Alliedsignal Inc.

Rutgers, the State University of New Jersey

Other

Joan V Burlew

Anthony J Fanelli

Mohammad Behi

Michael S Zedalis

Gary B Marsh

Brian Jeffrey Snow

Richard Lewis Duyckinck

Clifford P Ballard

Rick Duyckinck

Jerry C LaSalle

George A Glandz

William S Frei

Clifford Palmer Ballard, Jr

A composite molding compound comprising a combination of metal and ceramic powders is disclosed. The powders are combined with a binder, a liquid carrier and other processing additives in a manner to provide uniform distribution of two phases in a material format that facilitates the molding of complex parts at relatively low pressures and temperatures using conventional injection molding machines. The products formed from these molding compounds may be designed with tailored physical and mechanical properties such as thermal conductivity, thermal expansion coefficient, density, elastic modulus and wear properties.

Metal/ceramic composite molding material

This invention provides a process for forming sintered, molded articles having improved dimensional stability. More particularly, this invention pertains to process for forming heat sinks. This process includes forming a substantially uniform copper composition comprising a polysaccharide binder, water, and copper particles; molding the copper composition under conditions sufficient to form a solid molded intermediate; and sintering the solid molded intermediate at a sufficient temperature and for a sufficient time to form a heat sink.

Aqueous nonferrous feedstock material for injection molding

Molding compositions for shaping parts from stainless steel powders are disclosed. The process comprises the steps of forming a mixture comprising stainless steel powder, a gel-forming material having a gel strength, measured at a temperature between 0&deg; C. and about 30&deg; C. and a gel comprising about 1.5 wt % of the gel-forming material and water, of at least about 200 g/cm2, and water, and molding the mixture at a temperature sufficient to produce a self-supporting article comprising the powder and gel. The preferred gel-forming material is an agaroid and the preferred molding process is injection molding.

Stainless steel aqueous molding compositions

Recycled, reground ceramic powder is mixed with a liquid carrier, a binder and processing additives to form a material useful for molding complex-shaped parts at relatively low pressures in conventional injection molding equipment.

Process for forming an article from recycled ceramic molding compound

Molding compositions for shaping parts from stainless steel powders are disclosed. The process comprises the steps of forming a mixture comprising stainless steel powder, a gel-forming material having a gel strength, measured at a temperature between 0.degree. C. and about 30.degree. C. and a gel comprising about 1.5 wt % of the gel-forming material and water, of at least about 200 g/cm2, and water, and molding the mixture at a temperature sufficient to produce a self-supporting article comprising the powder and gel. The preferred gel-forming material is an agaroid and the preferred molding process is injection molding.

Process for making stainless steel aqueous molding compositions

Parts from ceramic and/or metal powder(s) are shaped by a process that comprises the steps of (1) forming a mixture comprising ceramic and/or metal powder(s), a gel-forming material chosen from the class of polysaccharides known as 'agaroids', a gel-forming solvent, and a gel strength enhancing agent, and said mixture being formed in a blender that provides a shearing action and being heated to raise the temperature of the mixture to about 70.degree. C. to 100.degree. C.; and (2) molding the mixture at a temperature sufficient to produce a self-supporting structure comprising the powder and gel. The parts exhibit excellent green strength and are rapidly fired without cracking, distortion or shrinkage problems.

Gel strength enhancing additives for agaroid-based injection molding

A process for shaping parts from ceramic powder that comprises the steps of (1) forming a concentrated mixture in excess of 40% ceramic solids by volume, the mixture comprising ceramic powder, a gel forming material chosen from the class of polysaccharides known as 'agaroids', and a gel forming material solvent and being formed in a blender that provides a shearing action and is heated to raise the temperature of the mixture to about 70.degree. C. to 100.degree. C.; and (2) molding the mixture at a temperature sufficient to produce a self-supporting structure comprising the powder and gel. The parts exhibit excellent green strength and are rapidly fired without cracking, distortion or shrinkage problems.

Aqueous process for injection molding ceramic powders at high solids

A ceramic element of a zirconia oxygen sensor is shaped from a powder mixture. The mixture, comprising a ceramic powder having an average particle size less than or equal to 1 micrometer, a gel-forming material and a gel forming material solvent, is molded at a temperature and pressure sufficient to produce the ceramic element having a density of at least 5.5 g/cm.sup.3.

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Rockaway, NJ, United States of America

Joan V Burlew