Silicon Carbide Patents (Class 501/88)
  • Patent number: 7368405
    Abstract: The present invention relates to a process of making silicon-silicon carbide ceramic using biopreform derived from monocotyledonous caudex plant stem. The present invention also provides a silicon-silicon carbide ceramic made using a biopreform derived from monocotyledonous caudex plant stem.
    Type: Grant
    Filed: December 30, 2002
    Date of Patent: May 6, 2008
    Assignee: Council of Scientific and Industrial Research
    Inventors: Omprakash Chakrabarti, Himadri Sekhar Maiti, Rabindranath Mazumdar
  • Publication number: 20080081757
    Abstract: A ceramic composite material is comprised of a fabric of fibers of an inorganic substance; and a matrix for combining the fibers. The matrix consists essentially of a ceramic. The matrix is formed by burying the fabric in a mixture of a powder of carbon, a powder of silicon and a medium including an organic solvent, producing an oscillation in the mixture to impregnate the fabric with the mixture, and calcining the fabric impregnated with the mixture.
    Type: Application
    Filed: March 29, 2007
    Publication date: April 3, 2008
    Applicants: Ishikawajima-Harima Heavy Industries Co., Ltd., The Society of Japanese Aerospace Companies, Inc.
    Inventors: Hiroshige MURATA, Takeshi Nakamura, Yasutomo Tanaka
  • Patent number: 7345849
    Abstract: The magnetic head slider material of the present invention is constituted by a sintered body containing 100 parts by weight of alumina, 20 to 150 parts by weight of titanium carbide and silicon carbide in total, and 0.2 to 9 parts by weight of carbon.
    Type: Grant
    Filed: June 27, 2005
    Date of Patent: March 18, 2008
    Assignees: TDK Corporation, SAE Magnetics (H.K.) Ltd.
    Inventors: Yukio Kawaguchi, Kei Sugiura, Masahiro Itoh, Minoru Sakurabayashi, Atsushi Hitomi, Cheng Yih Liu
  • Publication number: 20080064585
    Abstract: Multiphase ceramic nanocomposites having at least three phases are disclosed. Each of the at least three phases has an average grain size less than about 100 nm. In one embodiment, the ceramic nanocomposite is substantially free of glassy grain boundary phases. In another embodiment, the multiphase ceramic nanocomposite is thermally stable up to a temperature of at least about 1500° C. Methods of making such multiphase ceramic nanocomposites are also disclosed.
    Type: Application
    Filed: October 11, 2006
    Publication date: March 13, 2008
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Julin Wan, Sergio Paulo Martins Loureiro, Mohan Manoharan, Reza Sarrafi-Nour, Seth Thomas Taylor
  • Patent number: 7332221
    Abstract: A composite body produced by a reactive infiltration process that possesses high mechanical strength, high hardness and high stiffness has applications in such diverse industries as precision equipment and ballistic armor. Specifically, the composite material features a boron carbide filler or reinforcement phase, and a silicon component with a porous mass having a carbonaceous component. Potential deleterious reaction of the boron carbide with silicon during infiltration is suppressed by alloying or dissolving boron into the silicon prior to contact of the silicon infiltrant with the boron carbide. In a preferred embodiment of the invention related specifically to armor, good ballistic performance can be advanced by loading the porous mass or preform to be infiltrated to a high degree with one or more hard fillers such as boron carbide, and by limiting the size of the largest particles making up the mass.
    Type: Grant
    Filed: November 20, 2001
    Date of Patent: February 19, 2008
    Assignee: M Cubed Technologies, Inc.
    Inventors: Michael K. Aghajanian, Allyn L. McCormick, Bradley N. Morgan, Anthony F. Liszkiewicz, Jr.
  • Publication number: 20070191209
    Abstract: A ceramic material for an optical member which shows black, wherein the ceramic material comprises a reaction-sintered sintered ceramic body prepared by synthesizing a formed body of a mixture comprising a ceramic raw material and a component that accelerates blackening, making use of a reaction sintering; and wherein the ceramic material is a porous body.
    Type: Application
    Filed: February 13, 2007
    Publication date: August 16, 2007
    Applicants: FUJIFILM Corporation, FUJINON CORPORATION
    Inventors: Hideki Hyuga, Hideki Kita, Tetsuya Yamazaki, Yasunori Tanaka
  • Patent number: 7244685
    Abstract: A silicon carbide porous body of the present invention, comprising silicon carbide particles and metallic silicon bonded together in such a manner that pores are retained between the silicon carbide particles and/or between the silicon carbide particle and metallic silicon, wherein an oxide phase containing oxides of silicon, aluminum, and alkaline earth metal is buried in at least some of fine pore portions having a minimum distance of 10 ?m or less between the surfaces of the silicon carbide particles or between the surfaces of the silicon carbide particle and metallic silicon among the pores, and a ratio of a total volume of portions in which the oxide phase is not buried among the fine pore portions is 20% or less with respect to a total volume of portions in which the oxide phase is not buried among the pores including the fine pore portions.
    Type: Grant
    Filed: November 19, 2003
    Date of Patent: July 17, 2007
    Assignee: NGK Insulators, Ltd.
    Inventors: Masahiro Furukawa, Nobuyuki Tanahashi, Kenji Morimoto, Shinji Kawasaki
  • Patent number: 7238305
    Abstract: A sol-gel material with metal particles which can be used as a conductive adhesive for systems that have a high operating temperature is disclosed. The material is especially suitable for appliances equipped with a flat heating element, such as steam irons.
    Type: Grant
    Filed: April 5, 2004
    Date of Patent: July 3, 2007
    Assignee: Koninklijke Philips Electronics N.V.
    Inventors: Sandor Nemeth, Marcel Rene Boehmer, Gerard Cnossen
  • Patent number: 7235506
    Abstract: Silicon carbide matrix composite material (1) comprises silicon carbide matrix (2) as a host. The silicon carbide matrix (2) comprises first silicon carbide phase (3) of 0.1 to 10 ?m average crystal grain diameter and second silicon carbide phase (4) of 0.01 to 2 ?m average crystal grain diameter. In interstices of silicon carbide crystal grains constituting the silicon carbide matrix (2), liberated silicon phase (5) amounting to, for example, 5 to 50 mass % based on the composite material (1) is present continuously in network form. This fine structure enables realizing high strength and high toughness of the silicon carbide composite material (1).
    Type: Grant
    Filed: June 18, 2003
    Date of Patent: June 26, 2007
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Shoko Suyama, Tsuneji Kameda, Yoshiyasu Itoh
  • Patent number: 7235505
    Abstract: A slip-cast article former containing ternary ceramics, particularly of carbide and nitride materials, having the formula Mn+1AXn(MAX), where M is a transition metal, A is an element from Groups IA and IVA of the periodic table, X is nitrogen or carbon and n is 1, 2, or 3. The ternary ceramic article may be a glove or condom former. A process for making a ternary ceramic article employing a slip cast method.
    Type: Grant
    Filed: September 26, 2006
    Date of Patent: June 26, 2007
    Assignee: Ansell Healthcare Products LLC
    Inventors: Stanley J. Gromelski, Paul Cacioli, Richard L. Cox
  • Patent number: 7157393
    Abstract: A slip-casted article former containing ternary ceramics, particularly of carbide and nitride materials, having the formula M.sub.n+1AX.sub.n (MAX), where M is a transition metal, A is an element from Groups IIIA and IVA of the periodic table, X is nitrogen or carbon and n is 1, 2, or 3. The ternary ceramic article may be a glove or condom former. A process for making a ternary ceramic article employing a slip cast method.
    Type: Grant
    Filed: December 16, 2002
    Date of Patent: January 2, 2007
    Assignee: Arsell Healthcare Products LLC
    Inventors: Stanley J. Gromelski, Paul Cacioli, Richard L. Cox
  • Patent number: 7112547
    Abstract: Production processes of an inorganic fiber-bonded ceramic component comprising inorganic fibers mainly comprising Si, M, C and O, an inorganic substance mainly comprising Si and O and boundary layers comprising carbon as a main component; and an inorganic fiber-bonded ceramic component comprising inorganic fibers which are composed mainly of a sintered structure of SiC and contain specific metal atoms and boundary layers composed mainly of carbon, wherein a preliminary shaped material is set in a carbon die, covered with a carbon powder and then hot-pressed to load a pseudo-isotropic pressure on the preliminary shaped material; and a highly heat-resistant inorganic fiber-bonded ceramic component almost free from the occurrence of peelings of surface fibers or delamination, wherein fibers are aligned in a surface shape.
    Type: Grant
    Filed: August 6, 2003
    Date of Patent: September 26, 2006
    Assignee: UBE Industries, Ltd.
    Inventors: Shinji Kajii, Kenji Matsunaga, Toshihiko Hogami, Mitsuhiko Sato
  • Patent number: 7109138
    Abstract: The synergistic composition consists of a mixture of a source of pure silica such as silicon dioxide, a source of carbon such as activated charcoal, ?-silicon carbide and a source of iron such as ferric nitrate. The cost effective synergistic composition is useful for the preparation of improved silicon carbide powder containing at least 90% SiC preferably rich in the ?-phase. Silicon carbide powder finds wide usage in the manufacture of products suitable for refractory and engineering applications.
    Type: Grant
    Filed: October 27, 2004
    Date of Patent: September 19, 2006
    Assignee: Council of Scientific and Industrial Research
    Inventors: Siddhartha Bandyopadhyay, Himadri Sekhar Maityi
  • Patent number: 7083771
    Abstract: Method for producing silicon carbide fibers by mixing discontinuous isotropic carbon fibers with a silica source and exposing the mixture to a temperature of from about 1450° C. to about 1800° C. The silicon carbide fibers are essentially devoid of whiskers have excellent resistance to oxidation and excellent response to microwave energy, and can readily be formed into a ceramic medium employing conventional ceramic technology. The fibers also may be used for plastic and metal reinforcement.
    Type: Grant
    Filed: July 22, 2005
    Date of Patent: August 1, 2006
    Assignee: Advanced Composite Materials Corporation
    Inventors: Derek J. Angier, James F. Rhodes, William M. Rogers
  • Patent number: 7056849
    Abstract: A method of making nanoscale ordered composites of covalent ceramics through block copolymer-assisted assembly. At least one polymeric precursor is mixed with a block copolymer, and self-assembly of the mixture proceeds through an annealing process. During the annealing step, the polymeric precursor cross-links to form a structure robust enough to survive both the order-disorder transition temperature the block copolymer and the pyrolysis process, yielding ordered nanocomposites of high temperature ceramic materials. The method yields a variety of structures and morphologies. A ceramic material having at least one ceramic phase that has an ordered structure on a nanoscale and thermally stable up to a temperature of at least about 800° C. is also disclosed. The ceramic material is suitable for use in hot gas path assemblies, such as turbine assemblies, boilers, combustors, and the like.
    Type: Grant
    Filed: January 16, 2004
    Date of Patent: June 6, 2006
    Assignee: General Electric Company
    Inventors: Julin Wan, Azar Alizadeh, Sergio Paulo Martins Loureiro, Mohan Manoharan, Patrick Roland Lucien Malenfant, Eric James Crane Olson, Seth Thomas Taylor
  • Patent number: 7041266
    Abstract: Silicon carbide fibers are produced by mixing discontinuous isotropic carbon fibers with a silica source and exposing the mixture to a temperature of from about 1450° C. to about 1800° C. The silicon carbide fibers are essentially devoid of whiskers have excellent resistance to oxidation and excellent response to microwave energy, and can readily be formed into a ceramic medium employing conventional ceramic technology. The fibers also may be used for plastic and metal reinforcement.
    Type: Grant
    Filed: July 22, 2005
    Date of Patent: May 9, 2006
    Assignee: Advanced Composite Materials Corp.
    Inventors: Derek J. Angier, James F. Rhodes, William M. Rogers
  • Patent number: 7029511
    Abstract: A honeycomb structure 1 has a large number of through-holes 3 divided by partition walls 2 and extending in the axial direction, characterized in that the honeycomb structure contains a Si phase having a lattice constant controlled at 0.54302 to 0.54311 nm at room temperature. A process for producing the honeycomb structure 1, includes a firing step of firing a precursor of honeycomb structure, wherein the precursor contains a Si phase and the firing step is conducted using a furnace material free from any boron-containing compound. A process for producing the honeycomb structure 1, includes a firing step of firing a precursor of honeycomb structure, wherein a reduction percentage of Si content in Si phase after firing step relative to Si content in Si phase before firing step is suppressed at 10% by mass or less. Having an improved thermal conductivity, the honeycomb structure is superior in thermal shock resistance.
    Type: Grant
    Filed: January 24, 2003
    Date of Patent: April 18, 2006
    Assignee: NGK Insulators, Ltd.
    Inventors: Shuichi Ichikawa, Takashi Harada, Aiko Otsuka, Yukihisa Wada, Yoshinori Yamamoto
  • Patent number: 7029643
    Abstract: A method of producing a silicon carbide powder comprising sintering a mixture containing at least a silicon source and a carbon source wherein the carbon source is a xylene-based resin. Preferable are an embodiment in which the above-mentioned silicon source is an alkoxysilane compound, an embodiment in which the above-mentioned alkoxysilane compound is selected from an ethoxysilane oligomer and an ethoxysilane polymer, an embodiment in which the above-mentioned mixture is obtained by adding an acid to a silicon source, then, by adding a carbon source, and other embodiments. A silicon carbide powder produced by the above-mentioned method of producing a silicon carbide powder wherein the nitrogen content is 100 ppm or less is preferable. A sintered silicon carbide obtained by sintering the above-mentioned silicon carbide powder wherein the volume resistivity is 1×100 ?·cm or more.
    Type: Grant
    Filed: January 16, 2004
    Date of Patent: April 18, 2006
    Assignee: Bridgestone Corporation
    Inventors: Masashi Otsuki, Shigeki Endo
  • Patent number: 7022175
    Abstract: An initial solids mixture for a later organic coating, such as pigmented coatings, films, priming coats, etc., e.g., for a coil coating method in which an initial solids mixture is applied to a substrate, e.g., broad strip, and this is thereby pre-coated, wherein the initial solids mixture includes, as additive particles, boron carbide and/or silicon carbide and/or compounds of transition elements or lanthanides, the electrical conductivity of which is selected to be in the metallic range (?>102 1/?cm and ?<107 1/?cm), during the later coating, the additive particles have a continuous physical connection in at least one spatial direction.
    Type: Grant
    Filed: November 21, 2001
    Date of Patent: April 4, 2006
    Assignee: DaimlerChrysler AG
    Inventor: Anita Marten
  • Patent number: 7018947
    Abstract: Free standing articles of chemical vapor deposited silicon carbide with electrical resistivities of less than 0.9 ohm-cm are provided without substantially degrading its thermal conductivity or other properties.
    Type: Grant
    Filed: February 21, 2001
    Date of Patent: March 28, 2006
    Assignee: Shipley Company, L.L.C.
    Inventors: Jitendra S. Goela, Michael A. Pickering
  • Patent number: 7012035
    Abstract: Material from a fibre composite ceramic, constructed from a) a dense fabric or cluster of three-dimensional oriented fibres with a high thermal conductivity, b) a crystalline matrix of ?-silicon carbide, that is produced in a CVI process on the fibres, c) a matrix component of ?-silicon carbide that in a polymer infiltration and pyrolysis process is generated in pores of the fabric structure, starting from a suspension of silicon carbide powder in a polymer, and d) a further matrix component of ?-silicon carbide that is created in a CVI process in cracks and pores of the material, caused by the preceding pyrolysis process.
    Type: Grant
    Filed: February 6, 2003
    Date of Patent: March 14, 2006
    Assignee: MT Aerospace AG
    Inventor: August Mühlratzer
  • Patent number: 6995103
    Abstract: A silicon-containing composite body that would otherwise be brittle can be engineered to exhibit enhanced fracture toughness. Specifically, a silicon-ceramic composite body is produced, preferably by a reactive infiltration technique. The ceramic is selected such that it has a higher coefficient of thermal expansion (CTE) than does the silicon phase. At least at some point during processing, the silicon phase is at a temperature above its normal ductile/brittle transition temperature of about 500° C., and preferably above its melting point. The formed composite body containing the silicon phase is then cooled below its ductile/brittle transition. During cooling, the ceramic phase shrinks more than does the silicon phase, thereby placing the latter in a state of compressive stress. By the time the composite body has cooled to substantially ambient temperature, the induced compressive stress in the silicon phase is sufficient as to impart a measurable degree of semi-ductile character to the silicon phase.
    Type: Grant
    Filed: October 15, 2002
    Date of Patent: February 7, 2006
    Assignee: M Cubed Technologies, Inc.
    Inventor: Michael K. Aghajanian
  • Patent number: 6989428
    Abstract: The invention involves new syntheses for poly(methyl- and ethyl-silyne). The invention also includes silicon carbide (SiC) ceramics that can be produced from poly(methylsilyne), as well as other ceramics, which can be produced from these precursors by modified processing conditions.
    Type: Grant
    Filed: March 21, 2003
    Date of Patent: January 24, 2006
    Assignee: University of Massachusetts
    Inventors: Patricia A. Bianconi, Michael W. Pitcher, Scott Joray
  • Patent number: 6953539
    Abstract: A composite material includes an SiC porous ceramic sintered body, which is formed by preliminarily sintering a porous body, having a coefficient of thermal expansion lower than the coefficient of thermal expansion of copper to construct a network therein. A copper alloy impregnating the porous ceramic sintered body includes copper and one or more additive elements which are prepared to impart a coefficient of thermal conductivity of 160 W/mK or higher to the composite material. The additive elements include up to 5% of at least one element selected from Be, Al, Si, Mg, Ti, Ni, Bi, Te, Zn, Pb, Sn, and mish metal, and also contain unavoidable impurities and gas components.
    Type: Grant
    Filed: September 18, 2002
    Date of Patent: October 11, 2005
    Assignee: NGK Insulators, Ltd.
    Inventors: Shuhei Ishikawa, Tsutomu Mitsui, Ken Suzuki, Nobuaki Nakayama, Hiroyuki Takeuchi, Seiji Yasui
  • Patent number: 6953538
    Abstract: An electroconductive low thermal expansion ceramic sintered body is disclosed which containing a ?-eucryptite phase in a quantity of not less than 75 vol. % and not more than 99 vol. % and having an absolute value of thermal expansion coefficient of not more than 1.0×10?7/K at a temperature of 0° C. to 50° C., a volumetric specific resistance of not more than 1.0×107 ?·cm, and a specific rigidity of not less than 40 GPa/g/cm3.
    Type: Grant
    Filed: June 4, 2001
    Date of Patent: October 11, 2005
    Assignee: Nippon Steel Corporation
    Inventors: Fumiaki Takahashi, Tetsuro Nose, Masashi Nakabayashi
  • Patent number: 6939821
    Abstract: An opaque, low resistivity silicon carbide and a method of making the opaque, low resistivity silicon carbide. The opaque, low resistivity silicon carbide is doped with a sufficient amount of nitrogen to provide the desired properties of the silicon carbide. The opaque, low resistivity silicon carbide is a free-standing bulk material that may be machined to form furniture used for holding semi-conductor wafers during processing of the wafers. The opaque, low resistivity silicon carbide is opaque at wavelengths of light where semi-conductor wafers are processed. Such opaqueness provides for improved semi-conductor wafer manufacturing. Edge rings fashioned from the opaque, low resistivity silicon carbide can be employed in RTP chambers.
    Type: Grant
    Filed: June 6, 2002
    Date of Patent: September 6, 2005
    Assignee: Shipley Company, L.L.C.
    Inventors: Jitendra S. Goela, Michael A. Pickering
  • Patent number: 6936102
    Abstract: A highly corrosion-resistant SiC material is formed on a base body by a CVD process. The SiC material contains ?-SiC crystals so oriented that the ratio of the sum of peak intensities of x-ray diffraction for (220) and (311) planes of the ?-SiC csystals to the sum of peak intensities of x-ray diffraction for (111), (200), (220), (311) and (222) planes of the ?-Sic crystals is 0.15 or above. The SiC material may contain both ?-SiC crystals and ?-SiC crystals of 6H structure. A base body with a SiC material by a CVD process is used as an internal component member of a semiconductor device fabricating system.
    Type: Grant
    Filed: August 2, 2000
    Date of Patent: August 30, 2005
    Assignees: Tokyo Electron Limited, Toyo Tanso Co., Ltd.
    Inventors: Hayashi Otsuki, Satoru Nogami
  • Patent number: 6908667
    Abstract: A method is provided for producing a fiber-reinforced material which is composed, at least in a region of a surface layer, of a ceramic composite and has carbon-containing fibers reaction-bonded to a matrix containing the elements Si and C. In particular a method of producing fiber-reinforced silicon carbide is provided in which a structure of a matrix contains cracks and/or pores, at least at ambient temperature, because of a high thermal expansion coefficient compared with that of the fibers. Metals are selectively electrodeposited in the open pores and cracks of the matrix and, in particular, in a region of the electrically conductive reinforcing fibers. As a result, the open pores and cracks are filled and, in addition, metallic top layers are optionally formed that are firmly keyed to the ceramic composite and that may serve as an interlayer for glass top layers or ceramic top layers.
    Type: Grant
    Filed: June 25, 2002
    Date of Patent: June 21, 2005
    Assignee: SGL Carbon AG
    Inventors: Martin Christ, Michael Heine, Andreas Kienzle, Rainer Zimmermann-Chopin
  • Patent number: 6905992
    Abstract: A ceramic composite made by compacting a starting powder blend. The composite includes between about 50 volume percent and about 99 volume percent of a ceramic matrix; and between about 1 volume percent and about 50 volume percent as-processed silicon carbide whiskers. The ceramic composite having a fracture toughness (KIC) of greater than about 4.0 MPam1/2. The ceramic has a silicon carbide whisker density as measured in whiskers per square millimeter equal to or less than about 1500 times the volume percent of silicon carbide whiskers, but in a density sufficient for the ceramic composite to have the fracture toughness.
    Type: Grant
    Filed: July 30, 2002
    Date of Patent: June 14, 2005
    Assignee: Kennametal Inc.
    Inventors: Pankaj K. Mehrotra, Shanghua Wu
  • Patent number: 6903313
    Abstract: An electrical resistance heating element operable at extremely high temperature, up 2300° C. when used in a vacuum or in a reducing atmosphere, and up to bout 1200° C. when used in an oxidizing atmosphere. The element is formed substantially from titanium silicon carbide (Ti3SiC2), which is readily workable to enable it to be produced in different forms. It also has a higher mechanical strength than that of graphite heating elements.
    Type: Grant
    Filed: December 14, 2001
    Date of Patent: June 7, 2005
    Assignee: Sandvik AB
    Inventors: Mats Sundberg, Chet Popilowski
  • Patent number: 6896968
    Abstract: A protective coating for a carbon-containing component comprises a material selected from the group consisting of non-stoichiometric silicon and carbon; non-stoichiometric silicon and oxygen; non-stoichiometric silicon and nitrogen; compounds of silicon, oxygen, and carbon; compounds of silicon, oxygen and nitrogen; compounds of silicon, nitrogen, and carbon; and silicon.
    Type: Grant
    Filed: April 6, 2001
    Date of Patent: May 24, 2005
    Assignee: Honeywell International Inc.
    Inventor: Ilan Golecki
  • Patent number: 6890878
    Abstract: Provided is a catalyst formulation which exhibits extended catalyst life. The formulation comprises a mixture of a ceramic foam material uniformly interspersed between the solid catalyst particles, with the volume percent of ceramic material in the mixture preferably ranging from 20 to 60 volume %. The catalyst formulation is particularly applicable to solid catalyst particles comprised of a phosphoric acid impregnated substrate, and is particularly useful for processes such as catalytic hydrocarbon condensation processes.
    Type: Grant
    Filed: December 28, 2001
    Date of Patent: May 10, 2005
    Assignee: United Refining Company
    Inventor: John H. Moore
  • Patent number: 6887809
    Abstract: The invention relates to the field of ceramics and open-celled silicon carbide foam ceramics, which can find application, for example, as high temperature- and thermal shock-resistant silicon carbide foam. The aim of the invention is to disclose an open-celled silicon carbide foam ceramic with improved thermal shock resistance, which may be produced by a simple method. Said aim is achieved with an open-celled silicon carbide foam ceramic, the structure of which is made up of sintered silicon carbide with a 5 to 30% pore volume of closed pores with an average diameter of <20 ?m. The invention further relates to a method for the production of an open-celled silicon carbide foam ceramic, whereby coarse and fine silicon carbide powder in the ratio 20:80 to 80:20 parts are mixed and a suspension produced therefrom. An open-celled foam or open-celled network is then coated with said suspension, the foam or network material removed and sintering carried out at a temperature of >1800° C.
    Type: Grant
    Filed: August 3, 2001
    Date of Patent: May 3, 2005
    Assignee: Fraunhofer-Gesellschaft zur Foerderung der Angewandten Forschung E.V.
    Inventor: Jörg Adler
  • Patent number: 6881693
    Abstract: There are provided a high-strength zirconia-containing inorganic fiber having excellent alkali resistance, oxidation resistance, catalyst function and/or catalyst-carrying function and a process for the production thereof. The zirconia-containing inorganic fiber is a fiber which is formed of a composite oxide phase comprising a first phase mainly formed of a silica component or silicon carbide and a second phase formed of zirconia, and it is characterized in that the ratio of Zr slopingly increases toward the surface layer of the fiber.
    Type: Grant
    Filed: April 3, 2002
    Date of Patent: April 19, 2005
    Assignee: Ube Industries, Ltd.
    Inventors: Hiroyuki Yamaoka, Yoshikatsu Harada, Hidekuni Hayashi
  • Patent number: 6863759
    Abstract: Techniques to bond two or more smaller bodies or subunits to produce a unitary SiC composite structure extend the capabilities of reaction-bonded silicon carbide, for example, by making possible the fabrication of complex shapes. In a first aspect of the present invention, two or more preforms are bonded together with a binder material that imparts at least strength sufficient for handling during subsequent thermal processing. In a second aspect of the present invention, instead of providing the subunits to be bonded in the form of preforms, the subunits may be dense, SiC composite bodies, e.g., RBSC bodies. In each of the above embodiments, a preferable means for bonding two or more subunits combines aspects of adhesive and mechanical locking characteristics. One way to accomplish this objective is to incorporate a mechanical locking feature to the joining means, e.g., a “keyway” feature.
    Type: Grant
    Filed: January 23, 2002
    Date of Patent: March 8, 2005
    Assignee: M Cubed Technologies, Inc.
    Inventors: Michael A. Richmond, Michael K. Aghajanian, Allyn L. McCormick, W. Michael Waggoner, Brian E. Schultz
  • Patent number: 6844281
    Abstract: A preform for use in a metal matrix composite, particularly for a magnesium metal composite. In the preform the reinforcing material typically is silicon carbide, boron nitride, titanium nitride, carbon or graphite. The binder used in the preform is sintered magnesium fluoride, which avoids the known problems which result from the high reactivity of molten magnesium metal with other binders, such as silica and alumina, which results in the formation of magnesium oxide in the reinforced composite. The presence of magnesium oxide crystals in the metal matrix adversely affects the properties of the composite. The preform generally has a void volume of from about 50% to about 95%.
    Type: Grant
    Filed: November 18, 2002
    Date of Patent: January 18, 2005
    Assignee: Her Majesty the Queen in right of Canada, as represented by the Minister of Natural Resources
    Inventors: Jason S. H. Lo, Areekattuthazhayil K. Kuriakose, Raul Santos
  • Publication number: 20040238794
    Abstract: Metal-ceramic composite materials made by an infiltration technique have now been prepared using microwave energy as the heat source for thermal processing. Specifically, microwave energy has been used to heat and melt a source of silicon metal, which in turn has infiltrated carbon-containing preforms to make reaction-bonded silicon carbide composites, respectively. Both the time-at-temperature as well as the overall thermal cycle time have been greatly reduced, implying a large cost savings.
    Type: Application
    Filed: May 30, 2003
    Publication date: December 2, 2004
    Inventors: Prashant G. Karandikar, Michael K. Aghajanian, Luis Ortiz
  • Patent number: 6824862
    Abstract: Fiber-reinforced ceramic composites contain bundles, tows or hanks of long fibers, wherein the long fiber bundles, tows or hanks are completely surrounded by a short fiber-reinforced matrix, with the long and short fibers having, independently of one another, a mean diameter of from 4 to 12 &mgr;m and the long fibers having a mean length of at least 50 mm and the short fibers having a mean length of not more than 40 mm, a process for producing them and their use for producing clutch disks or brake disks.
    Type: Grant
    Filed: December 23, 2002
    Date of Patent: November 30, 2004
    Assignee: SGL Carbon AG
    Inventors: Moritz Bauer, Georg Burkhart, Martin Christ, Ronald Huener, Andreas Kienzle, Peter Winkelmann, Rainer Zimmermann-Chopin
  • Patent number: 6815038
    Abstract: A honeycomb structure constituted by cell partition walls (ribs) which form combined cells being composed of a plurality of cells adjacent to each other, and a honeycomb outer wall surrounding and holding outermost cells located at the circumference of combined cells, characterized in that cell partition walls and the honeycomb outer wall are formed by a bonded texture containing silicon carbide (SiC) as an aggregate and cordierite as a binder, and that the proportion (volume %) of silidon carbide (SiC) forming the bonded texture to the total of cordierite and silicon carbide (SiC) is 40 to 90%. This honeycomb structure can exceed required levels, in all of thermal conductivity, chemical durability, low thermal expansion and mechanical strength, producible at a low cost, and suitably used in a filter for purification of automobile exhaust gas, a catalyst carrier, etc.
    Type: Grant
    Filed: October 18, 2002
    Date of Patent: November 9, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Kenji Morimoto, Katsuhiro Inoue, Shinji Kawasaki, Hiroaki Sakai
  • Patent number: 6811868
    Abstract: The object of the present invention is to provide a ceramic body that can support a required amount of a catalyst component, without lowering the characteristics such as strength, being manufactured without forming a coating layer and providing a high performance ceramic catalyst that is excellent in practical utility and durability. A noble metal catalyst is supported directly on the surface of the ceramic body and the second component, consisting of compound or composite compound of element having d or f orbit in the electron orbits thereof such as W, Co, Ti, Fe, Ga and Nb, is dispersed in the first component made of cordierite or the like that constitutes the substrate ceramic. The noble metal catalyst can be directly supported by bonding strength generated by sharing the d or f orbits of the second component, or through interaction with the dangling bond that is generated in the interface between the first component and the second component.
    Type: Grant
    Filed: June 6, 2003
    Date of Patent: November 2, 2004
    Assignee: Denso Corporation
    Inventors: Jun Hasegawa, Tomomi Hase, Kazuhiko Koike, Miho Ito
  • Patent number: 6777361
    Abstract: 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: Grant
    Filed: October 29, 2002
    Date of Patent: August 17, 2004
    Assignee: Robert Bosch GmbH
    Inventors: Wilfried Aichele, Wolfgang Dressler, Christof Rau, Volker Knoblauch, Alexander Kloncynski, Horst Boeder
  • Patent number: 6777360
    Abstract: A ceramic material suitable for use in production of paving tiles, construction tiles, flooring in offices, flooring in machinery plants and so forth is obtained by a method comprising steps of mixing defatted bran derived from rice bran with a thermosetting resin before kneading, subjecting a kneaded mixture thus obtained to a primary firing in an inert gas at a temperature in a range of 700 to 1000° C., pulverizing the kneaded mixture after the primary firing into carbonized powders, kneading the carbonized powders with which ceramic powders, a solvent, and a binder as desired are mixed into a plastic workpiece (kneaded mass), pressure-forming the plastic workpiece at pressure in a range of 10 to 100 MPa, and subjecting a formed plastic workpiece thus obtained again to firing in an inert gas atmosphere at a temperature in a range of 100 to 1400° C.
    Type: Grant
    Filed: February 11, 2002
    Date of Patent: August 17, 2004
    Assignee: Minebea Co., Ltd.
    Inventors: Kazuo Hokkirigawa, Rikuro Obara, Motoharu Akiyama
  • Patent number: 6770583
    Abstract: A transition metal-containing ceramic made by the process comprising the step of pyrolyzing an organometallic linear polymer containing at least one metallocenylene unit, at least one silyl or siloxyl unit, and at least one acetylene unit to form a ceramic; where the ceramic has a ceramic yield of at least about 75% by weight. A transition metal-containing ceramic made by the process comprising the steps of: forming an organometallic linear polymer containing at least one metallocenylene, at least one silyl or siloxyl unit, and at least one acetylene unit; crosslinking said linear polymer through the acetylene units, thereby forming a thermoset; and pyrolyzing said thermoset to form a ceramic; where the ceramic has a ceramic yield of at least about 75% by weight.
    Type: Grant
    Filed: November 4, 2002
    Date of Patent: August 3, 2004
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: Teddy M. Keller
  • Patent number: 6767523
    Abstract: Method for producing discontinuous silicon carbide fibers, useful as heating elements in a low-energy microwave field, from discontinuous carbonized cotton fibers employing an admixture of carbonized cotton fibers, a metal salt promoter, calcium oxalate monohydrate, and low-density silicon dioxide. The admixture, in a dry state, is introduced into a preheated oven at about 1450 to 1750 degrees C. for between about one and five hours. Silicon carbide fibers and a sheet formed from the fibers are disclosed.
    Type: Grant
    Filed: July 16, 2002
    Date of Patent: July 27, 2004
    Assignee: Industrial Ceramic Solutions, LLC
    Inventor: Richard D. Nixdorf
  • Publication number: 20040135275
    Abstract: The present invention relates to a process of making silicon-silicon carbide ceramic using biopreform derived from monocotyledonous caudex plant stem. The present invention also provides a silicon—silicon carbide ceramic made using a biopreform derived from monocotyledonous caudex plant stem.
    Type: Application
    Filed: December 30, 2002
    Publication date: July 15, 2004
    Applicant: Council of Scientific and Industrial Research
    Inventors: Omprakash Chakrabarti, Himadri Sekhar Maiti, Rabindranath Mazumdar
  • Patent number: 6762140
    Abstract: The present application is directed to ceramic compositions and, more specifically, to a silicon carbide composition and method of making it through liquid phase sintering. In one embodiment, the present invention is directed to an unsintered ceramic body including at least one liquid phase sintering aid. The unsintered ceramic body further includes a boron containing compound, a free carbon containing compound, and silicon carbide. In another embodiment, the present invention is directed to a method of making a sintered ceramic body. The method includes combining at least one liquid phase sintering aid, a boron containing compound, a free carbon containing compound, and silicon carbide to form a green ceramic, shaping the green ceramic into a ceramic body, and sintering the ceramic body.
    Type: Grant
    Filed: April 29, 2002
    Date of Patent: July 13, 2004
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Vimal K. Pujari, William T. Collins, Matteo Scalabrino
  • Publication number: 20040110440
    Abstract: Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400° F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.
    Type: Application
    Filed: November 19, 2003
    Publication date: June 10, 2004
    Inventors: Janet B. Davis, David B. Marshall, Peter Ernest David Morgan, Kris Shigeko Oka
  • Patent number: 6746748
    Abstract: A honeycomb structure made of a silicon carbide-based porous body and having a number of through-holes extending in the axial direction, separated by partition walls. The strength and Young's modulus of the silicon carbide-based porous body satisfy the following relation: Strength (MPa)/Young's modulus (GPa)≧1.1. The honeycomb structure contains refractory particles such as silicon carbide particles and the like and yet can be produced at a relatively low firing temperature at a low cost, has a high strength and a high thermal shock resistance, and can be suitably used, for example, as a filter for purification of automobile exhaust gas by a treatment such as plugging of through-channel at its inlet or outlet, or as a catalyst carrier, even under a high SV condition.
    Type: Grant
    Filed: August 12, 2002
    Date of Patent: June 8, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
  • Patent number: 6736875
    Abstract: Composite cordierite honeycomb structures especially suitable for diesel exhaust filtration applications comprise a non-oxide polycrystalline phase constituting 10-70% by weight, with the remainder of the ceramic material constituting a cordierite phase, the non-oxide polycrystalline phase being selected from the group consisting of carbides, nitrides, and borides. Preferably the non-oxide phase is either polycrystalline silicon carbide or polycrystalline silicon nitride and has a particle aspect ratio of less than 3. Inventive ceramic bodies are porous with an open porosity of at least 30%, preferably between 40% and 60%, and a median pore size of at least 5 micrometers, more preferably greater than 8 micrometers and less than 12 micrometers.
    Type: Grant
    Filed: December 13, 2001
    Date of Patent: May 18, 2004
    Assignee: Corning Incorporated
    Inventors: Kishor P. Gadkaree, Yanxia Lu, Joseph F. Mach, Christopher J. Warren, Yuming Xie
  • Patent number: 6733736
    Abstract: A method of producing a silicon carbide powder comprising sintering a mixture containing at least a silicon source and a carbon source wherein the carbon source is a xylene-based resin. Preferable are an embodiment in which the above-mentioned silicon source is an alkoxysilane compound, an embodiment in which the above-mentioned alkoxysilane compound is selected from an ethoxysilane oligomer and an ethoxysilane polymer, an embodiment in which the above-mentioned mixture is obtained by adding an acid to a silicon source, then, by adding a carbon source, and other embodiments. A silicon carbide powder produced by the above-mentioned method of producing a silicon carbide powder wherein the nitrogen content is 100 ppm or less is preferable. A sintered silicon carbide obtained by sintering the above-mentioned silicon carbide powder wherein the volume resistivity is 1×100 &OHgr;·cm or more.
    Type: Grant
    Filed: April 25, 2002
    Date of Patent: May 11, 2004
    Assignee: Bridgestone Corporation
    Inventors: Masashi Otsuki, Shigeki Endo