Pore-forming Patents (Class 501/80)
  • Patent number: 10479717
    Abstract: A glass foam and methods of producing the same are disclosed. The glass foam is produced from a dried glass precursor gel having nanometer-sized pores and a bulk amorphous oxide-based matrix with an inorganic network of primary constituent oxides. One method includes obtaining the dried glass precursor gel, heating the dried glass precursor gel to a temperature below the melting point of the gel, maintaining the temperature for a time sufficient to expand the dried glass precursor gel, and expanding the dried glass precursor gel to form the glass foam.
    Type: Grant
    Filed: October 3, 2016
    Date of Patent: November 19, 2019
    Assignee: Owens-Brockway Glass Container Inc.
    Inventors: Scott Cooper, Varun Mukheja, Tilak Gullinkala
  • Patent number: 9822437
    Abstract: A process for producing a thermal barrier coating having an excellent thermal barrier effect and superior durability to thermal cycling. Also, a turbine member having a thermal barrier coating that has been formed using the production process, and a gas turbine. The process for producing a thermal barrier coating includes: forming a metal bonding layer (12) on a heat-resistant alloy substrate (11), and forming a ceramic layer (13) on the metal bonding layer (12) by thermal spraying of thermal spray particles having a particle size distribution in which the 10% cumulative particle size is not less than 30 ?m and not more than 100 ?m.
    Type: Grant
    Filed: August 30, 2010
    Date of Patent: November 21, 2017
    Assignee: MITSUBISHI HITACHI POWER SYSTEMS, LTD.
    Inventors: Taiji Torigoe, Ichiro Nagano, Ikuo Okada, Keizo Tsukagoshi, Kazutaka Mori, Yoshiaki Inoue, Yoshitaka Uemura, Yoshifumi Okajima, Hideaki Kaneko, Masahiko Mega
  • Patent number: 9574282
    Abstract: A protective coating for a surface exposed to hot gas flow comprises a thermal layer, a conducting layer and an abrasive layer. The thermal layer comprises alumina having a sufficient amount of impurities to lower the thermal layer thermal conductivity. The layer is formed from a powder having a thermal conductivity no more than 10 BTU in/hr ft2° F., and overlies the surface. The conducting layer overlies the thermal layer. The abrasive layer comprises abrasive particles bonded in a metal matrix that is electroplated onto the conducting layer.
    Type: Grant
    Filed: August 13, 2012
    Date of Patent: February 21, 2017
    Assignee: United Technologies Corporation
    Inventors: Joseph Parkos, Melvin Freling
  • Patent number: 9388082
    Abstract: The present invention aims at providing a porous molded product comprising magnesium and aluminum which is satisfactory in both of a specific surface area and mechanical properties, can be suitably used as filters, drying agents, adsorbents, purifying agents, deodorants, carriers for catalysts, etc., includes a large amount of micropores, and has a large specific surface area and a high strength, as well as a process for producing the porous molded product. The porous molded product of the present invention comprises at least magnesium and aluminum, and having a magnesium content of 10 to 50% by weight in terms of a magnesium atom, an aluminum content of 5 to 35% by weight in terms of an aluminum atom, a pore volume of 0.01 to 0.5 cm3/g, an average pore diameter of not more than 300 ? and an average collapse strength of not less than 3 kg, and can be produced by molding hydrotalcite comprising at least magnesium and aluminum and then calcining the resulting molded product at a temperature of 500 to 1500° C.
    Type: Grant
    Filed: December 25, 2008
    Date of Patent: July 12, 2016
    Assignee: TODA KOGYO CORPORATION
    Inventors: Shinji Takahashi, Naoya Kobayashi
  • Patent number: 9309027
    Abstract: A peelable sealing structure includes a sealing layer and one or more optional additional layers. The peelable sealing structure includes a sealing surface that is formable into a peelable seal upon contact with a sealing substrate at all temperatures in a peelable seal temperature range. Moreover, the peelable sealing structure comprises a thermoplastic polymer and an additive dispersed within at least a portion of the thermoplastic polymer with the peelable sealing structure defining the sealing surface.
    Type: Grant
    Filed: June 7, 2013
    Date of Patent: April 12, 2016
    Assignee: Intercontinental Great Brands LLC
    Inventors: Panagiotis Kinigakis, Kenneth Pokusa, Gary Albaum, Alexander Jones, Eric Frederickson
  • Patent number: 9120706
    Abstract: Provided is a method for producing a silicon carbide ceramic easily and simply producing a silicon carbide ceramic having a small amount in resistivity change due to temperature change and being capable of generating heat by current application; and having a forming raw material preparing step of mixing two or more kinds of silicon carbide ceramic powders containing 4H—SiC silicon carbide crystals at respectively different content ratio to prepare a forming raw material; a forming step of forming the forming raw material into a formed body; and a firing step of firing the formed body to produce a silicon carbide ceramic being adjusted at a content ratio of 4H—SiC silicon carbide crystal to a desired value.
    Type: Grant
    Filed: March 28, 2013
    Date of Patent: September 1, 2015
    Assignee: NGK Insulators, Ltd.
    Inventors: Atsushi Kaneda, Takayuki Inoue, Tsuyoshi Watanabe
  • Patent number: 9045371
    Abstract: A silicon carbide-based porous body comprising a plurality of silicon carbide (SiC) particles as an aggregate and a binder which binds the silicon carbide particles to each other, wherein the content of the binder, i.e. [100×binder/(silicon carbide particles+binder)] is 5 to 70% by volume, the open pore ratio is 30 to 70%, and the binder contains at least one member selected from the group consisting of a Ti silicide, a Zr silicide, a Mo silicide and a W silicide, in an amount of at least 60% by volume of the total binder. The silicon carbide-based porous body can avoid excessive temperature elevation when it is used as a filter and the particulate matter (PM) captured thereby is burnt and removed.
    Type: Grant
    Filed: December 8, 2008
    Date of Patent: June 2, 2015
    Assignee: NGK INSULATORS, LTD.
    Inventors: Masaaki Kawai, Yoshio Kikuchi
  • Publication number: 20150017418
    Abstract: A method for fabricating a porous framework includes contacting a substrate with a solution containing a plurality of component materials are dissolved in the solution. A solid composite made of the plurality of component materials is electrodeposited onto the substrate. A plurality of electrodepositing voltages is applied to vary a relative proportion of the component materials in the composite being electrodeposited, and at least one of the plurality of component materials is selectively etched away from the composite to form a plurality of pores.
    Type: Application
    Filed: July 12, 2013
    Publication date: January 15, 2015
    Inventors: Chun Kwan TSANG, Jian LU, Yang Yang LI
  • Patent number: 8920527
    Abstract: A ceramic abrasive grain product of a ceramic material composition, said ceramic abrasive grain product comprising at least fifty percent of abrasive grains having a uniform grain thickness of from 0.002 to 0.016 inches and a length such that the grain is self dressing when oriented such that the thickness of the grain is exposed to a workpiece, abrasive products made therefrom and method for manufacturing and using same.
    Type: Grant
    Filed: June 26, 2013
    Date of Patent: December 30, 2014
    Assignee: Washington Mills Management, Inc.
    Inventors: Robert Seider, Angelo R. Angelone
  • Patent number: 8906973
    Abstract: Disclosed and claimed herein are hybrid silica aerogels containing non-polymeric, functional organic materials covalently bonded at one or both ends to the silica network of the aerogels through a C—Si bond between a carbon atom of the organic material and a silicon atom of the aerogel network. Methods of their preparation are also disclosed.
    Type: Grant
    Filed: November 30, 2011
    Date of Patent: December 9, 2014
    Assignee: Aspen Aerogels, Inc.
    Inventors: Wendell E Rhine, Decio Coutinho, Kiranmayi Deshpande
  • Publication number: 20140342898
    Abstract: The present disclosure relates to porous ceramic articles and a method of making the same. The porous ceramic articles have microstructure of sinter bonded or reaction bonded large pre-reacted particles and pore network structure exhibiting large pore necks. The method of making the porous ceramic articles involves using pre-reacted particles having one or more phases. A plastic ceramic precursor composition is also disclosed. The composition includes a mixture of at least one of dense, porous, or hollow spheroidal pre-reacted particles and a liquid vehicle.
    Type: Application
    Filed: April 11, 2014
    Publication date: November 20, 2014
    Applicant: Corning Incorporated
    Inventors: Monika Backhaus-Ricoult, Christopher Raymond Glose
  • Publication number: 20140336033
    Abstract: Methods of making a porous cordierite ceramic honeycomb article are provided. In example methods, a batch composition includes a quantity of non-crosslinked pore former provided as a superaddition of about 20% or less of a dry weight of a quantity of inorganic components. Batch compositions are also provided that include a quantity of clay and other substantially nonfibrous inorganic components sufficient to yield an article including cordierite. Example batch compositions can include clay having a median particle size of about 7 ?m or less and/or provided in an amount that is 10% or less of the dry weight of the quantity of inorganic components.
    Type: Application
    Filed: July 25, 2014
    Publication date: November 13, 2014
    Inventor: William Peter Addiego
  • Patent number: 8780524
    Abstract: A ceramic electronic component includes a ceramic sintered body and an electrode provided on a surface of the ceramic sintered body. The electrode contains Ag. The ceramic sintered body contain glass material made of borosilicate glass. The glass material has closed pores and open pores therein. The closed pores and the open pores have diameters decreasing as being located away from the surface of the ceramic sintered body. This ceramic electronic component can prevent delamination of the electrode from the ceramic sintered body during a process of firing a green sheet.
    Type: Grant
    Filed: March 7, 2011
    Date of Patent: July 15, 2014
    Assignee: Panasonic Corporation
    Inventor: Noritaka Yoshida
  • Publication number: 20140167331
    Abstract: In a method for manufacturing a ceramic filter element for an exhaust gas filter of internal combustion engines, a combustible non-ceramic filter medium is shaped to a coil and impregnated with a ceramic slurry having a powder size distribution selected such that the ceramic filter element in the finished state has a desired porosity distribution that varies across the coil cross-section of the ceramic filter element.
    Type: Application
    Filed: September 5, 2013
    Publication date: June 19, 2014
    Applicant: MANN+HUMMEL GMBH
    Inventor: Andreas Franz
  • Patent number: 8728965
    Abstract: Provided is a method for producing a porous material, wherein porosity can be controlled to 50% or higher by means of a freezing method, pore size can be controlled to 10 ?m to 300 ?m, and pore diameter distribution is uniform. The method is a method for producing a porous material, comprising freezing a mixture of water and a raw material comprising at least any of a ceramic material, a resin, a metal, and precursors thereof from a specific portion of the mixture to use ice crystals produced at the time as a pore source and then heat-treating a dry material obtained by removing the ice from the frozen material, wherein the mixture of a raw material and water or the frozen material comprises an antifreeze protein.
    Type: Grant
    Filed: March 16, 2011
    Date of Patent: May 20, 2014
    Assignee: Nichirei Foods Inc.
    Inventors: Manabu Fukushima, Yuichi Yoshizawa, Norimitsu Murayama, Sakae Tsuda, Takeshi Koizumi, Toshifumi Inoue
  • Patent number: 8722188
    Abstract: Disclosed is a process for producing ceramic particles, such as proppants, that have at least 10 percent total porosity. The process includes forming a particle precursor that includes 5 percent to 30 percent of a first ceramic material and at least 40 percent of a second ceramic material. The sintering temperature of the first ceramic material may be lower than the sintering temperature of a second ceramic material. Heating the precursor to a maximum temperature above the sintering temperature of the first material and below the sintering temperature of the second material. Also disclosed is a ceramic article that has a particular combination of chemistry and alumina crystalline phase.
    Type: Grant
    Filed: December 31, 2009
    Date of Patent: May 13, 2014
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Tihana Fuss, Laurie San-Miguel, Kevin R. Dickson, Walter T. Stephens
  • Patent number: 8685125
    Abstract: Producing and using very low packing density ceramic abrasive grits comprising various fused aluminum oxide materials with or without other oxide additives, fused aluminum oxide-zirconium oxide co-fusions with or without other oxide additives, or sintered sol gel aluminum oxide materials with or without other oxide additives where the ceramic abrasive grains are preferably made by crushing bubbles of the material.
    Type: Grant
    Filed: June 5, 2013
    Date of Patent: April 1, 2014
    Assignee: Washington Mills Management, Inc.
    Inventors: Robert Seider, Angelo R. Angelone
  • Patent number: 8679385
    Abstract: A method of manufacturing a porous ceramic article is provided that includes injecting a gas into a precursor batch material. The gas is pressurized to a positive gauge pressure. Exemplary gasses that can be injected into the precursor batch material include at least one of nitrogen, helium, neon, argon, krypton, and xenon. Air can also be injected into the precursor batch material, including air in which at least a portion of CO2 and/or O2 naturally occurring in air has been removed.
    Type: Grant
    Filed: November 29, 2010
    Date of Patent: March 25, 2014
    Assignee: Corning Incorporated
    Inventor: Kevin Ying Chou
  • Patent number: 8658550
    Abstract: An oxide-ceramic forming clay comprising an oxide-ceramic forming material, a layered double hydroxide, a pore-forming agent, and water, wherein the amount of the pore-forming agent is between 3 and 50 parts by mass by superaddition to 100 parts by mass of a sum of the oxide-ceramic forming material and the layered double hydroxide and a sum of the pore-forming agent and an organic binder is between 5 and 55 parts by mass also by superaddition which has environment-friendly characteristics in a forming firing step, and usage thereof.
    Type: Grant
    Filed: April 1, 2009
    Date of Patent: February 25, 2014
    Assignee: NGK Insulators, Ltd.
    Inventor: Takahiro Tomita
  • Publication number: 20140007772
    Abstract: The present invention relates to a method of manufacturing a hydrogen transport membrane and the composite article itself. More specifically, the invention relates to producing a membrane substrate, wherein the ceramic substrate is coated with a metal oxide slurry, thereby eliminating the need for an activation step prior to plating the ceramic membrane through an electroless plating process.
    Type: Application
    Filed: July 5, 2012
    Publication date: January 9, 2014
    Inventors: Joseph M. SCHWARTZ, Joseph M. CORPUS, Hankwon LIM
  • Patent number: 8550257
    Abstract: A ceramic water purifying device is provided. The device includes a silver treated packed particle bed in one embodiment. The device may also include feldspar or bottled glass.
    Type: Grant
    Filed: June 2, 2010
    Date of Patent: October 8, 2013
    Inventor: Anthony Reid Harvey
  • Patent number: 8518528
    Abstract: A ceramic foam filter for molten aluminum alloys comprising an alumina silicate rich core and a boron glass shell and a chemical composition comprising: 20-70 wt % Al2O3, 20-60 wt % SiO2, 0-10 wt % CaO, 0-10 wt %; MgO and 2-20 wt % B2O3.
    Type: Grant
    Filed: April 2, 2007
    Date of Patent: August 27, 2013
    Assignee: Porvair PLC
    Inventors: Feng Chi, David P. Haack, Leonard S. Aubrey
  • Patent number: 8501296
    Abstract: Disclosed are high-porosity cordierite honeycomb substrates having a narrow pore size distribution, little or no microcracking, and high thermal shock resistance. The porous ceramic honeycomb substrates generally comprise a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite substrates.
    Type: Grant
    Filed: February 27, 2009
    Date of Patent: August 6, 2013
    Assignee: Corning Incorporated
    Inventor: Gregory Albert Merkel
  • Patent number: 8501650
    Abstract: Dry mix for treating refractory substrates, comprising combustible particles of at least one oxidizable substance which, in the presence of oxygen, gives rise to an exothermic reaction, and particles of at least one other substance, wherein these particles form together, during said exothermic reaction, a coherent mass capable of adhering to and/or interacting with the treated substrate, characterized in that it comprises, as particles of at least one other substance, particles of at least one expanding substance, in that the dry mix without the particles of this at least one expanding substance has a first bulk density and in that the mix comprising said at least one expanding substance has a second bulk density lower than said first bulk density.
    Type: Grant
    Filed: July 3, 2008
    Date of Patent: August 6, 2013
    Assignee: Fib-Services Intellectual S.A.
    Inventor: Osvaldo Di Loreto
  • Patent number: 8481438
    Abstract: Producing and using very low packing density ceramic abrasive grits comprising various fused aluminum oxide materials with or without other oxide additives, fused aluminum oxide-zirconium oxide co-fusions with or without other oxide additives, or sintered sol gel aluminum oxide materials with or without other oxide additives where the ceramic abrasive grains are preferably made by crushing bubbles of the material.
    Type: Grant
    Filed: June 13, 2008
    Date of Patent: July 9, 2013
    Assignee: Washington Mills Management, Inc.
    Inventors: Robert Seider, Angelo R. Angelone
  • Patent number: 8445395
    Abstract: A method of manufacturing a porous ceramic part, comprising the following steps in succession: a) preparing a mixture M containing a ceramic powder in suspension, at least one gelling agent and at least one foaming agent, at a mixing temperature which is higher than the gelling temperature of the gelling agent; b) shearing the mixture M at a foaming temperature which is higher than the gelling temperature, to obtain a foam; c) gelling the foam by cooling the mixture M to a temperature below the gelling temperature of the gelling agent; and d) drying the gelled foam to obtain a perform. According to the invention, a stabilizing agent is added to the mixture M, which agent has an instantaneous viscosity, in Pa·s, that increases by a factor of at least ten when a shear rate of the stabilizing agent is reduced from 100 s?1 to 0.
    Type: Grant
    Filed: July 26, 2005
    Date of Patent: May 21, 2013
    Assignee: Saint-Gobain Centre de Recherches et d'Etudes Europeen
    Inventors: Caroline Tardivat, Emmanuel Mercier, Christian His, Franceline Villermaux
  • Patent number: 8377370
    Abstract: Disclosed are high-porosity cordierite honeycomb substrates having fine pore size, narrow pore size distribution, little or no microcracking, and a high thermal shock resistance. The porous ceramic honeycomb substrates generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite substrates.
    Type: Grant
    Filed: March 5, 2010
    Date of Patent: February 19, 2013
    Assignee: Corning Incorporated
    Inventor: Gregory Albert Merkel
  • Patent number: 8323742
    Abstract: A process for foaming ceramic foams, in which the ceramic foams are produced from a precursor or a mixture of precursors which contain at least one ceramic-forming element and liberates at least one volatile reaction product during an inorganic gelation process. In one embodiment, foaming is based on a precursor containing crystals of the AlCl3(Pri2O) complex. The decomposition of the initial precursor produces polymerizing species dissolved in liquid isopropyl chloride. The solvent and growing AlOxCly(OPri)z species are mixed homogeneously so that the boiling point of the solution is raised above the boiling point of the pure isopropyl chloride. Polymerization takes place in the liquid until a critical polymer size is attained, whereupon a phase separation into polymer rich and solvent rich regions occurs. Since the expelled solvent is suddenly above its boiling point, bubbles start forming instantly.
    Type: Grant
    Filed: November 22, 2010
    Date of Patent: December 4, 2012
    Assignee: Cellaris Limited
    Inventors: Gideon Grader, Gennady Shter, Yoram Dehazan
  • Patent number: 8293362
    Abstract: A closed-cell foam glass structure comprising a multitude of micron-sized voids enclosed by interconnected glass membranes with sub-micron thickness wherein the voids are from about 30% to about 70% of the volume.
    Type: Grant
    Filed: July 29, 2010
    Date of Patent: October 23, 2012
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Alan L Huston, Brian L Justus
  • Patent number: 8262957
    Abstract: The present invention is a method for producing a ceramic porous body with high porosity and continuous macropores, which comprises mixing a ceramic powder with an aqueous solution of a gelable water-soluble polymer to form a slurry, gelling for a while to fix the tissue structure, freezing it to produce ice crystals in the gel tissue and creating structures that become continuous pores, thawing the ice by controlled atmospheric substitution-type drying method with the resulting water being replaced without damaging the gel, and then sintering it to produce a ceramic porous body having various porosities, pore diameters and pore shapes, while conventionally cracks and contraction were likely to occur during drying when the solids concentration of the slurry is less than 20 vol %, with the method of the present invention it is possible to control these problems even at a solids concentration of 10 vol % or less, manufacture and provide a ceramic porous body with a porosity of 72% to 99% and a compression stren
    Type: Grant
    Filed: February 20, 2008
    Date of Patent: September 11, 2012
    Assignee: National Institute of Advanced Industrial Science and Technology
    Inventors: Manabu Fukushima, Masayuki Nakata, Yuichi Yoshizawa
  • Publication number: 20120220443
    Abstract: The disclosure relates to ceramic-body-forming batch materials comprising at least one pore former and inorganic batch components comprising at least one silica source having a specified particle size distribution, methods of making ceramic bodies using the same, and ceramic bodies made in accordance with said methods. The disclosure additionally relates to methods for reducing pore size variability in ceramic bodies and/or reducing process variability in making ceramic bodies.
    Type: Application
    Filed: February 28, 2011
    Publication date: August 30, 2012
    Inventors: Daniel Edward McCauley, Anthony Nicholas Rodbourn, Patrick David Tepesch, Christopher John Warren
  • Patent number: 8236415
    Abstract: A strong, high density foam glass tile having a small pore size which can be used as a facade on both exterior and interior building walls. The foam glass tile of the present invention is strong enough that it can also be used as a structural member for a building. The foam glass tiles are very strong, and have a compression strength of 6000 psi (lb./sq. in.) or greater, and more particularly of 8000 lb./sq. in. or greater, and even more particularly of 10,000 lb./sq. in. or greater, and even more particularly of 12,000 lb./sq. in. or greater, and even more particularly of 14,000 lb./sq. in. or greater. These foam glass tiles will absorb more energy from an explosion, withstand higher heat and wind loading and other mechanical forces. The tiles of the present invention may have an average pore size of 1.0 mm or less, and preferably 0.7 mm or less, and more preferably 0.6 mm or less, and even more preferably 0.5 mm or less, and even more preferably 0.4 mm or less, and even more preferably 0.3 mm or less.
    Type: Grant
    Filed: March 27, 2007
    Date of Patent: August 7, 2012
    Inventors: Hamid Hojaji, Pedro M. Buarque de Macedo
  • Patent number: 8227363
    Abstract: Structurally stable and mechanically strong ceramic oxide aerogels are provided. The aerogels are cross-linked via organic polymer chains that are attached to and extend from surface-bound functional groups provided or present over the internal surfaces of a mesoporous ceramic oxide particle network via appropriate chemical reactions. The functional groups can be hydroxyl groups, which are native to ceramic oxides, or they can be non-hydroxyl functional groups that can be decorated over the internal surfaces of the ceramic oxide network. Methods of preparing such mechanically strong ceramic oxide aerogels also are provided.
    Type: Grant
    Filed: February 8, 2010
    Date of Patent: July 24, 2012
    Assignees: Ohio Aerospace Institute, The United States of America as represented by the Administrator of National Aeronautics and Space Administration
    Inventors: Nicholas Leventis, Mary Ann B. Meador, James C. Johnston, Eve F. Fabrizio, Ulvi F. Ilhan
  • Patent number: 8227364
    Abstract: The present invention relates to a porous planting medium containing minerals and a method for preparing the same, and more particularly, to a porous planting medium prepared by using bentonite and/or zeolite and minerals for promoting plant growth as raw materials and a method for preparing the same. The porous planting medium containing minerals according to the present invention can provide places where plants can grow due to the pores therein and create the ideal environment for plant growth due to minerals used therein. Also, since it is installed in a building with plant seeds germinated therein, it can provide effects of interior decoration, wood bathing due to anion generation and a pleasant interior environment.
    Type: Grant
    Filed: December 22, 2008
    Date of Patent: July 24, 2012
    Inventor: Se-Lin Lee
  • Patent number: 8197932
    Abstract: A large, high density foam glass tile which can be used as a facade on both exterior and interior building walls. The foam glass tile can also be used with other materials to form a panel or a composite. The present invention may be used on the critical surfaces of buildings at high risk for terrorist attacks, in combination with cement, steel or other high strength building materials. The present invention may also be used in surfaces of typical buildings. The present invention has the advantage of absorbing a substantial portion of a shock wave caused by an explosion. The present invention also has the advantage of being more resistant to earthquakes.
    Type: Grant
    Filed: June 6, 2011
    Date of Patent: June 12, 2012
    Inventors: Pedro M. Buarque de Macedo, Hamid Hojaji
  • Publication number: 20120135854
    Abstract: A method of manufacturing a porous ceramic article is provided that includes injecting a gas into a precursor batch material. The gas is pressurized to a positive gauge pressure. Exemplary gasses that can be injected into the precursor batch material include at least one of nitrogen, helium, neon, argon, krypton, and xenon. Air can also be injected into the precursor batch material, including air in which at least a portion of CO2 and/or O2 naturally occurring in air has been removed.
    Type: Application
    Filed: November 29, 2010
    Publication date: May 31, 2012
    Inventor: Kevin Ying Chou
  • Patent number: 8168113
    Abstract: A process for the preparation of a ceramic molded part from a suspension/dispersion with a solids content and a fluid content by depositing solids content at the periphery of a porous self-supporting support that is at least partially immersed in the suspension/dispersion and has the same shape as the molded part to be prepared, but with a reduced size, wherein: the solids content contains oxide-ceramic particles; the porous self-supporting support is detachably connected with a discharge in a zone that is not immersed in the suspension/dispersion; the suspension/dispersion is moved towards the porous self-supporting support by means of a positive pressure difference between a pressure prevailing in the suspension/dispersion and a pressure prevailing in the discharge; wherein the fluid content of the suspension/dispersion enters in the porous self-supporting support with depositing solids content at the periphery of the porous self-supporting support.
    Type: Grant
    Filed: October 4, 2007
    Date of Patent: May 1, 2012
    Assignee: Vita Zahnfabrik H. Rauter GmbH & Co. KG
    Inventors: Marc Stephan, Norbert Thiel, Enno Bojemüller
  • Publication number: 20120082603
    Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.
    Type: Application
    Filed: December 15, 2011
    Publication date: April 5, 2012
    Inventors: Charles E. Ramberg, Stephen A. Dynan, Jack A. Shindle
  • Patent number: 8138108
    Abstract: The present disclosure relates to aluminum titanate-containing ceramic-forming batch materials and methods using the same.
    Type: Grant
    Filed: February 27, 2009
    Date of Patent: March 20, 2012
    Assignee: Corning Incorporated
    Inventors: Patrick David Tepesch, Christopher John Warren
  • Patent number: 8133841
    Abstract: According to the present invention, there is provided a honeycomb catalytic structure comprising: a honeycomb structure comprising porous partition walls having a large number of pores, disposed so as to form a plurality of cells extending between the two end faces of the honeycomb structure and plugging portions disposed at either one end of each cell, and a catalyst layer containing a catalyst, supported at least on the inner surfaces of the pores of the honeycomb structure, wherein the mass of the catalyst layer per unit volume (1 cm3) of the honeycomb structure (g/cm3) is 60% or less of the volume of pores per unit volume (1 cm3) of the honeycomb structure (cm3/cm3).
    Type: Grant
    Filed: February 4, 2008
    Date of Patent: March 13, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Naomi Noda, Yukio Miyairi, Toshio Yamada
  • Patent number: 8097203
    Abstract: The invention describes a high porosity ceramic article and method of manufacturing the same and intermediate dried honeycomb green body articles. The article may have a total porosity of at least about fifty-five percent, above sixty percent, or even above sixty-five percent. The method of manufacture includes mixing a ceramic-forming powder, an organic pore former, water, and a crosslinker. Drying causes a condensation reaction between the pore former and the crosslinker thereby forming a network within the green body that strengthens the green body and reduces cracking. The pore former may include starch or an activated cellulose compounds. Secondary pore forming agents, such as graphite may also be included.
    Type: Grant
    Filed: January 29, 2007
    Date of Patent: January 17, 2012
    Assignee: Corning Incorporated
    Inventors: Weiguo Miao, Steven Bolaji Ogunwumi, Jianguo Wang
  • Publication number: 20120003464
    Abstract: The process for producing a porous ceramics shaped body comprises a step of firing a shaped body of a starting material mixture which contains an aluminum source powder and a titanium source powder, and the aluminum source powder satisfies the below formula (1a): (Da90/Da10)1/2<2??(1a) wherein Da90 is a particle diameter corresponding to a cumulative percentage of 90% on a volume basis and Da10 is a particle diameter corresponding to a cumulative percentage of 10% on a volume basis, and these are determined from a particle size distribution of the aluminum source powder measured by a laser diffractometry.
    Type: Application
    Filed: January 7, 2010
    Publication date: January 5, 2012
    Applicant: SUMITOMO CHEMICAL COMPANY, LIMITED
    Inventors: Kousuke Uoe, Keiichiro Suzuki, Hajime Yoshino
  • Patent number: 8088702
    Abstract: There is provided a bonding material composition capable of suppressing crack generation on an end face of a resultant honeycomb structure to a large extent by reducing anisotropy of Young's modulus after curing of the bonding material by the use of an isotropic filler without using inorganic fibers. The bonded body has two or more members unitarily bonded by means of a bonding material layer, and the relational expression of 0.5<Ez/Ex<1.5 is satisfied when a Young's modulus in a direction perpendicular to a bonded surface of the bonding material layer is Ez and a Young's modulus in a direction parallel to the bonded surface and parallel to a longer axial direction of the bonded surface is Ex and wherein the bonded material has a porosity of 25 to 85%.
    Type: Grant
    Filed: September 22, 2008
    Date of Patent: January 3, 2012
    Assignee: NGK Insulators, Ltd.
    Inventors: Takahiro Tomita, Kenji Morimoto
  • Publication number: 20110318565
    Abstract: A process for producing a porous ceramic body comprises a) mixing a coated porogen with a silicate or an oxide ceramic precursor, wherein the porogen is decomposable to gaseous decomposition products and optionally solid products upon heating, and is coated with a coating agent; b) forming a green body from the mixture obtained in step (a); and c) firing the green body obtained in step (b) to obtain the ceramic body, whereby the porogen decomposes to form pores within the ceramic body and the coating agent is deposited at the inner surface of the pores. The porogen is coated with a coating agent which, upon firing, is deposited at the inner surface of the ceramic pores, so that porous ceramics having decreased weight and improved porosity are obtained, while maintaining at the same time good mechanical strength. A green body and a porous ceramic body obtainable with the above-mentioned process are described too.
    Type: Application
    Filed: August 7, 2008
    Publication date: December 29, 2011
    Applicant: Imerys Ceramics France
    Inventor: Axel Mueller-Zell
  • Patent number: 8044105
    Abstract: A method of preparing a gelled ceramic-based foam comprising forming a slurry comprising at least water, a ceramic, albumin and an aldehyde, such that the ratio of the aldehyde to the albumin is from about 60:1 to about 200:1, and frothing the slurry, such that the albumin polymerizes to form a gelled ceramic-based foam. The foam shows improved capability to resist collapse during any subsequent handling, drying to greenware, or firing steps. This enables simplified and more economical production of highly porous ceramics.
    Type: Grant
    Filed: February 2, 2009
    Date of Patent: October 25, 2011
    Assignee: Dow Global Technologies LLC
    Inventors: Peter C. LeBaron, Thomas M. Paquette
  • Publication number: 20110241236
    Abstract: A method of forming granules, the method including forming a suspension of a nanopowder such as a nano zirconia powder containing yttria. The powder is formed from a suspension, and freon is added directly to the suspension as an additive. The suspension is then granulated by spray freeze drying, and the freon subsequently removed by heat treatment. The voids left by the vacated freon provide meso, micro and macro flaws or structural defects in the granules.
    Type: Application
    Filed: October 14, 2009
    Publication date: October 6, 2011
    Inventors: Annapoorani Ketharam, Balasubramaniam Vaidhyanathan, Bala Praveen Chakkravarthy Raghupathy, Jonathan Graham Peel Binner
  • Patent number: 8025838
    Abstract: The invention provides a process of making porous structures or materials, including the colloidal processing (e.g. slip casting, pressure casting, tape casting or electrophoretic deposition) of solid particle emulsions to form a green body that can be directly sintered without a de-binding step.
    Type: Grant
    Filed: June 27, 2006
    Date of Patent: September 27, 2011
    Assignee: K.U. Leuven Research & Development
    Inventors: Bram Neirinck, Jozef Vleugels, Jan Fransaer, Omer Van Der Biest
  • Publication number: 20110229389
    Abstract: Systems and methods for treating a fluid with a body are disclosed. Various aspects involve treating a fluid with a porous body. In select embodiments, a body comprises ash particles, and the ash particles used to form the body may be selected based on their providing one or more desired properties for a given treatment. Various bodies provide for the reaction and/or removal of a substance in a fluid, often using a porous body comprised of ash particles. Computer-operable methods for matching a source material to an application are disclosed. Certain aspects feature a porous body comprised of ash particles, the ash particles have a particle size distribution and interparticle connectivity that creates a plurality of pores having a pore size distribution and pore connectivity, and the pore size distribution and pore connectivity are such that a first fluid may substantially penetrate the pores.
    Type: Application
    Filed: June 3, 2011
    Publication date: September 22, 2011
    Inventors: Charles E. Ramberg, Stephen A. Dynan, Jack A. Shindle
  • Patent number: 8012904
    Abstract: The present invention provides porous ceramic materials having good resistance to heat, acid and base, comprising three or more oxides selected from an oxide of silicon (SiO), an oxide of aluminum (AlO), an oxide of a transition metal, MxOy, [wherein M represents a 4B, 5B or 6B-group transition metal which can be selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W or Ce, x represents an integer of 1 to 3, and y represents an integer of 1 to 3] and its preparation. By applying ceramic materials prepared according to the present invention that are structurally, thermally and chemically stable to a porous honeycomb support for the purification of exhaust gas or to a filter (DPF, Diesel Particulate Filter) for the purification of diesel engine exhaust gas, it is possible to prevent or remarkably reduce any structural destruction caused by corrosive gas, which results from employing a cordierite material as a structural support.
    Type: Grant
    Filed: March 7, 2006
    Date of Patent: September 6, 2011
    Assignee: KH Chemicals Co., Ltd.
    Inventor: Young Nam Kim
  • Publication number: 20110177933
    Abstract: Embodiments of the present invention provide cellular phosphate bodies formed using specialized steps to ensure a specific strength range, and specifically a compressive strength less than 100 pounds per square inch. Further embodiments relate to uses for various phosphate ceramics as vehicle arresting systems.
    Type: Application
    Filed: January 14, 2011
    Publication date: July 21, 2011
    Applicant: ENGINEERED ARRESTING SYSTEMS CORPORATION
    Inventors: Silvia C. Valentini, Youhong Li, Anthony Mario Coratolo