Including Nonsintering Burn-off, Volatilization, Or Melting Of Binder Patents (Class 264/656)
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Patent number: 9997353Abstract: A composite substrate includes a single crystal silicon layer on a glass or glass ceramic layer on a support layer can be used to form GaN layer without cracks. The glass or glass ceramic layer can have a set point and/or strain point below the deposition temperature of GaN, which can assist in releasing stress in the deposited GaN layer. Additionally, the composite substrate can be exposed to a heated and dry hydrogen ambient to reduce an oxide layer between the silicon layer and the glass or glass ceramic layer, to allow the formation of free standing GaN layer.Type: GrantFiled: April 26, 2017Date of Patent: June 12, 2018Inventors: Ananda H. Kumar, Srinivas H. Kumar, Tue Nguyen
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Patent number: 9969122Abstract: An additive manufacturing system may include a nozzle having an inlet for receiving a flowable material and an outlet for depositing the flowable material. The system also may include an applicator head surrounding at least a portion of the nozzle. Additionally, a roller may be mounted on the applicator head and rotatable about an axle. A coolant circuit may extend through at least a portion of the applicator head and through a lumen of the axle.Type: GrantFiled: November 7, 2017Date of Patent: May 15, 2018Assignee: THERMWOOD CORPORATIONInventor: Brian S. Smiddy
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Patent number: 9382611Abstract: 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: GrantFiled: June 5, 2012Date of Patent: July 5, 2016Assignee: Semiconductor Energy Laboratory Co., Ltd.Inventors: Shunpei Yamazaki, Tetsunori Maruyama, Yuki Imoto, Hitomi Sato, Masahiro Watanabe, Mitsuo Mashiyama, Kenichi Okazaki, Motoki Nakashima, Takashi Shimazu
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Publication number: 20150087492Abstract: A process for preparing a ceramic body having a surface roughness, said process comprising the step of depositing particles of a ceramic material on the surface of a ceramic basic body. The process is characterized in that separate agglomerates comprising at least two particles and a binder binding the particles together are deposited on the surface of the basic body by projecting the agglomerates towards the basic body.Type: ApplicationFiled: December 4, 2014Publication date: March 26, 2015Inventor: Marc Stephan
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Patent number: 8980139Abstract: A method of manufacturing a metal paste for an internal electrode according to the present invention includes preparing each of a metal powder and an organic vehicle; preparing a ceramic inhibitor powder in which a nano glass added with a rare-earth element is mixed; manufacturing a primary mixture by mixing the metal powder of 70 to 95 wt % and the ceramic inhibitor powder of 5 to 30 wt % when each of the metal powder, the organic vehicle, and the ceramic inhibitor powder in which the nano glass added with the rare-earth element is mixed is prepared; manufacturing a secondary mixture by mixing the primary mixture of 50 to 70 wt % and the organic vehicle of 30 to 50 wt % when the primary mixture is manufactured; and manufacturing the metal paste for the internal electrode by filtering the secondary mixture when the secondary mixture is manufactured.Type: GrantFiled: March 12, 2013Date of Patent: March 17, 2015Assignee: Samhwa Capacitor Co., Ltd.Inventors: Young Joo Oh, Jung Rag Yoon
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Publication number: 20130251900Abstract: Refractory metal and refractory metal carbide nanoparticle mixtures and methods for making the same are provided. The nanoparticle mixtures can be painted onto a surface to be coated and heated at low temperatures to form a gas-tight coating. The low temperature formation of refractory metal and refractory metal carbide coatings allows these coatings to be provided on surfaces that would otherwise be uncoatable or very difficult to coat, whether because they are carbon-based materials (e.g., graphite, carbon/carbon composites) or temperature sensitive materials (e.g., materials that would melt, oxidize, or otherwise not withstand temperatures above 800° C.), or because the high aspect ratio of the surface would prevent other coating methods from being effective (e.g., the inner surfaces of tubes and nozzles). The nanoparticle mixtures can also be disposed in a mold and sintered to form fully dense components.Type: ApplicationFiled: May 10, 2013Publication date: September 26, 2013Applicant: LOCKHEED MARTIN CORPORATIONInventor: Alfred A. Zinn
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Publication number: 20130106032Abstract: The present invention provides a method for sintering, comprising in the following order the steps of: providing a body in the green state or in the pre-sintered state on a support; providing a load on at least one spacer on the support such that the load is located above said body in the green state or in the pre-sintered state without contacting the body; heat treating the body in the green state or in the pre-sintered state at a temperature above the decomposition temperature of organic components contained in the green body and below the softening temperature or decomposition temperature of the spacer; heat treating the body in the green state or in the pre-sintered state at a temperature above the softening point or decomposition temperature of the spacer and below a sintering temperature such that the load contacts the body, and—sintering the body in the green state or pre-sintered state.Type: ApplicationFiled: June 30, 2011Publication date: May 2, 2013Applicant: Technical University of DenmarkInventor: Søren Linderoth
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Patent number: 8420006Abstract: A method of manufacturing a translucent ceramic is provided. The method comprises: mixing a raw powder and an organic binder and kneading them to obtain a compound, the raw powder containing an aluminum oxide powder and a magnesium oxide powder, and the organic binder containing a first organic component and a second organic component; molding the compound in a predetermined shape by an injection molding method to obtain a green body; debinding the organic binder contained in the green body to obtain a brown body; and sintering the brown body to obtain a sintered body of the translucent ceramic. When the softening point of the first organic component is defined as “T1” (° C.) and the softening point of the second organic component is defined as “T2” (° C.), the kneading step is carried out at a temperature in the range of T2 or higher but lower than T1 after the raw powder and the organic binder are preheated at a temperature in the range of T1 to T1+100(° C.). An orthodontic member is also provided.Type: GrantFiled: March 4, 2009Date of Patent: April 16, 2013Assignee: Seiko Epson CorporationInventors: Masaaki Sakata, Junichi Hayashi, Hideki Ishigami
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Patent number: 8404162Abstract: Composite materials and methods for making composites are provided. The method includes providing a nano-particulate-depletable material that includes a plurality of nano-particulates on or within a depletable material; positioning the nano-particulate-depletable material on or within a structural material; and depleting the depletable material such that the nano-particulates are selectively placed on or within the structural material. Depletion may include infusion of a resin into the structural material. The depletable material may be a polymeric foam, and the nano-particulates may be carbon nanotubes.Type: GrantFiled: December 22, 2009Date of Patent: March 26, 2013Assignee: Florida State University Research FoundationInventors: Okenwa O. I. Okoli, Myungsoo Kim
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Publication number: 20120220445Abstract: The present invention is a process for producing an aluminum titanate-based fired body, comprising shaping a starting material mixture containing inorganic compound source powders including an aluminum source powder and a titanium source powder, as well as an additive, degreasing the obtained shaped body at 150 to 900° C., and firing the degreased shaped body at not lower than 1300° C., wherein the inorganic compound source powders contain 1 to 5 parts by mass of particles having a particle diameter of not larger than 0.1 ?m in 100 parts by mass thereof.Type: ApplicationFiled: September 1, 2010Publication date: August 30, 2012Applicant: SUMITOMO CHEMICAL COMPANY, LIMITEDInventors: Kousuke Uoe, Masahiro Kan
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Patent number: 8197885Abstract: A method for producing a metal article according to one embodiment may include: Providing a supply of a sodium/molybdenum composite metal powder; compacting the sodium/molybdenum composite metal powder under sufficient pressure to form a preformed article; placing the preformed article in a sealed container; raising the temperature of the sealed container to a temperature that is lower than a sintering temperature of molybdenum; and subjecting the sealed container to an isostatic pressure for a time sufficient to increase the density of the article to at least about 90% of theoretical density.Type: GrantFiled: February 25, 2009Date of Patent: June 12, 2012Assignee: Climax Engineered Materials, LLCInventors: Dave Honecker, Christopher Michaluk, Carl Cox, James Cole
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Patent number: 8114336Abstract: Ceramic porous and non-porous articles are made by a process that includes a hardening step in which a fluid-containing ceramic composition is exposed to a solvent in which the fluid in the composition is soluble before the ceramic composition is solidified into the final ceramic article.Type: GrantFiled: March 4, 2008Date of Patent: February 14, 2012Assignee: Board Of Regents Of The University Of Texas SystemInventors: Yunzhi Yang, Yongxing Liu
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Patent number: 8012403Abstract: Porous ceramic and hybrid ceramic films are useful as low dielectric constant interlayers in semiconductor interconnects. (Hybrid ceramic films are defined as films that contain organic and ceramic molecular components in the structure, as, for example, organosilicates). This invention describes the usefulness of humidity treatments (using specific temperature/humidity treatments as illustrative examples) in increasing mechanical integrity of porous dielectric films with minimal detrimental effect on film porosity or dielectric constant and with no adverse impact on film quality. The efficacy of such treatments is illustrated using surfactant-templated mesoporous silicate films as an example. This invention also describes a specific family of additives to be used with highly pure alkali-metal-free ceramic and hybrid precursors for such dielectric films that will enable better control of the film porosity and quality and lower dielectric constants with the required mechanical integrity.Type: GrantFiled: September 14, 2001Date of Patent: September 6, 2011Assignee: Battelle Memorial InstituteInventors: Jerome C. Birnbaum, Glen E. Fryxell, Shari Li Xiaohong, Christopher A. Coyle, Glen C. Dunham, Suresh Baskaran, Ralph E. Williford
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Patent number: 8001691Abstract: A method for manufacturing a hydrodynamic bearing (30) comprises steps of: step (201): providing a substrate (10) with a plurality of protrusions (14) formed on a periphery thereof; step (202): placing the substrate in a middle of a hollow mold, then injecting a feedstock of powder and molten binder into the mold to surround the substrate under pressure, thus forming a desired bearing preform (20); step (203): separating the substrate from the bearing preform by means of catalytic debinding; step (204): separating the binder from the bearing preform; step (205): sintering the bearing preform; step (206): precision machining the bearing preform to form the desired hydrodynamic bearing.Type: GrantFiled: March 16, 2007Date of Patent: August 23, 2011Assignee: Foxconn Technology Co., Ltd.Inventor: Chuen-Shu Hou
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Patent number: 7993549Abstract: Process for producing carbon-ceramic brake discs comprising the following steps: production of a carbonized core body by press-molding a mixture containing reinforcing fibers and a binder, curing the binder by heating, and carbonizing by heating the press-molded body under exclusion of oxidizing substances to a temperature of between 750° C. and 1300° C., press-molding a moldable, reinforcing fiber-containing material onto the prefabricated carbonized core body which after the additional process steps produces the friction layer, curing the material for the friction layer, carbonizing the entire body and then infiltrating the composite body with liquid silicon.Type: GrantFiled: September 16, 2005Date of Patent: August 9, 2011Assignee: Audi AGInventors: Joachim Niewöhner, Markus Stettberger, Arno Sommer, Dunja Müller, Jens Rosenlöcher
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Patent number: 7993576Abstract: A method for producing a sintered body includes: a) molding a composition containing a powder primarily made of an inorganic material and a binder including an aliphatic carbonic acid ester based resin in a predetermined shape so as to obtain a compact; b) exposing the compact to a first atmosphere containing an alkaline gas and thus decomposing and removing the aliphatic carbonic acid ester based resin from the compact so as to obtain a degreased body; and c) sintering the degreased body so as to obtain a sintered body.Type: GrantFiled: March 14, 2008Date of Patent: August 9, 2011Assignee: Seiko Epson CorporationInventors: Masaaki Sakata, Nobuyuki Hamakura
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Patent number: 7926182Abstract: A method for manufacturing a hydrodynamic bearing with hydrodynamic pressure generating grooves comprises steps of: step 201: providing a substrate with a first annular protrusion and a plurality of projections formed on a periphery thereof, the projections being in a side of the first annular protrusion; step 202: placing the substrate in a middle of a hollow mold, then injecting a feedstock of powder and molten binder under pressure into the mold to surround the substrate, thus forming a desired bearing preform; step 203: separating the substrate from the bearing preform by means of catalytic debinding; step 204: separating the molten binder from the bearing preform; step 205: sintering the bearing preform to thereby form the hydrodynamic bearing.Type: GrantFiled: March 22, 2007Date of Patent: April 19, 2011Assignee: Foxconn Technology Co., Ltd.Inventor: Chuen-Shu Hou
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Patent number: 7854881Abstract: A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host.Type: GrantFiled: July 27, 2009Date of Patent: December 21, 2010Assignee: Geo2 Technologies, Inc.Inventor: James Jenq Liu
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Patent number: 7635446Abstract: An organic additive is removed from a ceramic honeycomb by an improved method by contacting each end of the extruded honeycomb with a member that has a gas permeability no greater than the outer wall, the member essentially covering the ends and heating the honeycomb to a temperature sufficient to remove the organic additive.Type: GrantFiled: August 18, 2006Date of Patent: December 22, 2009Assignee: Dow Global Technologies, Inc.Inventors: John Porter Henley, Avani Maulik Patel, Arthur Richard Prunier, Jr., Chan Han
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Patent number: 7567817Abstract: A porous ceramic substrate is disclosed that is fabricated from biosoluble ceramic fibers. Porosity and permeability of the substrate is provided by intertangled biosoluble fibers, that can be formed into a honeycomb form substrate through an extrusion process. The fibrous structure is formed from mixing biosoluble fibers with additives that include a bonding agent, and a fluid to provide an extrudable mixture. The structure is sintered at a temperature that exceeds the glass formation temperature of the bonding agent, but less than the maximum operational limits of the biosoluble fiber, to form a structure that has sufficient strength and porosity to provide for filtration and/or as a catalytic host.Type: GrantFiled: May 14, 2007Date of Patent: July 28, 2009Assignee: GEO2 Technologies, Inc.Inventors: James Jenq Liu, Bilal Zuberi
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Patent number: 7425284Abstract: The purpose of the invention is a process for making a solid part designed to form all or part of an anode for the production of aluminium by fused bath electrolysis, containing a cermet formed from at least one metallic oxide such as a mixed oxide with spinel structure, and at least one metallic phase, in which a mixed oxide is used containing a metal R in the form of a cation in its chemical structure, the said metal R being fully or partly reducible by a reduction operation during the manufacturing process, so as to form all or part of the said metallic phase. This process can provide a cermet with a uniform distribution of fine metallic particles.Type: GrantFiled: October 5, 2004Date of Patent: September 16, 2008Assignee: Aluminum PechineyInventors: Philippe Tailhades, Abel Rousset, Armand Gabriel, Véronique Laurent, Valérie Baco-Carles, Airy-Pierre Lamaze
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Patent number: 7399443Abstract: 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: GrantFiled: February 27, 2004Date of Patent: July 15, 2008Assignee: Lucent Technologies Inc.Inventors: Dennis S Greywall, Bernard Yurke
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Patent number: 7371704Abstract: An object of the present invention is to lower the sintering temperature required for a sintered body of yttrium-aluminum garnet, to improve the corrosion resistance of the sintered body and to prevent the reduction of the transmittance thereof. A sintered body of yttrium-aluminum garnet is produced from a source compound for yttrium and a source compound for aluminum using aluminum nitride as a sintering aid. It maybe considered that aluminum nitride reacts with alumina and yttria to generate liquid phase and to reduce the sintering temperature during the sintering process.Type: GrantFiled: December 8, 2003Date of Patent: May 13, 2008Assignee: NGK Insulators, Ltd.Inventor: Norikazu Niimi
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Patent number: 7303722Abstract: The present invention relates to a method of making a sintered body comprising one or more hard constituents in a binder phase by injection molding or extrusion. According to the invention, the binder system comprises 30-70 wt % poly(ethylene-co-vinylacetate) and balance (Polyethylene)-blend-(Poly(oxy-1,2-ethanediyl), .alpha.-hydro-.omega.-hydroxy)-based wax. The solids loading of the feedstock, ?, is 0.51<?<0.53, calculated using the equation: ? = ? f - ? b ? s - ? b where ?s is the density of the material as sintered, ?b is the density of the binder system and ?f is the density of the feedstock, measured with a helium pycnometer. Debinding is performed by heating in a furnace in flowing hydrogen atmosphere.Type: GrantFiled: August 25, 2004Date of Patent: December 4, 2007Assignee: Seco Tools ABInventors: Johnny Bruhn, Evert Löwdin, Tomas Rostwall
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Patent number: 7285241Abstract: The present invention relates to a method of making a sintered body comprising one or more hard constituents in a binder phase by injection molding or extrusion. According to the invention, the granulating agent during drying is an ethylene oxide polymer and the binder system is not miscible with that compound. The extraction step is performed in an alcohol based solvent at a temperature of 50-78° C., preferably 60-78° C.Type: GrantFiled: August 25, 2004Date of Patent: October 23, 2007Assignee: Seco Tools ABInventor: Mattias Puide
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Patent number: 7276203Abstract: A process for producing hollow bodies comprising fiber-reinforced ceramic materials, in which a green body comprising compressible cores and a mouldable composition comprising binders and fiber material which is pressed with compression of the core is produced, the green body is cured and carbonized and pyrolysed by heating in a nonoxidizing atmosphere and, if desired, the body is silicized, hollow bodies produced in this way and their use, in particular as brake and clutch disksType: GrantFiled: December 18, 2003Date of Patent: October 2, 2007Assignee: Audi AGInventors: Arno Sommer, Dieter Huber, Dunja Straub
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Patent number: 7238319Abstract: A method for fabricating a green ceramic article containing organic compounds. The method involves first heating the green ceramic article to sequentially remove the organic compounds such that the organic compound with the lowest weight loss onset temperature is substantially removed prior to the next higher weight loss onset temperature organic compound. The organic compounds include but are not limited to at least an oil or oil-based compound having a flash point or an ignition temperature, higher than the weight loss onset temperature. For this system the temperature during heating is maintained below the flash point of the oil or oil-based compound until substantial removal thereof from the green ceramic structural body. After the organic compounds are substantially removed, the green ceramic article is further fired to a temperature and for a time to obtain a final fired body.Type: GrantFiled: June 26, 2003Date of Patent: July 3, 2007Assignee: Corning IncorporatedInventors: John H. Brennan, Gregory P. Dillon, Tudor C. Gheorghiu, Michael J. Vayansky
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Patent number: 7235199Abstract: The invention relates to a process for the production of chromatography columns or capillaries containing sorbents of monolithic mouldings which can remain directly in their gelation mould after production. This is achieved by the process according to the invention, in which the gelation mould is repeatedly filled with the monomer sol.Type: GrantFiled: May 16, 2001Date of Patent: June 26, 2007Assignee: Merck Patent GmbHInventors: Dieter Lubda, Egbert Mueller
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Patent number: 7186360Abstract: Ceramic composite materials have unidirectional alignment of the reinforcing fibers. The ratio of the volume of the fiber strands of the reinforcing fibers to the volume of the matrix is at least 0.5. A process for their production involves initially coating the fiber strands or rovings of the reinforcing fibers with a sacrificial polymer. The coated fiber strands are processed with binder resins into unidirectionally reinforced CFK molded parts. The formed CFK bodies are carbonized to form CFC bodies. The CFC bodies are then silicized with liquid silicon. The liquid silicon diffuses into the pores formed in the CFC body and combines there at least partially with the carbon to form silicon carbide. The sacrificial polymer is pyrolized. The ceramic composite materials also can be used in fiber-reinforced ceramic structural parts.Type: GrantFiled: February 28, 2003Date of Patent: March 6, 2007Assignee: SGL Carbon AGInventor: Bodo Benitsch
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Patent number: 7160500Abstract: The present invention relates to a method of fabricating a micro device, comprising the steps of pressing an upper mold formed with a plurality of recesses for molding a plurality of rods and a lower mold formed with a seat recess for molding a plate supporting the plurality of rods against each other; injecting ceramic material mixed with a polymer into the mold; releasing a resultant ceramic molding mixed with the polymer from the molds; removing the polymer from the ceramic molding by burning out or melting away the polymer; sintering the ceramic molding; filling a polymer into spaces between the plurality of rods of the sintered ceramic molding so that the top surfaces of the plurality of rods are exposed to the outside; and removing the plate through a polishing process so that bottom surfaces of the plurality of rods are exposed to the outside.Type: GrantFiled: October 16, 2002Date of Patent: January 9, 2007Assignee: Korea Electronics Technology InstituteInventors: Joon-Shik Park, Soon-Sup Park, Suk-Won Jung, Jin-Woo Cho
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Patent number: 7128870Abstract: A method for manufacturing multilayer ceramic electronic components includes the steps of removing organic materials from multilayer ceramic bodies having internal electrodes and ceramic layers, and then sintering the multilayer ceramic bodies. After finishing the removing step, it is preferable that the amount of the remaining organic materials in the multilayer ceramic body is 0.5 to 8.5 weight %, more preferably 1.0 to 5.0 weight %. The removing process may be performed in a neutral, a reductive or inert atmosphere. It is also preferable that the organic materials removing temperature of the internal electrodes are controlled to be higher than that of the ceramic layer.Type: GrantFiled: June 24, 2003Date of Patent: October 31, 2006Assignee: Taiyo Yuden Co., Ltd.Inventor: Koji Otsuka
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Patent number: 6849570Abstract: The present invention relates to a process for the production of a titanium silicalite shaped body by: (a) forming a formable composition containing titanium silicalite, a binder and a pasting agent, so that the Curd curve of the formable composition has a plateau value in the range from 20 to 90 mm; (b) shaping the composition of step (a) to form a green body; (c) optionally drying and (d) calcining the green body, to a titanium silicalite shaped body obtainable by that process, and to the use of such titanium silicalite shaped bodies in the epoxidation of olefins or the ammoximation of ketones.Type: GrantFiled: March 21, 2001Date of Patent: February 1, 2005Assignee: Degussa AGInventors: Steffen Hasenzahl, Ralf Jantke
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Publication number: 20040222346Abstract: A spacer assembly has first and second spacers that are set up integrally on first and second surfaces, respectively, of a substrate. Each spacer is tapered toward its extended end. In forming the spacer assembly, first and second molding dies having through holes coated with a parting agent that contains an organic component are prepared, and these molding dies are located on the first and second surfaces of the substrate so as to be intimately in contact with them, individually. Thereafter, a spacer forming material is filled into the through holes of the molding dies and cured, whereupon the first and second spacers are formed integrally on the substrate surfaces.Type: ApplicationFiled: January 16, 2004Publication date: November 11, 2004Inventors: Masaru Nikaido, Satoshi Ishikawa, Kentarou Shimayama
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Patent number: 6803086Abstract: There are provided a porous honeycomb structure body capable of satisfying a pressure loss and isostatic strength which are mutually contradictory properties simultaneously and a method for manufacturing the same. In a porous honeycomb structure body having partition walls which contain cordierite as a primary crystal phase and have a porosity of 40 to 75% and an average pore diameter of 10 to 50 &mgr;m, porosity and an average pore diameter in a center portion of the structure body are made larger than porosity and an average pore diameter in a peripheral portion of the structure body.Type: GrantFiled: December 23, 2002Date of Patent: October 12, 2004Assignee: NGK Insulators, Ltd.Inventors: Yasushi Noguchi, Yukihisa Wada, Yumi Muroi
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Patent number: 6780353Abstract: Ultrasmall, complex-shaped high-precision micromolds are produced by controlled shrinkage upon sintering of green parts molded from mixtures of micrometer- or nanometer-sized particulates dispersed in an organic binder.Type: GrantFiled: October 8, 2001Date of Patent: August 24, 2004Inventors: Romain L. Billiet, Hanh T. Nguyen
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Publication number: 20040140596Abstract: A producing method of a porous Si3N4 having high porosity and formed of Si3N4 particles having a high aspect ratio includes the following steps. A compound of a rare earth element as a first sintering agent is mixed in an amount of 7.5-45 parts by mass, in terms of an oxide of the element, with respect to 100 parts by mass of Si powder to obtain mixed powder. A binder is added to the mixed powder, which is then molded into a molded body. The molded body is heated in a nitrogen atmosphere to 300-500° C. to remove the binder. The binder-removed body is heated in a nitrogen atmosphere to 1350-1500° C. for nitriding. The nitrided body is then sintered at 1750-1900° C. at a nitrogen pressure of 0.1-1 atmosphere.Type: ApplicationFiled: January 5, 2004Publication date: July 22, 2004Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.Inventors: Takeshi Satoh, Jin-joo Park
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Publication number: 20040135295Abstract: An object of the present invention is to lower the sintering temperature required for a sintered body of yttrium-aluminum garnet, to improve the corrosion resistance of the sintered body and to prevent the reduction of the transmittance thereof. A sintered body of yttrium-aluminum garnet is produced from a source compound for yttrium and a source compound for aluminum using aluminum nitride as a sintering aid. It maybe considered that aluminum nitride reacts with alumina and yttria to generate liquid phase and to reduce the sintering temperature during the sintering process.Type: ApplicationFiled: December 8, 2003Publication date: July 15, 2004Applicant: NGK INSULATORS, LTD.Inventor: Norikazu Niimi
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Patent number: 6746748Abstract: A honeycomb structure made of a silicon carbide-based porous body and having a number of through-holes extending in the axial direction, separated by partition walls. The strength and Young's modulus of the silicon carbide-based porous body satisfy the following relation: Strength (MPa)/Young's modulus (GPa)≧1.1. The honeycomb structure contains refractory particles such as silicon carbide particles and the like and yet can be produced at a relatively low firing temperature at a low cost, has a high strength and a high thermal shock resistance, and can be suitably used, for example, as a filter for purification of automobile exhaust gas by a treatment such as plugging of through-channel at its inlet or outlet, or as a catalyst carrier, even under a high SV condition.Type: GrantFiled: August 12, 2002Date of Patent: June 8, 2004Assignee: NGK Insulators, Ltd.Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
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Patent number: 6740287Abstract: A method of fabricating nanostructure bodies by integrating the steps of attriting precursor nanometer-sized particulate materials, desorbing the exposed surfaces of the attrited nanoparticulates, adsorbing a surfactant on at most 50% of the desorbed surfaces and dispersing the surfactant-coated nanoparticulates in an organic matrix to form a homogeneous thermoplastic compound from which green bodies are shaped, dewaxed and sintered.Type: GrantFiled: February 11, 2002Date of Patent: May 25, 2004Inventors: Romain Louis Billiet, Hanh T. Nguyen
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Patent number: 6740286Abstract: 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 in an inert gas or nitrogen gas at a pressure of no more than about 30 psi to provide consolidated and densified fibrous monolith composites.Type: GrantFiled: December 4, 2001Date of Patent: May 25, 2004Assignee: Advanced Ceramics Research, Inc.Inventors: Manish P. Sutaria, Mark J. Rigali, Ronald A. Cipriani, Gregory J. Artz, Anthony C. Mulligan
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Patent number: 6733703Abstract: Precise control of the shrinkage upon sintering of bodies made from mixtures of particulate materials and organic binders is achieved through precision pycnometry of the particulate materials and of the resulting sintered bodies, thus allowing a single molding tool to be used to produce parts in different sizes and from different materials and to tight manufacturing tolerances.Type: GrantFiled: September 20, 2001Date of Patent: May 11, 2004Inventors: Romain L. Billiet, Hanh Thi Nguyen
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Publication number: 20040081573Abstract: A method of fabricating an article, such as a prototype part or a tooling for injection molding, by way of selective laser sintering, using a composite powder system of a metal and/or ceramic powder with a polymer binder comprising thermoplastics and thermoset polymers, and a metal hydride powder to form a “green” article. After removal of unfused material from the green article it is placed in an oven or furnace in a non-reactive atmosphere such as, for example, nitrogen or argon, for subsequent heat treatment to decompose and drive off the binder and sinter the metal substrate particles prior to infiltration by a metal with a lower melting point. During the critical step of decomposing the binders, the metal hydride begins to decompose also and releases an in-situ concentration of hydrogen gas that creates the reducing conditions necessary to thoroughly decompose the polymer fragments so that the hydrocarbon fragments can escape the skeleton structure of the article.Type: ApplicationFiled: October 23, 2002Publication date: April 29, 2004Applicant: 3D SYSTEMS, INC.Inventor: Kenneth J. Newell
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Publication number: 20040079431Abstract: A pipe blanket is provided for wrapping around and insulating a pipe. The pipe blanket comprises an insulation mat having an outer surface and an inner surface adapted to lie adjacent the pipe when the pipe blanket is wrapped around the pipe. An outer cover of the pipe blanket is coupled to the outer surface of the insulation mat. The insulation mat is configured to enclose a variety of pipes having different sized diameters. The pipe blanket further includes a closure means configured for securing the insulation mat and outer cover about the pipe. The insulation mat further includes a plurality of pleats.Type: ApplicationFiled: September 4, 2003Publication date: April 29, 2004Inventor: Ronald E. Kissell
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Publication number: 20040065986Abstract: A method for manufacturing multilayer ceramic electronic components includes the steps of removing organic materials from multilayer ceramic bodies having internal electrodes and ceramic layers, and then sintering the multilayer ceramic bodies. After finishing the removing step, it is preferable that the amount of the remaining organic materials in the multilayer ceramic body is 0.5 to 8.5 weight %, more preferably 1.0 to 5.0 weight %. The removing process may be performed in a neutral, a reductive or inert atmosphere. It is also preferable that the organic materials removing temperature of the internal electrodes are controlled to be higher than that of the ceramic layer.Type: ApplicationFiled: June 24, 2003Publication date: April 8, 2004Inventor: Koji Otsuka
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Patent number: 6716512Abstract: A honeycomb structure having, in the axial direction, a number of through-channels separated by partition walls, which honeycomb structure contains refractory particles and a vitreous component and is porous. Although the honeycomb structure contains refractory particles such as silicon carbide particles or the like, it can be produced at a relatively low firing temperature; therefore, the honeycomb structure has a low production cost and a high yield and can be provided at a low price.Type: GrantFiled: September 14, 2001Date of Patent: April 6, 2004Assignee: NGK Insulators, Ltd.Inventors: Yoshinori Yamamoto, Naomi Noda, Takashi Harada
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Publication number: 20040012127Abstract: The invention proposes to produce a mixture that is shrink-resistant, or has a freely selectable degree of shrinkage, and can be used as a molding compound, and a method for producing a corresponding oxide-ceramic sintered body. The molding compound comprises an intermetallic compound and a wax. In the method for producing an oxide-ceramic sintered body, a green body is molded from a molding compound of this type, dewaxed and sintered in an oxidizing atmosphere to form a ceramic sintered body. The molding compound is suited for producing dentures and dental fillings.Type: ApplicationFiled: August 4, 2003Publication date: January 22, 2004Inventors: Joachim Binder, Jurgen Hausselt, Hans-Joachim Ritzhaupt-Kleissl, Kirsten Honnef, Ray Sikha, Volker Hennige
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Patent number: 6676887Abstract: An oxidation resistant carbon composite material comprises nanocrystalline silicon carbide regions distributed throughout a carbon matrix. The composite is prepared by intermixing in a solvent a silicon carbide precursor and a carbon precursor and forming a solution that is free of solids. After removing the solvent from the mixture, the remaining material is pyrolyzed and forms the characteristic nanocrystalline silicon carbide in a carbon matrix. A composite made by the subject method and a part made from the composite are also provided.Type: GrantFiled: February 7, 2001Date of Patent: January 13, 2004Assignee: Board of Trustees of Southern Illinois UniversityInventor: Khalid Lafdi
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Patent number: 6652801Abstract: A method for producing agglomerated boron carbide, including the steps of providing a boron carbide powder precursor having particle sizes smaller than about 1 micron in diameter, mixing the boron carbide powder precursor with binder solution to form a slurry, drying the slurry to yield a solid residue, crushing the solid residue to yield green boron carbide particles, and firing the green boron carbide particles. The resultant agglomerated boron carbide particles have diameters generally ranging from about 5 to about 20 microns. The agglomerated boron carbide particles are characterized as boron carbide grains of about 1-2 microns in diameter suspended in a vitreous boron oxide matrix.Type: GrantFiled: February 28, 2001Date of Patent: November 25, 2003Inventor: Gerard E. Parker
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Patent number: 6649244Abstract: A ceramic honeycomb catalyst carrier wherein a porosity is 20% or less and an average surface roughness (Ra) of a partition wall of the carrier is 0.5 &mgr;m or more is obtained by forming ceramic raw materials to obtain a ceramic honeycomb formed body; drying the ceramic honeycomb formed body to obtain a ceramic honeycomb dried-up body; roughening a surface of the partition wall of the ceramic honeycomb dried-up body by exposing the ceramic honeycomb dried-up body in an airflow in which polishing powders are included; and sintering the ceramic honeycomb dried-up body after a surface treatment, or, by forming ceramic raw materials to obtain a ceramic honeycomb formed body; drying and sintering the ceramic honeycomb formed body to obtain a ceramic honeycomb sintered body; and roughening a surface of the partition wall of the ceramic honeycomb sintered body by exposing the ceramic honeycomb sintered body in an airflow or a water flow in which polishing powders are included.Type: GrantFiled: January 17, 2002Date of Patent: November 18, 2003Assignee: NGK Insulators, Ltd.Inventors: Toshiyuki Hamanaka, Kyoko Makino, Yasushi Noguchi
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Patent number: 6641776Abstract: X-ray imageable articles, for instance surgical implements or parts therefore which are used in minimally invasive surgical procedures, may be prepared by a process including the steps of: (a) preparing a mixture composition comprising: i) radiolucent particulate material selected from ceramic materials, metallurgic materials, and combinations thereof and having a particulate size of no more than 40 microns, ii) radiopaque particulate material selected from ceramic materials, metallurgic materials, and combinations thereof and having a particulate size of no more than 40 microns, and (iii) at least one polymeric binder material; (b) injection molding the mixture composition into a preform; (c) optionally removing the binder material from the preform; and (d) sintering the preform.Type: GrantFiled: November 15, 2000Date of Patent: November 4, 2003Assignee: SciMed Life Systems, Inc.Inventors: Timothy J. Weaver, Dion Mraz