By Gas Blowing, Foaming Agent, Or In Situ Reactive Gas Generation Patents (Class 501/84)
  • Patent number: 10597545
    Abstract: A foam ink composition for printing porous structures comprises stabilizing particles and gas bubbles dispersed in a solvent. The stabilizing particles comprise a predetermined interfacial energy so as to exhibit a contact angle with the solvent of from about 15° to about 90°. At least a portion of the stabilizing particles are positioned at interfacial regions between the solvent and the gas bubbles, thereby stabilizing the gas bubbles in the foam ink composition. A 3D printed hierarchical porous structure comprises one or more continuous filaments arranged in a predetermined pattern on a substrate, the one or more continuous filaments comprising a sintered material and including a porosity of at least about 40 vol. %.
    Type: Grant
    Filed: May 16, 2016
    Date of Patent: March 24, 2020
    Assignee: President and Fellows of Harvard College
    Inventors: Jennifer A. Lewis, Joseph T. Muth
  • Patent number: 9963373
    Abstract: A method of making a foamed glass body, including preparing an admixture of powdered glass, at least one carbonate based foaming agent, and at least devitrification inhibitor, heating the admixture to a first temperature to soften the glass, heating the admixture to a second, higher temperature to foam the softened glass into a foamed glass body, and cooling the foamed glass body, wherein the temperature of the foamed glass body always remains too cold for silica crystal growth. The crystal silica content of the so-formed foamed glass body is less than 1 weight percent.
    Type: Grant
    Filed: September 17, 2014
    Date of Patent: May 8, 2018
    Assignee: Earthstone International LLC
    Inventors: Richard L. Lehman, Andrew Ungerleider
  • Patent number: 9777210
    Abstract: A novel inorganic fine particle reinforced foam system for an oil-gas field and preparation method thereof. The reinforced foam system comprises a gas phase and a liquid phase; the gas phase is nitrogen, carbon dioxide or the air; the liquid phase is prepared from, by mass: 0.2-0.8 wt % of a foaming agent, 0.5-2.0 wt % of novel inorganic fine particles and balance of water; the novel inorganic fine particles are fine particulate matter with diameters being smaller than or equal to 2.5 microns captured and screened from the atmosphere.
    Type: Grant
    Filed: August 4, 2016
    Date of Patent: October 3, 2017
    Assignee: CHINA UNIVERSITY OF PETROLEUM
    Inventors: Zhaomin Li, Qichao Lv, Binfei Li, Binglin Li, Songyan Li, Teng Lu, Qian Sun, Yajie Xu
  • Patent number: 9741477
    Abstract: To provide a zinc oxide-based varistor that exhibits adequate characteristics without using antimony. Disclosed is a sintered body for a varistor, including zinc oxide as a main component; 0.6 to 3.0 mol % of bismuth oxide in terms of bismuth (Bi); 0.2 to 1.4 mol % of cobalt oxide in terms of cobalt (Co); 0.1 to 1.5 mol % of chrome oxide in terms of chrome (Cr); and 0.1 to 1.5 mol % of manganese oxide in terms of manganese (Mn), wherein the contents of antimony (Sb), a rare earth element and tin (Sn) are not more than a level of impurities.
    Type: Grant
    Filed: December 5, 2014
    Date of Patent: August 22, 2017
    Assignee: HITACHI METALS, LTD.
    Inventors: Naoyuki Okamoto, Hiroyuki Ito, Toshiki Kida
  • Patent number: 9227873
    Abstract: A material is described in the form of a millimetric article constituted by coarse alumina particles with a median diameter in the range 10 to 200 ?m, said coarse particles being at a distance, from one interface to another, of less than 10 ?m, fine alumina particles with a median diameter in the range 0.5 to 10 ?m, said fine particles being at a distance, from one interface to another, of less than 5 ?m and being located in the space between the coarse particles, and a binder constituted by aluminium phosphate, said binder being located in the space between said fine and coarse particles, said material having a mesoporous volume, measured by mercury porosimetry, in the range 0.2 to 2 mL/g, a macroporous volume, measured by mercury porosimetry, in the range 0.05 to 0.2 mL/g and a BET specific surface area in the range 80 to 350 m2/g.
    Type: Grant
    Filed: November 27, 2012
    Date of Patent: January 5, 2016
    Assignee: IFP ENERGIES NOUVELLES
    Inventors: Stefania Cassiano Gaspar, Delphine Bazer-Bachi, Loic Rouleau, Eric Lecolier, Jerome Chevalier, Yves Jorand
  • Patent number: 9115029
    Abstract: An object of the invention is to provide, in porous thermal insulating firebricks formed by molding and drying bubble-containing slurry obtained by foaming slurry containing a fire resistant powder and water, a thermal insulating firebrick superior in thermal insulating property in spite of the same composition and porosity. A porous thermal insulating firebrick formed by molding and drying bubble-containing slurry obtained by foaming slurry containing a fire resistant powder with a heat resistant temperature of 1,000° C. or higher and water has the porosity of 60% or more, and 80% or more volume with respect to a total pore volume of the inside of the thermal insulating firebrick consists of pores having a pore size of 200 ?m or less.
    Type: Grant
    Filed: June 4, 2012
    Date of Patent: August 25, 2015
    Assignee: HINOMARU YOGYO CO., LTD.
    Inventors: Daisuke Taniyama, Yasunari Nagasaki, Akira Terasawa
  • Publication number: 20140371062
    Abstract: Disclosed herein is a ceramic body comprising at least one phase comprising a pseudobrookite-type crystal structure and at least one phase comprising zirconium tin titanate. Also disclosed are porous ceramic honeycomb structures comprising a ceramic body comprising at least one phase comprising a pseudobrookite-type crystal structure and at least one phase comprising zirconium tin titanate and methods of preparing a ceramic body comprising at least one phase comprising a pseudobrookite-type crystal structure and at least one phase comprising zirconium tin titanate.
    Type: Application
    Filed: June 18, 2013
    Publication date: December 18, 2014
    Inventors: Gregory Albert Merkel, Bryan Ray Wheaton
  • Patent number: 8846557
    Abstract: The present invention relates to a ceramic composition and a porous ceramic insulating material comprising the same, which is widely used as a core material in sandwich panels or fire doors. The ceramic composition comprises 44-60 wt % of glass powder, 8-15 wt % of fly ash, 4-8 wt % of surface treatment agent, and 23-29 wt % of water glass. The porous ceramic insulating material manufactured from the composition is lightweight and is an environmentally friendly material which generates no toxic gas when it catches fire. The ceramic insulating material can be produced at a low temperature of 800˜900° C., and thus has low production cost. In addition, it can be continuously manufactured in a sheet form.
    Type: Grant
    Filed: February 17, 2011
    Date of Patent: September 30, 2014
    Assignee: GMatex Co., Ltd.
    Inventors: Jae Young Rim, Jeong In Lim, Kil Sue Lhim
  • 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: 8598245
    Abstract: Methods of forming an insulating material comprising combining a polysilazane, a cross-linking compound, and a gas-generating compound to form a reaction mixture, and curing the reaction mixture to form a modified polysilazane. The gas-generating compound may be water, an alcohol, an amine, or combinations thereof. The cross-linking compound may be an isocyanate, an epoxy resin, or combinations thereof. The insulating material may include a matrix comprising one of a reaction product of a polysilazane and an isocyanate and a reaction product of a polysilazane and an epoxy resin. The matrix also comprises a plurality of interconnected pores produced from one of reaction of the polysilazane and the isocyanate and from reaction of the polysilazane and the epoxy resin. A precursor formulation that comprises a polysilazane, a cross-linking compound, and a gas-generating compound is also disclosed.
    Type: Grant
    Filed: April 14, 2011
    Date of Patent: December 3, 2013
    Assignee: Alliant Techsystems Inc.
    Inventors: Robert S. Larson, Michael E. Fuller
  • 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: 8323792
    Abstract: A method is provided for manufacturing spherical corundum grains having a bulk density between 1.5 kg/L and 2.5 kg/L, with aluminum oxide being melted in an electric arc furnace with the addition of 0.1 to 1% quartz sand, the melt being poured in a pouring quantity of less than 100 kg/min, and the pouring stream being blown using compressed air at a pressure between 3 to 10 bar.
    Type: Grant
    Filed: September 13, 2006
    Date of Patent: December 4, 2012
    Assignee: Center for Abrasives and Refractories Research & Development C.A.R.R.D. GmbH
    Inventors: Jean-André Alary, Sebastian Sachse
  • 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: 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
  • Patent number: 8129300
    Abstract: The invention relates to a porous, fired ceramic foam having a total porosity of between 50 and 92% and an intergranular porosity of at least 5%. In particular, the invention relates to a recrystallised silicon carbide foam.
    Type: Grant
    Filed: July 26, 2005
    Date of Patent: March 6, 2012
    Assignee: Saint Gobain Centre de Recherches et d'Etudes Europeen
    Inventors: Christian His, Samuel Prigent, Matteo Scalabrino, Franceline Villermaux
  • 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
  • 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
  • Patent number: 7976939
    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: December 16, 2003
    Date of Patent: July 12, 2011
    Inventors: Hamid Hojaji, Pedro M. Buarque de Macedo
  • Patent number: 7914718
    Abstract: Porous ceramic articles may be produced by using a gas as a pore former, where the gas is injected into a ceramic precursor batch material and mixed. Pressure is then applied to mixture such that the gas liquefies. The pressure is maintained during formation of a green body, maintaining the gas in a liquefied state. After formation of the green body, the pressure is removed whereby the gas returns to a gaseous state, creating pores in the green body. The green body may then be fired to produce a porous ceramic article.
    Type: Grant
    Filed: August 28, 2008
    Date of Patent: March 29, 2011
    Assignee: Corning Incorporated
    Inventors: Kevin Robert Brundage, Robert Leonard Bush, Roger A Rose, Yuxin Tang
  • Patent number: 7900474
    Abstract: Hollow glass microspheres are made using selenium oxide as the blowing agent. The use of selenium oxide provides two unique advantages: lower density and smaller hollow microspheres are obtained because loss of selenium oxide gas out of the liquid glass bubble during formation is slow, and the hollow microspheres will contain a vacuum due to the condensation of selenium oxide gas blowing agent upon cooling of the spheres below 315 deg. C.
    Type: Grant
    Filed: August 14, 2008
    Date of Patent: March 8, 2011
    Inventor: Warren R. Beck
  • Publication number: 20110020419
    Abstract: The invention relates to a porous osteoinductive calcium phosphate material having an average grain size in a range of 0.1-1.50 ?m, having a porosity consisting essentially only of micropores in a size range of 0.1-1.50 ?m, and having a surface area percentage of micropores in a range of 10-40%.
    Type: Application
    Filed: February 19, 2007
    Publication date: January 27, 2011
    Inventors: Huipin Yuan, Joost Dick De Bruijn
  • Patent number: 7788949
    Abstract: A method of making a closed-cell silica foam glass is provided which can include diffusing a substance into a porous glass substrate to form an impregnated substrate, sealing the impregnated glass substrate and heating to a first temperature, wherein the pressure is greater than one atmosphere, heating the container to a second temperature, wherein the second temperature is higher than first temperature, removing the solid glass, non-porous substrate, and heating the solid glass, non-porous substrate to a third temperature to soften the solid glass, non-porous substrate and thereby expand the solid glass, non-porous substrate. A closed-cell silica foam product is provided which can have a closed-cell structure and high temperature insulating property.
    Type: Grant
    Filed: May 18, 2007
    Date of Patent: September 7, 2010
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Alan L. Huston, Brian I. Justus
  • Patent number: 7737066
    Abstract: (1) A niobium monoxide powder for a capacitor represented by formula: NbOx (x=0.8 to 1.2) and optionally containing other elements in an amount of 50 to 200,000 ppm, having a tapping density of 0.5 to 2.5 g/ml, an average particle size of 10 to 1000 ?m, angle of repose from 10° to 60°, the BET specific surface area from 0.5 to 40 m2/g and a plurality of pore diameter peak tops in the pore distribution, and a producing method thereof; (2) a niobium monoxide sintered body, which is obtained by sintering the above niobium monoxide powder and, having a plurality of pore diameter peak tops in a range of 0.01 ?m to 500 ?m, preferably, the peak tops of two peaks among the plurality of pore diameter peak tops having a highest relative intensity are present in the range of 0.2 to 0.7 ?m and in the range of 0.7 to 3 ?m, respectively, and a producing method thereof; (3) a capacitor using the above sintered body and a producing method thereof; and (4) an electronic circuit and electronic device using the above capacitor.
    Type: Grant
    Filed: March 7, 2003
    Date of Patent: June 15, 2010
    Assignee: Showa Denko K.K.
    Inventors: Kazuhiro Omori, Kazumi Naito, Toshiya Kawasaki, Kouichi Wada
  • Patent number: 7732037
    Abstract: A conductive porous material includes a matrix having a sintered compact of an oxide, a communicating opening formed in the matrix, having a small diameter and being permeable to gas and impermeable to substance other than gas, and a conductive layer provided on an internal wall of the communicating opening and receiving a current to generate heat. As conductive material is used, an organic substance adheres on the internal wall of communicating opening. To address this, conductive layer is caused to generate heat to decompose and thus remove the organic substance and thus prevent the communicating opening from clogging.
    Type: Grant
    Filed: January 25, 2005
    Date of Patent: June 8, 2010
    Assignees: Towa Corporation, Japan Fine Chemicals Center
    Inventors: Takaki Kuno, Keiji Maeda, Yoshinori Noguchi, Satoshi Kitaoka, Naoki Kawashima
  • Patent number: 7718252
    Abstract: The inorganic fiber article according to the present invention is an inorganic fiber article comprising an inorganic coating layer having foams, the inorganic coating layer formed on at least a portion of the surface of an inorganic fiber molded body.
    Type: Grant
    Filed: January 29, 2007
    Date of Patent: May 18, 2010
    Assignee: Ibiden Co., Ltd.
    Inventors: Yasutaka Ito, Tsutomu Sato
  • Patent number: 7670979
    Abstract: A porous refractory product includes a matrix of sintered silicon carbide having a porosity of about 45% to about 65%. The matrix is formed by heating in a noble gas atmosphere a cast preform including a mixture of alpha-silicon carbide and boron carbide each having a particle size of less than about 1 micron. The heating causes the formation of gaseous SiO within the silicon carbide matrix, which, in turn, forms pores having an average size of less than about 1 micron. The porous refractory products herein are suitable for use in a variety of applications including for use in high temperature particulate filtering applications.
    Type: Grant
    Filed: October 5, 2007
    Date of Patent: March 2, 2010
    Assignee: CerCo LLC
    Inventors: Tariq Quadir, Corey Dunn
  • Patent number: 7658990
    Abstract: 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: Grant
    Filed: November 4, 2005
    Date of Patent: February 9, 2010
    Assignee: LG Chem, Ltd.
    Inventor: Sang-Ho Shin
  • Publication number: 20090325780
    Abstract: Described is a method to prepare wet foams exhibiting long-term stability wherein colloidal particles are used to stabilize the gas-liquid interface, said particles being initially inherently partially lyophobic particles or partially lyophobized particles having mean particle sizes from 1 nm to 20 ?m. In one aspect, the partially lyophobized particles are prepared in-situ by treating initially hydrophilic particles with amphiphilic molecules of specific solubility in the liquid phase of the suspension.
    Type: Application
    Filed: December 12, 2005
    Publication date: December 31, 2009
    Inventors: Ludwig J. Gauckler, André Studart, Elena Tervoort, Urs T. Gonzenbach, Iike Akartuna
  • Publication number: 20090298667
    Abstract: The present invention provides compositions and methods for producing porous ceramic articles. The compositions and methods comprise a ceramic precursor batch comprising an organic peroxide pore forming agent where the pore forming agent is an organo-adduct of hydrogen peroxide and an organic compound or an organic peroxide of the general formula R—O—O—R?. The organic peroxide pore forming agent is stable during extrusion and other methods for forming a green body and does not decompose until the green body is dried.
    Type: Application
    Filed: May 30, 2008
    Publication date: December 3, 2009
    Inventors: William Peter Addiego, Christopher Raymond Glose
  • Publication number: 20090220734
    Abstract: An aluminum titanate-based ceramic is provided having an anisotropic microstructure which includes the reaction products of a plurality of ceramic-forming precursors. The batch contains at least one precursor in fibrous form. The inorganic ceramic has low thermal expansion. Porous ceramic bodies and the method of manufacture are also provided.
    Type: Application
    Filed: December 11, 2008
    Publication date: September 3, 2009
    Inventors: Monika Backhaus-Ricoult, Christopher Raymond Glose, James William Zimmermann
  • Publication number: 20090202821
    Abstract: A method of making a porous sintered body includes a formation step S102 where a sintering compound which contains a binder and a sinterable powder material is into a predetermined shape; a degreasing steps S103, S104 and S105 where the binder is removed from a formed body obtained in the formation step; and a sintering step S108 where a degreased body after the degreasing step is sintered into a sintered body. The binder contains a component which drains at a temperature higher than a draining temperature of the pore formation material drains. The pore formation material is drained in the degreasing step, with part of the binder remaining un-drained. The present invention enables to manufacture porous sintered bodies which are highly porous, and highly accurate in shape and dimensions. The present invention also enables to manufacture porous sintered bodies which offer functionalities not available before.
    Type: Application
    Filed: October 13, 2005
    Publication date: August 13, 2009
    Applicant: TAISEI KOGYO CO., Ltd.
    Inventors: Shigeo Tanaka, Shinji Ishida, Kazuaki Nishiyabu
  • Publication number: 20090197756
    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: Application
    Filed: February 2, 2009
    Publication date: August 6, 2009
    Inventors: Peter C. LeBaron, Thomas M. Paquette
  • Publication number: 20090069167
    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: Application
    Filed: July 26, 2005
    Publication date: March 12, 2009
    Inventors: Caroline Tardivat, Emmanuel Mercier, Christian His, Franceline Villermaux
  • Publication number: 20090018009
    Abstract: The present invention relates to a method for preparing a porous ceramic material, particularly for thermal insulation, comprising the steps of: providing a first composition in the form of a stable aqueous colloidal solution of silica and oxides of alkaline metals; providing a second stable composition in the form of a suspension in an organic liquid of inorganic and/or organic particles, the second composition containing compounds which, when the second composition is mixed with the first composition, can destabilize the first composition, forming gel, and can form an organic polymeric net together with a blowing agent; mixing the first composition and the second composition to form a mixture; forming from the mixture a porous structure in gel form, where an organic structure supports inorganic structures being formed; solidifying the porous structure in gel form, obtaining a porous ceramic material in which an organic polymeric net surrounds inorganic portions.
    Type: Application
    Filed: February 16, 2007
    Publication date: January 15, 2009
    Inventor: Germano Zambaldo
  • Publication number: 20080312064
    Abstract: The invention relates to a porous, fired ceramic foam having a total porosity of between 50 and 92% and an intergranular porosity of at least 5%. In particular, the invention relates to a recrystallised silicon carbide foam.
    Type: Application
    Filed: July 26, 2005
    Publication date: December 18, 2008
    Inventors: Christian His, Samuel Prigent, Matteo Scalabrino, Franceline Villermaux
  • Publication number: 20080287281
    Abstract: The invention relates to a method for producing a wear-resistant reaction-bounded ceramic filtering membrane, during which a porous metallic or non-metallic support for producing a green body is provided with a suspension. This suspension is obtained from a dispersant and from a dispersed phase, and this dispersed phase can be obtained from at least one ceramic raw material from the group of metal nitrides and, optionally, from at least one other ceramic raw material. The invention provides that the green body produced in this manner is fired at a temperature ranging from 700° C. to 1250° C. under atmospheric pressure in a oxidizing atmosphere in order to obtain a phase change of at least the ceramic raw material.
    Type: Application
    Filed: May 13, 2006
    Publication date: November 20, 2008
    Applicant: ATECH INNOVATIONS GMBH
    Inventors: Peter Bolduan, Giovanni Catania, Peter Mund
  • Publication number: 20080248436
    Abstract: A method of filling cavities in refractory bodies, comprising lofting refractory fibers in flowing air, mixing lofted refractory fibers with refractory foam to generate a fibrous refractory foam, and filling a substantially enclosed cavity in a refractory material with fibrous refractory foam to produce a foam-filled cavity, heating the foam-filled cavity to a first drying temperature for sufficient time to dry the fibrous refractory foam filling, and heating the foam-filled cavity to a second substantially higher firing temperature to produce a fired body. The substantially enclosed cavity is defined by at least one refractory wall.
    Type: Application
    Filed: April 4, 2008
    Publication date: October 9, 2008
    Inventor: David Erhardt
  • Publication number: 20080179771
    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: Application
    Filed: January 29, 2007
    Publication date: July 31, 2008
    Inventors: Weiguo Miao, Steven Bolaji Ogunwumi, Jianguo Wang
  • Patent number: 7311965
    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: July 22, 2003
    Date of Patent: December 25, 2007
    Inventors: Hamid Hojaji, Pedro M. Buarque de Macedo
  • Patent number: 7279219
    Abstract: A porous calcium phosphate ceramic comprising a support portion having pores, and ring-shaped portions formed in the pores, the ring-shaped portions having pluralities of fine pores so that they have a network structure. A method for producing a porous calcium phosphate ceramic comprising stirring a slurry containing coarse calcium phosphate particles, fine calcium phosphate particles, a nonionic surfactant and a water-soluble high-molecular compound to foam the slurry; gelling the foamed slurry; and then drying the resultant get to obtain a sintered porous calcium phosphate ceramic; the nonionic surfactant being malamide and/or polyoxyethylene lauryl ether.
    Type: Grant
    Filed: November 26, 2004
    Date of Patent: October 9, 2007
    Assignee: PENTAX Corporation
    Inventor: Toshio Matsumoto
  • Patent number: 7045105
    Abstract: Methods of making porous calcium phosphate bone replacement materials are discussed.
    Type: Grant
    Filed: December 20, 2002
    Date of Patent: May 16, 2006
    Inventor: Richard J. Lagow
  • Patent number: 6998064
    Abstract: A thermochemically stable oxidic thermal insulating material presenting phase stability, which can be used advantageously as a thermal insulating layer on parts subjected to high thermal stress, such as turbine blades or such like. The thermal insulating material can be processed by plasma spraying and consists preferably of a magnetoplumbite phase whose preferred composition is MMeAl11O19, where M is La or Nd and where Me is chosen from among zinc, the alkaline earth metals, transition metals, and rare earths, preferably from magnesium, zinc, cobalt, manganese, iron, nickel and chromium.
    Type: Grant
    Filed: July 14, 2003
    Date of Patent: February 14, 2006
    Assignee: MTU Aero Engines GmbH
    Inventors: Rainer Gadow, Guenter Schaefer
  • Patent number: 6964809
    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: February 15, 2002
    Date of Patent: November 15, 2005
    Inventors: Hamid Hojaji, Pedro M. Buarque de Macedo
  • Patent number: 6812177
    Abstract: The object of the present invention is to provide a refractory having sufficient corrosion resistance against alkali vapors and excellent thermal shock resistance which is light in weight and suitable for glass tank furnaces. The present invention provides a high-alumina fused cast refractory comprising from 94 to 98% of Al2O3, from 1 to 6%, in total, of Na2O and/or K2O, which is mainly composed of &agr;-Al2O3 crystals and &bgr;-Al2O3 crystals, has pores dispersed in it and has a porosity of from 5 to 30%.
    Type: Grant
    Filed: January 31, 2002
    Date of Patent: November 2, 2004
    Assignee: Asahi Glass Company, Limited
    Inventor: Toshihiro Ishino
  • Publication number: 20040077480
    Abstract: A super-lightweight ceramic foam with a cellular structure effectively reinforced by ceramic short fibers, which has a density of 0.2 g/cm3 or less and a sufficient strength. The ceramic foam is prepared by evenly dispersing ceramic short fibers throughout a nonaqueous solvent through the use of the reactivity of metal alkoxide with the surface of the ceramic short fibers, adding into the nonaqueous solvent an aqueous slurry containing ceramic powder dispersed therein, allowing the evenly dispersed ceramic fibers to move into an aqueous phase separately from a nonaqueous solvent phase so as to obtain an aqueous slurry containing the ceramic fibers evenly dispersed therein, and foaming and firing the aqueous slurry.
    Type: Application
    Filed: October 3, 2003
    Publication date: April 22, 2004
    Applicant: NATIONAL INSTITUTE OF ADVANCED INDUSTRIAL SCIENCE AND TECHNOLOGY
    Inventors: Kazushi Kishi, Eiji Tani, Eishi Maeda
  • Patent number: 6713420
    Abstract: A porous ceramics body for in vivo or in vitro 1use in which a number of pores are closely distributed in three dimensional directions, adjoining pores thereof being partitioned by wall portions with respective communication ports to bring said adjoining pores into communication with each other such that a series of connected spherical pores are formed therewithin, said porous ceramics body being made of a sintered calcium phosphate body, characterized in that, within said sintered calcium phosphate body, pores each having a diameter of 5 microns (&mgr;m) or more account for 80% or more of all the pores in terms of volume whereas pores having a diameter of less than 5 microns (&mgr;m) account for less than 20% of all the pores in terms of volume as subjected to a mercury porosimeter measurement.
    Type: Grant
    Filed: October 10, 2001
    Date of Patent: March 30, 2004
    Assignees: Toshiba Ceramics Co., Ltd., Independent Administrative Institution National Institute for Materials Science, Toshiba Denko Co., Ltd.
    Inventors: Kohichi Imura, Takashi Umezawa, Akihiko Ichikawa, Katsuhiro Chaki