Fiber Embedded In A Ceramic, Glass, Or Carbon Matrix Patents (Class 428/293.4)
  • Patent number: 7488544
    Abstract: The disclosed invention relates to a ceramic composite, comprising: reinforcement fibers, the reinforcement fibers comprising alumina, zirconia or magnesium silicate; the reinforcement fibers containing microcracking; and deposits derived from a sol comprising alumina or zirconia and optionally a rare earth oxide reacted with the reinforcement fibers. A process for making the composite is also disclosed.
    Type: Grant
    Filed: May 4, 2006
    Date of Patent: February 10, 2009
    Assignee: Stanton Advanced Ceramics, LLC
    Inventors: Karl-Heinz Schofalvi, Gerald C. Dodds
  • Publication number: 20090029141
    Abstract: A mat-faced gypsum board and method of making thereof is provided having a particulate matter applied on an inner surface of the facer mat and extending partially into the mat from the inner surface thereof. The particulate matter, which is preferably a hydratable powder such as calcium sulfate hemihydrate, minimizes and, preferably, prevents bleed through of a gypsum slurry during formation of the gypsum board.
    Type: Application
    Filed: July 18, 2008
    Publication date: January 29, 2009
    Applicant: UNITED STATES GYPSUM COMPANY
    Inventors: Michael P. SHAKE, Qingxia LIU, Salvatore C. IMMORDINO, Dick C. ENGBRECHT, Donald L. ROELFS, Christopher R. NELSON, Wayne J. ROHRBAUGH, Joseph J. FEDORIS
  • Patent number: 7476439
    Abstract: The present invention provides a wet friction member exhibiting excellent dynamic friction performance and a carbon fiber composite material for manufacturing the wet friction member. A carbon fiber composite material 10 of the present invention contains carbon fibers 11 and a matrix 12 joining the carbon fibers 11 with each other, and the matrix has fine pores having diameters of 3.5 nm to 100 nm. Since the fine pores having diameters of a nanometer (nm) order is formed in the matrix 12 of the carbon fiber composite material 10, the specific surface area of the carbon fiber composite material 10 is increased. As a result, a wet friction member made of the carbon fiber composite material 10 has an improved dynamic friction performance.
    Type: Grant
    Filed: November 29, 2005
    Date of Patent: January 13, 2009
    Assignee: Honda Motor Co., Ltd.
    Inventors: Kentaro Komori, Satoshi Yoshida, Atsushi Takahashi
  • Publication number: 20090011213
    Abstract: A thermoplastic multilayer film includes an outer layer comprising a polymer comprising resorcinol arylate polyester chain members, and a base layer comprising about 2 wt % to about 98 wt % of an aromatic carbonate polymer or copolymer, and about 2 wt % to about 98 wt % of a polymer copolymer derived from a glycol portion comprising 1,4 cyclohexanedimethanol and ethylene glycol wherein the molar ratio of 1,4 cyclohexanedimethanol to ethylene glycol is about 1:1 to about 4:1, and an acid portion comprising an aromatic dicarboxylic acid.
    Type: Application
    Filed: July 3, 2007
    Publication date: January 8, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventor: Sandeep Tripathi
  • Publication number: 20080311373
    Abstract: An electromagnetic wave absorbing material and a method for preparing the same are disclosed. The electromagnetic wave absorbing material consists of liquid resin, carbon nanocapsules, carbon fiber and hollow glass microsphere. All components are mixed well to form the electromagnetic-wave absorbing material. The method for preparing the electromagnetic-wave absorbing materials includes steps of: mixing the liquid resin, carbon nanocapsules, carbon fiber and hollow glass microsphere well to form a slurry solution; pour the slurry solution into a mold; after curing and cooling, an electromagnetic-wave absorbing material is obtained. The electromagnetic-wave absorbing material with density ranging from 0.75 to 1.0 g/ml matches requirements of compact design and light weight in high technology industries.
    Type: Application
    Filed: June 12, 2007
    Publication date: December 18, 2008
    Inventors: Jen-Sung Hsu, Yuan-Yao Li, Meng-Tan Chiang, Chia-Tung Liu
  • Patent number: 7465481
    Abstract: The object the present invention is to provide an exterior molding body for automobile which is reinforced by a long fiber, is excellent in mechanical properties such as bending elastic modulus and bending strength, chemical resistance and heat resistance, is lightened, has high designability and is reduced in the anisotropy of linear expansion coefficient of molding body caused by the fiber orientation at filling thereof to a mold.
    Type: Grant
    Filed: September 7, 2005
    Date of Patent: December 16, 2008
    Assignee: Mitsubishi Engineering-Plastics Corporation
    Inventors: Hiroyuki Imaizumi, Motonori Ueda, Kouji Nishida, Kei Morimoto
  • Patent number: 7459207
    Abstract: The characteristic analysis of erosion of NB31 carbon-fiber composite enables the proposal of a novel carbon-fiber composite structure having a distinctly reduced erosion rate. Improvement only relates to the arrangement of the sewing and web fibers and to maintaining the structure of the pitch/carbon fibers, which consist of the main NB31 heat conducting components. The sewing and web fibers of the improved structure reinforce the rigidness/reinforce the thermal shield, compared to the NB31. The improved structure improves the erosion rate so it is 4-5 times lower compared to that of NB31.
    Type: Grant
    Filed: March 14, 2006
    Date of Patent: December 2, 2008
    Assignee: Forschungszentrum Karlsruhe GmbH
    Inventor: Sergey Peschany
  • Publication number: 20080261012
    Abstract: Heat-reflecting adhesive tape (1), preferably for wrapping elongate material such as, more particularly, leads or cable harnesses, having a tapelike backing (2) composed of an assembly comprising at least one first layer (2a), formed by a glass fabric having a basis weight of 30 to 200 g/m2, and at least one second layer (2b), formed by a metallic layer having a thickness of 10 to 40 ?m and a thermal effectiveness to SAE J2302 at 350° C. of greater than 45° C., and having a pressure-sensitive adhesive coating (3) applied at least to one side of the backing (2), the flexural rigidity of the adhesive tape in longitudinal and transverse direction being less than 500 mN, preferably less than 300 mN (as measured with a Softometer KWS basic 2000 mN from Wolf).
    Type: Application
    Filed: March 20, 2008
    Publication date: October 23, 2008
    Applicant: TESA AG
    Inventors: Patrick Kopf, Ronald Pfaff, Heike Moller
  • Publication number: 20080253939
    Abstract: A multilayer mat (10) for mounting a pollution control element (40) in a pollution control device (60). The mat comprises at least one non-intumescent layer comprising ceramic fibers and having a width defined by opposite lateral edges, and at least one intumescent layer comprising an intumescent material and having a width defined by opposite lateral edges. The width of the intumescent layer is less than the width of the non-intumescent layer. The intumescent layer can have an exposed major surface.
    Type: Application
    Filed: October 10, 2006
    Publication date: October 16, 2008
    Inventor: Loyd R. Hornback
  • Patent number: 7419714
    Abstract: A composite of polymer or ceramic material has reinforcing fibers. The composite is for use in manufacturing medical implants like osteosynthesis plates, endoprostheses, screw coupling elements, surgical instruments, and similar components. The fibers and fibrous parts are made from a material that absorbs X-rays so that it can be seen during X-ray examination.
    Type: Grant
    Filed: May 26, 1999
    Date of Patent: September 2, 2008
    Assignee: Sepitec Foundation
    Inventors: Fritz Magerl, Roger Roland Tognini, Erich Wintermantel, Jörg Mayer, Thomas Andreas Peter, Walter Spirig
  • Publication number: 20080206538
    Abstract: An automotive exterior resin part which is a molded article made of a long glass fiber reinforced polycarbonate resin/styrene-based resin, has been molded by injection molding, has a projected area of 200 cm2 or above and allows coating, plating or deposition, wherein the content of the glass fibers in the molded article is 25 to 50% by weight and the weight-average fiber length thereof is 0.5 to 2.0 mm, the centerline average surface roughnesses (Ra) over all faces to be subjected to coating, plating or deposition is 0.8 m or below and the maximum coefficient of linear expansion at 30 to 80° C. is 5×l0?5 or below.
    Type: Application
    Filed: February 19, 2008
    Publication date: August 28, 2008
    Applicant: TOYODA GOSEI CO., LTD.
    Inventors: Masahiro Katayama, Yuichi Oe, Hideaki Sakamoto, Hiroyuki Nakagawa
  • Patent number: 7413797
    Abstract: A backup thermal insulation plate includes a colloidal inorganic oxide-impregnated, pressed and dried high-temperature-resistant inorganic-fiber blanket or board, the plate having a use temperature up to at least about 1000° C. and maintaining mechanical integrity after exposure to the use temperature, the plate having a density greater than or equal to about 500 kg/m3, and a compression resistance of at least about 50 kgf/cm2.
    Type: Grant
    Filed: May 31, 2007
    Date of Patent: August 19, 2008
    Assignee: Unifrax ILLC
    Inventor: Mauricio Munhoz de Souza
  • Publication number: 20080176057
    Abstract: An object of the invention is to provide an inorganic board excellent in water absorption resistance, dimensional stability and/or frost damage resistance, and a method for producing the same. The inorganic board is produced through the following processes: preparing a slurry by dispersing a cement-based hydraulic material and a refined fiber reinforcing material into water, adding a saturated carboxylic acid to the slurry, and then the slurry is subjected to the steps of sheetmaking, dehydration, pressing and curing. The inorganic board comprising a refined fiber reinforcing material at 1-30 weight % based on the total solid content and a saturated carboxylic acid at 0.1-2.0% based on the total solid content.
    Type: Application
    Filed: October 17, 2007
    Publication date: July 24, 2008
    Applicant: NICHIHA CORPORATION
    Inventor: Masanori Ukai
  • Patent number: 7387828
    Abstract: The invention concerns a web comprising an intimate mixture of mixed slivers of long reinforcing staple fibres (14) obtained by stretch-breaking and long thermoplastic matrix fibres (15), those different fibres being parallel in the mixture.
    Type: Grant
    Filed: July 9, 2001
    Date of Patent: June 17, 2008
    Assignee: SA Schappe
    Inventors: Jean Guevel, Guy Bontemps
  • Patent number: 7387758
    Abstract: A ceramic article having improved interlaminar strength and a method of forming the article. The article may be a ceramic matrix composite article. The methods of forming the articles increase the interlaminar strength of the article by forming indentations in the article during processing. The indentations may be tabs that are formed such that they provide one or more beneficial features for ceramic articles, such as CMC articles and hybrid structures. The tabs may be any of a variety of shapes, orientations, spacings, and combinations. In an alternative embodiment, the indentations are formed by pulling one or more fibers from one side of the ceramic layer to the other side. The articles have increased surface area, which helps to increase the bonding strength between the ceramic layer and any thermal barrier coating layer and/or ceramic core in the ceramic article.
    Type: Grant
    Filed: February 16, 2005
    Date of Patent: June 17, 2008
    Assignee: Siemens Power Generation, Inc.
    Inventors: Gary B. Merrill, Jay A. Morrison
  • Patent number: 7378362
    Abstract: The present invention is a composite material, a process and a product formed by the process. The composite is formed by a process that includes forming a fibrous structure comprising fibers into a preform, coating the fibers of the fibrous structure preform with elemental carbon to impregnate that preform, infiltrating the preform with boron carbide to form an impregnated green body. The impregnated green body is infiltrated with liquid naphthalene or other carbon precursor, which is thereafter pyrolyzed to form a carbon char. Then, the char infiltrated green body is infiltrated with molten silicon to form a continuous matrix throughout the composite. The silicon in the continuous matrix is reacted with the carbon char to form silicon carbide.
    Type: Grant
    Filed: October 24, 2003
    Date of Patent: May 27, 2008
    Assignee: Goodrich Corporation
    Inventors: Thomas Dwayne Nixon, Sai-Kwing Lau, Edward R. Stover, Salvatore J. Calandra, Vijay V. Pujar, Lanny Ritz, Gary L. Clark, Steve T. Keller
  • Patent number: 7371471
    Abstract: An electromagnetic noise suppressing thin film has a structure including an inorganic insulating matrix made of oxie, nitride, fluoride, or a mixture thereof and columnar-structured particles made of a pure metal of Fe, Co, or Ni or an alloy containing at least 20 weight % of Fe, Co, or Ni and buried in an inorganic insulating matrix.
    Type: Grant
    Filed: March 8, 2005
    Date of Patent: May 13, 2008
    Assignee: NEC TOKIN Corporation
    Inventors: Shigeyoshi Yoshida, Hiroshi Ono, Yutaka Shimada, Tetsuo Itoh
  • Patent number: 7311964
    Abstract: A method of reinforcing a structural support, includes applying a reinforcement system comprising an AR-glass fibrous layer embedded in an inorganic matrix to the structural support. The AR-glass fibrous layer has a sizing applied thereon, and a resinous coating applied is applied over the sizing. The inorganic matrix is adherent to the resinous coating and the resinous coating is adherent to the sizing.
    Type: Grant
    Filed: July 30, 2002
    Date of Patent: December 25, 2007
    Assignee: Saint-Gobain Technical Fabrics Canada, Ltd.
    Inventors: Corina-Maria Aldea, David Geraint Roberts
  • Patent number: 7306665
    Abstract: A friction material composition containing a fibrous material, a binder and a friction adjusting agent, wherein the friction adjusting agent is secondary aggregates of an activated alumina being spherical and having a diameter of 10 to 300 ?m, or an activated alumina having a specific surface area of 100 to 400 m2/g and an average particle diameter of 1 to 200 ?m. The composition can be used for producing a friction material which exhibits significant improvement with respect to fading phenomenon, without adversely affecting its characteristics of attacking to a disc rotor, which is the article mating therewith, and without marked reduction of the friction coefficient at an elevated temperature, and is capable of controlling the thickness of the sliding film formed on a frictionally sliding face and preventing a high frequency noise (grabbing chatter).
    Type: Grant
    Filed: December 13, 2002
    Date of Patent: December 11, 2007
    Assignee: Hitachi Chemical Co., Ltd.
    Inventors: Teruyuki Nagayoshi, Noboru Suzuki, Manabu Ono
  • Patent number: 7282274
    Abstract: The present invention is an integral composite structural (ICS) material comprising an open metal structure having at least one external side and internal surfaces defining a plurality of open shapes with a ceramic matrix composite bonded to at least one external side and the surfaces of at least a substantial portion of the plurality of open shapes and occupying at least a substantial portion of the plurality of open shapes. The open metal structure, independent of the ceramic matrix composite, has a total metal volume percent in the range of about 10% to about 90%, with no dimension of any open shape being greater than about ¾ inch. The ceramic matrix layer covers a substantial portion of at least one external side of the open metal structure.
    Type: Grant
    Filed: November 7, 2003
    Date of Patent: October 16, 2007
    Assignee: General Electric Company
    Inventors: Michael Lee Millard, Horace Richardson, Jr., Joseph Anthony Corrado
  • Publication number: 20070237954
    Abstract: A process for the impregnation of carbon fiber bundles enables the carbon fiber bundles to be impregnated with a curable liquid resin without the impregnated fiber bundles sticking together. The fiber bundles are present in a mechanically generated fluidized bed during the impregnation and are held in the fluidized bed until the resin has been cured or at least dried. A resin-impregnated carbon fiber bundle, a shaped body and an intermediate body for silicization are also provided.
    Type: Application
    Filed: April 11, 2007
    Publication date: October 11, 2007
    Inventors: Andreas Kienzle, Ingrid Kratschmer
  • Patent number: 7264877
    Abstract: Sliding element for seals includes 25 to 75 weight % carbonaceous impalpable powdery aggregate of non-graphitizing carbon and/or graphitizing carbon and 20 to 50 weight % synthetic resin as binder. The sliding element is blended with the range of 5 to 25 weight % carbonaceous carbon fibers without surface treatment and inside the carbon matrix, the carbon fibers are randomly scattered.
    Type: Grant
    Filed: January 15, 2004
    Date of Patent: September 4, 2007
    Assignee: Eagle Industry Co., Ltd.
    Inventor: Hideki Tomoto
  • Patent number: 7238414
    Abstract: A fiber-reinforced composite body containing a first zone made of a ceramic matrix, which predominantly contains silicon carbide and, optionally, silicon and/or carbon and/or compounds thereof, and containing a second zone, which is located on a surface of the ceramic matrix zone and formed form a fiber-reinforced C/SiC ceramic. The fiber length decreases from the exterior of the fiber-reinforced ceramic zone up to the first zone and, optionally, up to one or more other zones that are arranged on the second zone. A method for producing the composite body is characterized by involving a joint infiltration at least of the first zone and of the second zone with liquid silicon and by the carrying out of a siliconization. A composite body of this type can be used, in particular, as armoring in the civil or military sectors.
    Type: Grant
    Filed: May 24, 2004
    Date of Patent: July 3, 2007
    Assignee: SGL Carbon AG
    Inventors: Bodo Benitsch, Michael Heine, Sven Schweizer, Rainer Zimmermann-Chopin
  • Publication number: 20070141318
    Abstract: A panel is provided having a surface layer. The surface layer includes a surface that is the exterior surface of the panel. The surface layer includes a blend of nucleated binder fibers and synthetic fibers and forms a finishable, substantially defect and porosity free surface layer based on visual inspection.
    Type: Application
    Filed: October 17, 2006
    Publication date: June 21, 2007
    Inventor: Garry E. Balthes
  • Patent number: 7223465
    Abstract: The present invention is a ceramic matrix composite turbine engine component, wherein the component has a region of expected higher interlaminate stress during normal engine operation. The component includes both coated fiber tows and uncoated fiber tows arranged together into a preselected form, wherein the uncoated fiber tows are located at predetermined regions of expected high interlaminate stress. The invention further includes method of manufacturing a CMC such as a composite turbine engine component, wherein the component has a region of expected higher interlaminate stress during engine operation.
    Type: Grant
    Filed: December 29, 2004
    Date of Patent: May 29, 2007
    Assignee: General Electric Company
    Inventors: Suresh Subramanian, James Dale Steibel, Douglas Melton Carper
  • Patent number: 7198839
    Abstract: The invented insulation is a ceramic fiber insulation wherein the ceramic fibers are treated with a coating which contains transition metal oxides. The invented process for coating the insulation is a process of applying the transition metal oxide coating to the fibers of the insulation after the fibers have been formed into a tile or other porous body. The coating of transition metal oxide lowers the transmittance of radiation through the insulation thereby lowering the temperature of the backface of the insulation and better protecting the structure that underlies the insulation.
    Type: Grant
    Filed: August 16, 2002
    Date of Patent: April 3, 2007
    Assignee: The Boeing Company
    Inventors: Alfred A. Zinn, Ryan Jeffrey Tarkanian
  • Patent number: 7168232
    Abstract: The present invention provides a synthetic fiber and methods for its use and formation. The present invention may comprise a fiber component that is a twisted bundle comprised of multiple strands of a nonfibrillating monofilament, the degree of twist being greater than about 0.9 turns/inch (about 0.36 turns/cm). The present invention may further comprise another fiber component, discrete from the twisted fiber component, that is fibrillated.
    Type: Grant
    Filed: August 1, 2003
    Date of Patent: January 30, 2007
    Assignee: Forta Corporation
    Inventors: Jeffrey B. Lovett, Daniel T. Biddle, H. Charles Pitts, Jr.
  • Patent number: 7153096
    Abstract: Embodiments of the invention relate to a robust turbine vane made of stacked airfoil-shaped CMC laminates. Each laminate has an in-plane direction and a through thickness direction substantially normal to the in-plane direction. The laminates have anisotropic strength characteristics in which the in-plane tensile strength is substantially greater than the through thickness tensile strength. Thus, the laminates can provide strength in the direction of high thermal gradients and, thus, withstand the associated high thermal stresses. The laminates are relatively weak in through thickness (interlaminar) tension, but, in operation, relatively low through thickness tensile stresses can be expected. The laminates can be strong in through thickness compression; accordingly, the laminate stack can be held in through thickness compression by one or more fasteners.
    Type: Grant
    Filed: December 2, 2004
    Date of Patent: December 26, 2006
    Assignee: Siemens Power Generation, Inc.
    Inventors: Daniel G. Thompson, Steven James Vance, Jay A. Morrison
  • Patent number: 7150837
    Abstract: Insulation materials suited to high temperature applications, such as the insulation of furnaces, are formed from a mixture of pitch carbon fibers, such as isotropic pitch carbon fibers, and a binder comprising a solution of sugar in water. The sugar solution is preferably at a concentration of from 20–60% sucrose to yield a low density material having high flexural strength and low thermal conductivity when carbonized to a temperature of about 1800° C.
    Type: Grant
    Filed: June 10, 2004
    Date of Patent: December 19, 2006
    Assignee: UCAR Carbon Company, Inc.
    Inventors: Charles C. Chiu, Irwin Charles Lewis, Ching-Feng Chang
  • Patent number: 7135226
    Abstract: A manufacturing method for a composite fabric material is disclosed, which includes: holding a bundle of fibers under tension, the fiber being continuous filaments of carbon fibers, aramid fibers, or glass fibers, etc.; placing a layer of a matrix material over and under the fiber bundle, the matrix material being a thermoplastic adhesive material such as polyamide resins, thermoplastic polyurethane, or polyester, etc.; heating the matrix material to melt it and applying a pressure on the layers while the fiber bundle is under tension; and cooling the layers, whereby the fibers are locked in place by the adhesive. Composite material layers produced by the above steps may be laminated and further processed or formed as desired. The composite fabric materials manufactured by this method have superior tensile properties, compression properties, impact properties, and impact dispersion and propagation properties compared to composite fabric materials made with conventional methods.
    Type: Grant
    Filed: September 27, 2004
    Date of Patent: November 14, 2006
    Inventor: Steve Nagamoto
  • Patent number: 7118802
    Abstract: A two-layer ceramic composite material, wherein the first predominantly load-bearing layer is an oxidic, carbon-free fiber-reinforced ceramic layer which is made by a colloidal process. The second predominantly thermally insulating layer is an oxide-ceramic foam. The colloidal process produces carbon-free oxide ceramics which, because of their high purity, have low dielectric losses in the entire usage temperature range. In addition, the colloidal process provides a simple and cost-effective production method.
    Type: Grant
    Filed: April 23, 2004
    Date of Patent: October 10, 2006
    Assignee: LFK-Lenkflugkoerpersysteme
    Inventors: Reinhard A. Simon, Helmut E. A. Knabe, Wolfgang Schäfer, Walter D. Vogel, Wilhelm Wulbrand, Wilhelm Hager, Kurt Lindner, Paul Hennig
  • Patent number: 7112547
    Abstract: Production processes of an inorganic fiber-bonded ceramic component comprising inorganic fibers mainly comprising Si, M, C and O, an inorganic substance mainly comprising Si and O and boundary layers comprising carbon as a main component; and an inorganic fiber-bonded ceramic component comprising inorganic fibers which are composed mainly of a sintered structure of SiC and contain specific metal atoms and boundary layers composed mainly of carbon, wherein a preliminary shaped material is set in a carbon die, covered with a carbon powder and then hot-pressed to load a pseudo-isotropic pressure on the preliminary shaped material; and a highly heat-resistant inorganic fiber-bonded ceramic component almost free from the occurrence of peelings of surface fibers or delamination, wherein fibers are aligned in a surface shape.
    Type: Grant
    Filed: August 6, 2003
    Date of Patent: September 26, 2006
    Assignee: UBE Industries, Ltd.
    Inventors: Shinji Kajii, Kenji Matsunaga, Toshihiko Hogami, Mitsuhiko Sato
  • Patent number: 7105224
    Abstract: The invention relates to oxide ceramic fiber composite materials that, e.g., according to the invention, are used in energy conversion installations. The present invention discloses a fundamentally new concept for the previously incompatible requirements of improved brittle fracture behavior to secure thermal shock stability and damage tolerance in the temperature range of <1000° C. and of mechanical high-temperature stability to guarantee long-term form stability (creep resistance) of components.
    Type: Grant
    Filed: May 21, 2004
    Date of Patent: September 12, 2006
    Assignee: Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V.
    Inventors: Andreas Krell, Dieter Sporn, Paul Blank
  • Patent number: 7093359
    Abstract: A method of manufacturing a composite structure uses a layer of an insulating material (22) as a mold for forming a substrate of a ceramic matrix composite (CMC) material (24). The insulating material may be formed in the shape of a cylinder (10) with the CMC material wound on an outer surface (14) of the cylinder to form a gas turbine combustor liner (20). Alternatively, the insulating material may be formed in the shape of an airfoil section (32) with the CMC material formed on an inside surface (36) of the insulating material. The airfoil section may be formed of a plurality of halves (42, 44) to facilitate the lay-up of the CMC material onto an easily accessible surface, with the halves then joined together to form the complete composite airfoil. In another embodiment, a box structure (102) defining a hot gas flow passage (98) is manufactured by forming insulating material in the shape of opposed airfoil halves (104) joined at respective opposed ends by platform members (109).
    Type: Grant
    Filed: September 17, 2002
    Date of Patent: August 22, 2006
    Assignee: Siemens Westinghouse Power Corporation
    Inventors: Jay A. Morrison, Gary Brian Merrill, Jay Edgar Lane, Steven C. Butner, Harry A. Albrecht, Scott M. Widrig, Yevgeniy P. Shteyman
  • Patent number: 7056574
    Abstract: A bond layer and a further layer on the bond layer, the bond layer comprising a silicon layer having a dispersion of fibers, wherein at least some of the fibers extend between the bond layer and the further layer. The fibers are formed from a material selected from the group consisting of (1) alumina, (2) yttria, (3) aluminum silicate, (4) silicon carbide, (5) silicon nitride, (6) compounds of rare earth elements, alkaline earth elements, aluminum, silicon, oxygen, yttrium, nitrogen, niobium, tantalum, hafnium, zirconium, carbon and mixtures of (1) thru (6).
    Type: Grant
    Filed: May 22, 2003
    Date of Patent: June 6, 2006
    Assignee: United Technologies Corporation
    Inventors: Greg C. Ojard, Harry E. Eaton, Shantikumar V. Nair, Yasser A. Gowayed
  • Patent number: 7048996
    Abstract: A temperature resistant material, comprising a temperature resistant matrix and a set of short metal fibers, which characterized in that the set of short metal fibers represents at least 0.5% by weight of the temperature resistant material. The set of short metal fibers has an equivalent diameter D in the range of 1 to 150 ?, and comprising curved fibers and entangled fibers. The curved fibers have an average length L in the range of 10 to 2000 ?.
    Type: Grant
    Filed: December 10, 2001
    Date of Patent: May 23, 2006
    Assignee: N.V. Bekaert S.A.
    Inventors: Ronny Losfeld, Lieven Anaf
  • Patent number: 7045207
    Abstract: Friction bodies made of a fiber-reinforced porous carbon material in which the reinforcing fibers are present in the form of woven fabrics, short fibers and/or long fibers and whose pores are filled with metals, wherein carbides of the metals filling the pores are present in the material in a mass fraction of not more than 10%, a process for their production and the use thereof in brake and clutch systems.
    Type: Grant
    Filed: May 26, 2004
    Date of Patent: May 16, 2006
    Assignee: SGL Carbon AG
    Inventors: Ronald Hüner, Xaver Rothmair
  • Patent number: 7037602
    Abstract: Multilayer composite for combustion chambers or nozzles of missiles, comprising an interior layer in contact with the combustion gases and an outer layer, wherein the interior layer is a fiber-reinforced ceramic whose matrix comprises phases of carbon and/or phases of silicon carbide and the outer layer is a polymer reinforced with carbon fibers, process for producing the same and combustion chambers and nozzles for missiles made of this composite.
    Type: Grant
    Filed: July 3, 2003
    Date of Patent: May 2, 2006
    Assignee: SGL Carbon AG
    Inventors: Bodo Benitsch, Udo Gruber, Sven Schweizer, Peter Winkelmann
  • Patent number: 6986940
    Abstract: A fiber reinforced composite article, comprising a matrix and reinforcing fibers and subjected during operation concurrently to a plurality of temperatures and stresses, varying between a plurality of regions of the article, experiences different stresses concurrently in different regions of the article. The article is provided with fiber reinforcement of a strength in each region greater than the stress experienced in that region. Such fiber reinforcement is provided through a member for inclusion in the matrix, for example in the form of at least one of a fabric, weave, braid, lay-up, etc. One form of such an article for use at relatively high temperatures is a turbine engine component, for example a gas turbine engine exhaust flap. Another form of such an article is a gas turbine engine blading component.
    Type: Grant
    Filed: July 27, 2000
    Date of Patent: January 17, 2006
    Assignee: General Electric Company
    Inventor: Douglas Melton Carper
  • Patent number: 6969546
    Abstract: A ceramic tile includes a ceramic core material and an oxide ceramic matrix composite (CMC), where the ceramic core material has at least one surface covered by the oxide CMC. The oxide CMC includes a ceramic fiber, with a cured metal oxide ceramic material impregnating the ceramic fiber. An exemplary embodiment of the ceramic tile provided as part of the invention further includes a tough low temperature cure coating (TLTC) which infiltrates the ceramic core surface before it is covered by the oxide CMC. The TLTC includes a cured ceramic powder together with a binder. The metal oxide ceramic material impregnating the ceramic fiber, and the TLTC are co-cured, meaning that neither is cured when the CMC is wrapped around a surface of the TLTC-infiltrated ceramic core, and a curing step is performed on both uncured ceramic materials at the same time.
    Type: Grant
    Filed: October 20, 2003
    Date of Patent: November 29, 2005
    Assignee: The Boeing Company
    Inventor: Robert A. DiChiara, Jr.
  • Patent number: 6936341
    Abstract: Process for a fiber-reinforced ceramic material whose reinforcing fibers are present in the form of at least one of woven fabrics, short fibers and long fibers, wherein the mass ratio of the fibers in the form of woven fabrics, short fibers and long fibers is 0-35:25-80:0-45 and at least a part of the reinforcing fibers has at least one protective layer of carbon produced by pyrolysis of resins or pitches, boron compounds or phosphorus compounds or combinations thereof which have been deposited thereon, a process for producing it and its use as material for brake linings
    Type: Grant
    Filed: March 12, 2004
    Date of Patent: August 30, 2005
    Assignee: SGL Carbon AG
    Inventors: Ronald Hüner, Moritz Bauer, Peter Winkelmann
  • Patent number: 6911251
    Abstract: An optically nonisotropic composite material. The composite material includes two materials, a transparent bulk optical material and radiation absorbing or reflecting fibers embedded within the bulk material. The fibers are substantially parallel to one another and tend to channel the radiation along the direction of the fibers. The bulk material may be a scintillator, in which case the fibers will tend to channel scintillating radiation along the direction of the fibers. The composite material may be used in a high spatial resolution x-ray device, such as a CT scanner. The composite material may also be used in an electromagnetic radiation detection device. Advantageously, the fibers tend to channel radiation along the fibers towards photodetector cells of the radiation detection device thereby increasing spatial resolution.
    Type: Grant
    Filed: March 15, 2002
    Date of Patent: June 28, 2005
    Assignee: General Electric Company
    Inventor: Steven Jude Duclos
  • Patent number: 6867155
    Abstract: A multiplayer composite doctor blade has a side edge configured for application to the surface of a rotating roll in a paper making machine. The doctor blade has an inner core and intermediate layers preferably enclosed by outer layers. The inner core is predominantly polymeric material. The intermediate layers on opposite sides of the core include reinforcing fibers. The side edge of the doctor blade has an abrasiveness as measured by ASTM test method D5181-91 of between about 4.0 to 5.0.
    Type: Grant
    Filed: March 28, 2002
    Date of Patent: March 15, 2005
    Assignee: Kadant Web Systems, Inc.
    Inventors: Allen J. Brauns, Stacey L. Jackson
  • Patent number: 6855428
    Abstract: The present invention is a composite material and process to produce same. That material comprises a fibrous structure which is initially predominantly coated with elemental carbon; that fibrous structure is then subsequently predominantly coated with at least one ceramic material, e.g., boron carbide, which is non-reactive with silicon. The composite material also comprises a silicon matrix which is continuous and predominantly surrounds the fibrous structure, which has been initially predominantly coated with elemental carbon and subsequently predominantly coated with at least one ceramic material. The matrix which has a fine grain crystalline structure of predominantly 20 microns or less in size. The at least one ceramic material is discontinuous within that matrix. The fibrous material pulls out of the elemental carbon, which initially predominantly coats that fibrous structure, when the composite is subjected to fracture.
    Type: Grant
    Filed: June 2, 2003
    Date of Patent: February 15, 2005
    Assignee: B. F. Goodrich Company
    Inventors: Sai-Kwing Lau, Salvatore J. Calandra, Thomas D. Nixon, Edward R. Stover
  • Patent number: 6844091
    Abstract: A flexible insulation blanket having a ceramic matrix composite (CMC) outer layer, and a method of producing a flexible insulation blanket having a smooth, aerodynamically suitable, outer surface by infiltrating ceramic material within the outer ceramic fabric layer of the flexible insulation blanket and curing the ceramic material to form a CMC layer. The CMC layer is cured while the blanket is under compression such that the resulting CMC layer has a smooth surface.
    Type: Grant
    Filed: November 11, 2002
    Date of Patent: January 18, 2005
    Assignee: The Boeing Company
    Inventors: Jerry Denham, Robert A. Dichiara, Jr., Vann Heng, Leanne L. Lehman, David Zorger
  • Patent number: 6838162
    Abstract: A composite material includes a ceramic matrix and two different fractions of fiber bundles, namely a reinforcing fiber bundle fraction and a matrix fiber bundle fraction having different average fiber bundle lengths. The fractions of fiber bundles are separated in a total fiber bundle distribution relative to a fiber bundle length by a minimum. A method for manufacturing a composite material and a method for manufacturing elements formed of a composite material are also provided.
    Type: Grant
    Filed: September 18, 2000
    Date of Patent: January 4, 2005
    Assignee: SGL Technik GmbH
    Inventors: Udo Gruber, Michael Heine, Andreas Kienzle
  • Publication number: 20040258900
    Abstract: A two-layer ceramic composite material, wherein the first predominantly load-bearing layer is an oxidic, carbon-free fiber-reinforced ceramic layer which is made by a colloidal process. The second predominantly thermally insulating layer is an oxide-ceramic foam. The colloidal process produces carbon-free oxide ceramics which, because of their high purity, have low dielectric losses in the entire usage temperature range. In addition, the colloidal process provides a simple and cost-effective production method.
    Type: Application
    Filed: April 23, 2004
    Publication date: December 23, 2004
    Inventors: Reinhard A. Simon, Helmut E.A. Knabe, Wolfgang Schafer, Walter D. Vogel, Wilhelm Wulbrand, Wilhelm Hager, Kurt Lindner, Paul Hennig
  • Patent number: 6824862
    Abstract: Fiber-reinforced ceramic composites contain bundles, tows or hanks of long fibers, wherein the long fiber bundles, tows or hanks are completely surrounded by a short fiber-reinforced matrix, with the long and short fibers having, independently of one another, a mean diameter of from 4 to 12 &mgr;m and the long fibers having a mean length of at least 50 mm and the short fibers having a mean length of not more than 40 mm, a process for producing them and their use for producing clutch disks or brake disks.
    Type: Grant
    Filed: December 23, 2002
    Date of Patent: November 30, 2004
    Assignee: SGL Carbon AG
    Inventors: Moritz Bauer, Georg Burkhart, Martin Christ, Ronald Huener, Andreas Kienzle, Peter Winkelmann, Rainer Zimmermann-Chopin
  • Patent number: 6818288
    Abstract: Fiber-reinforced ceramic composites which comprise at least two layers of a multidirectional woven fiber fabric as reinforcement, with at least 5% of the area of each layer of woven fiber fabric being permeated by matrix material, friction disks comprising these composites as core zone or support zone, a process for producing them and their use as brake disks or clutch disks.
    Type: Grant
    Filed: December 23, 2002
    Date of Patent: November 16, 2004
    Assignee: SGL Carbon AG
    Inventors: Moritz Bauer, Andreas Kienzle, Ingrid Kraetschmer, Mario Krupka
  • Patent number: 6815037
    Abstract: This invention provides a carrier member made of a UV resistant fiber-reinforced composite material where a UV resistant coating material is applied on the surface of the fiber-reinforced composite material and a process for producing thereof. A preferable fiber-reinforced composite material is a fiber-reinforced plastic or carbon fiber-reinforced carbon composite material. A UV resistant coating material is one or more selected from the group consisting of ceramics, cermets, metals and alloys. The carrier member is produced by coating the surface of the fiber-reinforced composite material with a UV resistant coating material by spraying. This carrier member is advantageous in that it can exhibit properties inherent to a fiber-reinforced composite material such as a light weight, higher rigidity and higher heat resistance and that it little contaminates a precision instrument material when being used in cleansing with UV.
    Type: Grant
    Filed: September 19, 2001
    Date of Patent: November 9, 2004
    Assignee: Nippon Mitsubishi Oil Corporation
    Inventors: Akio Ooshima, Takashi Kobayashi, Kenichi Aoyagi, Daisuke Uchida