Removal Of Liquid Component Or Carrier Through Porous Mold Surface Patents (Class 264/86)
  • Patent number: 5441682
    Abstract: 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: Grant
    Filed: July 28, 1993
    Date of Patent: August 15, 1995
    Assignee: The Boeing Company
    Inventors: Anna L. Baker, Darryl F. Garrigus
  • Patent number: 5433901
    Abstract: 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: Grant
    Filed: October 26, 1993
    Date of Patent: July 18, 1995
    Assignee: Vesuvius Crucible Company
    Inventors: Gilbert Rancoule, Jerald L. Bliton
  • Patent number: 5429781
    Abstract: 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: Grant
    Filed: April 9, 1993
    Date of Patent: July 4, 1995
    Assignee: Advanced Ceramics Corporation
    Inventor: Lionel C. Montgomery
  • Patent number: 5427722
    Abstract: 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: Grant
    Filed: June 11, 1993
    Date of Patent: June 27, 1995
    Assignee: General Motors Corporation
    Inventors: Richard E. Fouts, Robert P. Johnston
  • Patent number: 5422055
    Abstract: 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: Grant
    Filed: April 6, 1993
    Date of Patent: June 6, 1995
    Assignee: The Dow Chemical Company
    Inventors: Selim Yalvac, Robert L. McGee
  • Patent number: 5411804
    Abstract: 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: Grant
    Filed: August 4, 1993
    Date of Patent: May 2, 1995
    Assignee: Sugianikinzokukogyo Co. Ltd.
    Inventor: Nobuhiro Sugitani
  • Patent number: 5385701
    Abstract: 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: Grant
    Filed: July 24, 1992
    Date of Patent: January 31, 1995
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Tomoyuki Awazu, Yasushi Tsuzuki, Osamu Komura, Akira Yamakawa
  • Patent number: 5376321
    Abstract: 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: Grant
    Filed: August 27, 1991
    Date of Patent: December 27, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5372178
    Abstract: 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: Grant
    Filed: January 15, 1992
    Date of Patent: December 13, 1994
    Assignee: Lanxide Technology Company, LP
    Inventors: Terry D. Claar, Gerhard H. Schiroky, Donald P. Ripa, William B. Johnson
  • Patent number: 5368791
    Abstract: 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: Grant
    Filed: September 30, 1991
    Date of Patent: November 29, 1994
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5367116
    Abstract: 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: Grant
    Filed: June 2, 1993
    Date of Patent: November 22, 1994
    Assignee: Von Roll AG
    Inventor: Rudolf Frey
  • Patent number: 5358676
    Abstract: 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: Grant
    Filed: November 25, 1992
    Date of Patent: October 25, 1994
    Assignee: E. Khashoggi Industries
    Inventors: Hamlin M. Jennings, Per J. Andersen, Simon K. Hodson
  • Patent number: 5356578
    Abstract: 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: Grant
    Filed: January 11, 1993
    Date of Patent: October 18, 1994
    Assignee: Kawasaki Steel Corporation
    Inventors: Keiichiro Isomura, Toshihiko Funahashi, Ryojo Uchimura, Kazuki Ogasahara
  • Patent number: 5346660
    Abstract: 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: Grant
    Filed: February 23, 1993
    Date of Patent: September 13, 1994
    Assignee: Toto Ltd.
    Inventor: Akio Matsumoto
  • Patent number: 5320791
    Abstract: 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: Grant
    Filed: April 28, 1992
    Date of Patent: June 14, 1994
    Assignee: Mitsui Mining Company, Limited
    Inventors: Yoshiaki Saitou, Shigeyuki Date, Shinpei Nonaka, Takashi Shinbo, Hiroshi Nakamura
  • Patent number: 5306405
    Abstract: 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: Grant
    Filed: June 26, 1992
    Date of Patent: April 26, 1994
    Assignee: Minnesota Mining and Manufacturing Company
    Inventors: Robert D. Lorentz, Joseph H. Sexton
  • Patent number: 5302099
    Abstract: 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: Grant
    Filed: September 28, 1992
    Date of Patent: April 12, 1994
    Assignee: E. I. Du Pont de Nemours and Company
    Inventor: Franco L. Serafini
  • Patent number: 5302335
    Abstract: 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: Grant
    Filed: March 18, 1993
    Date of Patent: April 12, 1994
    Assignee: Dow Corning Toray Silicone Co., Ltd.
    Inventors: Tsutomu Naganawa, Isao Ona
  • Patent number: 5299621
    Abstract: 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: Grant
    Filed: September 19, 1991
    Date of Patent: April 5, 1994
    Assignee: Lanxide Technology Company, LP
    Inventors: Terry D. Claar, Gerhard H. Schiroky, Donald P. Ripa, William B. Johnson
  • Patent number: 5298213
    Abstract: 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: Grant
    Filed: May 5, 1993
    Date of Patent: March 29, 1994
    Assignee: Yan-Fei Ju
    Inventor: Wan-Tsai Shyu
  • Patent number: 5296175
    Abstract: 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: Grant
    Filed: July 21, 1992
    Date of Patent: March 22, 1994
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiroyuki Iwasaki, Syuji Sakai
  • Patent number: 5288443
    Abstract: 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: Grant
    Filed: December 24, 1992
    Date of Patent: February 22, 1994
    Assignee: General Motors Corporation
    Inventor: Howard H.-D. Lee
  • Patent number: 5277854
    Abstract: 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: Grant
    Filed: June 6, 1991
    Date of Patent: January 11, 1994
    Inventor: John F. Hunt
  • Patent number: 5271888
    Abstract: 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: Grant
    Filed: February 10, 1992
    Date of Patent: December 21, 1993
    Assignee: Specialty Management Group, Inc.
    Inventor: Wayne A. Sinsley
  • Patent number: 5266252
    Abstract: 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: Grant
    Filed: September 22, 1992
    Date of Patent: November 30, 1993
    Assignee: The United States of America as rperesented by the Administrator of the National Aeronautics and Space Administration
    Inventors: Gregory M. Buck, Peter Vasquez
  • Patent number: 5262122
    Abstract: 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: Grant
    Filed: December 10, 1991
    Date of Patent: November 16, 1993
    Assignee: Witec Cayman Patents, Ltd.
    Inventor: Raymond E. Wiech, Jr.
  • Patent number: 5260011
    Abstract: 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: Grant
    Filed: June 24, 1987
    Date of Patent: November 9, 1993
    Assignee: General Signal Corporation
    Inventors: Peter A. Wolter, Arthur N. Esposito
  • Patent number: 5256349
    Abstract: 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: Grant
    Filed: August 26, 1992
    Date of Patent: October 26, 1993
    Assignee: NKK Corporation
    Inventors: Kazuyoshi Sato, Masakazu Hara, Hisaya Kamura
  • Patent number: 5252273
    Abstract: 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: Grant
    Filed: May 23, 1991
    Date of Patent: October 12, 1993
    Assignee: Hitachi, Ltd.
    Inventors: Junji Sakai, Masahisa Sobue, Yoshiyuki Yasutomi
  • Patent number: 5250476
    Abstract: 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: Grant
    Filed: April 13, 1992
    Date of Patent: October 5, 1993
    Assignee: Haldor Topsoe A/S
    Inventors: Gurli Mogensen, Bruno Kindl
  • Patent number: 5248457
    Abstract: 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: Grant
    Filed: January 21, 1992
    Date of Patent: September 28, 1993
    Assignee: Megamet Industries
    Inventors: Gregory M. Brasel, Susan J. Brasel
  • Patent number: 5242649
    Abstract: 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: Grant
    Filed: April 19, 1991
    Date of Patent: September 7, 1993
    Assignee: Ube Industries, Ltd.
    Inventors: Akio Yamamoto, Hideo Uchiyama, Naohide Torigoe, Masaaki Nagai
  • Patent number: 5238628
    Abstract: 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: Grant
    Filed: April 9, 1992
    Date of Patent: August 24, 1993
    Assignee: Mitsubishi Denki Kabushiki Kaisha
    Inventors: Toshihiko Mori, Takaichi Suzuki
  • Patent number: 5227344
    Abstract: 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: Grant
    Filed: May 6, 1992
    Date of Patent: July 13, 1993
    Assignee: Japan Metals & Chemicals Co., Ltd.
    Inventors: Toshitsugu Matsuda, Sinichi Saitoh, Takao Yonezawa, Chorji Sakai, Hatsuyuki Abe
  • Patent number: 5211786
    Abstract: 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: Grant
    Filed: December 21, 1990
    Date of Patent: May 18, 1993
    Assignee: W. R. Grace & Co.-Conn.
    Inventors: Jack H. Enloe, John W. Lau
  • Patent number: 5205971
    Abstract: 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: Grant
    Filed: October 2, 1990
    Date of Patent: April 27, 1993
    Assignee: The Dow Chemical Company
    Inventors: Alan P. Croft, Brian D. Koblinski
  • Patent number: 5198167
    Abstract: 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: Grant
    Filed: October 31, 1989
    Date of Patent: March 30, 1993
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Tohru Ohta, Akimasa Daimaru, Masao Ichikawa, Hideyuki Fujishiro, Ryuichi Kubota, Takeyoshi Nakamura, Hisayoshi Harada, Hirotaka Koshitani, Tatsuya Suzuki, Teruo Hoshino
  • Patent number: 5194204
    Abstract: 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: Grant
    Filed: January 30, 1990
    Date of Patent: March 16, 1993
    Assignee: Hoechst CeramTec Aktiengesellschaft
    Inventors: Gunter Adasch, Jurgen Huber
  • Patent number: 5194268
    Abstract: 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: Grant
    Filed: November 12, 1991
    Date of Patent: March 16, 1993
    Assignee: The Dow Chemical Company
    Inventors: Norbert L. Bradley, Virgil W. Coomer
  • Patent number: 5190991
    Abstract: 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: Grant
    Filed: November 1, 1990
    Date of Patent: March 2, 1993
    Assignee: Nuturn Corporation
    Inventors: Euan Parker, Bruno Grele
  • Patent number: 5185113
    Abstract: 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: Grant
    Filed: June 19, 1992
    Date of Patent: February 9, 1993
    Assignee: Bayer Aktiengesellschaft
    Inventors: Johannes Seyer, Bernhard Freudenberg
  • Patent number: 5185020
    Abstract: 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: Grant
    Filed: August 26, 1991
    Date of Patent: February 9, 1993
    Assignee: The Furukawa Electric Co., Ltd.
    Inventors: Tsuguo Satoh, Takayuki Morikawa, Hiroshi Hihara, Takeshi Yagi, Kazuaki Yoshida
  • Patent number: 5183668
    Abstract: 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: Grant
    Filed: November 4, 1991
    Date of Patent: February 2, 1993
    Assignee: Inax Corporation
    Inventors: Kazushige Murata, Takeshi Ito
  • Patent number: 5169578
    Abstract: 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: Grant
    Filed: September 19, 1990
    Date of Patent: December 8, 1992
    Assignee: NGK Insulators, Inc.
    Inventor: Kaname Fukao
  • Patent number: 5167813
    Abstract: 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: Grant
    Filed: July 27, 1990
    Date of Patent: December 1, 1992
    Assignee: Kabushiki Kaisha Nagao Kogyo
    Inventors: Masashi Iwata, Won-Deok Yi, Niichi Hayashi, Shigeo Watanabe, Norio Ota
  • Patent number: 5167887
    Abstract: 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: Grant
    Filed: January 15, 1992
    Date of Patent: December 1, 1992
    Assignee: GTE Laboratories Incorporated
    Inventor: Sophia R. Su
  • Patent number: 5164138
    Abstract: 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: Grant
    Filed: September 7, 1990
    Date of Patent: November 17, 1992
    Assignee: Heliotronic Forschungs- und Entwicklungsgesellschaft fur Solarzellen-Grundstoffe mbH
    Inventors: Josef Dietl, Erhard Sirtl, Rolf Bauregger, Erich Bildl, Rudolf Rothlehner, Dieter Seifert, Hermann Dicker, Herbert Pichler
  • Patent number: 5164139
    Abstract: 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: Grant
    Filed: April 24, 1991
    Date of Patent: November 17, 1992
    Assignees: Sumitomo Pharmaceuticals Company, Limited, Koken Co., Ltd.
    Inventors: Keiji Fujioka, Shigeji Sato, Yoshio Sasaki, Hiromi Naito, Teruo Miyata, Masayasu Furuse
  • Patent number: 5160675
    Abstract: 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: Grant
    Filed: May 16, 1989
    Date of Patent: November 3, 1992
    Assignee: Tosoh Corporation
    Inventors: Tetsushi Iwamoto, Yasunobu Yoshida, Toshiaki Furuto, Koichi Sudo
  • Patent number: 5156856
    Abstract: 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: Grant
    Filed: November 27, 1987
    Date of Patent: October 20, 1992
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiroyuki Iwasaki, Syuji Sakai