US3819439A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making honeycomb of sinterable material employing stepwise coating of a resin-containing composition
Assignee: Hexcel Corp
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Filing: 1972-10-05
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Granted: 1974-06-25
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Expires: 1992-10-05
Abstract
Abstract Sinterable materials are employed in preparing regular honeycomb structures by preparing a sheet of a sinterable material and a resin binder, normally by coating a porous carrier with a light first coating of a composition containing a sinterable material and a resin binder. Node bonds are printed onto the sheet and the sheets are then stacked with the node bonds in appropriate spatial relationship. The stack is cured and the sheets are expanded in a warm aqueous environment to provide a green stock of honeycomb structure. The green stock is coated with additional coats of sinterable material and resin binder. The resulting honeycomb structure is then fired to provide a stable, highly uniform, expanded honeycomb structure of excellent strength and uniformity.
Inventors
- 👤 R Taylor
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-22 22:19
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/632; C04B35/634; C04B35/63404; C04B35/6342; B; B01; B01J; B01J35/00; B01J35/50; B01J35/56; B01J35/57; B01J37/00; B01J37/0009; B01J37/0018; C04B35/63424; C04B38/00; C04B38/0006; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1003; Y10T428/00; Y10T428/24; Y10T428/24149
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
13 words
A method according to claim 1, wherein said sinterable material is a ceramic.
Claim 2
Dependent Claim
16 words
A method according to claim 1, wherein said sinterable material is a metal or metal alloy.
Claim 3
Dependent Claim
39 words
A method according to claim 3, wherein the metal or metal alloy comprises at least one metal of the group consisting of copper, nickel, iron, cobalt, chromium, manganese, vanadium, molybdenum, or lanthanum is present as the metal or oxide.
Claim 4
Dependent Claim
24 words
A method according to claim 1, wherein said sinterable material is a combination of at least one metal and at least one metal oxide.
Claim 5
Independent Claim
141 words
A method for preparing ceramic honeycomb which comprises: coating a first ceramic-resin composition onto a flexible organic carrier, wherein the amount of ceramic material coated onto said carrier is from 10 to 50 weight percent of the total ceramic material coated onto said carrier; curing the resin to provide a flexible sheet with substantial mechanical stability; printing node bond adhesive lines onto one side of said sheet; stacking a plurality of sheets with the node bond adhesive lines in appropriate juxtaposition to provide a honeycomb structure on curing and expansion; curing said node bond adhesive lines and expanding said stack of sheets in a liquid medium to provide a honeycomb structure; coating said honeycomb structure with a second ceramic-resin composition to provide the remaining amount of ceramic material; and drying and sintering said honeycomb structure to provide a stable ceramic honeycomb.
Claim 6
Dependent Claim
21 words
A method according to claim 6, wherein the resin in said first ceramic-resin composition is a carboxy containing acrylic ester resin.
Claim 7
Dependent Claim
21 words
A method according to claim 7, wherein the resin of said second ceramic-resin composition is at least in part polyvinyl butyral.
Claim 8
Dependent Claim
21 words
A method according to claim 6, wherein said carrier is a porous paper of from 3 to 12 pounds per ream.
Claim 9
Dependent Claim
40 words
A method according to claim 1, wherein the ceramic of said first and second ceramic compositions is an alumino-silicate, as a fine powder of a size less than about 300 mesh, having from 1 to 10 weight percent of talc.
Claim 10
Dependent Claim
76 words
A method according to claim 6, wherein said first ceramic-resin composition has from 70 to 90 weight percent of the ceramic composition and from 10 to 30 weight percent of a resin composition comprising from 50 to 75 weight percent of a resin and from 50 to 25 weight percent of a plasticizer, said first ceramic-resin composition being dispersed in a hydroxylic liquid to provide a composition having from about 30 to 50 weight percent solids.
Claim 11
Independent Claim
190 words
A method for preparing a stable ceramic honeycomb structure which comprises: coating porous paper from 5 to 10 pounds per ream with a ceramic-resin composition dispersed in a hydroxylic medium, wherein the resin composition is present in from 15 to 20 weight percent of said ceramic-resin composition and is 55 to 65 weight percent of a carboxy modified acrylate resin and 35 to 45 weight percent of a compatible ester plasticizer and the ceramic Is an alumino-silicate of a mesh size not greater than about 250 mesh, to provide a lightly coated sheet; curing said resin composition at an elevated temperature; printing node bond adhesive lines on one surface of said coated sheet; stacking a plurality of said coated sheets with the node bond lines in appropriate juxtaposition to provide a honeycomb structure on curing and expansion; curing said node bond adhesive at an elevated temperature and under a mild positive pressure; expanding said stack of sheets with the aid of a warm hydroxylic media coating said expanded stack of sheets with a second ceramic-resin composition; and drying and sintering said expanded stack to provide a stable ceramic honeycomb structure.
Claim 12
Independent Claim
138 words
A method for preparing a stable metal or metal alloy honeycomb structure which comprises: coating porous paper of from 5 to 10 pounds per ream with a sinterable metal or metal alloy-resin composition dispersed in a hydroxylic medium to provide a lightly coated sheet; curing said resin composition at an elevated temperature; printing node bond adhesive lines on one surface of said coated sheet; stacking a plurality of said coated sheets with the node bond lines in appropriate juxtaposition, to provide a honeycomb structure on curing and expansion; curing said node bond adhesive at an elevated temperature; expanding said stack of sheets with the aid of a warm hydroxylic media; coating said expanded honeycomb structure with a second sinterable metal-resin composition; and drying and sintering said expanded stack to provide a stable metal or metal alloy honeycomb structure.
Claim 13
Dependent Claim
37 words
A method according to claim 13, wherein said metal is a powder of a size less than 250 mesh and said first metal-resin composition provides a minor proportion of the total metal of said metal honeycomb structure.
Claim 14
Dependent Claim
33 words
A method according to claim 13, wherein at least one member of the group of metals copper, nickel, iron, cobalt, chromium, manganese, vanadium, molybdenum, or lanthanum is present as the metal or oxide.
Claim 15
Dependent Claim
32 words
A method according to claim 13, wherein prior to sintering, all organic material is burned off at a temperature below 1500* F and the sintering is carried out in a non-oxidizing environment.
Claim 16
Dependent Claim
31 words
A method according to claim 13, wherein said resin of said first coating is a partially hydrolyzed acrylic resin, while the resin in subsequent coatings is a partially hydrolyzed ester resin.
Claim 17
Independent Claim
234 words
A method for preparing a stable metal honeycomb having at least one of the metals of the group copper or nickel which comprises: coating a porous paper carrier of from 5 to 10 pounds per ream with a copper and/or nickel-resin composition dispersed in a hydroxylic medium, wherein said resin composition is present in from 15 to 35 weight percent of said copper and/or nickel-resin composition, and is from about 65 to 90 weight percent of a carboxy modified acrylate resin and from 10 to 35 weight percent of a compatible ester plasticizer, to provide a lightly coated sheet; curing said resin composition at an elevated temperature; printing node bond adhesive lines on one surface of said coated sheet; stacking a plurality of said coated sheets with the node bond lines in appropriate juxtaposition to provide a honeycomb structure on curing and expansion; curing said node bond adhesive at an elevated temperature and under a mild positive pressure; expanding said stack of sheets with the aid of a warm hydroxylic media; coating the expanded stack of sheets with a second copper and/or nickel-resin composition, wherein the copper and/or nickel is present in at least 85 weight percent of the copper and/or nickel-resin composition; drying and burning organic matter at a temperature below 1500* F in an oxidizing environment; and sintering said copper and/or nickel at a tEmperature above 1500* F in a non-oxidizing environment.
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) | 1977-06-24 | 1977-12-24 | 1978-06-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-06-24 | 1981-12-24 | 1982-06-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-06-24 | 1985-12-24 | 1986-06-25 | $7700.00 | Window Closed / Lapsed |