And Silicon Compound Other Than Clay Patents (Class 501/128)
  • Patent number: 7112549
    Abstract: A low-thermal-expansion, rigid and wear-resistant ceramic is provided. The low-thermal-expansion ceramic of the invention includes 60 vol % to 99.9 vol % of at least one selected from the group consisting of cordierite, spodumene and eucryptite and 0.1 vol % to 40 vol % of at least one selected from the group consisting of carbides, nitrides, borides and silicides of group IVa elements, group Va elements and group VIa elements, and boron carbide. The ceramic has a porosity of 0.5% or less and a thermal expansion coefficient, at 10° C. to 40° C., of 1.5×10?6/° C. or less.
    Type: Grant
    Filed: September 20, 2001
    Date of Patent: September 26, 2006
    Assignee: Sumitomo Metal Industries, Ltd.
    Inventors: Yasuki Yoshitomi, Tadahisa Arahori
  • Patent number: 7101820
    Abstract: The disclosed invention relates to novel crystalline compositions which may be obtained by doping the alpha (?) form of AlPO4 ceramics, which find use as piezoelectric materials, stable supports for catalysts, biotechnology uses, and the like.
    Type: Grant
    Filed: May 26, 2004
    Date of Patent: September 5, 2006
    Assignee: E. I. du Pont de Nemours and Company
    Inventor: Pratibha Laxman Gai
  • Patent number: 7101821
    Abstract: This invention provides a silicon composition comprising at least 15 wt % of hydrolysed silicon compounds and at least 3 wt % of a binder material. The silicon composition is used in the manufacture of ceramics. The hydrolysed silicon compounds can for example be the gel produced by hydrolysing higher boiling point organohalosilanes produced in the manufacture of organohalosilanes or halosilanes by the direct process.
    Type: Grant
    Filed: May 27, 2003
    Date of Patent: September 5, 2006
    Assignee: Dow Corning Corporation
    Inventors: Hagen Demes, Helmut Fackler
  • Patent number: 7091146
    Abstract: Ceramics containing 80 wt % or greater of alumina (Al2O3), with Mn, Ti, Fe, Si, Ca and Mg, with Mn—Al spinal (MnO.Al2O3) crystals and anorthite crystals (CaO.Al2O3.2SiO2) generated by calcination, and having a volume resistivity of 1×1011 ?·cm or less. Preferably, the ceramics contains a combined weight of 2–11 wt % or greater of Mn, Ti and Fe as the oxides, 0.5 wt % or greater of Mn as manganese dioxide (MnO2), 0.5 wt % or greater of Ti as titanium oxide (TiO2), and 0.5 wt % or greater of Fe as iron oxide (Fe2O3).
    Type: Grant
    Filed: July 21, 2004
    Date of Patent: August 15, 2006
    Assignee: Sodick Co., Ltd.
    Inventors: Yoshiharu Okiyama, Ryo Yamaguchi
  • Patent number: 7074733
    Abstract: An unwrought refractory composition, in particular for producing glass furnace hearths, includes a base mixture comprising in wt. %: 1 to 6% of a hydraulic cement, and 94 to 99% of particles of at least a refractory material mainly consisting of alumina (Al2O3), zirconia (ZrO2) and silica (SiO2), the fraction of the particles of the base mixture having a size less than 40 ?m being distributed in wt. % relative to the weight of the base mixture, as follows: fraction<0.5 ?m: ?4%; fraction<2 ?m: ?5%; fraction<10 ?m: ?16%; fraction<40 ?m: 29–45%, the refractory composition further comprising, in wt. % relative to the weight of the base mixture: 0.02 to 0.08% of organic fibers, and 0.075 to 1% of a surfactant.
    Type: Grant
    Filed: November 19, 2002
    Date of Patent: July 11, 2006
    Assignee: Saint-Gobain Centre de Recherches Et d'Etudes Europeen
    Inventors: Jacques Marius Louis Guigonis, Thierry Claude Consales
  • Patent number: 7067445
    Abstract: A proppant mixture with an extended particle size distribution exhibits improved properties, such as crush strength and conductivity, as compared with a conventional product with a narrow size distribution.
    Type: Grant
    Filed: August 23, 2004
    Date of Patent: June 27, 2006
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Roy A. Webber, Danny L. Mickelson, Stephen K. Schubarth, Edwyn M. Snyder, Andrew T. Sheppard
  • Patent number: 7067447
    Abstract: A material (100) formed of a sintered aggregation of ceria particles (106), mullite particles (108) and an alumina matrix material (110). Differential thermal expansion of the ceria and mullite particles generates thermal stress sufficient to create micro-cracking of the ceria particles. The ratio of ceria to mullite may be selected to achieve a desired coefficient of thermal expansion for matching the thermal growth of a mating CMC material (102). The micro cracks provide the material with a desired degree of strain tolerance useful in high temperature applications such as a solid core gas turbine vane (20).
    Type: Grant
    Filed: September 4, 2003
    Date of Patent: June 27, 2006
    Assignee: Siemens Power Generation, Inc.
    Inventor: Christian X. Campbell
  • Patent number: 7063801
    Abstract: The invention relates to an improvement in tourmaline known as a functional ore. In particular, the invention provides a composite having a novel formation in which a far infrared radiation emitting property and others among tourmaline's properties are effectively exploited, a novel process for producing the composite, and composite materials to be used therefore.
    Type: Grant
    Filed: November 29, 2000
    Date of Patent: June 20, 2006
    Inventor: Hiroshi Sato
  • Patent number: 7037870
    Abstract: A ceramic sintered body comprising from 90 to 99.8% by volume of cordierite and from 0.2 to 10% by volume of mullite based on 100% by weight of a total sum of the contents of the cordierite and the mullite, and having a density of 2.48 g/cm3 or more.
    Type: Grant
    Filed: January 30, 2003
    Date of Patent: May 2, 2006
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Hiroshi Yamamoto, Eiji Miura, Takeshi Mitsuoka, Kazuhiro Urashima
  • Patent number: 7015167
    Abstract: A raw material with a high content of aluminum oxide has the following composition, in weight-percent, based on dry weight: Al2O3 ?50–80% MgO ??2–15% SiO2 ??1–15% CaO 0.5–20% Fe2O3 0.5–2% Na2O 0.5–2% Al (metallic) 0.1–2% AlN 0.1–1% K2O 0.1–1.5% F 0.1–2% Cl 0.1–0.8% balance in total, not to exceed ?5% loss on ignition, not to exceed 15% The main mineral constituents of the raw material are, in weight-percent aluminum hydroxide 20–60% corundum ?-Al2O3 10–40% spinel MgAl2O4 ?5–40% Specifically, the aluminum hydroxide is present as aluminum mono-hydroxide Al2O3.H2O and aluminum tri-hydroxide Al2O3.3H2O in a weight ratio exceeding 0.25.
    Type: Grant
    Filed: January 7, 2004
    Date of Patent: March 21, 2006
    Assignee: Aluminium-Salzschlacke Aufbereitungs GmbH
    Inventors: Reinhard Feige, Gerhard Merker, Jurgen Steyer
  • Patent number: 7001861
    Abstract: An aluminum titanate-based ceramic article having a composition comprising u (Al2O3—TiO2)+v (R)+w (3Al2O3—2SiO2)+x (Al2O3)+y (SiO2)+z (1.1SrO-1.5Al2O3-13.6SiO2—TiO2)+a (Fe2O3—TiO2)+b (MgO-2TiO2), where, R is SrO—Al2O3-2SiO2 or 11.2SrO-10.9Al2O3-24.1SiO2—TiO2, where u, v, w, x, y, z, a and b are weight fractions of each component such that (u+v+w+x+y+z+a+b=1), and 0.5<u?0.95, 0.01<v?0.5, 0.01<w?0.5, 0?x?0.5, 0?y?0.1, 0?z?0.5, 0<a?0.3, and 0?b?0.3. A method of forming the ceramic article is provided. The ceramic article is useful in automotive emissions control systems, such as diesel exhaust filtration.
    Type: Grant
    Filed: July 24, 2003
    Date of Patent: February 21, 2006
    Assignee: Corning Incorporated
    Inventors: George H. Beall, Isabelle M. Melscoet-Chauvel, Steven B. Ogunwumi, Dell J. St. Julien, Patrick D. Tepesch, Christopher J. Warren
  • Patent number: 6995105
    Abstract: The use of a three-component water-soluble polymer comprising 5–90% by weight of a component a), preferably of the maleic acid, fumaric acid or itaconic acid type, 5–90% by weight of a component b) essentially from the group consisting of 2-acrylamido-2-methylpropanesulfonic acid, vinylsulfonic acid and vinylphosphonic acid, and 5–90% by weight of a component c) comprising acrylic acid, methacrylic acid, acrylamide or methacrylamide, as fluidizer for refractory compositions comprising alumina cement is described. The copolymer, which has a preferred molecular weight Mw of <50,000, can also be combined with further quality-improving additives such as silica, lime or soda and further customary additives for refractory compositions.
    Type: Grant
    Filed: July 8, 1999
    Date of Patent: February 7, 2006
    Assignee: SKW Polymers GmbH
    Inventors: Steffen Wache, Johann Plank, Konrad Wutz, Manfred Bichler
  • Patent number: 6987077
    Abstract: A fired spinel complex oxide is produced by firing a mixture containing a slag by-produced in chromium refining, a reducer, and a silica-containing material, and is essentially composed of: 29 to 40 percent by weight of Fe2O3; 15 to 20 percent by weight of Al2O3; 9 to 14 percent by weight of MgO; 0 to 4 percent by weight of Na2O; 9 to 17 percent by weight of Cr2O3; 14 to 20 percent by weight of SiO2; and 2 percent by weight or less of CaO. The fired spinel complex oxide shows a Cu—K? X-ray diffraction pattern in which the ratio (b/a) of the diffraction peak intensity of the silica-containing material (b) in the vicinity of 2?=26.7° to the {113} plane diffraction peak intensity (a) in the vicinity of 2?=36° is 0.1 or less.
    Type: Grant
    Filed: June 10, 2004
    Date of Patent: January 17, 2006
    Assignee: Nippon Chemical Industrial Co., Ltd.
    Inventors: Nobuo Takagi, Masami Tadasa
  • Patent number: 6942713
    Abstract: An aluminum titanate-based ceramic body having a composition a formula comprising a(Al2O3.TiO2)+b(CaO.Al2O3.2SiO2)+c(SrO.Al2O3.2SiO2)+d(BaO.Al2O3.2SiO2)+e(3Al2O3.2SiO2)+f(Al2O3)+g (SiO2)+h(Fe2O3.TiO2)+i(MgO.2TiO2), wherein a, b, c, d, e, f, g, h, and i are weight fractions of each component such that (a+b+c+d+e+f+g+h+i)=1, wherein 0.5<a?0.95; 0?b?0.5; 0?c?0.5; 0?d?0.5; 0<e?0.5; 0?f?0.5; 0?g?0.1; 0?h?0.3; 0?i?0.3; b+d>0.01. A method of forming the ceramic body is provided. The ceramic body is useful in automotive emissions control systems, such as diesel exhaust filtration.
    Type: Grant
    Filed: September 30, 2004
    Date of Patent: September 13, 2005
    Assignee: Corning Incorporated
    Inventors: Steven B. Ogunwumi, Patrick D. Tepesch, Raja R. Wusirika
  • Patent number: 6936557
    Abstract: A novel multipurpose mineral composition capable of emitting a large quantity of far infrared rays, negative ions and oxygen heat is manufactured by setting up an iron railing, an iron rod and an iron plate on a brazier, placing a tinfoil on the iron plate, and layering yellow soil, kaolin, sericite, and biomineral in sequence on the tinfoil, while inserting the tinfoil between the layers, loading a pulverized elvan in the furnace, pulverizing a mixed stone including 40 wt % of germanium, 15 wt % of tourmaline, 30 wt % of zeolite, and 15 wt % of franklinite, to the particle size under about 44 ?m, and loading the pulverized mixed stone in an internal furnace which is made by winding a copper plate with a tinfoil and placed on the plurality of layers of the furnace, heating the pulverized mixed stone at about 1,000° C. for about seven days into a lump, and repulverizing the lump.
    Type: Grant
    Filed: May 28, 2002
    Date of Patent: August 30, 2005
    Inventor: Yong-Jin Park
  • Patent number: 6933255
    Abstract: A method of preparing beta-spodumene bodies from a plastic batch comprised entirely of minerals, absent a glass component. The resulting structure has a stoichiometry of 1:1:4 (Li2O:Al2O3:SiO2) to 1:1:11 (Li2O:Al2O3:SiO2), and exhibits a low coefficient of thermal expansion, high porosity and high strength, and is suitable for automotive catalytic converter substrates requiring a fast light-off time. There is also provided a ceramic article having a solid-solution of beta-spodumene ranging in molar ratio from 1:1:4 Li2O—Al2O3—SiO2 to 1:1:11 LiO2—Al2O3—SiO2 wherein a component selected from the group consisting of magnesium oxide (MgO), manganese oxide (MnO), and cobalt oxide (CoO) is substituted for lithium oxide (LiO2) at 10 to 65 mole %, and optionally a minor phase of mullite (3Al2O3-2SiO2) in an amount of up to 50% by weight.
    Type: Grant
    Filed: June 30, 2003
    Date of Patent: August 23, 2005
    Inventors: Douglas M. Beall, George H. Beall
  • Patent number: 6921578
    Abstract: A low reflection film comprising silica fine particles and a binder in a weight ratio proportion of 60:40 to 95:5 is obtained by mixing starting fine particles comprising at least non-aggregated silica fine particles with a mean particle size of 40-1000 nm and/or linear (chain-like) aggregated silica fine particles with a mean primary particle size of 10-100 nm, a hydrolyzable metal compound, water, and a solvent, hydrolyzing the hydrolyzable metal compound in the presence of the starting fine particles, and then coating the prepared coating solution onto a glass base substrate and subjecting it to heat treatment. The obtained low reflection film is a single-layer low reflection film with low reflectivity, excellent abrasion resistance, high film strength and excellent contamination removal property, and coating of the low reflection film onto glass base substrates can give low reflection glass articles.
    Type: Grant
    Filed: August 11, 2001
    Date of Patent: July 26, 2005
    Assignee: Nippon Sheet Glass Co., Ltd.
    Inventors: Toshifumi Tsujino, Hideki Okamoto, Tetsuro Kawahara
  • Patent number: 6919289
    Abstract: Methods and compositions are provided for making low temperature sintering ceramic bodies that have very low thermal expansion and low porosity.
    Type: Grant
    Filed: October 5, 2004
    Date of Patent: July 19, 2005
    Assignee: Carlisle FoodService Products, Incorporated
    Inventor: Gerard E. Parker
  • Patent number: 6849181
    Abstract: The invention is directed at a mullite-aluminum titanate porous diesel particulate filter constituting a porous ceramic body containing, expressed in terms of weight percent of the total body, of 60-90%, preferably 70-80%, most preferably 70% iron-aluminum titanate solid solution having a stoichiometry of Al2(1?x)Fe2xTiO5, where x is 0-0.1, and 10-40%, preferably 20-30%, most preferably 30% mullite (3Al2O3.2SiO2), and consists essentially, expressed in terms of weigh percent on the oxide basis, of 3 to 15% SiO2, 55 to 65% Al2O3, 22 to 40% TiO2, and 0 to 10% Fe2O3, and being useful for filtration of diesel exhaust. The inventive diesel particulate filter exhibits high interconnected open porosity and large median pore size, in combination with high permeability when fired to a temperature of between 1650° to 1700° C., along with high thermal shock resistance and good filtration capability.
    Type: Grant
    Filed: July 31, 2002
    Date of Patent: February 1, 2005
    Assignee: Corning Incorporated
    Inventors: Steven B. Ogunwumi, Patrick D. Tepesch
  • Publication number: 20040266606
    Abstract: Ceramics containing 80 wt % or greater of alumina (Al2O3), with Mn, Ti, Fe, Si, Ca and Mg, with Mn—Al spinel (MnO·Al2O3) crystals and anorthite crystals (CaO·Al2O3·2SiO2) generated by calcination, and having a volume resistivity of 1×1011 &OHgr;·cm or less. The ceramics contains a combined weight of 2-11 wt % or greater of Mn, Ti and Fe as the oxides, 0.5 wt % or greater of Mn as manganese dioxide (MnO2 ), 0.5 wt % or greater of Ti as titanium oxide (TiO2), and 0.
    Type: Application
    Filed: July 21, 2004
    Publication date: December 30, 2004
    Applicant: Sodick Co., Ltd.
    Inventors: Yoshiharu Okiyama, Ryo Yamaguchi
  • Publication number: 20040266600
    Abstract: A method of preparing beta-spodumene bodies from a plastic batch comprised entirely of minerals, absent a glass component. The resulting structure has a stoichiometry of 1:1:4 (LiO2:Al2O3:SiO2) to 1:1:11 (LiO2:Al203:SiO2), and exhibits a low coefficient of thermal expansion, high porosity and high strength, and is suitable for automotive catalytic converter substrates requiring a fast light-off time. There is also provided a ceramic article having a solid-solution of beta-spodumene ranging in molar ratio from 1:1:4 LiO2—Al2O3—SiO2 to 1:1:11 LiO2—Al2O3—SiO2 wherein a component selected from the group consisting of magnesium oxide (MgO), manganese oxide (MnO), and cobalt oxide (CoO) is substituted for lithium oxide (LiO2) at 10 to 65 mole %, and optionally a minor phase of mullite (3Al2O3-2SiO2) in an amount of up to 50% by weight.
    Type: Application
    Filed: June 30, 2003
    Publication date: December 30, 2004
    Inventors: Douglas M. Beall, George H. Beall
  • Publication number: 20040224835
    Abstract: A ceramic carrier comprising a substrate ceramic containing Mg, Al, Si and O as constituent elements and containing, as the second component, an element other than said constituent elements. The support contains many microvoids capable of absorbing thermal expansion, the porosity is larger than 28%, and the thermal expansion coefficient is smaller than 2.3×10−6/° C. The second component enables the direct loading of a catalytic component.
    Type: Application
    Filed: April 23, 2004
    Publication date: November 11, 2004
    Applicant: Denso Corporation
    Inventors: Tomomi Hase, Kazuhiko Koike, Shin-ichi Hirano
  • Patent number: 6815389
    Abstract: An economical and environment-friendly process for the synthesis of anionic clays with carbonate and/or hydroxide anions as the charge-balancing interlayer species is disclosed. The process involves reacting a slurry comprising an aluminum source and a magnesium source, the aluminum source comprising two types of aluminum-containing compounds, preferably aluminum trihydrate and/or thermally treated calcined aluminum trihydrate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.
    Type: Grant
    Filed: March 15, 2002
    Date of Patent: November 9, 2004
    Assignee: Akzo Nobel NV
    Inventors: Dennis Stamires, Michael F. Brady, William Jones, Fathi Kooli
  • Publication number: 20040204305
    Abstract: A batch, in particular for the production of refractory shaped bodies, includes a mixture of a refractory, metal oxide main component containing 40 to 60% by weight of Al2O3, a phosphate bond and finely particulate SiC having a grain size of <0.2 mm, and a process using the mixture for forming the batch to produce the refractory shaped bodies.
    Type: Application
    Filed: April 28, 2004
    Publication date: October 14, 2004
    Applicant: Refratechnik Holding GmbH
    Inventors: Heinrich Liever, Hans-Jurgen Klischat, Holger Wirsing
  • Publication number: 20040191154
    Abstract: The present invention relates to an icosahedral, quasicrystalline compound or compound present in the form of an approximant having the nominal composition: TivCrwAlxSiyOz, in which v=60-65; w=25-30; x=0-6; Y=8-15; z=8-20; and in which the atom percent of oxygen is in the range of between 8 and 15%, and that of aluminum in the range of between 2 to 5%. Due to their layered structure and ceramic intermediate layers, compounds of this type exhibit excellent properties, in particular for use as coatings for gas turbine components, such as for example, rotor blades or guide vanes.
    Type: Application
    Filed: March 31, 2003
    Publication date: September 30, 2004
    Inventors: Valery Shklover, Maxim Konter, Anton Kaiser, Kenneth Franklin Kelton
  • Patent number: 6780804
    Abstract: A proppant mixture with an extended particle size distribution exhibits improved properties, such as crush strength and conductivity, as compared with a conventional product with a narrow size distribution.
    Type: Grant
    Filed: January 24, 2003
    Date of Patent: August 24, 2004
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Roy A. Webber, Danny L. Mickelson, Stephen K. Schubarth, Edwyn M. Snyder, Andrew T. Sheppard
  • Patent number: 6774075
    Abstract: Ceramic mass and thermal transfer media suitable for use in thermal regenerative oxidizers made using a mixture of a ball clay, talc and optionally a dolomitic limestone have enhanced resistance to environments containing halogens and hydrogen halides. The media preferably comprises less than 0.25% by weight of alkali metal, expressed as the oxide, and has a cordierite: silica phase ratio of less than 1.2:1, as determined by X-ray diffraction.
    Type: Grant
    Filed: June 13, 2003
    Date of Patent: August 10, 2004
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: John S. Reid, Thomas Szymanski, Karen C. Beal
  • Publication number: 20040147388
    Abstract: A proppant mixture with an extended particle size distribution exhibits improved properties, such as crush strength and conductivity, as compared with a conventional product with a narrow size distribution.
    Type: Application
    Filed: January 24, 2003
    Publication date: July 29, 2004
    Applicant: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Roy A. Webber, Danny L. Mickelson, Stephen K. Schubarth, Edwyn M. Snyder, Andrew T. Sheppard
  • Patent number: 6753277
    Abstract: Ceramics comprising filler crystal particles having an average particle diameter of not smaller than 2.5 &mgr;m and a matrix crystal phase present on the grain boundaries of the filler crystal particles, the filler crystal particles being Al2O3 and the matrix crystal phase being diopside-type oxide crystals precipitated from the crystallized glass. The ceramics has a dielectric loss tangent at 60 to 77 GHz of not higher than 50×10−4, and can be effectively used as an insulating substrate in a wiring board for transmitting high-frequency signals.
    Type: Grant
    Filed: February 27, 2001
    Date of Patent: June 22, 2004
    Assignee: Kyocera Corporation
    Inventor: Yoshitake Terashi
  • Patent number: 6753299
    Abstract: An improved lightweight and highly permeable proppant composition for use in increasing the productivity of a gas or oil well. The proppant composition includes equal amounts by weight of uncalcined bauxite, uncalcined shale and quartz, held together with a binder formed of wollastonite and talc in an amount of less than 10% by weight of the composition. The proppant composition has an alumina content of less than 25% by weight of the composition and a silica content of over 45% by weight of the composition.
    Type: Grant
    Filed: November 9, 2001
    Date of Patent: June 22, 2004
    Assignee: Badger Mining Corporation
    Inventors: Eugene P. Lunghofer, Larry A. Wolfe
  • Patent number: 6749769
    Abstract: The disclosed invention relates to novel crystalline compositions which may be obtained by doping the alpha (&agr;) form of AlPO4 ceramics, which find use as piezoelectric materials, stable supports for catalysts, biotechnology uses, and the like.
    Type: Grant
    Filed: March 6, 2002
    Date of Patent: June 15, 2004
    Assignee: E. I. du Pont de Nemours and Company
    Inventor: Pratibha Laxman Gai
  • Publication number: 20040102307
    Abstract: This invention concerns a non-basic refractory batch as well as its use.
    Type: Application
    Filed: November 12, 2003
    Publication date: May 27, 2004
    Applicant: Refractory Intellectual Property GmbH & Co. KG
    Inventors: Malgorzata Bugajski, Karl-Heinz Dott, Alfons Lueftenegger
  • Publication number: 20040087430
    Abstract: The invention relates to a refractory material for cement industry kilns and the use thereof. The inventive material can be used inside cement industry kilns in order to counteract the thermal and physico-chemical deformation that occurs inside the said kilns.
    Type: Application
    Filed: December 22, 2003
    Publication date: May 6, 2004
    Inventor: Pedro Farjardo Sola
  • Publication number: 20040043889
    Abstract: A material (100) formed of a sintered aggregation of ceria particles (106), mullite particles (108) and an alumina matrix material (110). Differential thermal expansion of the ceria and mullite particles generates thermal stress sufficient to create micro-cracking of the ceria particles. The ratio of ceria to mullite may be selected to achieve a desired coefficient of thermal expansion for matching the thermal growth of a mating CMC material (102). The micro cracks provide the material with a desired degree of strain tolerance useful in high temperature applications such as a solid core gas turbine vane (20).
    Type: Application
    Filed: September 4, 2003
    Publication date: March 4, 2004
    Applicant: Siemens Westinghouse Power Corporation
    Inventor: Christian X. Campbell
  • Publication number: 20040020846
    Abstract: The invention is directed at a mullite-aluminum titanate porous diesel particulate filter constituting a porous ceramic body containing, expressed in terms of weight percent of the total body, of 60-90%, preferably 70-80%, most preferably 70% iron-aluminum titanate solid solution having a stoichiometry of Al2(1−x)Fe2xTiO5, where x is 0-0.1, and 10-40%, preferably 20-30%, most preferably 30% mullite (3Al2O3.2SiO2), and consists essentially, expressed in terms of weigh percent on the oxide basis, of 3 to 15% SiO2, 55 to 65% Al2O3, 22 to 40% TiO2, and 0 to 10% Fe2O3, and being useful for filtration of diesel exhaust. The inventive diesel particulate filter exhibits high interconnected open porosity and large median pore size, in combination with high permeability when fired to a temperature of between 1650° to 1700° C., along with high thermal shock resistance and good filtration capability.
    Type: Application
    Filed: July 31, 2002
    Publication date: February 5, 2004
    Inventors: Steven B. Ogunwumi, Patrick D. Tepesch
  • Patent number: 6677261
    Abstract: Strong, high-surface-area honeycombs of alumina or other ceramic composition are provided by compounding and shaping a moldable ceramic powder extrusion batches including a cellulosic temporary binder and a high-surface-area boehmite precursor for a permanent binder, hydrating the shaped honeycomb to develop a boehmite binding phase, and calcining the hydrated body to develop the binder and provide a ceramic honeycomb of high strength and porosity.
    Type: Grant
    Filed: July 31, 2002
    Date of Patent: January 13, 2004
    Assignee: Corning Incorporated
    Inventors: William P. Addiego, Cecilia S. Magee
  • Patent number: 6667262
    Abstract: The invention comprises a self-lubricating ceramic composite characterized as having a low porosity derived from a mixture of at least one ceramic powder preferably selected from the group consisting of silicon nitride, silicon carbide, zirconia, alumina, zirconium nitride, tungsten carbide, and titanium carbide; a cemetitious binder, effective amounts of at least one metal silicide, and at least one metal oxide. The ceramic powder mixture can be slurried with sufficient amounts of water and subsequently subjected to pressures of about 6.0 to 7.0 MPa in a mold at temperatures of about 125° to 175° C. to form a self-lubricating ceramic composite capable of maintaining hot-hardness temperatures above 750° C. These self-lubricating ceramic composites are particularly useful in the manufacture of high-performance turbine engines, including engine parts, bearings, gears, rotors and in other areas where high-heat lubricating properties of the ceramic composite are required.
    Type: Grant
    Filed: September 7, 2001
    Date of Patent: December 23, 2003
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Vinod S. Agarwala, Alfeo A. Conte, Jr.
  • Patent number: 6660673
    Abstract: In order to reduce wear on refractory linings due to corrosion and the infiltration of slags and molten metals, particulate materials containing TiO2 are added to the refractory products consisting of a mixture of aggregates and binding agents.
    Type: Grant
    Filed: July 24, 2000
    Date of Patent: December 9, 2003
    Assignee: Sachtleben Chemie GmbH
    Inventors: Djamschid Amirzadeh-Asl, Dieter Fünders
  • Publication number: 20030224921
    Abstract: A dielectric ceramic article precursor and a process for preparing a dielectric ceramic article are presented. The ceramic article precursor comprises a crystalline aluminosilicate zeolite or an amorphous aluminosilicate and a glass phase. The ceramic article precursor can optionally contain at least one forming aid selected from binders, plasticizers and surfactants. Metal oxide additives such as B2O3 or SnO2 as well as metal oxide precursor additives such as nitrates or carbonates of metals such as boron or tin can also be included in the ceramic article precursor. The process for preparing a dielectric ceramic article involves forming a mixture from the above components into a shaped article such as a tape and then calcining the shaped article at a temperature of about 700° C. to about 1000° C. for a time of about 0.5 to about 24 hours.
    Type: Application
    Filed: August 16, 2002
    Publication date: December 4, 2003
    Inventor: Robert L. Bedard
  • Patent number: 6649552
    Abstract: The subject of the invention is ceramic fibers for the reinforcement of refractory materials, being constituted by sintered bauxite fibers with a length/diameter greater than 10. Preferably, they have a cylindrical or prismatic shape truncated by two surfaces, for example, substantially planar surfaces perpendicular to the axis of the prism. They enable the mechanical strength and the lifetime of the refractory products to be significantly increased.
    Type: Grant
    Filed: September 13, 2000
    Date of Patent: November 18, 2003
    Assignee: Pem Abrasifs Refractaires
    Inventor: Jean-Andre Alary
  • Patent number: 6630199
    Abstract: A structure protected by a ceramic coating is prepared by providing a substrate having a surface, and depositing a layer of a sacrificial ceramic precursor material, preferably silica, onto the surface of the substrate. The method further includes furnishing a reactive gas, preferably an aluminum-containing gas, that is reactive with the sacrificial ceramic to produce a protective ceramic different from the sacrificial ceramic, and contacting the reactive gas to the layer of the precursor material to produce a protective ceramic layer.
    Type: Grant
    Filed: November 8, 2000
    Date of Patent: October 7, 2003
    Assignee: General Electric Company
    Inventors: Curtiss Mitchell Austin, Richard John Grylls
  • Patent number: 6623859
    Abstract: The object of the present invention is to save labor, reduce cost, and to make detergents and wax unnecessary. Water quality improving materials used in a washing device are provided, wherein; raw ceramic powder material containing tourmaline is adhered on the surfaces of ceramic carriers, and then fired to form tourmaline containing films, whereby washing powder is improved by activating water and the contained boric silica S1, S2 . . . adheres onto the surface W of an automobile, etc. As a form thereof, the boric silica S1, S2 . . . is adhered by an electrode position action due to the electrical charges generated by tourmaline and the water is activated by these electrical charges.
    Type: Grant
    Filed: September 29, 2000
    Date of Patent: September 23, 2003
    Assignees: Shibatatouki Co., Ltd., Echizenshikki Co., Ltd., Enuemu Co., Ltd.
    Inventor: Junro Ito
  • Patent number: 6620751
    Abstract: A structure for use in high temperature applications and including a porous ceramic material consisting essentially of about 50-90 percent by weight iron or magnesium stabilized aluminum titanate (AlTiO5) and about 10-50 percent by weight strontium feldspar (SrO.Al2O3.2SiO2), and having a coefficient of thermal expansion over a temperature range from room temperature to 1000° C. of about −10×10−7/° C. to +15×10−7/° C., a heat capacity at 500° C. greater than 3.2 J/cm3K, a porosity of about 15-50 percent by volume, preferably 40-50 percent by volume, and a median pore size of about 5-50 micrometers, preferably 8-15 micrometers. The structure is especially useful as a diesel exhaust particulate filter.
    Type: Grant
    Filed: March 14, 2002
    Date of Patent: September 16, 2003
    Assignee: Corning Incorporated
    Inventor: Steven B. Ogunwumi
  • Patent number: 6605557
    Abstract: Ceramic mass transfer media suitable for use in thermal regenerative oxidizers made using a mixture of a clay, talc and optionally a dolomitic limestone have enhanced resistance to environments containing halogens and hydrogen halides.
    Type: Grant
    Filed: May 4, 2001
    Date of Patent: August 12, 2003
    Assignee: Saint-Gobain Norpro Corporation
    Inventors: John S. Reid, Thomas Szymanski, Karen C. Beal
  • Publication number: 20030139280
    Abstract: An electroconductive low thermal expansion ceramic sintered body is disclosed which containing a &bgr;-eucryptite phase in a quantity of not less than 75 vol. % and not more than 99 vol. % and having an absolute value of thermal expansion coefficient of not more than 1.0×10−7/K at a temperature of 0° C. to 50° C., a volumetric specific resistance of not more than 1.0×107 &OHgr;·cm, and a specific rigidity of not less than 40 GPa/g/cm3.
    Type: Application
    Filed: November 25, 2002
    Publication date: July 24, 2003
    Inventors: Fumiaki Takahashi, Tetsuro Nose, Masashi Nakabayashi
  • Patent number: 6596665
    Abstract: A mullite composition is comprised substantially of mullite grains that are essentially chemically bound wherein the composition has at least two adjoining regions that have substantially different microstructures. The composition may be produced by forming a mixture of one or more precursor compounds having the elements present in mullite; shaping the mixture into a porous green shape applying a nucleation control agent to a portion of the porous green shape and then heating the porous green shape under an atmosphere and to a temperature sufficient to form the mullite composition.
    Type: Grant
    Filed: August 29, 2001
    Date of Patent: July 22, 2003
    Assignee: Dow Global Technologies Inc.
    Inventors: Sten A. Wallin, John R. Moyer, Arthur R. Prunier, Jr.
  • Patent number: 6589900
    Abstract: A ceramic product containing at least 70% lithium aluminium silicate of 100% total mass weight percent; and a non-wetting agent in the form of barium sulphate. Most preferably, the lithium aluminium silicate includes petalite in finely divided form which has been fired to a temperature between 1150° C. and 1210° C.
    Type: Grant
    Filed: April 23, 2001
    Date of Patent: July 8, 2003
    Assignee: Dakot CC
    Inventor: Dirk A. Kotze
  • Publication number: 20030109372
    Abstract: Rare-earth alloy is cast into a sheet (6) or the like by using a tundish (3, 13). The refractory material of the tundish used for casting does not necessitate preheating for improving the flowability of the melt (2). The refractory material used essentially consists of 70 wt % or more of Al2O3 and 30 wt % or less of SiO2, or 70 wt % or more of ZrO2 and 30 wt % or less of one or more of Y2O3, Ce2O3, CaO, MgO, Al2O3, TiO2 and SiO2. The refractory material has 1 g/cm3 or less of bulk density, has 0.5 kca/(mh° C.) or less of thermal conductivity in the temperature range of from 1200 to 1400° C., and has 0.5 wt % or less of ratio of ignition weight-loss under the heating condition of 1400° C. for 1 hour.
    Type: Application
    Filed: October 23, 2002
    Publication date: June 12, 2003
    Applicant: SHOWA DENKO K.K.
    Inventors: Hiroshi Hasegawa, Nobuhiko Kawamura, Shiro Sasaki, Yoichi Hirose
  • Publication number: 20030095905
    Abstract: Pyrogenically produced aluminum-silicon mixed oxides with a BET surface of more than 300 m2/g and a composition of 0.01 to 99.99% by wt. Al2O3, remainder SiO2 are produced in accordance with the method of flame pyrolysis or preferably flame hydrolysis by a joint combustion of the gaseous raw substances. They can be used to produce coating colors, especially for inkjet papers or inkjet foils or other inkjet materials.
    Type: Application
    Filed: July 22, 2002
    Publication date: May 22, 2003
    Inventors: Thomas Scharfe, Ronald Apel, Alfons Moster, Helmut Mangold, Ralph Brandes
  • Patent number: RE38888
    Abstract: A ceramic comprising predominately a cordierite-type phase approximating the stoichiometry Mg2Al4Si5O18 and having a coefficient of thermal expansion (25-800° C.) of greater than 4×10?7/° C. and less than 13×10?7/° C. and a permeability and a pore size distribution which satisfy the relation 2.108 (permeability)+18.511 (total pore volume)+0.1863 (percentage of total pore volume comprised of pores between 4 and 40 micrometers)>24.6. The ceramic is suitable in the fabrication of cellular, wall-flow, diesel particulate filters having a pressure drop in kPa that at an artificial carbon soot loading of 5 grams/liter and a flow rate of 26 scfm is less than 8.9-0.035 (number of cells per square inch)+300 (cell wall thickness in inches), a bulk filter density of at least 0.60 g/cm3 and a volumetric heat capacity of at least 0.67 J cm?3 K?1 as measured at 500° C.
    Type: Grant
    Filed: September 22, 2003
    Date of Patent: November 22, 2005
    Assignee: Corning Incorporated
    Inventors: Douglas M. Beall, David L. Hickman, Gregory A. Merkel