Including Plural Heating Steps Patents (Class 264/653)
  • Patent number: 10518326
    Abstract: Process for the additive manufacturing of at least one part by powder sintering or melting using at least one beam of energy. A step of deposition and selective melting of stacked layers of powder manufactures at least one intermediate element comprising the part and at least one local reinforcing element having a split tubular shape that surrounds one of the lateral end faces of the part and that face each of the frontal faces of said part adjacent to said end face, said reinforcing element extending in a direction substantially parallel to the stacking direction of the layers. The part and the local reinforcing element are separated.
    Type: Grant
    Filed: July 24, 2015
    Date of Patent: December 31, 2019
    Inventors: Pierre Pays, Bruno Nigaize
  • Patent number: 10464131
    Abstract: Successive layers of a wall of a part are deposited to form a first access channel extending from an exterior of the part to an interior of the part, as well as to form a distribution channel connecting an interior volume of the honeycomb infill to the first access channel. A binder matrix retaining sinterable powder is debound by flowing a debinding fluid through the first access channel and the distribution channel within the interior volume of the honeycomb infill.
    Type: Grant
    Filed: May 10, 2018
    Date of Patent: November 5, 2019
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 10272492
    Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. The support structure may be a multi-part support structure to mitigate mold lock or facilitate removal from enclosed spaces.
    Type: Grant
    Filed: March 24, 2017
    Date of Patent: April 30, 2019
    Assignee: Desktop Metal, Inc.
    Inventors: Michael Andrew Gibson, Jonah Samuel Myerberg, Ricardo Fulop, Ricardo Chin, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
  • Patent number: 9487445
    Abstract: A novel ceramic composition having a high relative dielectric constant. A ceramic composition includes a unit cell having at least two crystal structures selected from the group made of a monoclinic crystal, a tetragonal crystal, an orthorhombic crystal, and a rhombohedral crystal, characterized in that when the crystal structures are represented by the symmetry notation according to the Glazer method, namely xn1yn2zn3, n1, n2, and n3 are at least one selected from the group made of + and ?, or at least two selected from the group made of 0, +, and ?. By using this ceramic composition, a novel ceramic composition having a high relative dielectric constant can be obtained.
    Type: Grant
    Filed: March 24, 2014
    Date of Patent: November 8, 2016
    Inventors: Hidesada Natsui, Taku Masai, Sanshiro Aman
  • Publication number: 20150093283
    Abstract: Improved devices and methods for additive manufacturing of implant components are disclosed, including improvements relating to utilizing support structures, aligning implant designs within the manufacturing apparatus, and making patient-adapted implants.
    Type: Application
    Filed: April 13, 2013
    Publication date: April 2, 2015
    Inventors: Bob Miller, David P. Hesketh
  • 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: 8865054
    Abstract: A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder such that raw material paste including the titania particles, the alumina particles and the binder is prepared, extruding the raw material paste through a die for forming a honeycomb structure such that a body made of the raw material paste and having the honeycomb structure is formed, supporting the body extruded from the die on a holder while moving the holder along extrusion direction at a moving speed relative to an extruding speed of the raw material based on a target diameter size set for the body such that the diameter of the body held by the holder changes to the target diameter size, and sintering the body having the honeycomb structure with the target diameter size such that a ceramic body having the honeycomb structure with the target diameter size is formed.
    Type: Grant
    Filed: April 29, 2013
    Date of Patent: October 21, 2014
    Assignee: Ibiden Co., Ltd.
    Inventor: Kazunori Yamayose
  • Publication number: 20140138882
    Abstract: Methods of firing a cordierite green body to form a fired cordierite body. The green body comprises cordierite-forming raw materials and organic material, the body having a core portion and a skin portion. The green body is pre-heated to a pre-heat temperature that is less than a thermal decomposition temperature of the organic material. The green body is maintained at the pre-heat temperature for a period of time sufficient to minimize a temperature differential between the core portion and the skin portion. The green body is heated to a low firing temperature in a firing atmosphere sufficient to reduce a content of the organic material and to substantially remove chemically bound water from hydrous alumina. The green body is heated to a high firing temperature in a firing atmosphere sufficient to reduce the content of the organic material prior to a substantial removal of chemically bound water from clay.
    Type: Application
    Filed: November 21, 2012
    Publication date: May 22, 2014
    Inventors: Robert Joseph Castilone, Sriram Rangarajan Iyer, Mark Allen Spetseris, Jonathan Mark Stalker
  • Patent number: 8673796
    Abstract: To provide a light-transmitting window material made of a spinel sintered body, wherein the largest diameter of pores contained in the light-transmitting window material is not more than 100 ?m, and the number of pores having a largest diameter of not less than 10 ?m is not more than 2.0 per 1 cm3 of the light-transmitting window material, and wherein light scattering factors are further reduced, and a method for producing a spinel light-transmitting window material including the steps of preparing a spinel molded body; a primary sintering step of sintering the spinel molded body at normal pressure or less or in a vacuum at a temperature in the range of 1500 to 1900° C.; and a secondary sintering step of sintering the spinel molded body under pressure at a temperature in the range of 1500 to 2000° C., wherein the relative density of the spinel molded body after the primary sintering step is 95 to 96% and the relative density of the spinel molded body after the secondary sintering step is 99.8% or more.
    Type: Grant
    Filed: March 31, 2010
    Date of Patent: March 18, 2014
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Masashi Yoshimura, Masaki Fukuma, Yutaka Tsuji, Shigeru Nakayama
  • Patent number: 8636842
    Abstract: Disclosed is a method of manufacturing an artificial stone, and the method includes forming an artificial-stone paste which comprises 20-20 parts by weight of silica stone, metakaolim or silica fume, 200-300 parts by weight of quartz chips, 30-36 parts by weight if water, 1.5-3 part by weight of water-reducing agent and 0.2-3 parts by weight of pigment with response to 100 parts by weight of white cement; injecting the artificial-stone paste in a mold; primarily vacuum-molding the artificial-stone paste injected in the mold; secondarily vibration-molding the primarily molded artificial-stone paste; primarily curing the secondarily molded artificial-stone paste; secondarily curing the primarily cured artificial-stone paste, which induces a hydrothermal reaction and thus causes a pozzolanic reaction; releasing the secondarily cured artificial-stone paste from the mold; and surface-machining the released artificial-stone paste.
    Type: Grant
    Filed: January 11, 2012
    Date of Patent: January 28, 2014
    Assignee: LG Hausys, Ltd.
    Inventor: Chang Hwan Park
  • Patent number: 8475821
    Abstract: A method of manufacturing a bone prosthetic material, includes by forming tricalcium phosphate (TCP) particle precursor particles; by performing preliminary sintering on the TCP precursor particles at a temperature in a first temperature range to produce TCP particles of diameters in a predetermined diameter range; by granulating the TCP particles to produce granulated bodies; and by performing sintering on the granulated bodies at a temperature in a second temperature range to generate sinter assemblies. The second temperature range is higher than the first temperature range. In the bone prosthetic material manufactured thus, a first space in a range of 100 to 400 ?m is formed between adjacent two of a plurality of sintered assemblies. Each of the plurality of sintered assemblies includes tricalcium phosphate (TCP) particles which are subjected to sintering, and a second space in a range of 5 to 100 ?m is formed between adjacent two of the TCP particles. The second space communicates with the first space.
    Type: Grant
    Filed: June 5, 2009
    Date of Patent: July 2, 2013
    Assignee: Brain Base Corporation
    Inventors: Takamasa Saso, Ryuichi Mizutani
  • Patent number: 8454933
    Abstract: The invention provides a polycrystal magnesium oxide (MgO) sintered body which is capable of having a sintered density close to a theoretical density thereof. The MgO sintered body exhibits excellent mechanical properties and heat conductivity, while reducing contamination of an atmosphere due to gas generation. The invention also provides a production method for the sintered body. The polycrystal MgO sintered body has a unique crystalline anisotropy in which (111) faces are oriented along a surface applied with a uniaxial pressure at a high rate. The polycrystalline MgO sintered body is obtained by a method which includes the steps of: sintering an MgO raw material powder, having a particle size of 1 ?m or less, under a uniaxial pressure and then subjecting the sintered powder to a heat treatment under an atmosphere containing 0.05 volume % or more of oxygen, at a temperature of 1273 K or more for 1 minute or more.
    Type: Grant
    Filed: January 27, 2009
    Date of Patent: June 4, 2013
    Assignees: Nippon Tungsten Co., Ltd., Ube Material Industries, Ltd.
    Inventors: Mitsuyoshi Nagano, Masanobu Takasu, Yo Arita, Satoru Sano
  • Publication number: 20130043624
    Abstract: A green molded body comprises an organic binder and an inorganic compound source powder containing an aluminum source powder and a titanium source powder, wherein the organic binder is such that the viscosity at 20° C. of a 2 wt % aqueous solution of the organic binder is 5000 mPa·s or higher. A method for producing an aluminum titanate fired body includes the steps of molding a raw material mixture comprising an organic binder and an inorganic compound source powder containing an aluminum source powder and a titanium source powder to obtain a green molded body; heating the green molded body obtained at 150° C. to 900° C. to remove the organic binder; and firing the green molded body from which the organic binder has been removed, at 1300° C. or higher, wherein the organic binder is such that the viscosity at 20° C. of a 2 wt % aqueous solution of the organic binder is 5000 mPa·s or higher.
    Type: Application
    Filed: March 7, 2011
    Publication date: February 21, 2013
    Inventors: Masahiro Kan, Kousuke Uoe, Hajime Yoshino
  • Publication number: 20130011170
    Abstract: Provided is a sliding member having excellent adhesion and slidability suitable for use as a transfer pad in an image forming apparatus. A sliding member (10) includes a porous body (1) that is a sintered body of ultrahigh molecular weight polyethylene (UHMWPE) particles and having a surface of the porous body (1) as a sliding surface (5). The sliding surface (5) has a particle occupation ratio of 50% or less, and a surface roughness Ra of 2.0 ?m or less. The sliding member (10) can be obtained by heating the porous body obtained by cutting the sintered body of UHMWPE particles to make the sliding surface (5) smoother than before the heating.
    Type: Application
    Filed: November 11, 2010
    Publication date: January 10, 2013
    Inventors: Toshimitsu Tachibana, Katsuki Tsukamoto
  • Publication number: 20120312681
    Abstract: There have been cases where transistors formed using oxide semiconductors are inferior in reliability to transistors formed using amorphous silicon. Thus, in the present invention, a semiconductor device including a highly reliable transistor formed using an oxide semiconductor is manufactured. An oxide semiconductor film is deposited by a sputtering method, using a sputtering target including an oxide semiconductor having crystallinity, and in which the direction of the c-axis of a crystal is parallel to a normal vector of the top surface of the oxide semiconductor. The target is formed by mixing raw materials so that its composition ratio can obtain a crystal structure.
    Type: Application
    Filed: June 5, 2012
    Publication date: December 13, 2012
    Inventors: Shunpei Yamazaki, Tetsunori Maruyama, Yuki Imoto, Hitomi Sato, Masahiro Watanabe, Mitsuo Mashiyama, Kenichi Okazaki, Motoki Nakashima, Takashi Shimazu
  • Publication number: 20120304694
    Abstract: In a method for producing jewelry articles, forming a predetermined shape from a plurality of sinterable materials, heating the plurality of sinterable materials to a first temperature and for a first time period sufficient to produce a substrate that retains the predetermined shape during manipulation, cooling the substrate to a second temperature at which the substrate is manipulable, manipulating the substrate to incorporate at least one design feature in the substrate, heating the substrate to a third temperature and for a second time period sufficient to sinter the substrate, and cooling the substrate to obtain the jewelry article.
    Type: Application
    Filed: June 1, 2012
    Publication date: December 6, 2012
    Inventor: Andrew Derrig
  • Patent number: 8292982
    Abstract: A filter, in particular for a rotary separator, is produced using an energy beam melting process, for example an electron beam, starting from powder made from the same material as a porous filtering portion to be formed, for example from a titanium alloy; on the basis of a three-dimensional model comprising a cell structure defining the porous filtering portion, subsequent layers of powder are applied and locally melted, so as to form successive sections of the porous filtering portion; at the end of the forming process, the residual powder is evacuated from the pores.
    Type: Grant
    Filed: December 1, 2009
    Date of Patent: October 23, 2012
    Assignee: Avio S.p.A.
    Inventors: Paolo Gennaro, Maurizio Romeo, Giuseppe Bene, Franco Tortarolo, Giovanni Paolo Zanon
  • Patent number: 8278233
    Abstract: A translucent polycrystalline sintered body is mainly composed of an alumina, is suitable for the manufacture of an arc tube for a high-intensity discharge lamp, and has an average grain diameter of 35 to 70 ?m, preferably 50 to 60 ?m. In a case where the sintered body is in a 0.5-mm-thick flat plate shape, the in-line transmittance of the sintered body is 30% or more, preferably 50% or more. In this case, the ratio between maximum and minimum in-line transmittance values is 2:1 to 1:1 in the visible region of 360 to 830 nm. The bending strength of the sintered body is 250 MPa or more, preferably 300 MPa or more.
    Type: Grant
    Filed: September 8, 2010
    Date of Patent: October 2, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Sugio Miyazawa, Keiichiro Watanabe, Tsuneaki Ohashi, Hisanori Yamamoto
  • Patent number: 8221525
    Abstract: A method of oxygen enrichment in which a gaseous mixture containing O2 molecules and N2 molecules is provided to a feed side of a SAPO molecular sieve, oxygen enrichment membrane having pore sizes suitable for discriminating between O2 molecules and N2 molecules, resulting in selective transport of the O2 molecules through the membrane to a permeate side of the membrane. Also disclosed is a method for producing the membrane.
    Type: Grant
    Filed: July 16, 2010
    Date of Patent: July 17, 2012
    Assignee: Gas Technology Institute
    Inventors: Shiguang Li, Qinbai Fan
  • Publication number: 20120045633
    Abstract: An article for magnetic heat exchange comprises a monolithic working component comprising two or more portions. The two or more portions comprise amounts of La, Fe, Si and of one or more elements T and R suitable to produce a La1-aRa(Fe1-x-yTySix)13Hz phase, wherein T is one or more of the elements from the group consisting of Mn, Co, Ni and Cr and R is one or more of the elements from the group consisting of Ce, Nd, Y and Pr. The amount of the one or more elements T and R and the amount of Si is selected for each of the two or more portions to provide the two or more portions with differing Curie temperatures and, preferably, a density, d, within a range of ±5% of an average density, dav, of a total number of portions.
    Type: Application
    Filed: February 11, 2011
    Publication date: February 23, 2012
    Applicant: Vacuumschmelze GmbH & Co. KG
    Inventors: Matthias KATTER, Volker Zellmann, Alexander Barcza
  • Patent number: 8110140
    Abstract: In methods of manufacturing optical components for infrared-light or ultraviolet-light applications, by lessening the expense consumed during finishing processes, a technique for manufacturing ceramic optical components inexpensively is realized. Raw material powders whose main constituent is ZnS, ZnSe or Ge, for ceramics for infrared-light optical components, and whose main constituent is CaF2 or MaF2, for ceramics for ultraviolet-light optical components, are molded into molded masses; the molded masses are sintered into sinters; and by pressing the sinters through a heating and compressing process, net-shape ceramic sinters can be produced. Alternatively, a finishing process is carried out after they are pressed into near-net shape. By shaping into net shape or near-net shape, the finishing process can be omitted, or the finishing process time and processing expense taken up can be decreased.
    Type: Grant
    Filed: December 25, 2002
    Date of Patent: February 7, 2012
    Assignee: Sumimoto Electric Industries, Ltd.
    Inventor: Masato Hasegawa
  • Publication number: 20110260377
    Abstract: A method includes fabricating an energy detector using a sol-gel process.
    Type: Application
    Filed: May 20, 2011
    Publication date: October 27, 2011
    Inventor: Haochuan Jiang
  • Publication number: 20110097373
    Abstract: A method of manufacturing a bone prosthetic material, includes by forming tricalcium phosphate (TCP) particle precursor particles; by performing preliminary sintering on the TCP precursor particles at a temperature in a first temperature range to produce TCP particles of diameters in a predetermined diameter range; by granulating the TCP particles to produce granulated bodies; and by performing sintering on the granulated bodies at a temperature in a second temperature range to generate sinter assemblies. The second temperature range is higher than the first temperature range. In the bone prosthetic material manufactured thus, a first space in a range of 100 to 400 ?m is formed between adjacent two of a plurality of sintered assemblies. Each of the plurality of sintered assemblies includes tricalcium phosphate (TCP) particles which are subjected to sintering, and a second space in a range of 5 to 100 ?m is formed between adjacent two of the TCP particles. The second space communicates with the first space.
    Type: Application
    Filed: June 5, 2009
    Publication date: April 28, 2011
    Inventors: Takamasa Saso, Ryuichi Mizutani
  • Publication number: 20110052803
    Abstract: A method of forming a metal deposit on an ultra-hard material. In an embodiment, the method includes providing a plurality of ultra-hard particles, mixing the ultra-hard particles in a solution with a metal salt, drying the solution to create a mixture of metal salt particles adhered to surfaces of the ultra-hard particles, heating the mixture to convert the metal salt particles into metal deposits on the surfaces of the ultra-hard particles, and HTHP sintering the mixture of ultra-hard particles with the metal deposits to form a polycrystalline ultra-hard material.
    Type: Application
    Filed: August 27, 2010
    Publication date: March 3, 2011
    Inventors: Yahua Bao, Qingyuan Liu, Feng Yu, Charles J. Claunch
  • Patent number: 7892479
    Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.
    Type: Grant
    Filed: August 29, 2007
    Date of Patent: February 22, 2011
    Assignee: Newsouth Innovations Pty Limited
    Inventors: Obada Kayali, Karl John Shaw
  • Patent number: 7862764
    Abstract: Electromagnetic (EM) drying of a plugged ware is provided that includes subjecting the ware to an axially non-uniform EM radiation field that causes more EM radiation to be dissipated in either of the plugged regions than in the unplugged region. The EM radiation field is provided by a configurable applicator system that includes a feed waveguide and a conveyor path. The feed waveguide includes configurable slots. The configurable applicator system can be set to selectively vary the amount of EM radiation dissipated by each ware along the longitudinal axis of each ware as a function of ware position along the conveying path, thereby enhancing the EM drying process.
    Type: Grant
    Filed: March 28, 2008
    Date of Patent: January 4, 2011
    Assignee: Corning Incorporated
    Inventors: James Anthony Feldman, Jacob George, Kevin Robert McCann, Rebecca Lynn Schulz, Gary Graham Squier, Elizabeth Marie Vileno
  • Patent number: 7799417
    Abstract: A Si—SiC based fired body includes a plurality of silicon carbide (SiC) particles serving as an aggregate, and silicon (Si) which serves as a binder and which is filled into gaps between the above-described silicon carbide particles, wherein the maximum particle diameter of the above-described silicon carbide particles is 0.5 mm or more, the content of silicon is 5 to 40 percent by mass, and the porosity is 0 to 5%. Preferably, the Si—SiC based fired body is in a thick-walled shape having a thickness of 20 to 200 mm.
    Type: Grant
    Filed: September 28, 2007
    Date of Patent: September 21, 2010
    Assignees: NGK Insulators, Ltd., NGK Adrec Co., Ltd.
    Inventors: Tsuneo Komiyama, Osamu Yamakawa, Seiichi Hori
  • Patent number: 7763205
    Abstract: Method of fabricating RBSN parts in which the processing of compacts of silicon to produce reaction bonded silicon nitride products is accomplished in a continuous style furnace. The furnace of the preferred embodiment is arranged as a contiguous series of furnace sections or zones configured to have a part conveyor traveling slowly from one end to another to sequentially expose the parts to each zone. Each zone may for example be one foot long. The conveyor then travels at a rate of one foot per hour. Parts to be nitrided are settered onto kiln furniture plates while providing a minimum one-quarter inch clearance to all other parts. The parts on the plates are conveyed through the sequential temperature zones in a continuous fashion while under ambient pressure flowing nitrogen gas. The parts travel through the contiguous temperature zones at a constant rate of conveyance allowing the nitriding reaction to progress to completion.
    Type: Grant
    Filed: October 22, 2004
    Date of Patent: July 27, 2010
    Assignee: Ceradyne, Inc.
    Inventors: Edwin Todd Voiles, Bijana Mikijelj
  • 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
  • Patent number: 7687008
    Abstract: A method for producing a ceramic honeycomb filter having large numbers of flow paths partitioned by cell walls, the flow paths having plugs at positions separate from an end surface of the honeycomb filter, comprising the steps of introducing a base-forming material into the flow paths on one end surface side, charging a plug-forming material into flow paths to be provided with plugs from the other end surface side, and sintering it.
    Type: Grant
    Filed: January 29, 2007
    Date of Patent: March 30, 2010
    Assignee: Hitachi Metals, Ltd.
    Inventors: Shunji Okazaki, Yasuhiko Ohtsubo
  • Patent number: 7618551
    Abstract: Piezoelectric performance is improved in a piezoelectric ceramic having a perovskite-type crystal structure expressed by a general formula ABO3 and the B-site element including niobium. The piezoelectric ceramic has a perovskite-type crystal structure in which plural octahedrons formed of oxygen are arranged to share vertices thereof and elements are located at a center of eight octahedrons and at a center of each octahedron; wherein an element located at the center of eight octahedrons is A-site element, an element located at the center of each octahedron is B-site element, and a general formula of the perovskite-type crystal structure is ABO3; the B-site element includes niobium (Nb); and bismuth (Bi) content in composition of the piezoelectric ceramic is 100 ppm by weight or less.
    Type: Grant
    Filed: March 28, 2007
    Date of Patent: November 17, 2009
    Assignee: FUJIFILM Corporation
    Inventor: Shigenori Yuuya
  • Patent number: 7588628
    Abstract: The present invention provides methods for making a microporous ceramic material using a metal silicon powder and including a reaction sintering process of the silicon. A material for forming a microporous ceramic material used in these methods includes a metal silicon powder, a silicon nitride powder and/or a silicon carbide powder, and if desired, a yttrium oxide powder and/or an aluminum oxide powder. These methods can make a microporous ceramic material that can be used preferably as a gas or liquid filter, a catalyst carrier or a support of a gas separation membrane.
    Type: Grant
    Filed: October 10, 2007
    Date of Patent: September 15, 2009
    Assignees: Noritake Co., Limited, Chubu Electric Power Co., Inc.
    Inventors: Yasunori Ando, Seiji Yamada, Hisatomi Taguchi, Yosuke Takahashi, Shigeo Nagaya, Kiyoshi Komura
  • Patent number: 7556664
    Abstract: There is provided a plugged honeycomb structure 1 including: partition walls 2 disposed so as to form a plurality of cells 3 extending from one end face 42 to the other end face 44 in the axial direction, and plugged portions 4 disposed so as to plug the cells 3 at one of the end faces, and a production method thereof. In this honeycomb structure 1, the plugged portions 4 and partition walls surrounding the plugged portions are unitarily formed. The production method includes a forming step, a plugging step for filling a plugging material, and a firing step. The plugging material contains solid particles capable of unitarily joining with at least one kind of solid particles contained in a forming raw material in a firing step. A ratio of a dimensional change (%) upon forming the partition walls out of the partition wall-forming material to a dimensional change (%) upon forming the plugged portions out of the plugging material is controlled to be within the range of 0.7% to 1.3 in the firing step.
    Type: Grant
    Filed: March 19, 2004
    Date of Patent: July 7, 2009
    Assignee: NGK Insulators, Ltd.
    Inventors: Yukihito Ichikawa, Yasushi Noguchi
  • Patent number: 7544320
    Abstract: There is disclosed a method of manufacturing a porous ceramic structure, comprising the steps of: preparing a formed structure using a ceramic material containing a pore former and a binder; and drying and firing the formed structure, wherein the process of firing the formed structure comprises the steps of: holding a firing atmosphere temperature in a temperature range of ?50 to +10° C. with respect to a combustion start temperature of the binder from the time when the temperature reaches the combustion start temperature of the binder contained in the porous ceramic structure to be fired to the time when the binder is burnt out. According to this method, ceramic structures having not only a low porosity but also a high porosity can be manufactured without generating any crack during the firing.
    Type: Grant
    Filed: July 9, 2003
    Date of Patent: June 9, 2009
    Assignee: NGK Insulators, Ltd.
    Inventors: Yumi Toda, Yoshinori Yamamoto, Yukihisa Wada
  • Patent number: 7524546
    Abstract: A thermal insulating material which can be efficiently produced while the content of organic matters, such as organic fibers and/or an organic binder, is reduced to the same or lower degree as compared with the thermal insulating material used in a conventional pollution control device (e.g., catalytic converter), and which can be applied to a pollution control element (e.g., catalytic element) while avoiding, as much as possible, an unpleasant feeling to the operator. A thermal insulating material comprising a thermal insulating material body formed of a bulk material of inorganic fibers, and a coating provided on at least one surface of said thermal insulating material body.
    Type: Grant
    Filed: December 13, 2001
    Date of Patent: April 28, 2009
    Assignee: 3M Innovative Properties Company
    Inventors: Takuma Aizawa, Toshihiro Kasai, Takayuki Kawai, Toshiyuki Watanabe
  • Patent number: 7524451
    Abstract: An insulating target material for obtaining a conductive complex oxide film represented by a general formula ABO3, the insulating target material including an oxide of an element A, an oxide of an element B, and at least one of an Si compound and a Ge compound.
    Type: Grant
    Filed: August 15, 2006
    Date of Patent: April 28, 2009
    Assignee: Seiko Epson Corporation
    Inventors: Koji Ohashi, Setsuya Iwashita, Takeshi Kijima, Yasuaki Hamada
  • Publication number: 20090073802
    Abstract: The invention relates to a method of assembling an implantable miniature transponder (1) comprising an elongate tubular plastic enclosure (2) having a first end (6) of a cylindrical wall (4) defining a first circular open mouth (7), and a transponder unit (11). The method comprises the steps of inserting said transponder unit (11) into the enclosure (2), externally touching the first end (6), in particular being exposed to heat, with a forming tool (21a; 21b), and completely closing the first end (6) by reducing the width of the first mouth (7) by means of deforming the first end (6) inwards with the forming tool (21a; 21b) until the first mouth (7) is totally closed. In a further embodiment, a relative rotation between the enclosure (2) and the forming tool (21a; 21b) is caused. Further, the invention relates to a transponder (1) with a completely closed plastic enclosure (2), having a closed first end (6) and a closed second end (8), being a single thermoplastic piece.
    Type: Application
    Filed: September 11, 2008
    Publication date: March 19, 2009
    Applicant: DATAMARS SA
    Inventors: Luca NIZZOLA, Damien PACHOUD, Peter STEGMAIER
  • Publication number: 20090039570
    Abstract: A method of forming a component from solid freeform fabrication comprising the step of building an integral support around the component during manufacture thereof. The stiffness the support provides to the component is selected to minimise deformation of the component either during the manufacture of the component or during a subsequent heat treatment process.
    Type: Application
    Filed: July 15, 2008
    Publication date: February 12, 2009
    Applicant: ROLLS-ROYCE PLC
    Inventor: Daniel Clark
  • Publication number: 20090026665
    Abstract: High-density components and products as well as processes for making high-density components and products are disclosed. One exemplary component, among others, includes a boron carbide component comprised of a homogeneous boron carbide powder. The component has at least a 93% relative density (RD) and a Vickers hardness of at least 2000 kg/mm2.
    Type: Application
    Filed: May 4, 2005
    Publication date: January 29, 2009
    Inventors: Robert F. Speyer, Hyukjae Lee, Zhihao Bao
  • Patent number: 7470390
    Abstract: To provide a production method of a polycrystalline ceramic body with excellent density, a preparation step, a mixing step, a forming step and a heat-treating step are performed. In the preparation step, a coarse particle ceramic powder, and a fine particle powder having an average particle diameter of ? or less of the average particle diameter of the coarse particle ceramic powder are prepared. In the mixing step, the coarse particle ceramic powder and the fine particle powder are mixed to produce a raw material mixture. In the forming step, the raw material mixture is formed to a shaped body. In the heat-treating step, the shaped body is heated and thereby sintered to produce a polycrystalline ceramic body. In the heat-treating step, a temperature elevating process and a first holding process are performed and at the same time, a second holding process and/or a cooling process are performed.
    Type: Grant
    Filed: October 25, 2005
    Date of Patent: December 30, 2008
    Assignee: Denso Corporation
    Inventors: Masaya Nakamura, Toshiatsu Nagaya, Tatsuhiko Nonoyama, Hisaaki Takao, Yasuyoshi Saito, Takahiko Homma, Kazumasa Takatori
  • Patent number: 7287573
    Abstract: A green product for use in fabricating a ceramic article comprises a ceramic powder immobilized within a silicone matrix, wherein the silicone matrix comprises one or more cross linked or polymerized silicone monomers and/or oligomers, wherein the one or more cross linked or polymerized silicone monomers and/or oligomers have a alkenyl reactive functional group and a hydride reactive functional group. Processes for forming a green product and a ceramic core with the silicone monomers and/or oligomers are also disclosed.
    Type: Grant
    Filed: September 30, 2003
    Date of Patent: October 30, 2007
    Assignee: General Electric Company
    Inventors: Thomas McNulty, John Leman
  • Patent number: 7169198
    Abstract: The invention relates to a method for the production of a sintered, microcrystalline ?-Al2O3-based shaped body, which are used, for example, as abrasive bodies, wherein an ?-Al2O3 powder is used as starting material, said powder having an average particle diameter of <2 ?m, and processed with at least one binder and a solvent with the purpose of obtaining an extrudable material that is subsequently extruded. The extrudate is then further processed into a shaped body that is sintered at a temperature range of between 1300° C. and 1750° C.
    Type: Grant
    Filed: February 8, 2001
    Date of Patent: January 30, 2007
    Assignee: Treibacher Schleifmittel GmbH
    Inventors: Paul Moeltgen, Wilhelm Pirmin, Frank J. Clemens
  • Patent number: 7141089
    Abstract: 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: Grant
    Filed: June 26, 2003
    Date of Patent: November 28, 2006
    Assignee: Corning Incorporated
    Inventors: Douglas M. Beall, Gregory A. Merkel, Martin J. Murtagh
  • Patent number: 7033537
    Abstract: A process for producing a continuous alumina fiber blanket by heat treating an alumina fiber precursor formed from a spinning solution containing an aluminum compound, by using a specific high-temperature furnace capable of high-temperature heat treatment. According to this process, a continuous sheet (W) of alumina fiber precursor formed from a spinning solution containing an aluminum compound is supplied continuously into a high-temperature furnace and subjected to heat treatment while being conveyed in one direction by plural conveying mechanisms (2, 3) disposed in said high-temperature furnace. In this operation, the speed of said conveying mechanisms is reduced progressively in the direction of conveyance in correspondence to the rate of heat shrinkage of the continuous sheet (W) of alumina fiber precursor, thereby to lessen fiber crush in the alumina fiber precursor and obtain a continuous alumina fiber blanket with uniform thickness and high bulk density as well as high strength.
    Type: Grant
    Filed: January 23, 2003
    Date of Patent: April 25, 2006
    Assignee: Mitsubishi Chemical Functional Products, Inc.
    Inventors: Mamoru Shoji, Norio Ikeda, Toshiaki Sasaki
  • Patent number: 7022274
    Abstract: The present invention relates to an effective and rapid method and apparatus for sintering carbon filter blocks having a polymeric binder. The method employs direct contact heat transfer by gas molecule to powder particle, as opposed to conduction heat transfer from an external heating source, using commercially available sintered porous metal sheets and cylinders to form the mold and confine the powder, while allowing heated gas to pass uniformly through the mixture.
    Type: Grant
    Filed: November 25, 2003
    Date of Patent: April 4, 2006
    Assignee: Graver Technologies, LLC.
    Inventors: S. Dyer Harris, Joel T. Shertok, John K. LeSieur
  • Patent number: 6878313
    Abstract: To furnish stably a sintered nuclear fuel compact of uranium dioxide with a large grain diameter, a fabrication method therefor requires sintering a starting material at two stages in an oxidizing atmosphere and in a reducing atmosphere at relatively low temperatures. The starting material is either a powder mixture of uranium dioxide fresh material powder and triuranium octaoxide in a weight ratio of 75/25 ˜ 55/45 or pulverulent mixed uranium oxides yielding a final O/U ratio equal to that of the powder mixture. The sintering process in the oxidizing atmosphere involves at least one time period of a temperature rise to a higher temperature of 1200 to 1100° C. and at least one time period of a temperature drop to a lower temperature of up to 1080° C. A temperature difference between the higher and lower temperatures is preferred to be 50° C. or more.
    Type: Grant
    Filed: August 15, 2002
    Date of Patent: April 12, 2005
    Assignee: Nuclear Fuel Industries, Ltd.
    Inventors: Shin-ichi Kobayashi, Katsuo Fukumoto
  • Patent number: 6852392
    Abstract: A porous sheet is provided suitable for use as a substitute for natural leather for shoes, clothes, and a fiber composite sheet. The porous sheet is formed of an elastic polymer, has a thickness of 10 to 500 ?m, and has 500 to 15,000 fine pores mm2 inside, the fine pores having an average pore diameter of 1 to 20 ?m, and which has a breaking strength of 1 to 15 N/mm2 and a breaking elongation of 100 to 500%. A fiber composite sheet is also provided, wherein the porous sheet is laminated on a substrate made of a fiber aggregate as a main component.
    Type: Grant
    Filed: June 7, 2002
    Date of Patent: February 8, 2005
    Assignee: Teijin Limited
    Inventors: Masayoshi Kikuchi, Nobuo Ohkawa
  • Patent number: 6841119
    Abstract: A method to obtain a refractory carbide-based composite material, in particular as an article of a predetermined shape includes the following steps: molding of a porous blank from a mixture of powders of at least one carbide-forming metal and/or non-metal and at least one carbide, the amount of carbide component in the mixture of powders not exceeding 90%, heat treating the obtained porous blank in a hydrocarbonous atmosphere containing one or more hydrocarbons until the increase in its mass reaches 2-42%, thereby obtaining a semi-product, and heating the obtained semi-product in a non-oxidizing medium at a temperature of 1000-2000° C.
    Type: Grant
    Filed: November 8, 2000
    Date of Patent: January 11, 2005
    Assignee: FOC Frankenburg Oil Company Est.
    Inventors: Sergey Konstantinovich Gordeev, Leonid Yourevich Denisov, Vladimir Vladimirivich Morozov, Jan Cederstrom, Thommy Ekstrom
  • Patent number: 6783706
    Abstract: A method for dry process recycling of mixed (U,Pu)O2 oxide nuclear fuel waste, including a process for making fuel pellets of mixed (U,Pu)O2 oxide, including a dosage and a first mixture (1) of waste in powder form and, if required, of PuO2 and/or UO2 powders, a micronization (2) and a forced sieving (3) of said first mixture, another dosage and a second mixture (4) of the first sieved mixture, of UO2 powders and, if necessary, of the waste powder, pelletizing (6) the second mixture, and sintering (7) the resulting pellets; and a process for pre-treating the waste including pelletizing (20) and sintering (21) the powder waste to form waste pellets, and micronizing (23) the waste pellets to form the desired waste powder designed to be incorporated as waste powder, in the first (1) and/or second mixtures.
    Type: Grant
    Filed: July 24, 2001
    Date of Patent: August 31, 2004
    Assignee: Belgonucleaire SA
    Inventors: Alain Vandergheynst, Jean Van Vliet, Eduard Pelckmans
  • Patent number: 6777114
    Abstract: It is directed to a silicon carbide-based porous body, wherein said body is a porous one which contains silicon carbide particles as an aggregate and metallic silicon, and has an oxygen-containing phase at the surfaces of silicon carbide particles and/or metallic silicon or in the vicinity of the surfaces thereof. The silicon carbide-based porous body contains refractory particles such as silicon carbide particles or the like and yet can be produced at a relatively low firing temperature at a low cost, has a high thermal conductivity, and is superior in oxidation resistance, acid resistance, chemical resistance to ash and particulates.
    Type: Grant
    Filed: August 13, 2002
    Date of Patent: August 17, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Takahiro Tomita, Shuichi Ichikawa, Shinji Kawasaki, Hiroaki Sakai