US3926702A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Ceramic structures and process for producing the same
Assignee: Asamura Patent Office
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Filing: 1973-03-27
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Granted: 1975-12-16
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Expires: 1993-03-27
Abstract
Abstract A ceramic structure excellent in resistance to mechanical and thermal impacts can be obtained according to a process comprising a first step in which optional-shaped substrates composed of a ceramic material are subjected to primary firing, a second step in which the said substrates are coated with a substance capable of being made porous by secondary firing, a third step in which the said substrates are laminated each other so as to form fluid passages between the substrates, and a fourth step in which the laminated substrates are subjected to secondary firing to be chemically bonded to form a unit structure by means of the said substance capable of being made porous, thereby uniformly coating the said unit structure with the said substance which has been made porous. Further, the thus obtained structure is immersed in, for example, an alumina type ceramic solution and then subjected to tertiary firing to adhere the alumina type ceramic to the pores and surface of the ceramic layer on the said structure, whereby an inexpensive ceramic structure can be produced.
Inventors
- 👤 Masami Oki
- 👤 Ryuzo Hori
- 👤 Naoto Miwa
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 11:56
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/632; C04B35/634; C04B35/63448; C04B35/63472; C04B35/63476; B; B01; B01D; B01D53/00; B01D53/34; B01D53/74; B01D53/86; B32; B32B; B32B3/00; B32B3/26; C04B37/00; C04B37/001; C04B37/003; C04B37/005; B32B2315/00; B32B2315/02; C04B2235/00; C04B2235/65; C04B2235/656; C04B2235/6567; C04B2237/00; C04B2237/02; C04B2237/04; C04B2237/06; C04B2237/064; C04B2237/09; C04B2237/10; C04B2237/30; C04B2237/32; C04B2237/34; C04B2237/341; C04B2237/343; C04B2237/345; C04B2237/346; C04B2237/348; C04B2237/36; C04B2237/365; C04B2237/366; C04B2237/368; C04B2237/50; C04B2237/70; C04B2237/708; C04B2237/72; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24628; Y10T428/24661; Y10T428/24669; Y10T428/24694; Y10T428/24711; Y10T428/24727; Y10T428/24744; Y10T428/24942; Y10T428/24992; Y10T428/249921; Y10T428/249953; Y10T428/249967; Y10T428/24997; Y10T428/249981; Y10T428/249994
Claims Analysis
Total Claims: 8
Claim 1
Independent Claim
185 words
A PROCESS FOR PRODUCING A CERAMIC STRUCTURE WHICH COMPRISES FORMING IN A FIRST STEP OPTIONAL-SHAPED SUBSTRATES WITH A MIXTURE OF A CERAMIC MATERIAL, AN ORGANIC MATERIAL AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL AND THEN FIRING SAID SUBSTRATE; IN A SECOND STEP LAMINATING SAID SUBSTRATES TO FORM A STRUCTURE HAVING FLUID PASSAGES BETWEEN SAID SUBSTRATES; IN A THIRD STEP DIPPING SAID STRUCTURE IN A SLURRY CONSISTING OF THE SAME CERAMIC MATERIAL AS THE CERAMIC MATERIAL IN THE FIRST STEP, THE ORGANIC MATERIAL BEING PRESENT IN A GREATER AMOUNT THAN THAT EMPLOYED IN THE FIRST STEP AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL; IN A FOURTH STEP FIRING SAID DIPPED STRUCTURE TO FORM A POROUS CERAMIC LAYER ON THE INTERNAL AND EXTERNAL SURFACES OF SAID STRUCTURE; IN A FIFTH STEP DIPPING SAID STRUCTURE HAVING SAID POROUS CERAMIC LAYER IN A LIQUID CONTAINING AN ALUMINUM COMPOUND WHICH CAN BE TRANSFORMED TO Y- OR$-AL2O3 BY THERMAL DECOMPOSITION TO FILL THE PORES IN SAID LAYER WITH SAID ALUMINUM COMPOUND AND THEN FIRING SAID STRUCTURE TO THERMALLY DECOMPOSE SAID ALUMINUM COMPOUND TO Y- OR $-AL203. O
Claim 2
Dependent Claim
185 words
A PROCESS FOR PRODUCING A CERAMIC STRUCTURE WHICH COMPRISES FORMING IN A FIRST STEP OPTIONAL-SHAPED SUBSTRATES WITH A MIXTURE OF A CERAMIC MATERIAL, AN ORGANIC MATERIAL AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL AND THEN FIRING SAID SUBSTRATE; IN A SECOND STEP LAMINATING SAID SUBSTRATES TO FORM A STRUCTURE HAVING FLUID PASSAGES BETWEEN SAID SUBSTRATES; IN A THIRD STEP DIPPING SAID STRUCTURE IN A SLURRY CONSISTING OF THE SAME CERAMIC MATERIAL AS THE CERAMIC MATERIAL IN THE FIRST STEP, THE ORGANIC MATERIAL BEING PRESENT IN A GREATER AMOUNT THAN THAT EMPLOYED IN THE FIRST STEP AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL; IN A FOURTH STEP FIRING SAID DIPPED STRUCTURE TO FORM A POROUS CERAMIC LAYER ON THE INTERNAL AND EXTERNAL SURFACES OF SAID STRUCTURE; IN A FIFTH STEP DIPPING SAID STRUCTURE HAVING SAID POROUS CERAMIC LAYER IN A LIQUID CONTAINING AN ALUMINUM COMPOUND WHICH CAN BE TRANSFORMED TO Y- OR$-AL2O3 BY THERMAL DECOMPOSITION TO FILL THE PORES IN SAID LAYER WITH SAID ALUMINUM COMPOUND AND THEN FIRING SAID STRUCTURE TO THERMALLY DECOMPOSE SAID ALUMINUM COMPOUND TO Y- OR $-AL203. O
Claim 3
Dependent Claim
45 words
A process according to claim 1 in which said ceramic material is a powder containing predominantly ceramic materials selected from the group consisting of cordierite, alumina, mullite, beryllia, zircon, zirconia, titanium oxide, crystallized glass, silicon nitride, aluminum nitride, titanium boride, boron carbide and silicon carbide.
Claim 4
Dependent Claim
25 words
The process of claim 2 wherein the priming firing is effected at 500* to 1200*C.; and the secondary firing is effected at 500* to 1600*C.
Claim 5
Dependent Claim
25 words
The process of claim 2 wherein the primary firing is effected at 500* to 1200*C. and the secondary firing is effected at 500* to 1600*C.
Claim 6
Dependent Claim
187 words
A PROCESS FOR PRODUCING A CERAMIC STRUCTURE WHICH COMPRISES FORMING IN A FIRST STEP OPTIONAL-SHAPED SUBSTRATES WITH A MIXTURE OF A CERAMIC MATERIAL, AN ORGANIC MATERIAL AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL AND THEN FIRING SAID SUBSTRATE; IN A SECOND STEP DIPPING SAID STRUCTURE IN A SLURRY CONSISTING OF THE SAME CERAMIC MATERIAL SAME AS THE CERAMIC MATERIAL IN THE FIRST STEP, THE ORGANIC MATERIAL BEING PRESENT IN A GREATER AMOUNT THAN THAT EMPLOYED IN THE FIRST STEP AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL; IN A THIRD STEP LAMINATING SAID SUBSTRATES TO FORM A STRUCTURE HAVING FLUID PASSAGES BETWEEN SAID SUBSTRATES; IN A FOURTH STEP FIRING SAID DIPPED STRUCTURE TO FORM A POROUS CERAMIC LAYER ON THE INTERNAL AND EXTERNAL SURFACES OF SAID STRUCTURE; AND IN A FIFTH STEP DIPPING SAID STRUCTURE HAVING SAID POROUS CERAMIC LAYER IN A LIQUID CONTAINING AN ALUMINUM COMPOUND WHICH CAN BE TRANSFORMED TO Y- OR $AL2O3 BY THERMAL DECOMPOSITION TO FILL THE PORES IN SAID LAYER WITH SAID ALUMINUM COMPOUND AND THEN FIRING SAID STRUCTURE TO THERMALLY DECOMPOSE SAID ALUMINUM COMPOUND TO Y- OR $-AL2O3.
Claim 7
Dependent Claim
187 words
A PROCESS FOR PRODUCING A CERAMIC STRUCTURE WHICH COMPRISES FORMING IN A FIRST STEP OPTIONAL-SHAPED SUBSTRATES WITH A MIXTURE OF A CERAMIC MATERIAL, AN ORGANIC MATERIAL AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL AND THEN FIRING SAID SUBSTRATE; IN A SECOND STEP DIPPING SAID STRUCTURE IN A SLURRY CONSISTING OF THE SAME CERAMIC MATERIAL SAME AS THE CERAMIC MATERIAL IN THE FIRST STEP, THE ORGANIC MATERIAL BEING PRESENT IN A GREATER AMOUNT THAN THAT EMPLOYED IN THE FIRST STEP AND A SOLVENT CAPABLE OF DISSOLVING SAID ORGANIC MATERIAL; IN A THIRD STEP LAMINATING SAID SUBSTRATES TO FORM A STRUCTURE HAVING FLUID PASSAGES BETWEEN SAID SUBSTRATES; IN A FOURTH STEP FIRING SAID DIPPED STRUCTURE TO FORM A POROUS CERAMIC LAYER ON THE INTERNAL AND EXTERNAL SURFACES OF SAID STRUCTURE; AND IN A FIFTH STEP DIPPING SAID STRUCTURE HAVING SAID POROUS CERAMIC LAYER IN A LIQUID CONTAINING AN ALUMINUM COMPOUND WHICH CAN BE TRANSFORMED TO Y- OR $AL2O3 BY THERMAL DECOMPOSITION TO FILL THE PORES IN SAID LAYER WITH SAID ALUMINUM COMPOUND AND THEN FIRING SAID STRUCTURE TO THERMALLY DECOMPOSE SAID ALUMINUM COMPOUND TO Y- OR $-AL2O3.
Claim 8
Dependent Claim
45 words
A process according to claim 5 in which said ceramic material is a powder containing predominantly ceramic materials selected from the group consisting of cordierite, alumina, mullite, beryllia, zircon, zirconia, titanium dioxide, crystallized glass, silicon nitride, aluminum nitride, titanium boride, boron carbide, and silicon carbide.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-12-15 | 1979-06-16 | 1979-12-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-12-15 | 1983-06-16 | 1983-12-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-12-15 | 1987-06-16 | 1987-12-16 | $7700.00 | Window Closed / Lapsed |