US5066626A
Expired / Lapsed
US
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Ceramic materials for use in insert-casting and processes for producing the same
Assignee: NGK Insulators Ltd
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Filing: 1989-12-04
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Granted: 1991-11-19
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Expires: 2009-12-04
Abstract
Abstract A ceramic material for use in insert-casting, which contains not less than 65% by volume of aluminum titanate as a crystalline phase. The average particle diameter of crystals of the aluminum titanate is not less than 10 μm, and not more than 20% by volume of a glass phase containing a rare earth element in an amount of 0.5 to 16% by weight when calculated in the form of an oxide is contained. Young's modulus is 50 to 2,000 kgf/mm 2 . A process for producing the same is also disclosed, which includes the steps of preparing a powder by mixing a material, as an Al 2 O 3 source material, containing not more than 96% by weight of Al 2 O 3 and having an average particle size of not less than 3 μm, a material having an average particle diameter of not more than 3 μm as a TiO 2 source material, and a given rare earth element in an amount of 1.8% by weight when calculated in the form of an oxide, shaping the powder, and drying and firing the shaped body. The ceramic material has an actual break strain of not less than 6×10 -3 . The process for producing such a ceramic material includes a step of cooling the shaped body at a rate of at least not less than 500° C./hr in a temperature range not less than 200° C. during and/or after the firing.
Inventors
- 👤 Kaname Fukao
- 👤 Toshiyuki Hamanaka
- 👤 Takashi Harada
- 👤 Noboru Kondo
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 16:10
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/01; C04B35/46; C04B35/462; C04B35/478; C04B35/10; C04B35/111
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
110 words
A sintered ceramic material for use in insert casting, comprising: at least 65% by volume aluminum titanate as a crystalline phase, the diameter of crystals of aluminum titanate being at least 10 μm; and a glass intergranular phase present in an amount of not more than 20% by volume, said glass phase comprising a rare earth element in an amount of 0.5-16% by weight when calculated in the form of an oxide; wherein said sintered ceramic material has a porosity of 5-35%, a four-point bending strength of 0.2-1.7 kgf/mm 2 , a Young's modulus of 50-2,000 kgf/mm 2 and a reduction rate in cooling-heating cycling of not more than 9%.
Claim 2
Dependent Claim
110 words
A sintered ceramic material for use in insert casting, comprising: at least 65% by volume aluminum titanate as a crystalline phase, the diameter of crystals of aluminum titanate being at least 10 μm; and a glass intergranular phase present in an amount of not more than 20% by volume, said glass phase comprising a rare earth element in an amount of 0.5-16% by weight when calculated in the form of an oxide; wherein said sintered ceramic material has a porosity of 5-35%, a four-point bending strength of 0.2-1.7 kgf/mm 2 , a Young's modulus of 50-2,000 kgf/mm 2 and a reduction rate in cooling-heating cycling of not more than 9%.
Claim 3
Dependent Claim
22 words
The sintered ceramic material according to claim 1, wherein said material has a compression strength of 5 to 40 kgf/mm 2 .
Claim 4
Dependent Claim
37 words
The sintered ceramic material according to claim 1, further comprising a composition consisting essentially of 40 to 65% by weight of Al 2 O 3 and 30 to 65% by weight of TiO 2 as main ingredients.
Claim 5
Dependent Claim
39 words
The sintered ceramic material according to claim 3, further comprising not more than 10% by weight in total of at least one material selected from the group consisting of SiO 2 , MgO and Fe 2 O 3 .
Claim 6
Dependent Claim
23 words
The sintered ceramic material according to claim 1, wherein the amount of the rare earth element is not more than 1.8% by weight.
Claim 7
Dependent Claim
24 words
The sintered ceramic material according to claim 1, wherein said aluminum titanate is present in an amount of at least about 80% by volume.
Claim 8
Dependent Claim
24 words
The sintered ceramic material according to claim 1, wherein said aluminum titanate is present in an amount of at least about 90% by volume.
Claim 9
Dependent Claim
19 words
The sintered ceramic material according to claim 1, wherein said sintered ceramic material has a porosity of about 5-14%.
Claim 10
Dependent Claim
113 words
A sintered ceramic material for use in insert casting, comprising: at least 65% by volume aluminum titanate as a crystalline phase, the diameter of crystals of aluminum titanate being at least 10μm; and a glass intergranular phase present in an amount of not more than 20% by volume, said glass phase comprising a rare earth element in an amount of 0.5-16% by weight when calculated in the form of an oxide; wherein said sintered ceramic material has a porosity of 5-35%, a four point bending strength of 0.2-1.7 kgf/mm 2 , an actual rupture strain of not less than 6×10 -3 and a reduction rate in cooling-heating cycling of not more than 9%.
Claim 11
Dependent Claim
113 words
A sintered ceramic material for use in insert casting, comprising: at least 65% by volume aluminum titanate as a crystalline phase, the diameter of crystals of aluminum titanate being at least 10μm; and a glass intergranular phase present in an amount of not more than 20% by volume, said glass phase comprising a rare earth element in an amount of 0.5-16% by weight when calculated in the form of an oxide; wherein said sintered ceramic material has a porosity of 5-35%, a four point bending strength of 0.2-1.7 kgf/mm 2 , an actual rupture strain of not less than 6×10 -3 and a reduction rate in cooling-heating cycling of not more than 9%.
Claim 12
Dependent Claim
24 words
The sintered ceramic material according to claim 9, wherein said aluminum titanate is present in an amount of at least about 80% by volume.
Claim 13
Dependent Claim
24 words
The sintered ceramic material according to claim 9, wherein said aluminum titanate is present in an amount of at least about 90% by volume.
Claim 14
Dependent Claim
19 words
The sintered ceramic material according to claim 9, wherein said sintered ceramic material has a porosity of about 5-14%.
Claim 15
Dependent Claim
41 words
The sintered ceramic material according to claim 9, further comprising not more than 17% by volume of a glass containing a rare earth element in an amount of 0.5 to 16% by weight when calculated in the form of an oxide.
Claim 16
Dependent Claim
37 words
The sintered ceramic material according to claim 9, further comprising a composition consisting essentially of 40 to 65% by weight of Al 2 O 3 and 30 to 60% by weight of TiO 2 as main ingredients.
Claim 17
Dependent Claim
38 words
The sintered ceramic material according to claim 9, further comprising not more than 10% by weight total of at least one material selected from the group consisting of SiO 2 , MgO, and Fe 2 O 3 .
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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) | 1994-11-18 | 1995-05-20 | 1995-11-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-11-18 | 1999-05-20 | 1999-11-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-11-18 | 2003-05-20 | 2003-11-19 | $7700.00 | Window Closed / Lapsed |