- Patent Title: Processes for preparing porous ceramics for acoustic transducers
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Application No.: US17426998Application Date: 2021-03-09
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Publication No.: US11746062B2Publication Date: 2023-09-05
- Inventor: Barry J. Robinson , Brian G. Pazol
- Applicant: Airmar Technology Corporation
- Applicant Address: US NH Milford
- Assignee: AIRMAR TECHNOLOGY CORPORATION
- Current Assignee: AIRMAR TECHNOLOGY CORPORATION
- Current Assignee Address: US NH Milford
- Agency: Hamilton, Brook, Smith & Reynolds, P.C.
- International Application: PCT/US2021/021436 2021.03.09
- International Announcement: WO2021/188320A 2021.09.23
- Date entered country: 2021-07-29
- Main IPC: C04B35/491
- IPC: C04B35/491 ; C04B35/638 ; C04B38/06 ; H01L41/18 ; C04B35/634 ; H10N30/097 ; H10N30/853

Abstract:
A process for preparing a porous ceramic body includes forming a green body with a mixture of ceramic material powder, binder material, and pore-forming particles. The process further includes extracting the binder material, decomposing the pore-forming particles, and removing residual organic materials from the green body at respective, progressively higher pre-firing temperatures. After these three stages, the green body is sintered at a still-higher temperature to form the porous ceramic body. Embodiments facilitate manufacturing and can render most or all surface grinding unnecessary, allowing electrode deposition directly onto substantially non-porous surfaces of the porous ceramic body that are naturally formed during sintering. Advantageously, the green body may be formed into net shape by injection molding the mixture that includes the pore-forming particles, and embodiments can result in porous ceramic bodies that are much thicker than currently available, with better structural integrity.
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