Patent US1577103A successfully refreshed from Google Patents.
US4474731A
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US
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Process for the removal of carbon residues during sintering of ceramics
Assignee: International Business Machines Corp
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Filing: 1983-03-28
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Granted: 1984-10-02
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Expires: 2003-03-28
Abstract
Abstract A process is described for the sintering and densification of ceramic materials containing hydrocarbon materials to produce ceramic bodies substantially free from carbonaceous residues of such hydrocarbon materials by compacting ceramic particles and a binder containing a pyrolysis catalyst selected from the group consisting of nickel and palladium ions, heating in a low oxygen atmosphere to a temperature in the range of 350 DEG to 780 DEG C. to remove the carbonaceous residue and further heating the material to produce a sintered, dense ceramic body.
Inventors
- 👤 James M. Brownlow
- 👤 Thomas S. Plaskett
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 14:22
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/638; C04B35/64; H; H10; H10W; H10W99/00; H05; H05K; H05K1/00; H05K1/02; H05K1/03; H05K1/0306
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
121 words
A process for the sintering and densification of ceramic materials containing hydrocarbon materials in order to produce a sintered, dense ceramic body and substantially free from carbonaceous residues of said hydrocarbon materials comprising a. forming a compact of ceramic particles bonded together by a polymeric, hydrocarbon binder in which binder there is dissolved prior to sintering, a pyrolysis catalyst selected from the group consisting of nickel and palladium ions, b. heating said ceramic material in a low oxygen content atmosphere to a temperature in the range of from about 350° to 780° C., thereby substantially removing said carbonaceous residues from said compact, and c. further heating for a time and a temperature said compact to sinter and densify said ceramic material.
Claim 2
Dependent Claim
121 words
A process for the sintering and densification of ceramic materials containing hydrocarbon materials in order to produce a sintered, dense ceramic body and substantially free from carbonaceous residues of said hydrocarbon materials comprising a. forming a compact of ceramic particles bonded together by a polymeric, hydrocarbon binder in which binder there is dissolved prior to sintering, a pyrolysis catalyst selected from the group consisting of nickel and palladium ions, b. heating said ceramic material in a low oxygen content atmosphere to a temperature in the range of from about 350° to 780° C., thereby substantially removing said carbonaceous residues from said compact, and c. further heating for a time and a temperature said compact to sinter and densify said ceramic material.
Claim 3
Dependent Claim
25 words
The process of claim 1, wherein said catalyst is present in an amount of from about 1% to 5% by weight of said ceramic material.
Claim 4
Dependent Claim
23 words
The process of claim 1, wherein said heating prior to sintering is conducted for a period of from about 7 to 12 hours.
Claim 5
Dependent Claim
50 words
The process of claim 1, wherein the gas composition of said low oxygen content atmosphere during said heating to remove said carbonaceous residues comprises an H 2 to H 2 O ratio in the range of from about H 2 /H 2 O=about 5×10 -4 to about 5×10 -2 .
Claim 6
Dependent Claim
37 words
The process of claim 4, wherein said heating to sinter and densify is also conducted in a low oxygen content atmosphere wherein the gas composition comprises an H 2 /H 2 O less than 5×10 -2 .
Claim 7
Dependent Claim
51 words
The process of claim 4, wherein said heating prior to sintering is conducted for a period of from 7 to 12 hours and said heating to sinter and densify is conducted at a temperature in the range of from 920° to 980° C., for a period of up to 1 hour.
Claim 8
Dependent Claim
17 words
The process of claim 1, wherein said ceramic materials are composited with one or more conductive metals.
Claim 9
Dependent Claim
21 words
The process of claim 7, wherein said metals are selected from the group consisting of Mo, Ni, Co, Cu, W, Ag.
Claim 10
Dependent Claim
36 words
The process of claim 7, wherein said metals are in powdered form prior to sintering and are arranged to form one or more conductive paths which are integrally bonded to said ceramic after sintering is completed.
Claim 11
Dependent Claim
57 words
The process of claim 1 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 12
Dependent Claim
57 words
The process of claim 2 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 13
Dependent Claim
57 words
The process of claim 3 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 14
Dependent Claim
57 words
The process of claim 4 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 15
Dependent Claim
57 words
The process of claim 5 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 16
Dependent Claim
57 words
The process of claim 6 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 17
Dependent Claim
57 words
The process of claim 7 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 18
Dependent Claim
57 words
The process of claim 8 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 19
Dependent Claim
57 words
The process of claim 9 wherein said ceramic material comprises, in most percentages, the major constituent, SiO 2 , as substantial constituents, but not in excess of said SiO 2 content, Al 2 O 3 and MgO, and as minor constituents, not more than about 5% of B 2 O 3 and/or P 2 O 5 .
Claim 20
Dependent Claim
27 words
The process of claim 1 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 21
Dependent Claim
27 words
The process of claim 2 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 22
Dependent Claim
27 words
The process of claim 3 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 23
Dependent Claim
27 words
The process of claim 4 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 24
Dependent Claim
27 words
The process of claim 5 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 25
Dependent Claim
27 words
The process of claim 6 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 26
Dependent Claim
27 words
The process of claim 7 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 27
Dependent Claim
27 words
The process of claim 8 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 28
Dependent Claim
27 words
The process of claim 9 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 29
Dependent Claim
27 words
The process of claim 10 wherein said catalyst is a compound selected from the group consisting of nickel acetyl acetonate, nickel hexanoate, nickel acetate and palladium nitrate.
Claim 30
Dependent Claim
30 words
The process of claim 19 wherein said catalyst is nickel hexanoate in a concentration in the range of from about 9.3 to about 28% by weight of the said binder.
Claim 31
Dependent Claim
26 words
The process of claim 19 wherein said catalyst is nickel acetate in a concentration of from about 3.5 to about 11% by weight of said binder.
Claim 32
Dependent Claim
31 words
The process of claim 19 wherein said catalyst is palladium nitrate, Pd(NO 3 ) 2 , in a concentration of from about 2.5 to about 7.9% by weight of said binder.
References Cited (Backward Citations)
US3907710A
Cited
US4193793A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-10-02 | 1988-04-02 | 1988-10-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-10-02 | 1992-04-02 | 1992-10-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-10-02 | 1996-04-02 | 1996-10-02 | $7700.00 | Window Closed / Lapsed |