Pore-forming Patents (Class 501/80)
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Publication number: 20100034981Abstract: 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 the coil is 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 across the coil cross-section of the ceramic filter element.Type: ApplicationFiled: August 4, 2009Publication date: February 11, 2010Applicant: MANN+HUMMEL GMBHInventor: Andreas Franz
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Patent number: 7658990Abstract: A super lightweight ceramic panel for a non-bearing wall utilizing an expandable clay mineral and a process for preparing the same are provided. The super lightweight ceramic panel is comprised of a clay composition containing 90 to 98% by weight of an expandable clay mineral, 1.5 to 5% by weight of a flux (glass), and 0.5 to 5% by weight of silicon carbide, and is prepared by mixing and pressing the clay composition, followed by firing at a temperature of 1100 to 1200° C. The super lightweight ceramic panel in accordance with the present invention is a material having a light weight and exhibiting improvement in physical properties such as water resistance, flame retardancy, heat insulation and rigidity, via formation of closed pores inside the ceramic material.Type: GrantFiled: November 4, 2005Date of Patent: February 9, 2010Assignee: LG Chem, Ltd.Inventor: Sang-Ho Shin
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Publication number: 20100029462Abstract: A batch mixture including ceramic forming ingredients; a pore former mixture of a graphite and a starch; a hydroxypropyl methyl cellulose binder; and a liquid vehicle, as defined herein. Also disclosed is a method for producing a ceramic precursor article having enhanced throughputs in extrusion and drying as defined herein.Type: ApplicationFiled: August 1, 2008Publication date: February 4, 2010Inventors: Michael Edward DeRosa, Thomas Mark Dubots, Michelle Yumiko Ronco, Gary Graham Squier
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Publication number: 20100021734Abstract: Ceramic particles capable of increasing the reaction area with an eluate, etc. without decreasing the diameter of the particle per se and a producing method thereof are provided. A ceramic particles 10 of the present invention has an average particle diameter of 5 ?m or more and 5 mm or less and a plurality of open pores formed at the outer surface, and has two pore size distributions in the measurement by a mercury porosimeter, in which the two pore size distributions includes a first pore size distribution having a peak within a range of 300 nm or more and 20 ?m or less and a second pore size distribution having a peak in a range of 200 nm or less.Type: ApplicationFiled: July 22, 2009Publication date: January 28, 2010Inventors: Hideo Uemoto, Tomoki Sugino, Hiroyuki Goto, Taikei Yasumoto
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Patent number: 7648932Abstract: The invention relates to a process for the production of a molded porous ceramic article containing ?-SiC, which process comprises the following steps: the preparation of a molded article containing silicon and carbon and the subsequent pyrolysis and siliconization of the article containing silicon and carbon to form SiC. The invention further relates to a molded porous ceramic article containing SiC which has been produced from a molded article containing silicon and carbon.Type: GrantFiled: July 5, 2006Date of Patent: January 19, 2010Assignee: Mann+Hummel Innenraumfilter GmbH & Co. KGInventors: Lars Weisensel, Thomas Wolff, Heino Sieber, Peter Greil
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Publication number: 20090325442Abstract: The invention relates to a method for producing an in particular porous molded ceramic article, which molded ceramic article is optionally reinforced with fibers and/or a semi-finished textile product such as woven fabric, wherein a powder A and at least one further powder B are suspended in a liquid, after which a molded article is formed from the suspension produced in this manner optionally in combination with fibers and/or a semi-finished textile product and the molded article is optionally sintered. It is provided according to the invention that the powders A and B are suspended approximately at a pH value of the liquid at which a viscosity minimum of the suspension is given, whereby high solids contents in the suspension can be adjusted with low viscosities. This makes possible a rapid production of largely crack-free molded articles with advantageously low-defect structures.Type: ApplicationFiled: September 13, 2007Publication date: December 31, 2009Inventors: Reinhard Simon, Robert Danzer
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Publication number: 20090311650Abstract: 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: ApplicationFiled: October 4, 2007Publication date: December 17, 2009Inventors: Marc Stephan, Norbert Thiel, Enno Bojemüller
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Publication number: 20090305017Abstract: Porous ceramic part comprising a porous ceramic foam having a total porosity of between 50 and 92% and an intergranular porosity of at least 5%, walls of at least some of the cells of the ceramic foam being at least partly covered with an impregnation material. The invention relates in particular to a recrystallized silicon carbide foam impregnated with silicon.Type: ApplicationFiled: January 30, 2007Publication date: December 10, 2009Applicant: Saint-Gobain Centre De Recherches Et d'Etudes EuropeenInventors: Christian Claude His, Franceline Villermaux, Nicolas Raffin, Michel Dussaulx
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Publication number: 20090305882Abstract: Described is a porous ceramic body comprising zirconia having mesopores incorporated therein and the primary crystalline phase is tetragonal. When used as a carrier for a catalyst, the porous ceramic body has excellent crush resistance and a large total pore volume which results in an increase in the carrier's surface area onto which catalytic material may be deposited. Methods of making the carrier are also disclosed.Type: ApplicationFiled: February 1, 2007Publication date: December 10, 2009Applicant: Saint-Gobain Ceramics & Plastics, Inc.Inventors: Stephen Dahar, Mure Te
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Publication number: 20090298670Abstract: A method of removing graphite from a core region of a cordierite-forming green body and a method of firing a cordierite-forming green body to form a fired cordierite body. A dried cordierite-forming green body containing graphite is first heated so that the core region is at a first temperature in a range from about 950° C. up to about 1100° C. The green body is then either held at the first temperature or heated to a second temperature in a range from about 1050° C. up to about 1160° C.; in either case resulting in removal of a majority of graphite from the core region. The green body may then be heated to a third temperature in a range from about 1300° C. up to about 1350° C. at a second predetermined heating rate to remove any residual graphite from the core region and then heated to a temperature of at least 1390° C. to form the fired cordierite body.Type: ApplicationFiled: June 27, 2008Publication date: December 3, 2009Inventors: Martin Joseph Murtagh, Mark Allen Spetseris, Doug Wing
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Publication number: 20090298671Abstract: Silica-based materials and films having a dielectric constant of 3.7 or below and compositions and methods for making and using same are disclosed herein. In one aspect, there is provided a composition for preparing a silica-based material comprising an at least one silica source, a solvent, an at least one porogen, optionally a catalyst, and optionally a flow additive wherein the solvent boils at a temperature ranging from 90° C. to 170° C. and is selected from the group of compounds represented by the following formulas: HO—CHR8—CHR9—CH2—CHR10R11 where R8, R9, R10 and R11 can independently be an alkyl group ranging from 1 to 4 carbon atoms or a hydrogen atom; and R12—CO—R13 where R12 is a hydrocarbon group having from 3 to 6 carbon atoms; R13 is a hydrocarbon group having from 1 to 3 carbon atoms; and mixtures thereof.Type: ApplicationFiled: August 10, 2009Publication date: December 3, 2009Applicant: AIR PRODUCTS AND CHEMICALS, INC.Inventors: Scott Jeffrey Weigel, Shrikant Narendra Khot, James Edward Mac Dougall, Thomas Albert Braymer, John Francis Kirner, Brian Keith Peterson
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Publication number: 20090295007Abstract: 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: ApplicationFiled: May 19, 2009Publication date: December 3, 2009Inventor: William Peter Addiego
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Publication number: 20090297764Abstract: Disclosed are stabilized, high-porosity cordierite honeycomb substrates having little or no microcracking, and a 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: ApplicationFiled: May 28, 2009Publication date: December 3, 2009Inventors: Douglas Munroe Beall, George Halsey Beall
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Publication number: 20090270252Abstract: 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: ApplicationFiled: March 7, 2006Publication date: October 29, 2009Applicant: KH Chemicals Co., Ltd.Inventor: Young Nam Kim
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Publication number: 20090221414Abstract: The invention relates to ceramic slurry from which ductile ceramic fibrous composites can be produced. They can be stretched under tension without any of the brittleness typical for ceramic materials occurring.Type: ApplicationFiled: March 8, 2007Publication date: September 3, 2009Inventors: Walther Glaubitt, Arne Rudinger
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Publication number: 20090218711Abstract: The present invention provides a ceramic precursor batch composition comprising inorganic ceramic-forming ingredients, a binder, an aqueous solvent and a chaotropic agent. The presence of the chaotropic agent provides a composition with a lower viscosity and/or a greater batch stiffening temperature allowing for increased extrusion feedrates. Methods for producing a ceramic honeycomb body using the ceramic precursor batch composition of the present invention are also provided.Type: ApplicationFiled: February 28, 2008Publication date: September 3, 2009Inventors: David Dasher, Michael Edward DeRosa
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Publication number: 20090197756Abstract: 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: ApplicationFiled: February 2, 2009Publication date: August 6, 2009Inventors: Peter C. LeBaron, Thomas M. Paquette
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Publication number: 20090166214Abstract: The present invention relates to porous articles, including porous ceramic materials, which can be used in a variety of settings, but find particular use in connection with electrochemical devices such as fuel cells, as well as methods of their manufacture and use. The porous ceramic may have, in some aspects of the invention, an average pore size of between about 1 micrometer and about 300 micrometers, and in some cases, certain advantageous permeability characteristics with respect to species useful in certain types of electrochemical devices. In some cases, the ceramic may be sufficiently porous to allow gaseous molecules (e.g., air or oxygen, gaseous fuels, etc.) and/or liquids (e.g., water or liquid fuels) to be transported therethrough, and/or the ceramic may be substantially resistive or impermeable to a liquid such as a non-wetting liquid, for instance, a liquid metal such as liquid (molten) tin.Type: ApplicationFiled: May 2, 2008Publication date: July 2, 2009Applicant: CellTech Power LLCInventors: Tao T. Tao, Linda Bateman
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Publication number: 20090159853Abstract: A method for forming porous ceramic objects is provided, in which a suspension of ceramic precursor particles in a solution of gelatin is allowed to gel in the desired shape, and is then dried and sintered to the desired level of porosity.Type: ApplicationFiled: August 24, 2006Publication date: June 25, 2009Applicant: NANODYNAMICS, INC.Inventors: Suvankar Sengupta, Ramachandra Revur
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Publication number: 20090162414Abstract: A method for the production of a macroporous ceramic foam, wherein: (a) forming a ceramic slip comprising a substantially homogeneous mixture of a ceramic particulate, an organic binder in a liquid carrier, and optionally one or more surfactants, wherein at least one surfactant is present if the organic binder does not function as a surfactant, and wherein the ceramic slip preferably has a viscosity in the range of from 15 to 200 mPas?1; (b) foaming the ceramic slip; and (c) heating the foamed ceramic slip at a temperature sufficient to substantially burn out the organic binder. The macroporous ceramic foam is suitable for use in biomedical applications such as synthetic bones, tissue engineering scaffolds or drug delivery devices.Type: ApplicationFiled: July 9, 2008Publication date: June 25, 2009Applicant: Apatech LimitedInventors: Karin Angela Hing, William Bonfield
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Patent number: 7541303Abstract: The present invention provides materials and methods for the manufacture of high porosity ceramic exhaust filters employing relatively low amounts of pore formers, the filters combining efficient diesel particulate filtration with effective support for exhaust emissions control catalysts. Cordierite-forming ceramic batches comprising non-hydrated transition alumina powders of relatively large particle size provide high porosities with well-controlled pore sizes and with low filter thermal expansion coefficients and good mechanical strengths.Type: GrantFiled: December 21, 2005Date of Patent: June 2, 2009Assignee: Corning IncorporatedInventors: William Peter Addiego, Isabelle Marie Melscoet-Chauvel
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Patent number: 7538068Abstract: A carbon dioxide gas absorbent includes a porous body containing a lithium complex oxide. The porous body includes pores having a pore diameter distribution such that main pores which consist of first pores with a diameter of 10 to 100 ?m and second pores with a diameter larger than 100 ?m and 500 ?m or smaller occupy 80 to 100%, third pores with a diameter smaller than 10 ?m occupy 0 to 10% and fourth pores with a diameter larger than 500 ?m occupy 0 to 10%, the main pores have a pore diameter distribution such that the first pores occupy 15 to 85% and second pores occupy 15 to 85%.Type: GrantFiled: March 16, 2006Date of Patent: May 26, 2009Assignee: Kabushiki Kaisha ToshibaInventors: Masahiro Kato, Toshihiro Imada, Kenji Essaki
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Publication number: 20090088311Abstract: A porous bio-material and a method of preparation thereof. The method includes the following steps. First, a body is formed by mixing a bio-ceramic powder, a highly water-absorbing natural organic material and a liquid. Then, the body is partially dried to form a machinable porous bio-material. The sizes of pores and porosity can be tailored by controlling the extent of drying so that the porous bio-material with acceptable strength can be obtained.Type: ApplicationFiled: September 23, 2008Publication date: April 2, 2009Applicant: NATIONAL TAIWAN UNIVERSITYInventors: Wei-Hsing TUAN, Yueh-Han LEE, Hsueh-Hui KUO
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Publication number: 20090069167Abstract: 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: ApplicationFiled: July 26, 2005Publication date: March 12, 2009Inventors: Caroline Tardivat, Emmanuel Mercier, Christian His, Franceline Villermaux
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Publication number: 20090062105Abstract: A method of forming a porous ceramic article having a narrow pore distribution includes heating a green body containing ceramic forming raw materials in a firing environment that raising the temperature of the firing environment to a peak temperature, then reducing the temperature to a hold temperature in order to form porous ceramic.Type: ApplicationFiled: August 27, 2008Publication date: March 5, 2009Inventors: Martha Blanche Custer, Jennifer Lynn Lyon, Jianguo Wang
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Patent number: 7491330Abstract: A porous grog with a body composition of water, clay and combustible material. Further, an earthenware water purification filter utilizing the porous grog in the body composition of the filter. Further, an earthenware filter utilizing silver chloride treatment for water disinfection is disclosed. A water purification system incorporating said filter, said water purification system capable of removing about 99% of all particles not less than 1.0 micron is size, and removing virtually 100% of fecal coliform indicators. In other embodiments, methods of disinfecting pottery toilet liners including various open surfaces using silver chloride treatment are disclosed.Type: GrantFiled: October 22, 2004Date of Patent: February 17, 2009Inventor: Anthony Reid Harvey
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Patent number: 7488366Abstract: A ceramic porous body is provided, inclusing a plurality of pores formed in a ceramic substrate at a specified porosity. A pore part is discriminated from a non-pore part by binarizing a cross-sectional plane image of the substrate by image analysis. When a center line passing the central part of the pore part is drawn, the porosity (? (%)), a mean width (DP (?m)) of the pore part represented by a mean value of a distance, between outlines specifying the pore part, perpendicular to the center line, a mean length (L (?m)) of the pore part represented by a mean value of a length of the center line between adjacent branch points and a length of the center line between an end of the center line and the branch point, and a mean pore size (DH (?m)) satisfy a specified relationship.Type: GrantFiled: July 23, 2004Date of Patent: February 10, 2009Assignee: NGK Insulators, Ltd.Inventors: Masahiro Furukawa, Nobuyuki Tanahashi, Yuuichirou Tabuchi, Shinji Kawasaki
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Patent number: 7485594Abstract: A porous mullite composition is made by forming a mixture of one or more precursor compounds having the elements present in mullite (e.g., clay, alumina, silica) and a property enhancing compound. The property enhancing compound is a compound having an element selected from the group consisting of Mg, Ca, Fe, Na, K, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, B, Y, Sc, La and combination thereof. The mixture is shaped and to form a porous green shape which is heated under an atmosphere having a fluorine containing gas to a temperature sufficient to form a mullite composition comprised substantially of acicular mullite grains that are essentially chemically bound.Type: GrantFiled: May 1, 2007Date of Patent: February 3, 2009Assignee: Dow Global Technologies, Inc.Inventors: Chandan Saha, Sharon Allen, Chan Han, Robert T. Nilsson, Arthur R. Prunier, Jr., Aleksander J. Pyzik, Sten A. Wallin, Robin Ziebarth, Timothy J. Gallagher
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Publication number: 20090023576Abstract: A method for the surface treatment of bead polymers is to be prepared, by means of which bead polymers are treated in a particularly simple and effective manner such that upon addition to unfinished ceramic pieces, in particular, their strength and dimensional stability increase. To this end, the bead polymers are conducted to a device which is used for comminution, in particular, to a mill, in which the surface of the bead polymers is purposefully scratched or roughened in a uniformly mechanical manner.Type: ApplicationFiled: April 12, 2006Publication date: January 22, 2009Applicant: BAUER TECHNOLOGIES GMBHInventor: Ottmar Kryts
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Patent number: 7479265Abstract: This invention relates to ?-SiC foam parts with a specific surface area preferably equal to at least 5 m2/g and with at least two zones A and B with a different cellular porosity distribution, wherein the parts were made by chemical transformation of a porous precursor medium comprising at least two blocks A? and B?, each having a different cellular porosity distribution, and in that the at least two zones A and B are derived from the chemical transformation of the two blocks A? and B?. This foam, optionally after deposition of an active layer, may be used as a filter medium in cartridges designed for the purification of exhaust gases. The invention also relates to manufacturing processes for preparing such a filter medium.Type: GrantFiled: October 14, 2004Date of Patent: January 20, 2009Assignees: SICAT, Entre National de la Recherche Scientifigue, Universite Louis Pasteur de StrasbourgInventors: Charlotte Pham, Laurie Pesant, Pierre Bernhardt, Michel Wolf, Cuong Pham-Huu, Marc-Jacques Ledoux, Michel Kartheuser, Estelle Vanhaecke
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Publication number: 20090017283Abstract: Provided are a silicon carbide-based porous article comprising silicon carbide particles as an aggregate, metallic silicon and an aggregate derived from organometallic compound particles to form pores through volume shrinkage due to decomposition/conversion by heat treatment; and a method for producing the silicon carbide-based porous article, comprising, adding organometallic compound particles to form pores through volume shrinkage due to decomposition/conversion by heat treatment to a raw-material mixture containing silicon carbide particles and metallic silicon, then forming into an intended shape, calcinating and/or firing the resultant green body, forming pores through volume shrinkage due to decomposition/conversion of the organometallic compound particles, and the decomposed/converted substance of the organometallic compound particles being present as an aggregate in the porous article.Type: ApplicationFiled: August 19, 2008Publication date: January 15, 2009Applicant: NGK INSULATORS, LTD.Inventors: Takuya HIRAMATSU, Shinji KAWASAKI
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Publication number: 20090018008Abstract: Process for the preparation of a ceramic wherein: 50% to 75% by weight of a compound intended to form a conductive phase, and 25 % to 50% by weight of one or more materials allowing the formation of insulating phases composed of silicon nitride and modified silicon oxynitride are mixed in a receptacle containing a liquid after a thermal treatment leading to sintering of the ceramic; this mixture is subjected to grinding, drying and sieving operations; this mixture is pressed; and this mixture is sintered so as to obtain a ceramic with a porosity of between 0 and 30%. The sintering is carried out under a pressure of at least 50 bar of a gas which is inert towards the constituents of the mixture. Ceramic thus obtained and spark plug comprising it.Type: ApplicationFiled: June 18, 2008Publication date: January 15, 2009Applicant: VIBRO METER FRANCEInventors: Aurelien JANKOWIAK, Philippe BLANCHART, Frederic TRENIT
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Publication number: 20090007532Abstract: A method for manufacturing a composite ceramic body with occluding a plurality of pores that are open at its surface of a porous ceramic body, the method includes the steps of impregnating a polysilazane solution including polysilazane having a repetition structure of fundamental units of at least one of [—Si(H)(CnH2n+1) —NH—] and [—Si(CnH2n+1)2—NH—], and a predetermined organic solvent, into the plurality of pores of the porous ceramic body, and heating the porous ceramic body to convert the polysilazane in the plurality of pores into ceramic material.Type: ApplicationFiled: June 27, 2008Publication date: January 8, 2009Applicant: NORITAKE CO., LIMITEDInventors: Keita Miyajima, Yasunori Ando
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Publication number: 20090011919Abstract: A process for producing a honeycomb structure by obtaining clay from a cordierite-forming raw material containing an alumina source, a silica source, and a magnesia source; and forming the clay into a honeycomb shape, wherein a material having, in its volume particle size distribution, a 50 volume % particle size (V50) [?m] of 1 to 25 ?m is used, as each of alumina source, silica source, and magnesia source; and a material having, in the volume particle size distribution of the whole cordierite-forming raw material, a ratio of 90 volume % particle size (Vall90) [?m] to 10 volume % particle size (Vall10) [?m] [a volume particle size distribution ratio (Vall90/Vall10)] of 10 or less and a difference (Vall90?Vall10) between 90 volume % particle size (Vall90) [?m] and 10 volume % particle size (Vall10) [?m] of 25 ?m or less is used, as the cordierite-forming raw material.Type: ApplicationFiled: September 12, 2008Publication date: January 8, 2009Applicant: NGK INSULATORS, LTD.Inventors: Yasushi NOGUCHI, Takehiko WATANABE, Yukari NAKANE
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Publication number: 20090000260Abstract: A method of manufacturing a fibrous material includes mixing at least two cordierite precursor materials to form a mixture. One or more of the at least two cordierite precursor materials is in a form of a fiber and the mixture includes about 43% to about 51% by weight SiO2, about 36% to about 41% by weight Al2O3, and about 12% to about 16% by weight MgO. The method also includes extruding the mixture to create a fibrous body, and heat treating the fibrous body, at a temperature of about 1200° C. to about 1420° C., to form the fibrous material including about 50% to about 95% by weight cordierite. A fibrous body includes an extruded substrate having a plurality of fibers including about 50% to about 95% by weight cordierite. The extruded substrate has a coefficient of thermal expansion in at least one direction of less than about 3.8·10?6 per ° C.Type: ApplicationFiled: July 12, 2008Publication date: January 1, 2009Applicant: GEO2 Technologies, Inc.Inventors: James Jenq Liu, Bilal Zuberi, Rachel A. Dahl, William M. Carty
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Publication number: 20080318759Abstract: Process for producing a ceramic part from a ceramic powder, comprising the following successive steps: a step (a) of deagglomerating the ceramic powder in liquid phase; a step (b) of incorporating pore formers into the powder dispersion prepared in step (a); a step (c) of removing the liquid medium from the dispersion prepared in step (b); a step (d) of forming agglomerates form the powders obtained in step (c); a step (e) of removing the binder from the preform prepared in step (d); and a step (f) of sintering the binderless part prepared in step (e).Type: ApplicationFiled: November 3, 2006Publication date: December 25, 2008Applicant: L'Air Liquide Societe Anonyme Pour L'Exloitation Des Procedes Georges ClaudeInventors: Nicolas Richet, Pascal Del-Gallo, Laetitia epouse Pajot Trebuchaire, Christophe Chaput
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Patent number: 7468290Abstract: Low dielectric materials and films comprising same have been identified for improved performance when used as interlevel dielectrics in integrated circuits as well as methods for making same. In one aspect of the present invention, an organosilicate glass film is exposed to an ultraviolet light source wherein the film after exposure has an at least 10% or greater improvement in its mechanical properties (i.e., material hardness and elastic modulus) compared to the as-deposited film.Type: GrantFiled: July 21, 2003Date of Patent: December 23, 2008Assignee: Air Products and Chemicals, Inc.Inventors: Aaron Scott Lukas, Mark Leonard O'Neill, Jean Louise Vincent, Raymond Nicholas Vrtis, Mark Daniel Bitner, Eugene Joseph Karwacki, Jr.
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Publication number: 20080305951Abstract: The invention relates a method for incorporating a functional additive within a porous material, which method comprises impregnating the porous material with a slurry of a nano-sized material that carries the functional additive, wherein in the slurry the weight ratio of the additive (A) and the nano-sized material (B) is in the range of from 0.01 to 1.0 (A/B). The invention further relates to a porous material obtainable by said method.Type: ApplicationFiled: September 11, 2006Publication date: December 11, 2008Inventors: Jacobus Eversdijk, Cornelis Hermanus Rentrop, Michael Fritz Sailer, Rudolf Hartmut Cher, Diana Benz
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Publication number: 20080300127Abstract: A ceramic forming batch mixture including inorganic batch materials, such as sources of alumina, titania, and silica, a low amount of one or more pore formers including at least one starch; an organic binder; and a solvent. Also disclosed is a method for producing a ceramic article involving mixing the inorganic batch materials with the low amount of pore former, adding an organic binder and a solvent, forming a green body; and firing the green body. A green body having a low amount of the one or more pore formers including starch is disclosed.Type: ApplicationFiled: May 30, 2008Publication date: December 4, 2008Inventors: David Lambie Tennent, Christopher John Warren
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Publication number: 20080286524Abstract: A sintering aid for promoting sintering of ceramic particles and fine particles that are the same materials as ceramic particles and have smaller average particle diameter are mixed to obtain a puddle. The average particle diameter of ceramic particles is preferably about in a range of 5 to 100 ?m; the average particle diameter of the fine particles is preferably about in a range of 0.1 to 1.0 ?m, and the average particle diameter of the sintering aid is preferably about in a range of 0.1 to 10 ?m. As the sintering aid, for example, alumina is used. This puddle is extrusion molded into a honeycomb shape and the molded object is fired at a firing temperature lower than a temperature for sintering without mixing a sintering aid. The thermal conductivity of the obtained honeycomb structure 10 shows about 60% or more of the thermal conductivity of a fired body fired without adding a sintering aid to ceramic particles and shows about 12 W/m·K or more at 20° C.Type: ApplicationFiled: May 14, 2008Publication date: November 20, 2008Inventors: Kazushige Ohno, Kazutake Ogyu, Masayuki Hayashi
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Patent number: 7452591Abstract: A silicon carbide-based porous material characterized by comprising silicon carbide particles as an aggregate, metallic silicon and an oxide phase containing Si, Al and an alkaline earth metal; it is high in porosity and strength and superior in oxidation resistance and thermal shock resistance and, when used as a filter, is very low in risk of having defects such as cuts (which cause leakage of fluid) and the like, as well as in pressure loss.Type: GrantFiled: March 31, 2003Date of Patent: November 18, 2008Assignee: NGK Insulators, Ltd.Inventors: Yuuichirou Tabuchi, Masahiro Furukawa, Kenji Morimoto, Shinji Kawasaki
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Publication number: 20080269040Abstract: A sintered ceramics for mounting a light-emitting element, which is capable of realizing high optical reflectance over the entire region from ultraviolet radiation to visible light. The sintered ceramics has a light-reflective face of which reflectance to light in each wavelength in the range of 250 nm˜750 nm is 70% or more. The light-reflective face satisfies following reaction: |RA?RB|?20 when reflectance to light of 750 nm is defined as RA%, and reflectance to light of 300 nm is defined as RB. The sintered ceramics has not layer to be peeled from the light-reflective face when a Tape Peeling Test is carried out to the light-reflective face in accordance with the method described in JIS H8504 (1990).Type: ApplicationFiled: September 26, 2006Publication date: October 30, 2008Inventors: Ken Sugawara, Yuichiro Minabe, Takehiko Yoneda, Masao Ariyuki
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Publication number: 20080242529Abstract: A ceramic and metal composite and method of manufacture, is provided in which a ceramic phase is mixed with a metal phase to form a composite able to be applied to a substrate or formed to any shape/configuration required. For example, the composite can form, or be applied to a substrate for use as biomedical implants which can assist in and enhance osteo development or at least provide a material of better biocompatibility/bioactivity and osteo integration or infiltration with the composite. Advantageously, the ceramic and metal phases are bioactive/biocompatible. In a preferred embodiment, the composite is a homogenous mix ceramic and metal phase (and/or bioglasses) when analyzed on a micro meter scale.Type: ApplicationFiled: May 4, 2005Publication date: October 2, 2008Inventors: Xiaoxia Luo, Danyang Ying
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Publication number: 20080203627Abstract: Disclosed are ceramic articles comprising a sintered phase ceramic composition containing, as expressed on a weight percent oxide basis: a(Al2TiO5)+b(ZrTiO4)+c(Y2O3)+d(YPO4) wherein “a, b, c, and d” represent weight fractions of each component such that (a+b+c+d)=1.00 and wherein 0.5<a?0.95; 0?b?0.5, 0.0?c?0.10, and 0?d?0.5. Also disclosed are precursor batch compositions and methods for manufacturing the ceramic articles disclosed herein.Type: ApplicationFiled: February 27, 2007Publication date: August 28, 2008Inventors: Steven Bolaji Ogunwumi, Cameron Wayne Tanner
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Publication number: 20080167173Abstract: By engineering thermal spray parameters, such as temperature and velocity, and engineering feedstock powder size and morphology, ceramic coatings may be produced having desired mechanical and thermal properties. The ceramic thermal spray coating may have a microstructure having about 10-80% by cross-sectional area of a particulate phase based on surface area of the coating, and the particulate phase is uniformly distributed throughout the coating. The particulate phase is an unmelted portion of the thermal sprayed feedstock, which is highly porous and may be produced by agglomerating nanoparticles of the ceramic. Such coatings can be applied as TBCs or as abradable coatings.Type: ApplicationFiled: April 18, 2007Publication date: July 10, 2008Inventors: Rogerio S. Lima, Basil R. Marple, Christian Moreau
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Publication number: 20080125305Abstract: Aluminum titanate precursor batch compositions comprising a recycled aluminum titanate component, at least a portion of the recycled aluminum titanate component being comprised of a recycled pre-reacted aluminum titanate composition or alternatively of an un-reacted green aluminum titanate precursor composition, and methods for producing aluminum titanate ceramic articles utilizing the inventive batch compositions.Type: ApplicationFiled: November 29, 2006Publication date: May 29, 2008Inventors: John Paul Day, Robert John Locker, David Lambie Tennent, Christopher John Warren
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Publication number: 20080118894Abstract: Process for producing an inorganic-inorganic composite material, in which an open-pore, crystalline oxide ceramic shaped part is produced from an oxide ceramic powder or a powder of an oxide ceramic mixture after shape-imparting processing and presintering, an infiltration substance is applied to this shaped part in vacuo and at room temperature, and the oxide ceramic is sintered in a densifying manner under an air atmosphere and at ambient pressure to form an inorganic-inorganic composite material.Type: ApplicationFiled: January 27, 2005Publication date: May 22, 2008Inventors: Frank Rothbrust, Christian Ritzberger, Wolfram Holand, Volker Rheinberger
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Publication number: 20080047432Abstract: A porous substrate with a seed crystal-containing layer for manufacturing a zeolite membrane includes: a ceramic porous substrate, and a seed crystal-containing layer containing a zeolite powder to function as a seed crystal for forming a zeolite membrane and a ceramic powder and being loaded on a surface of the ceramic porous substrate and fired to fix the seed crystal-containing layer on the porous substrate. The porous substrate with a seed crystal-containing layer used for manufacturing a zeolite membrane can inhibit a defect such as a crack from being generated in the zeolite layer upon manufacture or use by manufacturing a zeolite membrane by the use of the substrate and can be subjected to air-spraying, washing, and processing for the purpose of removing a foreign substance, etc., prior to hydrothermal synthesis.Type: ApplicationFiled: August 16, 2007Publication date: February 28, 2008Applicant: NGK Insulators, Ltd.Inventors: Hisayoshi Nonaka, Kunio Nakayama, Kenji Yajima
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Publication number: 20080017573Abstract: An improved particulate filtration system has an inlet, for the fluid to be filtered, connected to a housing containing a filter medium such that the fluid passes through the filter medium, and an outlet for the filtered fluid to exit. The filtration system's improvement is the filter medium being comprised of a porous ceramic of fused platelet grains. In a particular embodiment, the porous ceramic is a celsian porous ceramic, where the celsian grains have a hexagonal morphology and display a continuous volume thermal expansion coefficient from 100° C. to 1000° C.Type: ApplicationFiled: July 20, 2007Publication date: January 24, 2008Inventors: Aleksander J. Pyzik, Robert A. Newman, Nicholas M. Shinkel
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Patent number: 7311965Abstract: 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: GrantFiled: July 22, 2003Date of Patent: December 25, 2007Inventors: Hamid Hojaji, Pedro M. Buarque de Macedo