Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Of inorganic materials
Patent
1984-02-28
1986-04-01
Miller, Edward A.
Plastic and nonmetallic article shaping or treating: processes
Pore forming in situ
Of inorganic materials
2105101, B29C 2760
Patent
active
H00000485
ABSTRACT:
An open porous ceramic article having an outer skin and an open porous interior. The interior has a continuous matrix of ceramic material which includes a plurality of chambers of predetermined shape and size distributed throughout the matrix. The chambers are in communication with one another; the passageways are smaller in cross-sectional area than the chambers connected thereby. With its skin removed, the article may be used as a filter for molten metal. With its skin intact, the article is useful as thermal insulation.
The open porous ceramic article may be made by coating a predetermined volume of thermally degradable beads with a predetermined quantity of binder capable of taking a set and thereafter molding the coated beads under pressure in a mold until the binder is set. A slurry of ceramic material fills the interstices of the mass of the coated beads. After the ceramic slurry has set, the resulting block is dried to remove the excess moisture from the ceramic material. Thereafter the dried block is heated to cause the beads to degrade and volatilize leaving a porous block of ceramic greenware which is thereafter further heated to complete manufacture of the article. The coated beads may be formed into a porous block in a mold prior to introduction of the ceramic slurry. Alternatively, the coated beads and the ceramic slurry may be mixed together before molding.
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Kennecott Corporation
Miller Edward A.
Ronyak David M.
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