Embodying Fibers Interengaged Or Between Layers (e.g., Paper, Etc.) Patents (Class 428/608)
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Patent number: 5198308Abstract: A femoral component of a knee prosthesis, including a cobalt-based alloy substrate and a titanium fiber metal pad bonded thereto by means of an interlayer of a cobalt-based alloy including nickel. More specifically, a method of bonding a titanium porous surface to a cobalt-based alloy in an orthopaedic implant device, by first applying an interlayer of a cobalt-based alloy including nickel to the substrate and then bonding a porous structure to the interlayer. In one embodiment, an interlayer of L-605 is first applied to a substrate of Co-Cr-Mo by diffusion bonding at approximately 2200.degree. F. and then a fiber metal pad of CP-titanium is diffusion bonded to the interlayer at approximately 1650.degree. F. A layer of CP-titanium may optionally be placed intermediate the fiber metal pad and interlayer before the second diffusion step. In an alternative embodiment, MP-35N alloy may be substituted for the L-605 alloy.Type: GrantFiled: December 21, 1990Date of Patent: March 30, 1993Assignee: Zimmer, Inc.Inventors: H. Ravindranath Shetty, Mark A. Heldreth, Jack E. Parr
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Patent number: 5192624Abstract: The improved sound absorbing material comprises an aluminum base expanded metal (or an aluminum base metal screen) which is laminated with an aluminum base metal foil (or a thin resin film), or additionally with an aluminum base metal fiber layer. The aluminum base metal foil (or thin resin film) has ruptures, which vibrate in the process of sound absorption to permit the sound absorbing material to exhibit excellent sound-absorbing characteristics over a broad frequency range. The improved sound absorbing material can be produced by a process which comprises the steps of preparing a laminate comprising the members described above and pressing the laminate so that the individual members are compressed together while forming ruptures in a regular pattern in the aluminum base metal foil (or thin resin film).Type: GrantFiled: April 12, 1991Date of Patent: March 9, 1993Assignee: Unix Corporation Ltd.Inventor: Toru Morimoto
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Patent number: 5173367Abstract: Fiber-reinforced ceramic composites are obtained by the use of a prepreg comprising sized carbon fibers bonded together with a matrix composition which comprises about 25-60% by weight of a polysilazane and about 75-40% by weight of at least two ceramic powders selected from silicon metal, silicon carbide and silicon boride powders.Type: GrantFiled: January 15, 1991Date of Patent: December 22, 1992Assignee: Ethyl CorporationInventors: Eric W. Liimatta, William E. Moehle, Conrad J. Langlois, Jr.
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Patent number: 5116438Abstract: A beta phase nickel aluminide microalloyed with gallium having improved ductility. Nickel aluminide intermetallics alloyed with up to about 0.25 atomic percent gallium have significantly improved room temperature ductility over conventional unalloyed beta phase nickel aluminides or beta phase nickel aluminides alloyed with higher percentages of gallium.Type: GrantFiled: March 4, 1991Date of Patent: May 26, 1992Assignee: General Electric CompanyInventors: Ramgopal Darolia, David F. Lahrman
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Patent number: 5098795Abstract: The invention comprises new materials useful in a wide variety of terrestrial and space applications. In one aspect, the invention comprises a flexible cloth-like material comprising a layer of flexible woven ceramic fabric bonded with a layer of metallic foil. In another aspect, the invention includes a flexible fluid impermeable barrier comprising a flexible woven ceramic fabric layer having metal wire woven therein. A metallic foil layer is incontinuously welded to the woven metal wire. In yet another aspect, the invention includes a material comprising a layer of flexible woven ceramic fabric bonded with a layer of an organic polymer. In still another aspect, the invention includes a rigid fabric structure comprising a flexible woven ceramic fabric and a resinous support material which has been hardened as the direct result of exposure to ultraviolet light. Inventive methods for producing such material are also disclosed.Type: GrantFiled: August 10, 1988Date of Patent: March 24, 1992Assignee: Battelle Memorial InstituteInventors: Brent J. Webb, Zen I. Antoniak, John T. Prater, John G. DeSteese
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Patent number: 5096739Abstract: A novel method is presented for synthesizing ultrafine fiber composite materials by laser induced coevaporation of a metallic target and a ceramic target in the presence of a heated tungsten filament, within a reducing environment. The species produced by rapid condensation from the resultant laser plume, along with the products derived from the chemical transport reactions involving the heated filament, form layers of composite material comprising a metal matrix and a random weave fiber network. In a preferred embodiment of the present invention, composite layers are formed on a nickel alloy substrate surface at a rate of about 1 micron per second. The matrix of the composite films is either aluminum or tungsten and the dispersed phase is amorphous silica fibers. The diameter of the fibers are between 25 and 120 nm depending on the laser beam materials interaction time.Type: GrantFiled: November 27, 1989Date of Patent: March 17, 1992Assignee: The University of ConnecticutInventors: Peter R. Strutt, Gan-Moog Chow
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Patent number: 5089356Abstract: A solder joint between two surfaces comprising an intermediate composite solder preform, said preform comprising metal coated carbon fibers contained in a metal matrix, said fibers comprising from 2 to 80 percent by volume of the composite, said metal matrix melting at a temperature below 600.degree. C. and containing at least 15 weight percent tin.Type: GrantFiled: September 17, 1990Date of Patent: February 18, 1992Assignee: The Research Foundation of State Univ. of New YorkInventor: Deborah D. L. Chung
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Patent number: 5080963Abstract: A new class of composites results from a matrix of carbon fibers, including graphite fibers, interwoven in a network of fused metal fibers. The composites can be fabricated to have varying surface area, void volume, and pore size while maintaining high electrical conductivity. Composites are readily prepared from a preform of a dispersion of carbon fibers, metal fibers, and an organic binder such as cellulose, by heating the preform at a temperature sufficient to fuse the metal fibers and to volatilize at least 90% of the binder with a loss of less than about 25%, and usually under 10%, by weight of carbon fiber.Type: GrantFiled: May 24, 1989Date of Patent: January 14, 1992Assignee: Auburn UniversityInventors: Bruce J. Tatarchuk, Millard F. Rose, Aravamuthan Krishnagopalan, John N. Zabasajja, David A. Kohler
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Patent number: 5035484Abstract: A surface of an optical fiber is coated by a method for coating a surface of an optical fiber with carbon comprising steps of introducing an optical fiber in a reaction chamber containing a coating raw material comprising carbon, hydrogen and halogen atoms and depositing on the surface of the optical fiber a carbon layer formed from the raw material by chemical vapor deposition, whereby the coated optical fiber has improved initial tensile strength and absorbs less hydrogen.Type: GrantFiled: December 21, 1989Date of Patent: July 30, 1991Assignee: Sumitomo Electric Industries, Ltd.Inventors: Yoichi Ishiguro, Masaharu Ooe, Kohei Kobayashi, Gotaro Tanaka, Minoru Watanabe
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Patent number: 5028490Abstract: The present invention provides a discontinuous metal/polymer composite, with a metal layer, formed from a plurality of fine metal strands, which may be used, for example, in static or EMI shielding. The metal layer comprises a plurality of fine metal strands provided on the substrate, the metal strands individually having a cross-section with an area of about 100 to 100,000 .mu.m.sup.2 and the cross-section of the individual metal strands having a flat portion and an arcuate portion. The metal and polymer may be selected so that the composite is capable of being thermoformed without loss of electrical conductivity or transparency.Type: GrantFiled: November 14, 1988Date of Patent: July 2, 1991Assignee: Minnesota Mining and Manufacturing Co.Inventors: David C. Koskenmaki, Clyde D. Calhoun, Brett E. Huff
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Patent number: 4987034Abstract: Disclosed herein is an exhaust gas cleaning device which is suitable for arrangement at an intermediate point in an exhaust gas system of an automotive vehicle and has good efficiency. The exhaust gas cleaning device includes a metal-made carrier body for an exhaust gas cleaning catalyst. The carrier body is composed of a multi-layered composite body by superposing one over the other at least one planar metal band made of a thin metal sheet and at least one corrugated metal band made of another thin metal sheet and defining many network-patterned gas flow passages along a central axis thereof to allow an exhaust gas to axially flow as streams through the gas flow passages. At least one of the bands defines many holes and many raised portions, preferably, ridges around or near the respective holes. As an alternative, at least one of the bands is made of a metal wire net.Type: GrantFiled: April 4, 1990Date of Patent: January 22, 1991Assignee: Usui Kokusai Sangyo Kabushiki KaishaInventors: Yuzo Hitachi, Kazunori Takikawa
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Patent number: 4973521Abstract: Bonding pressure is uniformly applied to the lay-up (70) of a bonded product (10) by the disposition of flexible, compressible, perforated sheet material (85) within the lay-up during the manufacture of the product by diffusion bonding.Type: GrantFiled: July 21, 1988Date of Patent: November 27, 1990Assignee: United Technologies CorporationInventors: John M. Graff, Leon Stoltze
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Patent number: 4968550Abstract: An indium-metal braid-indium sandwich is formed by applying indium ribbons to upper and lower surfaces of a metal braid and then working the sandwich, e.g., between rollers. The resulting product has enhanced tensile strength and stiffness, yet retains the attributes of indium for application as a gasket, gland, or seal.Type: GrantFiled: April 20, 1989Date of Patent: November 6, 1990Assignee: Indium Corporation of AmericaInventor: Paul A. Socha
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Patent number: 4933240Abstract: A wear-resistant surface structure having a high resistance to impact and thermal shock, suitable for a wide variety of tools and implements, is prepared by bonding carbide particles together with a substantially pure copper matrix in the absence of oxygen. The carbide-copper surface structure can be bonded to the working surface of a ferrous tool simultaneously with the aforementioned bonding process, or at a later time. Although attachment of the surface structure to a ferrous tool normally requires heating of the tool to a softening temperature, such softening may be corrected by subsequently quenching the combined ferrous tool and carbide-copper surface structure from an austenitizing temperature without cracking the copper matrix. Refractory sheet materials are used to contain the carbide and matrix material during liquefaction of the matrix material during the formation of the surface structure.Type: GrantFiled: October 26, 1987Date of Patent: June 12, 1990Inventor: William R. Barber, Jr.
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Patent number: 4927683Abstract: A color-bearing textile product which comprises fibers, a silver-gray metal layer formed on the surface of said fibers by sputtering, and a metal layer or metal compound layer of chromatic color formed on the surface of said metal layer by sputtering. The silver-gray metal layer is, for example, formed of titanium. The metal layer or metal compound layer of chromatic color is, for example, formed of gold, silver, copper, brass, or titanium nitride.Type: GrantFiled: November 19, 1987Date of Patent: May 22, 1990Assignee: Toyoda Gosei Co., Ltd.Inventor: Masatoshi Tsutsui
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Patent number: 4904541Abstract: A mesh for incorporation in a seat cushion, the mesh having a plurality of wire lengths with each wire length being wound to follow a generally helical path so that each wire provides a plurality of convolutions, the mesh being provided with mesh parameters so as to inhibit penetration and cutting.Type: GrantFiled: November 2, 1988Date of Patent: February 27, 1990Assignee: Hunter Wire Products LimitedInventor: Terry Askew
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Patent number: 4900599Abstract: An improved method of forming an article includes providing continuous woven, flat, helical tape of filaments and a continuous flat, helical tape of foil. The two helical tapes are interleaved to form a helical assembly having turns of filaments alternating with turns of foil. Deformation forces are applied against the turns of the helical assembly in a direction parallel to the central axis of the helix to bond the turns of the tapes of foil and filament together while maintaining the filaments free of axially extending forces. During the bonding of the turns of the helical foil and filament tapes, the tapes may be bonded to a housing or other component of an article to be reinforced. Radial reinforcing can be provided by including in the helical assembly a layer having filaments with central axes which are radial relative to the central axes of the filaments of the helical tape.Type: GrantFiled: February 1, 1988Date of Patent: February 13, 1990Assignee: Airfoil Textron Inc.Inventor: Gordon S. Doble
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Patent number: 4865933Abstract: A high tensile strength fibrous material is coated with an extruded, corrosion-resistant metal to form a composite wire which is used in the formation of a grid element for a battery.Type: GrantFiled: May 23, 1988Date of Patent: September 12, 1989Inventors: Richard J. Blanyer, Charles L. Mathews
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Patent number: 4863807Abstract: A multi-layered insulating piston cap for cast metal pistons having an insulating, perforated metal sheet layer. A piston cap is provided having a top sheet continuous layer made of a heat and corrosion resistant metal for protecting the piston cap, a second layer made of heat and corrosion resistant metal sheet having a plurality of spaced apart perforations for providing trapped air spaces, a third layer made of a heat and corrosion resistant metal foil for sealing the perforations, and a fourth layer or porous, heat and corrosion resistant metal for anchoring the piston cap to the piston. One coined geometry can be used when blanking various sized cross-sections of piston cap.Type: GrantFiled: September 19, 1988Date of Patent: September 5, 1989Assignee: Facet Enterprises, Inc.Inventor: Stephen Krasicky, Jr.
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Patent number: 4837053Abstract: Filaments are coated with MgO to create an effective diffusion barrier between the filament and the matrix in a metal matrix composite, thereby improving the strength and the service life of the composite.Type: GrantFiled: August 23, 1988Date of Patent: June 6, 1989Assignee: The Aerospace CorporationInventors: Wei H. Kao, Howard A. Katzman, Eric M. Slater
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Patent number: 4834693Abstract: A high specific modulus shaft for use in a dynamic assembly such as a gas turbine engine is constructed having a metal outer tubular shaft to transmit the torque and an interior shaft constructed of a metal and high modulus filament composite material bonded to the inner diameter of the outer shaft. The outer shaft may be constructed of steel or titanium or superalloy such as Inconel 718. The inner shaft may be constructed of an aluminum matrix in which multiple boron filaments are embedded in axial alignment or of a titanium matrix in which boron filaments coated with silicon carbide or boron carbide are similarly embedded.Type: GrantFiled: August 17, 1987Date of Patent: May 30, 1989Assignee: Avco CorporationInventors: Daniel D. Profant, Jeremy J. Walters
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Patent number: 4830932Abstract: Light alloy articles comprising a body of light alloy having a composite layer of heat-resistant fibers and light alloy and bonded to said body, and a surface layer of heat-resisting alloy sprayed onto said composite layer exhibit improved integrity and heat resistance when the heat-resisting alloy is plasma sprayed onto one surface of a preform of fibers and the light alloy is then cast to the opposite surface of the preform such that an interfacial layer is defined between the composite layer and the surface layer in which the fibers and light alloy are integrally incorporated with the heat-resisting alloy.Type: GrantFiled: June 15, 1988Date of Patent: May 16, 1989Assignee: Toyota Jidosha Kabushiki KaishaInventors: Tadashi Donomoto, Atsuo Tanaka, Yoshiaki Tatematsu
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Patent number: 4828932Abstract: A porous metallic material of the present invention is constructed of a laminate consisting of an expanded metal and a fibrous metallic fiber both of which are pressed to be joined to each other under pressure. This porous metallic material is excellent in bending strength and workability. The porous metallic materials may be laminated to a honeycomb structural element and a rigid plate so as to form a porous structural material. To this porous metallic material may be also laminated a decorative layer so as to form a porous decorative sound absorbing material. The present invention provides the above-mentioned products and method for manufacturing the same.Type: GrantFiled: May 11, 1987Date of Patent: May 9, 1989Assignees: Unix Corporation Ltd., Toru MorimotoInventors: Toru Morimoto, Fumihiro Nakagawa
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Patent number: 4817853Abstract: In order to accommodate post-manufacturing, or secondary operations in precision assemblies using composite materials, where the secondary operations consist of drilling, machining, grinding, lapping, or other material-removing processing, without the need to resort to expensive diamond tooling and while maintaining needed structural integrity, a composite formed of a base material, a matrix, and a machineable material is provided. The matrix is bonded to the base material and the machineable material is rendered integral with the matrix and sufficiently thick to accommodate subsequent material-removing processing to a precision dimension.Type: GrantFiled: November 26, 1986Date of Patent: April 4, 1989Assignee: Sundstrand CorporationInventors: John F. Scanlon, Thomas A. Bolgert, David W. Okey, William D. Sherman
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Patent number: 4816347Abstract: A combination of unique properties of (i) high strength and stiffness at temperatures up to about of 1500.degree. F., (ii) good room temperature mechanical properties including good ductility and (iii) improved resistance to matrix cracking is achieved in a titanium structure by forming a hybrid titanium alloy matrix composite in which the matrix consists of layers of at least two alloys, i.e. a high temperature-resistant titanium aluminide alloy and a ductile, lower modulus titanium alloy, that are bonded metallurgically to each other in various embodiments. A reinforcing material in the form of filaments, fibers or wiskers, e.g. silicon carbide, can be embedded within either or both types of the titanium layers.Type: GrantFiled: May 29, 1987Date of Patent: March 28, 1989Assignee: Avco Lycoming/Subsidiary of Textron, Inc.Inventors: Dan G. Rosenthal, Joseph A. Goebel
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Patent number: 4792645Abstract: Disclosed herein is a process for producing electroconductive fibrous shaped-articles comprising the steps of:soaking water-absorptive fibrous shaped-articles in a palladium hydrosol containing a cationic surfactant, an anionic surfactant, a non-ionic surfactant or a mixture thereof, and after (i) drying the thus treated shaped-articles, (ii) washing the thus treated shaped-articles with water or (iii) washing the thus treated shaped-articles and then drying, subjecting the thus obtained, shaped-articles on which colloidal palladium is adsorbed to chemical plating, thereby obtaining the electroconductive fibrous shaped-articles of which fibers thereof are subjected to metallizing plating.Type: GrantFiled: August 28, 1985Date of Patent: December 20, 1988Assignees: The Agency of Industrial Science & Technology, Toda Kogy Corp.Inventors: Yukimichi Nakao, Kyoji Kaeriyama, Yoshio Suda, Tomoyuki Imai, Osamu Oze, Nanao Horiishi
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Patent number: 4782992Abstract: An improved method of forming an article includes providing continuous, woven, flat, helical tape of filaments and a continuous flat, helical tape of foil. The two helical tapes are interleaved to form a helical assembly having turns of filaments alternating with turns of foil. Deformation forces are applied against the turns of the helical assembly in a direction parallel to the central axis of the helix to bond the turns of the tapes off oil and filament together while maintaining the filaments free of axially extending forces. During the bonding of the turns of the helical foil and filament tapes, the tapes may be bonded to a housing or other component of an article to be reinforced. Radial reinforcing can be provided by including in the helical assembly a layer having filaments with central axes which are radial relative to the central axes of the filaments of the helical tape.Type: GrantFiled: November 21, 1986Date of Patent: November 8, 1988Assignee: Textron Inc.Inventor: Gordon S. Doble
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Patent number: 4759994Abstract: A sandwich-type structure comprises two external metal plates and an inner core held between the two external plates and constituted by a metallic screen netting or grid. In order to be easily stamped said structure comprises, between the plates, a layer of adhesive making the bond between the plates and the core. This adhesive is located only inside the meshes of the core, whereas the contact zones between the core and the plates are left free of adhesive. In the case where all three elements are in weldable metal, spot welding remains possible, if necessary, on the periphery or through the mass, these weld points being in this latter case sufficiently far apart to allow a geometrical deformation of the meshes of the metallic netting or grid constituting the core.Type: GrantFiled: July 28, 1986Date of Patent: July 26, 1988Inventor: Hugues Lesourd
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Patent number: 4755313Abstract: Insulating device for high and low temperatures with at least one insulating material, characterized by the feature that the insulating material is formed at least in part of total reflecting fibers.Type: GrantFiled: August 8, 1985Date of Patent: July 5, 1988Assignee: Brown, Boveri & Cie AGInventors: Georg Wahl, Franz Schmaderer, Cord-Henrich Dustmann, Harald Reiss, Botho Ziegenbein
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Patent number: 4753850Abstract: A fiber reinforced metal laminate and method of preparation. The metal layers are of aluminum or aluminum alloy. An aluminum containing solder layer is disposed on inner surfaces of the metal layers. The fibers are silicone-carbide, boron or silicon-carbide coated boron and located between the solder layers. These layers are heated under pressure to a temperature above the melting point of the solder and below the melting point of the metal layer.Type: GrantFiled: September 30, 1987Date of Patent: June 28, 1988Assignee: Vereingte Aluminium -Werke A.G.Inventors: Gerhard Ibe, Wolfgang Gruhl
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Patent number: 4697324Abstract: This invention includes a continuous in-plane spiral of monofilament/metallic ribbon which forms a preform for metal matrix composite fabrication. The purpose is to provide continuous spiral filament reinforcement around a hole or central core. This spiral monolayer is fabricated by co-winding the filament and a ribbon or wire made from the intended composite material around a mandrel. Monolayers so constructed could then be stacked to form cylindrical or torus-shaped components and consolidated in a direction parallel to the axis of the shape.Type: GrantFiled: December 6, 1984Date of Patent: October 6, 1987Assignee: Avco CorporationInventors: William F. Grant, Gary W. Burt, Albert J. Kumnick
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Patent number: 4629397Abstract: A structural component which is coolable for use under high thermal load conditions, such as a turbine blade, has a metallic support core with cooling ducts separated by lands in its surface. The core and its cooling ducts and lands are enclosed by an inner layer of metal felt and an outer layer of heat insulating ceramic material which partially penetrates into the metal felt to form a bonding zone between the felt and the ceramic material. Thus, any heat passing through the ceramic layer is introduced into the large surface area of the metal felt enabling the latter to efficiently introduce the heat into a cooling medium flowing in the ducts, thereby preventing thermal loads from adversely affecting the metal core to any appreciable extent.Type: GrantFiled: July 2, 1984Date of Patent: December 16, 1986Assignee: MTU Motoren-und Turbinen-Union Muenchen GmbHInventor: Klaus Schweitzer
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Patent number: 4622270Abstract: An inorganic fiber-reinforced metallic composite material comprising a matrix of a metal or its alloy and inorganic fibers as a reinforcing material, characterized in that(a) the inorganic fibers are inorganic fibers containing silicon, either titanium or zirconium, nitrogen and oxygen and being composed of(i) an amorphous material consisting substantially of Si, M, N and O, or(ii) an aggregate consisting substantially of ultrafine crystalline particles with a particle diameter of not more than 500 .ANG. of Si.sub.2 N.sub.2 O, MN, Si.sub.3 N.sub.4 and/or MN.sub.1-x, and amorphous SiO.sub.2 and MO.sub.2, provided that in the above formulae, M represents titanium or zirconium, and x is a number represented by 0<x<1, or(iii) a mixture of the amorphous material (i) and the aggregate (ii), and(b) said metal is selected from the group consisting of aluminum, magnesium, and titanium, or(c) said alloy is selected from the group consisting of aluminum alloys, magnesium alloys and titanium alloys.Type: GrantFiled: November 1, 1985Date of Patent: November 11, 1986Assignee: Ube Industries, Ltd.Inventors: Takemi Yamamura, Masahiro Tokuse, Teruhisa Furushima
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Patent number: 4614690Abstract: An inorganic fiber-reinforced metallic composite material comprising a matrix of a metal or its alloy and inorganic fibers as a reinforcing material, characterized in that(a) the inorganic fibers are inorganic fibers containing silicon, either titanium or zirconium, carbon and oxygen and being composed of(i) an amorphous material consisting substantially of Si, M, C and O, or(ii) an aggregate consisting substantially of ultrafine crystalline particles with a particle diameter of not more than 500 .ANG. of .beta.-SiC, MC, a solid solution of .beta.-SiC and MC and MC.sub.1-x, and amorphous SiO.sub.2 and MO.sub.2, provided that in the above formulae, M represents titanium or zirconium, and x is a number represented by 0<x<1, or(iii) a mixture of the amorphous material (i) and the aggregate (ii),(b) the inorganic fibers have an initial degradation speed of not more than about 0.3 kg/mm.sup.2.sec.sup.Type: GrantFiled: April 16, 1985Date of Patent: September 30, 1986Assignee: UBE Industries, Ltd.Inventors: Takemi Yamamura, Masahiro Tokuse, Yoshiharu Waku
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Patent number: 4601955Abstract: In construction of a composite material for decorative applications such as eyeglass frames, adjusted addition of whiskers to metal matrix provides the product with light weight, rich anticorrosion, high strength and, rich elasticity. Additional core-to-sheath cladding further improves workability without any influence on the light weight characteristics.Type: GrantFiled: July 17, 1985Date of Patent: July 22, 1986Assignee: Nippon Gakki Seizo Kabushiki KaishaInventors: Kazuo Kurahashi, Nobutoshi Onodera
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Patent number: 4601956Abstract: This composite material includes reinforcing hybrid fiber mixture material in a matrix of metal which is aluminum, magnesium, copper, zinc, lead, tin, or an alloy having these as principal components. The hybrid fiber mixture is a mixture of amorphous alumina-silica fiber material and mineral fiber material. The amorphous alumina-silica fiber material has as principal components 35% to 80% by weight of Al.sub.2 O.sub.3 and 65% to 20% by weight of SiO.sub.2, with a content of other substances of less than or equal to 10% by weight, with the percentage of non fibrous particles included therein being less than or equal to about 17% by weight, and with the percentage of non fibrous particles with diameters greater than 150 microns being less than or equal to 7% by weight. And the mineral fiber material has as principal components SiO.sub.2, CaO, and Al.sub.2 O.sub.3, the content of MgO being less than or equal to 10% by weight, the content of Fe.sub.2 O.sub.Type: GrantFiled: May 16, 1985Date of Patent: July 22, 1986Assignee: Toyota Jidosha Kabushiki KaishaInventor: Tadashi Dohnomoto
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Patent number: 4600661Abstract: This composite material includes reinforcing carbon fibers and a matrix metal which is an alloy containing from 2% to about 8% by weight of Zn, less than about 2% by weight of Zr, less than about 1% by weight of Al, and balance substantially Mg. Thereby, the strength of the composite material is found to be substantially improved. Preferably, the content of Zn in the matrix metal may be from 3% to about 7.5% by weight, even more preferably this content of Zn in the matrix metal may be from 4.5% to about 7% by weight, and optimally it may be 6% by weight. Preferably, the content of Zr in the matrix metal is less than about 0.18% by weight, and preferably the content of Al in the matrix metal is less than about 0.6% by weight. The carbon fibers may desirably be high strength carbon fibers, i.e. carbon fibers which have low graphitization level.Type: GrantFiled: April 16, 1985Date of Patent: July 15, 1986Assignee: Toyota Jidosha Kabushiki KaishaInventors: Tadashi Dohnomoto, Atsuo Tanaka
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Patent number: 4595638Abstract: This composite material includes reinforcing hybrid fiber mixture material in a matrix of metal which is aluminum, magnesium, copper, zinc, lead, tin, or an alloy having these as principal components. The hybrid fiber mixture is a mixture of alumina fiber material and mineral fiber material. The alumina fiber material has principal components of at least about 80% by weight of Al.sub.2 O.sub.3 and remainder substantially SiO.sub.2. And the mineral fiber material has as principal components SiO.sub.2, CaO, and Al.sub.2 O.sub.3, the content of MgO being less than or equal to 10% by weight, the content of Fe.sub.2 O.sub.3 being less than or equal to 5% by weight, and the content of other inorganic substances being less than or equal to 10% by weight, with the percentage of non fibrous particles being less than or equal to 20% by weight, and with the percentage of non fibrous particles with diameters greater than 150 microns being less than or equal to 7% by weight.Type: GrantFiled: May 16, 1985Date of Patent: June 17, 1986Assignee: Toyota Jidosha Kabushiki KaishaInventors: Tadashi Dohnomoto, Masahiro Kubo
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Patent number: 4595637Abstract: Disclosed is a process for plasma spraying small metal fibers, to adhere them to the surface of a workpiece, and articles made using the process. The process is especially useful for improving the strength of plasma arc coatings, as well as for improving the bonding of plasma arc coatings to substrates. To make an improved ceramic faced metal article, fibers are sprayed onto the workpiece by injecting fibers into the plasma stream external to the plasma gun nozzle. Then, plasma sprayed ceramic particles are caused to surround the fibers as a matrix. The optional interposition of a removable polymer material on the workpiece surface, after the fibers are sprayed but before the ceramic matrix is sprayed, provides an effective way of providing a low stiffness connector between a low thermal expansion coefficient ceramic material and a high expansion coefficient metal substrate. The connector alleviates strains from thermal expansion differences.Type: GrantFiled: October 24, 1983Date of Patent: June 17, 1986Assignee: United Technologies CorporationInventors: Harry E. Eaton, Richard C. Novak
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Patent number: 4590132Abstract: This composite material includes reinforcing alumina-silica fiber material in a metal matrix. The alumina-silica reinforcing fibers have principal components about 35% to about 65% by weight of SiO.sub.2, about 35% to about 65% by weight of Al.sub.2 O.sub.3, and a content of other substances of less than or equal to about 10% by weight, with the weight percentage of the mullite crystalline form therein being at least about 15%, and with the weight percentage of included non fibrous particles with diameter greater than or equal to 150 microns being not more than about 5%. And the matrix metal is selected from the group consisting of aluminum, magnesium, copper, zinc, lead, tin, and alloys having these as principal components. The volume proportion of the alumina-silica fibers should be at least 0.5%. Within these constraints, the qualities of the composite material with regard to wear, and wear on a mating member, and hardness, bending strength, and tensile strength, are good.Type: GrantFiled: April 23, 1985Date of Patent: May 20, 1986Assignees: Toyota Jidosha Kabushiki Kaisha, Isolite Babcock Refractories Co., Ltd.Inventors: Tadashi Dohnomoto, Masahiro Kubo, Haruo Kito
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Patent number: 4573872Abstract: A heat resistance structure adapted to be used in a passage of a high temperature fluid, comprises a heat resistant metal plate having a smooth outer surface, a layer of a substance having a high heat transmission resistance extended along an internal surface of the metal plate, and heat conductive bodies provided in close contact with the layer, all being arranged in this order from the outer surface of the structure to the interior of the structure. A plurality of coolant passages are further provided through each of the heat conductive bodies.Type: GrantFiled: October 26, 1983Date of Patent: March 4, 1986Assignee: Tokyo Shibaura Denki Kabushiki KaishaInventor: Yuji Nakata
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Patent number: 4546048Abstract: A composite thermal shield includes an external solid layer of heat and corrosion-resistant metal bonded to a permeable layer of metal. The composite is mechanically affixed to the substrate metal of an engine component, by a method wherein the substrate metal becomes entrained within the interstices of the permeable metal layer. In a first preferred form the permeable metal layer is comprised of a fibrous stainless steel woven wire mesh which is sintered or brazed to the external stainless steel heat and corrosion-resistant layer. In a preferred process, an aluminum substrate piston is formed to include the composite shield, whereby the aluminum is pressed into the permeable layer during formation of the piston in a mold. In a second preferred form, the piston includes an insulation layer wherein two layers of stainless steel wire mesh have an intermediate stainless steel layer sandwiched between them.Type: GrantFiled: March 23, 1984Date of Patent: October 8, 1985Assignee: Dana CorporationInventor: William D. Guenther
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Patent number: 4530884Abstract: A ceramic-metal composite laminate capable of exposure to high temperature differentials without damage, consisting of an inner ceramic layer, an outer metal layer and an intermediate interface layer of a low modulus metallic low density structure having a high melting point. The ceramic layer is secured to the low modulus structure directly or through an intermediate ceramic-metal composite, and the outer metal layer is brazed to the intermediate low modulus layer. Thermal strains caused by a temperature differential between the inner and outer layers are taken up without harmful effect by the intermediate low modulus layer.Type: GrantFiled: March 3, 1983Date of Patent: July 23, 1985Assignee: Brunswick CorporationInventors: Arnold R. Erickson, Carlino Panzera, Robert P. Tolokan
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Patent number: 4465741Abstract: A fiber-reinforced metal composite material comprising a metal or alloy as the matrix and an inorganic fiber as the reinforcing material, characterized in that at least one element selected from the group consisting of tin, cadmium and antimony in the form of simple substance or organic or inorganic compound is incorporated into the matrix metal in an amount of 0.0005 to 10% by weight (calculated in terms of the element) so as to enhance the mechanical strength of the composite material.Type: GrantFiled: July 23, 1981Date of Patent: August 14, 1984Assignee: Sumitomo Chemical Company, LimitedInventors: Kohji Yamatsuta, Ken-ichi Nishio
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Patent number: 4457979Abstract: A fiber reinforced metal type composite material. The reinforcing fiber is alumina fiber formed from at least 80% by weight alumina and the remainder silica, with the alpha alumina content of the alumina approximately between about 5% and about 60% by weight of the total amount of alumina. The matrix metal is selected from the group consisting of aluminum, magnesium, and their alloys. Thereby mechanical strength, resistance to wear, and workability of the fiber reinforced metal type composite material are good, and also friction wear on elements which frictionally rub against and mate with components made of the fiber reinforced metal type composite material is low.Type: GrantFiled: June 25, 1982Date of Patent: July 3, 1984Assignee: Toyota Jidosha Kabushiki KaishaInventors: Tadashi Donomoto, Mototsugu Koyama, Joji Miyake, Yoshio Fuwa
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Patent number: 4450207Abstract: A fiber reinforced metal type composite material is composed essentially of a mass of reinforcing fibers intimately compounded with a matrix metal. The reinforcing fibers are either alumina fibers, carbon fibers, or a mixture thereof. The matrix metal is an alloy consisting essentially of between about 0.5% and about 4.5% magnesium, less than about 0.2% each of copper and titanium, less than about 0.5% each of silicon, zinc, iron, and manganese, and the remainder aluminum. Preferably, the amount of magnesium is between about 0.7% and about 4.5%, and even more preferably it is between about 1.0% and about 4.0%.Type: GrantFiled: August 24, 1983Date of Patent: May 22, 1984Assignee: Toyota Jidosha Kabushiki KaishaInventors: Tadashi Donomoto, Atsuo Tanaka, Yoshiaki Tatematsu, Tsugio Akai
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Patent number: 4354075Abstract: An electrical contact element is made of material which is resistant to metal migration and which contains a major proportion by weight, at least two metallic components which are soluble in each other and form a composite material. At least one of the components consists of a noble metal, and the metallic components are heterogeneously embedded in the composite material as pure metallic components. A process for making such a contact element comprises forming jacket wires, made of the metallic components, into clusters and metallurgically joining the wires by plastic shaping to form the composite material.Type: GrantFiled: October 1, 1980Date of Patent: October 12, 1982Assignee: G. RauInventors: Dieter Stockel, Hans H. Kocher
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Patent number: 4351326Abstract: A copper wire for intrauterine contraceptive devices is disclosed as having a core wire of a flexible tough metal nobler than copper and a copper coating fixed on the core wire by means of a thin diffusion layer.Type: GrantFiled: October 3, 1980Date of Patent: September 28, 1982Assignee: Outokumpu OyInventor: Ahti A. Kosonen
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Patent number: 4344591Abstract: Multiwall insulating sandwich panels are provided for thermal protection of hypervelocity vehicles and other enclosures. In one embodiment of the invention the multiwall panels are formed of alternate layers of dimpled and flat metal (titanium alloy) foil sheets and beaded scarfed edge seals to provide enclosure thermal protection up to 1000.degree. F. An additional embodiment employs an intermediate fibrous insulation for the sandwich panel to provide thermal protection up to 2000.degree. F. and a third embodiment employs a silicide coated columbium waffle as the outer panel skin and fibrous layered intermediate protection for thermal environment protection up to 2500.degree. F.The use of multiple panels of the present invention on an enclosure facilitate repair and refurbishment of the thermal protection system due to the simple support provided by the tab and clip attachment for the panels.Type: GrantFiled: September 5, 1979Date of Patent: August 17, 1982Assignee: The United States of America asrepresented by the Administrator of the National Aeronautics and Space AdministrationInventor: Liam R. Jackson
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Patent number: RE32549Abstract: This invention relates to a laminated article, particularly to such an article comprising a gauze pack containing two or more gauzes such as are typically used as catalyst catchment or getter means in nitric acid production plants.Specifically, this invention provides a gauze pack segment suitable for locating in planar contiguous relationship with one or more further gauze pack segments to provide a gauze pack having a predetermined, for example, a regular geometric shape comprises a plurality of superposed gauze segments having at least when assembled substantially identical shape and area and held in fixed relationship one with another.Type: GrantFiled: September 24, 1984Date of Patent: November 24, 1987Assignee: Johnson Matthey & Co., LimitedInventors: David C. Bishop, Alan E. Heywood