And Aluminum Compound (e.g., Clay, Aluminum Oxide, Etc.) Patents (Class 501/100)
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Patent number: 5302563Abstract: The present invention discloses an alkali oxide free low density refractory material especially adapted for use as a disposable liner material for molten metal containing vessels. This material includes about 0.1 to about 2 weight percent of a stiffening agent, about 0.1 to about 2 weight percent of a set retarding agent, about 0.1 to 6 weight percent of density reducing materials, about 0.1 to about 5 weight percent of a plasticizer, up to about 2 weight percent of a secondary binder, and the balance of a refractory aggregate which is preferably MgO. The stiffening agent and set retarding agent are used in substantially the same amounts to provide the disclosed refractory material with increased resistance to slumping while, at the same time, allowing spraying apparatus residence times of up to 30-40 minutes without clogging. The composition includes less than about 0.Type: GrantFiled: March 6, 1992Date of Patent: April 12, 1994Assignee: Minerals Technologies, Inc.Inventors: Charles R. Rumpeltin, Julie A. Dody
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Patent number: 5286685Abstract: The invention relates to refractory materials which comprise:(A) grains of at least one refractory material whose melting point and thermal decomposition temperature are higher than 1700.degree. C.;(B) a binding matrix which binds these grains together and predominantly consists of aluminum nitride AlN of hexagonal structure and/or of at least one of the polytypes of AlN; and(C) hexagonal boron nitride particles and/or crystalline graphite flakes dispersed in the binding matrix.Applications in iron and steel metallurgy, in particular as plates in a slide closure device.Type: GrantFiled: December 7, 1992Date of Patent: February 15, 1994Assignee: Savoie RefractairesInventors: Jacques P. R. Schoennahl, Michel Dussaulx
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Patent number: 5250479Abstract: The invention concerns a fired magnesia-carbon shape having a combination of properties making it especially suitable for slide gate plates, inserts for such plates and for pouring nozzles useful in casting aggressive steels. The fired refractory shape is formed from a batch consisting essentially of, by weight percent,2 to 8 finely divided graphite (natural or synthetic);3 to 8 aluminum metal powder;1 to 5 of finely divided silica and/or a silicon yielding powder;an effective amount of carbon bond forming resins;and the balance coarse and fine magnesia grains.The magnesia grains should contain less than about 0.02 weight percent boron oxide. After firing, the shape is characterized by a carbon bonding system including a spinel (magnesia-alumina) phase plus aluminum carbide bonding the magnesia-carbon matrix. The refractory shape is preferably carbon impregnated after firing to further enhance its properties.Type: GrantFiled: April 16, 1992Date of Patent: October 5, 1993Assignee: Vesuvius Crucible CompanyInventors: Gilbert Rancoule, Duane L. DeBastiani
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Patent number: 5246897Abstract: Hydrophilic graphite-base powder is provided wherein hydrophilic small particles of such as silicon carbide or silica are mixed with a graphite powder and the small particles are attached to each surface of the graphite particles by performing a mechanical impact treatment in a high-speed gas flow. By combining the graphite-base powders with refractory compound powders of such as magnesia or alumina to be a powder mixture for monolithic refractories containing graphite, a formed body of the powder mixture having a large bulk density can be provided and a service life thereof is comparable to that of a shaped refractory, and labor and energy necessary for the production process and the operation are saved.Type: GrantFiled: July 31, 1992Date of Patent: September 21, 1993Assignee: Asahi Glass Company Ltd.Inventors: Yasushi Ono, Satoshi Sakamoto
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Patent number: 5240498Abstract: Provided is a carbonaceous binder composition which comprises a polymerized and dehydrated carbohydrate, a monomer or polymer of resorcinol, and water. It is important that the carbohydrate is a polymer when combined with the remaining components of the composition. Polymerization of the carbohydrate prior to being combined with the other components of the composition has been found to result in an increased carbon yield upon pyrolysis of the binder. The binder composition also has an effective shelf life of three months or longer and gives off no objectionable smell either before or after being pyrolyzed. More importantly, the binder is also free of any skin or respiratory irritants, and is in effect non-carcinogenic.Type: GrantFiled: January 9, 1991Date of Patent: August 31, 1993Assignee: Martin Marietta Magnesia Specialties Inc.Inventors: Ralph Matalon, Keith Bridger, Francis W. Henry
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Patent number: 5235662Abstract: The present invention provides a method of annealing optical glass layers, said method comprising the step of heating glass layers having an area greater than 0.01 cm.sup.2 to a temperature of between about 350 deg. C. and 1000 deg. C. in less than 10 minutes. The upper limit of the glass area that can be treated is limited only by the size of the quartz chamber. Current state-of-the-art chambers can accomodate glass areas of about 0.01 cm.sup.2 to about 324 cm.sup.2. According to another aspect of the invention, there is also provided an optical waveguide glass layer, treated according to the method of this invention, disposed on an integrated optical device.Type: GrantFiled: January 2, 1992Date of Patent: August 10, 1993Assignee: Eastman Kodak CompanyInventors: Eric T. Prince, Sebastian F. Prospero, Mark M. Romach
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Patent number: 5219807Abstract: A burned, high-purity refractory, specifically a chrome-alumina, alumina-chrome and picrochromite composition, which contains less than 5 ppm total soluble chromium. Such products are obtained by adding to the starting mix less than 5 wt. % (often less than 3 wt. %) zircon, titania, molybdic oxide, boric acid, carbon black, or silica.Type: GrantFiled: June 27, 1991Date of Patent: June 15, 1993Assignee: Indresco Inc.Inventors: Stanley R. Pavlica, Dwight S. Whittemore
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Patent number: 5214010Abstract: A refractory composition consisting essentially of, for each 100 wt. % thereof, about 40 to 80 wt. % of an alumina, about 5 to 30 wt. % of a zirconia-containing grain, about 2 to 10 wt. % of a carbon, and about 1 to 12 wt. % of an oxidation and erosion resistance additive, the method of making refractory shapes utilizing such composition, and the resultant shapes.Type: GrantFiled: June 10, 1992Date of Patent: May 25, 1993Assignee: Indresco, Inc.Inventor: Dwight S. Whittemore
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Patent number: 5212126Abstract: A monolithic refractory with improved resistance to molten aluminum and a method of imparting the resistance by adding 0.2 to 1 wt.% polyvinyl chloride powder to the base mix.Type: GrantFiled: June 10, 1991Date of Patent: May 18, 1993Assignee: Dresser Industries, Inc.Inventors: Lawrence D. Fitch, Thomas R. Kleeb
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Patent number: 5212125Abstract: A process for producing a sintered AlN ceramic body by mixing an organic solution comprising a hydrocarbon solvent and an organometallic compound with AlN powder to produce a slurry, removing the solvent from the slurry to form a mixture of organometallic compound and AlN, forming the mixture into a shape, and heating the shape in a non-oxidizing atmosphere to sintering temperature to obtain densification.Type: GrantFiled: November 20, 1990Date of Patent: May 18, 1993Assignee: The Carborundum CompanyInventors: David D. Marchant, Joseph R. Fox, Timothy W. Brauneck
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Patent number: 5188989Abstract: An oxidation-resistant carbon-containing refractory shape having on the surface thereof exposed to oxidation an oxidation-resistant glaze coating, said glaze coating consisting essentially of the reaction product of a zinc borosilicate frit and a clay; and the method of forming said coating on a refractory shape comprising applying to at least a portion of the shape an aqueous suspension of a fluxed mix consisting essentially of a zinc borosilicate and a clay, drying said coating, and firing said coated refractory shape at a temperature and for a time sufficient to cause the borosilicate and clay in said mix to react and form a substantially uniform glaze coating.Type: GrantFiled: December 1, 1987Date of Patent: February 23, 1993Assignee: Dresser IndustriesInventors: Howard M. Winkelbauer, Eugene T. Rushe
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Patent number: 5147834Abstract: An improved gunning composition for use in the steel industry includes between 60-75% by weight of a refractory base material, 10-20% by weight of silicon carbide, 7-15% by weight of ball clay, 4-8% by weight of a silica binder material, and, optionally, 5-10% by weight of a graphite material. The silica binder replaces binders composed of petroleum pitch or clay. The silica binder causes the composition to have (1) better adhesion, (2) less cracking, (3) improved strength, and (4) increased resistance to oxidation, corrosion and erosion.Type: GrantFiled: August 19, 1991Date of Patent: September 15, 1992Assignee: Magneco/Metrel, Inc.Inventor: Subrata Banerjee
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Patent number: 5145811Abstract: Improved inorganic ceramic papers comprising heterogeneous grades of ceramic fibers, namely small, high surface area fibers and at least one larger, lower surface area ceramic fiber are bonded into a matrix with the aid of an inorganic binder system having at least one metal oxide with an average particle size below 200 nm. Multiple different grades of inorganic ceramic fibers and small particle size inorganic binders impart good tensile strength and flexibility characteristics in the same sheet.Type: GrantFiled: July 10, 1991Date of Patent: September 8, 1992Assignee: The Carborundum CompanyInventors: Timothy S. Lintz, Julie A. Golebiewski
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Patent number: 5128284Abstract: This invention relates to a process for the preparation of a crystalline compound having an empirical formula LaCr.sub.x A.sub.1-x O.sub.4 .multidot.yH.sub.2 O where A is a metal selected from the group consisting of Mg, Sr, Ca and Ba, x ranges from 0.99 to about 0.7 and y ranges from 0 to 0.15. The process comprises adding a solution of the appropriate metal salts to a solution of ammonium hydroxide thereby precipitating a hydroxide gel intermediate, which is dried and calcined in air to yield the resultant crystalline compound which has a huttonite structure. Additionally, this invention relates to a process for the preparation of a ceramic powder having the empirical formula LaCr.sub.x A.sub.1-x O.sub.3, where A is a metal selected from the group consisting of Mg, Sr, Ca and Ba and x ranges from 0.99 to about 0.7. Finally, a ceramic composition having the empirical formula LaCr.sub.x S.sub.1-x O.sub.4 .multidot.yH.sub.2 O having a huttonite structure is also disclosed.Type: GrantFiled: June 14, 1991Date of Patent: July 7, 1992Assignee: Allied-Signal Inc.Inventors: William L. Olson, Beili Li, Jean Yamanis
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Patent number: 5120689Abstract: Process for production of a ceramic material, e.g. a carbide, nitride, boride or silicide, by reacting at least one compound of a metallic or non-metallic element having two or more groups reactive with hydroxyl groups with at least one organic compound having two or more hydroxyl groups to form an oxygen-containing polymeric product, heating the polymeric product to produce a coked product containing carbon and an oxide of the metallic or non-metallic element, and heating the coked product to produce a ceramic material, in which the proportion by weight of carbon to the oxide of the metallic or non-metallic element in the coked product is in the range from 50% to 150% of the proportion which is theoretically required to produce the ceramic material.Type: GrantFiled: November 13, 1990Date of Patent: June 9, 1992Assignee: Imperial Chemical Industries plcInventors: James D. Birchall, Mary Mockford, David R. Stanley
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Patent number: 5096858Abstract: A method of producing ceramic composites of Al.sub.2 O.sub.3 reinforced by shaped SiC particles preferably shaped as fine particles (random), platelets, whiskers or fibres by in situ production of SiC particles by heating a mixture of carbon particles of the desired shape with silicates of Al.sub.2 O.sub.3 to a temperature above 1500.degree. C., convert the silicates and carbon to Al.sub.2 O.sub.3 and SiC to produce in situ SiC particles of the desired shape and provide a ceramic powder that may be densified by techniques such as hot pressing, isostatic pressing or sintering.Type: GrantFiled: March 12, 1991Date of Patent: March 17, 1992Assignee: The University of British ColumbiaInventors: Asoke C. Das Chaklader, Sankar Das Gupta
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Patent number: 5077246Abstract: A method for the preparation of ceramic composites containing at least aluminum oxide and aluminum boride, and the composite materials that result from the method. Intimate mixtures of finely-divided powdered aluminum metal and anhydrous boric oxide, with ratios (by weight) of about 0.5 to twenty parts of aluminum metal to one part of boric oxide, are subjected to a temperature to cause a complete reaction between the starting materials. If the ratio is above about 1.25 parts of aluminum to one part of boric oxide, the resultant product will include aluminum in addition to the aluminum oxide and aluminum boride. The ratio is selected to provide the desired hardness and toughness. Ratios between about 1 and 1.2 provide a composite having the highest hardness, with greater amounts of aluminum metal providing increased toughness. Several compositions are described, with hot pressing typically being used to provide the desired heating cycle.Type: GrantFiled: June 4, 1990Date of Patent: December 31, 1991Assignee: Apollo Concepts, Inc.Inventors: Samuel C. Weaver, Sally G. Padron
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Patent number: 5064787Abstract: An improved ramming composition for use in the iron and steel industry includes between 65-80% by weight mullite, 5-15% by weight silicon carbide, 2-5% by weight graphite, 2-6% by weight ball clay, and 5-10% by weight of a binder formed from a dispersion of 15-70% by weight silica in water. The silica binder replaces binders composed of petroleum pitch, clay, or other organic materials. The silica binder causes the ramming composition to have a longer use life, increased strength, and reduced tendency to crack, oxidize or smoke.Type: GrantFiled: November 20, 1989Date of Patent: November 12, 1991Assignee: Magneco/Metrel, Inc.Inventor: Subrata Banerjee
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Patent number: 5057155Abstract: A mold forming material contains 1-20% by weight of spodumene. Spodumene is a lithium mineral whose theoretical composition formula is Li.sub.2 O Al.sub.2 O.sub.3 4SiO.sub.2. If casting is performed using a mold forming material containing spodumene, a casting which is satisfactory in appearance and accuracy is obtained.Type: GrantFiled: June 18, 1990Date of Patent: October 15, 1991Assignee: Okazaki Minerals & Refining Co., Ltd.Inventors: Susumu Nakayama, Shogo Ishizaki, Toru Iwaki
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Patent number: 5051301Abstract: A composite comprised of a ceramic matrix and a plurality of layers of boron nitride coated fibrous material, said coated fibrous material comprising at least about 10% by volume of said composite, and said matrix having a thermal expansion coefficient which ranges from lower than that of said coated fibrous material to less than about 15% higher than that of said coated fibrous material.Type: GrantFiled: December 8, 1989Date of Patent: September 24, 1991Assignee: General Electric CompanyInventors: Raj N. Singh, Achuta R. Gaddipati
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Patent number: 5041512Abstract: An organoaluminum polymer formed from R.sub.3 A1 and dialkylaluminum amide that is useful for forming shaped articles of inorganic aluminum nitride alone or with nitrides (other than AlN), oxides, borides, carbides or combinations thereof; R being selected from hydrogen; C.sub.1 to C.sub.10 alkyl; halogen; and substituted or unsubstituted phenyl, naphthyl and biphenyl; no more than two of the R groups being alkyl.Type: GrantFiled: April 14, 1989Date of Patent: August 20, 1991Assignee: E. I. Du Pont de Nemours and CompanyInventor: Frederick N. Tebbe
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Patent number: 5035919Abstract: Disclosed herein are a refractory repairing material for repairing a brick comprising a mixture of 70 to 80 wt % of alumina having not more than 1 mm of grain size, which comprises 25 to 30 wt % of the above amount with a grain size not passing through a 325 mesh and 45 to 50 wt % of the above amount with a grain size passing through a 325 mesh; 1 to 7 wt % of carbonaceous material having a grain size passing through a 60 mesh; 1 to 5 wt % of magnesia having a grain size passing through a 325 mesh; and 10 to 25 wt % of aluminum phosphate, and a method of repairing a plate-like brick.Type: GrantFiled: August 30, 1990Date of Patent: July 30, 1991Assignees: Toshiba Ceramics Co., Ltd., Sumitomo Metal Indus., Ltd.Inventors: Takao Sugino, Toshio Kawamura, Masamichi Asai, Hiroshi Yamada, Kenichi Mukoyama, Akira Takahashi, Hiroshi Hikima
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Patent number: 5036026Abstract: A sintered body of aluminum nitride having a density of not smaller than 3.1 g/cm.sup.3, a coefficient of thermal conductivity of not smaller than 100 W/mk and preferably an average particle size of not larger than 5 .mu.m, which comprises aluminum nitride as a main component, 0.01 to 10.0% by weight of at least one oxide selected from oxides of the IIa and IIIa elements of the Periodic Table, 2.0% by weight or less of oxygen which is not contained in the oxide of the IIa and IIIa element and 1.0% by weight or less of at least one impurity metal which is not the IIa or IIIa element which has good thermal conductivity.Type: GrantFiled: September 25, 1990Date of Patent: July 30, 1991Assignee: Sumitomo Electric Industries, Ltd.Inventors: Akira Yamakawa, Hitoyuki Sakanoue, Hisao Takeuchi
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Patent number: 5030595Abstract: The present invention relates to an unfired refractory brick for use in reducing conditions at temperatures above 1800.degree. F. The brick comprises a matrix of alumino-silicate clays, alumino-silicate-aggregates and high alumina aggregates. It also has 2 to 20% by weight of finally ground silicon carbide and 2 to 20% by weight of fine carbon particles distributed throughout the matrix. The matrix also includes a water soluble ammonium lignin sulphonate as a chemical binding agent. The brick of the present invention finds particular use in a furnace for kiln baking anodes used in the electrolytic production of aluminum metal.Type: GrantFiled: November 1, 1989Date of Patent: July 9, 1991Assignee: Clayburn Industries, Ltd.Inventors: Derek Albon, Mary A. Windfeld, Ronald W. Smith
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Patent number: 5026672Abstract: A sintered body of tin oxide is made by forming a finely divided mixture containing at least about 0.2 weight percent ZnO, at least about 0.2 weight percent SiO.sub.2, up to about 0.5 weight percent Al.sub.2 O.sub.3, balance pure SnO.sub.2, with the sum of the proportions of ZnO and SiO.sub.2 being less than about 2 weight percent. The mixture is compacted and heated to a sintering temperature. The tin oxide may be doped with antimony.Type: GrantFiled: June 25, 1990Date of Patent: June 25, 1991Assignee: Tektronix, Inc.Inventor: Michel L. Bayard
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Patent number: 5011799Abstract: A method of producing ceramic composites of Al.sub.2 O.sub.3 reinforced by shaped SiC particles preferably shaped as fine particles (random), platelets, whiskers or fibres by in situ production of SiC particles by heating a mixture of carbon particles of the desired shape with silicates of Al.sub.2 O.sub.3 to a temperature above 1500.degree. C., convert the silicates and carbon to Al.sub.2 O.sub.3 and SiC to produce in situ SiC particles of the desired shape and provide a ceramic powder that may be densified by techniques such as hot pressing, isostatic pressing or sintering.Type: GrantFiled: September 14, 1990Date of Patent: April 30, 1991Inventors: Asoke C. Das Chaklander, Sankar Das Gupta
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Patent number: 5011802Abstract: A coking process in which tar impregnated refractory products are heated in a muffle within a furnace to a temperature sufficient to cause emission or release of the volatile constituents in the tars and pitches used for impregnation, whether by decomposition or distillation, for a time which is sufficient to remove substantially all of such constituents from the products, characterized by heating the refractory products in a muffle within the furnace while maintaining a positive pressure within the muffle during the emission of the volatile constituents, and thereafter cooling the refractories in a substantially nonoxidizing atmosphere. After the temperature of the refractory products is low enough to avoid any thermal shocking of the brick the brick are removed from the furnace and the muffle.Type: GrantFiled: January 22, 1990Date of Patent: April 30, 1991Assignee: A.P. Green Industries, Inc.Inventors: Orville Hunter, Jr., James L. Hill, David E. Potts
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Patent number: 5002908Abstract: A resin bonded refractory composition of increased pressability and consequently increased density and strength is made by adding potassium borate to prior art refractory compositions.Type: GrantFiled: October 30, 1989Date of Patent: March 26, 1991Assignee: National Refractories & Minerals CorporationInventor: Nicholas Cassens, Jr.
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Patent number: 4988647Abstract: A process of forming a coherent refractory mass on a surface comprises projecting against that surface, together with oxygen, a mixture of refractory particles and fuel which reacts in an exothermic manner with the projected oxygen to release sufficient heat to melt at least the surfaces of the refractory particles and thus form the refractory mass. The projected mixture contains, as fuel, finely divided particles of at least one element which is oxidizable to form a refractory oxide and it also contains carbonaceous particles which are of such a size or composition that carbon particles become occluded in the formed refractory mass. The mixture may contain, as said fuel, finely divided particles having a mean grain size of less than 50 .mu.m of silicon, aluminum and/or magnesium. The carbonaceous particles may comprise a carbonaceous core which is covered by a mantle inhibiting oxidation of the core.Type: GrantFiled: October 4, 1988Date of Patent: January 29, 1991Assignee: GlaverbelInventors: Leon-Philippe Mottet, Pierre Robyn, Pierre Laroche
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Patent number: 4970180Abstract: Disclosed herein are a refractory repairing material for repairing a brick comprising a mixture of 70 to 80 wt % of alumina having not more than 1 mm of grain size, which comprises 25 to 30 wt % of the above amount with a grain size not passing through a 325 mesh and 45 to 50 wt % of the above amount with a grain size passing through a 325 mesh; 1 to 7 wt % of carbonaceous material having a grain size passing through a 60 mesh; 1 to 5 wt % of magnesia having a grain size passing through a 325 mesh; and 10 to 25 wt % of aluminum phosphate, and a method of repairing a plate-like brick.Type: GrantFiled: September 1, 1989Date of Patent: November 13, 1990Assignees: Toshiba Ceramics Co., Ltd., Sumitomo Metal Industries, Ltd.Inventors: Takao Sugino, Toshio Kawamura, Masamichi Asai, Hiroshi Yamada, Kenichi Mukoyama, Akira Takahashi, Hiroshi Hikima
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Patent number: 4946809Abstract: A soluble, processible ceramic precursor, comprising A1N and BN in fixed proportion, which on pyrolysis is transformed into pure carbon free A1NBN ceramic, of the formula:R.sub.3 N.X.sub.2 A1n(SiR'.sub.3)B(NH.sub.2)NHSiR'.sub.3wherein R and R' are independently lower alkyl groups or isomers thereof having from one to about five carbon atoms.Also disclosed are methods for making the precursor, and methods for thermally decomposing the precursor to form coatings, thin films, and shaped articles of substantially pure A1NBN ceramic.Type: GrantFiled: May 26, 1989Date of Patent: August 7, 1990Assignee: Ultraystems Defense and Space, Inc.Inventors: Kazimiera J. L. Paciorek, James H. Nakahara
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Patent number: 4931415Abstract: There is disclosed a raw composition, as well as a fired shape, known in the art as a clay-bonded graphite crucible for melting metals, which contains a quantity of fused silica and is particularly adaptable to melting metals in high-energy, induction furnaces.Type: GrantFiled: May 4, 1988Date of Patent: June 5, 1990Assignee: Ferro CorporationInventors: George W. Neudeck, Paul H. Rieth
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Patent number: 4920084Abstract: In processes of forming a refractory mass on a surface, a mixture of refractory particles and oxidizable particles which react exothermically with oxygen to generate sufficient heat to soften or melt at least the surfaces of the refractory particles are sprayed against that surface to bring about formation of said refractory mass. To promote the reliable and consistent formation of a durable refractory mass, the granulometry of the particles which are sprayed in the mixture is such that the 80% and 20% grain sizes of the refractory particles (that is, the screen mesh sizes G.sub.80 and G.sub.20 through which respectively 80% and 20% by weight of the particles will pass) have a mean greater than the mean of the 80% and 20% grain sizes of the oxidizable particles and the size range spread factor f(G) of the refractory particles is at least 1.Type: GrantFiled: October 6, 1988Date of Patent: April 24, 1990Assignee: GlaverbelInventors: Pierre Robyn, Leon-Philippe Mottet, Pierre Deschepper
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Patent number: 4913408Abstract: A refractory liner composition which consists essentially of carbon and a composite selected from the group consisting of zirconia and O'-sialon and zirconia and silicon oxynitride.Type: GrantFiled: September 6, 1988Date of Patent: April 3, 1990Assignee: Vesuvius Crucible CompanyInventors: Dale B. Hoggard, Han K. Park, Fiona C. R. Morrison
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Patent number: 4871698Abstract: The invention is directed to improved carbon containing refractory compositions and sintered bodies made therefrom which are particularly resistant to slag and metal erosion and to thermal shock. This is achieved by combining grains or powders of SiAlON and/or silicon nitride with elemental carbon in the form of graphite, carbon black or charcoal. The particulate materials are mixed with a carbonaceous binder such as resin or pitch, pressed to shape and fired in a reducing atmosphere. Small amounts of antioxidants are also added to protect the carbon bond phase against slag attack. Additional amounts of a less expensive refractory grain or powder are also optionally added to the mix to dilute the more expensive SiAlON and/or silicon nitride.Type: GrantFiled: November 9, 1987Date of Patent: October 3, 1989Assignee: Vesuvius Crucible CompanyInventors: Mark K. Fishler, Dale B. Hoggard
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Patent number: 4870037Abstract: The invention is directed to a lining composition for submerged entry pouring nozzles and like shapes used in the continuous casting of metals, particularly aluminum killed, low carbon steels. The lining prevents harmful buildup of alumina and other oxides within the nozzle bore which may cause premature nozzle clogging. The nozzle liner comprises a carbon-bonded, SiAlON-graphite refractory material. Small amounts of antioxidants and additional amounts of less expensive refractory grain or powder are also added to dilute the more expensive SiAlON material.Type: GrantFiled: September 23, 1987Date of Patent: September 26, 1989Assignee: Vesuvius Crucible CompanyInventors: Dale B. Hoggard, Han K. Park
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Patent number: 4837230Abstract: Ceramic composite articles having high flexural and tensile strength are produced by introducing multiple layers of a ceramic matrix material onto a ceramic reinforcement fabric. Crack propagation in the resulting structure is inhibited by applying refractory interface layers intermediate successive ceramic matrix layers. Such ceramic composite articles are particularly useful for high temperature applications requiring a high degree of strength, such as rocket motor insulation and turbine blades, combustion chambers, and after burners for jet motors.Type: GrantFiled: July 21, 1988Date of Patent: June 6, 1989Assignee: Kaiser AerotechInventors: Shih-Huei Chen, H. O. Davis
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Patent number: 4830992Abstract: A carbon containing refractory comprising, by weight: 5 to 60% of AZT clinker mainly constituted by ZrO.sub.2, Al.sub.2 O.sub.3, TiO.sub.2 and SiO.sub.2 ; 3 to 40% of a carbon source; and the balance being at least one or two refractories selected from a group consisting of alumina, magnesia, zirconia, mullite, spinel, calcia, and fused quartz.Type: GrantFiled: October 25, 1988Date of Patent: May 16, 1989Assignee: Shinagawa Refractories Co., Ltd.Inventors: Kenji Ichikawa, Noboru Tsukamoto, Hitoshi Iwado, Eishi Iida
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Patent number: 4803182Abstract: A ceramics-based manufacturing material and a coating material are disclosed, both of which are used in high-temperature structures and applications. The ceramics-based manufacturing material may be used for building structural blocks or members, such as refractory bricks, that require the mechanical strength and thermal resistance when they are exposed to the high temperatures of 1,500.degree. C. or above. Those bricks made of the material disclosed provides the mechanical strength and heat resistance better than the conventional ones. The coating material may be used for forming a thermal resistant layer on metal or other material bases. Both materials have substantially the similar compositions, either of which may have the alternative use, such as the manufacturing material or the coating material. Simply adding an appropriate amount of water to either makes it a coating material. In either case, the requirements for the high temperature resistance and mechanical strength can be satisfied.Type: GrantFiled: December 14, 1987Date of Patent: February 7, 1989Inventor: Sadanobu Ishikawa
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Patent number: 4800137Abstract: A composite layer aluminum nitride-base sintered body has on at least one surface of AlN-base sintered body having a first layer and a second layer. The first layer is 100 parts by weight of at least one component selected from the group consisting of W, Mo, borides thereof and carbides thereof as a first component (s), and 0.1-50 parts by weight of AlN second component. The second layer has at least one component selected from the group consisting of W, Mo, borides thereof and carbides thereof. The thickness of said first layer is 0.5-40 .mu.m, and the sum of thickness of the first and second layers is 1-50 .mu.m. The AlN may also include sintering aids of oxides of rare earth metal and alkaline earth metals. Hydrides and oxides of Ti, Zr, Nb, V and Mn may be included in the first layer composition.Type: GrantFiled: May 18, 1987Date of Patent: January 24, 1989Assignee: NGK Spark Plug Co., Ltd.Inventors: Akiyasu Okuno, Masakazu Watanabe, Kazuhiko Ikoma
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Patent number: 4798814Abstract: A shaped article comprises a continuous alumina-silica of alumina-boria-silica first phase, an in-situ generated discontinuous carbon second phase, and a discontinuous silicon carbide third phase, said article being stable to an oxidative atmosphere when heated to 1300.degree. C. for at least 2 hours.Type: GrantFiled: August 24, 1987Date of Patent: January 17, 1989Assignee: Minnesota Mining and Manufacturing CompanyInventors: George F. Everitt, Terence P. Johnson, Lien-Huong A. Pham
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Patent number: 4787965Abstract: The invention concerns a coating for providing protection from corrosion and oxidation in the hot state, which coating is intended for the carrier bars of prebaked anodes and the emergent, or exposed, carbonaceous part of said anodes for Hall-Heroult electrolysis tanks, which elements are formed of a composition of carbonaceous aggregate selected from coke, graphite, semi-graphite and electrode scrap, together with calcium aluminate cement having an alumina content which is at least equal to 70% and a total amount of troublesome impurities (SiO.sub.2, Fe.sub.2 O.sub.3, TiO.sub.2, K.sub.2 O, Cr.sub.2 O.sub.3 and Mn.sub.2 O.sub.3) of less than 5% and preferably less than 2%. The protective coating may further comprise an addition of alumina powder in a proportion which can be up to 50% of the weight of the aggregate and an addition of 0.01% to 5% of metal powder such as passivated aluminium powder of a grain size of less than 0.1 mm. The coating may be used in the form of paste or be applied by spray gun.Type: GrantFiled: November 6, 1987Date of Patent: November 29, 1988Assignees: Societe Des Electrodes, Refractaires Savoie (SERS)Inventors: Gabriel Audras, Bernard Samanos
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Patent number: 4780434Abstract: A refractory composition which is suitable for forming a sliding gate to be used at the bottom of a ladle or tundish is provided. The refractory composition comprises 10 to 30 parts by weight of an alumina-magnesia spinel material containing 40 to 70% by weight of Al.sub.2 O.sub.3, 25 to 60% by weight of MgO and 10% or less of impurities, and 70 to 90 parts by weight of a magnesia material containing at least 90% by weight of MgO, wherein the composition contains 10 to 25% by weight of Al.sub.2 O.sub.3 and 75 to 90% by weight of MgO. 1 to 10 parts by weight of Al.sub.2 O.sub.3 material may be further added together with the alumina-magnesia spinel material and the magnesia material, to form the refractory composition.Type: GrantFiled: December 22, 1986Date of Patent: October 25, 1988Assignee: Toshiba Ceramics, Co., Ltd.Inventors: Takashi Watanabe, Takumi Nishio, Yoshihisa Kato, Kazuhide Kawai, Satoshi Doro, Takafumi Nishibe, Takahiro Fukaya
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Patent number: 4775504Abstract: Alumina-carbon-based refractory plates for the sliding nozzle are produced from alumina powder and carbon powder of specific particle diameter, in addition to the conventional refractory materials. The plates are durable and have good resistance to molten steel because of a compact structure which prevents the sticking of molten steel.Type: GrantFiled: August 13, 1986Date of Patent: October 4, 1988Assignee: Kurosaki Refractories Co., Ltd.Inventors: Hiroshi Shikano, Toshihiro Suruga
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Patent number: 4732878Abstract: A shaped article comprises a continuous alumina-silica first phase, an in-situ generated discontinuous carbon second phase, and optionally a discontinuous silicon carbide third phase, said article being stable to an oxidative atmosphere when heated to 1300.degree. C. for at least 30 minutes.Type: GrantFiled: September 26, 1986Date of Patent: March 22, 1988Assignee: Minnesota Mining and Manufacturing CompanyInventors: George F. Everitt, Terence P. Johnson, Lien-Huong T. Pham
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Patent number: 4680278Abstract: A process for preparing aluminum nitride powder, which comprises mixing (i) aluminum hydroxide powder, (ii) carbon powder or a substance capable of forming carbon powder by heating and (iii) at least one of additives selected from the group consisting of aluminum nitride powder, silicon nitride powder, silicon carbide powder and powder of substances capable of forming the powder corresponding to these powders, and baking the mixture thus obtained in a non-oxidative atmosphere containing nitrogen. The process is useful for preparing aluminum nitride powder having small particle size and small particle size distribution and also having a uniform shape of particles, at a lower temperature and in a shorter period of time.Type: GrantFiled: December 23, 1985Date of Patent: July 14, 1987Assignee: Kabushiki Kaisha ToshibaInventors: Hiroshi Inoue, Akihiko Tsuge, Katsutoshi Komeya
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Patent number: 4676412Abstract: Refractory nozzles including a so-called long nozzle, an upper nozzle, a lower nozzle, and an immersion nozzle made from high-alumina refractory material, graphite powder, silica powder and other minor constitutents wherein a major part of the high-alumina refractory material is thermospherized particles of about 0.3 to 3.0 mm in diameter which have good spalling and corrosion resistance. Revolving and rolling ability of the thermospherized particles gives far-reaching capability of pressing force deep into the nozzle center portion during shape-forming by a compaction press. Hence more uniform products can be obtained, and a less expensive unidirectional compaction process can be used instead of a high cost isostatic process for compaction.Type: GrantFiled: September 23, 1985Date of Patent: June 30, 1987Assignee: Harima Refractories Co., Ltd.Inventors: Akihiro Tsuchinari, Osamu Shimobayashi, Hisahiro Hattori
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Patent number: 4639474Abstract: A monolithic refractory composition having relatively high thermal conductivity and a relatively high degree of water insolubility consisting essentially of, by weight, 50-75% coarse grain flake graphite; 5-30% fine grain flake graphite; and the remainder crude clay; and the addition based upon the total weight of said mix of 10-25% liquid phenolic resin in combination with an alcoholic solvent, and a resin curing agent.Type: GrantFiled: December 8, 1983Date of Patent: January 27, 1987Assignee: Dresser Industries, Inc.Inventor: Thomas F. Vezza
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Patent number: 4634685Abstract: A refractory article for casting of liquid melts, especially steel, fabricated from a mixture of Al.sub.2 O.sub.3, graphite, a flux component, a synthetic resin binder and a metallic powder. The flux component contains a first flux with a melting point from 550.degree. to 900.degree. C. and a second flux that becomes active in the mixture in a temperature ranging from 1350.degree. and 1550.degree. C. The refractory article need not be heated before use, and the carbon contained therein, which determines the strength of the article, is retained for a much longer period during use, so that the article will have a long service life.Type: GrantFiled: October 31, 1985Date of Patent: January 6, 1987Assignee: Didier-Werke AGInventors: Siegfried Pohl, Ernst Luhrsen, Peter Jeschke, Ortwin Rave, Martin Kienow, Werner Richter
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Patent number: 4627945Abstract: An alumina-carbon shape is manufactured from a composition comprising 1-8 weight percent fine silicon, 1-16 weight percent reactive alumina, 1-30 weight percent calcined fluidized bed coke, 1-30 weight percent of a spalling inhibiting additive, and the balance of the mix synthetic alumina, plus the additions of 5-10 weight percent of a high carbon yielding resin as a molding vehicle and 0.5-4 weight percent solvent, and up to 2 weight percent of a low temperature curing agent, such as, paraformaldehyde or hydrochloric acid. The mix is formed at ambient temperature into a shape through an injection molding process. Solidification is accomplished by curing in the mold at a temperature less than 100.degree. C. After stripping the shape from the mold, the solvents are removed from the shape by drying at a temperature above 100.degree. C. The shapes are then heated to a temperature above 550.degree. C. to coke the resin.Type: GrantFiled: July 27, 1984Date of Patent: December 9, 1986Assignee: Dresser Industries, Inc.Inventors: Howard M. Winkelbauer, Ke-Chin Wang, Frank H. Walther, Jr., Donald F. Stock