Refractory Patents (Class 501/94)
  • Patent number: 9849632
    Abstract: A molding apparatus includes a heating section, a spreading section, a molding section, a drawing section and a curing section. The heating section which heats a mold material including particles and a binder agent which bonds together the particles, to a temperature equal to or higher than the melting point of the binder agent and forms a fluid mold material. The spreading section forms a mold layer by spreading the fluid mold material. The molding section layers the mold layers. The drawing section applies UV ink to a desired region of the mold layer. The curing section cures the UV ink applied to the desired region of the mold layer.
    Type: Grant
    Filed: December 2, 2014
    Date of Patent: December 26, 2017
    Assignee: Seiko Epson Corporation
    Inventor: Koki Hirata
  • Patent number: 8999484
    Abstract: A composition for applying to a honeycomb body includes a refractory filler, an organic binder, an inorganic binder, and a liquid vehicle, wherein the refractory filler, the particle size distribution of the refractory filler, the organic binder, and the inorganic binder are selected such that, when the composition is applied to plug a plurality of channels of the honeycomb body, the plug depth variability is reduced.
    Type: Grant
    Filed: August 30, 2012
    Date of Patent: April 7, 2015
    Assignee: Corning Incorporated
    Inventors: Colby William Audinwood, Anthony Joseph Cecce, Toka M Culbertson, Courtney Spencer Warren
  • Publication number: 20150057144
    Abstract: A bicontinuous non-porous microstructure comprising a refractory phase and a non-refractory phase, wherein the refractory phase substantially comprises one or more refractory elements and the non-refractory phase comprises a void filled by one or more materials that are different than a material comprising the non-refractory phase in a bicontinuous network from which the nanocomposite refractory material is formed and methods of making the same are disclosed.
    Type: Application
    Filed: August 26, 2013
    Publication date: February 26, 2015
    Applicant: The Johns Hopkins University
    Inventors: Jonah Erlebacher, Ian McCue
  • Publication number: 20150030856
    Abstract: New methods for synthesizing boron-modified silazanes, their use as polymer-derived ceramic precursors, and polymer-derived ceramics and composites formed therefrom are disclosed. The polymeric ceramic precursors comprise a boron-modified silazane that is a room temperature liquid-phase polymer comprising a backbone having recurring monomeric repeat units comprising boron-nitrogen bonds. Nanocomposites comprising polymer-derived ceramics and carbon nanotubes are also disclosed.
    Type: Application
    Filed: February 7, 2013
    Publication date: January 29, 2015
    Inventors: Gurpreet Singh, Romil Bhandavat
  • Patent number: 8828540
    Abstract: A process for manufacturing an article includes the steps of applying a quantity of a refractory metal sufficient to produce a coating on a carbon based felt; processing thermally a refractory metal coated carbon based felt at a temperature and for a period of time sufficient to form a ceramic based felt; and cooling the ceramic based felt under a controlled atmosphere.
    Type: Grant
    Filed: June 16, 2006
    Date of Patent: September 9, 2014
    Assignee: United Technologies Corporation
    Inventors: Wayde R. Schmidt, Robert A. Barth
  • Patent number: 8828534
    Abstract: The method comprises: using chemical vapor infiltration to form a first continuous interphase on the fibers of a fiber structure made of refractory fibers, the interphase having a thickness of no more than 100 nanometers; impregnating the fiber structure with a consolidation composition comprising a carbon or ceramic precursor resin; forming a fiber preform that is consolidated by shaping the impregnated fiber structure and using pyrolysis to transform the resin into a discontinuous solid residue of carbon or ceramic; using chemical vapor infiltration to form a second continuous interphase layer; and densifying the preform with a refractory matrix. This preserves the capacity of the fiber structure to deform so as to enable a fiber preform to be obtained that is of complex shape, while nevertheless guaranteeing the presence of a continuous interphase between the fibers and the matrix.
    Type: Grant
    Filed: April 6, 2012
    Date of Patent: September 9, 2014
    Assignee: Herakles
    Inventors: Eric Philippe, Eric Bouillon
  • Publication number: 20140234653
    Abstract: A thermal spray powder of the present invention contains a rare earth element and a group 2 element, which belongs to group 2 of the periodic table. The thermal spray powder, which contains a rare earth element and a group 2 element, is formed, for example, from a mixture of a rare earth element compound and a group 2 element compound or from a compound or solid solution containing a rare earth element and a group 2 element. The thermal spray powder may further contain a diluent element that is not a rare earth element or a group 2 element and is not oxygen, which is at least one element selected, for example, from titanium, zirconium, hafnium, vanadium, niobium, tantalum, zinc, boron, aluminum, gallium, silicon, molybdenum, tungsten, manganese, germanium, and phosphorus.
    Type: Application
    Filed: September 26, 2012
    Publication date: August 21, 2014
    Applicants: TOKYO ELECTRON LIMITED, FUJIMI INCORPORATED
    Inventors: Hiroaki Mizuno, Junya Kitamura, Yoshiyuki Kobayashi
  • Publication number: 20140235426
    Abstract: A ceramic powder and method of forming the ceramic powder capable of being used in coatings to allow components to survive in high temperatures environments, such as the hostile thermal environment of a gas turbine engine. The ceramic powder includes powder particles each having an inner core formed of a first material and an outer region formed of a second material. The inner core has a lower thermal conductivity than the outer region, and the outer region is more erosion resistance relative to the inner core.
    Type: Application
    Filed: February 18, 2013
    Publication date: August 21, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Surinder Singh Pabla, Joshua Lee Margolies, Padmaja Parakala
  • Publication number: 20140234634
    Abstract: A thermal spray powder of the present invention contains a rare earth element and a diluent element that is not a rare earth element or oxygen, which is at least one element selected, for example, from zinc, silicon, boron, phosphorus, titanium, calcium, strontium, and magnesium. A sintered body of a single oxide of the diluent element has an erosion rate under specific etching conditions that is no less than 5 times the erosion rate of an yttrium oxide sintered body under the same etching conditions.
    Type: Application
    Filed: September 26, 2012
    Publication date: August 21, 2014
    Applicants: FUJIMI INCORPORATED, TOKYO ELECTRON LIMITED
    Inventors: Hiroaki Mizuno, Junya Kitamura, Yoshiyuki Kobayashi
  • Publication number: 20140228211
    Abstract: The present invention relates to a novel process for producing ceramic materials, in particular refractory materials having a reduced relative density. In particular, the invention relates to a process for producing light, refractory materials having non-contiguous pores based on shaped and unshaped materials. These materials can be used as working lining in high-temperature applications. The process is based on the production of spherical, closed and isolated pores in the microstructure of the material. The pores having a pore diameter which can be set in a targeted manner are generated by use of polymer particles, in particular polymethacrylates, in particular polymers or copolymers prepared by means of suspension polymerization, as pore formers which can be burnt out. The polymers or copolymers are present in the form of small spheres having a defined diameter.
    Type: Application
    Filed: August 23, 2012
    Publication date: August 14, 2014
    Applicant: Evonik Roehm GmbH
    Inventors: Tadeusz Von Rymon Lipinski, Bruno Keller, Frank Beissmann, Peter Neugebauer, Ruth Kernke, Dirk Poppe
  • Publication number: 20140228198
    Abstract: A pressure casting slip for producing a refractory ceramic for use as a heat shield, e.g. in the hot gas path of gas turbine units, includes a particulate mixture of at least two materials having different coefficients of thermal expansion and also organic and/or inorganic binders and floating agents. The particulate mixture has a multimodal particle size distribution divided into 10-20 percent by weight of coarse particles in the size range 1-5 mm in diameter, 10-20 percent by weight of medium particles in the size range 0.5-1 mm in diameter and 60-80 percent by weight of fine particles in the size range up to 0.5 mm in diameter which together make up 100 percent by weight of the particle mixture.
    Type: Application
    Filed: August 1, 2012
    Publication date: August 14, 2014
    Applicant: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Christos Aneziris, Nora Gerlach, Holger Grote, Uwe Klippel, Friederike Lange, Stefan Schafföner, Harm Speicher
  • Patent number: 8741212
    Abstract: Composite bodies made by a silicon metal infiltration process that feature a silicon intermetallic, e.g., a metal silicide. Not only does this give the composite material engineer greater flexibility in designing or tailoring the physical properties of the resulting composite material, but the infiltrant also can be engineered compositionally to have much diminished amounts of expansion upon solidification, thereby enhancing net-shape-making capabilities. These and other consequences of engineering the metal component of composite bodies made by silicon infiltration permit the fabrication of large structures of complex shape.
    Type: Grant
    Filed: March 14, 2012
    Date of Patent: June 3, 2014
    Inventors: Michael K. Aghajanian, Allyn L. McCormick, Michael S. Epperly
  • Publication number: 20140144183
    Abstract: Low-carbon monolithic refractories are provided. Methods of manufacturing glass employing low-carbon monolithic refractories are also provided. Methods and apparatuses for glass manufacture for reducing the formation of carbon dioxide blisters during glass manufacture are also provided.
    Type: Application
    Filed: November 28, 2012
    Publication date: May 29, 2014
    Inventors: Memduh Demirbas, Ralph Alfred Langensiepen, David Myron Lineman, Christopher Charles Tournour, Randy Dean Ziegenhagen
  • Publication number: 20140131928
    Abstract: A reactive liquid ceramic binder suitable for the production of ceramic products from ceramic powders is provided. The reactive liquid ceramic binder contains organo-modified siloxane compounds, wherein the liquid organo-modified siloxane compounds contain organoalkoxysiloxane units according to general formula (I) wherein R1=alkyl radical and/or aryl radical, R2=H and/or alkyl radical with 1 to 4 carbon atoms, a?0 and ?2, and b>0 and ?3, with the proviso that a+b?1 and ?4.
    Type: Application
    Filed: January 16, 2014
    Publication date: May 15, 2014
    Applicant: Evonik Goldschmidt GMBH
    Inventors: Thomas Ebbrecht, Tadeusz von Rymon Lipinski, Stefan Silber, Bernd Weyershausen
  • Publication number: 20140128242
    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: Application
    Filed: June 4, 2012
    Publication date: May 8, 2014
    Applicant: HINOMARU YOGYO CO., LTD.
    Inventors: Daisuke Taniyama, Yasunari Nagasaki, Akira Terasawa
  • Patent number: 8709960
    Abstract: Provided here is a method of producing a monolithic body from a porous matrix, comprising: (i) providing a porous matrix having interstitial spaces and comprising at least a first reactant; (ii) contacting the porous matrix with an infiltrating medium that carries at least a second reactant; (iii) allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product; and (iv) allowing the at least first product to form and fill at least a portion of the interstitial spaces of the porous matrix, thereby producing a monolithic body, wherein the monolithic body does not comprise barium titanate.
    Type: Grant
    Filed: January 4, 2011
    Date of Patent: April 29, 2014
    Assignee: Rutgers, The State University of New Jersey
    Inventors: Richard E. Riman, Vahit Atakan
  • Publication number: 20140094356
    Abstract: A treatment process, an oxide-forming treatment composition, and a treated component are disclosed. The treatment process includes applying an oxide-forming treatment composition to a ceramic coating and heating the oxide-forming treatment composition to form an oxide within the ceramic coating. The oxide-forming treatment composition includes a solute and a corrosion inhibitor. The oxide-forming treatment composition is super-saturated with the corrosion inhibitor. The treated component includes a ceramic coating and one or both of a corrosion inhibitor and an oxide formed by an oxide-forming treatment composition having the corrosion inhibitor. The corrosion inhibitor and the oxide-forming treatment composition are within the ceramic coating.
    Type: Application
    Filed: September 28, 2012
    Publication date: April 3, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Yuk-Chiu LAU, Vinod Kumar PAREEK, Joshua L. MARGOLIES, Raymond Grant ROWE
  • Publication number: 20140072805
    Abstract: A refractory material that can withstand high temperatures in an oxidizing medium and containing at least: a first constituent corresponding to hafnium, or to a non-oxide compound of hafnium, or circular in a or a non-oxide compound of zirconium, or corresponding to a mixture of at least two metals and/or compounds selected from hafnium a non-oxide compound of hafnium, zirconium, and a non-oxide compound of zirconium; a second constituent corresponding to the boron or to a non-oxide compound of boron, or corresponding to a mixture of boron and a non-oxide compound of boron; and a third constituent corresponding to a rare earth RE or to a non-oxide compound of the rare earth RE, or corresponding to a mixture of rare earth RE and a non-oxide compound of the rare earth RE, where RE is selected from scandium, yttrium, and the lanthanides. The material contains neither silicon nor a compound of silicon.
    Type: Application
    Filed: December 5, 2011
    Publication date: March 13, 2014
    Applicants: CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE, HERAKLES
    Inventors: Anne-Sophie Andreani, Angeline Poulon, Francis Rebillat, Jacques Thebault, Anne Sauveroche
  • Patent number: 8658054
    Abstract: In order to achieve the object of providing a mixture by means of which, in particular, sintered moldings can be obtained that are virtually free of surface stains produced by soot particles, a mixture is proposed which comprises at least one pressing aid and at least one additive, wherein the additive is selected from a group of substances which have releasable carbon dioxide.
    Type: Grant
    Filed: July 12, 2011
    Date of Patent: February 25, 2014
    Assignee: GKN Sinter Metals Holding GmbH
    Inventors: Rene Lindenau, Lars Wimbert
  • Publication number: 20130344319
    Abstract: Advanced environmental barrier coating bond coat systems with higher temperature capabilities and environmental resistance are disclosed. These bond coat systems can be applied to ceramic substrates such as SiC/SiC ceramic matrix composite substrates, and can provide protection from extreme temperature, mechanical loading and environmental conditions, such as in high temperature gas turbines. Example bond coat systems can include either an advanced silicon/silicide component, an oxide/silicate component, or a combination thereof.
    Type: Application
    Filed: June 21, 2013
    Publication date: December 26, 2013
    Inventors: Dongming Zhu, Janet B. Hurst
  • Patent number: 8575051
    Abstract: The invention relates to a heat sink comprising a diamond-containing composite material. In addition to a diamond content of 40-90% by volume, the composite material further comprises from 0.005 to 12% by volume of a silicon-carbon compound, from 7 to 49% by volume of an Ag-, Au- or Al-rich phase and less than 5% by volume of a further phase, with the volume ratio of the Ag-, Au or Al-rich phase to silicon carbide being greater than 4 and at least 60% of the diamond surface being covered by the silicon-carbon compound. Preferred production processes include atmospheric pressure and pressure-aided infiltration techniques. The component is suitable, in particular, as heat sink for semiconductor components.
    Type: Grant
    Filed: January 20, 2004
    Date of Patent: November 5, 2013
    Assignee: Plansee SE
    Inventor: Arndt Lüdtke
  • Publication number: 20130267403
    Abstract: A reactive ceramic binder in liquid form suitable for producing ceramic products from ceramic powder. The reactive, liquid ceramic binder includes liquid organomodified siloxane compounds having organoalkoxysiloxane units of the general formula (I) where the radicals R1 are, independently of one another, identical or different alkyl, alkaryl or aryl radicals which may be interrupted by ether functions, the radicals R2 are, independently of one another, identical or different radicals selected from H and/or alkyl radicals having from 1 to 6 carbon atoms, the radicals R3 are, independently of one another, identical or different divalent, saturated or unsaturated hydrocarbon radicals which have from 1 to 30 carbon atoms and may be interrupted by ether functions, “a” is greater than or equal to 0 and less than or equal to 2.5, “b” is greater than 0 and less than or equal to 3, and 1?a+b?3.
    Type: Application
    Filed: April 2, 2013
    Publication date: October 10, 2013
    Inventors: Tadeusz von Rymon Lipinski, Sascha Herrwerth, Thomas Ebbrecht, Frank Koenig, Michael Ferenz
  • Publication number: 20130249136
    Abstract: A low-water-content castable composition produces cast products with an increased modulus of rupture, an increased cold crushing strength, and decreased porosity. The composition employs closed fractions of constituent particles with specified populations and specified gaps in the particle size distribution to produce these properties. The composition is suitable for refractory applications.
    Type: Application
    Filed: May 22, 2013
    Publication date: September 26, 2013
    Applicant: VESUVIUS CRUCIBLE COMPANY
    Inventor: Justin Teiken
  • Patent number: 8518242
    Abstract: Catalysts are disclosed comprising fibrous substrates having silica-containing fibers with diameters generally from about 1 to about 50 microns, which act effectively as “micro cylinders.” Such catalysts can dramatically improve physical surface area, for example per unit length of a reactor or reaction zone. At least a portion of the silica, originally present in the silica-containing fibers of a fibrous material used to form the fibrous substrate, is converted to a zeolite (e.g., having a SiO2/Al2O3 ratio of at least about 150) that remains deposited on these fibers. The fibrous substrates possess important properties, for example in terms of acidity, which are useful in hydroprocessing (e.g., hydrotreating or hydrocracking) applications.
    Type: Grant
    Filed: May 26, 2011
    Date of Patent: August 27, 2013
    Assignee: UOP LLC
    Inventors: Antoine Negiz, Hui Wang
  • Publication number: 20130183531
    Abstract: An article which includes a structure of a ceramic material that has a composition SiOxMzCy, where Si is silicon, O is oxygen, M is at least one metal and C is carbon and wherein x<2, y>0 and z<1 and x and z are non-zero.
    Type: Application
    Filed: January 18, 2012
    Publication date: July 18, 2013
    Inventors: Wayde R. Schmidt, Paul Sheedy, Tania Bhatia Kashyap, Daniel G. Goberman, Xia Tang
  • Patent number: 8460601
    Abstract: The invention provides a vessel for molten metal comprising a vessel body formed of an alumina-silica-based material, and a protective layer formed of a silicon nitride- alumina-based material provided on the inner surface of the vessel body, wherein the material for the vessel body is adjusted to have an alumina content x of 72 to 95 parts by weight per 100 total parts by weight of alumina and silica, and the material for the protective layer is adjusted to have a silicon nitride content y per 100 total parts by weight of silicon nitride and alumina in such a manner that y applies to the following formulae: (1) y<?1.1x+128 and (2) y>?0.5x+62.5. The present invention provides a vessel for molten metal having excellent durability and corrosion resistance against hot molten metal.
    Type: Grant
    Filed: March 10, 2009
    Date of Patent: June 11, 2013
    Assignee: Nippon Crucible Co., Ltd.
    Inventors: Hideaki Ohashi, Nobuyuki Oka, Hirokazu Asada
  • Publication number: 20130136893
    Abstract: Disclosed are ceramic articles comprising ceramic honeycomb bodies and an aqueous composition, for example in the form of a cold-set plug, as well as processes for preparing ceramic articles and processes for making an aqueous composition for use with ceramic articles, for example as a cold-set plug composition.
    Type: Application
    Filed: November 30, 2011
    Publication date: May 30, 2013
    Inventors: Keith Norman Bubb, Anthony Joseph Cecce, Thomas Richard Chapman
  • Patent number: 8435477
    Abstract: Methods are described that have the capability of producing submicron/nanoscale particles, in some embodiments dispersible, at high production rates. In some embodiments, the methods result in the production of particles with an average diameter less than about 75 nanometers that are produced at a rate of at least about 35 grams per hour. In other embodiments, the particles are highly uniform. These methods can be used to form particle collections and/or powder coatings. Powder coatings and corresponding methods are described based on the deposition of highly uniform submicron/nanoscale particles.
    Type: Grant
    Filed: September 22, 2011
    Date of Patent: May 7, 2013
    Assignee: NanoGram Corporation
    Inventors: Nobuyuki Kambe, Shivkumar Chiruvolu
  • Publication number: 20130008748
    Abstract: A friction disc (2) with an anti-abrasion layer (1) and integrated wear indication, the friction disc (2) having a friction surface (2?) which is completely covered by the anti-abrasion layer (1). At least one indication surface element (3) which occupies a part of the friction surface (2?) and differs from at least one of the components friction surface (2?) and anti-abrasion layer (1) of the friction disc (2) in at least one of the features coloring and texture is provided between the anti-abrasion layer (1) and the friction disc (2). Compositions of the anti-abrasion layer (1) of the friction disc (2).
    Type: Application
    Filed: March 16, 2011
    Publication date: January 10, 2013
    Applicant: DAIMLER AG
    Inventors: Oliver Lembach, Ralph Mayer
  • Patent number: 8349752
    Abstract: The present invention provides a plate brick having a low amount of generation of smoke and a gas with a pungent odor during use, and exhibiting high durability. A plate brick of the present invention is obtained by: adding an organic binder to a refractory raw material mixture containing 0.5 to 20 mass % of aluminum and/or aluminum alloy; kneading the mixture with the organic binder; forming the kneaded mixture into a shaped body; and subjecting the shaped body to a heat treatment at a temperature of 400 to 1000° C., wherein the plate brick is obtained without being impregnated with a carbon-containing liquid material comprising tar or pitch, after the heat treatment. The plate brick has a compressive strength of 180 MPa or more, and a weight-increasing rate of 1% or less as measured in a hydration test using an autoclave.
    Type: Grant
    Filed: March 25, 2009
    Date of Patent: January 8, 2013
    Assignee: Krosakiharima Corporation
    Inventors: Yasuaki Shin, Kazuo Ito, Michihiko Ichimaru, Tamotsu Wakita, Masamichi Asai
  • Publication number: 20120289396
    Abstract: Disclosed is a method for making a refractory material from aluminum residues of aluminum recycling. At first, the aluminum residues is mixed with adhesive solution so that the percentage by weight of the adhesive solution is 5 wt % to 10 wt %. The mixture is granulated into grains. The grains are filled in a mold, pressed and then removed from the mold so that the grains are turned into a green body. The green body is heated in a furnace at a range of temperature from 1100° C. to 1400° C. so that the grains are sintered and become a refractory material.
    Type: Application
    Filed: May 12, 2011
    Publication date: November 15, 2012
    Applicant: ATOMIC ENERGY COUNCIL-INSTITUTE OF NUCLEAR ENERGY RESEARCH
    Inventors: Sheng -Fu Yang, Chun-Yen Yeh, Yen-Hua Chang, To-Mei Wang, Wen-Cheng Lee, Kin-Seng Sun, Chin-Ching Tzeng
  • Publication number: 20120276387
    Abstract: It is provided a high-temperature assembly that is favorable for increasing the sealing property at the boundary area between a first member and a second member that are used in a high-temperature environment. Further it is provided a method for producing the high-temperature assembly, and a heat-resistant sealing material. The heat-resistant sealing material, which is disposed at the boundary area between a first member and a second member, comprises ceramic particles made of a plurality of materials which form a ceramics the volume of which increases when the ceramics is synthesized.
    Type: Application
    Filed: November 15, 2010
    Publication date: November 1, 2012
    Applicant: TYK CORPORATION
    Inventors: Hirokatsu Hattanda, Tomohiro Yotabun
  • Publication number: 20120277087
    Abstract: Composite bodies made by a silicon metal infiltration process that feature a silicon intermetallic, e.g., a metal silicide. Not only does this give the composite material engineer greater flexibility in designing or tailoring the physical properties of the resulting composite material, but the infiltrant also can be engineered compositionally to have much diminished amounts of expansion upon solidification, thereby enhancing net-shape-making capabilities. These and other consequences of engineering the metal component of composite bodies made by silicon infiltration permit the fabrication of large structures of complex shape.
    Type: Application
    Filed: March 14, 2012
    Publication date: November 1, 2012
    Inventors: Michael K. Aghajanian, Allyn L. McCormick, Michael S. Epperly
  • Publication number: 20120276365
    Abstract: A refractory, porous ceramic composite including crystalline mullite (3Al2O3+2SiO2 or 3Al6Si2O11) and a crystalline phase of LaPO4 is formed from a mullite-LaPO4 sol-gel by annealing the dried gel. During the annealing process, particle sintering and self-foaming occur in the glassy state, and pores are produced due at least in part to the release of entrapped gases that form during the pyrolysis of the gel. The resulting crystalline composite, or crystalline nanocomposite, has a high porosity and is dimensionally and chemically stable at high temperatures. The composite also has a high degree of structural (e.g., mechanical) stability, related at least in part to the fine texturing and mixing of the mullite and LaPO4 during preparation of the sol. The resulting ceramic composite shows little or no shrinkage or expansion between about 1000C and about 1200° C.
    Type: Application
    Filed: November 23, 2010
    Publication date: November 1, 2012
    Inventors: William Petuskey, Feng He
  • Patent number: 8282755
    Abstract: A method for producing a ceramic material is disclosed. A ceramic raw material mixture is produced by comminuting and mixing starting materials containing Pb, Zr, Ti, Nd and oxygen. Nickel or an nickel compound is introduced. The raw material mixture is calcined and a ceramic is sintered.
    Type: Grant
    Filed: July 1, 2011
    Date of Patent: October 9, 2012
    Assignee: Epcos AG
    Inventors: Michael Schossmann, Georg Kuegerl, Alexander Glazunov
  • Patent number: 8277878
    Abstract: A transparent polycrystalline ceramic having scattering and absorption loss less than 0.2/cm over a region comprising more than 95% of the originally densified shape and a process for fabricating the same by hot pressing. The ceramic can be any suitable ceramic such as yttria (Y2O3) or scandia (Sc2O3) and can have a doping level of from 0 to 20% and a grain size of greater than 30 ?m, although the grains can also be smaller than 30 ?m. Ceramic nanoparticles can be coated with a sintering aid to minimize direct contact of adjacent ceramic powder particles and then baked at high temperatures to remove impurities from the coated particles. The thus-coated particles can then be densified by hot pressing into the final ceramic product. The invention further provides a transparent polycrystalline ceramic solid-state laser material and a laser using the hot pressed polycrystalline ceramic.
    Type: Grant
    Filed: January 13, 2012
    Date of Patent: October 2, 2012
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Jasbinder S. Sanghera, Guillermo R. Villalobos, Woohong Kim, Shyam S. Bayya, Bryan Sadowski, Ishwar D. Aggarwal
  • Publication number: 20120227445
    Abstract: A refractory object can include at least 10 wt % Al2O3. In an embodiment, the refractory object can further include a dopant including an oxide of a rare earth element, Ta, Nb, Hf, or any combination thereof. In another embodiment, the refractory object may have a property such that the averaged grain size does not increase more than 500% during sintering, an aspect ratio less than approximately 4.0, a creep rate less than approximately 1.0×10?5 ?m/(?m×hr), or any combination thereof. In a particular embodiment, the refractory object can be in the form of a refractory block or a glass overflow forming block. The glass overflow forming block can be useful in forming an Al—Si—Mg glass sheet. In a particular embodiment, a layer including Mg—Al oxide can initially form along exposed surfaces of the glass overflow forming block when forming the Al—Si—Mg glass sheet.
    Type: Application
    Filed: March 9, 2012
    Publication date: September 13, 2012
    Applicant: SAINT-GOBAIN CERAMICS & PLASTICS, INC.
    Inventors: Olivier Citti, Andrea Kazmierczak
  • Patent number: 8242037
    Abstract: Methods of making and compositions of dense sintered ceramic nano- and micro-composite materials that are highly stable in a variety of conditions and exhibit superior toughness and strength. Liquid feed flame spray pyrolysis techniques form a plurality of nanoparticles (e.g., powder), each having a core region including a first metal oxide composition comprising Ce and/or Zr or other metals and a shell region including a second metal oxide composition comprising Al or other metals. In certain aspects, the core region comprises a partially stabilized tetragonal ZrO2 and the shell region comprises an ?-Al2O3 phase. The average actual density of the ceramic after sintering is greater than 50% and up to or exceeding 90% of a theoretical density of the ceramic.
    Type: Grant
    Filed: July 23, 2009
    Date of Patent: August 14, 2012
    Assignee: The Regents of the University of Michigan
    Inventors: Richard M. Laine, Min Kim
  • Publication number: 20120183790
    Abstract: This invention relates to thermal spray composite coatings on a metal or non-metal substrate. The thermal spray composite coatings comprise a ceramic composite coating having at least two ceramic material phases randomly and uniformly dispersed and/or spatially oriented throughout the ceramic composite coating. At least a first ceramic material phase is present in an amount sufficient to provide corrosion resistance to the ceramic composite coating, and at least a second ceramic material phase is present in an amount sufficient to provide plasma erosion resistance to the ceramic composite coating. This invention also relates to methods of protecting metal and non-metal substrates by applying the thermal spray coatings. The composite coatings provide erosion and corrosion resistance at processing temperatures higher than conventional processing temperatures used in the semiconductor etch industry, e.g., greater than 100° C.
    Type: Application
    Filed: July 12, 2011
    Publication date: July 19, 2012
    Inventors: Christopher Petorak, Graeme Dickinson, Neill Jean McDill
  • Patent number: 8222171
    Abstract: A method for the production of a ceramic substrate for a semiconductor component, includes the steps of producing paper containing at least cellulose fibers, as well as a filler to be carbonized and/or SiC, pyrolizing the produced paper, and siliconizing the pyrolyzed paper.
    Type: Grant
    Filed: July 13, 2007
    Date of Patent: July 17, 2012
    Assignee: Schunk Kohlenstofftechnik GmbH
    Inventors: Marco Ebert, Martin Henrich, Andreas Lauer, Gotthard Nauditt, Thorsten Scheibel, Roland Weiss
  • Patent number: 8217751
    Abstract: An article is provided that includes a plurality of layers. Each layer includes a sinterable mass having a sinter temperature that is less than about 1000 degrees Celsius, and an inner electrode proximate to the sinterable mass. The inner electrode includes a material having a melting point that is within a determined temperature range of about 10 degrees Celsius to about 200 degrees Celsius relative to the sintering temperature. A method to make the article is also provided.
    Type: Grant
    Filed: September 29, 2008
    Date of Patent: July 10, 2012
    Assignee: General Electric Company
    Inventors: Daniel Qi Tan, Patricia Chapman Irwin, Abdelkrim Younsi
  • Patent number: 8211278
    Abstract: Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB2) and metal additives. The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity. The electrodes may be durable and used in aluminum electrolysis cells.
    Type: Grant
    Filed: July 28, 2010
    Date of Patent: July 3, 2012
    Assignee: Alcoa Inc.
    Inventors: Douglas A. Weirauch, Jr., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
  • Patent number: 8207813
    Abstract: A varistor pre-assembly includes an electrode formable structure and a sinterable mass proximate to electrode formable structure. The electrode formable structure includes a material having a melting point that may be within a determined temperature relative to a sintering temperature of the sinterable mass. The electrode formable structure and sinterable mass may form a varistor when simultaneously subjected to the sintering temperature, which may be less than about 1000 degrees Celsius. A method to make the article is also provided.
    Type: Grant
    Filed: September 4, 2008
    Date of Patent: June 26, 2012
    Assignee: General Electric Company
    Inventors: Daniel Qi Tan, Patricia Chapman Irwin, Abdelkrim Younsi, Yingneng Zhou
  • Patent number: 8197780
    Abstract: A method of producing a boron suboxide composite material having improved fracture toughness.
    Type: Grant
    Filed: May 4, 2011
    Date of Patent: June 12, 2012
    Assignee: Element Six (Production) (Pty) Ltd.
    Inventors: Geoffrey John Davies, Iakovos Sigalas, Mathias Herrmann, Thembinkosi Shabalala
  • Patent number: 8143182
    Abstract: The present invention provides a fused ceramic particle, having the following chemical composition, in percentages by weight based on the oxides and for a total of 100%: 50%<ZrO2+HfO2<70%; 10%<SiO2<30%; 6.5%<MgO<9.5%; Al2O3 in a quantity such that the MgO/Al2O3 weight ratio is in the range 2.4 to 6.6; 0.1%<Y2O3; CeO2<10%; and less than 0.6% of other oxides. Use in particular as milling agents, wet medium dispersion agents, propping agents, heat exchange agents, or for the treatment of surfaces.
    Type: Grant
    Filed: April 7, 2009
    Date of Patent: March 27, 2012
    Assignee: Saint-Gobain Centre de Recherches Et d'Etudes Europeen
    Inventors: Yves Boussant-Roux, Emmanuel Nonnet
  • Patent number: 8105509
    Abstract: A transparent polycrystalline ceramic having scattering and absorption loss less than 0.2/cm over a region comprising more than 95% of the originally densified shape and further provides a process for fabricating the same by hot pressing. The ceramic can be any suitable ceramic such as yttria (Y2O3) or scandia (Sc2O3) and can have a doping level of from 0 to 20% and a grain size of greater than 30 ?m, although the grains can also be smaller than 30 ?m. In a process for making a transparent polycrystalline ceramic in accordance with the present invention, ceramic nanoparticles can be coated with a sintering aid to minimize direct contact of adjacent ceramic powder particles and then baked at high temperatures to remove impurities from the coated particles. The thus-coated particles can then be densified by hot pressing into the final ceramic product. The invention further provides a transparent polycrystalline ceramic solid-state laser material and a laser using the hot pressed polycrystalline ceramic.
    Type: Grant
    Filed: November 18, 2009
    Date of Patent: January 31, 2012
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Jasbinder S. Sanghera, Guillermo R Villalobos, Woohong Kim, Shyam S Bayya, Ishwar D. Aggarwal, Bryan Sadowski
  • Publication number: 20110315046
    Abstract: A method of fabricating a composite powder includes forming a plurality of loose particles having discrete regions of a first material and discrete regions of a second material that is different than the first material. At least one of the first material and the second material includes a chemical precursor to a third, different material.
    Type: Application
    Filed: June 28, 2010
    Publication date: December 29, 2011
    Inventors: Paul Sheedy, Wayde R. Schmidt
  • Publication number: 20110319252
    Abstract: A composite powder includes a plurality of loose particles having discrete regions of a first material and discrete regions of a second material that is different than the first material. At least one of the first material and the second material is a chemical precursor to a third material.
    Type: Application
    Filed: June 28, 2010
    Publication date: December 29, 2011
    Inventors: Wayde R. Schmidt, Paul Sheedy
  • Publication number: 20110311820
    Abstract: A hardfacing composition (32) that includes a plurality of hard particles (54) wherein the hard particles (54) include a mode particle size distribution, one particle size distribution smaller than the mode particle size distribution, and an other particle size distribution larger than the mode particle size distribution. There is an absence of any substantial fluctuations in the particle size distribution between the mode particle size distribution and the one particle size distribution. There is an absence of any substantial fluctuations in the particle size distribution between the mode particle size distribution and the other particle size distribution.
    Type: Application
    Filed: August 30, 2011
    Publication date: December 22, 2011
    Applicant: Kennametal Inc.
    Inventor: Moira E. MacLeod
  • Publication number: 20110236695
    Abstract: A composite article includes a substrate and a protective layer disposed on the substrate. The protective layer has a silicon-aluminum-carbon-nitrogen solid solution composition and microstructure.
    Type: Application
    Filed: March 29, 2010
    Publication date: September 29, 2011
    Inventor: Wayde R. Schmidt