Removal Of Liquid Component Or Carrier Through Porous Mold Surface Patents (Class 264/86)
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Patent number: 5441682Abstract: A method of forming a ceramic composite including glass bonded microparticles. The process includes the steps of: felting a slurry of microparticles to form a mat; drying the mat; infusing a sol-gel binder into the mat; gelling the binder; and curing the binder.Type: GrantFiled: July 28, 1993Date of Patent: August 15, 1995Assignee: The Boeing CompanyInventors: Anna L. Baker, Darryl F. Garrigus
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Patent number: 5433901Abstract: The invention encompasses a method for manufacturing a high density indium oxide/tin oxide (ITO) sintered body, as well as the ITO sintered body itself. The method produces an ITO sintered body of high homogeneity for use as a sputtering target in manufacturing processes where thin, transparent and electrically conductive ITO layers are deposited over transparent substrates. The method comprises the steps of preparing a slurry whose solid constituents consist of a finely divided mixture of between 99 and 50 weight percent of In.sub.2 O.sub.3 and 1 to 50 weight percent of SnO.sub.2, and between about 0.05 through 0.25 percent of a sintering agent formed from an oxide of, only one of the group consisting of aluminum, magnesium, yttrium, and silicon; forming the resulting slurry into a green body having a density of between about 4.0 and 4.8 gm/c.sup.3 and heating the green body to a sintering temperature of between about 1500 and 1600 C.Type: GrantFiled: October 26, 1993Date of Patent: July 18, 1995Assignee: Vesuvius Crucible CompanyInventors: Gilbert Rancoule, Jerald L. Bliton
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Patent number: 5429781Abstract: The method of the present invention comprises preparing a liquid slurry composed of a refractory material in powder form and a deflocculent composed of a vinyl chloride and vinyl acetate resin dissolved in an organic solvent and cold pressing and pressureless sintering to form a shaped refractory article.Type: GrantFiled: April 9, 1993Date of Patent: July 4, 1995Assignee: Advanced Ceramics CorporationInventor: Lionel C. Montgomery
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Patent number: 5427722Abstract: A method of making a hollow-shaped green ceramic article by pressure slip casting in a slip casting mold having a porous mold part with porosity channels opening at the surface of the mold cavity. A slip composition is formed having solid phase components with an average particle size distribution less than the cross-sectional dimension of mold porosity channels, and also having a flocculating agent to cause agglomeration of the solid phase particles into floccules larger than the porosity channel dimension.The molding cavity is filled with the slip composition, and the same is then hydrostatically pressurized while withdrawing slip filtrate from the mold cavity via the mold porosity channels for a time sufficient to deposit to a desired thickness a layer of solids. Excess slip is then removed from the molding cavity to provide an exposed interior surface on the deposit layer.Type: GrantFiled: June 11, 1993Date of Patent: June 27, 1995Assignee: General Motors CorporationInventors: Richard E. Fouts, Robert P. Johnston
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Patent number: 5422055Abstract: A process for preparing a fiber reinforced, glass matrix composite article of manufacture. The process employs an aqueous wet-laid technique by forming a dilute aqueous slurry of solids comprising glass fibers, reinforcing fibers and binder material which may be partially or completely fibrous. The dilute aqueous slurry is destabilized and the solids are collected on a porous support means. They are then dewatered and dried to form the composite mat which can be hot-pressed into an article of manufacture. The hot-pressed article of manufacture may then be heated, in the absence of pressure, to a temperature above the softening point of the glass, but below the degradation temperature of the reinforcing fibers, to provide a lofted composite.Type: GrantFiled: April 6, 1993Date of Patent: June 6, 1995Assignee: The Dow Chemical CompanyInventors: Selim Yalvac, Robert L. McGee
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Patent number: 5411804Abstract: The present invention relates to a heat resistant composition which exhibits excellent heat and wear resistances after being cured. Further, it has excellent releaseability and durability, and the cured film thereof has a more excellent stability than a prior art adhesive of this type, by preparing it from two components: a powder mixture consisting of 20% by weight or more of zirconium oxide, 1 to 10% by weight of sodium titanate, 2 to 15% by weight of yttria based on the zirconium oxide and the balance of silica; and a sodium silicate containing a small amount of water added thereto.Type: GrantFiled: August 4, 1993Date of Patent: May 2, 1995Assignee: Sugianikinzokukogyo Co. Ltd.Inventor: Nobuhiro Sugitani
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Patent number: 5385701Abstract: Disclosed herein are a method for molding a high density and homogeneous silicon nitride ceramics within a short time and an apparatus used for the method. A gel-like slurry mixture which is a mixture of ceramic powders consisting mainly of Si.sub.3 N.sub.4 and a liquid and has a powder content of from 45 vol % to 60 vol % is fluidized by imparting thereto a strain by vibration, and the mixture under the fluidized state is filled into, and molded by, a mold. Preferably, the entire part or a part of the mold is made of a liquid permeable material. The vibration preferably has an acceleration of from 0.1 G to 150 G and an amplitude of 1 .mu.m to 1 cm. Furthermore, the viscosity of the slurry filled into the mold is preferably from 2,000 to 20,000 cps.Type: GrantFiled: July 24, 1992Date of Patent: January 31, 1995Assignee: Sumitomo Electric Industries, Ltd.Inventors: Tomoyuki Awazu, Yasushi Tsuzuki, Osamu Komura, Akira Yamakawa
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Patent number: 5376321Abstract: A method of producing a patterned shaped article includes the steps of constituting a patterning form by disposing at a prescribed position within a main form for molding the shaped article an auxiliary form of a configuration appropriate for a pattern to be formed, charging a dry material for pattern formation into the patterning form at a prescribed form cavity portion thereof, charging a base-course material for forming the base course of the shaped article into the remaining space of the patterning form not filled with the pattern material, removing the auxiliary form, causing the pattern material and base-course material charged into the patterning form to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.Type: GrantFiled: August 27, 1991Date of Patent: December 27, 1994Assignee: CCA Inc.Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
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Patent number: 5372178Abstract: This invention relates generally to a novel method of preparing self-supporting bodies, and novel products made thereby. In its more specific aspects, this invention relates to a method for producing self-supporting bodies comprising one or more boron-containing compounds (e.g., a boride or a boride and a carbide, etc.) by reactive infiltration of molten parent metal into a preform comprising boron carbide or a boron donor material combined with a carbon donor material and, optionally, one or more inert fillers, to form the body. Specifically, a boron carbide material or combination of a boron donor material and a carbon donor material, and in either case, optionally, one or more inert fillers, are sedimentation cast, spray coated, tapped, slip cast, pressed, etc., onto or into a body and into a particular desired shape.Type: GrantFiled: January 15, 1992Date of Patent: December 13, 1994Assignee: Lanxide Technology Company, LPInventors: Terry D. Claar, Gerhard H. Schiroky, Donald P. Ripa, William B. Johnson
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Patent number: 5368791Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a cell form having a plurality of cells arranged in a contiguous manner, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into prescribed cells of the cell form, charging a base-course material for forming the base course of the shaped article into the remaining space of the main form not filled with the pattern-course material, removing the cell form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.Type: GrantFiled: September 30, 1991Date of Patent: November 29, 1994Assignee: CCA Inc.Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
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Patent number: 5367116Abstract: Solid residues obtained in flue gas purification, in particular flue dusts, are disposed in an environmentally compatible and economical manner by acid extracting heavy metals from the residues, precipitating the heavy metals from the extract, separating the precipitate from the mother liquor, subjecting the precipitate containing heavy metals to mechanical stress during which procedure the water contained in the precipitate is released and the precipitate itself is resuspended, and then adding a hydraulic binder to the resuspended precipitate containing heavy metals and/or to the extracted residues separately from one another. The binder-containing mixture can be used to form moldings which, after hardening, are employed for the erection of boundary walls in a landfill, Additionally or alternatively, the plastic binder-containing mixture can be introduced in the form of layers into preformed landfill spaces, where it then hardens.Type: GrantFiled: June 2, 1993Date of Patent: November 22, 1994Assignee: Von Roll AGInventor: Rudolf Frey
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Patent number: 5358676Abstract: The present invention relates to hydraulically bonded cement compositions and methods of manufacture. Hydraulically bonded cement compositions and methods of manufacture include materials prepared by manipulating under pressure powdered hydraulic cement compositions using known or novel powder packing, casting, or expanding techniques, such that air within the powdered hydraulic cement is successfully removed while the cement is formed into a self-supporting near net final position. Thereafter, the formed hydraulic cement article is hydrated without mechanical mixing of the cement and water.Type: GrantFiled: November 25, 1992Date of Patent: October 25, 1994Assignee: E. Khashoggi IndustriesInventors: Hamlin M. Jennings, Per J. Andersen, Simon K. Hodson
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Patent number: 5356578Abstract: A mold for molding an industrial product from a powder by slip casting, which has good water-absorptivity, long life, high strength and excellent mold-releasability and is constituted from a composite base material of boron nitride and other ceramic constituents. With this mold, molding of ceramic products and the like can be performed with high efficiency without causing clogging.Type: GrantFiled: January 11, 1993Date of Patent: October 18, 1994Assignee: Kawasaki Steel CorporationInventors: Keiichiro Isomura, Toshihiko Funahashi, Ryojo Uchimura, Kazuki Ogasahara
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Patent number: 5346660Abstract: A powder molding is manufactured from various powdery materials including an inorganic material, an organic material, a metallic material, etc., according to a wet forming process. A powdery material and a solvent are mixed into a mixture so that the mixture exhibits a dilatant flow. The mixture is molded into a molding of desired shape, and then the molding is dried.Type: GrantFiled: February 23, 1993Date of Patent: September 13, 1994Assignee: Toto Ltd.Inventor: Akio Matsumoto
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Patent number: 5320791Abstract: Molded articles of high-purity alumina fibers, which are porous materials in which heat resistance is high, and in particular, deformation and linear shrinkage in heat cycles at a temperature more than 1700.degree. C. are small. The production method comprising spinning a spinning solution containing an alumina fiber precursor as the main component to obtain precursor fibers, prefiring these precursor fibers at 400.degree. to 1000.degree. C. to form prefired fibers, and then molding and calcining these prefired fibers. Sintering between the fibers can be achieved at a relatively low temperature. In particular, even when no inorganic binder component is added, the molded articles of high-purity alumina fibers can be obtained by a simple process.Type: GrantFiled: April 28, 1992Date of Patent: June 14, 1994Assignee: Mitsui Mining Company, LimitedInventors: Yoshiaki Saitou, Shigeyuki Date, Shinpei Nonaka, Takashi Shinbo, Hiroshi Nakamura
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Patent number: 5306405Abstract: A method for preparing a slurry target for use in a sputtering apparatus. The target material is ground into a powder form, and mixed with a solvent to form a slurry. The slurry is poured into a target mold and allowed to slow dry by evaporation at or near room temperature. The target is mechanically stable, can be positioned in any orientation without falling out of the mold, and resists failure from thermal stresses during sputtering.Type: GrantFiled: June 26, 1992Date of Patent: April 26, 1994Assignee: Minnesota Mining and Manufacturing CompanyInventors: Robert D. Lorentz, Joseph H. Sexton
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Patent number: 5302099Abstract: Concrete forms utilizing a laminated concrete form liner including a porous fabric laminated to a drainage scrim. The laminated form liner is untensioned and used in combination with a support to form a concrete casting system wherein the porous fabric side of the laminated form liner is placed directly in contact with the concrete. The drainage scrim enhances the ability of the form liner to remove excess water from the surface of the concrete.Type: GrantFiled: September 28, 1992Date of Patent: April 12, 1994Assignee: E. I. Du Pont de Nemours and CompanyInventor: Franco L. Serafini
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Patent number: 5302335Abstract: A method for the fabrication of water-repellent hardened moldings wherein the diorganopolysiloxane is not discharged into the effluent water during the molding or forming process and the molding itself is free of nonuniformities in its water repellency. The method for the preparation of water-repellent hardened moldings includes forming a slurry of a mixture including a calcareous raw material and a siliceous raw material in an arbitrary quantity of water; emulsifying a diorganopolysiloxane using nonionic surfactant and adding this emulsion to the slurry at a temperature at or above the cloud point of the nonionic surfactant; subsequentially draining off the water, then molding or forming, and finally drying or steam-curing to produce the water-repellent hardened molding.Type: GrantFiled: March 18, 1993Date of Patent: April 12, 1994Assignee: Dow Corning Toray Silicone Co., Ltd.Inventors: Tsutomu Naganawa, Isao Ona
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Patent number: 5299621Abstract: This invention relates generally to a novel method of preparing self-supporting bodies, and novel products made thereby. In its more specific aspects, this invention relates to a method for producing self-supporting bodies comprising one or more boron-containing compounds, e.g., a boride or a boride and a carbide, by reactive infiltration of molten parent metal into a preform comprising boron carbide or a boron donor material combined with a carbon donor material and, optionally, one or more inert fillers, to form the body. Specifically, a boron carbide material or combination of a boron donor material and a carbon donor material, and in either case, optionally, one or more inert fillers, are sedimentation cast, slip cast or pressed onto or into a body and into a particular desired shape.Type: GrantFiled: September 19, 1991Date of Patent: April 5, 1994Assignee: Lanxide Technology Company, LPInventors: Terry D. Claar, Gerhard H. Schiroky, Donald P. Ripa, William B. Johnson
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Patent number: 5298213Abstract: A method of making a ceramic burner head includes the steps of forming a positive mold that conforms to the shape of a burner head and providing a partition plate to the positive mold; forming a negative plaster mold by the use of the positive mold; introducing a ceramic slurry into a mold cavity of the negative mold; causing the ceramic slurry in contact with a surrounding wall that confines the mold cavity of the negative plaster mold to possess a layer of dried ceramic with a predetermined thickness, and to further possess a hollow portion that is confined by the layer of dried ceramic and that is filled with a non-dried ceramic; removing the negative plaster mold and providing the layer of dried ceramic with burner holes; and sintering the layer of dried ceramic to form the ceramic burner head.Type: GrantFiled: May 5, 1993Date of Patent: March 29, 1994Assignee: Yan-Fei JuInventor: Wan-Tsai Shyu
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Patent number: 5296175Abstract: A mold for forming a molded body from a slurry including an impermeable mold part having a cavity for retaining the slurry and a permeable mold provided on a side of a molding surface with a membrane filter. A method of forming a molded body from a slurry includes steps of introducing the slurry into a cavity of a mold including an impermeable mold part and a permeable mold part provided on a side of a molding surface with a membrane filter, and removing a solvent medium of the slurry through the permeable mold part. A pressure casting molding method of forming a high dense ceramic molded body by pouring a ceramic slurry into a mold through a pouring portion thereof and pressurizing the ceramic slurry on a side of the pouring portion while removing a solvent medium of the slurry on the other side of the mold through a permeable mold part of the mold.Type: GrantFiled: July 21, 1992Date of Patent: March 22, 1994Assignee: NGK Insulators, Ltd.Inventors: Hiroyuki Iwasaki, Syuji Sakai
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Patent number: 5288443Abstract: A mold release agent is provided which is compatible for use with slip casting molds formed from alumina, which are more durable than conventional gypsum molds. The preferred mold release agent is a suspension whose suspended solid matter is water-insoluble, organic, and composed of fine natural or synthetic powders or fibers. The mold release agent forms a layer of particles and/or fibers on the mold cavity surface which promotes the ease by which the cast article can be removed from the alumina mold. The mold release agent is readily burned out during subsequent firing or sintering operations, so as not to leave an undesirable residue in the surface of the fired or sintered ceramic article. Furthermore, the mold release agent does not have an undesirable effect on the microstructure of the as-cast or sintered ceramic article, nor does its use result in any detectible surface or internal cracks in the as-cast or sintered ceramic article.Type: GrantFiled: December 24, 1992Date of Patent: February 22, 1994Assignee: General Motors CorporationInventor: Howard H.-D. Lee
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Patent number: 5277854Abstract: Method and apparatus to form grids of open cells from fibers, especially wood fibers and fibers from waste paper and mixed waste materials. The invention utilizes a screen carrying a plurality of elastomeric pads of predetermined sizes arranged thereon in predetermined spaced relation to each other. The fiber is deposited between the pads but not above the pads. The deposited fibers and the pads are compressed normal to the screen, which causes the fiber in the spaces between the pads to be consolidated both normal and parallel to the screen, resulting in a open grid having cells of the shape of the pads. Numerous variations are provided including several continuous production embodiments. The invention uses state of the art technology for virtually all aspects.Type: GrantFiled: June 6, 1991Date of Patent: January 11, 1994Inventor: John F. Hunt
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Patent number: 5271888Abstract: The present invention relates to an improved process and partible mold for forming a light-weight synthetic ceramic log for use in natural gas, propane and wood-burning fireplaces and stoves which are both fully-vented and non-vented depending upon the particular design of the heat generating equipment. In the subject process, a flexible porous patterned screen is formed simulating the exterior bark portion of a tree or log having a reverse image. Such screen is designed with both porous and non-porous surface characteristics for mounting as a separate element within the partible mold. The flexible porous patterned screen is mounted within the partible mold having major interior surface areas which are capable of connection to a vacuum source for withdrawing water from a liquid composition containing ceramic fibers to rapidly form the ceramic log within the mold during short periods of vacuum molding.Type: GrantFiled: February 10, 1992Date of Patent: December 21, 1993Assignee: Specialty Management Group, Inc.Inventor: Wayne A. Sinsley
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Patent number: 5266252Abstract: An improved process for slip casting ceramic articles that does not employ parting agents and affords the casting of complete, detailed, precision articles that do not possess parting lines. A wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip is poured therein. After a ceramic shell of desired thickness has set up in the shell mold, excess ceramic slip is poured out. While still wet, the shell mold is peeled from the ceramic shell to expose any delicate or detailed parts, after which the ceramic shell is cured to provide a complete, detailed, precision ceramic article without parting lines.Type: GrantFiled: September 22, 1992Date of Patent: November 30, 1993Assignee: The United States of America as rperesented by the Administrator of the National Aeronautics and Space AdministrationInventors: Gregory M. Buck, Peter Vasquez
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Patent number: 5262122Abstract: The disclosure relates to a method of binder removal from a green body before sintering or the like wherein the green body is initially heated to a temperature above the melting or flow point of the binder to liquify the binder and, at the elevated temperature, a small portion of the green body is brought into intimate contact with a non-supporting porous body of lower capillarity potential for the liquid binder. The liquid is drawn from all parts of the green body to the region of contact between the porous body and the green body and enters the body of lower capillarity potential preferentially, removing liquid from the green body through the surface of the green body only at said region of contact. The draining is continued with or without further increase in temperature until the green body is opened or becomes permeable.Type: GrantFiled: December 10, 1991Date of Patent: November 16, 1993Assignee: Witec Cayman Patents, Ltd.Inventor: Raymond E. Wiech, Jr.
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Patent number: 5260011Abstract: The method of making refractory ceramic products in which a slurry is formed of water, powdered alumina, and amorphous fibers containing AL.sub.2 O.sub.3 and SiO.sub.2, the volume of water in the slurry being sufficient to permit the slurry to flow under vibration but insufficient to permit the slurry to flow without vibration, the fibers having a molecular ratio of Al.sub.2 O.sub.3 to SiO.sub.2 substantially less than 3 to 2 and the molecular ratio of Al.sub.2 O.sub.3 to SiO.sub.2 in the combined slurry being at least 3 to 2, thereater placing the slurry in a liquid absorbing mold and vibrating the slurry to fill the mold, then permitting the mold to absorb a portion of the water from the slurry to form a body, then removing the body from the mold and drying the body, and thereafter heating the body to combine silica and alumina from the fibers and powdered alumina to recrystalize the fibers in the from of mullite.Type: GrantFiled: June 24, 1987Date of Patent: November 9, 1993Assignee: General Signal CorporationInventors: Peter A. Wolter, Arthur N. Esposito
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Patent number: 5256349Abstract: A light weight formed body used for building materials, heat-insulating materials, furnitures, backing materials and the like, and a method for producing the same. In the light weight formed body and in the manufacturing method thereof, the principal material is a surface-reformed slag of which the reforming involves reforming through the dissolution reaction and the hydration reaction of glass and the reforming through dehydration of the surface-reformed slag above mentioned under heating, and one or more of a polymer dispersion, a reinforcing fiber, a coagulant, a light weight aggregate, a thickener, a dispersing agent, a pigment, a synthetic pulp, a needle- to fiber-shaped calcium silicate hydrate and a hydraulic gypsum are further used together with the above principal material.Type: GrantFiled: August 26, 1992Date of Patent: October 26, 1993Assignee: NKK CorporationInventors: Kazuyoshi Sato, Masakazu Hara, Hisaya Kamura
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Patent number: 5252273Abstract: A casting method for manufacturing various types of ceramics products having an intricate configuration and a partly diversified wall thickness, such as compressor scroll blade and a screw rotor, by casting a slurry including ceramics, etc. in a mold, includes an arrangement wherein the mold is partly or entirely formed of a flexible gel material which can be melted by heating at a temperature lower than the boiling point of the dispersion medium, whereby the stresses generated when molding the product can be mitigated. Thus, the molding of a product having a high level of dimensional accuracy can be carried out with ease.Type: GrantFiled: May 23, 1991Date of Patent: October 12, 1993Assignee: Hitachi, Ltd.Inventors: Junji Sakai, Masahisa Sobue, Yoshiyuki Yasutomi
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Patent number: 5250476Abstract: Ceramic binder for forming and processing ceramic ware, comprising a sol-gel of a mixture of highly charged metal hydroxy cations and one or more low charged metal hydroxy cations, which are able to form an aqueous sol.Type: GrantFiled: April 13, 1992Date of Patent: October 5, 1993Assignee: Haldor Topsoe A/SInventors: Gurli Mogensen, Bruno Kindl
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Patent number: 5248457Abstract: Particulate bearing precursor components are formed into intricate shapes yet possess controlled porosity by injection molding a mixture of particulate materials, thermosetting condensation resins, and low temperature catalysts. The mixture, when flowed into a mold cavity of an appropriate shape and heated, initiates a curing reaction which binds particulates together with a film that leaves the space between the particulates open. A positive volume change occurs during cure, providing for a more uniform pressure profile in the part. Also, a condensate is produced during the curing step which, when vented from the mold in strategic locations, allows manipulation of the curing reaction. This provides the ability to affect local density in the vicinity of the vent. Thus, one can correct for artificially, or incorrectly induced density or porosity gradients, and improve dimensional accuracy and other attributes of the subsequent processing steps.Type: GrantFiled: January 21, 1992Date of Patent: September 28, 1993Assignee: Megamet IndustriesInventors: Gregory M. Brasel, Susan J. Brasel
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Patent number: 5242649Abstract: A hydrated calcium silicate slurry composition is made up of 100 parts by weight of hydrated calcium silicate, 5 to 40 parts by weight of a powdered resin and water and molded articles are produced therefrom. In addition to the above components, 1 to 30 parts by weight of a reinforcing fiber and/or 20 to 35 parts by weight (as solids) of a latex or emulsion may be used. When the latex or emulsion is used, the powdered resin is reduced to an amount of 5 to 20 parts by weight. Since the molded calcium silicate articles have a superior workability and a good thermal dimensional stability, they are very useful especially in the preparation of molds or models where high levels of processing precision and thermal stability are required.Type: GrantFiled: April 19, 1991Date of Patent: September 7, 1993Assignee: Ube Industries, Ltd.Inventors: Akio Yamamoto, Hideo Uchiyama, Naohide Torigoe, Masaaki Nagai
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Patent number: 5238628Abstract: A shaped product having a shape corresponding to a flare-like deflection yoke core is formed from clay as a raw material of ferrite by a wet molding method; parting grooves are formed in the inner or outer circumferential surface of the shape product while it is green; and the thus obtained shaped product is dried and calcined, whereby a deflection yoke core is produced.Type: GrantFiled: April 9, 1992Date of Patent: August 24, 1993Assignee: Mitsubishi Denki Kabushiki KaishaInventors: Toshihiko Mori, Takaichi Suzuki
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Patent number: 5227344Abstract: Ceramic composite articles having dispersed whiskers or platelets oriented parallel to an outer surface of the articles and in two-dimensionally random directions thereof. The articles may be made by forming and sintering under a pressure of about 1 to 10 atmospheres without using hot press methods or hot isostatic pressing methods.Type: GrantFiled: May 6, 1992Date of Patent: July 13, 1993Assignee: Japan Metals & Chemicals Co., Ltd.Inventors: Toshitsugu Matsuda, Sinichi Saitoh, Takao Yonezawa, Chorji Sakai, Hatsuyuki Abe
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Patent number: 5211786Abstract: The present invention overcomes the problems caused by certain intergranular phases present during hot pressing. The invention provides a method of removing such problematic intergranular phases while avoiding problems of non-uniformity. In one aspect, the invention encompasses an improvement in a method of sintering a green body by hot pressing, where the green body contains ceramic grains to be sintered and material capable of existing as intergranular phase material during sintering. The improvement embraces hot pressing the body in the presence of a permeable material adapted to receive at least a portion of intergranular phase material as the sintering takes place or after the sintering has been completed.Type: GrantFiled: December 21, 1990Date of Patent: May 18, 1993Assignee: W. R. Grace & Co.-Conn.Inventors: Jack H. Enloe, John W. Lau
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Patent number: 5205971Abstract: Non-whiteware ceramic articles having an increased green strength are prepared from slip compositions containing a polyalkylene polyamine as an additive or a mixture of a polyalkylene polyamine and binder as an additive. An example of such an additive is tetraethylenepentamine or a mixture of tetraethylenepentamine and a styrene butadiene latex.Type: GrantFiled: October 2, 1990Date of Patent: April 27, 1993Assignee: The Dow Chemical CompanyInventors: Alan P. Croft, Brian D. Koblinski
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Patent number: 5198167Abstract: In a process for molding a fiber molding for a fiber-reinforced composite material with short fibers oriented in one direction, a slurry molding material having short fibers dispersed in a liquid is used, and pressing forces are applied to the molding material from two directions substantially perpendicular to each other within a mold, while removing the liquid.Type: GrantFiled: October 31, 1989Date of Patent: March 30, 1993Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Tohru Ohta, Akimasa Daimaru, Masao Ichikawa, Hideyuki Fujishiro, Ryuichi Kubota, Takeyoshi Nakamura, Hisayoshi Harada, Hirotaka Koshitani, Tatsuya Suzuki, Teruo Hoshino
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Patent number: 5194204Abstract: A process for making a ceramic dipping former from silicized silicon carbide by making an absorbent negative mold of the ceramic dipping former containing preparing a suspension containing at least two particle size fractions of silicon carbide, a binder and water and pouring the suspension into the absorbent negative mold, drying the suspension in the absorbent negative mold, opening the absorbent negative mold and removing a silicon carbide green body, and further drying and silicizing the green body in a drying oven at a temperature between approximately 1400.degree. C. to 1750.degree. C. under reduced pressure.Type: GrantFiled: January 30, 1990Date of Patent: March 16, 1993Assignee: Hoechst CeramTec AktiengesellschaftInventors: Gunter Adasch, Jurgen Huber
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Patent number: 5194268Abstract: A method and apparatus for injection molding of ceramic suspensions is disclosed wherein an elastomeric bladder is disposed within a mold cavity of a mold. The elastomeric bladder, in a relaxed state, can be tubular or can be formed by bonding together sheets of material. A ceramic suspension is injected into the elastomeric bladder, whereby the elastomeric bladder is distended. Distention of the elastomeric bladder applies a significant force to the ceramic suspension for preventing jetting and formation of knit lines within the ceramic suspension. The ceramic suspension distends the elastomeric bladder until the mold cavity is filled. The ceramic suspension is then exposed to conditions sufficient to cause the injected ceramic suspension to form a molded ceramic greenware composite. The molded ceramic greenware composite can then be removed from the mold for drying and for debindering and densification to form a finished ceramic part.Type: GrantFiled: November 12, 1991Date of Patent: March 16, 1993Assignee: The Dow Chemical CompanyInventors: Norbert L. Bradley, Virgil W. Coomer
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Patent number: 5190991Abstract: A brake lining is made from a preform which has been formed by a compression step parallel to that surface of the brake lining preform which is to be the braking surface of the lining in use and has subsequently been compressed in a direction substantially normal to said surface to form the lining. The preform can be made by dewatering an aqueous slurry of the brake lining ingredients prior to the first compression step.Type: GrantFiled: November 1, 1990Date of Patent: March 2, 1993Assignee: Nuturn CorporationInventors: Euan Parker, Bruno Grele
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Patent number: 5185113Abstract: Slip-cast ceramic component having an internal chamfer which is optionally interrupted by an internally projecting area, obtainable by providing a slip cast blank of the ceramic component with uniform thickness and desired internal configuration wherein the volume corresponding to the internal chamfer is outwardly disposed and which is removed by external machining to arrive at the geometry of the ceramic component. The component is useful, inter alia, as a spacer ring which serves for the positioning of honeycomb-shaped catalyst blocks in exhaust gas lines.Type: GrantFiled: June 19, 1992Date of Patent: February 9, 1993Assignee: Bayer AktiengesellschaftInventors: Johannes Seyer, Bernhard Freudenberg
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Patent number: 5185020Abstract: A silica-based glass rod is inserted into a space portion of a mold. Then, a slurry, which is obtained by dispersing a silica glass powder material in pure water, is poured into a molding space between the glass rod and the inner surface of the mold, whereby a porous glass shaped body is formed around the glass rod. Drying this shaped body results in a silica glass base material which includes the glass rod and the porous glass shaped body surrounding the same.Type: GrantFiled: August 26, 1991Date of Patent: February 9, 1993Assignee: The Furukawa Electric Co., Ltd.Inventors: Tsuguo Satoh, Takayuki Morikawa, Hiroshi Hihara, Takeshi Yagi, Kazuaki Yoshida
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Patent number: 5183668Abstract: Herein disclosed is a pressurized slip casting apparatus which includes an upper mold carried vertically movably on a replacer which is made horizontally movably on a horizontal rail; and a lower mold for receiving the upper mold in alignment, when the upper mold descends, to cast a slip under pressure inbetween thereby to prepare a green body of a sanitation fixture or the like. Dehydrating assembly is carried vertically movably on the replacer. A spongy member is attached to the lower end of the dehydrating assembly for absorbing the water from the inside of the lower mold. A push plate is arranged at the side of the lower mold for pushing the spongy member to dehydrate the same.Type: GrantFiled: November 4, 1991Date of Patent: February 2, 1993Assignee: Inax CorporationInventors: Kazushige Murata, Takeshi Ito
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Patent number: 5169578Abstract: A slip casting mold suitable to be used for the production of a hollow ceramic article for insert casting can be easily produced by a method wherein granules having an average grain size of at least 30 .mu.m are adhered to the surface of a mold to produce a mold having a 10 point average surface roughness R.sub.z of at least 30 .mu.m, and the resulting mold is used in the production of the slip casting mold.Type: GrantFiled: September 19, 1990Date of Patent: December 8, 1992Assignee: NGK Insulators, Inc.Inventor: Kaname Fukao
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Patent number: 5167813Abstract: Disclosed are a process for laminating a functionally gradient material and a laminating apparatus for the same. The process therefor includes a suspending step and a functionally gradient material laminating step. In the functionally gradient material laminating step, solid-liquid separation is carried out to a suspension while varying the mixing rates of the suspension particles contained therein continuously or in a multi-staged stepwise manner. Therefore, the functionally gradient material layer thus laminated offers a composition gradient varying continuously or in a multi-staged stepwise manner in the thicknesswise direction thereof in a superior continuity, and the composition fluctuates less in the planewise direction thereof. In addition, the process and the laminating apparatus have obviated the atomizing and the spraying which adversely affect a working environment.Type: GrantFiled: July 27, 1990Date of Patent: December 1, 1992Assignee: Kabushiki Kaisha Nagao KogyoInventors: Masashi Iwata, Won-Deok Yi, Niichi Hayashi, Shigeo Watanabe, Norio Ota
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Patent number: 5167887Abstract: A method of making fully dense, crack-free silicon nitride articles using polysilanes as a binder. Polysilane is dissolved in a solvent and a silicon nitride composition including a densification aid is added to form a homogeneous mixture. The mixture is dried to form a powder, and molded at a temperature less than 100.degree. C. to form a molded article. Alternatively, the slurry is poured into a mold and vacuum filtered to form a cake, then isostatically pressed at a temperature of approximately 90.degree. C. The molded article or pressed cake is heated at a rate of approximately 5.degree. C./min to about 900.degree. C. in a nonoxidizing atmosphere and held at about 900.degree. C. for a time sufficient to decompose the polysilane. The article is sintered in a nonoxidizing atmosphere at a temperature of about 1685.degree.-1900.degree. C. to form a silicon nitride article free of cracks and having a density greater than 3.5 g/cc.Type: GrantFiled: January 15, 1992Date of Patent: December 1, 1992Assignee: GTE Laboratories IncorporatedInventor: Sophia R. Su
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Patent number: 5164138Abstract: A novel material can be obtained by chemical reaction from elemental or alloyed silicon powder, to which fillers are optionally added. The novel material, which can be worked mechanically, can be further refined by means of subsequent heat treatment and/or surface coating, and can in many cases be used instead of polycrystalline or sintered silicon.Type: GrantFiled: September 7, 1990Date of Patent: November 17, 1992Assignee: Heliotronic Forschungs- und Entwicklungsgesellschaft fur Solarzellen-Grundstoffe mbHInventors: Josef Dietl, Erhard Sirtl, Rolf Bauregger, Erich Bildl, Rudolf Rothlehner, Dieter Seifert, Hermann Dicker, Herbert Pichler
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Patent number: 5164139Abstract: A method for drying a wetted molded product of pasty high viscous composition which comprises subjecting the molded product to a dehydration process while wholly or partially contacting the product with an open-cell foamed hydrophobic porous membrane.Type: GrantFiled: April 24, 1991Date of Patent: November 17, 1992Assignees: Sumitomo Pharmaceuticals Company, Limited, Koken Co., Ltd.Inventors: Keiji Fujioka, Shigeji Sato, Yoshio Sasaki, Hiromi Naito, Teruo Miyata, Masayasu Furuse
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Patent number: 5160675Abstract: A sputter target for producing electroconductive transparent films, which comprises indium oxide and tin oxide and having a shape such that not less than 80% by weight of the target is present in an erosion area on sputtering, and a process for manufacturing the sputtering target which comprises molding a slurry or a powder mixture containing indium oxide and tin oxide into a molded shape and sintering the molded shape are disclosed.Type: GrantFiled: May 16, 1989Date of Patent: November 3, 1992Assignee: Tosoh CorporationInventors: Tetsushi Iwamoto, Yasunobu Yoshida, Toshiaki Furuto, Koichi Sudo
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Patent number: 5156856Abstract: A mold for forming a molded body from a slurry including an impermeable mold part having a cavity for retaining the slurry and a permeable mold provided on a side of a molding surface with a membrane filter. A method of forming a molded body from a slurry includes steps of introducing the slurry into a cavity of a mold including an impermeable mold part and a permeable mold part provided on a side of a molding surface with a membrane filter, and removing a solvent medium of the slurry through the permeable mold part. A pressure casting molding method of forming a high dense ceramic molded body by pouring a ceramic slurry into a mold through a pouring portion thereof and pressurizing the ceramic slurry on a side of the pouring portion while removing a solvent medium of the slurry on the other side of the mold through a permeable mold part of the mold.Type: GrantFiled: November 27, 1987Date of Patent: October 20, 1992Assignee: NGK Insulators, Ltd.Inventors: Hiroyuki Iwasaki, Syuji Sakai