Sintered Product Patents (Class 521/919)
  • Patent number: 8349752
    Abstract: The present invention provides a plate brick having a low amount of generation of smoke and a gas with a pungent odor during use, and exhibiting high durability. A plate brick of the present invention is obtained by: adding an organic binder to a refractory raw material mixture containing 0.5 to 20 mass % of aluminum and/or aluminum alloy; kneading the mixture with the organic binder; forming the kneaded mixture into a shaped body; and subjecting the shaped body to a heat treatment at a temperature of 400 to 1000° C., wherein the plate brick is obtained without being impregnated with a carbon-containing liquid material comprising tar or pitch, after the heat treatment. The plate brick has a compressive strength of 180 MPa or more, and a weight-increasing rate of 1% or less as measured in a hydration test using an autoclave.
    Type: Grant
    Filed: March 25, 2009
    Date of Patent: January 8, 2013
    Assignee: Krosakiharima Corporation
    Inventors: Yasuaki Shin, Kazuo Ito, Michihiko Ichimaru, Tamotsu Wakita, Masamichi Asai
  • Patent number: 7758779
    Abstract: A reinforced carbon foam material is formed from carbon fibers incorporated within a carbon foam's structure. First, carbon fiber bundles are combined with a liquid resol resin. The carbon fiber bundles separate into individual carbon fiber filaments and disperse throughout the liquid resol resin. Second, the carbon fiber resin mixture is foamed thus fixing the carbon fibers in a permanent spatial arrangement within the phenolic foam. The foam is then carbonized to create a carbon fiber reinforced foam with improved graphitic characteristics as well as increased strength. Optionally, various additives can be introduced simultaneously with the addition of the carbon fiber bundles into the liquid resol, which can improve the graphitic nature of the final carbon foam material and/or increase the foam's resistance to oxidation.
    Type: Grant
    Filed: December 29, 2005
    Date of Patent: July 20, 2010
    Assignee: GrafTech International Holdings Inc.
    Inventors: Douglas J. Miller, Irwin C. Lewis, Richard L. Shao, Mehmet Suha Yazici
  • Patent number: 7282466
    Abstract: The invention relates to sulfur-functionalized polymer gels and carbon gels, including aerogels, and such carbon gels containing platinum or metal nanoparticles. The platinum-containing gels may be useful as fuel-cell electrodes.
    Type: Grant
    Filed: November 5, 2004
    Date of Patent: October 16, 2007
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Jeffrey W Long, Debra R Rolison, Wendy Baker
  • Patent number: 7056455
    Abstract: The present invention comprises a novel process for the preparation of carbon based structured materials with controlled topology, morphology and functionality. The nanostructured materials are prepared by controlled carbonization, or pyrolysis, of precursors comprising phase separated copolymers. The precursor materials are selected to phase separate and self organize in bulk, in solution, in the presence of phase selective solvents, at surfaces, interfaces or during fabrication, into articles, fibers or films exhibiting well-defined, self-organized morphology or precursors of well-defined, self-organized, bi- or tri-phasic morphology. Compositional control over the (co)polymers provides control over the structure of the phase separated precursor whose organization therein dictates the nanostructure of the material obtained after carbonization or pyrolysis, wherein each dimension of the formed structure can be predetermined.
    Type: Grant
    Filed: April 6, 2002
    Date of Patent: June 6, 2006
    Assignee: Carnegie Mellon University
    Inventors: Krzysztof Matyjaszewski, Tomasz Kowalewski, David N. Lambeth, James Spanswick, Nicolay V. Tsarevsky
  • Patent number: 6224961
    Abstract: Porous, absorbent macrostructures having improved fluid handling capabilities that include inter-particle bonded aggregates, and are useful in absorbent articles, such as diapers, adult incontinence pads and sanitary napkins, are disclosed. The inter-particle bonded aggregates of these macrostructures are made from mixtures of particulate absorbent polymers having different fluid handling properties, different shapes, or both. These macrostructures can be made from a wider variety of hydrogel-forming absorbent polymers without sacrificing desired fluid handling properties, and without being prone to gel blocking.
    Type: Grant
    Filed: March 1, 1999
    Date of Patent: May 1, 2001
    Assignee: The Procter & Gamble Company
    Inventors: Kesyin F. Hsueh, Reiko Sasaki
  • Patent number: 6171532
    Abstract: In a process for stabilizing a foamed starting slip material, the starting slip material which is foamed comprises the following constituents: a. inorganic sinterable material, b. a source of blowing gas, c. a framework former which forms a framework when the pH of the starting slip material is changed, d. pH control material, e. liquid, f. if desired, one or more of the following materials: dispersant binder viscosity modifier, and the pH of the starting slip material is changed to initiate or accelerate the formation of the framework from the framework former.
    Type: Grant
    Filed: November 17, 1998
    Date of Patent: January 9, 2001
    Assignee: BASF Aktiengesellschaft
    Inventor: Hans-Josef Sterzel
  • Patent number: 6136948
    Abstract: A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 .mu.m, provided further that the number average ratio of particles smaller than 53 .mu.m is greater than 80%, the remaining larger particles being in the size range from 53 .mu.m to 180 .mu.m. A powder with slow recrystallization rates, as evidenced by non-overlapping or slightly overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10.degree. C. to 20.
    Type: Grant
    Filed: July 14, 1997
    Date of Patent: October 24, 2000
    Assignee: DTM Corporation
    Inventors: Elmer Douglas Dickens, Jr., Biing Lin Lee, Glenn Alfred Taylor, Angelo Joseph Magistro, Hendra Ng, Kevin P. McAlea, Paul F. Forderhase
  • Patent number: 6074475
    Abstract: A low-density, syntactic foam material is provided according to the invention. The syntactic foam material is prepared by mixing together a plurality of microballoons and a finely divided solid thermosetting resin. Fibers are also preferably incorporated into the material during processing to impart specific properties. The mixture is heated to allow the thermosetting resin to flow and wet the microballoons in the mixture. The mixture is then cured to set and crosslink the thermosetting resin to form the syntactic foam of the invention. The syntactic foam material has highly uniform properties and can be used in aerospace applications.
    Type: Grant
    Filed: February 10, 1999
    Date of Patent: June 13, 2000
    Assignee: McDonnell Douglas Corporation
    Inventors: Edward S. Harrison, Donald J. Bridges, James L. Melquist
  • Patent number: 6068915
    Abstract: A low-density, syntactic foam material is provided according to the invention. The syntactic foam material is prepared by mixing together a plurality of microballoons and a finely divided solid thermosetting resin. Fibers are also preferably incorporated into the material during processing to impart specific properties. The mixture is heated to allow the thermosetting resin to flow and wet the microballoons in the mixture. The mixture is then cured to set and crosslink the thermosetting resin to form the syntactic foam of the invention. The syntactic foam material has highly uniform properties and can be used in aerospace applications.
    Type: Grant
    Filed: November 6, 1997
    Date of Patent: May 30, 2000
    Assignee: McDonnell Douglas Corporation
    Inventors: Edward S. Harrison, Donald J. Bridges, James L. Melquist
  • Patent number: 5990268
    Abstract: A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 .mu.m, provided further that the number average ratio of particles smaller than 53 .mu.m is greater than 80%, the remaining larger particles being in the size range from 53 .mu.m to 180 .mu.m. A powder with slow recrystallization rates, as evidenced by non-overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10.degree. C. to 20.degree. C.
    Type: Grant
    Filed: November 21, 1996
    Date of Patent: November 23, 1999
    Assignee: DTM Corporation
    Inventors: Elmer Douglas Dickens, Jr., Biing Lin Lee, Glenn Alfred Taylor, Angelo Joseph Magistro, Hendra Ng
  • Patent number: 5989467
    Abstract: The present invention is embodied in a ceramic foam made by mixing a liquid pre-ceramic resin and a liquid phenolic resin, allowing the resultant mixture to chemically foam, curing the mixture for a time and at a temperature sufficiently to convert the mixture to a polymeric foam, and then heating the resultant polymeric foam for a time and at a temperature sufficient to break-down polymers of the polymeric foam and convert the polymeric foam to a ceramic foam. The ceramic foam of the present invention contains residual decomposed components of the liquid phenolic resin and/or liquid pre-ceramic resin.
    Type: Grant
    Filed: March 4, 1997
    Date of Patent: November 23, 1999
    Assignee: Northrop Grumman Corporation
    Inventors: David Eric Daws, Nicholas T. Castellucci, Harry Wellington Carpenter, Mary Wagner Colby
  • Patent number: 5705538
    Abstract: A foamed polyvinylchloride (PVC) material is produced by mixing of 100 mass parts of PVC with 0.5-5 mass parts of sodium alkyl sulfonate, molding of the obtained composition and followed by heating for foaming at 190.degree.-300.degree. C. for 3-20 mins. Molding is performed either under 0.5-400 MPa and 20.degree.-170.degree. C., followed by heating to 140.degree.-150.degree. C. in the closed space, or in a free state in the form of 2-16 mm thickness layer. In the latter case the layer before foaming can be subjected to packing.
    Type: Grant
    Filed: April 3, 1995
    Date of Patent: January 6, 1998
    Assignee: Polimerplast
    Inventors: Igor Victorovich Morozov, Lyubov Dmitrievna Strelkova, Yuliya Vladimirovna Razborova, Pyotr Mikhailovich Traskin, German Valeryevich Gordeyev, Valery Innokentyevich Yemelyanov, Valery Iosifovich Kharitonov, Anatoly Fyodorovich Perevalov, Vladimir Yevgenyevich Popov, Vyacheclav Nikolayevich Kovalev
  • Patent number: 5677047
    Abstract: A substantially cylindrical bar of microporous PTFE is non-fibrillated and incorporates pores within any cylindrical surface within the bar centred about the central longitudinal axis of the bar that are of substantially uniform size and are substantially uniformly distributed within that surface. The process for producing such a bar includes the step of applying a substantially radial compressive force to pre-heated and cooled granules of PTFE and subsequently re-heating and cooling the compressed granules, while a film of non-fibrillated, microporous PTFE is formed from the cooled bar, the plane of the film being perpendicular to the direction of the radial compressive force whereby the pores within any plane substantially perpendicular to the thickness of the film are of substantially uniform size and are substantially uniformly distributed within that plane and all such parallel planes.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: October 14, 1997
    Assignee: British Technology Group Limited
    Inventor: Thomas Ronald Thomas
  • Patent number: 5677031
    Abstract: A porous polytetrafluoroethylene (PTFE) structure particularly for use as a liquid filter comprises particles of granular-type PTFE fused together to form a porous integral network. The structure is formed by spraying an aqueous suspension of granular PTFE particles and baking at a temperature of 335.degree.-350.degree. C. Typically the specific gravity is 0.8 to 1.54. The crystallinity is less than 95%. The structure may be supported on a perforate substrate such as stainless steel mesh.
    Type: Grant
    Filed: May 2, 1995
    Date of Patent: October 14, 1997
    Assignee: W. L. Gore & Associates, Inc.
    Inventors: Andrew Miller Allan, Brian Andrew Barker
  • Patent number: 5648450
    Abstract: A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 .mu.m, provided further that the number average ratio of particles smaller than 53 .mu.m is greater than 80%, the remaining larger particles being in the size range from 53 .mu.m to 180 .mu.m. A powder with slow recrystallization rates, as evidenced by non-overlapping or slightly overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10.degree. C. to 20.
    Type: Grant
    Filed: June 17, 1996
    Date of Patent: July 15, 1997
    Assignee: DTM Corporation
    Inventors: Elmer Douglas Dickens, Jr., Biing Lin Lee, Glenn Alfred Taylor, Angelo Joseph Magistro, Hendra Ng, Kevin P. McAlea, Paul F. Forderhase
  • Patent number: 5643512
    Abstract: The present invention is embodied in a method of producing a ceramic foam. The steps for producing the ceramic foam include first mixing a liquid pre-ceramic resin with a liquid phenolic resin, second allowing the resultant mixture to chemically foam, third curing the mixture for a time and at a temperature sufficiently to convert the mixture to a polymeric foam, and then heating the resultant polymeric foam for a time and at a temperature sufficiently to completely break-down polymers of the polymeric foam and convert the polymeric foam to a ceramic foam.
    Type: Grant
    Filed: August 16, 1995
    Date of Patent: July 1, 1997
    Assignee: Northrop Grumman Corporation
    Inventors: David Eric Daws, Nicholas T. Castellucci, Harry Wellington Carpenter, Mary Wagner Colby
  • Patent number: 5641442
    Abstract: An air-permeable and water-permeable rubber includes by weight 100 parts of a rubber, about 30 to 80 parts of a plastic, about 1 to 5 parts of a cross-linking agent, about 1 to 10 parts of a vulcanizing agent, about 1 to 10 parts of a rubber accelerator, 0 to about 100 parts of a filler, and 0 to about 10 parts of an anti-aging agent. Such air-permeable and water-permeable rubber has excellent air-permeability, water-permeability, softness, and elasticity. The present invention also includes a method for producing the above rubber.
    Type: Grant
    Filed: February 9, 1994
    Date of Patent: June 24, 1997
    Assignee: Industrial Technology Research Institute
    Inventor: Ruey-Sheng Shih
  • Patent number: 5527877
    Abstract: A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 .mu.m, provided further that the number average ratio of particles smaller than 53 .mu.m is greater than 80%, the remaining larger particles being in the size range from 53 .mu.m to 180 .mu.m. A powder with slow recrystallization rates, as evidenced by non-overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10.degree. C. to 20.degree. C.
    Type: Grant
    Filed: August 30, 1994
    Date of Patent: June 18, 1996
    Assignee: DTM Corporation
    Inventors: Elmer D. Dickens, Jr., Biing L. Lee, Glenn A. Taylor, Angelo J. Magistro, Hendra Ng, Kevin McAlea, Paul F. Forderhase
  • Patent number: 5514231
    Abstract: A substantially cylindrical bar of microporous PTFE is non-fibrillated and incorporates pores within any cylindrical surface within the bar centred about the central longitudinal axis of the bar that are of substantially uniform size and are substantially uniformly distributed within that surface. The process for producing such a bar includes the step of applying a substantially radial compressive force to pre-heated and cooled granules of PTFE and subsequently re-heating and cooling the compressed granules, while a film of non-fibrillated, microporous PTFE is formed from the cooled bar, the plane of the film being perpendicular to the direction of the radial compressive force whereby the pores within any plane substantially perpendicular to the thickness of the film are of substantially uniform size and are substantially uniformly distributed within that plane and all such parallel planes.
    Type: Grant
    Filed: April 14, 1995
    Date of Patent: May 7, 1996
    Assignee: British Technology Group Limited
    Inventor: Thomas R. Thomas
  • Patent number: 5510176
    Abstract: The polytetrafluoroethylene (PTFE) porous film of the invention is characterized in that the film is formed from a PTFE resin molding powder obtained by suspension polymerization and has a porosity of 40 to 80%, and removal ratio of uniform particle having a 0.2 .mu.m diameter of less than 99% or bubble point of not less than 3 kg/cm.sup.2. This PTFE porous film is obtained by a process of compression-molding a PTFE resin molding powder to prepare a preform, sintering the preform at a temperature not lower than its melting point, processing the preform into films, then laminating at least two of the obtained films, fusing the films to unite them, and subjecting the obtained film to uniaxial or biaxial stretching at a temperature not higher than the melting point of PTFE. If desired, the finally obtained film may be subjected to heat setting. In the PTFE porous film of the invention, pores are nearly round and the diameters of the pores are almost uniform.
    Type: Grant
    Filed: August 26, 1994
    Date of Patent: April 23, 1996
    Assignees: Mitsubishi Kasei Corporation, Nippon Valqua Industries, Ltd.
    Inventors: Atsushi Nakamura, Satoshi Nakashima
  • Patent number: 5468543
    Abstract: The invention concerns a process for manufacturing a strip of ski-coating material made of polyethylene of ultra high molecular weight, wherein a ski-coating strip material 4 manufactured to a thickness of 0.5 to 1.5 mm by a screw extruder, a ram extruder or press sintering with subsequent peeling is made to pass continuously first through a heating zone 1 in which it is heated to temperature above 140.degree. C. and then through a cooling zone consisting of two sizing plates 2, 2' in which it is cooled to a temperature equal to or lower than ambient. This process produces a ski coating of which the crystalline proportion can be adjusted within a range of 25 and 60%, as a result of which improved gliding by the ski coating on snow and improved wax acceptance is assured in comparison with the known methods.
    Type: Grant
    Filed: May 19, 1993
    Date of Patent: November 21, 1995
    Assignee: Isosport Verbundbauteile Gesellschaft m.b.H.
    Inventor: Robert Schamesberger
  • Patent number: 5428076
    Abstract: Flexible, porous, absorbent polymeric macrostructures having flexibility even after extended periods at elevated temperatures and/or low humidities are disclosed. The macrostructure comprises an interparticle crosslinked aggregate and an effective amount of a suitable plasticizer. The macrostructures are suitable for use, for example, in disposable absorbent articles such as diapers.
    Type: Grant
    Filed: October 4, 1994
    Date of Patent: June 27, 1995
    Assignee: The Procter & Gamble Company
    Inventor: Donald C. Roe
  • Patent number: 5397759
    Abstract: Hollow porous microspheres of uniform diameter and of uniform wall thickness are disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have uniform void content and the interconnecting voids are uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles. The hollow porous microspheres include microspheres in which the interconnecting voids have been closed and sealed.
    Type: Grant
    Filed: July 9, 1992
    Date of Patent: March 14, 1995
    Inventor: Leonard B. Torobin
  • Patent number: 5385780
    Abstract: Particles of a fine powder of a thermoplastic synthetic resin (host powder) having a suitable broad range between its initial glass transition temperature (initial T.sub.g) and its final T.sub.g, are partially coated with an anti-caking coating powder (coating powder) by blending at an elevated temperature to form "mottled" particles. The elevated temperature is defined in relation to the initial and final T.sub.g s as: (initial T.sub.g -20).degree. C. but below the final T.sub.g. Mottled particles, without being encapsulated, have the unique ability to maintain their individual particulate characteristics at a temperature at least 10.degree. C. above the initial T.sub.g of the uncoated host powder, and flow freely under applied pressure. Such pressure is applied by a rolling drum which spreads the mottled particles onto a target bed where they are selectively sintered With a controlled high energy beam, usually a laser beam.
    Type: Grant
    Filed: July 14, 1993
    Date of Patent: January 31, 1995
    Assignee: The B. F. Goodrich Company
    Inventor: Biing-Lin Lee
  • Patent number: 5372766
    Abstract: Flexible, porous, absorbent polymeric macrostructures having flexibility even after extended periods at elevated temperatures and/or low humidities are disclosed. The macrostructure comprises an interparticle crosslinked aggregate and an effective amount of a suitable plasticizer. The macrostructures are suitable for use, for example, in disposable absorbent articles such as diapers.
    Type: Grant
    Filed: March 31, 1994
    Date of Patent: December 13, 1994
    Assignee: The Procter & Gamble Company
    Inventor: Donald C. Roe
  • Patent number: 5324753
    Abstract: Foamed propylene polymer articles are prepared by subjecting pre-foamed beads, that consist essentially of propylene polymers having a melt strength from 5 to 40 cN, to thermoforming by sintering.
    Type: Grant
    Filed: September 10, 1993
    Date of Patent: June 28, 1994
    Assignee: Himont Incorporated
    Inventors: Giuseppe Lesca, Daniele Romanini, Annibale Vezzoli
  • Patent number: 5324561
    Abstract: Porous, absorbent macrostructures that, upon contacting liquids such as water or body exudates (e.g., urine), swell and imbibe such liquids, and are useful in absorbent articles such as diapers, adult incontinence pads, and sanitary napkins are disclosed. These porous macrostructures comprise bonded absorbent particles that are surface crosslinked with cationic, preferably polymeric, amino-epichlorohydrin adducts.
    Type: Grant
    Filed: October 2, 1992
    Date of Patent: June 28, 1994
    Assignee: The Procter & Gamble Company
    Inventors: Ebrahim Rezai, Frank H. Lahrman, Toshiaki Iwasaki
  • Patent number: 5225123
    Abstract: Method for making hollow microspheres of substantially uniform diameter and of substantially uniform wall thickness is disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have substantially uniform void content and the interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles. The method includes heating the microspheres for a sufficient period of time to close and seal the interconnecting void.
    Type: Grant
    Filed: June 13, 1990
    Date of Patent: July 6, 1993
    Inventor: Leonard B. Torobin
  • Patent number: 5212143
    Abstract: Hollow porous microspheres of substantially uniform diameter and of substantially uniform wall thickness are disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have substantially uniform void content and the interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles.
    Type: Grant
    Filed: May 5, 1988
    Date of Patent: May 18, 1993
    Inventor: Leonard B. Torobin
  • Patent number: 5154866
    Abstract: A molding process for preparing long and thick, large porous PTFE articles comprising preparation steps of a powder for molding which includes a step of gelation of PTFE powder; a pre-forming step by a ram-extrusion; a baking step of the pre-formed article under a non-constrained circumstance; and if necessary, a cooling step; said powder for molding being containing a binder which has a melting point of lower than that of PTFE and does not decompose at a baking temperature of PTFE.
    Type: Grant
    Filed: April 2, 1992
    Date of Patent: October 13, 1992
    Assignee: Daikin Industries, Ltd.
    Inventors: Norimasa Honda, Hirokazu Yukawa
  • Patent number: 5124188
    Abstract: Absorbent polymeric macrostructures that are porous and comprise an interparticle crosslinked aggregate having a circumscribed dry volume greater than about 10.0 mm.sup.3. The interparticle crosslinked aggregrate comprises a multiplicity of precursor particles of substantially water-soluble, absorbent, hydrogel-forming, polymer material; and an interparticle crosslinking agent reacted with the polymer material of the precursor particles to form crosslink bonds between the precursor particles. Because of the particulate nature of the precursor particles, the macrostructure has pores between adjacent precursor particles. The pores are interconnected by intercommunicating channels such that the macrostructure is liquid permeable.
    Type: Grant
    Filed: April 2, 1990
    Date of Patent: June 23, 1992
    Assignee: The Procter & Gamble Company
    Inventors: Donald C. Roe, Frank H. Lahrman, Charles J. Berg
  • Patent number: 5124364
    Abstract: A composite foam of low thermal conductivity comprisesa) 20-80% by volume of silica aerogel particles having a mean diameter of from 0.1 to 20 mm and a density of from 0.08 to 0.40 g/cm.sup.3,b) 20-80% by volume of styrene polymer foam which surrounds the particles of component a) and binds them to one another and has a density of from 0.01 to 0.15 g/cm.sup.3, and, if desired,c) conventional additives in effective amounts.
    Type: Grant
    Filed: December 2, 1991
    Date of Patent: June 23, 1992
    Assignee: BASF Aktiengesellschaft
    Inventors: Bernardo Wolff, Frieder Hohwiller, Guenther Seybold
  • Patent number: 5102597
    Abstract: Absorbent polymeric macrostructures that are porous and comprise an interparticle crosslinked aggregate having a circumscribed dry volume greater than about 10.0 mm.sup.3. The interparticle crosslinked aggregate comprises a multiplicity of precursor particles of substantially water-insoluble, absorbent, hydrogel-forming, polymer material; and an interparticle crosslinking agent reacted with the polymer material of the precursor particles to form crosslink bonds between the precursor particles. Because of the particulate nature of the precursor particles, the macrostructure has pores between adjacent precursor particles. The pores are interconnected by intercommunicating channels such that the macrostructure is liquid permeable.
    Type: Grant
    Filed: May 24, 1991
    Date of Patent: April 7, 1992
    Assignee: The Procter & Gamble Company
    Inventors: Donald C. Roe, Frank H. Lahrman, Charles J. Berg
  • Patent number: 5035275
    Abstract: The thermal shrinkage and pyrolysis rate of plastic foam moldings are successfully controlled by coating the expandable plastic beads used in the preparation of the moldings with varying amounts of substantially water-insoluble inorganic siliceous materials. The plastic foam moldings are useful as patterns in an evaporative casting process, wherein the molding is vaporized and replaced by molten metal.
    Type: Grant
    Filed: October 25, 1989
    Date of Patent: July 30, 1991
    Assignee: Arco Chemical Technology, Inc.
    Inventor: Takeshi Yamaguchi
  • Patent number: 4977196
    Abstract: High molecular weight polyester resins such as polyethylene terephthalate, are sometimes produced from low molecular weight polyester prepolymers having the same composition by solid state polymerization. The low molecular weight polyester prepolymers which are used in such solid state polymerizations are normally prepared by conventional melt polymerizations and are generally in the form of pellets or chips. Solid state polymerization rates can be greatly improved by utilizing polyester prepolymers which are in the form of porous pills. By utilizing polyester prepolymers that are in the form of porous pills, higher molecular weights can be achieved after shorter solid state polymerization times.This invention relates to an improved process for solid state polymerizing porous pills which are made by compacting fine fibers of the polyester prepolymer.
    Type: Grant
    Filed: December 26, 1989
    Date of Patent: December 11, 1990
    Assignee: The Goodyear Tire & Rubber Company
    Inventor: Steven N. Scannapieco
  • Patent number: 4957945
    Abstract: There is a growing demand for high molecular weight polyester resin. For instance, the market for high molecular weight polyethylene terephthalate resin is rapidly expanding. High molecular polyethylene terephthalate resin is currently being used in vast quantities in manufacturing bottles for carbonated beverages, trays for frozen foods which can be heated in either microwave ovens or convection ovens, and in tire cord. There is a growing trend toward higher molecular weights in many applications for such polyester resins. Unfortunately, it becomes progressively more difficult and expensive to produce polyester resins having higher and higher molecular weights utilizing standard commercial polymerization techniques. This invention discloses a technique by which polyester resin having extremely high molecular weight can be prepared utilizing a very rapid solid state polymerization process.
    Type: Grant
    Filed: January 2, 1990
    Date of Patent: September 18, 1990
    Assignee: The Goodyear Tire & Rubber Company
    Inventor: Gerald Cohn
  • Patent number: 4942092
    Abstract: An extruded porous article, which can be prepared by a ram-extruding method, comprising an aggregated aromatic polyimide powder which has a heat loss ratio of not more than 2 wt. %, the heat loss ratio being measured at 360.degree. C. for 1 hour, and a mean particle size in the range of 1 to 40 .mu.
    Type: Grant
    Filed: April 17, 1989
    Date of Patent: July 17, 1990
    Assignees: UBE Industries, Ltd., NTN-Rulon Industries, Ltd.
    Inventors: Seiichirou Takabayashi, Masaki Egami
  • Patent number: 4925880
    Abstract: Porous shaped articles made from a molded composite of ultra high molecular weight polyethylene and polyethylene wax are disclosed. These articles are produced by free-sintering a non intensively mixed blend of UHMW-PE particles and particles of a polyethylene wax. The process involves mixing the UHMW-PE and wax both in powdered form until a heterogeneous mixture is formed, but under conditions which do not lead to any substantial fracturing of the UHMW-PE particles or melting of either component. The heterogeneous mix is then transferred to a press mold to form a shape and pressure is applied sufficient only to maintain the enclosed volume of the shape. The mold is heated to a temperature above the melting point of the UHMW-PE for a period of time to allow the particles to soften, expand, and contact one another at their surfaces. The mixture is then quickly cooled.
    Type: Grant
    Filed: August 3, 1989
    Date of Patent: May 15, 1990
    Assignee: Hoechst Celanese Corporation
    Inventor: Harvey L. Stein
  • Patent number: 4912176
    Abstract: Sinterd molded article having improved thermal resistance and strength formed from a homogeneous mixture comprising from about 5 to 75 percent by weight polybenzimidazole and from about 95 to 25 percent by weight of a polyaryleneketone.
    Type: Grant
    Filed: April 13, 1989
    Date of Patent: March 27, 1990
    Assignee: Hoechst Celanese Corporation
    Inventors: Edwardo Alvarez, Lorenzo P. DiSano, Bennett C. Ward
  • Patent number: 4882113
    Abstract: A composition comprising a homogenous mixture of unsintered porous fluoropolymer particles and fluoroelastomers, processes for manufacturing the composition, and devices made from the composition.
    Type: Grant
    Filed: January 26, 1989
    Date of Patent: November 21, 1989
    Assignee: Baxter International Inc.
    Inventors: Roger Tu, Wilfred F. Mathewson
  • Patent number: 4880843
    Abstract: Porous shaped articles made from a molded composite of ultra high molecular weight polyethylene and polyethylene wax are disclosed. These articles are produced by free-sintering a non intensively mixed blend of UHMW-PE particles and particles of a polyethylene wax. The process involves mixing the UHMW-PE and wax both in powdered form until a heterogeneous mixture is formed, but under conditions which do not lead to any substantial fracturing of the UHMW-PE particles or melting of either component. The heterogeneous mix is then transferred to a press mold to form a shape and pressure is applied sufficient only to maintain the enclosed volume of the shape. The mold is heated to a temperature above the melting point of the UHMW-PE for a period of time to allow the particles to soften, expand, and contact one another at their surfaces. The mixture is then quickly cooled.
    Type: Grant
    Filed: March 28, 1988
    Date of Patent: November 14, 1989
    Assignee: Hoechst Celanese Corporation
    Inventor: Harvey L. Stein
  • Patent number: 4870116
    Abstract: A dye-containing porous plastic element, comprising a plastic body having interconnected capillary passageways, and a dry, water-soluble dye located within the passageways. The passageways extend to at least one surface of the body, and the size of the passageways are such that the body, when contacted with water, can absorb the water to wet the dye and make it soluble. The plastic body comprises fused granules of plastic interspersed with dry granules of dye. The plastic granules may have a diameter, prior to fusion, of between about 50 and 800 microns, preferably between about 100 and 300 microns. The dry dye comprises between about 5 percent and 35 percent of the element, by weight, and preferably between about 10 percent and 20 percent.
    Type: Grant
    Filed: December 19, 1988
    Date of Patent: September 26, 1989
    Inventor: Irving M. Wolbrom
  • Patent number: 4863974
    Abstract: The present invention provides for a bone growth material for filling in defects or hollow portions of bones to be ingrown by and coalesce with bone tissues wherein the bone growth material is comprised of expanded PTFE and calcium phosphate.
    Type: Grant
    Filed: August 3, 1988
    Date of Patent: September 5, 1989
    Assignee: W. L. Gore & Associates, Inc.
    Inventors: Robert S. Mallouk, William P. Mortimer, Jr.
  • Patent number: 4849497
    Abstract: High molecular weight polyester resins such as polyethylene terephthalate, are sometimes produced from low molecular weight polyester prepolymers having the same composition by solid state polymerization. The low molecular weight polyester prepolymers which are used in such solid state polymerizations are normally prepared by conventional melt polymerizations and are generally in the form of pellets or chips. Solid state polymerization rates can be greatly improved by utilizing polyester prepolymers which are in the form of porous pills. By utilizing polyester prepolymers that are in the form of porous pills, higher molecular weights can be achieved after shorter solid state polymerization times.This invention relates to an improved process for solid state polymerizing porous pills which are made by compacting fine fibers of the polyester prepolymer.
    Type: Grant
    Filed: August 3, 1988
    Date of Patent: July 18, 1989
    Assignee: The Goodyear Tire & Rubber Company
    Inventor: Steven N. Scannapieco
  • Patent number: 4797243
    Abstract: A dye-containing porous plastic element, comprising a plastic body having interconnected capillary passageways, and a dry, water-soluble dye located within the passageways. The passageways extend to at least one surface of the body, and the size of the passageways are such that the body, when contacted with water, can absorb the water to wet the dye and make it soluble. The plastic body comprises fused granules of plastic interspersed with dry granules of dye. The plastic granules may have a diameter, prior to fushion, of between about 50 and 800 microns, preferably between about 100 and 300 microns. The dry dye comprises between about 5 percent and 35 percent of the element, by weight, and preferably between about 10 per cent and 20 percent .
    Type: Grant
    Filed: April 4, 1988
    Date of Patent: January 10, 1989
    Inventor: Irving M. Wolbrom
  • Patent number: 4777154
    Abstract: Hollow microspheres are made by a process which comprises forming a film of a dispersed particle film-forming composition (containing dispersed particles, a binder, a film stabilizing agent and a continuous liquid phase) across a coaxial blowing nozzle, applying a blowing gas at a positive pressure on the inner surface of the dispersed particle composition film to blow the film and form, in the region of the coaxial blowing nozzle orifice, hollow dispersed particle microspheres having stable film walls, removing the hollow microspheres, treating them to bring dispersed particles into point to point contact and harden them to obtain hollow green microspheres, and subsequently subjecting them to a sufficiently high temperature for a sufficient period of time to remove the continuous liquid phase and to sinter the dispersed particles at their points of contact to form within the walls of said hollow microspheres interconnecting voids that are continuous from the outer wall surface to the inner wall surface of th
    Type: Grant
    Filed: July 28, 1986
    Date of Patent: October 11, 1988
    Inventor: Leonard B. Torobin
  • Patent number: 4772516
    Abstract: A method for producing methylpolydisilylazane polymers of reduced chloride content that exhibit no increase in pyrophoricity and exhibit improved shelf life. The methylpolydisilylazane polymers of reduced chloride content are useful in the production of silicon nitride and silSTATEMENT OF GOVERNMENT RIGHTSThe United States Government has rights in this invention pursuant to Contract Number F33615-85-C-5006 awarded by the United States Air Force.
    Type: Grant
    Filed: November 9, 1987
    Date of Patent: September 20, 1988
    Inventor: Louis G. Mahone
  • Patent number: 4760102
    Abstract: A porous polytetrafluoroethylene material produced by forming a mixture of an adequate amount of a liquid lubricant and polytetrafluoroethylene fine powder having an average molecular weight of at least 6,000,000, an amorphous index larger than 0.1 and a number average primary particle size of 0.1 to 0.8 microns, and a clear endothermic peak at a temperature of 347.+-.3.degree. C. and an another endothermic peak or shoulder at a temperature between 330.degree. C. and the temperature of said clear endothermic peak on a crystalline melting chart recorded by a differential scanning calorimeter, removing the lubricant to obtain an unsintered PTFE material and expanding the unsintered polytetrafluoroethylene material at least monoaxially at a temperature higher than the melting point of polytetrafluoroethylene.
    Type: Grant
    Filed: July 15, 1986
    Date of Patent: July 26, 1988
    Assignees: Nitto Electric Industrial Co., Ltd., Daikin Kogyo Co., Ltd.
    Inventors: Yasuhiro Moriyama, Shoji Suzuki, Atsuo Yoshimura, Kanji Kawakami, Jyuzaemon Hoashi, Syozo Fumoto, Kiyoshi Oshita
  • Patent number: 4735626
    Abstract: New dynamic air freshener unit comprises a porous synthetic polymer support impregnated with a fragrance. The synthetic polymer support is one produced by:(a) bonding together small particles of solid polymer;(b) coagulating polymer solutions in a non-solvent for the polymer; or(c) expanding a thermoplastic or thermosetting plastic by means of a blowing agent; to form a porous body.The unit is especially useful in vacuum cleaners.
    Type: Grant
    Filed: July 6, 1987
    Date of Patent: April 5, 1988
    Assignees: Reckitt & Colman Products Limited, Porvair Limited
    Inventors: Brian R. Smith, Arthur W. R. Balkham
  • Patent number: 4725392
    Abstract: A new type of aromatic polyamide powder including a large number of fine coalescible particles which have an average size of from 0.1 to 10 .mu.m, which include at least one aromatic amide polymer including 40 to 100 molar % of recurring m-phenylene isophthalamide units and 0 to 60 molar % of at least one other type of additional recurring aromatic amide units, for example, m-phenylene terephthalamide units, and which coalesce with each other to form porous agglomerates having an average size of from 10 to 400 .mu.m and a surface area of from 1 to 20 m.sup.2 /g, and can be compression molded, optionally in mixture with a reinforcing additive, for example, aromatic polyamide fibers having a length of 3 mm or less, at a temperature of 200.degree. to 400.degree. C. under a pressure of 300 to 1000 kg/cm.sup.2 for 20 minutes to 5 hours, to produce shaped articles having excellent mechanical properties and appearance.
    Type: Grant
    Filed: July 8, 1987
    Date of Patent: February 16, 1988
    Assignee: Teijin Limited
    Inventors: Hideo Matsui, Hiroshi Fujie, Takashi Noma