Abstract: A method for compounding gel-free injection molding feed stock for injection molding net-shape ceramic parts, including the steps of: mixing inorganic particles with non-gel forming water soluble organic binders having molecular weight between 1000 and 1,000,000 and that are between 0.5 weight % and 10 weight % based upon the inorganic particles, along with plasticizers, water and processing aids in a mixer to form a mixture, wherein the non-gel forming water soluble organic binders are composed of high and low molecular weight organic binders; compounding the mixed inorganic particles and the non-gel forming water soluble organic binders at a high temperature in the range of between 70° and 98° Centigrade, under shear force, to form a homogenous viscous slurry in the range of 5×103 and 7×104 Pa.sec at a shear rate of 10 sec?1; cooling the homogenous viscous slurry to room temperature to form a compounded solid mass.

Abstract: A method of producing a ceramic object includes producing particles of a type A and a type B. Each particle has a dimension of at least 5 ?m and each type of particle includes a ceramic material that is based on a mixture of silver oxide, niobium oxide and tantalum oxide. The method includes producing a particle mixture by mixing the types of particles, producing a green compact by compressing the particle mixture, and sintering the green compact.

Abstract: Gypsum-based molding materials are customized by hydrating the molding material to workable (malleable) consistency with a moistening solution containing 0.001 to 35% polytetrafluoroethylene. The addition of latex results in a more flowable material.

Abstract: Round and spherical titanium dioxide scouring media and a method for producing the media are disclosed. The scouring media is effective in removing titanium dioxide buildup on the walls of a titanium dioxide reaction vessel. The method consists of forming green titanium dioxide pellets in a high intensity mixer by mixing commercially available titanium dioxide dust, water and a surfactant. The high intensity mixer produces substantially round, and spherical green pellets which are subsequently sized and sintered in a kiln to form round and spherical titanium dioxide sintered pellets that are suitable as a scouring media. The high intensity mixer allows the operator to closely control the size and shape of the pellets during the forming process to produce substantially round and spherical green pellets. Because the sintered titanium dioxide pellets are substantially round and spherical in shape, they are much less abrasive to the walls of the reaction vessel.

Abstract: The invention relates to a process for producing a molding, characterized in that a silicatic solid is mixed with a solution comprising a first silicatic binder and the mixture is then press-molded, and the compression molding is then post-treated with a solution comprising a second silicatic binder, and to silicatic moldings obtainable by this process, and also to their use as construction material, insulator material, gasket material or fire-resistant material.

Abstract: A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.

Abstract: A dielectric ceramic article precursor and a process for preparing a dielectric ceramic article are presented. The ceramic article precursor comprises a crystalline aluminosilicate zeolite or an amorphous aluminosilicate, a zinc oxide additive and a glass phase. The ceramic article precursor can optionally contain at least one forming aid selected from binders, plasticizers and surfactants. The process for preparing a dielectric ceramic article involves forming a mixture from the above components into a shaped article such as a tape and then calcining the shaped article at a temperature of about 700° C. to about 1000° C. for a time of about 0.5 to about 24 hours.

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.

Abstract: A method of making an EUV lithography stage structure includes depositing a layer of a Ti doped SiO2 glass powder in a confined region to provide an underlying layer; applying a binder to form a primitive with the binder bonding the glass powder together at one or more selected regions; depositing an above layer of the glass powder above the deposited layer; applying the binder to the above layer with the binder bonding the glass powder together at one or more selected regions; repeating the deposition and binding steps to produce a number of successive layers with the binder bonding the successive layers together; and removing the unbonded glass powder to provide a bonded glass powder lithography stage structure which is then sintered and densified into a densified nonpowder glass lithography stage.

Abstract: A honeycomb structure body which has a number of passages partitioned with partition walls and penetrating along the axial direction. A porous honeycomb structure body which contains refractory grains as filler, one or more elements selected from the group consisting of the rare earth elements, alkaline earth elements, Al, and Si, and the crystal containing one or more kinds of these elements. The present honeycomb structure body contains refractory grains such as silicon carbide grains and the like, but it can be produced at a relatively low firing temperature at a low price, it is sufficiently porous and high in specific surface area, and it can be used as a filter for purifying automobile exhaust gas, a catalyst carrier, and the like under the high SV conditions.

Abstract: An improvement in a method of forming ceramic articles comprising an oil component or extrusion aid, the improvement including removing a substantial portion of the oil component, prior to firing, by applying a solvent to the green ceramic article to dissolve the oil component.

Abstract: 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.

Abstract: 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.

Abstract: A method of making a product which is generally impervious to water including the steps of making a generally homogenous mixture of slate particles and clay, wetting the mixture as necessary to produce a formable composition, forming the wet mixture to a desired configuration, at least partially drying the formed mixture and subjecting the dried formed mixture to a temperature of at least 1100° C. for a time sufficient for at least some of the clay to convert into a binder to bind together the slate particles.

Abstract: A method of producing a substantially regular cylindrical body that consists of a deformable material, especially a sintered metal blank. The blank is provided with an interior helical recess. The blank is first produced with a substantially linear course of the interior recess, for example by extrusion. The body is cut to a defined length and is subjected to a rolling movement by a friction surface while being supported across its entire length on a support. The speed of the rolling movement changes in a linear and continuous manner across the length of the body, thereby regularly twisting the body.

Abstract: A ceramic honeycomb structure has an open frontal area of 50% to 85%, a porosity of 0.1% to 10%, and a proportion of the volume of pores of 1 &mgr;m or larger in diameter, in total pore volume, of 20% or more; a regenerative thermal oxidizer using the ceramic honeycomb structure. The ceramic honeycomb structure has a small porosity and, therefore, has a sufficient heat accumulation capacity and hardly causes floating by gas pressure; has controlled pore diameters and, therefore, hardly shows adsorption of VOC or the like, or rupture; and has controlled contraction and, therefore, has a large GSA.

Abstract: A molded honeycomb material is obtained by subjecting a mixture of a raw material powder and a binder to extrusion molding. In the honeycomb material, no open pores are present, and the binder includes a thermoplastic material which is molten at the molding temperature. A process for producing the above molded honeycomb material includes heating a mixture of a raw material powder and a binder to a molding temperature to melt the binder, subjecting the mixture to extrusion molding, and cooling and solidifying the extrudate. The honeycomb material has a small partition wall thickness and can be mass-produced without impairing the product quality.

Abstract: A method of forming substantially spherical ceramic beads that includes conveying an aqueous ceramic slurry to a nozzle tip that is immersed in an inert water-immiscible fluid layer. The nozzle tip is spaced a predetermined distance away from a rotating disk that is also immersed in the immiscible fluid layer. The rotating disk creates a shear force that at the nozzle tip that dislodges droplets of the aqueous ceramic slurry from the nozzle tip into the immiscible fluid layer. Once dislodged, the droplets assume a substantially spherical shape and a substantially mono-modal size distribution. The droplets are permitted to pass from the immiscible fluid layer into an aqueous gelling solution wherein the droplets are converted into rigid beads. In a preferred embodiment of the invention, the rigid beads are recovered from the gelling solution, washed, and then sintered to obtain a density of greater than about 98% of theoretical density and a sphericity of greater than about 0.95.

Abstract: An open-cell glass crystalline porous material made from hollow microspheres which are cenospheres obtained from fly ash, having an open-cell porosity of up to 90 vol. % is produced. The cenospheres are separated into fractions based on one or more of grain size, density, magnetic or non-magnetic, and perforated or non-perforated. Selected fractions are molded and agglomerated by sintering with a binder at a temperature below the softening temperature, or without a binder at a temperature about, or above, the softening temperature but below the temperature of liquidity. The porous material produced has an apparent density of 0.3-0.6 g/cm3, a compressive strength in the range of 1.2-3.5 MPa, and two types of openings: through-flow wall pores in the cenospheres of 0.1-30 micrometers, and interglobular voids between the cenospheres of 20-100 micrometers.

Abstract: A method for preparing flat foils having a high density includes the steps of mixing a powdered material with a binder to form a green sheet. The green sheet is exposed to a high intensity radiative source adapted to emit radiation of wavelengths corresponding to an absorption spectrum of the powdered material. The surface of the green sheet is heated while a lower sub-surface temperature is maintained. An apparatus for preparing a foil from a green sheet using a radiation source is also disclosed.

Abstract: A method and an apparatus for sintering a compact of particulate material for a ceramic or of particles of a metal, or a ceramic precursor film, wherein the sintering is performed by heating and burning the compact or the ceramic precursor film while applying centrifugal force to the compact or the ceramic precursor film.

Abstract: 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.

Abstract: In insulator including alumina as a main component, a Na component in the insulator is set in the range of 0.07 to 0.5 wt % as Na2O. While the Na component content is as high as to have conventionally been regarded to be beyond the common sense, with this range of the Na component content, insulation resistance, mechanical strength and the like at high temperature are unexpectedly not reduced and an insulator with performances comparable to those of an insulator from conventional low soda alumina lower in Na component content than the above described range can be obtained. As a result, medium soda alumina and regular soda alumina that are much lower in cost than conventionally used low soda alumina can be used instead of the low soda alumina, so that dramatic reduction in production costs of insulator 2 for a spark plug 100 and in addition, of the spark plug 100 using the insulator 2 are realized.

Abstract: The present invention provides a carbon heating element having an arbitrary specific resistance and an arbitrary shape which are arbitrary necessary as a heating element, and a method of producing the same. The carbon heating element is obtained by uniformly dispersing one or at least two metal or metalloid compounds into a composition having shapability and showing a high yield of a carbon residue after firing, shaping the dispersed material-containing mixture thus obtained, and firing the shaped material under a nonoxidizing atmosphere.

Abstract: The present invention related to a method for producing agglomerated boron carbide. One form of the present invention includes 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.

Abstract: Exemplary silicon carbide ceramic bodies are produced according to the invention. An exemplary ceramic body includes silicon carbide in major amounts and an organic gelation agent in a minor amount. An exemplary ceramic body exhibits sufficient density and hardness to function as body armor.

Abstract: A process for producing a monolithic ceramic electronic component, which includes: providing a ceramic slurry, a conductive paste, and a ceramic paste; forming a plurality of composite structures each comprising a ceramic green sheet produced by shaping the ceramic slurry, internal circuit element films formed by applying the conductive paste partially onto a main surface of the ceramic green sheet so as to provide step-like sections, and a ceramic green layer which compensates for spaces defined by the step-like sections, the ceramic green layer being formed by applying the ceramic paste onto the region on the main surface of the sheet on which the element films are not formed, so as to substantially compensate for the spaces; forming a green laminate by laminating the composite structures; and firing the green laminate, wherein the ceramic paste contains ceramic powder, an organic solvent, and an organic binder.

Abstract: A powder bed (32) is built up by repeated deposition of a slurry that contains powder. Layers are made by depositing a liquid dispersion of the desired powdered material, which then slip-casts into the forming powder bed to make a new layer (34). The slurry may be deposited in any suitable manner, such as by raster or vector scanning, or by a plurality of simultaneous jets that coalesce before the liquid slip-casts into the bed, or by individual drops, the deposits of which are individually controlled, thereby generating a regular surface for each layer.

Abstract: An improved submerged entry nozzle is provided which is useful in the casting of aluminum killed molten steel. The nozzle has an improved slagline sleeve or collar which surrounds the outer portion of the nozzle to protect it from corrosion during the casting process. The slagline sleeve is made from resin bonded zirconia/graphite which has been formulated so that upon curing of the resin to form resite, there is a reduction in the contractile tendency which results in a reduction in stress fracturing. The reduction of the contractile tendency and the resulting resistance to stress fracturing is achieved by adding an effective amount of calcium oxide to the resin-zirconia-graphite mixture which is used to form the sleeve.

Abstract: A process for the removal of binder material from powder injected molded parts that employs a low pressure plasma reactor to generate reactive species which react with the binder material in the injected molded part is presented. The reactive species cause the binder material to break down into smaller molecules and thereby be removed from the injected molded part.

Abstract: This invention provides a production method for a ceramic structure capable of making a extrusion rate coefficient, in extruding of a ceramic structure, greater than that of prior art technologies. In a production method for a ceramic structure by the steps of mixing and kneading a ceramic batch material containing at least ceramic powder and water, extruding the mixture so kneaded, and drying and sintering a resulting extrudate, a water-insoluble liquid lubricant consisting of acyl glycerin and/or a derivative is added to the ceramic batch material.

Abstract: A method of making a water-based ceramic that contains carrageenan and various average-molecular-weight preparations of poly(ethylene oxide). Various other materials can be added to yield mixtures appropriate for specialized applications.

Abstract: A permanent, biocompatible material for soft tissue augmentation. The biocompatible material comprises a matrix of smooth, round, finely divided, substantially spherical particles of a biocompatible ceramic material, close to or in contact with each other, which provide a scaffold or lattice for autogenous, three dimensional, randomly oriented, non-scar soft tissue growth at the augmentation site. The augmentation material can be homogeneously suspended in a biocompatible, resorbable lubricious gel carrier comprising a polysaccharide. This serves to improve the delivery of the augmentation material by injection to the tissue site where augmentation is desired. The augmentation material is especially suitable for urethral sphincter augmentation, for treatment of incontinence, for filling soft tissue voids, for creating soft tissue blebs, for the treatment of unilateral vocal cord paralysis, and for mammary implants. It can be injected intradermally, subcutaneously or can be implanted.

Abstract: A method for producing ceramic bodies, particularly ceramic foils, from a castable slip made of a dispersion of a ceramic powder in a solvent. A dispersion of an aqueous vinyl-acetate homopolymer or an aqueous vinyl-acetate/ethene copolymer being used as the solvent.

Abstract: The well known slip casting process for the production of ceramic green parts, in which hardening is achieved by water removal with porous molds, is characterized by disadvantages in terms of strength, shrinkage during drying and problems with cracking during drying. The present invention avoids these disadvantages and produces ceramic green parts by changing the surface potential of powder particles in the slip instead of by removing water. Further more the coagulation strength is increased by adding polymers or extremely fine divided colloidal particles.

Abstract: A method of forming Sarira is disclosed. The present method employs bone ash being introduced to a melting aid to form phosphate ceramic material.

Abstract: A method of making a product such as a tile which comprises the steps of making a generally homogenous mixture of slate particles and clay powder, wetting the mixture as necessary to produce a formable composition, forming the wet mixture to a desired configuration, at least partially drying the formed wet mixture and subjecting the dried formed mixture to a temperature of at least 1100° C. for a time sufficient for at least some of the clay to convert into a binder to bind together the slate particles.

Abstract: A method of manufacturing a ceramic body and a gas sensor is disclosed. The method comprises mixing a ceramic material and an organometallic material with a solvent to form a mixture. The organometallic material comprises both a metallic component and an organic ligand. The mixture is disposed onto a surface, dried, and removed to form the ceramic body. The sensor is made by disposing the ceramic body adjacent to an unfired electrolyte body having an electrode disposed on each side thereof to form a green sensor. The green sensor is co-fired to form the sensor.

Abstract: A suspension adhesive comprised of a matrix material and a particulate filler material is useful for bonding, sealing, repairing, and modifying ceramic, glass, and powdered metal components in a light source. A method for making the suspension adhesive includes the selection of a filler material and a volume percentage of the filler material. Additionally, a matrix material is selected and the filler material is dispersed throughout the matrix material. The suspension adhesive is used to bond and seal components to form, for example, an arc tube for a light source.

Abstract: Provided is a process of manufacturing a bio-ceramic ball, the process including the steps of pulverizing a raw material containing 35% of coal sludge remaining after ion milling, 15% of a ceramic material consisting of quartz, 5% of peridot having evening emerald components, 4% of emerald which is a green precious stone and 41% of approximately 40 sorts of other minerals, including elvan, into less than or equal to 700 mesh, mixing the pulverized raw material with extracts containing 30% of pine leaves, 20% of mugwort, 15% of motherwort, 10% of Polygoni multiflori Radix and 25% of approximately 30 sorts of other plant medicines, and agitating in a tank, primarily heating the mixed and agitated materials in a crucible at a temperature of approximately 1300° C.

Abstract: The disclosure describes a method to fabricate nanostructures by integrating the steps of attriting precursor nanometer-sized particulate materials, desorbing the exposed surfaces of the attrited nanoparticulates, adsorbing a surfactant on at least 50% of the desorbed surfaces and dispersing the surfactant-coated nanoparticulates in an organic matrix to form a homogeneous thermoplastic compound from which green nanostructures are shaped, dewaxed and sintered. The method substantially overcomes the problems of aggregation, contamination and pyrophoricity inherent in nanoparticulates.

Abstract: A cordierite material batch is incorporated with 2 to 6 wt. % of binder reversibly gelling under heat. The binder is composed of a binder (A) and a binder (B), where 2% aqueous solution of the binder (A) has a viscosity of 5000 cP or less at 20° C., 2% aqueous solution of the binder (B) has a viscosity of 20000 cP or more at 20° C., and binder (A)/binder (B) (wt. ratio) is 10/90 to 50/50. According to the method, there can be provided a cordierite-based ceramic honeycomb structure suitable for mass production and giving the structure of thin wall by improving formability of the cordierite body (in particular, lubricity) at the time of extrusion.

Abstract: Disclosed is a method for producing an SiC preform of a high volume fraction used for the manufacture of a metal matrix composite. The method involves the steps of mixing SiC particles of different particle sizes each selected from a range of 0.2 to 48 &mgr;m with an organic binder, an inorganic binder, an aggregating agent, and distilled water, thereby producing a mixture, and stirring the mixture in accordance with a ball milling process, thereby producing a slurry containing the SiC particles, pouring the slurry containing the SiC particles into a mold having upper and lower molds respectively provided with absorbent bodies, and squeezing the slurry in the mold, thereby reducing a residual moisture content of the slurry, completely drying the slurry reduced in residual moisture content, thereby producing an SiC preform, and calcinating the SiC preform. The preform is impregnated with a metal matrix while maintaining a high reinforcement volume fraction of 70 vol % or more.

Abstract: The invention relates to a method for producing a solid molded article, in particular a ceramic and/or metallic article made of pulverized particles. The invention also relates to stable dispersions of pulverized particles in an aqueous fluid medium, solid molded articles made of pulverized particles, and sintered ceramic and/or metallic molded articles.

Abstract: A health support device having a lamination of a semiconductor film on a surface of a partially-reduced sintered material of titanium oxide. The semiconductor film is preferably a p-type semiconductor film of silicon or germanium. The partially-reduced sintered material is preferably represented by TiO2−x, where 0<×<0.5. The thickness of the semiconductor film is preferably from 1 nm to 500 nm. In production, a mixture of a titanium oxide powder and a binder is press-molded, and the molded material is sintered at a temperature of from 500° C. to 1100° C. in a vacuum, inert or reducing atmosphere. A p-type semiconductor film is formed on a surface of the resulting partially-reduced sintered material of titanium oxide.

Abstract: The disclosure describes a method to fabricate nanostructures containing isotropically distributed, interconnected pores having cross-sectional diameters in the nanometer and Angstrom range by integrating the steps of attriting precursor nanometer-sized particulate materials, desorbing the exposed surfaces of the attrited nanoparticulates, adsorbing a surfactant on 25-50% of the desorbed surfaces and dispersing the surfactant-coated nanoparticulates in an organic matrix to form a homogeneous thermoplastic compound from which green nanostructures are formed, dewaxed and sintered to the desired degree of microporosity.

Abstract: A procedure is provided for bringing an incompletely densified cast radome to a desired final or near final shape through the use of one or more conformal tools during a high temperature firing operation. A conformal firing tool is defined in this case as a mandrel or mold made from a high temperature material, such as a graphite composite, that represents the desired shape of the finished radome. The process consists of firing the cast radome body over a mandrel, or inside a mold, or in combination with the two, such that the tools impart a desired dimensionality to the cast part as it densities and flows at high temperature.

Abstract: Semiconductor wire bonding tools used in the assembly and interconnection of integrated circuits (ICs) are micromolded from a mixture of ultrafine particulate materials mixed with an organic binder. Following extraction of the binder the green bonding tools are sintered during which they undergo isotropic, constant and accurately predetermined shrinkage. Hence semiconductor wire bonding tools can be produced with virtually no limit to miniaturization, thus allowing the fabrication of higher integrated semiconductor products.

Abstract: A continuous process for the manufacture of a ceramic sintered compact wherein the process comprises the steps of: forming a green compact from a powder mixture comprising a first component comprising compounds which contain elements of silicon, aluminum, oxygen and nitrogen; and the powder mixture further comprising a second component comprising a compound of at least one element selected from the group consisting of yttrium, scandium, cerium, lanthanum and the metals of the lanthanide series, and the second component comprising between 0.1 and 10 weight percent of the powder mixture; heat treating the green compact wherein the heat treatment comprises continuously passing the green compact through at least one heating zone so as to produce a sintered compact.

Abstract: A method to produce polycrystalline sapphire or ruby watch jewels is disclosed. Green watch jewels are formed from a mixture of fine ceramic powders with a thermoplastic binder. Following extraction of the binder the parts are sintered to net shape and full density. The method obviates the inefficient and labor intensive technique of monocrystalline watch jewel manufacturing. The purity of the raw materials and processing conditions result in sintered polycrystalline rubies or sapphires with homogeneous microstructures, small grain size and hardness similar to that of their synthetic monocrystalline counterparts.