Patent US4758272A successfully refreshed from Google Patents.
US4758272A
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Porous metal bodies
Assignee: Corning Glass Works
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Filing: 1987-05-27
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Granted: 1988-07-19
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Expires: 2007-05-27
Abstract
Abstract This invention is concerned with the production of hard, porous, sintered bodies consisting essentially of Al and Fe with, optionally, Sn and/or Cu and/or Cr. The mechanism of the invention relies upon the presence of a small amount of Mg and/or Ca to act as a getter for oxygen. In the preferred embodiment, particles of the metals can be extruded into honeycomb structures which can then be fired in the presence of Mg and/or Ca to yield sound high cell density structures of controlled porosity.
Inventors
- 👤 Kim D. Pierotti
- 👤 Raja R. Wusirika
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 07:26
CPC Classifications
C; C22; C22C; C22C38/00; C22C38/16; C22C33/00; C22C33/02; C22C33/0257; C22C33/0278; B; B01; B01D; B01D39/00; B01D39/14; B01D39/20; B01D39/2027; B01D39/2031; B01D39/2034; B22; B22F; B22F3/00; B22F3/10; B22F3/1003; B22F3/11; B22F3/1103; C22C1/00; C22C1/04; B22F2998/00; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24149
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
68 words
A hard, porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20%, at least some and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca.
Claim 2
Dependent Claim
68 words
A hard, porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20%, at least some and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca.
Claim 3
Dependent Claim
39 words
A body according to claim 1 wherein said Al is present in an amount of 12-16%, said Fe is present in an amount of 70-90%, and said alkaline earth metal is present in an amount of a few ppm.
Claim 4
Dependent Claim
26 words
A body according to claim 1 wherein said Sn is present in a amount of 3-7% and said Cu is present in an amount of 3-8.5%.
Claim 5
Dependent Claim
18 words
A body according to claim 3 wherein said Cr is present in an amount of at least 5%.
Claim 6
Dependent Claim
22 words
A body according to claim 1 having a porosity of about 25-75% by volume with pores ranging between 1-100 microns in size.
Claim 7
Dependent Claim
119 words
A hard, porous honeycomb structure having a cell density of at least 10 cells/in 2 with the walls of said cells having a thickness of at least 75 microns, said structure being composed of a material having a porosity of about 25-75% by volume, with pores ranging between about 1-100 microns in size, and consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-40% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than about 1% of a alkaline earth metal selected from the group consisting of Mg and Ca.
Claim 8
Dependent Claim
119 words
A hard, porous honeycomb structure having a cell density of at least 10 cells/in 2 with the walls of said cells having a thickness of at least 75 microns, said structure being composed of a material having a porosity of about 25-75% by volume, with pores ranging between about 1-100 microns in size, and consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-40% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than about 1% of a alkaline earth metal selected from the group consisting of Mg and Ca.
Claim 9
Dependent Claim
27 words
A structure according to claim 6 wherein said cell density ranges between about 50-600 cells/in 2 and said cell walls range in thickness between about 100-700 microns.
Claim 10
Dependent Claim
27 words
A structure according to claim 6 wherein the porosity of said material ranges about 40-60% by volume and the size of the pores ranges about 10-50 microns.
Claim 11
Independent Claim
186 words
A method for producing a hard porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca, which comprises the steps of: (a) preparing a homogenous mixture of particulate Al, Fe, and, optionally, Sn, Cu, and Cu in the proper proportions with at least 0.5% particulate alkaline earth metal or an amount of a particulate readily-vaporizable alkaline earth metal compound sufficient to yield at least 0.5% alkaline earth metal in an organic binder/vehicle; (b) forming said mixture into a shape of a desired configuration; and then (c) firing said shape in an essentially non-oxidizing atmosphere to a temperature between about 1000°-1400° C. for a sufficient length of time to vaporize off any excess alkaline earth metal and to sinter the metal particles together into a sound, integral body of desired porosity.
Claim 12
Independent Claim
186 words
A method for producing a hard porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca, which comprises the steps of: (a) preparing a homogenous mixture of particulate Al, Fe, and, optionally, Sn, Cu, and Cu in the proper proportions with at least 0.5% particulate alkaline earth metal or an amount of a particulate readily-vaporizable alkaline earth metal compound sufficient to yield at least 0.5% alkaline earth metal in an organic binder/vehicle; (b) forming said mixture into a shape of a desired configuration; and then (c) firing said shape in an essentially non-oxidizing atmosphere to a temperature between about 1000°-1400° C. for a sufficient length of time to vaporize off any excess alkaline earth metal and to sinter the metal particles together into a sound, integral body of desired porosity.
Claim 13
Dependent Claim
43 words
A method according to claim 9 wherein said formed mixture of Step (b) is first dried at ambient temperature or at an elevated temperature below about 500° C. to volatilize off said organic binder/vehicle medium, and then fired to sinter the particles together.
Claim 14
Dependent Claim
23 words
A method according to claim 9 wherein said particulate materials are of a size to pass a No. 100 United States Standard Sieve.
Claim 15
Dependent Claim
74 words
A method according to claim 9 wherein said mixture of Step (a) is extruded into a honeycomb structure and then fired to produce a sound, integral honeycomb structure having a cell density of at least 10 cells/in 2 with the walls of said cells having a thickness of at least 75 microns, the material comprising said structure having a porosity of about 25-75% by volume with pores ranging between about 1-100 microns in size.
Claim 16
Independent Claim
201 words
A method for producing a hard porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca, which comprises the steps of: (a) preparing a homogenous mixture of particulate Al, Fe, and, optionally, Sn, Cu, and Cr in the proper proportions in an organic binder/vehicle medium; (b) forming said mixture into a shape of a desired configuration; and then (c) firing said shape in an essentially non-oxidizing atmosphere to a temperature between about 1000°-1400° C. in close relation to, but at least partially out of contact with, a source of particulate alkaline earth metal selected from the group of Mg and Ca or a particulate readily-vaporizable alkaline earth metal compound for a sufficient length of time to cause vapors of said alkaline earth metal to contact the particulate Fe and Al and to sinter the metal particles together into a sound, integral body of desired porosity.
Claim 17
Independent Claim
201 words
A method for producing a hard porous body consisting essentially, as analyzed in weight percent, of 5-50% Al, 30-90% Fe, the sum Al and Fe constituting at least 80% of the total composition, 0-10% Sn, 0-10% Cu, 0-10% Cr, the sum Sn and Cu and Cr being less than 20% at least some, and not more than 1% of an alkaline earth metal selected from the group consisting of Mg and Ca, which comprises the steps of: (a) preparing a homogenous mixture of particulate Al, Fe, and, optionally, Sn, Cu, and Cr in the proper proportions in an organic binder/vehicle medium; (b) forming said mixture into a shape of a desired configuration; and then (c) firing said shape in an essentially non-oxidizing atmosphere to a temperature between about 1000°-1400° C. in close relation to, but at least partially out of contact with, a source of particulate alkaline earth metal selected from the group of Mg and Ca or a particulate readily-vaporizable alkaline earth metal compound for a sufficient length of time to cause vapors of said alkaline earth metal to contact the particulate Fe and Al and to sinter the metal particles together into a sound, integral body of desired porosity.
Claim 18
Dependent Claim
43 words
A method according to claim 13 wherein said formed mixture of Step (b) is first dried to ambient temperature or at an elevated temperature below about 500° C. to volatilize off said organic binder/vehicle medium, and then fired to sinter the particles together.
Claim 19
Dependent Claim
23 words
A method according to claim 13 wherein said particulate materials are of a size to pass a No. 100 United States Standard Sieve.
Claim 20
Dependent Claim
74 words
A method according to claim 13 wherein said mixture of Step (a) is extruded into a honeycomb structure and then fired to produce a sound, integral honeycomb structure having a cell density of at least 10 cells/in 2 with the walls of said cells having a thickness of at least 75 microns, the material comprising said structure having a porosity of about 25-75% by volume with pores ranging between about 1-100 microns in size.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-07-19 | 1992-01-18 | 1992-07-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-07-19 | 1996-01-18 | 1996-07-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-07-19 | 2000-01-18 | 2000-07-19 | $7700.00 | Window Closed / Lapsed |