November 15, 2011
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Shigeru Ichikawa, Sumio Kamiya, Koji Yamada, Hironori Sasaki
  • Publication number: 20110174145
    Abstract: Armor with ceramic material and transformed nanotube material produced during/via process transformation, the transformed material in one aspect being graphene ribbon-like material; in one aspect, with the ceramic material including nanotubes subjected to pressure and sintering to effect the transformation; and methods for making such armor. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).
    Type: Application
    Filed: January 16, 2010
    Publication date: July 21, 2011
    Inventors: Douglas Charles Ogrin, Kyle Ryan Kissell, Kurt Lee Lundberg, John Richard Tidrow
  • Publication number: 20110169182
    Abstract: The inventive subject matter provides methods of manufacturing bulk absorbers and noise suppression panels.
    Type: Application
    Filed: October 23, 2008
    Publication date: July 14, 2011
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: James Piascik, Reza Oboodi, James F. Stevenson, Martin Carlin Baker, Siu-Ching D. Lui
  • 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
  • Publication number: 20110003138
    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: Application
    Filed: September 16, 2010
    Publication date: January 6, 2011
    Inventors: Andreas Kienzle, Johann Daimer
  • Patent number: 7854882
    Abstract: A method for preparing a high-temperature heat-resistant composite material by combining a mixture of submicron alumina powder and submicron silica powder, wherein the ratio of alumina to silica is from about 4:1 to about 5:1, submicron Group II metal oxide powder, and a Group I metal silicate solution to form a slurry, wherein the weight of the Group II metal oxide powder is an amount corresponding to about 5% to about 10% of the weight of the silicate solution; contacting reinforcing high-temperature resistant fibers with the slurry to form a composite precursor composition; and curing the composition at a temperature sufficient to produce the high-temperature heat-resistant composite material capable of resisting temperatures up to about 1400° C. Composite materials prepared according to the method and articles incorporating the material are also presented.
    Type: Grant
    Filed: March 26, 2007
    Date of Patent: December 21, 2010
    Assignee: Rutgers, The State University
    Inventor: Perumalsamy Naidu Balaguru
  • 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
  • Patent number: 7686989
    Abstract: A method for manufacturing a dental restoration, including: determining an external form and dimensions available for a completed restoration; obtaining an image of a natural tooth to be replaced with the restoration or a tooth corresponding therewith, wherein the image comprises at least the external surface visible in use of the to be replaced or corresponding tooth, with variations in the appearance therein; defining locally on and at least to visible depth below the surface of appearance-determining properties of at least one material to be applied for the restoration in accordance with the obtained image and the variations in the appearance therein; constructing the restoration, including the steps of: providing at least one material to be applied in non-cohesive form; and providing cohesion to the material in accordance with the available form and dimensions.
    Type: Grant
    Filed: April 19, 2002
    Date of Patent: March 30, 2010
    Assignee: Degudent GmbH
    Inventor: Joseph M. Van der Zel
  • Patent number: 7666344
    Abstract: The disclosed invention relates to ceramic matrix composites with ceramic fiber reinforcements.
    Type: Grant
    Filed: March 11, 2008
    Date of Patent: February 23, 2010
    Assignee: Stanton Advanced Ceramics, Inc.
    Inventors: Karl-Heinz Schofalvi, Gerald C. Dodds
  • Publication number: 20100001441
    Abstract: A procedure for manufacturing bricks from geological silts and drillings obtained from drilling operations is described, which comprises the step of mixing a volume of geological cuttings obtaining through the discarded material from the drilling of a well, such a as a water well, hydrocarbon prospecting, or any other fluid prospecting well. The geological cuttings are made of sands and geological clays, and they are then mixed in adequate proportions with commercial clays, fibrous organic material and water, until reaching the necessary plasticity allowing performing the subsequent molding operation with said mixture. The molded blocks and bricks thus obtained are then subjected to a baking thermal operation, obtaining desiccated bricks and blocks with the necessary mechanical resistance properties and hardness as required by a building material.
    Type: Application
    Filed: July 7, 2009
    Publication date: January 7, 2010
    Inventor: Veronica Tito
  • Patent number: 7550107
    Abstract: A method of forming a ceramic matrix composite (CMC) article (30) or a composite article (60) that minimizes the risk of delaminations while simultaneously maintaining a desired degree of porosity in the material. A pressure P applied against a surface of the article during a sintering process is controlled to be high enough to resist a separation force between the plies (66) of the CMC material (62) caused by anisotropic shrinkage of the material and/or to resist a separation force caused by differential shrinkage between the CMC material and an adjoined monolithic ceramic material (64). The pressure is also controlled to be low enough to avoid undue consolidation of the materials and to provide a desired degree of porosity in the sintered article. The pressure may be applied by delta-alpha tooling, and it may be varied verses the time of the sintering heating and/or across the article surface.
    Type: Grant
    Filed: July 25, 2005
    Date of Patent: June 23, 2009
    Assignee: Siemens Energy, Inc.
    Inventors: Jay A. Morrison, Jay E. Lane
  • Publication number: 20090136734
    Abstract: A unidirectional resin infused panel. An illustrative embodiment of the unidirectional resin infused panel includes a plurality of laminated plies of a unidirectional fiber material each comprising a plurality of unidirectional reinforcing fibers. An unbound section is provided along the reinforcing fibers and generally free from fill-binding material. A first bound section having a fill-binding material is provided along the reinforcing fibers on a first side of the unbound section. A second bound section having a fill-binding material is provided along the reinforcing fibers on a second side of the unbound section. A cured resin is infused in the plurality of laminated plies of a unidirectional fiber material.
    Type: Application
    Filed: November 26, 2007
    Publication date: May 28, 2009
    Inventors: Thomas R. Berkel, Panagiotis George
  • Publication number: 20090011208
    Abstract: Ceramics are made of preceramic paper or board structures in a particular shape previously represented in a paper structure, in which the preceramic papers or boards have a content of ceramic fillers between 30 and 95 wt-%, with the ceramic fillers having a particle size <30 ?m. A method for manufacturing such ceramics and the use thereof are also provided.
    Type: Application
    Filed: August 28, 2006
    Publication date: January 8, 2009
    Inventors: Andreas Hofenauer, Renate Kirmeier, Ralf Markusch, Hans Windsheimer, Nahum Travitzky, Peter Greil
  • Patent number: 7465489
    Abstract: This invention deals with a family of inorganic-organic hybrid, melt-extruded filaments having variable cross-sectional geometry with a cross-sectional area ranging between 100 ?2 and 4 mm2, wherein the inorganic component comprises at least 10 weight percent of the total system and is present as dispersed micro-/nanoparticles in an organic absorbable or non-absorbable matrix representing no more than 90 weight percent. Hybrid filaments are particularly useful for the production of absorbable/disintegratable coil components of an absorbable/disintegratable endoureteral stent and radiopaque surgical markers or sutures.
    Type: Grant
    Filed: November 15, 2006
    Date of Patent: December 16, 2008
    Assignee: Poly-Med, Inc.
    Inventors: Shalaby W Shalaby, Kenneth W Clinkscales, Kimberly A. Carpenter
  • Patent number: 7413700
    Abstract: A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.
    Type: Grant
    Filed: January 3, 2007
    Date of Patent: August 19, 2008
    Assignee: Siemens Power Generation, Inc.
    Inventors: Gary B. Merrill, Jay E. Lane, Steven C. Butner, Robert Kreutzer, Jay A. Morrison
  • Patent number: 7404922
    Abstract: A powdery mixture of fine SiC powder with one or more oxide sintering additives of Al2O3, Y2O3, SiO2 and CaO is blended and uniformly dispersed in a polymeric SiC precursor to prepare a matrix-forming polymeric slurry. A preform of SiC fiber, which has quasi-stoichiometric composition with high crystallinity, is impregnated with the polymeric slurry and then hot-pressed at a temperature of 1600° C. or higher in presence of a liquid phase. Since the heat-resistant SiC fiber is used as strengthening fiber, the prepreg is sintered to a dense SiC composite excellent in mechanical properties by one-step hot-pressing.
    Type: Grant
    Filed: October 25, 2001
    Date of Patent: July 29, 2008
    Assignee: Japan Science and Technology Corporation
    Inventors: Akira Kohyama, Yutai Katoh
  • Patent number: 7399443
    Abstract: Carbon particles, such as, carbon fibrils and carbon nanotube molecules, may be assembled into substantially pure aligned fibers by a) dispersing the carbon particles within a curable liquid, b) aligning the carbon particles by flowing the mixture of curable liquid and carbon particles down a tapering tube, and c) curing the flowing mixture of curable liquid and carbon particles in the general vicinity of the end of the tapering tube to form a fiber. The curable liquid may be cured using ultraviolet light. The solidified mixture may be further processed by d) heating the fiber so as to cause the volatile elements of the solidified curable liquid portion to substantially dissipate from the fiber, e) twisting the fiber to increase its density, f) heating the fiber to sinter the carbon particles within the fiber, and g) cladding the fiber. The resulting fiber may then be spooled onto a take-up drum.
    Type: Grant
    Filed: February 27, 2004
    Date of Patent: July 15, 2008
    Assignee: Lucent Technologies Inc.
    Inventors: Dennis S Greywall, Bernard Yurke
  • Patent number: 7318906
    Abstract: A preformed of SiC fiber, which is coated with one or more of C, BN and SiC, is impregnated with a slurry, which suspends fine SiC powder and a sintering additive therein. The impregnated preform is hot-pressed at 1600-1800° C. with a pressure of 10 MPa or more. The sintering additive may be one or more of Al2O3, Y2O3, SiO2 and CaO. The slurry may futher contain a silicone polymer selected from polycarbosilane, polyvinylsilane and polymethylsilane. Reaction of SiC fiber with a matrix is inhibited by the coating, so as to manufacture a SiC fiber-reinforced SiC-matrix composite remarkably improved in mechanical properties.
    Type: Grant
    Filed: October 25, 2001
    Date of Patent: January 15, 2008
    Assignee: Japan Science and Technology Corporation
    Inventors: Akira Kohyama, Yutai Katoh
  • Patent number: 7300621
    Abstract: A green body ceramic matrix composite material (30) is formed using ceramic fibers (32) in an intermediate state disposed in a green body ceramic matrix material (34). The fibers may be in either a dry but unfired (green) condition or in a partially fired condition. Selective control of the degree of pre-firing (pre-shrinkage) of the fibers may be used to control the level of residual stresses within the resulting refractory material resulting from differential shrinkage of the fibers and the matrix material during processing of the composite material.
    Type: Grant
    Filed: March 16, 2005
    Date of Patent: November 27, 2007
    Assignee: Siemens Power Generation, Inc.
    Inventor: Gary Brian Merrill
  • Patent number: 7175798
    Abstract: An improved cutting tool insert and a method for the preparation of such cutting tool insert, having a sintered alumina and silicon carbide whisker composite material body, comprising the steps of milling and mixing the powdered starting materials of said composite material and forming said material into a preformed workpiece, heating up said workpiece at a heating rate of from about 20 to about 60° C. per minute to a sintering temperature of between from about 1600 to about 2300° C., and holding at said sintering temperature for a holding time of from about 5 to about 60 minutes at a pressure of between from about 20 to about 100 MPa.
    Type: Grant
    Filed: January 26, 2004
    Date of Patent: February 13, 2007
    Assignee: Sandvik Intellectual Property AB
    Inventor: Gunnar Brandt
  • Patent number: 7063812
    Abstract: Methods for consolidation and densification of fibrous monolith composite structures are provided. Consolidation and densification of two- and three-dimensional fibrous monolith components having complex geometries can be achieved by pressureless sintering. The fibrous monolith composites are formed from filaments having at least a first material composition generally surrounded by a second material composition. The composites are sintered at a pressure of no more than about 30 psi to provide consolidated and densified fibrous monolith composites.
    Type: Grant
    Filed: May 24, 2004
    Date of Patent: June 20, 2006
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: Manish P. Sutaria, Mark J. Rigali, Ronald A. Cipriani, Gregory J. Artz, Anthony C. Mulligan
  • Patent number: 6899837
    Abstract: A modified alkali silicate composition for forming an inorganic network. The modified alkali silicate matrix is made by reacting an alkali silicate (or its precursors such as an alkali hydroxide, a SiO2 source and water), an acidic oxoanionic compound such as phosphoric acid, water and optionally one or more multivalent cation(s) selected from Groups 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or 16 of the periodic table such as an alkaline earth salt, water and optional processing aids. An inorganic matrix composite can be prepared by applying a slurry of the modified aqueous alkali silicate composition to a reinforcing medium and curing the composite at a temperature from about 15° C. up to 1000° C. and a pressure of up to 20,000 psi for typical high-performance organic polymer processing (temperatures about 15° C. to about 200° C. and pressures <200 psi). The composite can be shaped by compression molding as well as other known fabrication methods.
    Type: Grant
    Filed: July 21, 2004
    Date of Patent: May 31, 2005
    Assignee: Goodrich Corporation
    Inventors: Anthony M. Mazany, John W. Robinson, Craig L. Cartwright
  • Patent number: 6852271
    Abstract: A flexible insulation blanket having a smoothly surfaced, secondarily bonded, ceramic matrix composite (CMC) outer layer, and a method of producing a flexible insulation blanket having a secondarily bonded CMC layer by forming a CMC prepreg layer comprising a woven ceramic fabric layer impregnated with a pre-ceramic slurry and layering the prepreg layer with a flexible insulation blanket. The blanket and prepreg layer are then compressed such that the prepreg layer abuts a rigid smoothly surfaced plate and the ceramic material is cured by heating while under compression. Pressure is then released and the insulation is fired to sinter the ceramic material of the CMC layer.
    Type: Grant
    Filed: August 11, 2003
    Date of Patent: February 8, 2005
    Assignee: The Boeing Company
    Inventor: Robert A. DiChiara, Jr.
  • Publication number: 20040222571
    Abstract: An actively-cooled, fiber-reinforced ceramic matrix composite thrust chamber for liquid rocket propulsion systems is designed and produced with internal cooling channels. The monocoque tubular structure consists of an inner wall, which is fully integrated to an outer wall via radial coupling webs. Segmented annular void spaces between the inner wall, outer wall and adjoining radial webs form the internal trapezoidal-shaped cooling channel passages of the tubular heat exchanger. The manufacturing method enables producing any general tubular shell geometry ranging from simple cylindrical heat exchanger tubes to complex converging-diverging, Delaval-type nozzle structures with an annular array of internal cooling channels. The manufacturing method allows for transitioning the tubular shell structure from a two-dimensional circular geometry to a three-dimensional rectangular geometry.
    Type: Application
    Filed: June 14, 2004
    Publication date: November 11, 2004
    Inventor: Wayne S. Steffier
  • Publication number: 20040217520
    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: Application
    Filed: February 19, 2004
    Publication date: November 4, 2004
    Applicant: 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: 6787235
    Abstract: A carbon based material produced from the consolidation of amorphous carbon by elevated temperature compression. The material having unique chemical and physical characteristics that lend themselves to a broad range of applications such as in electrical, electrochemical and structural fields.
    Type: Grant
    Filed: December 10, 2002
    Date of Patent: September 7, 2004
    Assignee: Reticle, Inc.
    Inventors: Carl C. Nesbitt, Xiaowei Sun
  • Publication number: 20040155387
    Abstract: A composite material includes a plurality of continuous graphite fiber strands, bundles, or other such fiber configurations disposed within a hardened ceramic matrix. The continuous graphite fiber strands are preferably covered or “pegged” with a ceramic slurry (e.g., a porcelain ceramic slurry), attached to a pre-formed foundation, then fired to produce a fiber-enhanced ceramic structure. In this way, a may be efficiently fabricated for use in applications requiring high-strength materials capable of withstanding temperature extremes.
    Type: Application
    Filed: February 6, 2003
    Publication date: August 12, 2004
    Inventor: Joseph D. Fivas
  • Patent number: 6734262
    Abstract: An electrically conductive thermoplastic composition with a superior ability to be heated rapidly in an electromagnetic field comprises a polyetherimide resin, a polyester resin, and electrically conductive filler. Such compositions display good dimensional stability at elevated temperatures especially when heated rapidly using electromagnetic radiation, which renders them useful in articles and operations where rapid assembly is important.
    Type: Grant
    Filed: January 7, 2002
    Date of Patent: May 11, 2004
    Assignee: General Electric Company
    Inventor: Niraj C. Patel
  • Patent number: 6726866
    Abstract: In a method of manufacturing a friction member used for a vibration wave driving apparatus including a vibration member, a contact member which is brought into frictional contact with the vibration member and relatively moved by vibrations produced in the vibration member, and the friction member formed on one of friction portions of the vibration member and contact member, a molded member is formed by compression molding of a plastic powder and an additive, a sintered member is formed by sintering the molded member, a sheet is formed by cutting the sintered member in the form of a sheet, and a modified layer formed by cutting is removed from the friction surface of the sheet.
    Type: Grant
    Filed: August 20, 2003
    Date of Patent: April 27, 2004
    Assignee: Canon Kabushiki Kaisha
    Inventors: Satoru Kitajima, Yutaka Maruyama
  • Patent number: 6716376
    Abstract: The invention relates to a process for producing a fiber composite material containing fibers with a high hot strength, in particular based on carbon, silicon, boron and/or nitrogen, a pressing compound being produced from fibers, a binder and, if appropriate, fillers and/or additives, which is then pressed in a press mold to form a green body. Various pressing compounds are produced, which contain fibers of different qualities and/or in different proportions, and the press mold is filled with the various pressing compounds in a number of successive steps. The invention also relates to a fiber composite material of this nature.
    Type: Grant
    Filed: November 1, 2000
    Date of Patent: April 6, 2004
    Assignee: DaimlerChrysler AG
    Inventors: Tilmann Haug, Kolja Rebstock, Christian Schwarz
  • Patent number: 6716782
    Abstract: A porous ceramic fiber insulating material and method of making a material having a combination of silica (SiO2) and alumina (Al2O3) fibers, and boron-containing powders is the topic of the new invention. The insulative material is composed of about 60 wt % to about 80 wt % silica fibers, about 20 wt % to about 40 wt % alumina fibers, and about 0.1 wt % to about 1.0 wt % boron-containing powders. A specific boron-containing powder used for this invention is boron carbide powder which provide boron-containing by-products, which aid in fusion and sintering of the silica and alumina fibers. The material is produced by forming an aqueous slurry, blending and chopping the fibers via a shear mixer, orienting the fibers in the in-plane direction, draining water from the fibers, pressing the fibers into a billet, heating the fibers to remove residual water, and firing the billet to fuse the fibers of the material. After sintering, bulk density of the new insulation material ranges from 6 to 20 lb/ft3.
    Type: Grant
    Filed: August 16, 2002
    Date of Patent: April 6, 2004
    Assignee: The Boeing Company
    Inventors: Vann Heng, Karrie Ann Hinkle, Mary Ann Santos
  • Publication number: 20040029704
    Abstract: Production processes of an inorganic fiber-bonded ceramic component comprising inorganic fibers mainly comprising Si, M, C and O, an inorganic substance mainly comprising Si and O and boundary layers comprising carbon as a main component; and an inorganic fiber-bonded ceramic component comprising inorganic fibers which are composed mainly of a sintered structure of SiC and contain specific metal atoms and boundary layers composed mainly of carbon, wherein a preliminary shaped material is set in a carbon die, covered with a carbon powder and then hot-pressed to load a pseudo-isotropic pressure on the preliminary shaped material; and a highly heat-resistant inorganic fiber-bonded ceramic component almost free from the occurrence of peelings of surface fibers or delamination, wherein fibers are aligned in a surface shape.
    Type: Application
    Filed: August 6, 2003
    Publication date: February 12, 2004
    Inventors: Shinij Kajii, Kenji Matsunaga, Toshihiko Hogami, Mitsuhiko Sato
  • Patent number: 6660115
    Abstract: A method of manufacturing a ceramic matrix composite comprises forming a slurry comprising a ceramic sol, filler particles and a solvent and forming laminates of fibers (12). The laminates of fibers (12) are impregnated with the slurry and are stacked (14) on a mold (10). The stack (14) of laminates of fibers (12) is covered by a porous membrane (16), a breather fabric (18) and a vacuum bag (20). The vacuum bag (20) is evacuated and is heated to a temperature of 60° C. for 10 hours to produce a ceramic matrix composite. The ceramic matrix composite is then heated to a temperature of 1200° C. at atmospheric pressure to sinter the ceramic matrix composite.
    Type: Grant
    Filed: September 18, 2002
    Date of Patent: December 9, 2003
    Assignee: Rolls-Royce plc
    Inventors: Edwin G Butler, Anthony G Razzell, John Dominy, Paul A Doleman, Ihsan A H Al-Dawery
  • Patent number: 6613255
    Abstract: A method of making a permeable fiber-reinforced ceramic body comprising mixing an organic particulate with silica fiber, alumina fiber, alumina borosilicate fiber, a dispersant, and water to produce a slurry of fibrous ceramic material. The slurry is then placed within a mold and vaccuum pressure is applied thereto to substantially remove the water to form a fibrous ceramic body. The fibrous ceramic body is then dried and sintered to a temperature sufficient to bond the ceramic material together to form a porous ceramic article. Simultaneously, the fibrous ceramic body is heated to a temperature sufficient to generally burn off the organic particulate to create voids interconnecting the pores to form a permeable fiber reinforced porous ceramic article.
    Type: Grant
    Filed: April 13, 2001
    Date of Patent: September 2, 2003
    Assignee: The Boeing Company
    Inventor: Robert A. DiChiara, Jr.
  • Patent number: 6596199
    Abstract: Carbon fiber-filled PC-ABS resin compositions which have improved electrical properties at a given level of carbon fibers, and which do not suffer from as significant a decrease in impact strength as would result from the introduction of generic carbon fibers are achieved using carbon fibers treated with a polyamide terpolymer binder. The bundles are dispersed within the PC-ABS blend. The compositions can be used for injection molding of articles for use as components in applications requiring static dissipation and/or EMI shielding. Such articles include, but are not limited to electronic devices, dust handling equipment and notebook computer enclosures.
    Type: Grant
    Filed: February 27, 2001
    Date of Patent: July 22, 2003
    Assignee: General Electric Company
    Inventor: Nirajkumar Patel
  • Patent number: 6540945
    Abstract: Carbon fiber-filled, thermoplastic resin compositions having improved electrical properties at a given level of carbon fibers are formed from thermoplastic resin and carbon fibers associated into bundles with a binder. The thermoplastic resin and the binder are selected to be incompatible such that the adhesion of the fiber to the resin is poor. An exemplary composition is formed from a thermoplastic polymer selected from among polystyrene, high impact polystyrene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyphenylene ether, polyether imide and blends thereof; and carbon fibers associated into bundles with a polyamide terpolymer binder. The bundles are dispersed within the thermoplastic polymer. The compositions can be used for injection molding of articles for use as components in applications requiring static dissipation and/or EMI shielding. Such articles include electronic devices, dust handling equipment and notebook computer enclosures.
    Type: Grant
    Filed: February 27, 2001
    Date of Patent: April 1, 2003
    Assignee: General Electric Company
    Inventors: Kazunao Kubotera, Nirajkumar Patel