With Nonmetal Constituent - Silicon(si) Considered A Metal (e.g., Cermet, Etc.) Patents (Class 75/230)
  • Publication number: 20030200836
    Abstract: A solder powder comprises solder particles having a distribution such that the number of particles having a particle diameter of 20 &mgr;m or less is 30% or less, wherein the oxygen content is 500 ppm or less. A flux for solder paste comprises an organic acid component consisting of an organic acid ester and an ester decomposer catalyst, an organic halogen compound, a reducing agent and a resin component. A solder paste mainly comprises a flux and a solder powder, wherein the water content of the solder paste is 0.5% by weight or less.
    Type: Application
    Filed: April 7, 2003
    Publication date: October 30, 2003
    Applicant: SHOWA DENKO K.K.
    Inventors: Hitoshi Amita, Takashi Shoji, Shunsuke Nagasaki, Yoshinori Shibuya, Isamu Taguchi, Noriko Murase
  • Patent number: 6627148
    Abstract: A magnesium hydrogen storage alloy that has been hydrided and compacted into highly dense pellets for shipment and use, a method for making said magnesium alloy and a method for the safe, economical shipment of said hydrided magnesium hydrogen storage material.
    Type: Grant
    Filed: August 8, 2000
    Date of Patent: September 30, 2003
    Assignee: Energy Conversion Devices, Inc.
    Inventors: Stanford R. Ovshinsky, Rosa T. Young, Ned T. Stetson, Vitaliy Myasnikov
  • Patent number: 6621399
    Abstract: A powder core is obtained by compaction-forming magnetic powder. The magnetic powder is an alloy comprising 1-10 wt % Si, 0.1-1.0 wt % O, and balance Fe. An insulator comprising SiO2 and MgO as main components is interposed between powder particles having a particle size of 150 &mgr;m or less.
    Type: Grant
    Filed: January 17, 2002
    Date of Patent: September 16, 2003
    Assignee: NEC Tokin Corporation
    Inventors: Teruhiko Fujiwara, Masayoshi Ishii, Yoshitaka Saito
  • Publication number: 20030101849
    Abstract: Compositions of a manganese sulfide (MnS) compound useful as additives for making a sintered product are disclosed, in which molybdenum (Mo) or Fe—Mo is added to the MnS compound to improve machinability and to obtain a more stable MnS compound, thereby reducing any change in weight and size in a sintering process. The compositions can suppress erosion of parts in a sintering furnace during a sintering process, prevent sooting on a surface of the sintered product from occurring, and enhance resistance to moisture in the air to keep the sintered product in the air for a long time.
    Type: Application
    Filed: August 14, 2002
    Publication date: June 5, 2003
    Inventors: Dong Kyu Park, Hyung Bum Kim
  • Patent number: 6569524
    Abstract: The present invention provides a composite material having comparatively high thermal conductivity and a small coefficient of thermal expansion, which is low cost and preferable as a heatsink material. A graphite powder and an alloy powder, whose main constituent is Ag and Cu, and including Ti, etc., which is selected from the elements belonging to 4A, 5A and 6A groups, are blended together, and are heated at a higher temperature than the melting point of the alloy in a vacuum state or in a gas atmosphere of He, Ar or hydrogen. A coating layer of metal carbide such as TiC is formed on the surface of the graphite grains, and at the same time, they are transformed into a sintered body. The composite material thus obtained is such that the relative density thereof is 70% or more, thermal conductivity thereof is 220 W/m·K or more at room temperature, and the mean coefficient of thermal expansion from the room temperature to 200° C. is 5 through 15×10−6/°C.
    Type: Grant
    Filed: June 22, 2001
    Date of Patent: May 27, 2003
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Chihiro Kawai, Hirohiko Nakata
  • Publication number: 20030075014
    Abstract: Cotton-like aggregates (B) including grinding chips from an iron-based metal and a grinding fluid containing oil and water are compression molded for forming a brittle compact (C) having the fibrous grinding chips roughly sheared and excessive water and oil removed therefrom. The brittle compact (C) is crushed for further finely shearing the grinding chips and the resultant grinding chips are mixed with a solidification assistant (D) for producing an iron-based powder material (E) containing the solidification assistant (D).
    Type: Application
    Filed: September 4, 2002
    Publication date: April 24, 2003
    Inventors: Masataka Ishihara, Akio Maemoto, Mitsuma Matsuda, Yoshihiro Seo, Shouichi Kashino
  • Patent number: 6551375
    Abstract: Tungsten powder is mixed with a second powder metal and a binder to be used as small arms projectiles and shot pellets for use in shot guns which is cost effective to produce and which can perform ballistically. Ballistic performance equal to or superior to that of lead would be offered by a material having a specific gravity equal to or greater than lead. The non-toxic projectiles are manufactured in a cost-effective process; yet still produces projectiles and shot pellets that can perform ballistically. This projectile composition can perform substantially as well as lead and lead alloys or better without the need to fabricate the composition from a high temperature molten state which requires large amounts of energy input. In one particular embodiment of the invention, the tungsten powder is blended with iron powder and Portland Cement for constructing projectiles. The tungsten, iron and Portland Cement (W/Fe Portland cement) shot provides a satisfactory substitute for lead shot.
    Type: Grant
    Filed: March 6, 2001
    Date of Patent: April 22, 2003
    Assignee: Kennametal Inc.
    Inventors: David Richard Siddle, Joseph Matthew Tauber, Francois-Charles Henri Dary
  • Publication number: 20030047029
    Abstract: Nonstick ceramo-metallic coating for cooking utensils The invention concerns a non-stick coating (4) for cooking utensils (1) characterized in that it is selected among the group comprising (a) ceramics alone selected among titanium oxynitride, titanium suboxides, titanium subnitrides, spinels, mixed spinels ; and (b) ceramo-metallic mixtures wherein the ceramics are selected among titanium oxynitrides, titanium suboxides, titanium subnitrides, spinels, cerium fluoride, silicon carbide, pyrolitic carbon, boron carbide, and the metal is titanium.
    Type: Application
    Filed: September 27, 2002
    Publication date: March 13, 2003
    Inventors: Bernard Hansz, Christhope Malavolta, Emmanuel Brugger, Paul Dodane, Christian Coddet
  • Publication number: 20030047028
    Abstract: Exchangeable metal ions are removed from an amorphous composite metal oxide and different metal ions are introduced to manufacture a nanomaterial of composite metal oxide. Based on this method, it is possible to reliably form composite metal oxide nanomaterials over a wide range of compositions.
    Type: Application
    Filed: August 8, 2002
    Publication date: March 13, 2003
    Inventors: Toyoki Kunitake, Izumi Ichinose, Rie Takaki, Junhui He
  • Patent number: 6489928
    Abstract: Provided is a composite dielectric molded product exhibiting excellent properties such as the antenna gain and side lobe, etc. when used for a lens antenna, and exhibiting less variation of properties in one individual product and between individual products. The composite dielectric molded product is formed by molding a composite dielectric material containing a dielectric inorganic filler and an organic polymer material so that the dielectric constant anisotropy is in the range of about 1.00 to 1.05.
    Type: Grant
    Filed: October 17, 2001
    Date of Patent: December 3, 2002
    Assignee: Murata Manufacturing Co., Ltd.
    Inventor: Kiyoyasu Sakurada
  • Publication number: 20020152839
    Abstract: Shaped bodies containing particulate iron materials, such as cast pellets, briquettes and the like, with sufficient strength to withstand temperatures of up to at least 1000° C. can be obtained by using a fully hydrated high-alumina cement as the binder. The strength of the pellets at elevated temperatures can be further enhanced by adding small amounts of bentonite, silica fume or other suitable supplementary cementing materials, and super plasticizer. The iron particulate materials, typically having a size range of from about 0.01 mm to 6 mm, include ore fines, sinter fines, BOF and EAF dusts, mill scale, and the like. Powdered carbonaceous material, such as ground coal or coke, may also be added to the pellets. The shaped bodies are suitable for use in blast furnaces, basic oxygen furnaces, and in DRI processes.
    Type: Application
    Filed: April 16, 2002
    Publication date: October 24, 2002
    Inventors: Jay Aota, Lucie Morin
  • Publication number: 20020124687
    Abstract: A niobium powder is described which when formed into an electrolytic capacitor anode, the anode has the capacitance of at least 62,000 CV/g. Methods of making flaked niobium powder which have high capacitance capability when formed into electrolytic capacitor anodes is also described. Besides niobium, the present invention is also applicable to other metals, including valve metals.
    Type: Application
    Filed: February 1, 2002
    Publication date: September 12, 2002
    Inventors: Kurt A. Habecker, James A. Fife
  • Patent number: 6447569
    Abstract: A blade material, containing diamond particles below about 100 &mgr;m in diameter, is formed as a cutting material where the diamond particles serve as cutting agents while being fixed in a retaining matrix. The retaining matrix substantially includes Titanium or a Titanium alloy containing more than about 50 wt % of Titanium and fixes the diamond particles in place through a multi-step process.
    Type: Grant
    Filed: July 12, 2000
    Date of Patent: September 10, 2002
    Inventor: Kimiko Sueta
  • Patent number: 6423196
    Abstract: A method for making a nickel/silicon sputter target, targets made thereby and sputtering processes using such targets. The method includes the step of blending molten nickel with sufficient molten silicon so that the blend may be cast to form an alloy containing no less than 4.5 wt .% silicon. Preferably, the cast ingot is then shaped by rolling it to form a plate having a desired thickness. Sputter targets so formed are capable of use in a conventional magnetron sputter process; that is, one can be positioned near a cathode in the presence of an electric potential difference and a magnetic field so as to induce sputtering of nickel ion form the sputter target onto the substrate.
    Type: Grant
    Filed: March 24, 2000
    Date of Patent: July 23, 2002
    Assignee: Tosoh SMD, Inc.
    Inventor: Eugene Y. Ivanvov
  • Publication number: 20020078793
    Abstract: Highly filled composite materials, e.g. comprising approximately 60 volume % or greater of finely powdered particles of filler in a polymer matrix, are made by dissolving polymer in a volatilisable solvent, adding filler and forming a homogeneous mixture by high shear mixing. Most solvent is then removed while maintaining homogeneity in the mixture, preferably by evaporation in a high shear mill. Then, extruding a thin layer of the composite material and removing remaining solvent, as by heating. Bodies are formed from the dried layer, which are heated and pressed to melt and disperse melted polymer into the interstices between filler particles. Thereby, certain polymers unusable at low solids contents become effective bonding materials at high solids contents. Filler materials are chosen to tailor electrical and physical properties of the articles, which may comprise substrates for electronic circuits. Suitable polymers are certain polyarylene ethers soluble in cyclohexanone.
    Type: Application
    Filed: October 5, 2001
    Publication date: June 27, 2002
    Inventors: Richard A. Holl, Philip L. Lichtenberger, Kenneth S. Yao
  • Patent number: 6398843
    Abstract: A dispersion-strengthened material is described which comprises aluminium or aluminium alloy containing a substantially uniform dispersion of ceramic particles to confer dispersion strengthening which is inherently stable at high working temperatures, the ceramic particles having a diameter of less than 400 nm, and preferably in the range 10 nm to 100 nm. Suitable ceramic dispersoids include Al2O3, TiO2, Al3C4, ZrO2, Si3N4, SiC, SiO2.
    Type: Grant
    Filed: May 4, 2000
    Date of Patent: June 4, 2002
    Assignee: Qinetiq Limited
    Inventor: Andrew Tarrant
  • Patent number: 6391082
    Abstract: Composite materials comprising at least 60 volume %, preferably 70 volume %, of particles of finely powdered filler material in a matrix of poly(arylene ether) polymer material are made by forming a mixture of the components, forming the required bodies therefrom, and then heating and pressing the bodies to a temperature sufficient to melt the polymer and to a pressure sufficient to disperse the melted polymer into the interstices between the filler particles. Surprisingly these polymer materials can only be effective as bonding materials when the solids content is as high as that specified, since with lower contents the resultant bodies are too friable. This is completely contrary to accepted prior art practice which considers that composites are progressivly weakened as the solids content is increased, so that such content must be limited.
    Type: Grant
    Filed: July 2, 1999
    Date of Patent: May 21, 2002
    Assignee: Holl Technologies Company
    Inventor: Richard A. Holl
  • Patent number: 6387148
    Abstract: The present invention provides a hydrogen absorbing alloy compact for use as the negative electrode of an alkaline rechargeable battery which is made without the aid of a current-collecting support, contains a binder dispersed in the interstices formed by mutual contact of hydrogen absorbing alloy particles and on the alloy surfaces, and has a bulk density of 3.5 to 6.0 g/cm3. The present invention also provides a compact electrode which is made by forming a porous hydrogen absorbing alloy compact containing neither current-collecting support nor binder, impregnating the compact with an aqueous solution (or solvent solution) of a binder, and then drying the compact to remove the water (or solvent) alone, so that the strength of the compact is increased and good electrical contact between alloy particles is established.
    Type: Grant
    Filed: July 27, 2000
    Date of Patent: May 14, 2002
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Hajime Nakano, Noriaki Hamaya, Satoshi Shima
  • Patent number: 6379417
    Abstract: The present invention provides a nickel cermet, which includes: 35% to 70% by weight of a nickel phase, and 65% to 30% by weight of zirconium oxide phase, wherein the zirconium oxide is stabilized in cubic form by 5 to 20 moles of yttrium oxide for each 100 moles of said zirconium oxide, and the metal nickel and zirconium oxide phases, upon X ray diffraction analysis are distinct and homogeneously distributed; and is prepared by a process that includes: a) dispersing zirconia stabilized by yttria having a particle size of between 1 and 40 &mgr;m , in demineralized water to prepare a suspension; b) dissolving a hydrosoluble and thermodecomposable nickel salt in demineralized d water to prepare a solution; c) mixing the nickel solution with the suspension and homogenizing the resulting dispersion by magnetic stirring for a time of between 5 and 40 minutes; d) eliminating the water from the dispersion by a system capable of operating without, or almost without, decomposition phenomena to obtain a solid th
    Type: Grant
    Filed: May 24, 1999
    Date of Patent: April 30, 2002
    Assignee: Eniricerche S.p.A.
    Inventors: Giampietro Piro, Maria Federica Gagliardi, Alessandro Selvaggi
  • Publication number: 20020038582
    Abstract: Composite materials comprising at least 60 volume %, preferably 70 volume %, of particles of finely powdered filler material in a matrix of poly(arylene ether) polymer material are made by forming a mixture of the components, forming the required bodies therefrom, and then heating and pressing the bodies to a temperature sufficient to melt the polymer and to a pressure sufficient to disperse the melted polymer into the interstices between the filler particles. Surprisingly these polymer materials can only be effective as bonding materials when the solids content is as high as that specified, since with lower contents the resultant bodies are too friable. This is completely contrary to accepted prior art practice which considers that composites are progressivly weakened as the solids content is increased, so that such content must be limited.
    Type: Application
    Filed: July 2, 1999
    Publication date: April 4, 2002
    Inventor: RICHARD A. HOLL
  • Patent number: 6338753
    Abstract: Powder product for the protection of molds for centrifugal casting of cast iron tubes, and a method for its production. The powder contains a mixture of a silicon-based inoculating agent and a mineral powder, the silicon-based inoculating product comprising waste masses from synthesis of alkyl- or aryl- halosilanes, from which tin and optionally copper has been removed. The mineral powder may contain at least one material selected from the group consisting of carbon and a fluoride.
    Type: Grant
    Filed: January 5, 1999
    Date of Patent: January 15, 2002
    Assignee: Pechiney Electrometallurgie
    Inventors: Thomas Margaria, Roland Siclari
  • Patent number: 6319485
    Abstract: A magnetic material made up of an assembly of particles substantially consisting of an &agr;″-Fe16N2 crystal having a body-centered tetragonal system (bct). The magnetic material has a high saturated magnetic flux density and is directly synthesized by reacting fine particles of &agr;-Fe and a nitrogen-containing gas at a temperature of 200° C. or lower. By the synthesis of this invention, &agr;″-Fe16N2, which is a metastable compound conventionally deposited accompanied with phase transformation of crystallization from a martensite phase of &agr;′-Fe(N), is obtained as an isolated bulk substance in a single phase.
    Type: Grant
    Filed: January 19, 1999
    Date of Patent: November 20, 2001
    Assignee: Dowa Mining Co., Ltd.
    Inventors: Akira Nagatomi, Fumikazu Kanamaru, Shinichi Kikkawa
  • Patent number: 6299424
    Abstract: When sliding elements, slide bushings, vanes and Oldham rings employed in various types of refrigeration compressors and other applications meet the following conditions, they resist sticking to aluminum-base components, resist depletion of the oil film on slide faces, and exhibit excellent wear resistance. Firstly, the elements must comprise an iron-base sinter having closed cells on at least the slide face. Secondly, in order for the oil film to be maintained on the slide face by the closed cells and to enhance lubricating properties, the proportion of closed cells having circular-equivalent diameter of 10 &mgr;m or less, i.e. the number of ≦10 &mgr;m cells/total number of cells, must equal 85% or more, and the opening area of the closed cells on the slide face must equal 5% or less. Finally, the sliding element density must be 7.3 g/cm3 or higher.
    Type: Grant
    Filed: April 11, 2000
    Date of Patent: October 9, 2001
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Yoshiyuki Futagami, Hideo Hirano, Hideto Oka, Masahiro Tsubokawa
  • Patent number: 6296681
    Abstract: The present invention relates to a sinter and a casting comprising a high-hardness glassy alloy containing at least Fe and at least a metalloid element and having a temperature interval &Dgr;Tx of a supercooled liquid as expressed by &Dgr;Tx=Tx−Tg (where, Tx is a crystallization temperature and Tg is a glass transition temperature) of at least 20° C., which permit easy achievement of a complicated concave/convex shape.
    Type: Grant
    Filed: September 29, 1999
    Date of Patent: October 2, 2001
    Assignee: Alps Electric Co., Ltd.
    Inventors: Takao Mizushima, Akihiro Makino, Akihisa Inoue
  • Patent number: 6284060
    Abstract: A magnetic core of a compressed compact comprises a mixture of magnetic powder and a spacing material, wherein the distance between adjacent magnetic powder particles is controlled by the spacing material. In this constitution, a magnetic core low in core loss, high in magnetic permeability, and excellent in direct-current superposing characteristic is realized.
    Type: Grant
    Filed: September 4, 1998
    Date of Patent: September 4, 2001
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Nobuya Matsutani, Yuji Mido
  • Patent number: 6268412
    Abstract: Molding compositions for shaping parts from stainless steel powders are disclosed. The process comprises the steps of forming a mixture comprising stainless steel powder, a gel-forming material having a gel strength, measured at a temperature between 0° C. and about 30° C. and a gel comprising about 1.5 wt % of the gel-forming material and water, of at least about 200 g/cm2, and water, and molding the mixture at a temperature sufficient to produce a self-supporting article comprising the powder and gel. The preferred gel-forming material is an agaroid and the preferred molding process is injection molding.
    Type: Grant
    Filed: May 12, 2000
    Date of Patent: July 31, 2001
    Assignee: Rutgers, The State University of New Jersey
    Inventors: Michael Sean Zedalis, Rick Duyckinck, Brian Snow, Anthony Fanelli, Joan Virginia Burlew
  • Publication number: 20010008094
    Abstract: Nickel cermet consisting of from 35 to 70% by weight of a metal nickel phase and 65 to 30% by weight of a zirconium oxide (zirconia) phase stabilized in cubic form by 5 to 20 moles of yttrium oxide (yttria) for each 100 moles of zirconium oxide, the two phases, upon X ray diffractometric analysis, being distinct and homogeneously distributed, characterized in that it is obtained by a process comprising the following steps:
    Type: Application
    Filed: May 24, 1999
    Publication date: July 19, 2001
    Inventors: GIAMPIETRO PIRO, MARIA FEDERICA GARLIARDI, ALESSANDRO SELVAGGI
  • Patent number: 6254657
    Abstract: Disclosed is a molding method for powder particles, which is excellent in molding performance, and which makes it possible to obtain a preliminary molded product excellent in strength by enhancing mutual bonding between particles in the preliminary molded product. A molding apparatus for powder particles includes an outer frame die having a mold space with a lower punch and an upper punch to be slidably fitted thereto. Slight clearances exist between the outer frame die and the lower and upper punches. A mixture is prepared by mixing a powdery raw material with a liquid additive to cause an exothermic reaction therewith.
    Type: Grant
    Filed: August 17, 1999
    Date of Patent: July 3, 2001
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventor: Mitsuo Kuwabara
  • Patent number: 6231277
    Abstract: A cermet tool that has excellent thermal crack resistance, while maintaining plastic deformation resistance, wear resistance and a long service life even when it is used for intermittent cutting is disclosed. The cermet tool comprises Ni or Ni and Co in a total amount of 4-20 wt. %, Ti in an amount of 50-60 wt. %, V, Cr, Zr, Nb, Mo, Hf, Ta, and W in a total amount of 30-40 wt. %, C in an amount of 5-10 wt. %, and N in an amount of 3-8 wt. %. The carbonitride phase contains grains of a Ti carbonitride phase containing Ti in an amount of 90 wt. % or more with respect to all the metal components of the phase. When the cross-sectional microcrystalline structure of the cermet is observed, the ratio of “total area of grains of the Ti carbonitride phase having a ratio of Dmax/Dmin of 1.5 or more” to “total area of the hard phase” is 50% or more.
    Type: Grant
    Filed: October 28, 1998
    Date of Patent: May 15, 2001
    Assignee: NGK Spark Plug Co., Ltd.
    Inventor: Kohei Abukawa
  • Patent number: 6214079
    Abstract: A method for fabricating a triphasic composite such as a WC/Co/diamond composite with a high volume fraction of diamond in a WC/Co matrix. The method involves sintering of a WC/Co powder compact to develop a porous preform, which displays some rigidity and strength, infiltrating the porous preform with a controlled distribution of carbon, and high pressure/high temperature treatment of the carbon-containing WC/Co preform to transform the carbon to diamond. The distribution of diamond in the composite can be functionally graded to provide a WC/Co core and a diamond-enriched surface, wherein all three phases form an interconnected structure in three dimensions. Such a tricontinuous structure combines high strength and toughness with superior wear resistance, making it attractive for applications in machine tools and drill bits.
    Type: Grant
    Filed: December 21, 1999
    Date of Patent: April 10, 2001
    Assignee: Rutgers, The State University
    Inventors: Bernard H. Kear, Rajendra K. Sadangi, Larry E. McCandlish, Oleg Voronov
  • Patent number: 6183606
    Abstract: A method of producing high coercivity FePt—Si3N4 granular composite thin films for magnetic recording media is invented. The method includes magnetron co-sputtering of FePt and Si3N4 targets at controlled sputtering power and sputtering argon gas pressure to form a selective composition of granular FePt—Si3N4 thin film on a low temperature substrate, then post-annealed in vacuum at selective time period and temperature. Two kinds of FePt targets can be used. One is the FePt alloy target. The other one is a composite target consisting of an iron disk overlaid with small Pt pieces. This arrangement provides a wide range of effective target compositions and therefore film compositions. FePt—Si3N4 films were deposited on natural oxidized silicon wafer or quartz glass substrate at room temperature. The as-deposited film has soft magnetic properties and granular structure with soft magnetic &ggr;-FePt particles dispersed in amorphous Si3N4 matrix.
    Type: Grant
    Filed: November 3, 1999
    Date of Patent: February 6, 2001
    Assignee: National Science Council of Republic of China
    Inventors: Po-Cheng Kuo, Chih-Ming Kuo
  • Patent number: 6179894
    Abstract: A method for producing high-density powder metallurgy articles formed of hard powder materials, and particularly hard ferromagnetic materials that yield powder metallurgy magnets exhibiting improved magnetic properties as compared to powder metallurgy magnets formed of pure iron. The method generally entails the use of a powder of a material that is harder than iron, and then encapsulating each particle of the powder with a layer of iron. The powder is then compacted, by which the particles are adhered together to form a powder metallurgy article. As a result of forming a sufficiently thick encapsulating layer of iron on each powder particle, the powder can be compacted to a greater density than would be possible without the encapsulating layer of iron. If a ferromagnetic material is used, the resulting magnetic article is capable of exhibiting magnetic properties superior to a substantially identical pure iron powder metallurgy magnet.
    Type: Grant
    Filed: November 29, 1999
    Date of Patent: January 30, 2001
    Assignee: Delphi Technologies, Inc.
    Inventor: David Earl Gay
  • Patent number: 6159265
    Abstract: The object is to provide a powdered metal injection compacting composition adapted to give compacts free from deformation, cracking or blistering without being compromised in compactability or debinder characteristic and without the aid of a special jig.This composition comprises a metal powder and an organic binder comprising (A) a crystalline resin having a melting point of not less than 150.degree. C., (B) an organic compound the weight loss on heating of which begins at a temperature below 150.degree. C. and (C) a composite acrylic resin, the composite acrylic resin mentioned above being a resin obtainable by dispersing a solution comprising the following components (C1).about.(C3) in an aqueous medium containing a dispersant and carrying out a suspension polymerization reaction:(C1) an ethylene-vinyl acetate copolymer or an ethylene-ethyl acrylate copolymer,(C2) a (meth)acrylic ester monomer or a mixture of a (meth)acrylic ester monomer and a styrenic monomer, and(C3) a polymerization initiator.
    Type: Grant
    Filed: February 11, 2000
    Date of Patent: December 12, 2000
    Assignees: Dai-Ichi Kogyo Seiyaku Co., Ltd., Dai-Ichi Ceramo Ltd.
    Inventors: Hiromitsu Kinoshita, Tetsuo Shiraiwa, Hidetaka Uraoka, Nobuo Ochiai
  • Patent number: 6159264
    Abstract: Composite materials comprising at least 60 volume %, preferably 70 volume %, of particles of finely powdered filler material in a matrix of poly(arylene ether) polymer material are made by forming a mixture of the components, forming the required bodies therefrom, and then heating and pressing the bodies to a temperature sufficient to melt the polymer and to a pressure sufficient to disperse the melted polymer into the interstices between the filler particles. Surprisingly these polymer materials can only be effective as bonding materials when the solids content is as high as that specified, since with lower contents the resultant bodies are too friable. This is completely contrary to accepted prior art practice which considers that composites are progressivly weakened as the solids content is increased, so that such content must be limited.
    Type: Grant
    Filed: July 2, 1999
    Date of Patent: December 12, 2000
    Assignee: Holl Technologies Company
    Inventor: Richard A. Holl
  • Patent number: 6149704
    Abstract: A dust core ferromagnetic powder comprises a ferromagnetic metal powder, an insulating material, and a lubricant. The insulating material comprises a phenol resin and/or a silicone resin, and the lubricant comprises at least one compound selected from the group consisting of magnesium stearate, calcium stearate, strontium stearate, and barium stearate. It is possible to achieve a dust core having high saturation magnetic flux density, low losses, and satisfactory permeability with its dependence on frequency being improved.
    Type: Grant
    Filed: July 29, 1999
    Date of Patent: November 21, 2000
    Assignee: TDK Corporation
    Inventors: Hideharu Moro, Takeo Tsukada, Katsuhiko Wakayama
  • Patent number: 6143052
    Abstract: A hydrogen storage material is disclosed with no collapse due to pulverization of hydrogen storage alloy particles by repeated hydrogen absorption and desorption thereby permitting repeated use while manifesting excellent electric and thermal conductivities. Pressure molding of hydrogen storage alloy particles, each being covered with a plated metal film having microgranules of a thermoplastic resin, at a temperature higher than a glass transition temperature or a melting point of and below a thermal decomposition temperature of the thermoplastic resin can produce a porous hydrogen storage material of hydrogen storage alloy particles being bonded to each other via the thermoplastic resin. The hydrogen storage material can become firm and strong because the plated metal films covering the hydrogen storage alloy particles are clasped with each other complexly.
    Type: Grant
    Filed: June 29, 1998
    Date of Patent: November 7, 2000
    Assignee: Kiyokawa Plating Industries, Co., Ltd.
    Inventors: Tadashi Kiyokawa, Hajime Kiyokawa, Masayuki Takashima
  • Patent number: 6143051
    Abstract: A friction material comprising a sintered mass of iron in which graphite particles are dispersed, which sintered mass is formed from between 13 and 22 vol. % of iron fibers, between 13 and 22 vol. % of iron particles having a particle size of 10-400 .mu.m, between 40 and 70 vol. % of graphite particles having a particle size of 25-3000 .mu.m, and between 10 and 15 vol. % of a metallic binder having a melting point of 800-1140.degree. C., and a method of preparing such a friction material, wherein a mixture of these components is compressed at a pressure of at least 100 MPa so as to form a compact having a desired form and size, and where the compact thus formed is sintered at a temperature between 800 and 1140.degree. C. for a period of time which is sufficiently long for achieving concretion of iron fibers, iron particles and metallic binder.
    Type: Grant
    Filed: May 20, 1999
    Date of Patent: November 7, 2000
    Assignees: A/S Roulunds Fabriker, Volvo Truck Corporation
    Inventors: Ole Kr.ae butted.mer, Niels Brams.o slashed., Erik Simonsen, Noel De Leon, Knud Strande, Rolf Tornberg, Claes Kuylenstierna
  • Patent number: 6089843
    Abstract: An outer rotor and an inner rotor are formed of sintered aluminum alloy. The sintered aluminum alloy contains 0.5 wt % to 11 wt % of aluminum nitride. Porosity of the sintered aluminum alloy for outer rotor is 3 vol % to 15 vol %. Porosity of the sintered aluminum alloy for inner rotor is 2 vol % to 10 vol %. Outer rotor and inner rotor are set in a pump case. A rotary driving shaft formed of steel is inserted to a through hole of inner rotor. A press fit member is inserted at a press fit surface of inner rotor and rotary driving shaft. Accordingly, sliding members formed of sintered aluminum alloy which reduces seizure and abrasive wear of the inner and outer rotors can be provided, and in addition, an oil pump of which wear and damage at the inner rotor inner diameter surface is suppressed, can be provided.
    Type: Grant
    Filed: September 10, 1998
    Date of Patent: July 18, 2000
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventor: Katsuyoshi Kondoh
  • Patent number: 6077327
    Abstract: There is disclosed a method of producing an aluminum composite material in which the content of silicon carbide can be made higher as compared with conventional methods, and the production cost is low, and the method can be carried out easily. An aluminum composite material of low-thermal expansion and high-thermal conductivity is produced by this method. A mixture of powder of aluminum metal or an alloy thereof and silicon carbide powder is pressurized and compacted to form a green compact. Subsequently, this green compact is charged into a mold, and is heated and compacted into a predetermined shape at a temperature not less than a melting point of the aluminum metal or the alloy thereof.
    Type: Grant
    Filed: March 20, 1997
    Date of Patent: June 20, 2000
    Assignee: Hitachi Metals, Ltd.
    Inventors: Shigeyuki Hamayoshi, Satoshi Fukui, Kenichiro Shimizu, Masahiko Ohshima
  • Patent number: 6068813
    Abstract: The present invention provides a method of making metallurgical powder compositions and a method of using the metallurgical powder compositions produced. The method of the present invention includes providing a prealloy powder containing iron and one or more alloying additives that is preferably molybdenum, and admixing the iron-based prealloy powder with a copper containing powder having a weight average particle size of 60 microns or less, and a nickel containing powder having a weight average particle size of 20 microns. The mixture containing the iron-based prealloy powder, copper containing powder, and nickel containing powder is bonded in some manner to facilitate adhesion of the prealloy powder with the other alloying powders. Preferably, a binding agent is used to effect bonding. The metallurgical powder compositions thus produced have, for example, improved mechanical strength properties when formed into metal parts.
    Type: Grant
    Filed: May 26, 1999
    Date of Patent: May 30, 2000
    Assignee: Hoeganaes Corporation
    Inventor: Frederick J. Semel
  • Patent number: 6063209
    Abstract: A magnetic core of a compressed compact comprises a mixture of magnetic powder and a spacing material, wherein the distance between adjacent magnetic powder particles is controlled by the spacing material. In this constitution, a magnetic core low in core loss, high in magnetic permeability, and excellent in direct-current superposing characteristic is realized.
    Type: Grant
    Filed: April 17, 1998
    Date of Patent: May 16, 2000
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Nobuya Matsutani, Yuji Mido
  • Patent number: 6051045
    Abstract: This invention is directed to metal-matrix composites which include a substantially continuous phase of metal and reinforcing ceramic particulate substantially uniformly dispersed therein and comprising at least two of barium titanium, titanium dioxide, and titanium nitride. The composite may include other reinforcing ceramic particulate materials like metal carbides such as titanium carbide and other titanates like calcium titanate. The reinforcing particulate can comprise up to about 70 volume percent of the composite and have an average particle diameter of between about 0.1 micron and 100 microns. In forming the composite, the metal powder employed has an average particle diameter between about 1 and 20 microns. The composite is useful to manufacture, e.g., automotive parts such as brake rotors and structural components.
    Type: Grant
    Filed: January 16, 1996
    Date of Patent: April 18, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventors: Chaitanya Kumar Narula, Sabine R. Nakouzi-Phillips, Gary Mark Crosbie
  • Patent number: 5993508
    Abstract: Silicon-containing residues, as they accumulate especially during the synthesis of organosilanes out of metallic silicon, and especially methyl chloride, are processed according to the invention to briquettes, being additives for the quality adjustment of cast iron being produced in a cupola furnace in order to avoid either costly regeneration for the recovering of the valuable components or the total dumping of said silicon-containing residues. Besides the silicon-containing residue the briquettes contain 1-10 percent by weight of cardboard fiber, 5-40 percent by weight of hydraulic cement and 0-20 percent by weight of additional additives having influence on the quality of the cast iron. The cement- and cardboard fiber-containing briquettes are mechanically and thermally sufficiently stable with respect to the operation of the melting furnace. The yielding rate of the inserted small-sized silicon in the cast iron is about 85% and reaches thereby the same range of lumpy ferrosilicon.
    Type: Grant
    Filed: January 23, 1997
    Date of Patent: November 30, 1999
    Assignee: Elkem ASA
    Inventor: Lutz Stephan
  • Patent number: 5984995
    Abstract: This invention relates to a method of manufacturing heat cells which are based on a specific iron oxidation chemistry and having specific physical dimensions and fill characteristics. This method uses direct compaction of powdered ingredients into granules, pellets, tablets, slugs, and/or the like. These heat cells, which can be incorporated into disposable body wraps, provide a controlled and sustained temperature for consistent, convenient, and comfortable heat application for treating temporary or chronic pain. This invention also relates to said exothemic compositions incorporated into said heat cells.
    Type: Grant
    Filed: March 29, 1996
    Date of Patent: November 16, 1999
    Assignee: The Procter & Gamble Company
    Inventor: Richard Keim White
  • Patent number: 5980604
    Abstract: Spray atomization of molten metal and/or intermetallic matrix composites reinforced with ceramic particles is practiced by atomizing the matrix into micron sized droplets and depositing the semisolid droplets in a bulk deposition upon a temperature controlled substrate. The semiliquid droplets are injected with refinement particles while in a range of 0 to 40% by volume solid phase and deposited on the substrate surface while in a 40 to 90% by volume solid phase. Refined grain morphology, increased solid solubility, nonequilibrium phases, absence of macro segregation, and elimination of the need to handle fine reactive particles are all achieved by performing the spray deposition process under a controlled atmosphere. Materials fabricated by the process exhibit unusual combinations of properties, such as spatially varying properties.
    Type: Grant
    Filed: June 13, 1996
    Date of Patent: November 9, 1999
    Assignee: The Regents of the University of California
    Inventor: Enrique J. Lavernia
  • Patent number: 5976215
    Abstract: An iron-based powder mixture for powder metallurgy, comprising: an iron-based powder, and from 0.05 to 0.50% by weight of a thermoplastic resin powder which comprises 50% or more by weight of units of at least one monomer selected from the group consisting of acrylic esters, methacrylic esters, and aromatic vinyl compounds, and whose average primary particle size is from 0.03 to 5 .mu.m, whose average agglomeration particle size is from 5 to 50 .mu.m, and whose average molecular weight measured by the specific viscosity of a solution is from 30000 to 5000000.
    Type: Grant
    Filed: August 20, 1998
    Date of Patent: November 2, 1999
    Assignee: Kawasaki Steel Corporation
    Inventors: Satoshi Uenosono, Yukiko Ozaki, Kuniaki Ogura, Toshio Nagase, Takeo Kobayashi
  • Patent number: 5976695
    Abstract: Thermally sprayable powders for the formation of abradable seals and abradable seals formed by thermally spraying the powders include an alloyed metal phase material and a solid lubricant ceramic phase material. The alloyed metal phase material includes a major amount of a matrix metal which can be one or more of Ag or Cu, at least one melting point depressing metal which can be one or more of Si, B, Mn, or Al, and at least one oxidation resistant metal which can be one or more of Al, Cr, or Si. The solid lubricant ceramic phase is preferably hexagonal boron nitride, molybdenum sulphide, graphite, talc, bentonite or mica. Abradable seals formed by thermally spraying the powders are suitable for use with Ti alloy blades at temperatures up to 700.degree. C.
    Type: Grant
    Filed: October 2, 1996
    Date of Patent: November 2, 1999
    Assignee: Westaim Technologies, Inc.
    Inventors: Karel Hajmrle, Hougong Wang
  • Patent number: 5968449
    Abstract: An object of the present invention is to provide an iron base Si--Mn alloy or an iron base Si--Mn--Ni alloy which can be easily crushed and can be manufactured in large quantity, and alloy powder thereof.An iron base Si--Mn--Ni alloy having good crushability and alloy powder thereof, comprising:C: 0.40 to 1.20% by weight,Si: 5.0 to 12.0% by weight,Mn: 19.0 to 42.0 % by weight, or Ni: not more than 30% by weight, and the balance being Fe, with the following equations satisfied: Si.gtoreq.11.89-2.92 C-0.077 Mn, Vickers hardness (Hv).gtoreq.550, and area ratio of dendrite structure .ltoreq.50%.An iron base Si--Mn--Ni alloy having good crushability and alloy powder thereof, comprising:C: 0.40 to 1.20% by weight,Si: 5.0 to 12.0% by weight,Mn: 19.0 to 42.0% by weight, or Ni: not more than 30% by weight, and the balance being Fe, with the following equations satisfied: Si.ltoreq.8.3 C+0.14 Mn, and relative permeability (.mu.).ltoreq.1.10.
    Type: Grant
    Filed: January 20, 1998
    Date of Patent: October 19, 1999
    Assignees: Nippon Steel Welding Products & Engineering Co., Ltd., Japan Metals & Chemicals Co., Ltd.
    Inventors: Koichi Aoki, Atsuo Onoda, Masao Kamada, Hitoshi Nishimura, Kuniteru Suzuki, Shunji Kikuchi
  • Patent number: 5900558
    Abstract: A container packed with a mixture of powders classified respectively into two or at least three particle-size distribution groups which are different in average particle size, the powders comprising a hydrogen absorbing alloy singly or the combination of such an alloy and a substance not absorbing hydrogen. The mixture is at least 0.03 to not greater than 0.50 in the ratio d.sub.2 /d.sub.1 wherein d.sub.1 is the average particle size of the powder having the particle-size distribution of the largest average particle size, and d.sub.2 is the average particle size of the powder having the particle-size distribution of the second largest average particle size. The weight ratio of the powder to the total weight of the powders is greater when that powder has a particle-size distribution of larger average particle size.
    Type: Grant
    Filed: July 28, 1997
    Date of Patent: May 4, 1999
    Assignee: Sanyo Electric Co., Ltd.
    Inventors: Hiroshi Nakamura, Shin Fujitani, Yumiko Nakamura, Hiroshi Watanabe, Ikuo Yonezu, Takahiro Yonesaki, Kouichi Nishimura
  • Patent number: 5897830
    Abstract: A consumable billet for melting and casting a metal matrix composite component is made of a consolidated powder metal matrix composite having a titanium or titanium alloy matrix reinforced with particles. The preferred billet is a blended and sintered powder metal composite billet incorporating titanium carbide or titanium boride into a Ti--6Al--4V alloy.
    Type: Grant
    Filed: December 6, 1996
    Date of Patent: April 27, 1999
    Assignee: Dynamet Technology
    Inventors: Stanley Abkowitz, Susan M. Abkowitz, Paul F. Weihrauch, Harold L. Heussi, Walter Zimmer