EP0488716B1
Expired / Lapsed
EP
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Sintered metal bodies and manufacturing method therefor
Assignee: NGK Insulators Ltd
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Filing: 1991-11-28
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Granted: 1997-03-05
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Expires: 2011-11-28
Abstract
No abstract record available.
Inventors
- 👤 Takashi Harada
- 👤 Yoshihiro Fujiwara
- 👤 Fumio Abe
- 👤 Tsuneaki Ohasi
- 👤 Hiroshige Mizuno
- 👤 Kevin R. Brundage
- 👤 Srinivas H. Swaroop
- 👤 David F. Thompson
- 👤 Raja R. Wusirika
- 👤 David S. Weiss
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-07 20:39
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/20; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J; B01J23/00; B01J23/70; B01J23/76; B01J23/84; B01J23/85; B01J23/86; B01J23/862; C; C22; C22C; C22C1/00; C22C1/04; C22C1/05; C22C1/059; C22C32/00; C22C32/001; C22C32/0015; C22C33/00; C22C33/02; C22C33/0257; C22C33/0278; C22C33/0285; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12493; Y10T428/12535; Y10T428/12611
Claims Analysis
Total Claims: 44
Claim 1
Independent Claim
126 words
A sintered metal body having a composition consisting of, in percent by weight:- 5 to 40% Cr; 2 to 30% Al; component A, which is present in an amount of up to 5%, contains at least B in an amount of at least 0.01% and not more than 5% and optionally contains at least one element selected from: Y, lanthanides, Zr, Hf, Ti, Si, alkaline earth metals, Cu and Sn; optionally: up to 4% of additive, selected from oxides of the lanthanide elements and yttrium, added as oxide to the starting material mix; up to 1% N; up to 1% C; and up to 3% 0; the balance being Fe and unavoidable impurities; wherein said body has an open porosity no greater than 50% by volume.
Claim 2
Dependent Claim
19 words
A body of claim 1 wherein the Si content in said composition is no greater than 1% by weight.
Claim 3
Dependent Claim
53 words
A body of claim 1 wherein Cr is present in the range 12 to 30%, Al is present in the range 4 to 12% and component A provides: 0.1 to 1% of at least one element selected from Y, lanthanide series, Zr and Hf, 0 to 3% Si and 0.01 to 0.2% B.
Claim 4
Dependent Claim
37 words
A body of claim 1 wherein Cr is present in the range 12 to 25%, aluminium is present in the range 2 to 10%, and component A provides 0 to 2% Si and 0.01 to 0.1% B.
Claim 5
Dependent Claim
13 words
A body of claim 4 wherein component A comprises 0.1 to 2% Y.
Claim 6
Dependent Claim
38 words
A body of claim 1 wherein Cr is present in the range 10 to 25%, Al is present in the range 5 to 15%, and component A provides 0.02 to 0.1% B and no greater than 1% Si.
Claim 7
Dependent Claim
20 words
A body of any one of claims 1 to 6 wherein Si is present in the range 0 to 0.05%.
Claim 8
Dependent Claim
15 words
A body of claim 7 wherein Si is present in the range 0 to 0.03%.
Claim 9
Dependent Claim
32 words
A body of claim 1 wherein Cr is present in the range 5 to 15%, Al is present in the range 5 to 15%, and component A comprises 0.02 to 0.2% B.
Claim 10
Dependent Claim
13 words
A body of claim 9 wherein component A comprises 0.2 to 0.5% Y.
Claim 11
Dependent Claim
24 words
A body of any one of claims 1 to 10 wherein the whole or part of said rare earth oxide additive is yttrium oxide.
Claim 12
Dependent Claim
36 words
A body of claim 11 wherein Cr is present in the range 10 to 25%, and aluminium is present in the range 5 to 15%, said rare earth oxide additive comprising 0.35 to 1.0% yttrium oxide.
Claim 13
Dependent Claim
66 words
A body of claim 1 wherein Cr is present in the range 12 to 30%, aluminium is present in the range 4 to 12%, 0.1 to 1% of said rare earth oxide additive is present, and said component A provides 0.1 to 1% of at least one element selected from Y, lanthanide series, Zr and Hf, 0.5 to 3% Si and 0.01 to 0.2% of B.
Claim 14
Dependent Claim
49 words
A body of claim 1 wherein said component A provides only boron and Si, the boron being present in an amount of from 0.01 to 0.5% by weight of said body and the Si being present in an amount of no greater than 1% by weight of said body.
Claim 15
Dependent Claim
29 words
A body of claim 1 wherein said component A provides only boron, the boron being present in an amount of from 0.01 to 0.5% by weight of said composition.
Claim 16
Dependent Claim
21 words
A body of claim 13 wherein the total amount of boron is from 0.02 to 0.1% by weight of said composition.
Claim 17
Dependent Claim
43 words
A body of claim 1 wherein Cr is present in the range 5 to 25%, Al is present in the range 5 to 15%, component A provides 0.02 to 0.10% boron, and said rare earth oxide additive provides 0.1 to 1.0% yttrium oxide.
Claim 18
Dependent Claim
27 words
A body of claim 17 wherein Cr is present in the range 5 to 15%, and said rare earth oxide additive provides 0.2 to 0.8% yttrium oxide.
Claim 19
Dependent Claim
49 words
A body of claim 1 wherein Cr is present in the range 12 to 25%, aluminium is present in the range 2 to 10%, component A provides only 0.02 to 0.10% B and 0 to 2% Si, and said rare earth oxide additive provides 0.10 to 1% yttrium oxide.
Claim 20
Dependent Claim
20 words
A body of any one of the preceding claims having an open porosity of 0 to about 30% by volume.
Claim 21
Dependent Claim
16 words
A body of any one of the preceding claims having an oxide coating on its surface.
Claim 22
Dependent Claim
13 words
A body of any one of the preceding claims having a honeycomb structure.
Claim 23
Dependent Claim
13 words
A body of claim 22 wherein said body is an extruded honeycomb structure.
Claim 24
Dependent Claim
18 words
A sintered metal body of any one of the preceding claims which is used as a catalyst carrier.
Claim 25
Dependent Claim
32 words
A monolith catalyst for purification of automobile exhaust gas, comprising: a catalyst carrier which is the body of any one of the preceding claims, and a catalyst supported on the catalyst carrier.
Claim 26
Dependent Claim
22 words
A heat resistant heater comprising: the body of any one of claims 1 to 23; and heating means provided on the body.
Claim 27
Dependent Claim
17 words
A heater of claim 26 which further comprises a catalyst supported on the surface of the body.
Claim 28
Dependent Claim
19 words
A monolith catalyst of claim 25 or a heater of claim 27 wherein the catalyst is a three-way catalyst.
Claim 29
Dependent Claim
39 words
A catalytic converter comprising: a main monolith catalyst, and a heater placed upstream of the main monolith catalyst, the heater comprising: the body of any one of claims 1 to 23, and heating means provided on the sintered body.
Claim 30
Dependent Claim
28 words
A catalytic converter comprising: the body of any one of claims 1 to 23, a catalyst supported on said metal body, and heating means provided on said body.
Claim 31
Dependent Claim
54 words
A catalytic converter according to claim 30, comprising: a main monolith catalyst, and one or more heaters in tandem with said main monolith catalyst, each of said one or more heaters comprising: the said body, and heating means provided on the body, with at least one of said heaters having a catalyst supported thereon.
Claim 32
Dependent Claim
24 words
A catalytic converter of claim 29, 30 or 31 having one heater with a catalyst thereon and placed upstream of said main monolith catalyst.
Claim 33
Dependent Claim
21 words
A catalytic converter of claim 32 having one heater with a catalyst thereon and placed downstream of said main monolith catalyst.
Claim 34
Dependent Claim
16 words
A catalytic converter of claim 32 having electrodes provided on the body as said heating means.
Claim 35
Dependent Claim
16 words
A heater of claim 33 which further comprises a resistance adjusting type mechanism between the electrodes.
Claim 36
Independent Claim
67 words
A method for manufacturing a heat-resistant sintered metal body as claimed in any one of claims 1 to 19, which comprises: a) mixing metal powders and, optionally, rare earth oxide powders suitable to result, after step (c) below, in said body; b) forming a green body from the resulting mixed powders; and c) sintering said green body in a non-oxidizing atmosphere to form said sintered metal body.
Claim 37
Dependent Claim
12 words
A method of claim 36 wherein said body has a honeycomb structure.
Claim 38
Dependent Claim
39 words
A method of claim 37 comprising the additional step of heat-treating the said sintered body in an oxidizing atmosphere at a sufficient temperature for a sufficient time to form an oxide coating on the surfaces of said sintered body.
Claim 39
Dependent Claim
53 words
A method of claim 36 wherein said forming is done by a method which comprises the steps of: a) mixing said metal powders and said rare earth oxide powders with an organic binder and vehicle to form a relatively homogeneous wet mixture; and b) forming said green body by extruding said wet mixture.
Claim 40
Dependent Claim
10 words
A method of claim 39 wherein said vehicle is water.
Claim 41
Dependent Claim
15 words
A method of claim 39 wherein said green body is extruded into a honeycomb structure.
Claim 42
Dependent Claim
16 words
A method of claim 36 wherein the sintering temperature is in the range 1000°C to 1400°C.
Claim 43
Dependent Claim
14 words
A method of claim 36 wherein the sintering is done in a hydrogen atmosphere.
Claim 44
Dependent Claim
18 words
A method of claim 36 wherein said body has an open porosity of 0% to 30% by volume.
References Cited (Backward Citations)
No citation records indexed.
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