By Volatilizing Or Heat Expansion Of Water Or Other Noncombustible Material Patents (Class 501/85)
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Patent number: 11154849Abstract: A method of manufacturing a honeycomb metal structure includes providing a substrate comprising iron (Fe) and a container containing water; coating at least a part of the substrate with a viscid material whose viscidity is increased by moisture; attaching metal powder onto the viscid material; adhering the metal powder to the substrate due to an increase in viscidity of the viscid material by evaporating a portion of the water in the container and supplying moisture to the viscid material; and generating an uneven structure made of the metal powder bonded to the substrate by performing a heat treatment on the substrate to which the metal powder is adhered. The heat treatment may include performing a first heat treatment on the substrate to generate an intermetallic layer at an interface between the substrate and the metal powder; and performing a second heat treatment to dissolve the intermetallic compound layer.Type: GrantFiled: January 23, 2019Date of Patent: October 26, 2021Assignee: Korea Institute of Science and TechnologyInventors: Ji Young Byun, Sang Hoon Kim, Jong Sik Kim
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Patent number: 9533919Abstract: A method for fabricating a ceramic material includes impregnating a porous structure with a mixture that includes a preceramic polymer and a filler. The filler includes at least one free metal. The preceramic polymer material is then rigidized to form a green body. The green body is then thermally treated to convert the rigidized preceramic polymer material into a ceramic matrix located within pores of the porous structure. The same thermal treatment or a second, further thermal treatment is used to cause the at least one free metal to move to internal porosity defined by the ceramic matrix or pores of the porous structure.Type: GrantFiled: October 12, 2011Date of Patent: January 3, 2017Assignee: United Technologies CorporationInventors: Wayde R. Schmidt, Tania Bhatia Kashyap, Paul Sheedy
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Patent number: 9315425Abstract: The present embodiments disclosed herein are related to methods of preparing a macroporous ceramic body. According to some embodiments, a first mixture of ceramic-forming components is combined with a polymer network structure to form a second intermediate mixture comprising a polymer network. The polymer network is then removed in the drying and/or sintering step leaving an interconnected open pore network within the ceramic body. In some embodiments, the macroporous ceramic body comprises a three-dimensional, porous network comprising pores of about 3 mm to 11 mm.Type: GrantFiled: October 28, 2013Date of Patent: April 19, 2016Assignee: UNIVERSITI BRUNEI DARUSSALAMInventors: Piyasiri Ekanayake, Mohammad Iskandar bin Pg Hj Petra
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Publication number: 20150038318Abstract: A building brick with cellular structure comprising a porous material, said porous material being obtained by a process comprising the following successive steps: a step a) of synthesis of quicklime; a step b) of mixing said quicklime, water and silica; a step c) of introduction of a nucleating agent; a step d) of hydrothermal synthesis to obtain a ceramic mass, and a step e) of drying said ceramic mass obtained in step d).Type: ApplicationFiled: December 12, 2012Publication date: February 5, 2015Inventors: Pascal Del-Gallo, Nicolas Richet, Sebastien Goudalle
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Publication number: 20150018195Abstract: The invention relates to a method for preparing a ceramic material, in particular porcelain, having a porous, foam-like structure, comprising the steps of providing a clay composition comprising kaolin clay; alkali metal salt and/or alkaline earth metal salt, or a mixture thereof; a plastic mineral clay; and a frit; and water; shaping said composition in a mould; drying said composition in said mould by subjecting it to temperatures below 140° C.; firing said composition in said mould by subjecting it to temperatures within the range of 700-1200° C. The invention also pertains to objects made of this foamed ceramic material.Type: ApplicationFiled: March 13, 2013Publication date: January 15, 2015Applicant: Joris Laarman Studio BVInventor: Marjan Van Aubel
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Patent number: 8728965Abstract: 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: GrantFiled: March 16, 2011Date of Patent: May 20, 2014Assignee: Nichirei Foods Inc.Inventors: Manabu Fukushima, Yuichi Yoshizawa, Norimitsu Murayama, Sakae Tsuda, Takeshi Koizumi, Toshifumi Inoue
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Patent number: 8722188Abstract: 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: GrantFiled: December 31, 2009Date of Patent: May 13, 2014Assignee: Saint-Gobain Ceramics & Plastics, Inc.Inventors: Tihana Fuss, Laurie San-Miguel, Kevin R. Dickson, Walter T. Stephens
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Patent number: 8323742Abstract: 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: GrantFiled: November 22, 2010Date of Patent: December 4, 2012Assignee: Cellaris LimitedInventors: Gideon Grader, Gennady Shter, Yoram Dehazan
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Patent number: 8262957Abstract: 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 strenType: GrantFiled: February 20, 2008Date of Patent: September 11, 2012Assignee: National Institute of Advanced Industrial Science and TechnologyInventors: Manabu Fukushima, Masayuki Nakata, Yuichi Yoshizawa
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Patent number: 7914874Abstract: Disclosed are ceramic batch compositions for forming porous ceramic articles. The ceramic forming precursor batch compositions include ceramic forming inorganic batch components and a cyclododecane pore forming agent. Also disclosed are methods for manufacturing porous ceramic articles.Type: GrantFiled: March 31, 2008Date of Patent: March 29, 2011Assignee: Corning IncorporatedInventors: David Henry, Yves A. H. Brocheton
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Patent number: 7788949Abstract: 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: GrantFiled: May 18, 2007Date of Patent: September 7, 2010Assignee: The United States of America as represented by the Secretary of the NavyInventors: Alan L. Huston, Brian I. Justus
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Patent number: 7737066Abstract: (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: GrantFiled: March 7, 2003Date of Patent: June 15, 2010Assignee: Showa Denko K.K.Inventors: Kazuhiro Omori, Kazumi Naito, Toshiya Kawasaki, Kouichi Wada
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Publication number: 20100056355Abstract: 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: ApplicationFiled: August 28, 2008Publication date: March 4, 2010Inventors: Kevin Robert Brundage, Robert Leonard Bush, Roger A. Rose, Yuxin Tang
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Patent number: 7670979Abstract: 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: GrantFiled: October 5, 2007Date of Patent: March 2, 2010Assignee: CerCo LLCInventors: Tariq Quadir, Corey Dunn
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Publication number: 20090247389Abstract: There is provided a method for manufacturing cordierite ceramics by forming and heating a cordierite-forming raw material containing ?-alumina. A degree of orientation [expressed by (I006/(I300+I006) where Ihkl is height of X-ray diffraction intensity of a hkl face of an ?-alumina crystal] by X-ray diffraction measurement of an ?-alumina crystal in a formed article of the raw material for forming cordierite is 0.10 or more. A crystal structure of alumina used as a material for a cordierite-forming raw material was studied. The method can provide cordierite ceramics having improved thermal resistance and thermal shock resistance by the use of an ?-alumina crystal having a specific shape.Type: ApplicationFiled: March 2, 2009Publication date: October 1, 2009Applicant: NGK Insulators, Ltd.Inventors: Atsushi Watanabe, Yuji Katsuda, Yohei Ono
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Publication number: 20090093358Abstract: 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: ApplicationFiled: October 5, 2007Publication date: April 9, 2009Applicant: CERCO LLCInventors: Tariq Quadir, Corey Dunn
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Publication number: 20090057939Abstract: Disclosed are ceramic batch compositions for forming porous ceramic articles. The ceramic forming precursor batch compositions include ceramic forming inorganic batch components and a cyclododecane pore forming agent. Also disclosed are methods for manufacturing porous ceramic articles.Type: ApplicationFiled: March 31, 2008Publication date: March 5, 2009Inventors: David Henry, Yves A.H. Brocheton
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Patent number: 7053016Abstract: A ceramic porous body is provided which uses a binder made of a glass that has excellent acid resistance and alkali resistance and which can be used for a long period of time as a filtration filter. The ceramic porous body is formed from ceramic particles that are bonded using a glass binder comprising 5 to 20 mol % of a plurality of metal oxides, selected from the group consisting of Li2O, Na2O, K2O, MgO, CaO, SrO and BaO and containing at least two alkali metal oxides selected from the group consisting of Li2O, Na2O and K2O as an essential component, at least 3 mol % of at least one of ZrO2 and TiO2 as a total amount, and SiO2 and incidental impurities as the balance.Type: GrantFiled: December 3, 2002Date of Patent: May 30, 2006Assignee: NGK Insulators, Ltd.Inventors: Takahiro Mizuno, Manabu Isomura, Tomonori Takahashi
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Patent number: 6833337Abstract: The present invention is a method for fabricating shaped monolithic ceramics and ceramic composites, and the ceramics and composites made thereby. The method of the present invention includes three basic steps: (1) Synthesis or other acquisition of a porous preform with an appropriate composition, pore fraction, and overall shape is prepared or obtained. The pore fraction of the preform is tailored so that the reaction-induced increase in solid volume can compensate partially or completely for such porosity. It will be understood that the porous preform need only be sufficiently dimensionally stable to resist the capillary action of the infiltrated liquid reactant; (2) Infiltration: The porous preform is infiltrated with a liquid reactant; and (3) Reaction: The liquid reactant is allowed to react partially or completely with the solid preform to produce a dense, shaped body containing desired ceramic phase(s).Type: GrantFiled: May 30, 2002Date of Patent: December 21, 2004Assignee: The Ohio State UniversityInventors: Kenneth H. Sandhage, Pragati Kumar
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Patent number: 6818579Abstract: A ceramic material, includes SiO2 and Na2O and/or K2O. The material is characterized by a porosity of over 60% and by pores, more than 70% of which have a pore size ranging between 0.1 and 15 &mgr;m. The ceramic material can be used as filtering material, for water storage and as adsorbent material.Type: GrantFiled: November 25, 2002Date of Patent: November 16, 2004Assignee: Pfleiderer Infrastrukturtechnik GmbH & Co. KGInventor: Antonio Giangrasso
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Patent number: 6811602Abstract: A process for preparing a silicate porous product, which comprises a step of forming a clay mineral into a dispersion by means of a dispersant, a step of removing gases dissolved in the dispersion, a step of freezing the dispersion and drying it in its frozen state under reduced pressure, and a step of firing the dried product obtained by the drying.Type: GrantFiled: March 27, 2002Date of Patent: November 2, 2004Assignee: Asahi Glass Company, LimitedInventors: Yoshihisa Beppu, Shinji Kondoh
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Patent number: 6777361Abstract: A ceramic composite material, for example, a ceramic molded body or a layer obtained by pyrolysis of a starting mixture, containing at least one polymer precursor material and at least one filler, which has an average particle size of less than 200 nm. Such a composite material may be used, for example, for producing fibers, filters, catalyst support materials, ceramic sheathed-element glow plugs, metal-containing reactive composite materials, porous protective shells for sensors, ceramic or partially ceramic coatings or microstructured ceramic components.Type: GrantFiled: October 29, 2002Date of Patent: August 17, 2004Assignee: Robert Bosch GmbHInventors: Wilfried Aichele, Wolfgang Dressler, Christof Rau, Volker Knoblauch, Alexander Kloncynski, Horst Boeder
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Patent number: 6664205Abstract: The present invention is a porous sound-absorbing ceramic form made of a porous ceramic material with communicating pores and having a bulk specific gravity of 0.5 to 1.0. The porous ceramic material consists essentially of 100 parts by weight of perlite having a particle diameter of 0.50 to 2.0 mm, 100 to 200 parts by weight of at least one sintered material selected from the group consisting of fly ash, chamotte, wollastonite, slag, silica, volcanic ejecta, rock, and clay mineral as a matrix material, and 10 to 20 parts by weight of an inorganic binder, which have been sintered so that the matrix material, together with the binder, surrounds the perlite particles. The perlite particles form communicating openings at mutually contacting portions thereof, so that the internal pores are communicating pores.Type: GrantFiled: June 4, 2002Date of Patent: December 16, 2003Assignee: Oda Construction Co., Ltd.Inventors: Kazuo Oda, Noriho Oda, Nobuaki Miyao
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Patent number: 6620749Abstract: Ultra-high temperature, light-weight, black ceramic insulation having a density ranging from about 0.12 g/cc. to 0.6 g/cc. such as ceramic tile is obtained by pyrolyzing siloxane gels derived from the reaction of at least one organo dialkoxy silane and at least one tetralkoxy silane in an acid or base liquid medium. The reaction mixture of the tetra- and dialkoxy silanes also may contain an effective amount of a mono- or trialkoxy silane to obtain the siloxane gels. The siloxane gels are dried at ambient temperatures and pressures to form siloxane ceramic precursors without significant shrinkage. The siloxane ceramic precursors are subsequently pyrolyzed, in an inert atmosphere, to form the black ceramic insulation comprising atoms of silicon, carbon and oxygen. The ceramic insulation can be characterized as a porous, uniform ceramic tile resistant to oxidation at temperatures ranging as high as 1700° C.Type: GrantFiled: October 9, 2001Date of Patent: September 16, 2003Assignee: HC Chem Research and Service Corp.Inventors: Ming-Ta S. Hsu, Timothy S. Chen
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Patent number: 6620458Abstract: A two-step method for producing monolithic alumina aerogels having porosities of greater than 80 percent. Very strong, very low density alumina aerogel monoliths are prepared using the two-step sol-gel process. The method of preparing pure alumina aerogel modifies the prior known sol method by combining the use of substoichiometric water for hydrolysis, the use of acetic acid to control hydrolysis/condensation, and high temperature supercritical drying, all of which contribute to the formation of a polycrystalline aerogel microstructure. This structure provides exceptional mechanical properties of the alumina aerogel, as well as enhanced thermal resistance and high temperature stability.Type: GrantFiled: September 27, 2001Date of Patent: September 16, 2003Assignee: The Regents of the University of CaliforniaInventors: John F. Poco, Lawrence W. Hrubesh
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Patent number: 6602449Abstract: A method of producing ceramic foam wherein a precursor including an AlCl3 (Pri2O) complex is decomposed to form a mixture of a polymerizing species and liquid isopropyl chloride and the mixture is foamed. The foamed mixture is sintered and/or calcined to produce a ceramic foam.Type: GrantFiled: September 28, 2000Date of Patent: August 5, 2003Assignee: Cellaris LimitedInventors: Gideon Grader, Gennady Shter, Yoram Dehazan
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Patent number: 6541108Abstract: The process of the invention characterized in that to 100 parts by weight of a silicate powder having 2000-8000 m2/g specific surface, 1-10 parts by weight of gas-forming material with particle size of 10-100 &mgr;m and 0.5-15 parts by weight of montmorillonite, 0.5-2 parts by weight of alkali hydrogen phosphate or alkali dihydrogen phosphate or a mixture of alkali metal phosphate and sodium silicate in form of aqueous solution, 0.01-5 parts by weight of rare earth metal oxide or a mixture of such oxides were added, then the mixture obtained is homogenized, pre-dried, coated with 1-5 parts by weight of titanium oxide and/or titanium oxide hydroxide and/or aluminum oxide hydroxide, then subjected to heat treatment at 720-1000° C., and the mixture obtained is molded. The subject of the invention: also the product of the above process.Type: GrantFiled: July 10, 2000Date of Patent: April 1, 2003Inventors: László Hoffmann, István {haeck over (J)}alsowszky, Emma Hoffmann, Rita Rostás, Jenó Fehér, Zsolt Fejér
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Patent number: 6399528Abstract: The present invention relates to a porous aluminum oxide structure comprising Al2O3 and Zr, the structure having an open porosity greater than about 30% and an average pore size from about 20 nm to about 1000 nm, wherein the Zr, expressed as ZrO2, has a concentration less than about 5 weight % of the weight of the Al2O3.Type: GrantFiled: March 5, 2001Date of Patent: June 4, 2002Assignee: Fraunhofer-Gesellschaft zur Forderung der Angewandten Forschung e.V.Inventors: Andreas Krell, Frank Buse, Hongwei Ma
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Publication number: 20020038919Abstract: A method of forming foamed articles suitable for refractory, thermal insulation and construction application in a form such as bricks, blocks, slabs and discs includes the preparation of homogeneous mixture of at least one oxygen-containing, water-insoluble raw material having a particle size <200 microns and at least one gas forming reagent having a particle size <130 microns. The mixture is humidified and shaped and then heated to a formation temperature sufficient to melt the raw material to develop an oxygen-containing molten liquid phase. This phase reacts at the formation temperature with the gas-forming reagent to induce a foamed structure which is then cooled to a solid state. The raw materials preferably make up 99-99.95 wt % of the mixture, and the gas forming reagent makes up the balance.Type: ApplicationFiled: May 21, 2001Publication date: April 4, 2002Inventors: Vladimir Gontmakher, Evgueni Pevzner
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Patent number: 6339034Abstract: Ultra-high temperature, light-weight, ceramic insulation such as ceramic tile is obtained by pyrolyzing a siloxane gel derived from the reaction of at least one organo dialkoxy silane and at least one tetralkoxy silane in an acid or base liquid medium. The reaction mixture of the tetra- and dialkoxy silanes may contain also an effective amount of a mono- or trialkoxy silane to obtain the siloxane gel. The siloxane gel is dried at ambient pressures to form a siloxane ceramic precursor without significant shrinkage. The siloxane ceramic precursor is subsequently pyrolyzed, in an inert atmosphere, to form the black ceramic insulation comprising atoms of silicon, carbon and oxygen. The ceramic insulation, can be characterized as a porous, uniform ceramic tile resistant to oxidation at temperatures ranging as high as 1700° C. and is particularly useful as lightweight tiles for spacecraft and other high-temperature insulation applications.Type: GrantFiled: January 24, 2000Date of Patent: January 15, 2002Assignee: HC Chem Research & Service Corp.Inventors: Ming-Ta S. Hsu, Timothy S. Chen
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Patent number: 6331496Abstract: The composite includes inorganic fiber for reinforcement and a matrix of 40 to 95% by weight of silicon carbide ceramic and 5 to 60% by weight of an oxide phase dispersed in the silicon carbide ceramic. The oxide phase forms a continuous network structure in the matrix and includes ZrSiO4, BaO—MgO—Al2O3—SiO2 glass ceramic or Sro—Al2O3—SiO2 glass ceramic. The matrix surrounds and fills voids between the inorganic fiber.Type: GrantFiled: February 25, 1999Date of Patent: December 18, 2001Assignee: Research Institute of Advanced Material Gas-Generator, Ltd.Inventor: Tetsuo Nakayasu
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Patent number: 6284688Abstract: Substantially dry, self-hardening, thermally activated refractory compositions, suitable for use to produce linings for furnaces or metallurgical vessels such as ladles, tundishes or launders, comprise particulate refractory material, an inorganic binder having associated therewith chemically or physically bound water such as sodium metasilicate pentahydrate or tribasic sodium phosphate dodecahydrate, and an element or compound, such as aluminium, which will react exothermically with the inorganic binder. The compositions may also contain an inhibitor such as a mineral oil or a vegetable oil to inhibit premature exothermic reaction.Type: GrantFiled: April 7, 1995Date of Patent: September 4, 2001Assignee: Foseco International LimitedInventors: Gerd Trinkl, Manfred Fessel, Vincent Edward Mellows, Reinhard Stötzel
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Patent number: 6251819Abstract: Silicon carbide foam useful as a catalyst support has a BET specific surface area of at least 5 m2/g, and a compression strength exceeding 0.2 MPa. The foam is prepared by impreganting an organic foam with a suspension of silicon in a resin containing a cross-linking agent, incompletely cross-linking the resin, carbonizing the foam and resin, and carburizing the silicon.Type: GrantFiled: February 15, 2000Date of Patent: June 26, 2001Assignee: Pechiney RechercheInventors: Marie Prin, Benoist Ollivier
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Patent number: 5962352Abstract: A method for fabricating a porous composite oxide is provided. The method includes the steps of: (a) slowly mixing a solution including a silicon oxide source and a solution including an aluminum oxide source; (b) adding hydrochloric acid to the mixed solution prepared in said step (a) to obtain a sol; and (c) adding sodium hydroxide to said sol, reacting the obtained resultant at room temperature for 30 minutes to 12 hours, and drying the resultant. The porous composite oxide has an abundance of fine pores and the distribution of pore size is relatively uniform, so that the porous composite oxide is suitable for a carrier.Type: GrantFiled: July 11, 1997Date of Patent: October 5, 1999Assignee: Samsung Electronics Co., Ltd.Inventors: Ho-jin Kweon, Kae-dong Baek, Soon-kyo Hong, Dong-gon Park, Hye-jin Kim
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Patent number: 5958363Abstract: Transparent, monolithic metal oxide aerogels of varying densities are produced using a method in which a metal alkoxide solution and a catalyst solution are prepared separately and reacted. The resulting hydrolyzed-condensed colloidal solution is gelled, and the wet gel is contained within a sealed, but gas permeable, containment vessel during supercritical extraction of the solvent. The containment vessel is enclosed within an aqueous atmosphere that is above the supercritical temperature and pressure of the solvent of the metal alkoxide solution.Type: GrantFiled: October 29, 1998Date of Patent: September 28, 1999Assignee: The Regents of the University of CaliforniaInventor: Paul R. Coronado
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Patent number: 5958831Abstract: SiC foam-based catalyst carrier in the form of a moulded part having walls reinforced with a SiC skin having mechanical characteristics higher than those of the foam, this skin allowing the carrier to be handled and used without damage.Type: GrantFiled: October 21, 1997Date of Patent: September 28, 1999Assignee: Pechiney RechercheInventors: Marie Prin, Benoit Ollivier, Airy Pierre Lamaze
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Patent number: 5849055Abstract: A process for producing inorganic microspheres (solid spheres or hollow spheres), which comprises pulverizing a material by wet pulverization to an average particle size of at most 5 .mu.m to obtain a slurry of a pulverized powder material, spraying the slurry to form liquid droplets, and heating the liquid droplets to fuse or sinter the powder material to obtain inorganic microspheres.Type: GrantFiled: March 7, 1997Date of Patent: December 15, 1998Assignee: Asahi Glass Company Ltd.Inventors: Kiyotaka Arai, Kenji Yamada, Hachiro Hirano, Masakuni Satoh
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Patent number: 5833728Abstract: Provided is a method for the efficient preparation of fine hollow spherical glassy bodies having a high strength and excellent whiteness from a volcanic vitreous deposit as the starting material. The fine hollow spherical glassy bodies as desired can be prepared by dispersing 100 parts by weight of a powder of a volcanic vitreous deposit in an aqueous solution containing 1 to 10 parts by weight of aluminum sulfate, adding an aqueous alkaline solution to this liquid suspension to cause deposition of an alumina hydrate onto the surface of the particles of said powder and washing and drying of the solid material followed by a heat treatment for 1 second to 1 minute at a temperature of 900.degree. to 1100.degree. C.Type: GrantFiled: March 27, 1997Date of Patent: November 10, 1998Assignee: Agency of Industrial Science and TechnologyInventors: Kunio Kimura, Hiroyuki Nakamura, Yukiyoshi Tamoto, Junichi Kimoto, Hiromi Okada
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Patent number: 5827457Abstract: A method for manufacturing a lightweight foamed ceramic body from components comprising: (a) at least one expandable volcanic mineral; (b) at least one alkaline earth metal oxide, hydroxide, or carbonate, (c) at least one inorganic binder and (d) a foaming stabilizer, the method comprising: (1) sintering and expanding a mixture of components (a) to (d); (2) mixing the sintered and expanded material with water; (3) grinding the mixture of sintered and expanded material with water to form a ground mixture; (4) drying said ground mixture to form a dried mixture; (5) crushing said dried mixture to form a fine powder; (6) shaping said powder into a desired form to form a powder form; and (7) sintering said powder form. The ceramic material is preferably manufactured in a tunnel-type kiln. The resulting foamed ceramic is not only light in weight, but excellent in insulating properties due to its discrete cell of closed cellular structure. The foamed ceramic is useful in structural and building materials.Type: GrantFiled: September 29, 1997Date of Patent: October 27, 1998Inventor: Chao-Ming Tseng
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Patent number: 5772735Abstract: Supported inorganic membranes capable of molecular sieving, and methods for their production, are provided. The subject membranes exhibit high flux and high selectivity. The subject membranes are substantially defect free and less than about 100 nm thick. The pores of the subject membranes have an average critical pore radius of less than about 5 .ANG., and have a narrow pore size distribution. The subject membranes are prepared by coating a porous substrate with a polymeric sol, preferably under conditions of low relative pressure of the liquid constituents of the sol. The coated substrate is dried and calcined to produce the subject supported membrane. Also provided are methods of derivatizing the surface of supported inorganic membranes with metal alkoxides. The subject membranes find use in a variety of applications, such as the separation of constituents of gaseous streams, as catalysts and catalyst supports, and the like.Type: GrantFiled: July 18, 1997Date of Patent: June 30, 1998Assignees: University of New Mexico, Sandia Natl LaboratoriesInventors: Rakesh Sehgal, Charles Jeffrey Brinker
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Patent number: 5759932Abstract: An improved thermal barrier coating for metal substrates such as superalloys is provided. The coating is a slurry composition, comprising spheres of zirconia, at least some of which are hollow, contained within a porous oxide matrix, such as aluminosilicate. The slurry composition can be applied by slurry casting or similar techniques to the desired surface. Coating methods involve the application of successive layers of variations of the slurry composition, with various curing techniques used between layers and after the final coating is applied. Another embodiment of this invention embraces a composite coating, comprising (i) an oxide matrix phase; (ii) zirconia spheres embedded in the oxide matrix; and (iii) a porous phase.Type: GrantFiled: November 8, 1996Date of Patent: June 2, 1998Assignee: General Electric CompanyInventors: D. Sangeeta, Lawrence Edward Szala, David Winfield Woodruff, Bangalore Aswatha Nagaraj, Daniel Scott McAtee, Clifford Lawrence Spiro
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Patent number: 5705448Abstract: A gas generating substance is added to an aqueous dispersion containing refractory particles and a polymerizable monomer and the pressure and/or temperature are adjusted so that the substance generates the gas before the polymerization gets underway; to control the formation of pores.Type: GrantFiled: November 4, 1996Date of Patent: January 6, 1998Assignee: Dytech Corporation LimitedInventors: Rodney Martin Sambrook, Robert Terence Smith
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Patent number: 5674792Abstract: A shaped body of amorphous silicon dioxide, which has a chemical purity of at least 99.9% and a cristobalite content of at most 1% and which is impermeable to gas, is known. To provide shaped bodies of amorphous silicon dioxide which have a high precision, which can be small or large in size and of simple to complicated shape, which have a chemical purity of at least 99.9%, are impermeable to gas above wall thicknesses of 1 mm, which have a high cold flexural strength, low thermal conductivity and low radiation of heat, which are thermal shock resistant and can be exposed repeatedly or also long-term to temperatures in the range from 1000.degree. to 1300.degree. C. and which can be welded in a sharply delineated manner without spreading joins and which have a low spectral transmission from the ultraviolet to the middle infrared spectral region, the shaped body is opaque, contains pores, at a wall thickness of 1 mm has a direct spectral transmission which is virtually constant in the wavelength range from .Type: GrantFiled: April 24, 1996Date of Patent: October 7, 1997Assignee: Heraeus Quarzglas GmbHInventors: Stephan Moritz, Wolfgang Englisch
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Patent number: 5614255Abstract: Proposed is an efficient method for the preparation of vitreous hollow microspheres from particles of a vitreous volcanic deposit by a heat treatment to effect expansion of the particles by foaming. The inventive method comprises a step, prior to the heat treatment for expansion of the particles, in which the starting particles are dispersed in an aqueous medium containing aluminum sulfate and urea each in a specified concentration followed by a heating treatment of the dispersion so as to deposit a coating layer of aluminum hydroxide on the particle surface so that the efficiency of foaming can be greatly improved without the disadvantage of particle agglomeration.Type: GrantFiled: July 9, 1996Date of Patent: March 25, 1997Assignee: Japan as represented by Director General of Agency of Industrial Science and TechnologyInventors: Kunio Kimura, Hiroyuki Nakamura, Yukiyoshi Tamoto, Junichi Kimoto, Hiromi Okada
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Patent number: 5563106Abstract: A method of making a porous refractory article and a dispersion of particles in a liquid carrier, the method involving forming a dispersion of particles in a liquid carrier, introducing gas into the dispersion, removing the liquid carrier to provide a solid article having pores derived from the bubbles and wherein the dispersion has a critical viscosity below the level at which the introduction of gas cannot take place and above the level which entrapped gas bubbles will tend to escape and with the dispersion having the same critical viscosity.Type: GrantFiled: December 20, 1995Date of Patent: October 8, 1996Assignee: Dytech Corporation LimitedInventors: Jonathan G. P. Binner, Robert T. Smith, Jutta Reichert, Rodney M. Sambrook
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Patent number: 5503931Abstract: An improved moisture absorbing amorphous silicate material formed by the steps of: parboiling rice under 22 psi and at a temperature above 212 degrees F. to force bran into the rice grain and dissolve cellulose from the rice hulls creating voids in the rice hulls; drying the parboiled rice; milling the parboiled rice into grain, bran, and broken rice hulls; separating the broken rice hulls from the grain and bran; and burning the broken rice hulls at high temperatures to produce a skeletal residue of amorphous silicate material. Several uses of the amorphous silicate material are disclosed.Type: GrantFiled: August 10, 1994Date of Patent: April 2, 1996Inventor: Elstun F. Goodman, Sr.
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Patent number: 5441919Abstract: Ceramic foams in which the open cells are connected by a three-dimensional, substantially continuous ceramic matrix formed of interconnected hollow ligaments, are made from an open-cell, reticulated precursor metal, i.e. a metal foam. The precursor metal first is treated so as to allow a support coating to form thereon, and thereafter the coated precursor is heated above the melting point of the metal in the presence of an oxidant to form an oxidation reaction product.Type: GrantFiled: March 21, 1994Date of Patent: August 15, 1995Assignee: Lanxide Technology Company, LPInventors: Eugene S. Park, Steven D. Poste
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Patent number: 5395805Abstract: Transparent, monolithic metal oxide aerogels of varying densities are produced using a method in which a metal alkoxide solution and a catalyst solution are prepared separately and reacted. The resulting hydrolyzed-condensed colloidal solution is gelled, and the wet gel is contained within a sealed, but gas permeable, containment vessel during supercritical extraction of the solvent. The present invention is especially advantageous for making metal oxides other than silica that are prone to forming opaque, cracked aerogels.Type: GrantFiled: March 25, 1993Date of Patent: March 7, 1995Assignee: Regents of the University of CaliforniaInventors: Michael W. Droege, Paul R. Coronado, Lucy M. Hair
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Patent number: 5358910Abstract: The preparation of porous ceramic bodies by sintering certain curable organopolysiloxanes filled with silicon carbide powders. This process is advantageous in that the green bodies have relative high strengths and thus can be easily handled and, if desired, machined before sintering.Type: GrantFiled: September 20, 1993Date of Patent: October 25, 1994Assignee: Dow Corning CorporationInventors: William H. Atwell, Chandan K. Saha, Gregg A. Zank
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Patent number: 5340514Abstract: The present invention relates to a process of using shirasu balloon powder as a material to manufacture pottery products where;white pottery products of light weight, highly white coloring, uniformly distributed density and satisfactory strength can be obtained by removing impurities such as iron from the shirasu balloon powder and diffusing the shirasu balloon powder uniformly in the body and reinforcement agent, ornon-white pottery products of light weight, uniformly distributed density and satisfactory strength can be obtained by diffusing the shirasu balloon powder uniformly in the body and reinforcement agent without removing impurities such as iron from the shirasu balloon powder.Type: GrantFiled: September 29, 1992Date of Patent: August 23, 1994Assignees: Setoseido Kabushiki Kaisha, Iwaki Glass Co., Ltd., Tokai Kogyo Kabushiki KaishaInventors: Ryoziro Taniguchi, Takao Yamaguchi, Osamu Saito