With Trivalent Metal Compound (e.g., Yttrium, Rare Earth, Or Aluminum Compound, Etc.) Patents (Class 501/97.2)
  • Patent number: 11046617
    Abstract: A tape casting slurry composition for preparing a silicon nitride sintered body is provided. The tape casting slurry composition exhibits a viscosity suitable for tape casting, and thus, can easily control the area and thickness of the prepared green sheet, thereby preparing a large area silicon nitride sintered body having a thickness of a circuit board without post-processing processes such as grinding, and the like. Therefore, according to the present invention, a silicon nitride sintered body can be prepared using low cost raw materials by a simplified process, thereby securing efficiency and economic feasibility of the preparation process.
    Type: Grant
    Filed: September 19, 2018
    Date of Patent: June 29, 2021
    Inventors: Jungyu Kim, Dong Oh Shin, Jung Min Ko
  • Patent number: 10348061
    Abstract: The spark plug includes an insulator formed of an alumina-based sintered body, and the insulator contains Si, Ba, and a rare earth element. In an analysis of the insulator by using a scanning transmission electron microscope having an electron-probe diameter of 1 nm, Si and a rare earth element are detected at a crystal grain boundary having a thickness of 15 nm or less, a content of an alkaline earth metal is less than a detection limit at the crystal grain boundary, and a diffraction spot is present in an electron diffraction pattern of a portion where Ba is detected.
    Type: Grant
    Filed: June 26, 2018
    Date of Patent: July 9, 2019
    Assignee: NGK SPARK PLUG CO., LTD.
    Inventors: Hideto Yamada, Haruki Yoshida, Kuniharu Tanaka, Michitaka Yamada, Yusuke Nomura
  • Patent number: 9663407
    Abstract: The present invention provides a silicon nitride wear resistant member comprising a silicon nitride sintered compact containing ?-Si3N4 crystal grains as a main component, 2 to 4% by mass of a rare earth element in terms of oxide, 2 to 6% by mass of Al in terms of oxide, and 0.1 to 5% by mass of Hf in terms of oxide, wherein the silicon nitride sintered compact has rare earth-Hf—O compound crystals; in an arbitrary section, an area ratio of the rare earth-Hf—O compound crystals in a grain boundary phase per unit area of 30 ?m×30 ?m is 5 to 50%; and variation of the area ratios of the rare earth-Hf—O compound crystals between the unit areas is 10% or less. Due to above structure, there can be provided a wear resistant member comprising the silicon nitride sintered compact having an excellent wear resistance and processability.
    Type: Grant
    Filed: June 11, 2014
    Date of Patent: May 30, 2017
    Assignees: Kabushiki Kaisha Toshiba, Toshiba Materials Co., Ltd.
    Inventor: Haruhiko Yamaguti
  • Patent number: 9334193
    Abstract: A wear resistant member formed of ceramic sintered body mainly composed of silicon nitride, the ceramic sintered body containing 10 to 3500 ppm of an Fe component in terms of Fe element, more than 1000 ppm to 2000 ppm of a Ca component in terms of Ca element, and 1 to 2000 ppm of a Mg component in terms of Mg element, wherein a ?-phase ratio of silicon nitride crystal grains is 95% or more, a maximum longer diameter of the silicon nitride crystal grains is 40 ?m or less, Ca component existing in grain boundary phase is not detected by XRD (X-ray Diffraction method), and each of dispersions in Vickers hardness, fracture toughness and density of the wear resistant member is within a range of ±10%. According to this structure, there can be obtained a wear resistant member comprising a ceramic sintered body improved in grinding-work property in addition to an excellent wear resistant property.
    Type: Grant
    Filed: February 10, 2011
    Date of Patent: May 10, 2016
    Assignees: KABUSHIKI KAISHA TOSHIBA, TOSHIBA MATERIALS CO., LTD.
    Inventor: Minoru Takao
  • Publication number: 20150093540
    Abstract: There is disclosed a porous material. The porous material contains aggregates, and a bonding material which bonds the aggregates to one another in a state where pores are formed among the aggregates, the bonding material contains crystalline cordierite, the bonding material further contains a rare earth element or a zirconium element, and a ratio of a mass of the bonding material to a total mass of the aggregates and the bonding material is from 12 to 45 mass %. The bonding material preferably contains, in the whole bonding material, 8.0 to 15.0 mass % of MgO, 30.0 to 60.0 mass % of Al2O3, 30.0 to 55.0 mass % of SiO2, and 1.5 to 10.0 mass % of a rare earth oxide or zirconium oxide.
    Type: Application
    Filed: September 5, 2014
    Publication date: April 2, 2015
    Inventors: Shuichi ICHIKAWA, Atsushi MIZUNO
  • Patent number: 8920868
    Abstract: A process for preparing a ceramic body having a surface roughness, said process comprising the step of depositing particles of a ceramic material on the surface of a ceramic basic body. The process is characterized in that separate agglomerates comprising at least two particles and a binder binding the particles together are deposited on the surface of the basic body by projecting the agglomerates towards the basic body.
    Type: Grant
    Filed: October 29, 2010
    Date of Patent: December 30, 2014
    Assignee: Straumann Holding AG
    Inventor: Marc Stephan
  • Publication number: 20140370232
    Abstract: There is disclosed a porous material containing aggregates; and a composite binding material which binds the aggregates to one another in a state where pores are formed and in which mullite particles that are reinforcing particles are dispersed in cordierite that is a binding material, and a content of metal silicon is smaller than 15 mass %. Preferably, to a total mass of the aggregates, the composite binding material and the metal silicon, a lower limit value of a content of the composite binding material is 12 mass %, and an upper limit value of the content of the composite binding material is 50 mass %. Preferably, to the total mass, a lower limit value of a content of the mullite particles is 0.5 mass %, and an upper limit value of the content of the mullite particles is 15 mass %. A porous material having a high thermal shock resistance is provided.
    Type: Application
    Filed: September 4, 2014
    Publication date: December 18, 2014
    Inventors: Yunie IZUMI, Yoshimasa KOBAYASHI
  • Patent number: 8772190
    Abstract: The invention concerns a sintered ceramic component of silicon nitride or sialon suitable as rolling element in a bearing and a manufacturing method for making such ceramic components. The ceramic component has high density and a homogeneous and fine microstructure, giving the component excellent mechanical properties. Manufacturing of the sintered ceramic component by SPS is cost-effective and rapid.
    Type: Grant
    Filed: August 29, 2008
    Date of Patent: July 8, 2014
    Assignee: AB SKF
    Inventors: Zhijian Shen, Saeid Esmaeilzadeh, Katarina Flodstrom, Charlotte Vieillard
  • Patent number: 8741797
    Abstract: A composite article having a body including a first phase that includes a nitride material, a second phase that includes a carbide material, and a third phase having one of an amorphous phase material with a nitrogen content of at least about 1.6 wt % or an amorphous phase material comprising carbon.
    Type: Grant
    Filed: September 27, 2012
    Date of Patent: June 3, 2014
    Assignee: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Christopher J. Reilly, Vimal K. Pujari, Edmund A. Cortellini, David M. McElwee
  • Patent number: 8673795
    Abstract: A silicon nitride material is disclosed which has properties necessary for efficient operation of a corona discharge igniter system in an internal combustion gas engine allowing an increase in fuel efficiency of over 10%. The material is disclosed in a range of compositions, all of which exhibit high dielectric strengths, high mechanical strength, thermal shock resistance and fracture toughness, low dielectric constant and loss tangent and electrical resistivity, all of which significantly increase the efficiency of the igniter system over current state of the art alumina insulators. Moreover, the materials retain their dielectric strength and structural integrity at elevated temperatures, up to 800° C.-1000° C. One embodiment comprises a sintered silicon nitride process comprising powder batching, binder removal and sintering. In the preferred embodiment the method of manufacture for silicon nitride is an SRBSN process comprising powder batching, powder pressing, binder removal, nitriding and sintering.
    Type: Grant
    Filed: December 16, 2011
    Date of Patent: March 18, 2014
    Assignee: Ceradyne, Inc.
    Inventor: Biljana Mikijelj
  • Patent number: 8652981
    Abstract: Silicon nitride materials with high strength, fracture toughness values, and Weibull moduli simultaneously, due to unique large grain reinforcing microstructures and well engineered grain boundary compositions. The invention demonstrates that, surprisingly and contrary to prior art, a silicon nitride material can be made which simultaneously has high strength above about 850-900 MPa, a Weibull above about 15 and high fracture toughness (above about 8 and 9 MPa·m1/2), and has reinforcing grains longer than 5 ?m, typically longer than 10 ?m in the microstructure without compromising its properties and reliability. The product of this invention can be processed using a variety of densification methods, including gas-pressure sintering, hot pressing, hot isostatic pressing, but is not limited to these, and does not require multiple heat treatments for all of these features to be achieved.
    Type: Grant
    Filed: January 21, 2010
    Date of Patent: February 18, 2014
    Assignee: Ceradyne, Inc.
    Inventor: Biljana Mikijelj
  • Patent number: 8586493
    Abstract: A silicon nitride sintered body, wherein in a silicon nitride substrate consisting of crystal grains of ?-type silicon nitride and a grain boundary phase containing at least one type of rare earth element (RE), magnesium (Mg) and silicon (Si), the grain boundary phase consists of an amorphous phase and a MgSiN2 crystal phase. The X-ray diffraction peak intensity of any crystal plane of a crystal phase containing the rare earth element (RE) is less than 0.0005 times the sum of the diffraction peak intensities of (110), (200), (101), (210), (201), (310), (320) and (002) of the crystal grains of the ?-type silicon nitride; and the X-ray diffraction peak intensity of (121) of the MgSiN2 crystal phase is 0.0005 to 0.003 times the sum of the X-ray diffraction peak intensities of (110), (200), (101), (210), (201), (310), (320) and (002) of the crystal grains of the ?-type silicon nitride.
    Type: Grant
    Filed: July 3, 2009
    Date of Patent: November 19, 2013
    Assignee: Hitachi Metals, Ltd.
    Inventors: Youichirou Kaga, Junichi Watanabe
  • Patent number: 8579513
    Abstract: A sliding member includes a silicon nitride sintered compact containing a rare earth element of 7 to 18 mass % in terms of oxide and at least one element M selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W of 0.1 to 3 mass % in terms of oxide, and having a total content of impurity positive ion elements of 0.3 mass % or less and a thermal conductivity of 60 W/m·K or higher. The silicon nitride sintered compact includes silicon nitride crystal grains and a grain boundary phase, and has a ratio of crystalline compound phases in the grain boundary phase of 20% or more in area ratio, and an average grain size of the crystalline compound phases of 0.5 ?m or less. The sliding member is used, for example, as a bearing ball 2.
    Type: Grant
    Filed: July 25, 2007
    Date of Patent: November 12, 2013
    Assignees: Kabushiki Kaisha Toshiba, Toshiba Materials Co., Ltd.
    Inventor: Minoru Takao
  • Patent number: 8496718
    Abstract: A silicon nitride cutting tool comprising a sintered product is disclosed. The sintered product comprises silicon nitride, at least one rare earth element compound, and a magnesium compound. The silicon nitride cutting tool further comprises a surface region and an inside region comprising the sintered product with varying content ratios of component compounds to provide enhanced wear and fracture resistance.
    Type: Grant
    Filed: March 25, 2009
    Date of Patent: July 30, 2013
    Assignee: Kyocera Corporation
    Inventors: Takashi Watanabe, Tatsuyuki Nakaoka, Takero Fukudome, Shuichi Tateno, Hiroshi Yoshimitsu
  • Patent number: 8492300
    Abstract: An insert includes a silicon nitride sintered body including ?-Si3N4 as a main component, Mg, and a rare-earth element Re (Y, La, Ce, Er, Dy, Yb). A content of Mg in terms of MgO is 1.0-7.0 mol %, a content of Re in terms of an oxide thereof is 0.4-1.0 mol %, and a total content of Mg and Re is from 1.7 to less than 7.5 mol %. The insert has a graded composition in which oxygen content increases from a surface of the sintered body toward an inside thereof such that 0.8-1.5 mass % of oxygen is contained in a region of less than 0.5 mm inside from the surface, 1.1-2.3 mass % of oxygen is contained in a region of 0.5 mm or more inside from the surface, and a difference in oxygen content between the regions is 0.1-1.0 mass %.
    Type: Grant
    Filed: March 14, 2008
    Date of Patent: July 23, 2013
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Ryoji Toyoda, Yusuke Suzuki, Yuki Hatano
  • Patent number: 8377837
    Abstract: A wear resistant member formed of silicon nitride sintered body having a volume of 4000 mm3 or more, the silicon nitride sintered body containing 1 to 5 mass % of a rare earth component in terms of rare earth element, 1 to 6 mass % of an Al component in terms of Al element, 10 to 3500 ppm of an Fe component in terms of Fe element, and 10 to 1000 ppm of a Ca component in terms of Ca element, wherein a ?-phase ratio of silicon nitride crystal grains is 95% or more, a maximum longer diameter of the silicon nitride crystal grains is 40 ?m or less, and each of dispersions in Vickers hardness and fracture toughness of an inner portion of the wear resistant member is within a range of ±10%. According to this structure, the wear resistant member can be manufactured with a low cost, and there can be provided a wear resistant member comprising a silicon nitride sintered body excellent in reliability and the dispersion in characteristics is effectively suppressed.
    Type: Grant
    Filed: April 9, 2009
    Date of Patent: February 19, 2013
    Assignees: Kabushiki Kaisha Toshiba, Toshiba Materials Co., Ltd.
    Inventor: Minoru Takao
  • Patent number: 8354353
    Abstract: Composite materials composed of cubic boron nitride (cBN) and a matrix component of various ceramic oxides, nitrides, and solid solutions of matrix materials as well as whisker reinforcements. Methods of manufacture and their use in high performance machining of ferrous metals are also claimed and disclosed.
    Type: Grant
    Filed: September 17, 2009
    Date of Patent: January 15, 2013
    Assignee: Diamond Innovations, Inc.
    Inventors: Malik Abds-Sami, Stephen Dole
  • Patent number: 8133830
    Abstract: A silicon nitride sintered compact contains silicon nitride grains, and a sintering aid component in a range of 2 to 15 mass %. The silicon nitride grains include needle crystal grains each having a long diameter L of 10 ?m or less and a ratio (L/S) of the long diameter L to a short diameter S of 5 or more, by 50% or more in area ratio in a crystalline structure of the silicon nitride sintered compact. The silicon nitride sintered compact is used as a sliding member like a bearing ball (2).
    Type: Grant
    Filed: March 11, 2008
    Date of Patent: March 13, 2012
    Assignees: Kabushiki Kaisha Toshiba, Toshiba Materials Co., Ltd.
    Inventors: Minoru Takao, Michiyasu Komatsu
  • Patent number: 8071496
    Abstract: A silicon nitride-melilite composite sintered body in accordance with the invention includes silicon nitride and a melilite Me2Si3O3N4, where Me denotes a metal element combining with silicon nitride to generate the melilite. The silicon nitride-melilite composite sintered body contains Si in a range of 41 to 83 mole percent in Si3N4 equivalent and Me in a range of 13 to 50 mole percent in oxide equivalent. The silicon nitride-melilite composite sintered body has an average thermal expansion coefficient that is arbitrarily adjustable in a range of 2 to 6 ppm/K at temperatures of 23 to 150° C. The silicon nitride-melilite composite sintered body has a high Young's modulus, a high mechanical strength, and excellent sintering performance. A device used for inspection of semiconductor in accordance with the invention utilizes such a silicon nitride-melilite composite sintered body.
    Type: Grant
    Filed: November 11, 2009
    Date of Patent: December 6, 2011
    Assignee: NGK Spark Plug Co., Ltd.
    Inventors: Yasushi Hara, Tetsuya Maeda, Akifumi Tosa, Takenori Sawamura
  • Patent number: 8071495
    Abstract: A densified silicon nitride body can be formed using a lanthana-based sintering aid. The composition may exhibit properties that provide a material useful in a variety of applications that can benefit from improved wear characteristics. The composition may be densified by sintering and hot isostatic pressing.
    Type: Grant
    Filed: December 21, 2007
    Date of Patent: December 6, 2011
    Assignee: Ceramatec, Inc.
    Inventors: Vimal K. Pujari, William T. Collins
  • Publication number: 20110266719
    Abstract: The invention concerns a sintered ceramic component of silicon nitride or sialon suitable as rolling element in a bearing and a manufacturing method for making such ceramic components. The ceramic component has high density and a homogeneous and fine microstructure, giving the component excellent mechanical properties. Manufacturing of the sintered ceramic component by SPS is cost-effective and rapid.
    Type: Application
    Filed: August 29, 2008
    Publication date: November 3, 2011
    Applicant: AB SKF
    Inventors: Zhijian Shen, Saeid Esmaeilzadeh, Katarina Flodstrom, Charlotte Vieillard
  • Patent number: 7968484
    Abstract: A high-strength, fracture-resistant silicon nitride ceramic material that includes about 5 to about 75 wt-% of elongated reinforcing grains of beta-silicon nitride, about 20 to about 95 wt-% of fine grains of beta-silicon nitride, wherein the fine grains have a major axis of less than about 1 micron; and about 1 to about 15 wt-% of an amorphous intergranular phase comprising Si, N, O, a rare earth element and a secondary densification element. The elongated reinforcing grains have an aspect ratio of 2:1 or greater and a major axis measuring about 1 micron or greater. The elongated reinforcing grains are essentially isotropically oriented within the ceramic microstructure. The silicon nitride ceramic exhibits a room temperature flexure strength of 1,000 MPa or greater and a fracture toughness of 9 MPa-m(1/2) or greater. The silicon nitride ceramic exhibits a peak strength of 800 MPa or greater at 1200 degrees C.
    Type: Grant
    Filed: September 7, 2007
    Date of Patent: June 28, 2011
    Assignee: UT-Battelle, LLC
    Inventors: Paul F. Becher, Hua-Tay Lin
  • Patent number: 7964296
    Abstract: High-volume, fully dense, multi-component monoliths with microstructurally indistinguishable joints that can be used as refractory, corrosion and wear resistant components in the non-ferrous metal industry. The Si3N4 monoliths according to the invention comprise at least 90% by weight ?-type Si3N4 and up to 10% by weight of a predominantly amorphous binder phase, said binder phase being formed from compositions of the rare earth metal —Al—Si—O—N, rare earth metal —Mg—Si—O—N or Mg—Si—O—N systems. Preferably the rare earth metal is yttrium (Y). The monoliths have a volume of greater than 250 cm3. A method of making the multi-component monoliths is achieved by simultaneously joining and uniaxially hot pressing an assembly of reaction bonded silicon nitride bodies (RBSN bodies). RBSN bodies are placed in contact with each other in the substantial absence of any interlayer or ceramic paste in between.
    Type: Grant
    Filed: July 27, 2007
    Date of Patent: June 21, 2011
    Assignee: Ceradyne, Inc.
    Inventor: Biljana Mikijelj
  • Publication number: 20110117344
    Abstract: A coated material for a cutting tool can realize long life-time under severe cutting processing conditions such as high-speed processing, high-feed-rate processing, higher hardness of a material to be cut, cutting of a difficult-to-cut material, etc. In a coated material in which a coating is coated on the surface of a substrate, at least one layer of the coating is a hard film having a cubic metallic compound which includes at least one metal element M selected from Al, Si, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, and at least one element selected from C, N and O. An X-ray intensity distribution of an ? axis in a pole figure for a (111) plane of the hard film has a maximum intensity in an ? angle range of 75 to 90°, and an X-ray intensity distribution of an ? axis in a pole figure for a (220) plane of the hard film has a maximum intensity in an ? angle range of 75 to 90°.
    Type: Application
    Filed: July 13, 2009
    Publication date: May 19, 2011
    Applicant: TUNGALOY CORPORATION
    Inventors: Lu Chen, Mamoru Kohata
  • Publication number: 20110111205
    Abstract: Disclosed is a porous sintered reaction-bonded silicon nitride ceramic, which includes an array of sintered granules having fine pore channels in the sintered granules and coarse pore channels formed between the sintered granules, and in which the pore channel size is controlled so that both coarse pores and fine pores are formed together in the ceramic, thus simultaneously enhancing air permeability and capturing efficiency. A method of manufacturing the porous sintered reaction-bonded silicon nitride ceramic is also provided.
    Type: Application
    Filed: August 19, 2010
    Publication date: May 12, 2011
    Applicant: KOREA INSTITUTE OF MACHINERY & MATERIALS
    Inventors: Young Jo PARK, Boo Won Park, In Hyuck Song
  • Patent number: 7888277
    Abstract: A precursor of a ceramic adhesive suitable for use in a vacuum, thermal, and microgravity environment. The precursor of the ceramic adhesive includes a silicon-based, preceramic polymer and at least one ceramic powder selected from the group consisting of aluminum oxide, aluminum nitride, boron carbide, boron oxide, boron nitride, hafnium boride, hafnium carbide, hafnium oxide, lithium aluminate, molybdenum silicide, niobium carbide, niobium nitride, silicon boride, silicon carbide, silicon oxide, silicon nitride, tin oxide, tantalum boride, tantalum carbide, tantalum oxide, tantalum nitride, titanium boride, titanium carbide, titanium oxide, titanium nitride, yttrium oxide, zirconium boride, zirconium carbide, zirconium oxide, and zirconium silicate. Methods of forming the ceramic adhesive and of repairing a substrate in a vacuum and microgravity environment are also disclosed, as is a substrate repaired with the ceramic adhesive.
    Type: Grant
    Filed: November 18, 2009
    Date of Patent: February 15, 2011
    Assignee: COI Ceramics, Inc
    Inventors: James A. Riedell, Timothy E. Easler
  • Publication number: 20100304951
    Abstract: It is intended to provide a taphole mix capable of forming SiC bonds with minimum of an excess and a deficiency in components thereof, and excellent in drillability. A fine particle fraction having a particle diameter of 75 ?m or less is comprised of three components consisting of a silicon nitride-based material, a carbon-based material, and roseki, or comprised of the three component, and one or more selected from the group consisting of an alumina-based material, a silicon carbide-based material, a rare-earth element oxide-based material, clay, a high-purity silica-based material containing SiO2 in an amount of 80 mass % or more, a boron compound-based material in an amount of less than 0.3 mass % with respect to 100 mass % of the silicon nitride-based material, and a metal powder in an amount of less than 10 mass % with respect to 100 mass % of the carbon-based material.
    Type: Application
    Filed: October 18, 2007
    Publication date: December 2, 2010
    Applicant: KROSAKIHARIMA CORPORATION
    Inventor: Yutaka Kitazawa
  • Patent number: 7749931
    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: Grant
    Filed: February 13, 2007
    Date of Patent: July 6, 2010
    Assignees: FUJIFILM Corporation, Fujinon Corporation
    Inventors: Hideki Hyuga, Hideki Kita, Tetsuya Yamazaki, Yasunori Tanaka
  • Patent number: 7749932
    Abstract: A sintered product of silicon nitride includes a crystal phase mainly having silicon nitride crystal grains and an amorphous grain-boundary phase located on the grain boundaries of the silicon nitride crystal grains. The grain-boundary phase contains lanthanum, aluminum, magnesium, silicon, and oxygen. The sintered product described above contains 0.1% by mass or more of lanthanum on an oxide basis, 0.05 to 0.6% by mass of aluminum on an oxide basis, 0.3% by mass or more of magnesium on an oxide basis, and 2.5% by mass or less of oxygen. The total amount of lanthanum on an oxide basis, aluminum on an oxide basis, and magnesium on an oxide basis is 3.5% by mass or less.
    Type: Grant
    Filed: February 21, 2008
    Date of Patent: July 6, 2010
    Assignee: Kyocera Corporation
    Inventors: Takero Fukudome, Shuichi Tateno, Hiroshi Yoshimitsu, Takashi Watanabe, Tatsuyuki Nakaoka
  • Publication number: 20100054652
    Abstract: A silicon nitride sintered compact contains silicon nitride grains, and a sintering aid component in a range of 2 to 15 mass %. The silicon nitride grains include needle crystal grains each having a long diameter L of 10 ?m or less and a ratio (L/S) of the long diameter L to a short diameter S of 5 or more, by 50% or more in area ratio in a crystalline structure of the silicon nitride sintered compact. The silicon nitride sintered compact is used as a sliding member like a bearing ball (2).
    Type: Application
    Filed: March 11, 2008
    Publication date: March 4, 2010
    Inventors: Minoru Takao, Michiyasu Komatsu
  • Patent number: 7638200
    Abstract: A composition and method for fabricating high-density Ta—Al—O, Ta—Si—N, and W—Si—N sputtering targets, having particular usefulness for the sputtering of heater layers for ink jet printers. Compositions in accordance with the invention comprise a metal component, Si3N4, and a sintering aid so that the targets will successfully sputter without cracking, etc. The components are combined in powder form and pressure consolidated under heated conditions for a time sufficient to form a consolidated blend having an actual density of greater that about 95% of the theoretical density. The consolidated blend may then be machined so as to provide the final desired target shape.
    Type: Grant
    Filed: August 27, 2003
    Date of Patent: December 29, 2009
    Assignees: Tosoh SMD, Inc., Hewlett-Packard Company
    Inventors: David B. Smathers, Frank S. Valent, Michael J. Regan
  • Patent number: 7628878
    Abstract: A precursor of a ceramic adhesive suitable for use in a vacuum, thermal, and microgravity environment. The precursor of the ceramic adhesive includes a silicon-based, preceramic polymer and at least one ceramic powder selected from the group consisting of aluminum oxide, aluminum nitride, boron carbide, boron oxide, boron nitride, hafnium boride, hafnium carbide, hafnium oxide, lithium aluminate, molybdenum silicide, niobium carbide, niobium nitride, silicon boride, silicon carbide, silicon oxide, silicon nitride, tin oxide, tantalum boride, tantalum carbide, tantalum oxide, tantalum nitride, titanium boride, titanium carbide, titanium oxide, titanium nitride, yttrium oxide, zirconium diboride, zirconium carbide, zirconium oxide, and zirconium silicate. Methods of forming the ceramic adhesive and of repairing a substrate in a vacuum and microgravity environment are also disclosed, as is a substrate repaired with the ceramic adhesive.
    Type: Grant
    Filed: September 15, 2005
    Date of Patent: December 8, 2009
    Assignee: COI Ceramics, Inc.
    Inventors: James A. Riedell, Timothy E. Easler
  • Patent number: 7612006
    Abstract: To provide a sintered silicon nitride with conductivity and densification, an oxide of titanium group elements, such as titanium oxide, hafnium oxide, zirconium oxide and the like, aluminum oxide and/or aluminum nitride is added as needed to silicon nitride-oxidant of rare-earth elements-aluminum oxide system or silicon nitride-oxide of rare-earth elements-magnesia system, and then specified quantity of carbon nonotube (CNT) is added to the above mixture. CNT generates silicon carbide after the reaction with contiguous or proximal silicon nitride and the like depending on the sintering duration at high temperature. Since silicon carbide is generated along with nanotubes, the silicon carbide functions as conductor with excellent heat resistance, corrosion resistance and the like.
    Type: Grant
    Filed: September 27, 2005
    Date of Patent: November 3, 2009
    Assignee: Yokohama TLO Company, Ltd.
    Inventors: Katsutoshi Komeya, Junichi Tatami, Takeshi Meguro, Tomofumi Katashima, Toru Wakihara
  • Patent number: 7588628
    Abstract: The present invention provides methods for making a microporous ceramic material using a metal silicon powder and including a reaction sintering process of the silicon. A material for forming a microporous ceramic material used in these methods includes a metal silicon powder, a silicon nitride powder and/or a silicon carbide powder, and if desired, a yttrium oxide powder and/or an aluminum oxide powder. These methods can make a microporous ceramic material that can be used preferably as a gas or liquid filter, a catalyst carrier or a support of a gas separation membrane.
    Type: Grant
    Filed: October 10, 2007
    Date of Patent: September 15, 2009
    Assignees: Noritake Co., Limited, Chubu Electric Power Co., Inc.
    Inventors: Yasunori Ando, Seiji Yamada, Hisatomi Taguchi, Yosuke Takahashi, Shigeo Nagaya, Kiyoshi Komura
  • Patent number: 7521388
    Abstract: A silicon nitride abrasion resistant member is formed of silicon nitride sintered body containing 2% to 4% by mass of a rare earth element in terms of oxide thereof as a sintering aid, 2% to 6% by mass of an Al component in terms of oxide thereof, and 2% to 7% by mass of silicon carbide. The silicon nitride sintered body has a porosity of 1% or less, a three-point bending strength of 800 to 1000 MPa, and a fracture toughness of 5.7 to 6.5 MPa·m1/2. According to this structure, even when an inexpensive silicon nitride powder manufactured by metal nitriding method is used, there can be provided a silicon nitride abrasion resistant member having a mechanical strength, high abrasion resistance, and a rolling life, equal to or higher than those of conventional silicon nitride sintered bodies, and excellent workability, and a method for manufacturing the member can be provided.
    Type: Grant
    Filed: September 27, 2004
    Date of Patent: April 21, 2009
    Assignees: Kabushiki Kaisha Toshiba, Toshiba Materials Co., Ltd.
    Inventors: Michiyasu Komatsu, Minoru Takao
  • Patent number: 7498284
    Abstract: A nitride glass with the general formula ?x?y?z is provided wherein ? is a glass modifier comprising at least one electropositive element. ? comprises Si, B, Ge, a and/or Al. ? is N or N together with O, whereby the atomic ratio of O:N is in the interval from 65:35 to 0:100.
    Type: Grant
    Filed: January 14, 2004
    Date of Patent: March 3, 2009
    Assignee: Diamorph AB
    Inventor: Saeid Esmaeilzadeh
  • Patent number: 7494949
    Abstract: A silicon nitride-bonded SiC refractory is provided, which includes SiC as a main phase and Si3N4 and/or Si2N2O as a secondary phase and which has a bending strength of 150 to 300 MPa and a bulk density of 2.6 to 2.9. A method for producing a silicon nitride-bonded SiC refractory is also provided, which comprises a step of mixing 30 to 70% by mass of a SiC powder of 30 to 300 ?m as an aggregate, 10 to 50% by mass of a SiC powder of 0.05 to 30 ?m, 10 to 30% by mass of a Si powder of 0.05 to 30 ?m, and 0.1 to 3% by mass, in terms of oxide, of at least one member selected from the group consisting of Al, Ca, Fe, Ti, Zr and Mg.
    Type: Grant
    Filed: July 23, 2004
    Date of Patent: February 24, 2009
    Assignees: NGK Insulators, Ltd., NGK Adrec Co., Ltd.
    Inventors: Toshiharu Kinoshita, Tsuneo Komiyama
  • Publication number: 20090029843
    Abstract: High-volume, fully dense, multi-component monoliths with microstructurally indistinguishable joints that can be used as refractory, corrosion and wear resistant components in the non-ferrous metal industry. The Si3N4 monoliths according to the invention comprise at least 90% by weight ?-type Si3N4 and up to 10% by weight of a predominantly amorphous binder phase, said binder phase being formed from compositions of the rare earth metal —Al—Si—O—N, rare earth metal —Mg—Si—O—N or Mg—Si—O—N systems. Preferably the rare earth metal is yttrium (Y). The monoliths have a volume of greater than 250 cm3. A method of making the multi-component monoliths is achieved by simultaneously joining and uniaxially hot pressing an assembly of reaction bonded silicon nitride bodies (RBSN bodies). RBSN bodies are placed in contact with each other in the substantial absence of any interlayer or ceramic paste in between.
    Type: Application
    Filed: July 27, 2007
    Publication date: January 29, 2009
    Inventor: Biljana Mikijelj
  • Patent number: 7402541
    Abstract: The present invention provides silicon nitride with tungsten carbide additives in a sinterable material comprising silicon nitride and tungsten carbide, in which the silicon nitride content is a minimum of about 80% and wherein the total nitride component is about 28-40 w/w % N2, and further comprising about 1.5-3.5 w/w % Al, about 2-6 w/w % Y, about 1.5-7 w/w % W, and about 3-9 w/w % O2. which after sintering will produce ceramic bodies with a high degree of toughness suitable for armor applications.
    Type: Grant
    Filed: March 16, 2006
    Date of Patent: July 22, 2008
    Inventor: Michael Cohen
  • Patent number: 7375046
    Abstract: A yttria sintered body is provided which includes yttria as a principal ingredient and 5 to 40 vol. % silicon nitride, and which exhibits enhanced corrosion resistance and mechanical strength.
    Type: Grant
    Filed: February 14, 2006
    Date of Patent: May 20, 2008
    Assignee: NGK Insulators, Ltd.
    Inventors: Yasufumi Aihara, Hiroto Matsuda
  • Patent number: 7294596
    Abstract: A sintered ceramic material comprises a crystalline phase and an intergranular phase comprising a glass phase. The material is manufactured from a starting powder being mixed with an additive comprising one or more metal from a group of Li, Na, Mg, Ca, Sr, Ba, Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Th, Pa or U. The additive is in non oxide form, or in a form which transforms to a metal or nitride during a synthesis in nitrogen atmosphere and the resulting glass phase having a high nitrogen content with a N:O ratio higher than 35:65 and a glass transition temperature above 950° C.
    Type: Grant
    Filed: March 14, 2005
    Date of Patent: November 13, 2007
    Assignee: Diamorph Ceramic AB
    Inventor: Saeid Esmaeilzadeh
  • Patent number: 7244376
    Abstract: In hexaboride particles having particles of a hexaboride of at least one element (X) selected from Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Sr and Ca, or a dispersion of such particles, the surfaces of the hexaboride particles have physically been coated with a surface treatment agent containing silicon, selected from a silazane type treatment agent, a chlorosilane type treatment agent, an inorganic treatment agent having at least one alkoxyl group in the molecular structure, and an organic treatment agent having at least one alkoxyl group at a molecular terminal or in the side chain, or have been coated with the surface treatment agent, having chemically combined with hexaboride particles on the surfaces of the hexaboride particles.
    Type: Grant
    Filed: January 26, 2004
    Date of Patent: July 17, 2007
    Assignee: Sumitomo Metal Mining Co., Ltd.
    Inventor: Hiromitsu Takeda
  • Patent number: 7244686
    Abstract: The present invention is directed to bearings produced from a silicon nitride material. The silicon nitride material consists of a sintering aid selected from the group consisting of Al2O3 and Y2O3, silicon dioxide, and optionally, up to 10 mole %, based on the amount of silicon nitride, of an additive that reacts with silicon nitride, said additive selected from the group consisting of TiO2, WO3, MoO3 and mixtures thereof.
    Type: Grant
    Filed: October 19, 2006
    Date of Patent: July 17, 2007
    Assignee: H.C. Starck Ceramics GmbH & Co. KG
    Inventors: Gerhard Wötting, Mathias Herrmann, Grit Michael, Stefan Siegel, Lutz Frassek
  • Patent number: 7192899
    Abstract: A silicon nitride sintered body exhibiting a high heat conductivity, the silicon nitride sintered body includes a rare earth element in an amount of 2 to 17.5 mass % in terms of the oxide thereof, Fe in an amount of 0.07 to 0.5 mass % in terms of the oxide thereof, Ca in an amount of 0.07 to 0.5 mass % in terms of the oxide thereof, Al in an amount of 0.1 to 0.6 mass % in terms of the oxide thereof, Mg in an amount of 0.3 to 4 mass % in terms of the oxide thereof, and Hf in an amount not larger than 5 mass % (including 0 mass %) in terms of the oxide thereof.
    Type: Grant
    Filed: February 9, 2006
    Date of Patent: March 20, 2007
    Assignees: Kabushiki Kaisha Toshiba, Toshiba Materials Co., Ltd.
    Inventor: Michiyasu Komatsu
  • Patent number: 7157394
    Abstract: A silicon nitride based ceramic, that is highly effective for use as a cutting tool for the high speed machining of cast irons, that is essentially a homogeneous mixture consisting of both crystalline and whisker forms of beta silicon nitride that are interstitially bonded by a stoichiometrically balanced glass mixture of magnesia, silica, yttria and zirconia, where the ratios of each have been controlled to increase the eutectic point and refractoriness of the mixed glass.
    Type: Grant
    Filed: July 17, 2004
    Date of Patent: January 2, 2007
    Inventor: James Hugo Adams, Sr.
  • Patent number: 7129191
    Abstract: The present invention consists of a synergistic mixture of Si3N4, Al2O3, AlN, SiO2 and Nd2O3. The cost effective synergistic composition is useful for the preparation of dense neodymium stabilised ?-Si3N4-?-SiAlON composite of the order of >98% theoretical density, having high hardness and high fracture toughness. The dense ?-Si3N4-?-SiAlON composite will be useful for low temperature applications as wear parts like bearing and roller materials and particularly for grinding and milling operations like grinding balls.
    Type: Grant
    Filed: October 27, 2004
    Date of Patent: October 31, 2006
    Assignee: Council of Scientific and Industrial Research
    Inventors: Siddhartha Bandyopadhyay, Himadri Sekhar Maity
  • Patent number: 7109139
    Abstract: The present invention provides a process for the manufacture of dense neodymium stabilized ?-Si3N4-?-SiAlON composite, wherein a synergistic composition essentially consisting of Si3N4, Al2O3, AlN, SiO2 and Nd2O3 as starting materials is mixed in proportion to make a total of 100 mole in the mixed batch, passing the powder through 100 mesh, pressing the powder to form green compacts, sintering the green compacts at a temperature in the range of 1700° to 1900° C. in nitrogen atmosphere. The process of the present invention provides neodymium stabilized ?-Si3N4-?-SiAlON composites by processing a composition from the system Si3N4—Al2O3.AlN—Nd2O3.9AlN—SiO2 resulting into dense product of the order of >98% theoretical density with the advantages such as cost effectiveness, high hardness and high fracture toughness.
    Type: Grant
    Filed: October 27, 2004
    Date of Patent: September 19, 2006
    Assignee: Council of Scientific and Industrial Research
    Inventors: Siddhartha Bandyopadhyay, Himadri Sekhar Maity
  • Patent number: 7056850
    Abstract: The present invention provides a wear resistant member composed of silicon nitride sintered body containing 2–10 mass % of rare earth element in terms of oxide thereof as sintering agent, 2–7 mass % of MgAl2O4 spinel, 1–10 mass % of silicon carbide, and 5 mass % or less of at least one element selected from the group consisting of Ti, Zr, Hf, W, Mo, Ta, Nb and Cr in terms of oxide thereof, wherein a porosity of said silicon nitride sintered body is 1 vol. % or less, a three-point bending strength is 900 MPa or more, and a fracture toughness is 6.3 MPa·m1/2 or more. According to the above structure of the present invention, there can be provided a silicon nitride wear resistant member and a method of manufacturing the member having a high strength and a toughness property, and particularly excellent in rolling and sliding characteristics.
    Type: Grant
    Filed: July 23, 2002
    Date of Patent: June 6, 2006
    Assignee: Kabushiki Kaisha Toshiba
    Inventor: Michiyasu Komatsu
  • Patent number: 7041366
    Abstract: The invention provides porous silicon nitride ceramics that having uniform, fine closed pores and a manufacturing method thereof. Metal Si powder is mixed with a sintering additive, followed by thermal treatment, which is a pre-process for forming a specific grain boundary phase. Two-stage thermal treatment is thereafter performed by microwave heating at a temperature of 1000° C. or more. The metal Si powder is thereafter subjected to a nitriding reaction from its surface, the metal Si is thereafter diffused to nitride formed on the outer shell thereof such that porous silicon nitride ceramics having uniform, fine closed pores can be produced. Having a high ratio of closed pores and being superior in electrical/mechanical characteristics, the porous silicon nitride ceramics can display excellent characteristics if used, for example, for an electronic circuit board that requires an anti-hygroscopicity, a low dielectric constant, a low dielectric loss, and mechanical strength.
    Type: Grant
    Filed: March 22, 2002
    Date of Patent: May 9, 2006
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Michimasa Miyanaga, Osamu Komura
  • Patent number: 6977233
    Abstract: Sintered silicon nitride products comprising predominantly ?-silicon nitride grains in combination with from about 0.1 to 30 mole % silicon carbide, and grain boundary secondary phases of scandium oxide and scandium disilicate. Such products have high fracture toughness, resistance to recession, and resistance to oxidation at temperatures of at least 1500° C. Methods for preparing sintered silicon nitride products are also disclosed.
    Type: Grant
    Filed: July 15, 2003
    Date of Patent: December 20, 2005
    Assignee: Honeywell International, Inc.
    Inventors: Chien-Wei Li, Bjoern Schenk, James V. Guiheen