Porous Component Patents (Class 428/550)
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Publication number: 20040043241Abstract: A porous molybdenum disilicide-based material prepared by preheating a preform consisting of size-controlled molybdenum (Mo) powder and content-controlled silicon (Si) powder and igniting the preform to initiate self-propagating high temperature synthesis, and a method for preparing the same, are disclosed. The method comprises the steps of a) mixing molybdenum (Mo) powder and silicon (Si) powder in the stoichiometric ratio of 1:2; b) molding the mixed powder into a preform; c) preheating the preform under inert atmosphere; and d) igniting the top end of the preheated perform. The porous molybdenum disilicide-based material can control its pore size by appropriately controlling the size of molybdenum (Mo) powder, the content of silicon (Si) powder and preheating condition. Therefore, since the pore size gradient of the porous material is possible to form, the porous material can be used for filters with improved dirt-holding capacity.Type: ApplicationFiled: October 9, 2002Publication date: March 4, 2004Applicant: Korea Institute of Machinery and MaterialsInventors: In-Hyuck Song, Hai-Doo Kim, Jung-Yeul Yun
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Patent number: 6656624Abstract: The present invention is a polarized gas separator useful in the bipolar construction of a fuel cell stack. It comprises a porous conductive substrate and a barrier layer, the barrier layer having a first side and a second side, and laterally extending through the porous conductive substrate so that a first portion of the porous conductive substrate extends from the first side of the barrier layer and a second portion of the porous conductive substrate extends from the second side of the barrier layer. Effectively, the polarized gas separator is a single component system that not only enhances power performance of fuel cell stacks but also defeats several problems previously unsolvable by conventional bipolar plate assemblies.Type: GrantFiled: December 19, 2000Date of Patent: December 2, 2003Assignee: Reliant Energy Power Systems, Inc.Inventor: George R. King
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Patent number: 6569358Abstract: The method of preparing the porous material incorporating ultrafine metal particles comprises the following steps: (1) preparing surface-protected ultrafine metal particles by reducing metal ions in the presence of molecules such as dodecanethiol molecules; (2) immersing a wet gel in a solution of the ultrafine metal particles, thus forming an ultrafine metal particle/wet gel composite in which the ultrafine metal particles are incorporated in the wet gel; and (3) drying the ultrafine metal particle/wet gel composite to form a porous body.Type: GrantFiled: March 20, 2002Date of Patent: May 27, 2003Assignee: National Institute of Advanced Industrial Science and TechnologyInventors: Yutaka Tai, Koji Tajiri, Masao Watanabe, Sakae Tanemura
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Patent number: 6558810Abstract: Formation of sintered metal fiber porous mats used as burner faces and filters comprises dispersing metal fibers in a viscous aqueous solution of one or more cellulose ethers, vacuum molding the dispersed metal fibers on a foraminous support, eliminating residual aqueous cellulose ether from the vacuum molded metal fiber porous mat, and sintering the mat. Water solutions of methylcellulose and/or hydroxypropyl methylcellulose having a viscosity of at least about 1500 centipoises are often used pursuant to this invention.Type: GrantFiled: September 4, 2001Date of Patent: May 6, 2003Inventor: Paul W. Garbo
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Patent number: 6548183Abstract: A metal-based composite material is formed by impregnating a matrix metal of Al or Al alloy into ores of a porous preform of a hydrogenatable metal having a metal hydride in at least a part of its surface.Type: GrantFiled: December 21, 2000Date of Patent: April 15, 2003Assignees: Tocalo Co., Ltd., Honda Giken Kogyo Kabushiki KaishaInventors: Yoshifumi Kobayashi, Nobuyuki Kuroki, Fumiyoshi Kurosu
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Patent number: 6534191Abstract: A method for the hardening treatment of a sintered alloy includes compressing an iron-based sinterable material to form a compact, providing a surface of the compact with a coating material containing aluminum or an aluminum alloy that melts at a temperature lower than the sintering temperature of the compact, and sintering the compact provided with the coating material, so as to form an intermediate compound of iron and aluminum in a surface layer of the compact.Type: GrantFiled: January 26, 2001Date of Patent: March 18, 2003Assignee: Suzuki Motor CorporationInventor: Toshio Yamauchi
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Patent number: 6511758Abstract: A porous structural material having a solid shape with a curved surface of which the dimensional accuracy is high and the uses are wide is produced. The porous structural material is made form metallic chips containing at least one kind of ingredients, and comprises a solid-shaped body having a smooth and curved surface, the solid-shaped body being reformed by compacting a plate-shaped intermediate product in the hot state, the product being a molding with heating under a pressure while being highly electrified.Type: GrantFiled: February 27, 2001Date of Patent: January 28, 2003Assignee: Suitaya Co., Ltd.Inventor: Katsumi Kaitani
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Patent number: 6498127Abstract: Disclosed is a composite sliding material consisting of a back metal, a porous alloy layer which is formed on the surface of the back metal by sintering a copper alloy powder, and a resin layer which is formed so as to impregnate into and cover the porous alloy layer. The alloy layer consists of sintered copper alloy particles and has a thickness of superimposed plural particles. The copper alloy powder has an average particle size of 25 to 100 &mgr;m so that the composite sliding material has smallersliding-contact resistance.Type: GrantFiled: October 17, 2000Date of Patent: December 24, 2002Assignee: Daido Metal Company Ltd.Inventors: Takahiro Niwa, Nobutaka Hiramatsu, Takayuki Shibayama
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Patent number: 6465133Abstract: A metallic porous body comprises a metallic framework having a three-dimensional network with a continuous-pore structure formed by linking sub-stantially polyhedral cells. The substantially polyhedral cells have an average cell diameter of about 200 to about 300 &mgr;m and an average window diameter of about 100 to about 200 &mgr;m. The metallic porous body can be obtained by the following method, for instance: First, a plastic porous body is provided that has an average cell diameter of about 200 to about 300 &mgr;m and an average window diameter of about 100 to about 200 &mgr;m. Second, a conductive layer is formed on a surface of the framework of the plastic porous body to produce a conductive porous body having a resistivity of about 1 k&OHgr;·cm or less. Finally, a continuous metal-plated layer is formed on a surface of the conductive layer by electroplating, with the conductive porous body serving as the cathode.Type: GrantFiled: May 9, 2000Date of Patent: October 15, 2002Assignee: Sumitomo Electric Industries, Ltd.Inventors: Ayao Kariya, Noriki Hayashi, Shinji Inazawa, Masatoshi Majima
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Patent number: 6444330Abstract: A sandwich component, which comprises at least two massive metallic sheet metal parts located opposite one another and a metal powder layer to be expanded, which is arranged between the sheet metal parts, is shown, in which the sandwich component has additional reinforcing elements in individual cross-sectional areas, and the said reinforcing elements are connected in a positive-locking manner to the expanded metal powder layer surrounding same, and the said metal powder layer is in turn connected to the outer, massive metallic sheet metal parts in such a way that it cannot be detached without destruction.Type: GrantFiled: December 12, 2000Date of Patent: September 3, 2002Assignee: ZF Lemförder Metallwaren AGInventor: Olaf Abels
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Patent number: 6423422Abstract: A high strength spongy sintered metal composite sheet comprising a porous spongy sintered metal layer having continuous holes, and a high strength sintered, dense metal reinforcing layer having a porosity smaller than the porosity of the spongy sintered metal layer, laminated thereon, wherein the sintered, dense metal reinforcing layer has a thickness of 0.5-30% thickness with respect to the entire high strength spongy sintered metal composite sheet.Type: GrantFiled: April 8, 1999Date of Patent: July 23, 2002Assignee: Mitsubishi Materials CorporationInventors: Masahiro Wada, Yoshitaka Mayuzumi, Koji Hoshino, Saburou Wakita
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Patent number: 6395403Abstract: A novel precious metal doped porous metal catalyst is disclosed. The precious metal is present in from 0.01 to 1.5 weight percent and distributed throughout the particles of porous metal to provide a surface to bulk ratio distribution of not greater than 60. The present invention is further directed to a process of forming said doped catalyst and to improved processes of catalytic hydrogenation of organic compounds.Type: GrantFiled: July 6, 2001Date of Patent: May 28, 2002Assignee: W. R. Grace & Co.Inventor: Stephen Raymond Schmidt
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Patent number: 6395402Abstract: Provided are methods of preparing an electrically conductive polymeric foam. The methods include the following steps: (a) contacting a polymeric foam with a surfactant solution; (b) contacting the polymeric foam with a sensitizing solution; (c) contacting the polymeric foam with an activation solution; and (d) forming at least one metallic layer on the polymeric foam with an electroless plating process. Also provided are electrically conductive polymeric foams formed by such methods. The present methods and foams have particular applicability to the manufacture of EMI (electromagnetic interference) shielding devices.Type: GrantFiled: June 9, 2000Date of Patent: May 28, 2002Assignee: Laird Technologies, Inc.Inventors: Michael Lambert, Satish Chandra, Tony Sosnowski
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Patent number: 6342306Abstract: A bearing material includes a backing metal and a porous sintered metal layer sintered onto a surface of the backing metal, particles of an inorganic substance being contained at grain boundaries of the porous sintered metal layer. The porous sintered metal layer contains tin, nickel, phosphorus, and copper, and the particles of the inorganic substance are those of at least one of graphite, boron nitride, graphite fluoride, calcium fluoride, aluminum oxide, silicon oxide, and silicon carbide.Type: GrantFiled: November 3, 1999Date of Patent: January 29, 2002Assignee: Oiles CorporationInventors: Hideo Ozawa, Hiroshi Tsuji, Hirotsugu Tomita
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Publication number: 20010055694Abstract: A high strength spongy sintered metal composite sheet comprising a porous spongy sintered metal layer having continuous holes, and a high strength sintered, dense metal reinforcing layer having a porosity smaller than the porosity of the spongy sintered metal layer, laminated thereon, wherein the sintered, dense metal reinforcing layer has a thickness of 0.5-30% thickness with respect to the entire high strength spongy sintered metal composite sheet.Type: ApplicationFiled: April 8, 1999Publication date: December 27, 2001Inventors: MASAHIRO WADA, YOSHITAKA MAYUZUMI, KOJI HOSHINO, SABUROU WAKITA
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Patent number: 6322902Abstract: There are disclosed copper-base and/or iron-base contact materials which contain a Pb intermetallic compound dispersedly precipitated therein and which have highly improved sliding properties. Double layered contact elements improved in oil impregnation and lubricity are formed by sinter bonding the above contact materials to an iron-base metal backing, respectively. Economical producing methods for such double layered contact materials are also disclosed. In the copper-base and/or iron-base contact materials, one or more kinds of Pb intermetallic compounds are dispersedly precipitated.Type: GrantFiled: January 22, 1999Date of Patent: November 27, 2001Assignee: Komatsu Ltd.Inventors: Takemori Takayama, Yoshikiyo Tanaka
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Patent number: 6314870Abstract: A device for improving the efficiency, safety and cleanliness of cooking on a grill wherein the device is placed between the item being cooked and the heat source. Said device being a chamber with dimensions proportional to those of the cooking surface. The chamber is encased by a top surface and a bottom surface. The bottom surface is to be compatible with and coated by an oxidation catalyst, constructed by one or more layers, have structural integrity and constructed so that gases can pass freely through the structure while any liquids or solids falling from above would be interrupted by impingement. The top surface is to be compatible with and coated by an oxidation catalyst and having a structure constructed of one or more layers which would allow substantial flow of liquids and gases. The top and bottom surface forming a chamber with dimensions of separation ranging from 0.1 inches to 6 inches. The top layer to be optimized for collecting and oxidizing the fats and oils to reduce flame but not smoke.Type: GrantFiled: July 3, 2000Date of Patent: November 13, 2001Assignee: Advanced Catalyst Systems, LLCInventors: Tracy D. Staller, Larry E. Campbell
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Patent number: 6309758Abstract: A novel precious metal doped porous metal catalyst is disclosed. The precious metal is present in from 0.01 to 1.5 weight percent and distributed throughout the particles of porous metal to provide a surface to bulk ratio distribution of not greater than 60. The present invention is further directed to a process of forming said doped catalyst and to improved processes of catalytic hydrogenation of organic compounds.Type: GrantFiled: May 6, 1999Date of Patent: October 30, 2001Assignee: W. R. Grace & Co.-Conn.Inventor: Stephen Raymond Schmidt
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Patent number: 6251526Abstract: The cast part (1) comprises a basic body (2) of a first material and a coating of at least one second material. The second material is applied to a co-cast skeleton structure (3) on the surface (20) of the basic body, with it forming a covering (4) or a covering layer (42).Type: GrantFiled: February 2, 1999Date of Patent: June 26, 2001Assignee: Sulzer Innotec AGInventor: Fritz Staub
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Patent number: 6224989Abstract: A cylinder block for an automotive engine that includes a sintered cylindrical body made of a first metal, the sintered cylindrical body having a plurality of pores. A powder of a second metal is dispersed into the pores of the sintered cylindrical body, and a cylinder block body is disposed around the sintered cylindrical body while filling the pores of the sintered cylindrical body. The main body is made of a third metal and integrally formed with the sintered cylindrical body by an intemetallic compound formed by a reaction between the first, second, and third metals.Type: GrantFiled: February 25, 1999Date of Patent: May 1, 2001Assignee: Hyundai Motor CompanyInventor: Jun-su Kim
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Patent number: 6218025Abstract: A sintered electrode of high-melting metal (for example tungsten) is produced from spherical metal powder having a well defined particle size. The mean particle size is from 5 to 70 &mgr;m. The particle size distribution covers a range from at most 20% below to at most 20% above the mean particle size.Type: GrantFiled: August 18, 1998Date of Patent: April 17, 2001Assignee: Patent- Truchand-Gesellschaft fuer Elektrische Gluelampen mbHInventors: Dietrich Fromm, Bernhard Altmann, Wolfram Graser, Peter Schade
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Patent number: 6114048Abstract: The invention provides for a functionally-graded metal substrate that is made of at least two metal compositions, a functional insert and a surrounding body that surrounds the functional insert. In a preferred embodiment of the invention a functional insert powder composition of loose powder metal is placed in a compact of a surrounding body powder composition and both metal compositions are sintered in a sintering furnace to form a sintered part. The sintered part is infiltrated in part or in whole with a molten metal compound to produce a functionally graded metal substrate having a density of at least 90% of theoretical. A heat-generating component such as a chip can be attached to the metal substrate for use in microelectronic packaging. When the functionally-graded metal substrate has two discrete compositions of copper/tungsten the surrounding body which has a CTE that ranges from about 5.6ppm/.degree. C. to about 7 ppm/.degree. C.Type: GrantFiled: September 4, 1998Date of Patent: September 5, 2000Assignee: Brush Wellman, Inc.Inventors: David E. Jech, Jordan P. Frazier, Richard H. Sworden, Juan L. Sepulveda
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Patent number: 6089444Abstract: Process for bonding a copper substrate to a tungsten substrate by providing a thin metallic adhesion promoting film bonded to a tungsten substrate and a functionally graded material (FGM) interlayer bonding the thin metallic adhesion promoting film to the copper substrate. The FGM interlayer is formed by sintering a stack of individual copper and tungsten powder blend layers having progressively higher copper content/tungsten content, by volume, ratio values in successive powder blend layers in a lineal direction extending from the tungsten substrate towards the copper substrate. The resulting copper to tungsten joint well accommodates the difference in the coefficient of thermal expansion of the materials.Type: GrantFiled: September 2, 1997Date of Patent: July 18, 2000Assignee: McDonnell Douglas CorporationInventors: Kevin T. Slattery, Daniel E. Driemeyer, John W. Davis
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Patent number: 6063715Abstract: A reinforced ceramic fiber enclosure for muffle furnaces and the like defining a cavity therewithin includes a perforate metallic skeleton defining at least a portion of the peripheral wall of the enclosure and fibrous insulation encapsulating the skeleton with fibers of the insulation extending through the perforations of the skeleton. In some embodiments the enclosure is of rectangular cross section with base, top and side walls. The top and side walls generally extend over only a portion of the length of the enclosure, and mounting and support flanges are desirably provided on at least the front end of the skeleton. To make the enclosure, the skeleton is supported on the exterior of a vacuum mold in spaced relationship thereto, and the mold and skeleton are immersed in slurry of ceramic fibers and a bonding agent therefor. The vacuum drawn through the mold causes the fibers and bonding agent to deposit on the mold and encapsulate the skeleton with fibers extending through the perforations of the skeleton.Type: GrantFiled: December 9, 1998Date of Patent: May 16, 2000Assignee: Degussa-Ney Dental, Inc.Inventors: John H. Holbeck, Richard D. Roy
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Patent number: 5988488Abstract: Process for bonding a copper substrate to a tungsten substrate by providing a thin metallic adhesion promoting film bonded to a tungsten substrate and a functionally graded material (FGM) interlayer bonding the thin metallic adhesion promoting film to the copper substrate. The FGM interlayer is formed by thermal plasma spraying mixtures of copper powder and tungsten powder in a varied blending ratio such that the blending ratio of the copper powder and the tungsten powder that is fed to a plasma torch is intermittently adjusted to provide progressively higher copper content/tungsten content, by volume, ratio values in the interlayer in a lineal direction extending from the tungsten substrate towards the copper substrate. The resulting copper to tungsten joint well accommodates the difference in the coefficient of thermal expansion of the materials.Type: GrantFiled: September 2, 1997Date of Patent: November 23, 1999Assignee: McDonnell Douglas CorporationInventors: Kevin T. Slattery, Daniel E. Driemeyer
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Patent number: 5874168Abstract: There is provided a fluorocarbon compound-hydrogen storage alloy composite which has a sufficient water-repellent property and can efficiently absorb a hydrogen gas. The composite comprises hydrogen storage alloy particles which have a plated metal film covering at least a part of the particles, the plated metal film containing at least one fine particle of a fluorocarbon compound. Examples of the metal used for plating include Ni, Cu, Co, Ni-P, Ni-W, Ni-W-P, Ni-B, Ni-W-B, Cu-Ni, Cu-P, Co-P, Co-B, and Co-W. Polytetrafluoroethylene is preferably used for the fluorocarbon compound. The fluorocarbon compound hydrogen storage alloy composite is prepared by electrolytically plating the hydrogen storage alloy particles in a pyrophosphate bath with fine particles of a fluorocarbon compound dispersed therein.Type: GrantFiled: August 1, 1996Date of Patent: February 23, 1999Assignee: Kiyokawa Plating Industries, Co., Ltd.Inventors: Hajime Kiyokawa, Masayuki Takashima, Susumu Yonezawa
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Patent number: 5863670Abstract: A joint of Ti--Al intermetallic compounds, comprising a plurality of base members made of a Ti--Al intermetallic compound and having Ti--Al lamellar grains, and a junction provided between the base members, made of a Ti--Al intermetallic compound and having Ti--Al lamellar grains, wherein some of the lamellar grains of the junction extend into the base members, and some of the lamellar grains of each base member may extend into the junction or pass through the junction into the other base member.Type: GrantFiled: April 18, 1996Date of Patent: January 26, 1999Assignee: NHK Spring Co., Ltd.Inventors: Kohei Taguchi, Michihiko Ayada
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Patent number: 5864743Abstract: A method for making multi-channel structures suitable for use as filters, catalyst carriers or the like. A composite rod comprising an outer shell and an inner core is formed of respective mixtures of powders. The mixture for the outer shell comprises a sinterable powdered structural material such as ceramics, metals, intermetallics, and a powdered binder. The inner core comprises a powdered carbon channel-forming filler material such as graphite or amorphous carbon, and a powdered binder. The composite rod may be deformed, as by extrusion, to reduce its diameter. A bundle of composite rods is assembled and deformed, as by extrusion, to reduce the diameter of the bundle and of its component composite rods. Further bundles of the reduced diameter bundles of composite rods may be likewise deformed by extrusion to reduce further the diameter of the component composite rods of the successive bundles, thereby also increasing the number of such rods per given cross section area of the bundle.Type: GrantFiled: November 6, 1996Date of Patent: January 26, 1999Assignee: Materials and Electrochemical Research (MER) CorporationInventors: Lev J. Tuchinskiy, Robert A. Mallia
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Patent number: 5848351Abstract: The porous metallic material of the present invention has an overall porosity of 80 to 99%, and a skeleton in a three dimensional network structure which is entirely composed of a sintered metal powder having a porosity of 10 to 60%. The specific surface area is very high, for example, 300 to 11000 cm.sup.2 /cm.sup.3. The porous metallic material can be reinforced by a reinforcing plate. The porous metallic material is also suitable for an electrode of an alkaline secondary battery and enables achievement of increases in the life and the amount of the active material contained therein. The porous metallic material can be produced by preparing a foamable slurry containing a metal powder, forming the foamable slurry, drying the formed product, preferably after foaming, and finally burning the dry formed product.Type: GrantFiled: March 10, 1997Date of Patent: December 8, 1998Assignee: Mitsubishi Materials CorporationInventors: Kouji Hoshino, Yoshitaka Mayuzumi, Tohru Kohno, Norikazu Komada
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Patent number: 5846664Abstract: A process is provided for the manufacture of porous metal components. The process involves preparing a colloidal suspension comprising a metal-containing powder in admixture with a binder system, and a plasticizer in an organic solvent. Optionally, a particulate pore forming agent may be added to the suspension. The suspension is cast into a thin sheet and air dried to thereby form a tape. The tapes are layered and formed by compacting at predetermined pressures to laminate the tapes, thus forming a green body. Optionally, a second pore-forming agent may be introduced between, or associated with, the tape layers. The green body is heated at a controlled rate to form a brown body, and finally sintered under controlled conditions to produce the finished component.Type: GrantFiled: January 6, 1997Date of Patent: December 8, 1998Assignee: Westaim Technologies, Inc.Inventors: Christine E. Third, Stephen F. J. Corbin, Prasad S. Apte
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Patent number: 5759227Abstract: A valve seat for an internal combustion engine provided with a base member, wherein said base member comprises; a matrix of iron-based alloy comprising (a) carbon in a range of 0.5-1.5 weight % based on weight of said base member, (b) at least one element selected from a group consisting of nickel, cobalt and molybdenum in a range of 2.0-20.0 weight % in total based on weight of said base member and (c) iron as a remainder; cobalt-based hard particles dispersed in said matrix in a range of 26-50 weight % based on weight of said base member.Type: GrantFiled: February 24, 1997Date of Patent: June 2, 1998Assignees: Nippon Piston Ring Co., Ltd., Honda Giken Kogyo K.K.Inventors: Teruo Takahashi, Toshiaki Sato
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Patent number: 5732322Abstract: The disclosure describes a resin composition for a sliding member, comprising 1 to 25 wt % of component A selected from the group consisting of phosphates and barium sulfate, 1 to 15 wt % of component B selected from the group consisting of magnesium silicate and mica, and 5 to 50 wt % of component C selected from the group consisting of lead, tin, lead-tin alloy and mixtures thereof, the balance of polytetrafluoroethylene.Type: GrantFiled: May 22, 1995Date of Patent: March 24, 1998Assignee: Oiles CorporationInventors: Takashi Nakamaru, Sumihide Yanase, Akihiko Okimura
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Patent number: 5710382Abstract: Aluminum nitride powder, aluminum nitride platelets, powdered solid solutions of aluminum nitride and at least one other ceramic material such as silicon carbide, and composites of aluminum nitride and transition metal borides or carbides are prepared by combustion synthesis at low gaseous nitrogen pressures. Porous bodies of aluminum nitride or composites of aluminum nitride and transition metal borides or carbides are also prepared by combustion synthesis at these pressures. The porous bodies are suitable for infiltration, either as formed or after being coated with at least one layer of a silicate material, by polymers or metals. The powders are also suitable for preparing dense sintered bodies. The aluminum nitride powder is also used to prepare AlN sintered bodies.Type: GrantFiled: January 31, 1996Date of Patent: January 20, 1998Assignee: The Dow Chemical CompanyInventors: Stephen D. Dunmead, William G. Moore, Kevin E. Howard, Kevin C. Morse, Theresa A. Guiton
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Patent number: 5683797Abstract: The present invention is a method for manufacturing inorganic membranes which are capable of separating oxygen from oxygen-containing gaseous mixtures. The membranes comprise a porous composite of a thin layer of a multicomponent metallic oxide which has been deposited onto a porous support wherein the pores of the multicomponent metallic oxide layer are subsequently filled or plugged with a metallic-based species. The inorganic membranes are formed by depositing a porous multicomponent metallic oxide layer onto the porous support to form a porous composite having a network of pores capable of transporting gases. The network of pores are plugged or filled by organometallic vapor infiltration to form an inorganic membrane having essentially no through porosity.Type: GrantFiled: March 19, 1996Date of Patent: November 4, 1997Assignee: Air Products and Chemicals, Inc.Inventors: Michael Francis Carolan, Paul Nigel Dyer, Stephen Mark Fine, Alexander Makitka, III, Robin Edward Richards, Leslie Errol Schaffer
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Patent number: 5654106Abstract: A method of making an article by joining together at least two porous components is described, the method comprising the steps of making at least two generally tubular PM components to be joined in the axial direction, each component having an axial length less than that of the tubular article; the at least two components both having interconnected porosity and each having at least one mutual mating face; assembling the at least two components together so that the at least one mutual mating faces are in proximity to each other; placing an infiltrant material in the bore of the assembled components; heating the assembled components to melt the infiltrant material and cause it to infiltrate the interconnected porosity at least in the region of the mutual mating faces so as to cause the components to become bonded together by the infiltrant material. Examples of the manufacture of valve guides are given.Type: GrantFiled: March 20, 1995Date of Patent: August 5, 1997Assignee: Brico Engineering LimitedInventors: Charles Grant Purnell, Helen Ann Brownlie
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Patent number: 5652877Abstract: The present invention relates to alloys in which the essential constituent is aluminum, metal deposits produced from these alloys, substrates coated with these alloys and the applications of these alloys. The alloys of the present invention are characterized in thatthey have the following atomic composition (I):Al.sub.a Cu.sub.b Co.sub.b' (B,C).sub.c M.sub.d N.sub.e I.sub.f(I)a+b+b'+c+d+e+f=100, expressed as number of atoms, a.gtoreq.50, 0.ltoreq.b<14, 0.ltoreq.b'.ltoreq.22, 0<b+b'.ltoreq.30, 0.ltoreq.c.ltoreq.5, 8.ltoreq.d.ltoreq.30, 0.ltoreq.e.ltoreq.4, f.ltoreq.2, where M represents one or more elements chosen from Fe, Cr, Mn, Ni, Ru, Os, Mo, V, Mg, Zn and Pd; N represents one or more elements chosen from W, Ti, Zr, Hf, Rh, Nb, Ta, Y, Si, Ge and the rare earths; I represents the inevitable production impurities;and they contain at least 30% by mass of one or more quasicrystalline phases.Type: GrantFiled: April 5, 1995Date of Patent: July 29, 1997Assignee: Centre National de la RechercheInventors: Jean-Marie Dubois, Antoine Pianelli
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Patent number: 5649278Abstract: Aluminum nitride powder, aluminum nitride platelets, powdered solid solutions of aluminum nitride and at least one other ceramic material such as silicon carbide, and composites of aluminum nitride and transition metal borides or carbides are prepared by combustion synthesis at low gaseous nitrogen pressures. Porous bodies of aluminum nitride or composites of aluminum nitride and transition metal borides or carbides are also prepared by combustion synthesis at these pressures. The porous bodies are suitable for infiltration, either as formed or after being coated with at least one layer of a silicate material, by polymers or metals.Type: GrantFiled: September 26, 1995Date of Patent: July 15, 1997Assignee: The Dow Chemical CompanyInventors: Stephen D. Dunmead, William G. Moore, Kevin E. Howard, Kevin C. Morse
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Patent number: 5643683Abstract: A wet type sliding apparatus in which a multilayer sliding member is used in the presence of a lubricating oil, characterized in that the multilayer sliding member is composed of (1) a backing metal layer, (2) a porous, sintered layer provided thereon and (3) a surface layer consisting essentially of polyetheretherketone formed by impregnating and coating the porous, sintered layer with a sliding resin consisting essentially of polyetheretherketone. The above sliding member has a small friction coefficient and excellent wear resistance. In particular, the sliding noise can be more effectively inhibited by adjusting the face roughness of the surface layer of the sliding member to 2 .mu.m or less.Type: GrantFiled: January 24, 1996Date of Patent: July 1, 1997Assignee: Daido Metal Company Ltd.Inventors: Tadashi Tanaka, Hidehiko Tamura, Takahiro Niwa, Izumi Maruyama, Yoshihiro Fukutani
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Patent number: 5641817Abstract: This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds and sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat. Another preferred embodiment of the invention involves the fabrication of preforms used in the formation of composite articles.Type: GrantFiled: June 7, 1995Date of Patent: June 24, 1997Assignee: Lanxide Technology Company, LPInventors: Michael Kevork Aghajanian, Jonathan Wayne Hinton, Alexander Lukacs, III, James Allen Jensen, Marc Stevens Newkirk, Ratnesh Kumar Dwivedi
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Patent number: 5634189Abstract: A structural component is formed with an outer shell of sintered, solid, powder particles, and a porous core of sintered, hollow, bodies arranged in layers. The hollow bodies are of increased diameter in the layers in a direction from the outer periphery of the core towards the center of the core. The material of the outer shell and of the core is a metal or ceramic.Type: GrantFiled: November 14, 1994Date of Patent: May 27, 1997Assignee: Mtu Motoren-Und Turbinen Union Munchen GmbHInventors: Axel Rossmann, Wilfried Smarsly
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Patent number: 5590383Abstract: A porous membrane produced by preparing a slurry made from at least one micropyretic substance and at least one liquid carrier. The slurry is dried into a green form having a desired geometric configuration. Combustion of the green form produces the porous membrane.Type: GrantFiled: August 29, 1994Date of Patent: December 31, 1996Assignee: Micropyretics Heaters International, Inc.Inventors: Jainagesh A. Sekhar, James J. Liu, Naiping Zhu
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Patent number: 5580665Abstract: An article essentially consisting of one or more of Ti-Al intermetallic compounds is fabricated so as to have a volume ratio of voids no more than 3.5%, by preparing a mixture of materials selected from a group consisting of Ti, Ti alloys, Al, Al alloys, and Ti-Al compounds, having a composition suitable for forming a desired Ti-Al intermetallic compound, and heating said mixture so that said mixture may be sintered. Typically, the temperature and pressure for the heating or sintering process is appropriately selected so that the desired porosity may be obtained. The mechanical strength of an article according to the present invention is not only improved but is highly predictable, or, in other word, highly reliable. The fabrication costs can be reduced because the fabrication process involves only relatively low temperatures when pressing and heating the work at the same time.Type: GrantFiled: June 6, 1995Date of Patent: December 3, 1996Assignee: NHK Spring Co., Ltd.Inventors: Kohei Taguchi, Michihiko Ayada, Hideo Shingu
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Patent number: 5564064Abstract: A method for forming a gas-filled consolidated metal billet, involving preparing a metallic shell container, filling the shell with a metal core material and pressurized gas, and consolidating the shell and its contents to form the billet. The consolidated billet is further formed in the same manner as solid metal components by conventional wrought mill working technologies. After thus forming a shaped billet having a predetermined, desired geometry, it is subjected to a heat treatment that expands the gas trapped within the core, to produce in situ a metal body having an integral sandwich-type structure with a solid metal facing and a porous metal core.Type: GrantFiled: February 3, 1995Date of Patent: October 8, 1996Assignee: McDonnell Douglas CorporationInventor: Ricky L. Martin
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Patent number: 5529602Abstract: Disclosed is a sintered iron alloy and a method of manufacturing the same. The sintered alloy comprises: an alloy matrix and a lead phase for imparting lubricability to the sintered alloy. The alloy matrix comprises a first alloy phase being composed of 0.5 to 3% nickel by weight, 0.5 to 3% molybdenum by weight, 5.5 to 7.5% cobalt by weight, 0.6 to 1.2% carbon by weight, and the balance iron, and a second alloy phase being composed of 26 to 30% molybdenum by weight, 7 to 9% chromium by weight, 1.5 to 2.5% silicon by weight, and the balance cobalt. The content of the lead phase in the sintered alloy is not more than 3.5% by weight. The lead phase is dispersed in the alloy matrix and a pore which is formed in the alloy matrix. The ratio of the lead dispersed in the alloy matrix to the total lead phase is 60% by weight or more, and the lead phase dispersed in the alloy matrix is particles in which the maximum particle size is 10 .mu.m or less.Type: GrantFiled: February 22, 1995Date of Patent: June 25, 1996Assignees: Hitachi Powdered Metals Co., Ltd., Nissan Motor Co., Ltd.Inventors: Kei Ishii, Yoshimasa Aoki, Hideaki Kawata, Akira Fujiki, Katsuyuki Nakamura, Kazuhiko Takahashi
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Patent number: 5523183Abstract: A battery electrode is provided comprising a porous, pleated metal structure, preferably comprising nickel as its substrate.Type: GrantFiled: October 18, 1994Date of Patent: June 4, 1996Assignee: Pall CorporationInventors: Paul C. Koehler, Stephen Geibel, Ralph B. Di Palma
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Patent number: 5516592Abstract: A method for preparing foamed aluminum alloy composites comprising the steps of: (a) placing a liquid hardness-reinforcement composition into a tank, the hardness-reinforcement composition containing about 54.about.64 wt. % of an inorganic powder, about 35.about.45 wt. % of a nonflammable curable resin, and about 1 wt. % of a curing agent; (b) placing a foamed aluminum alloy plate having an internal porous body into the tank containing the hardness-reinforcement composition, then applying a pressure of about 10.about.50 Kg/cm.sup.2 onto the foamed aluminum alloy plate for about one to two hours so as to allow the hardness-reinforcement composition to soak into the foamed aluminum alloy plate and form a coated layer on the surface of the porous body; (c) removing the foamed aluminum alloy plate that has been coated with a layer of the hardness-reinforcement composition from the tank; and (d) drying and curing the curable nonflammable resin so as to form the foamed aluminum alloy composite.Type: GrantFiled: January 20, 1995Date of Patent: May 14, 1996Assignee: Industrial Technology Research InstituteInventors: Chin-Chan Yang, Kou-Chang Su, Wen-Chi Chen, Shan-Chang Chueh
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Patent number: 5508114Abstract: A method of manufacturing a lead-provided porous metal sheet comprises the steps of: forming a porous metal material having a metal layer on a surface of a framework of a porous base material comprising a foamed sheet and the like, by plating the porous base material and/or applying fine metal powders thereto; passing the porous metal material through a pair of rolls having a plurality of projections formed thereon to compress the porous metal material against the projections and reduce or eliminate pores so as to form one or more recesses extending; and forming solid metal portions by applying fine metal powders to the entire recesses.Type: GrantFiled: December 9, 1994Date of Patent: April 16, 1996Assignee: Katayama Special Industries, Inc.Inventor: Hirofumi Sugikawa
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Patent number: 5507879Abstract: In a fine structure of a thermoelectric material, fine particles of a material exhibiting Seebeck effect are electrically linked in a loosely contacted state with one another without fusing, having spaces formed at clearances among the fine particles. A method of manufacturing the thermoelectric material comprises a step of compacting fine particles made of a material exhibiting Seebeck effect through a cold pressing. Also, disclosed is a sensor for quantitatively sensing a substance, which comprises a pellet of a powder thermoelectric material, where a temperature difference is generated between two points inside the piece of thermoelectric material. The sensor further includes thermocouples connected to a heater plate (6) and a cooling plate, and a controller which is electrically connected in the loop circuit of the thermocouples for detecting thermoelectric current corresponding to the temperature difference, thereby to control the heating of the heater plate.Type: GrantFiled: June 8, 1993Date of Patent: April 16, 1996Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Hisaaki Gyoten, Yasushi Nakagiri, Yoshiaki Yamamoto
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Patent number: 5470636Abstract: A magnetic recording medium having a substrate made of aluminum or aluminum alloy and an anodic-oxide film, e.g., alumite film, formed by effecting the anodic oxidation process, wherein the surface of the alumite film has protruding portions formed in addition to micro-irregularities which are formed in response to the cell-pore structure of the alumite film and height of the protruding portions is higher than that of the micro-irregularity, and density of the protruding portions is ranging from 10.sup.2 to 10.sup.7 per one square millimeter, these protruding portions are formed by processing the alumite film in the fluorine-contained solution (e.g., hydrofluoric acid) or in solution containing one of the acid (HCl), base (NaOH) and strong-acid salt ((NH.sub.4)SO.sub.4), Cr film and magnetic film are sequentially formed on the alumite film by the sputtering process.Type: GrantFiled: March 13, 1992Date of Patent: November 28, 1995Assignee: Yamaha CorporationInventors: Yukio Wakui, Yoshiki Nishitani, Kenichi Miyazawa
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Patent number: RE35367Abstract: A dental material of a metal composition for reinforcing the metal framework of a dental restoration comprising an aggregate combination of metal particles including a first high fusing temperature precious metal component and a second low fusing temperature component which form a porous sponge-like structure upon heat treatment.Type: GrantFiled: March 5, 1993Date of Patent: October 29, 1996Inventors: Itzhak Shoher, Aharon Whiteman