Composites (continuous Matrix With Dispersed Fiber Phase) Patents (Class 501/95.2)
  • Patent number: 10011902
    Abstract: A method of fabricating a composite material part, the method including making a consolidated fiber preform, the fibers of the preform being carbon or ceramic fibers and being coated with an interphase; obtaining a consolidated and partially densified fiber preform, the partial densification comprising using chemical vapor infiltration to form a first matrix phase on the interphase; and continuing densification of the fiber preform by infiltrating an infiltration composition containing at least silicon and at least one other element suitable for lowering the melting temperature of the infiltration composition to a temperature less than or equal to 1150° C.
    Type: Grant
    Filed: July 15, 2014
    Date of Patent: July 3, 2018
    Assignee: HERAKLES
    Inventors: Eric Philippe, Eric Bouillon, Emilie Courcot, Sébastien Jimenez
  • Patent number: 9382899
    Abstract: Disclosed is a wind turbine, which comprises a rotatable structure being coupled to a hub of the wind turbine and to a generator rotor comprising a brake disc, a stationary structure being coupled to a generator stator and comprising a stator frame and a safety bearing element. The rotatable structure is rotatably coupled to the stationary structure, wherein the stator frame comprises a brake mounting section to which a calliper brake is mountable such that the brake disc is breakable by the mounted calliper brake. The safety bearing element is mounted to the brake mounting section such that the brake disc is in slidable contact with the safety bearing element if a distance between the brake mounting section and the brake disc is reduced below a predetermined reference value.
    Type: Grant
    Filed: December 4, 2013
    Date of Patent: July 5, 2016
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Uffe Eriksen, Claus Johansen, Jens Anton Agerskov Veng
  • Patent number: 9327976
    Abstract: The present invention relates to a hydroxyapatite multi-substituted with, physiologically compatible ion species and to its biohybrid composite with a natural and/or synthetic polymer, which are useful in the preparation of a biomimetic bone substitute for treating bone tissue defects. Furthermore, the present invention relates to a method for their preparation and uses.
    Type: Grant
    Filed: October 12, 2006
    Date of Patent: May 3, 2016
    Assignees: C.N.R. CONSIGLIO NAZIONALE DELLE RICERCHE, FIN-CERAMICA FAENZA S.P.A.
    Inventors: Elena Landi, Anna Tampieri, Giancarlo Celotti, Simone Sprio, Daniele Pressato, Claudio De Luca
  • Patent number: 9156741
    Abstract: The present invention provides a method of preparing a carbon fiber-reinforced silicon carbide composite material, wherein carbon nanotubes are formed in the composite material, and then metal silicon is melted and infiltrated into the composite material, so the amount of unreacted metal is reduced and the strength of the composite material is improved, and provides a carbon fiber-reinforced silicon carbide composite material prepared by the method.
    Type: Grant
    Filed: October 3, 2013
    Date of Patent: October 13, 2015
    Assignee: KOREA INSTITUTE OF ENERGY RESEARCH
    Inventors: Se-Young Kim, Nam-Jo Jeong, In-Sub Han, Sang-Kuk Woo, Doo-Won Seo, Kang Bai, Ji-Haeng Yu, Sun-Dong Kim
  • Publication number: 20150141235
    Abstract: A method of fabricating a carbon fiber-reinforced article includes providing carbon fibers that have surfaces that include an initial interfacial bonding strength capacity with respect to bonding with boron nitride. The surfaces are then modified to reduce the initial interfacial bonding strength capacity. A layer of boron nitride is then deposited on the modified surfaces and the carbon fibers are then embedded in a ceramic matrix. A carbon fiber-reinforced article includes the carbon fibers, the layer of boron nitride on the surfaces of the carbon fibers, and the ceramic matrix. The article exhibits non-brittle fracture.
    Type: Application
    Filed: December 28, 2012
    Publication date: May 21, 2015
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Michael A. Kmetz, Sam Frueh
  • Publication number: 20150065331
    Abstract: An expandable refractory for high temperature sealing, the expandable refractory includes un-expanded vermiculite and one or more mixtures of ceramic fibers in a water based refractory binder.
    Type: Application
    Filed: September 5, 2013
    Publication date: March 5, 2015
    Applicant: FUELCELL ENERGY, INC.
    Inventors: Dennis Robert Farrenkopf, Michael Quatannens
  • Patent number: 8962504
    Abstract: The disclosure provides novel graphene-reinforced ceramic composites and methods for making such composite materials.
    Type: Grant
    Filed: July 27, 2012
    Date of Patent: February 24, 2015
    Assignee: Arizona Board of Regents on Behalf of The University of Arizona
    Inventors: Erica L. Corral, Luke S. Walker, Victoria R. Marotto, Mohammad A. Rafiee, Nikhil Koratkar
  • Publication number: 20150033714
    Abstract: Provided are a holding material for a gas treatment device, which is inexpensive, has a simple structure, and exhibits high holding force, a gas treatment device, and a method for manufacturing the same. A holding material for a gas treatment device according to the present invention is a holding material, which is a holding material to be arranged, in a gas treatment device including a treatment structure and a casing for housing the treatment structure, between the treatment structure and the casing, the holding material including silica fibers and an alumina sol in an amount of 3 parts by mass or more in terms of a solid content with respect to 100 parts by mass of the silica fibers.
    Type: Application
    Filed: November 14, 2012
    Publication date: February 5, 2015
    Applicant: NICHIAS CORPORATION
    Inventors: Junya Satoh, Nobuya Tomosue, Kazutoshi Isomura, Kiyoshi Sato, Tadashi Sakane, Hiroki Nakamura
  • Patent number: 8940391
    Abstract: Methods of producing silicon carbide fibers. The method comprises reacting a continuous carbon fiber material and a silicon-containing gas in a reaction chamber at a temperature ranging from approximately 1500° C. to approximately 2000° C. A partial pressure of oxygen in the reaction chamber is maintained at less than approximately 1.01×102 Pascal to produce continuous alpha silicon carbide fibers. Continuous alpha silicon carbide fibers and articles formed from the continuous alpha silicon carbide fibers are also disclosed.
    Type: Grant
    Filed: October 8, 2010
    Date of Patent: January 27, 2015
    Assignee: Advanced Ceramic Fibers, LLC
    Inventors: John E. Garnier, George W. Griffith
  • Patent number: 8932971
    Abstract: A material composed of a large fraction of aluminum oxide, zirconium oxide and strontium aluminate.
    Type: Grant
    Filed: April 25, 2008
    Date of Patent: January 13, 2015
    Assignee: CeramTec GmbH
    Inventors: Meinhard Kuntz, Peter Schröter, Wolfgang Jaschinski, Volker Sommer
  • Patent number: 8932970
    Abstract: Hardness, ageing resistance, wetting behavior in relating to water and high thermal conductivity are known characteristics of sintered molded bodies consisting of aluminum oxide; high strength and a high resistance to cracking, i.e., damage tolerance are known characteristics of sintered molded bodies consisting of zirconium oxide. These properties are combined in a material having a large fraction of aluminum oxide, zirconium oxide and optionally strontium aluminate.
    Type: Grant
    Filed: April 25, 2008
    Date of Patent: January 13, 2015
    Assignee: CeramTec GmbH
    Inventors: Meinhard Kuntz, Ana Herrán Fuertes, Kilian Friederich, Norbert Schneider
  • Publication number: 20150004393
    Abstract: A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers.
    Type: Application
    Filed: January 18, 2013
    Publication date: January 1, 2015
    Inventors: Joseph Pegna, John L. Schneiter, Kirk L. Williams, Ramkiran Goduguchinta
  • Patent number: 8916618
    Abstract: The invention is directed to a method for recycling an organic-matrix composite material. The organic-matrix composite material comprises a first component comprising at least one organic matrix polymer and at least one solid second component being compatible with said first component and being structurally different from said first component, wherein said at least one organic polymer has thermosetting properties at room temperature and wherein said polymer comprises thermally reversible cross-links The method of the invention comprises —heating the organic-matrix composite material to a temperature at which at least part of the thermally reversible cross-links cleave and at which temperature the first component as a viscosity of at most 500 Pa·s, as measured by oscillatory measurements on an Anton Paar MCR 301 rheometer using parallel plate geometry; and —separating the at least part of said first component from said second component.
    Type: Grant
    Filed: October 13, 2009
    Date of Patent: December 23, 2014
    Assignee: Nederlandse Organisatie voor Toegepast-Natuurwetenschappelijk Onderzoek TNO
    Inventors: Maria Elizabeth Louise Wouters, Rudolf Hartmut Fischer
  • Publication number: 20140342899
    Abstract: A friction material contains: at least one kind of a titanate compound having a shape having a plurality of convex portions; and a bio-soluble inorganic fiber. In the titanate compound, a three-dimensional shape of a particle thereof has a plurality of convex portions.
    Type: Application
    Filed: September 13, 2012
    Publication date: November 20, 2014
    Applicant: AKEBONO BRAKE INDUSTRY CO., LTD.
    Inventors: Eri Itami, Hiroshi Yamamoto, Takayuki Watanabe, Katsuji Seki
  • Patent number: 8865301
    Abstract: A composition having nanoparticles of a refractory-metal boride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component, boron, and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles, boron, and an organic compound having a char yield of at least 60% by weight to form a precursor mixture. A composition having nanoparticles of a refractory-metal boride that is not in the form of a powder.
    Type: Grant
    Filed: February 15, 2013
    Date of Patent: October 21, 2014
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Teddy M Keller, Andrew Saab, Matthew Laskoski, Syed B Qadri
  • Patent number: 8822023
    Abstract: A composition having nanoparticles of a refractory-metal carbide or refractory-metal nitride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles with an organic compound having a char yield of at least 60% by weight to form a precursor mixture.
    Type: Grant
    Filed: January 25, 2013
    Date of Patent: September 2, 2014
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Teddy M Keller, Andrew Saab, Matthew Laskoski, Manoj K. Kolel-Veetil, Syed B Qadri
  • Publication number: 20140200130
    Abstract: A method of forming a ceramic matrix composite structure. The method comprises forming at least one prepregged composite material comprising a ceramic fiber preform and a pre-ceramic matrix slurry. The at least one prepregged composite material is placed over at least one surface of a tool using an advanced fiber placement apparatus to form an at least partially uncured composite material structure. The at least partially uncured composite material structure is exposed at least to elevated temperatures to convert the at least partially uncured composite material structure into a ceramic matrix composite structure. A system for forming a ceramic matrix composite structure, an advanced fiber placement apparatus, and a ceramic matrix composite structure are also described.
    Type: Application
    Filed: January 14, 2013
    Publication date: July 17, 2014
    Applicant: COI Ceramics, Inc.
    Inventors: Andrew Szweda, Thomas Barrett Jackson
  • Patent number: 8758908
    Abstract: Aqueous precursor solutions are described that comprise at least one monazite-based material precursor, at least one xenotime-based material precursor or a combination thereof; and a plurality of fine suspended particles of an oxide material. Contemplated oxide composites, as described herein, comprise a plurality of fibers surrounded by at least one monazite or xenotime-based material, wherein the oxide composite has nearly a fully dense matrix. Contemplated embodiments disclosed herein provides a method for producing an oxide composite with nearly fully dense matrix and with all fibers surrounded by a monazite- or xenotime-based material that prevents embrittlement at temperatures at least as high as 1200° C.
    Type: Grant
    Filed: March 7, 2008
    Date of Patent: June 24, 2014
    Assignee: Teledyne Scientific & Imaging, LLC
    Inventors: David B. Marshall, Janet B. Davis, Peter E. D. Morgan
  • Publication number: 20140127083
    Abstract: A method of treating tough inorganic fiber bundles including opening a plurality of the tough inorganic fiber bundles such that tough inorganic fibers can be dispersed in a liquid slurry to lay down a homogenous fiber aggregate, wherein the tough inorganic fibers have a crush settle volume of greater than 250 ml, optionally greater than 450 ml. Also, a method of treating tough inorganic fiber bundles including dispersing a plurality of the tough inorganic fiber bundles in a slurry with a dilution of about 0.1% to about 2%, optionally about 0.1% to about 1%, effective to lay down a homogenous fiber aggregate, wherein the tough inorganic fibers have a crush settle volume of greater than 250 ml, optionally greater than 450 ml.
    Type: Application
    Filed: November 1, 2013
    Publication date: May 8, 2014
    Inventors: Kelvin WEEKS, Adam Kelsall
  • Patent number: 8696807
    Abstract: A porous ceramic (honeycomb) structure skin coating and a method of producing a porous ceramic structure skin coating which provides a hardshell, strong, acid- and alkali-resistant, chip-resistant ceramic honeycomb structure coating which resists pollution control catalyst from being absorbed into the skin coating.
    Type: Grant
    Filed: July 12, 2013
    Date of Patent: April 15, 2014
    Assignee: Unifrax I LLC
    Inventors: Joseph A. Fernando, Kenneth B. Miller
  • Patent number: 8609562
    Abstract: Disclosed is a method of producing a plate brick, which comprises: adding an organic binder to a refractory raw material mixture containing aluminum and/or an aluminum alloy; kneading them; forming the kneaded mixture into a shaped body; and burning the shaped body in a nitrogen gas atmosphere at a temperature of 1000 to 1400° C., wherein: when a temperature of a furnace atmosphere is 300° C. or more, the atmosphere is set to a nitrogen gas atmosphere; and when the temperature of the furnace atmosphere is 1000° C. or more, an oxygen gas concentration in the atmosphere is maintained at 100 volume ppm or less, and a sum of a carbon monoxide gas concentration and a carbon dioxide gas concentration is maintained at 1.0 volume % or less.
    Type: Grant
    Filed: December 18, 2009
    Date of Patent: December 17, 2013
    Assignee: Krosakiharima Corporation
    Inventors: Keiichiro Akamine, Katsumi Morikawa, Joki Yoshitomi, Tsuneo Kayama
  • Patent number: 8604149
    Abstract: The invention relates to a method for producing a polysilane-polycarbosilane copolymer solution. Said method comprises the preparation of a polysilane, obtained by the disproportionation of a methylchlorodisilane or a mixture of methylchlorodisilanes of formula Si2MenC16-n with a Lewis base as the catalyst, a subsequent thermal cross-linking of the polysilane to form an infusible polysilane-polycarbosilane copolymer that is soluble in inert solvents, in addition to the production of said solution by the dissolution of the polysilane-polycarbosilane copolymer in an inert solvent. The invention also relates to a method for producing oxygen-depleted ceramic fibers and other molded bodies with a composition similar to that of SiC. Said method comprises the spinning of the solution to obtain green fibers according to the dry spinning method and the pyrolysis of the dried green fibers in an inert gas atmosphere or a reductive atmosphere.
    Type: Grant
    Filed: May 2, 2005
    Date of Patent: December 10, 2013
    Assignee: Fraunhofer-Gesellschaft zur Foerderung der angewandten Forschung e.V.
    Inventors: Juergen Clade, Erich Seider, Dieter Sporn, Erika Brendler, Thomas Lange, Gerhard Roewer, Dorit Mainhold
  • Publication number: 20130225391
    Abstract: To provide a highly bio-soluble fibrous shaped refractory article which can develop desired heat resistance without containing ceramic fibers such as aluminum silicate fibers, alumina powder and silica powder and can be provided at a low production cost and a low product cost. An inorganic fibrous shaped refractory article comprising 2 to 95 mass % of bio-soluble inorganic fibers having a dissolution ratio in a physiological saline at 40° C. of 1 mass % or more, 2 to 95 mass % of inorganic powder having a needle-like crystal structure and 3 to 32 mass % of a binder, and in particular, it is an inorganic fibrous refractory article wherein the inorganic powder having the needle-like crystal structure has an average length of 1 to 3000 ?m and an aspect ratio of 1 to 1000.
    Type: Application
    Filed: December 24, 2010
    Publication date: August 29, 2013
    Applicant: NICHIAS CORPORATION
    Inventors: Koji Iwata, Ken Yonaiyama
  • Publication number: 20130210605
    Abstract: A refractory composition and processes for manufacture are provided where the compositions possess improved refractory alkali resistance and superior handling properties. Compositions and processes for their manufacture may include a plurality of ceramic particles and a binder sintered to the particles wherein the binder includes crystalline aluminum orthophosphate distributed as the result of an in situ reaction of aluminum metaphosphate with alumina. Kits provided according to the invention provide materials for use in manufacture of a composition where the kit includes aluminum metaphosphate and a nonfacile additive.
    Type: Application
    Filed: March 22, 2011
    Publication date: August 15, 2013
    Applicant: STELLAR MATERIALS INCORPORATED
    Inventor: Jens Decker
  • Publication number: 20130196133
    Abstract: A composition having nanoparticles of a refractory-metal boride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component, boron, and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles, boron, and an organic compound having a char yield of at least 60% by weight to form a precursor mixture. A composition having nanoparticles of a refractory-metal boride that is not in the form of a powder.
    Type: Application
    Filed: February 15, 2013
    Publication date: August 1, 2013
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Teddy M. Keller, Andrew Saab, Matthew Laskoski, Syed B. Qadri
  • Publication number: 20130196132
    Abstract: A composition having nanoparticles of a refractory-metal carbide or refractory-metal nitride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles with an organic compound having a char yield of at least 60% by weight to form a precursor mixture.
    Type: Application
    Filed: January 25, 2013
    Publication date: August 1, 2013
    Applicant: The Government of the United States as represented by the Secretary of the Vavy
    Inventors: Teddy M. Keller, Andrew Saab, Matthew Laskoski, Manoj K. Kolel-Veetil, Syed B. Qadri
  • Patent number: 8466076
    Abstract: The present invention pertains to a process for producing unmeltable polysilane-polycarbosilane copolymers which are soluble in inert solvents, comprising the steps providing the product of a disproportionation of a methylchlorodisilane or a mixture of several methylchlorodisilanes of the composition Si2MenCl6-n, wherein n=1?4, wherein the disproportionation was carried out with a Lewis base as a catalyst, wherein this product is a chlorine-containing, crude polysilane/oligosilane containing hydrocarbon groups, and thermally postcrosslinking the crude polysilane/oligosilane to a polysilane-polycarbosilane copolymer, characterized in that the chlorine content of the polysilane-polycarbosilane copolymer is lowered by reacting the crude polysilane/oligosilane with a substitution agent, by which chlorine bound therein is replaced with a chlorine-free substituent. Green fibers and low-oxygen/oxygen-free ceramic fibers with a very low chlorine content can be produced using this process.
    Type: Grant
    Filed: December 21, 2009
    Date of Patent: June 18, 2013
    Assignee: Fraunhofer-Gesellschaft zur Foerderung der angewandten Forschung e.V.
    Inventors: Arne Ruedinger, Juergen Clade, Heiko Spaniol, Dieter Sporn
  • Patent number: 8455379
    Abstract: A ceramic article comprises ceramic fibers having an aspect ratio of greater than or equal to 10:1, ceramic particles, and an inorganic binder comprising silica. Greater than 90 out of 100 ceramic fibers are randomly oriented in three dimensions in the ceramic article, and greater than 85 out of 100 ceramic fibers are spaced at least one ceramic fiber diameter away from an adjacent ceramic fiber. The ceramic article has a consistent density of from 0.9 to 1.1 g/cm3 in x-, y-, and z-dimensions and has a uniform strength in three dimensions as measured in accordance with ASTM C1424.
    Type: Grant
    Filed: April 10, 2012
    Date of Patent: June 4, 2013
    Assignee: Century, Inc.
    Inventors: Thomas W. McCullough, James E. Schuetz, Thomas D. Wood
  • Patent number: 8450228
    Abstract: In a carbon-containing refractory composed of a refractory aggregate, a carbon based raw material, and a carbon bond connecting between the refractory aggregate or the carbon based raw material, transition metal-containing nanoparticles having particle diameters of 1,000 nm or less and containing a transition metal are contained in the above-described carbon bond while being dispersed. When the carbon-containing refractory is heat-treated, flexible structures of carbon fiber-shaped textures having diameters of 50 nm or less are formed in the inside of a carbon bond and, thereby, an increase in strength, a reduction in modulus of elasticity, and a reduction in thermal expansion coefficient are facilitated. Therefore, a carbon-containing refractory exhibiting high thermal shock resistance, high abrasion resistance, and high corrosion resistance are provided.
    Type: Grant
    Filed: April 19, 2006
    Date of Patent: May 28, 2013
    Assignee: Krosaki Harima Corporation
    Inventors: Katsumi Morikawa, Koichi Haren, Joki Yoshitomi, Toshiyuki Hokii, Keisuke Asano
  • Publication number: 20130116109
    Abstract: The invention relates to a process for producing a ceramic matrix composite (CMC) part by infiltration of a suspension (S) of a ceramic powder into a fibrous reinforcement (14). A suspension (S) of ceramic powder containing particles of chosen particle size, dispersed in at least one solvent, is prepared. The infiltration of the suspension is carried out in a single step in the fibrous reinforcement (14) positioned between a mould (12) and a permeable membrane (16), which makes it possible to apply a vacuum (V) and to subsequently remove the solvent from the suspension through the permeable membrane (16). The invention applies to the production of large-sized parts of complex shape, in particular in the field of aeronautics and aerospace engineering.
    Type: Application
    Filed: April 18, 2011
    Publication date: May 9, 2013
    Inventors: Marie-Hélène Ritti, Bertrand Laine, Michel Parlier, Aurélie Julian-Jankowiak
  • Patent number: 8409491
    Abstract: A tough ultra-high temperature ceramic (UHTC) composite comprises grains of UHTC matrix material, such as HfB2, ZrB2 or other metal boride, carbide, nitride, etc., surrounded by a uniform distribution of acicular high aspect ratio reinforcement ceramic rods or whiskers, such as of SiC, is formed from uniformly mixing a powder of the UHTC material and a pre-ceramic polymer selected to form the desired reinforcement species, then thermally consolidating the mixture by hot pressing. The acicular reinforcement rods may make up from 5 to 30 vol % of the resulting microstructure.
    Type: Grant
    Filed: August 22, 2011
    Date of Patent: April 2, 2013
    Assignee: The United States of America as Represented by the Administrator of the National Aeronautics & Space Administration (NASA)
    Inventors: Margaret M Stackpoole, Matthew J Gasch, Michael W Olson, Ian W. Hamby, Sylvia M Johnson
  • Patent number: 8313853
    Abstract: A thin, flexible, porous ceramic composite (PCC) film useful as a separator for a molten-salt thermal battery comprises 50% to 95% by weight of electrically non-conductive ceramic fibers comprising a coating of magnesium oxide on the surface of the fibers in an amount in the range of 5% to 50% by weight. The ceramic fibers comprise Al2O3, AlSiO2, BN, AlN, or a mixture of two or more of the foregoing; and the magnesium oxide coating interconnects the ceramic fibers providing a porous network of magnesium oxide-coated fibers having a porosity of not less than 50% by volume. The pores of the film optionally can include a solid electrolyte salt. A laminated electrode/PCC film combination is also provided, as well as a thermal battery cell comprising the PCC film as a separator.
    Type: Grant
    Filed: December 1, 2008
    Date of Patent: November 20, 2012
    Inventor: Thomas D. Kaun
  • 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
  • Patent number: 8263512
    Abstract: A porous ceramic (honeycomb) structure skin coating and a method of producing a porous ceramic structure skin coating which provides a hardshell, strong, acid- and alkali-resistant, chip-resistant ceramic honeycomb structure coating which resists pollution control catalyst from being absorbed into the skin coating.
    Type: Grant
    Filed: December 8, 2009
    Date of Patent: September 11, 2012
    Assignee: Unifrax I LLC
    Inventors: Joseph A. Fernando, Kenneth B. Miller
  • Patent number: 8236718
    Abstract: The application discloses and claims an oxidation resistant, continuous-fiber-reinforced ceramic composition, durable at temperatures above 1000° C., and capable of taking on any arbitrary near net shape formed without machining and tooling. The composition of the invention comprises a fine grained ceramic matrix which in turn comprises a mixture of a ZrB2 phase and a SiC phase with the matrix being reinforced with SiC or C or an oxide fiber, resulting in a fine grained ZrB2—SiC matrix with domain sizes ?0.5 ?m. The ZrB2 phase of the invention is capable of forming small microcrystalline domains ?0.5 ?m upon heat treatment. The composition the invention also comprises a fiber reinforced composite with a high degree of filling and densification of its preform resulting in a composition containing a low level of porosity and high fiber volume fraction.
    Type: Grant
    Filed: June 23, 2009
    Date of Patent: August 7, 2012
    Inventors: Larry J. Kepley, George M. Jacobsen
  • Publication number: 20120196146
    Abstract: One embodiment is a gas turbine engine component including a metal foam nanofiber composite. Another embodiment is a gas turbine engine component including a ceramic foam nanofiber composite. Other embodiments include unique gas turbine engine components including foam nanofiber composites.
    Type: Application
    Filed: December 24, 2011
    Publication date: August 2, 2012
    Inventor: Edward Claude Rice
  • Patent number: 8168291
    Abstract: In various embodiments, composite materials containing a ceramic matrix and a carbon nanotube-infused fiber material are described herein. Illustrative ceramic matrices include, for example, binary, ternary and quaternary metal or non-metal borides, oxides, nitrides and carbides. The ceramic matrix can also be a cement. The fiber materials can be continuous or chopped fibers and include, for example, glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers and aluminum oxide fibers. The composite materials can further include a passivation layer overcoating at least the carbon nanotube-infused fiber material and, optionally, the plurality of carbon nanotubes. The fiber material can be distributed uniformly, non-uniformly or in a gradient manner in the ceramic matrix. Non-uniform distributions may be used to form impart different mechanical, electrical or thermal properties to different regions of the ceramic matrix.
    Type: Grant
    Filed: November 23, 2010
    Date of Patent: May 1, 2012
    Assignee: Applied Nanostructured Solutions, LLC
    Inventors: Tushar K. Shah, Harry C. Malecki, Murray N. Carson
  • Patent number: 8153541
    Abstract: A ceramic article comprises ceramic fibers having an aspect ratio of greater than 3:1 and ceramic particles. The ceramic fibers are substantially randomly oriented in three dimensions in the ceramic article. A method of forming the ceramic article includes the step of providing a composition including ceramic fibers having an aspect ratio of greater than 3:1 and ceramic particles. The composition is extruded through a multi-screw extruder having at least three intermeshing screws to form an extrudate. The extrudate is heated to form the ceramic article.
    Type: Grant
    Filed: July 17, 2008
    Date of Patent: April 10, 2012
    Assignee: Century, Inc.
    Inventors: Thomas W. McCullough, James E. Schuetz, Thomas D. Wood
  • Patent number: 8114799
    Abstract: A ceramic matrix composite with a ceramic matrix and a gradient layering of coating on ceramic fibers. The coating typically improves the performance of the composite in one direction while degrading it in another direction. For a SiC-SiC ceramic matrix composite, a BN coating is layered in a gradient fashion or in a step-wise fashion in different regions of the article comprising the ceramic. The BN coating thickness is applied over the ceramic fibers to produce varying desired physical properties by varying the coating thickness within differing regions of the composite, thereby tailoring the strength of the composite in the different regions. The coating may be applied as a single layer as a multi-layer coating to enhance the performance of the coating as the ceramic matrix is formed or infiltrated from precursor materials into a preform of the ceramic fibers.
    Type: Grant
    Filed: August 25, 2009
    Date of Patent: February 14, 2012
    Assignee: General Electric Company
    Inventors: Suresh Subramanian, James Steibel, Douglas Carper, Toby Darkins, Jr.
  • Patent number: 8088697
    Abstract: A fibrous ceramic material including a plurality of fibers entangled with one another. The fibrous ceramic material includes at least one connector projecting between the fibers. At least a portion of the fibers have the connectors extending between and attach the fibers to one another. A method of manufacturing the fibrous ceramic material includes providing a precursor material having a plurality of fibers. A holder is provided for holding the precursor material. The precursor material is placed on the holder and both are heated to between about 1500 degrees Celsius and about 1700 degrees Celsius to form the fibrous ceramic material, thereby causing connectors to project from a portion of the fibers and attach the fibers to one another.
    Type: Grant
    Filed: September 18, 2008
    Date of Patent: January 3, 2012
    Assignee: FuelCell Energy, Inc.
    Inventors: Chao-Yi Yuh, Dana A. Kelley, Nikhil H. Jalani
  • Patent number: 8058197
    Abstract: This invention provides carbon composite materials, which comprise metal carbide particles, at least the particle surfaces or the entirety of which are metal carbides, synthesized in situ from a metal source, i.e., at least one member selected from the group comprising metal particles, metal oxide particles, and composite metal oxide particles, and a carbon source, i.e., a thermosetting resin, dispersed in a carbon, carbon fiber, or carbon/carbon fiber matrix, and contain no free metal particles. This invention also provides a method for producing such composite carbon materials, which enables the production of carbon composite materials having a high coefficient of friction, high thermostability, and abrasion resistance.
    Type: Grant
    Filed: July 23, 2010
    Date of Patent: November 15, 2011
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Shigeru Ichikawa, Sumio Kamiya, Koji Yamada, Hironori Sasaki
  • Patent number: 7951736
    Abstract: An SiC fiber bonded ceramic constituted of both a base material which comprises both inorganic fibers made mainly of a sintered SiC structure containing 0.01 to 1 wt % of oxygen (O) and at least one of Groups 2A, 3A and 3B metals and a 1 to 100-nm and carbon (C)-base boundary layer formed among the fibers and a surface part which is made mainly of an SiC-base ceramic structure and formed on at least part of the surface of the base material, characterized in that the boundary portion between the surface part and the base material takes such a gradient structure that the structure of the base material changes into the structure of the surface part gradually and continuously.
    Type: Grant
    Filed: September 11, 2007
    Date of Patent: May 31, 2011
    Assignee: Ube Industries, Ltd
    Inventors: Kenji Matsunaga, Shinji Kajii, Toshihiko Hogami
  • Publication number: 20110124483
    Abstract: In various embodiments, composite materials containing a ceramic matrix and a carbon nanotube-infused fiber material are described herein. Illustrative ceramic matrices include, for example, binary, ternary and quaternary metal or non-metal borides, oxides, nitrides and carbides. The ceramic matrix can also be a cement. The fiber materials can be continuous or chopped fibers and include, for example, glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers and aluminum oxide fibers. The composite materials can further include a passivation layer overcoating at least the carbon nanotube-infused fiber material and, optionally, the plurality of carbon nanotubes. The fiber material can be distributed uniformly, non-uniformly or in a gradient manner in the ceramic matrix. Non-uniform distributions may be used to form impart different mechanical, electrical or thermal properties to different regions of the ceramic matrix.
    Type: Application
    Filed: November 23, 2010
    Publication date: May 26, 2011
    Applicant: APPLIED NANOSTRUCTURED SOLUTIONS, LLC
    Inventors: Tushar K. SHAH, Harry C. Malecki, Murray N. Carson
  • Publication number: 20110071015
    Abstract: A method for preparing a high-temperature heat-resistant composite material by combining a mixture of submicron alumina powder and submicron silica powder, wherein the ratio of alumina to silica is from about 4:1 to about 5:1, submicron Group II metal oxide powder, and a Group I metal silicate solution to form a slurry, wherein the weight of the Group II metal oxide powder is an amount corresponding to about 5% to about 10% of the weight of the silicate solution; contacting reinforcing high-temperature resistant fibers with the slurry to form a composite precursor composition; and curing the composition at a temperature sufficient to produce the high-temperature heat-resistant composite material capable of resisting temperatures up to about 1400° C. Composite materials prepared according to the method and articles incorporating the material are also presented.
    Type: Application
    Filed: November 16, 2010
    Publication date: March 24, 2011
    Applicant: Rutgers, The State University
    Inventor: Perumalsamy Naidu Balaguru
  • Publication number: 20110071013
    Abstract: A ceramic matrix composite is formed from a non-oxide ceramic and continuous ceramic fibers. The matrix includes a hafnium donor in the matrix in an amount sufficient to harden the composite at elevated temperatures to prevent ablation of the composite. The matrix also includes a boron donor in the matrix in an amount sufficient to lower the glass transition temperature of the composite to flow over cracks formed in the composite. The method to form the matrix is selected from polymer infiltration pyrolysis, chemical vapor infiltration, and sequential polymer infiltration pyrolysis and chemical vapor infiltration.
    Type: Application
    Filed: September 24, 2009
    Publication date: March 24, 2011
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Kirk C. Newton, Michael A. Kmetz
  • Publication number: 20110071014
    Abstract: A method of forming a highly densified chemical matrix composite CMC from a preform of a matrix of a non-oxide ceramic and continuous ceramic fibers. An interface coating is added, followed by partially densifying the preform with a resin to increase the density of the preform using a polymer infiltration pyrolysis PIP) process one or more times. A chemical vapor infiltration (CVI) process is used to bring the CMC to a final desired density.
    Type: Application
    Filed: September 24, 2009
    Publication date: March 24, 2011
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Michael A. Kmetz, Kirk C. Newton
  • Patent number: 7893000
    Abstract: Boron carbide ceramics produced by spark sintering methods have more desirable mechanical properties than conventionally produced carbides. The boron carbide ceramics include amorphous boron, amorphous carbon, and Al2O3 powder as a sintering aid. The boron carbides may also contain a carbon nano fiber in a nearly homogeneously dispersed state. The sintered compact has a relative density of a boron carbide ceramic of approximately not less than 99%. The boron carbide ceramics are prepared preferably by subjecting a mixed powder of the starting raw materials and the carbon nano fiber to simultaneous synthesis and sintering using the spark plasma sintering method.
    Type: Grant
    Filed: August 16, 2010
    Date of Patent: February 22, 2011
    Assignee: The Doshisha
    Inventors: Ken Hirota, Yoshihiro Nakayama, Shingo Nakane
  • Patent number: 7858554
    Abstract: A porous cordierite substrate and a method of forming a porous cordierite substrate including providing a fiber that includes at least one cordierite precursor material and providing at least one organic binder material. The fiber and the organic binder material are mixed with a fluid. The mix of fiber, organic binder material and fluid is extruded into a green substrate. The green substrate is fired to enable the formation of bonds between the fibers and to form a porous cordierite fiber substrate.
    Type: Grant
    Filed: May 24, 2007
    Date of Patent: December 28, 2010
    Assignee: Geo2 Technologies, Inc.
    Inventors: James Jenq Liu, Bilal Zuberi, Jerry G. Weinstein, Rachel A. Dahl, William M. Carty
  • Patent number: 7854882
    Abstract: A method for preparing a high-temperature heat-resistant composite material by combining a mixture of submicron alumina powder and submicron silica powder, wherein the ratio of alumina to silica is from about 4:1 to about 5:1, submicron Group II metal oxide powder, and a Group I metal silicate solution to form a slurry, wherein the weight of the Group II metal oxide powder is an amount corresponding to about 5% to about 10% of the weight of the silicate solution; contacting reinforcing high-temperature resistant fibers with the slurry to form a composite precursor composition; and curing the composition at a temperature sufficient to produce the high-temperature heat-resistant composite material capable of resisting temperatures up to about 1400° C. Composite materials prepared according to the method and articles incorporating the material are also presented.
    Type: Grant
    Filed: March 26, 2007
    Date of Patent: December 21, 2010
    Assignee: Rutgers, The State University
    Inventor: Perumalsamy Naidu Balaguru
  • Patent number: RE42775
    Abstract: Insulation materials suited to high temperature applications, such as the insulation of furnaces, are formed from a mixture of pitch carbon fibers, such as isotropic pitch carbon fibers, and a binder comprising a solution of sugar in water. The sugar solution is preferably at a concentration of from 20-60% sucrose to yield a low density material having high flexural strength and low thermal conductivity when carbonized to a temperature of about 1800° C.
    Type: Grant
    Filed: November 4, 2008
    Date of Patent: October 4, 2011
    Assignee: GrafTech International Holdings Inc.
    Inventors: Charles C. Chiu, Irwin Charles Lewis, Ching-Feng Chang