Elemental Carbon Containing Patents (Class 501/99)
  • Patent number: 6846763
    Abstract: A refractory repair batch material includes a refractory, in particular a basic resistor component in granule form and a binder system. The binder system contains at least one hard bitumen component in granule form, at least one ignitable metal powder and at least one combustible mineral oil.
    Type: Grant
    Filed: November 18, 2003
    Date of Patent: January 25, 2005
    Assignee: Refratechnik Holding GmbH
    Inventors: Helge Jansen, Heinrich Grosse Daldrup
  • Patent number: 6844281
    Abstract: A preform for use in a metal matrix composite, particularly for a magnesium metal composite. In the preform the reinforcing material typically is silicon carbide, boron nitride, titanium nitride, carbon or graphite. The binder used in the preform is sintered magnesium fluoride, which avoids the known problems which result from the high reactivity of molten magnesium metal with other binders, such as silica and alumina, which results in the formation of magnesium oxide in the reinforced composite. The presence of magnesium oxide crystals in the metal matrix adversely affects the properties of the composite. The preform generally has a void volume of from about 50% to about 95%.
    Type: Grant
    Filed: November 18, 2002
    Date of Patent: January 18, 2005
    Assignee: Her Majesty the Queen in right of Canada, as represented by the Minister of Natural Resources
    Inventors: Jason S. H. Lo, Areekattuthazhayil K. Kuriakose, Raul Santos
  • Publication number: 20040248723
    Abstract: A ceramic component is disclosed, including a sintered ceramic body from a composition comprising a first ceramic material, and a plurality of inclusions in the ceramic body, each inclusion comprising graphite and a second ceramic material.
    Type: Application
    Filed: June 4, 2003
    Publication date: December 9, 2004
    Applicant: Saint-Gobain Ceramics & Plastics, Inc.
    Inventors: Vimal Pujari, Jeffrey J. Kutsch
  • Patent number: 6821919
    Abstract: A nanocomposite having titanium aluminum carbon nitride and amorphous carbon is disclosed, and the nanocomposite comprises a titanium aluminum carbon nitride grain of nanometer scale and an amorphous carbon matrix, wherein the titanium aluminum carbon nitride grain of nanometer scale is embedded into the amorphous carbon matrix. The method for coating the nanocomposite of titanium aluminum carbon nitride-amorphous carbon on a substrate comprises: depositing the substrate in a reaction chamber; and igniting plasma to clean and remove an oxide layer and adsorptive on the substrate; injecting a reaction gas. The reaction gas is activated and thermal decomposed by plasma to form the nanocomposite coating layer of titanium aluminum carbon nitride-amorphous carbon on the surface of the substrate.
    Type: Grant
    Filed: November 27, 2002
    Date of Patent: November 23, 2004
    Assignee: National Cheng Kung University
    Inventors: Ming-Hsiung Hon, Jiann Shieh
  • Publication number: 20040207133
    Abstract: A carbon fiber-carbon matrix reinforced ceramic composite comprises a carbon fiber-carbon matrix reinforcement embedded within a ceramic matrix. The ceramic matrix does not penetrate into the carbon fiber-carbon matrix reinforcement to any significant degree. The carbide matrix is a formed in situ solid carbide of at least one metal having a melting point above about 1850 degrees centigrade. At least when the composite is intended to operate between approximately 1500 and 2000 degrees centigrade for extended periods of time the solid carbide with the embedded reinforcement is formed first by reaction infiltration. Molten silicon is then diffused into the carbide. The molten silicon diffuses preferentially into the carbide matrix but not to any significant degree into the carbon-carbon reinforcement.
    Type: Application
    Filed: April 15, 2004
    Publication date: October 21, 2004
    Inventors: Brian Williams, Robert Benander
  • Patent number: 6803108
    Abstract: Carbon fiber bundles may be dispersed into substantially single mono-filaments in pitch by stirring a mixture of fibers and pitch at a temperature at which the pitch has a viscosity of about 0.1 to about 5 poise. The resulting fiber pitch binder contains about 0.5 to about 10.0 wt. % carbon fibers substantially dispersed as substantially single mono-filaments which are randomly oriented which may then be used directly as a binder for producing carbon bodies, for example, graphite electrodes, pinstock or specialty graphite articles. This unique binder using an economical amount of carbon fibers has the capacity to increase the strength and reduce the coefficients of thermal expansion of the resulting carbon products in more than one direction due to the random orientation of the carbon fibers.
    Type: Grant
    Filed: February 11, 2002
    Date of Patent: October 12, 2004
    Assignee: UCAR Carbon Company Inc.
    Inventors: Irwin C. Lewis, Terrence A. Pirro
  • Publication number: 20040172885
    Abstract: An ultra-hard semiconductive polycrystalline diamond (PCD) material formed with semiconductive diamond particles doped with and additive, as for example, Li, Be or Al and/or insulative diamond particles having semiconductive surfaces, tools incorporating the same, and methods for forming the same, are provided. The ultra-hard PCD material may be formed using a layer of insulative diamond grit feedstock that includes additives therein, then sintering to convert a plurality of the diamond crystals to include a semiconductive surface. In another embodiment, the ultra-hard PCD material is formed by sintering semiconductive diamond grit feedstock consisting of diamond crystals doped with an additive as for example Li, Al or Be. The ultra-hard semiconductive PCD cutting layer exhibits increased cuttability, especially in EDM and EDG cutting operations. A cutting element is provided having such a PCD layer. Furthermore, a bit is provided having a cutting element having such a PCD layer.
    Type: Application
    Filed: March 19, 2004
    Publication date: September 9, 2004
    Inventor: Stewart Middlemiss
  • Patent number: 6787494
    Abstract: An molded product of activated carbon produced by molding a kneaded mixture containing an activated carbon, a solvent, and a phenol-aldehyde type resin being solid in a normal temperature and containing 50 to 95% by weight of components soluble in the solvent used, drying and curing the molding, and then carbonizing the molding in an inert gas has a high adsorption capability and a high mechanical strength, e.g., a compressive strength, especially the strength after being contacted with an acid or water.
    Type: Grant
    Filed: January 16, 2002
    Date of Patent: September 7, 2004
    Assignee: Japan EnviroChemicals, Ltd.
    Inventors: Masanori Tsuji, Masaaki Kameno, Keizo Furukawa
  • Patent number: 6770583
    Abstract: A transition metal-containing ceramic made by the process comprising the step of pyrolyzing an organometallic linear polymer containing at least one metallocenylene unit, at least one silyl or siloxyl unit, and at least one acetylene unit to form a ceramic; where the ceramic has a ceramic yield of at least about 75% by weight. A transition metal-containing ceramic made by the process comprising the steps of: forming an organometallic linear polymer containing at least one metallocenylene, at least one silyl or siloxyl unit, and at least one acetylene unit; crosslinking said linear polymer through the acetylene units, thereby forming a thermoset; and pyrolyzing said thermoset to form a ceramic; where the ceramic has a ceramic yield of at least about 75% by weight.
    Type: Grant
    Filed: November 4, 2002
    Date of Patent: August 3, 2004
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: Teddy M. Keller
  • Publication number: 20040106508
    Abstract: A ceramic-containing disperse substance is proposed, having a ceramic component, a solvent and a dispersing agent, the ceramic component being present at least largely in the form of primary particles having an average particle size of 5 nm to 50 nm. The ceramic component in the material further has a specific surface of 20 m2/g to 120 m2/g. Besides that, a method for producing this disperse substance is proposed, the ceramic starting component being submitted to a preparation step together with the dispersing agent and the solvent, by which the average particle size of the ceramic starting powder is reduced, so that the ceramic-containing disperse substance is created. The proposed disperse substance is suitable, together with an additionally added binding agent and a plasticizer, especially for use in thick-film pastes such as the ones used in screen-printing methods or for the production of ceramics fired in a post-firing method.
    Type: Application
    Filed: November 6, 2002
    Publication date: June 3, 2004
    Inventors: Gerd Scheying, Ingrid Wuehrl, Petra Kuschel
  • Publication number: 20040106509
    Abstract: Refractories obtained by molding a refractory raw material composition containing a refractory raw material including graphite grains having an average grain size of 500 nm or less or a refractory raw material including graphite grains obtained by graphitizing carbon black and a refractory filler. Or refractories containing carbonaceous grains (A) selected from carbon black or graphite grains obtained by graphitizing carbon black and having a DBP absorption (x) of 80 ml/100 g or more, carbonaceous grains (B) selected from carbon black and graphite grains obtained by graphitizing carbon black and having a DBP absorption (x) of less than 80 ml/100 g, and a refractory filler. Refractories excellent in corrosion resistance, oxidation resistance and thermal shock resistance, especially carbon-contained refractories having a low carbon content are thereby provided.
    Type: Application
    Filed: September 8, 2003
    Publication date: June 3, 2004
    Inventors: Tsunemi Ochiai, Shigeyuki Takanaga
  • Publication number: 20040102306
    Abstract: The invention relates to a refractory repair batch material, which includes a refractory, in particular basic resistor component in granule form and a binder system, the binder system containing at least one hard bitumen component in granule form, at least one ignitable metal powder and at least one combustible mineral oil.
    Type: Application
    Filed: November 18, 2003
    Publication date: May 27, 2004
    Inventors: Helge Jansen, Heinrich Grosse Daldrup
  • Publication number: 20040097360
    Abstract: A fiber-reinforced composite ceramic has a matrix containing SiC and/or Si with a density of greater than 2.5 g/cm3 and an elongation at break of more than 0.3%. A method for fabricating the composite ceramic includes producing a blend containing carbon fibers, carbonizable bonding resin and additional carbon material which has a raw density in a range between 0.7 and 1.8 g/cm3, pressing the blend into a fiber-reinforced green body, carbonizing the green body in order to produce a C/C body, and infiltrating the C/C body with a silicon melt. The fabricated composite ceramic is used as a lining material or armor plating, or for producing reflective surfaces.
    Type: Application
    Filed: September 15, 2003
    Publication date: May 20, 2004
    Inventors: Bodo Benitsch, Udo Gruber, Oswin Ottinger, Eugen Pfitzmaier
  • Publication number: 20040076810
    Abstract: A composite high temperature insulator (A) includes a planar layer (10) having anisotropic thermal conductivity properties. A second planar layer (12) is formed from a rigid insulation material, such as a carbonized mixture of carbon fibers and a binder. The second layer is coextensive with the first layer and is preferably bonded thereto by a carbonaceous cement (44). When used to insulate a heat source, such as a furnace (50), convective heat is directed back to the source by the reflective surface (16) of the inner, anisotropic layer (10). Heat which enters the anisotropic layer is dissipated evenly through the plane of the layer along a plurality of heat paths defined by a plurality of layers (14) of flexible graphite. Accordingly, heat which reaches the outer, second layer (12) results in fewer hot spots than occur with a conventional rigid insulation material, thereby reducing the total amount of insulation material required to achieve a desired level of thermal insulation.
    Type: Application
    Filed: October 17, 2002
    Publication date: April 22, 2004
    Applicant: UCAR Carbon Company Inc.
    Inventors: David P. Blain, Robert E. Smith
  • Patent number: 6716800
    Abstract: A composite body of silicon carbide having binderless, allotropic carbon granules distributed throughout is produced. The nominal size of the binderless allotropic carbon granules can range from 5 to 500 micrometers. The concentration of the binderless allotropic carbon particles can vary from 1.0 to 35.0 weight percent. The process to produce such a composite body is to sinter silicon carbide with binderless, carbon-yielding precursor granules. The composite body is utilized in tribological applications. The dense, impervious silicon carbide-binderless carbon composite exhibits excellent physical and tribological characteristics when used as a mechanical face seal, a sliding bearing arrangement, or some other rubbing component.
    Type: Grant
    Filed: April 12, 2002
    Date of Patent: April 6, 2004
    Assignee: John Crane Inc.
    Inventors: Joseph F. Demendi, Xin Chen, William R. Clemens
  • Patent number: 6709999
    Abstract: A molded part of a ceramic material derived from polymers includes a composite body of a single-phase or multi-phase, amorphous, partially crystalline or crystalline matrix of silicon carbide (SiC), silicon nitride (Si3N4), silicon dioxide (SiO2) or mixtures thereof. The matrix contains graphite inclusions and the density of the ceramic material is at least 85% of the theoretical value. The molded part is produced by subjecting a mixture formed of a polymer component in an amount of 30 to 80 wt. % referred to the total weight of the mixture, fillers in an amount of 0 to 30 wt. % and graphite in an amount of 10 to 70 wt. %, to a forming process with heating to effect crosslinking of the polymer components, followed by a pyrolysis process. In particular, the molded parts are produced from polymers of the group including polysilanes, polysiloxanes, polysilazanes or polycarbosilanes. A process for producing ceramic molded parts and a sliding element having a molded part are also provided.
    Type: Grant
    Filed: June 18, 2001
    Date of Patent: March 23, 2004
    Assignee: SGL Carbon AG
    Inventors: Peter Greil, Oliver Dernovsek, Hans-Michael Güther, Ulrich Wislsperger
  • Patent number: 6703117
    Abstract: A friction or sliding body includes at least two composite materials reinforced with fiber bundles and containing a ceramics matrix. A first composite material forms the outside of the sliding body as a friction layer and a second composite material forms a supporting body joined areally to the friction layer. The fiber bundle lengths of the friction layer are significantly shorter than the fiber bundle lengths of the supporting body. The fiber bundles of the friction layer have a clear alignment perpendicular to the surface. The surface of the friction layer is formed substantially only of small regions of free carbon with a diameter of at most 1.2 mm, and a total fraction of the area of free carbon on the surface is at most 35%. The surface has an extremely fine crack structure and the friction layer exhibits virtually no stresses in the vicinity of the surface. A process for producing a friction or sliding body and a brake disc or brake lining are also provided.
    Type: Grant
    Filed: May 28, 2002
    Date of Patent: March 9, 2004
    Assignee: SGL Carbon AG
    Inventors: Udo Gruber, Michael Heine, Andreas Kienzle
  • Publication number: 20040033361
    Abstract: Disclosed herein is an inner tube of glass-like carbon for CVD apparatus and a process for production thereof. The inner tube has its surface roughened without increase in metal impurities which cause particles. It has improved adhesion to CVD deposit film and also has a high degree of roundness. The surface roughness (on both the inner and outer surfaces) is 0.1-10 &mgr;m measured according to JIS B0601. The concentration of metal impurities (iron, copper, chromium, sodium, potassium, calcium, magnesium, and aluminum) in the surface is less than 50×1010 atoms/cm2.
    Type: Application
    Filed: August 1, 2003
    Publication date: February 19, 2004
    Applicant: Kabushiki Kaisha Kobe Seiko Sho(Kobe Steel, Ltd.)
    Inventor: Maki Hamaguchi
  • Publication number: 20040029706
    Abstract: The present invention is directed towards a ceramic nanocomposite comprising a nanostructured carbon component inside a ceramic host. The ceramic nanocomposite may further comprise vapor grown carbon fibers. Such nanostructured carbon materials impart both structural and thermal barrier enhancements to the ceramic host. The present invention is also directed towards a method of making these ceramic nanocomposites and for methods of using them in various applications.
    Type: Application
    Filed: February 13, 2003
    Publication date: February 12, 2004
    Inventors: Enrique V. Barrera, Leonard Lee Yowell, Brian Mitchell Mayeaux, Erica L. Corral, Joseph Cesarano
  • Patent number: 6645425
    Abstract: The invention relates to a refractory batch containing at least one refractory metal oxide component, at least one binder component, such as resin or pitch, if appropriate antioxidants, at least one carbon carrier, such as soot and/or graphite, and reinforcement fibers which are formed from a stainless steel material, which at the temperatures of use forms a coat of the refractory metal oxide on its surface, and to a shaped body made from the batch and to a process for producing the shaped body.
    Type: Grant
    Filed: June 1, 2000
    Date of Patent: November 11, 2003
    Assignee: Refractechnik Holding GmbH
    Inventors: Hans Wienand, Helge Jansen, Peter Bartha
  • Patent number: 6637629
    Abstract: The invention presents an immersion nozzle having corrosion resistance to steel of high oxygen content or type of steel treated with calcium, and capable of preventing adheres and deposits of molten steel and oxide inclusions on the nozzle inner wall, in which at least a part of its portion contacting with molten steel is composed of a refractory material containing 50 wt. % or more of a principal component including one or more types of magnesia, alumina, spinel, zirconia, mullite, and silica, and also 0.3 to 15 wt. % of boron nitride, and an organic binder.
    Type: Grant
    Filed: May 13, 2002
    Date of Patent: October 28, 2003
    Assignee: Toshiba Ceramics Co., Ltd.
    Inventors: Hiroshi Ohtsuka, Etuhiro Hasebe, Kouji Enomoto
  • Publication number: 20030195122
    Abstract: A composite body of silicon carbide having binderless, allotropic carbon granules distributed throughout is produced. The nominal size of the binderless allotropic carbon granules can range from 5 to 500 micrometers. The concentration of the binderless allotropic carbon particles can vary from 1.0 to 35.0 weight percent. The process to produce such a composite body is to sinter silicon carbide with binderless, carbon-yielding precursor granules. The composite body is utilized in tribological applications. The dense, impervious silicon carbide-binderless carbon composite exhibits excellent physical and tribological characteristics when used as a mechanical face seal, a sliding bearing arrangement, or some other rubbing component.
    Type: Application
    Filed: April 12, 2002
    Publication date: October 16, 2003
    Applicant: John Crane Inc.
    Inventors: Joseph F. Demendi, Xin Chen, William R. Clemens
  • Publication number: 20030167969
    Abstract: Ceramic friction linings comprising a material consisting essentially of metal oxides which are present in the form of a sintered ceramic or in the form of ceramic particles bound by carbon and/or carbides, processes for producing them and their use in combination with ceramic friction bodies, in particular for high-performance brakes
    Type: Application
    Filed: March 5, 2003
    Publication date: September 11, 2003
    Inventors: Ronald Huener, Moritz Bauer, Peter Winkelmann
  • Publication number: 20030075251
    Abstract: A method of handling liquid non-ferrous metals in which the liquid metal is treated while coming into contact with a solid refractory material. The invention is characterised in that the solid material is Ti3SiC2. According to one preferred embodiment, the liquid material is aluminium or aluminium alloys.
    Type: Application
    Filed: October 16, 2002
    Publication date: April 24, 2003
    Inventors: Mats Sundberg, Jan-Olof Olsson, Chet Popilowski
  • Publication number: 20030060354
    Abstract: An improved process of curing resin-bonded refractory brick lining of a ladle within a housing by heating the brick in air at an effective temperature to produce resin vapors and transferring the vapors from the ladle comprising transferring the vapors at a temperature above the condensation temperature of the transferred vapors to an auxiliary burner to effect combustion of the transferred vapors to produce non-toxic gases. The process provides an efficacious and environmentally sound treatment of resin-bonded refractory bricks.
    Type: Application
    Filed: May 20, 2002
    Publication date: March 27, 2003
    Inventors: Paul W. Loukas, Manfred Sallaberger
  • Publication number: 20020183189
    Abstract: A carbonaceous refractory material is produced by adding an organic binder to a mixture containing a carbonaceous material comprising a carbonaceous raw material comprising calcined anthracite, calcined coke, artificial graphite or natural graphite or a mixture thereof at 50 to 85% as the principal raw material, alumina particle at 5 to 15%, metal silicon particle at 5 to 15%, and one or two or more of titanium carbide powder, titanium nitride powder and titanium carbonitride powder at 5 to 20% in total, kneading and molding the resulting mixture and baking the molded article under non-oxidizing atmosphere. By using the carbonaceous refractory material as the inner lining material for the side wall and bottom of blast furnace hearth, the consumption of the inner lining material due to the dissolution thereof in melted pig iron can be decreased, and simultaneously, the abrasion due to the flow of melted pig iron can be decreased, which works to prolong the life of the blast furnace.
    Type: Application
    Filed: November 28, 2001
    Publication date: December 5, 2002
    Inventors: Akio Ishii, Hitoshi Nakamura, Michio Nitta, Tsutomu Wakasa, Hirofumi Mikami, Yoshiyuki Yamagami
  • Publication number: 20020177517
    Abstract: An improved submerged entry nozzle is provided which is useful in the casting of aluminum killed molten steel. The nozzle has an improved slagline sleeve or collar which surrounds the outer portion of the nozzle to protect it from corrosion during the casting process. The slagline sleeve is made from resin bonded zirconia/graphite which has been formulated so that upon curing of the resin to form resite, there is a reduction in the contractile tendency which results in a reduction in stress fracturing. The reduction of the contractile tendency and the resulting resistance to stress fracturing is achieved by adding an effective amount of calcium oxide to the resin-zirconia-graphite mixture which is used to form the sleeve.
    Type: Application
    Filed: February 11, 2002
    Publication date: November 28, 2002
    Applicant: Baker Refractories, Inc.
    Inventors: Donald B. Hoover, Franklin A. Renda, Donald J. Griffin, Colin Richmond
  • Patent number: 6475426
    Abstract: In the continuous casting of molten metal, the invention describes a refractory article for reducing deposition of inclusions on a surface contacting the stream of molten metal. The article comprises a first composition and a second composition on at least a portion of the contacting surface. The second composition includes a resin-bonded refractory composition comprising a refractory aggregate and a reactive metal. The resin-bonded refractory composition reduces deposition of inclusions relative to standard carbon-bonded or castable refractories. The second composition is particularly effective as a nose of a stopper rod or a liner for a nozzle, shroud or slide gate plate.
    Type: Grant
    Filed: March 27, 2001
    Date of Patent: November 5, 2002
    Assignee: Vesuvius Crucible Company
    Inventors: Priyadarshi G. Desai, Johan L. Richaud, Duane L. DeBastiani
  • Publication number: 20020155941
    Abstract: A ceramic material suitable for use in production of paving tiles, construction tiles, flooring in offices, flooring in machinery plants and so forth is obtained by a method comprising steps of mixing defatted bran derived from rice bran with a thermosetting resin before kneading, subjecting a kneaded mixture thus obtained to a primary firing in an inert gas at a temperature in a range of 700 to 1000° C., pulverizing the kneaded mixture after the primary firing into carbonized powders, kneading the carbonized powders with which ceramic powders, a solvent, and a binder as desired are mixed into a plastic workpiece (kneaded mass), pressure-forming the plastic workpiece at pressure in a range of 10 to 100 MPa, and subjecting a formed plastic workpiece thus obtained again to firing in an inert gas atmosphere at a temperature in a range of 100 to 1400° C.
    Type: Application
    Filed: February 11, 2002
    Publication date: October 24, 2002
    Inventors: Kazuo Hokkirigawa, Rikuro Obara, Motoharu Akiyama
  • Patent number: 6464932
    Abstract: An unburned carbon-containing refractory suitable for lining a molten metal container, which can prevent deformation of the outer steel shell, improve the life of the container, suppress reduction in molten steel temperature, and minimize energy losses without sacrificing the life of the wear lining. A molten metal container capable of reducing energy losses and having stable durability is also provided. The unburned carbon-containing refractory contains a refractory aggregate and 30% by weight or less of a carbon raw material containing at least graphite, wherein the carbon content X (% by weight) and the thermal conductivity &lgr;(W/m° C.) of the refractory satisfy the relationship: &lgr;≦0.8X+7, and the refractory contains 20 parts by weight or more of a refractory aggregate having an apparent porosity of 10% or smaller and a greater size than 1 mm per 100 parts by weight of the total of the refractory aggregate and the carbon raw material.
    Type: Grant
    Filed: May 30, 2000
    Date of Patent: October 15, 2002
    Assignee: Shinagawa Refractories Co., Ltd.
    Inventors: Osamu Nomura, Yasuhiro Hoshiyama, Atsushi Torigoe
  • Patent number: 6461991
    Abstract: A re-usable alumina-magnesia graphite refractory suitably used for a refractory for continuous casting, such as a long nozzle used for pouring a molten metal from a ladle capable of re-use or intermittent use to a tundish, an immersion nozzle used for charging a molten metal from a tundish to a mold and a long stopper for controlling the flow rate of the molten steel; and produced by blending 3 to 60 wt % of magnesia having a particle size of 0.02 to 1.0 mm to a compound comprising mainly alumina and graphite, and kneading, molding, and baking the compound. The raw material compound comprising mainly alumina and graphite can contain spinel or zirconia.
    Type: Grant
    Filed: August 24, 2000
    Date of Patent: October 8, 2002
    Assignee: Krosaki Corporation
    Inventors: Koji Ogata, Shoji Iitsuka
  • Publication number: 20020128144
    Abstract: A filler sand for a ladle tap hole valve contains 45 to 55 mass % of zircon sand, 30 to 40 mass % of chromite sand and 10 to 20 mass % of silica sand and is blended externally with 0.05 to 5 mass % of carbon black calculated based on the total amount of the sands; or contains 30 to 90 mass % of chromite sand and 10 to 70 mass % of silica sand and is optionally blended externally with 0.05 to 5 mass % of carbon black, wherein 95 mass % or more of the chromite sand consists of particles having diameters falling within a range of 150 to 850 &mgr;m, 60 mass % or more of the chromite sand consists of particles having diameters falling within a range of 212 to 600 &mgr;m, 95 mass % or more of the silica sand consists of particles having diameters falling within a range of 300 to 1180 &mgr;m, and 90 mass % or more of the silica sand consists of particles having diameters falling within a range of 600 to 1180 &mgr;m.
    Type: Application
    Filed: November 20, 2001
    Publication date: September 12, 2002
    Applicant: NKK CORPORATION
    Inventors: Manabu Tano, Hideto Takasugi, Hirohisa Nakajima, Akira Shirayama, Manabu Arai, Atsushi Tsunoda, Masaki Komatani
  • Patent number: 6420293
    Abstract: A ceramic matrix nanocomposite having enhanced mechanical behavior is made up of a nanotube filler composed of at least one nanotube material, and a ceramic matrix composed of a nanocrystalline ceramic oxide. A method for producing ceramic articles having improved fracture toughness includes combining of a nanotube filler made up of a nanotube material and a ceramic matrix made up of a nanocrystalline ceramic oxide, forming an article therefrom, and sintering the article under elevated pressure at elevated temperature.
    Type: Grant
    Filed: August 25, 2000
    Date of Patent: July 16, 2002
    Assignee: Rensselaer Polytechnic Institute
    Inventors: Sekyung Chang, Robert H. Doremus, Richard W. Siegel, Pulickel M. Ajayan
  • Patent number: 6364944
    Abstract: A method of making an aggregate having a carbon phase and a silicon-containing species phase is described and includes introducing a carbon black-yielding feedstock and a silicon-containing compound feedstock into different stages of a multi-stage reactor. The reactor operates at a sufficient temperature to decompose the silicon-containing compound and to form a carbon black phase from the carbon black-yielding feedstock. At least one of the feedstocks may include a diluent, such as an alcohol, water, and aqueous based solution, and mixtures thereof.
    Type: Grant
    Filed: December 2, 1999
    Date of Patent: April 2, 2002
    Assignee: Cabot Corporation
    Inventors: Khaled Mahmud, Meng-Jhiao Wang, Yakov Kutsovsky
  • Patent number: 6355206
    Abstract: SiC—C/C composite materials having a suitable kinetic coefficient of friction, good corrosion resistance in strongly oxidizing and corrosive environments, good creep resistance and spalling resistance, and high hardness. The materials are hardly oxidized or abraded even when exposed to high temperatures, while maintaining the excellent impact resistance and light weight of C/C composites. Molten metal pumps using the materials are provided from which components do not dissolve into the molten metal even when used in molten metal and have sufficient thermal impact resistance and oxidation resistance.
    Type: Grant
    Filed: February 2, 2000
    Date of Patent: March 12, 2002
    Assignee: NGK Insulators, Ltd.
    Inventors: Shigeru Hanzawa, Kenji Nakano
  • Publication number: 20020005147
    Abstract: In a coating material for the inner surface of a cathode-ray tube comprising an aqueous dispersion medium containing silicates of lithium and potassium and a dispersing agent, and a graphite particles and, if necessary, particles of the other specific metal compounds suspended therein, the invention is characterized in that the molar ratio of potassium to lithium is in the range of 1 to 9, and the molar ratio of silicon dioxide to the total quantity of oxides of lithium and potassium is in the range of 2.5 to 3.5, and the obtained coating material is most suitable for suppressing the quantities of gases released from the inner coating, for making good use of gas-adsorbing ability of graphite, and for increasing the degree of vacuum in the cathode-ray tube.
    Type: Application
    Filed: April 26, 2001
    Publication date: January 17, 2002
    Inventor: Hiroshi Shimbori
  • Patent number: 6316106
    Abstract: A filler sand for a ladle tap hole valve contains 70 to 90 wt % of chromite sand and 10 to 30 wt % of silica sand and is blended externally with 0.05 to 5 wt % of carbon black calculated based on the total amount of the chromite sand and the silica sand; or contains 70 to 90 wt % of chromite sand and 10 to 30 wt % of silica sand, wherein the chromite sand has a particle diameter distribution such that 99% or more of the chromite sand consists of particles having diameters ranging from 150 to 850 &mgr;m and that 95% or more of the chromite sand consists of particles having diameters ranging from 200 to 600 &mgr;m, and the silica sand has a particle diameter distribution such that 95% or more of the silica sand consists of particles having diameters ranging from 150 to 850 &mgr;m and that 80% or more of the silica sand consists of particles having diameters ranging from 200 to 600 &mgr;m.
    Type: Grant
    Filed: January 19, 1999
    Date of Patent: November 13, 2001
    Assignees: NKK Corporation, Nippon Rotary Nozzle Co., Ltd.
    Inventors: Hideto Takasugi, Manabu Tano, Takeshi Ishii, Shinichi Akai, Akira Shirayama, Hirohisa Nakashima
  • Patent number: 6313055
    Abstract: A refractory castable composition is disclosed comprising one hundred weight percent of a refractory composition comprising from about 60 to 90 weight percent of a refractory aggregate, from about 2 to 25 weight percent of an ultrafine refractory material having an average particle diameter size less than or equal to about 3 microns, from about 0.5 to 15 weight percent of a binder, and from about 0.05 to 2.0 weight percent of a dispersant, wherein all or a portion of the ultrafine refractory material comprises a thermal black such that the refractory composition comprises from about 2 to 15 weight percent of the thermal black, and from about 3 to 10 weight percent water based upon 100 weight percent of the refractory composition, and wherein the water is present in an amount sufficient to achieve a castable consistency. A method of installing the refractory castable composition is also disclosed.
    Type: Grant
    Filed: August 20, 1998
    Date of Patent: November 6, 2001
    Assignee: Harbison-Walker Refractories Company
    Inventor: Robert M. Cullen
  • Publication number: 20010021686
    Abstract: The invention relates to a carbon-graphite material with an embedded additive. So that the carbon-graphite material is distinguished by a low coefficient of friction and low wear, it is proposed that the additive is one or several synthetic mechanically resistant materials of a mean grain size between 0.1 to 10 &mgr;m.
    Type: Application
    Filed: June 19, 1997
    Publication date: September 13, 2001
    Inventors: GUNTER RINN, HANS LIPPER, RAINER SPERLING, KARL-HEINZ SAUER
  • Patent number: 6287714
    Abstract: A method comprising incorporation of an inorganic polymer precursor of a grain growth inhibitor into nanostructured materials or intermediates useful for the production of nanostructured materials. The precursor/nanostructured material composite is optionally heat treated at a temperature below the grain growth temperature of the nanostructured material in order to more effectively disperse the precursor. The composites are then heat treated at a temperature effective to decompose the precursor and to form nanostructured materials having grain growth inhibitors uniformly distributed at the grain boundaries. Synthesis of the inorganic polymer solution comprises forming an inorganic polymer from a solution of metal salts, filtering the polymer, and drying. Alloying additives as well as grain growth inhibitors may be incorporated into the nanostructured materials.
    Type: Grant
    Filed: August 21, 1998
    Date of Patent: September 11, 2001
    Assignee: Inframat Corporation
    Inventors: Danny T. Xiao, Chris W. Strock, Donald M. Wang, Peter R. Strutt
  • Patent number: 6255241
    Abstract: A fullerene-dispersed ceramic is produced by an improved method in which C60 or like fullerene, and C16TMA or like surfactant, are dissolved in a solution of metallic compound, such as zirconyl nitrate, to form a colloidal solution. A gel is formed from the colloidal solution by changing its hydrogen ion concentration. The gel is dried and subjected to heat treatment, to eliminate remaining solvent and surfactant, and thereby stably obtain the desired fullerene-dispersed ceramic powder in which the fullerene is uniformly dispersed and which is essentially free from carbon other than fullerene.
    Type: Grant
    Filed: September 27, 1999
    Date of Patent: July 3, 2001
    Assignee: The University of Tokyo
    Inventors: Kun-ichi Miyazawa, Itaru Honma, Junya Yano, Kunio Ito, Toru Kuzumaki
  • Patent number: 6245698
    Abstract: A process for making a porous ceramic composite with a bimodal pore size distribution includes the steps of mixing an organosilicon precursor, an alcohol, water, a catalyst, granules, particles, whiskers or powders of a fumed silica and granules, particles, whiskers or powders of a ceramic material and a combustible material having a diameter in a range of 500 angstroms to 500 microns to form a mixture, pouring the mixture into a mold, allowing the mixture to gel form a ceramic composite and drying the ceramic composite. The process also includes the step of heating the ceramic composite in either air or oxygen to burn away the combustible material. The organosilicon precursor is selected from a group consisting of tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane and tetrabutoxysilane. The alcohol is selected from the group consisting of methanol, ethanol, propanol and butanol.
    Type: Grant
    Filed: August 5, 1993
    Date of Patent: June 12, 2001
    Inventors: Edward J. A. Pope, John D. MacKenzie
  • Patent number: 6231787
    Abstract: The invention relates to a method for producing powdery, vitreous carbon, and a paste made therefrom for producing resistive films having predetermined electrical conductivity. In production methods known in the art, pyrolysis of acrylamides is performed in mixture with water-soluble salts and, following pyrolysis, the powdered portion of the vitreous carbon is recovered by dissolving the salt component in water. The vitreous carbon is then dried, and the powder obtained in this manner is pulverized once again, as needed. A disadvantage of this method is that it is very time-consuming. In the solution now recommended, a preferably aromatic polymer is cured into a resin that is cross-linked in three dimensions, and in this state is ground to a powder prior to pyrolysis. Pyrolysis of the resulting powder is performed in a nitrogen atmosphere, so that powdered, vitreous carbons having different resistivities are obtained by using different final pyrolysis temperatures in each pyrolysis process.
    Type: Grant
    Filed: December 1, 1999
    Date of Patent: May 15, 2001
    Assignee: Preh-Werke GmbH & Co., KG
    Inventors: Peter Ambros, Hugo Johannes, Franz Kissner
  • Patent number: 6225248
    Abstract: High-temperature, lightweight, ceramic carbon insulation is prepared by coating or impregnating a porous carbon substrate with a siloxane gel derived from the reaction of an organodialkoxy silane and an organotrialkoxy silane in an acid or base medium in the presence of the carbon substrate. The siloxane gel is subsequently dried on the carbon substrate to form a ceramic carbon precursor. The carbon precursor is pyrolyzed, in an inert atmosphere, to form the ceramic insulation containing carbon, silicon, and oxygen. The carbon insulation is characterized as a porous, fibrous, carbon ceramic tile which is particularly useful as lightweight tiles for spacecraft.
    Type: Grant
    Filed: November 2, 1998
    Date of Patent: May 1, 2001
    Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space Administration
    Inventors: Daniel B. Leiser, Ming-ta S. Hsu, Timothy S. Chen
  • Patent number: 6136227
    Abstract: The object of the invention is to provide carbon-containing refractories which give off little decomposition gas having an offensive odor, exhibit excellent spalling resistance, and are equal or superior in kneading properties and molding properties to the refractories containing a phenolic resin as a binder; and a process for producing the same. To accomplish the object, the invention is characterized by replacing a conventionally employed phenolic resin binder with saccharified starch and/or reduced saccharified starch, a binder containing 40% to 80% by weight of saccharified starch and/or reduced saccharified starch and 20% to 60% by weight of water, or a binder containing 40% to 80% by weight of saccharified starch and/or reduced saccharified starch, 1% to 25% by weight of water, and 5% to 50% by weight of an alcohol having a boiling point of not lower than 80.degree. C.
    Type: Grant
    Filed: August 12, 1997
    Date of Patent: October 24, 2000
    Assignee: Shinagawa Refractories Co., Ltd.
    Inventors: Takashi Yamamura, Osamu Nomura, Hidenori Tada, Atsushi Torigoe
  • Patent number: 6113802
    Abstract: An insulation material which is substantially free of fibers and which has a density of less than about 2.5 g/cc and a thermal conductivity of less than about 5 W/Km is formed from a composition comprising at least about 2%, by weight, carbon. The insulation material is resistant to thermal shock and is easily machined.
    Type: Grant
    Filed: March 19, 1998
    Date of Patent: September 5, 2000
    Assignee: Micropyretics Heaters International, Inc.
    Inventor: Srinivas Penumella
  • Patent number: 6087034
    Abstract: Flexible graphite sheet having embedded ceramic fibers extending from its opposite planar surfaces into the sheet to provide permeability of the sheet to gases so that it is useful as an electrode in electrochemical fuel cells.
    Type: Grant
    Filed: July 9, 1998
    Date of Patent: July 11, 2000
    Assignee: UCAR Graph-Tech Inc.
    Inventor: Robert Angelo Mercuri
  • Patent number: 6030552
    Abstract: The invention relates to a method for producing powdery, vitreous carbon, and a paste made therefrom for producing resistive films having predetermined electrical conductivity. In production methods known in the art, pyrolysis of acrylamides is performed in mixture with water-soluble salts and, following pyrolysis, the powdered portion of the vitreous carbon is recovered by dissolving the salt component in water. The vitreous carbon is then dried, and the powder obtained in this manner is pulverized once again, as needed. A disadvantage of this method is that it is very time-consuming. In the solution now recommended, a preferably aromatic polymer is cured into a resin that is cross-linked in three dimensions, and in this state is ground to a powder prior to pyrolysis. Pyrolysis of the resulting powder is performed in a nitrogen atmosphere, so that powdered, vitreous carbons having different resistivities are obtained by using different final pyrolysis temperatures in each pyrolysis process.
    Type: Grant
    Filed: April 9, 1998
    Date of Patent: February 29, 2000
    Assignee: Preh-Werke GmbH & Co. KG
    Inventors: Peter Ambros, Hugo Johannes, Franz Kissner
  • Patent number: 6004671
    Abstract: A reinforcement for composite materials is disclosed, which comprises a number of filaments of inorganic long fiber and glass and/or glass ceramic present in the gaps among the filaments and having a wire or tape form. Also disclosed is a metallic or ceramic composite material composed of a plurality of the reinforcements and a metal or intermetallic compound or ceramic which is present in the gaps among the individual reinforcements.
    Type: Grant
    Filed: January 13, 1995
    Date of Patent: December 21, 1999
    Assignee: Research Institute of Advanced Material Gas-Generator, Ltd.
    Inventors: Takemi Yamamura, Mitsuhiko Sato, Makoto Tamura, Shinji Kajii, Yasuo Matsumori, Yoshikatu Harada
  • Patent number: 5998318
    Abstract: There is provided a sintered silicon carbide with graphite added thereto having excellent lubrication characteristics. The sintered silicon carbide with graphite added thereto contains 10-30 wt. % of natural graphite flakes having an average grain size of 8-100 .mu.m and the remainder silicon carbide and a sintering aid, and having a relative density of 80-92%.
    Type: Grant
    Filed: March 10, 1998
    Date of Patent: December 7, 1999
    Assignees: Tanken Seal Seiko Co., Ltd., Syowa Denko K.K.
    Inventors: Hiroshi Takanami, Yukio Ishii, Mamoru Asuwa