US2005281701A1PendingUtilityA1

Densified particulate/binder composites

35
Individually held — no corporate assignee on recordPriority: Dec 9, 2002Filed: Jun 9, 2005Published: Dec 22, 2005
Est. expiryDec 9, 2022(expired)· nominal 20-yr term from priority
Inventors:Robert LynchJonathan L. RolfeMark Jasmin
G21K 1/025B22F 2998/00B22F 2998/10B22F 3/22B22F 2999/00
35
PatentIndex Score
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Cited by
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Claims

Abstract

A system and method to produce high density precision composite devices. A system and method to consolidate a high density composite within details of a mold. One method includes creating a densified composite within the mold. Another method includes densifying a pre-mixed composite within a mold. A very high density precision molded composite device.

Claims

exact text as granted — not AI-modified
1 . A method of manufacturing a collimator comprising: 
 placing a particulate material in a mold;    placing a binder in the mold;    forming a composite comprising about 90-99% by weight of the particulate material, and about 1-10% by weight of the binder.    
   
   
       2 . The method of  claim 1  wherein the forming step comprises curing the composite in the mold.  
   
   
       3 . The method of  claim 1  wherein the forming step comprises removing a portion of the binder from the composite.  
   
   
       4 . The method of  claim 3  wherein the removing includes displacing binder from the composite.  
   
   
       5 . The method of  claim 1  further comprising applying a vacuum to the particulate material.  
   
   
       6 . The method of  claim 1  further comprising applying vibration to the particulate material.  
   
   
       7 . The method of  claim 6  wherein the step of applying vibration comprises applying sound waves to the particulate material.  
   
   
       8 . The method of  claim 1  further comprising applying gravitational force to the mold.  
   
   
       9 . The method of  claim 8  wherein the gravitational force includes centrifugal force.  
   
   
       10 . The method of  claim 3  wherein the removing step occurs prior to a curing step.  
   
   
       11 . The method of  claim 1  wherein the removing step comprises mechanically removing the binder from at least a portion of the composite.  
   
   
       12 . The method of  claim 1  wherein the particulate material comprises a heavy metal.  
   
   
       13 . The method of  claim 12  wherein the heavy metal comprises tungsten  
   
   
       14 . The method of  claim 12  wherein the heavy metal is selected from the group consisting of tungsten, osmium, platinum, gold, rhenium, tantalum and mixtures thereof.  
   
   
       15 . The method of  claim 1  wherein the particulate material comprises spheroidal particles.  
   
   
       16 . The method of  claim 1  wherein the particulate material comprises more than one size of particles.  
   
   
       17 . The method of  claim 1  wherein the binder comprises an epoxy resin.  
   
   
       18 . The method of  claim 1  wherein the binder comprises material selected from the group consisting of polyester and acrylic fluorosilicone resin.  
   
   
       19 . The method of  claim 1  wherein the particulate material has a specific gravity SG P  and the binder has specific gravity SG B  wherein the ratio of SG P :SG B  is approximately 8.  
   
   
       20 . The method of  claim 1  further comprising placing a surfactant in the mold.  
   
   
       21 . A method of manufacturing a collimator comprising: 
 combining 90-99% by weight of a particulate material and 1-10% by weight of a binder;    mixing the particulate material and binder into a composite;    placing the composite in a mold; and    curing the composite.    
   
   
       22 . The method of  claim 21  further comprising removing a portion of the binder from the composite.  
   
   
       23 . The method of  claim 21  wherein the combining and mixing steps take place in the mold.  
   
   
       24 . The method of  claim 21  further comprising applying a vacuum to the composite.  
   
   
       25 . The method of  claim 21  further comprising applying vibration to the composite.  
   
   
       26 . The method of  claim 25  wherein the step of applying vibration comprises applying sound waves to the particulate material.  
   
   
       27 . The method of  claim 21  further comprising applying gravitational force to the mold.  
   
   
       28 . The method of  claim 22  wherein the removing step occurs prior to the curing step.  
   
   
       29 . The method of  claim 22  wherein the removing step comprises mechanically removing the binder from at least a portion of the composite.  
   
   
       30 . The method of  claim 21  wherein the particulate material comprises a heavy metal.  
   
   
       31 . The method of  claim 30  wherein the heavy metal comprises tungsten  
   
   
       32 . The method of  claim 30  wherein the heavy metal is selected from the group consisting of tungsten, osmium, platinum, gold, rhenium, tantalum and mixtures thereof.  
   
   
       33 . The method of  claim 21  wherein the particulate material comprises spheroidal particles.  
   
   
       34 . The method of  claim 21  wherein the particulate material comprises more than one size of particles.  
   
   
       35 . The method of  claim 21  wherein the binder comprises an epoxy resin.  
   
   
       36 . The method of  claim 21  wherein the particulate material has a specific gravity SG P  and the binder has specific gravity SG B  wherein the ratio of SG P :SG B  is approximately 8.  
   
   
       37 . The method of  claim 21  further comprising adding a surfactant to the composite.  
   
   
       38 . A collimator comprising: 
 a composite of about 90-99% by weight of a particulate material and about 1-10% by weight of a binder.    
   
   
       39 . The collimator of  claim 38  wherein the particulate material comprises a heavy metal.  
   
   
       40 . The collimator of  claim 38  wherein the heavy metal comprises tungsten  
   
   
       41 . The collimator of  claim 38  wherein the heavy metal is selected from the group consisting of tungsten, osmium, platinum, gold, rhenium, tantalum and mixtures thereof.  
   
   
       42 . The collimator of  claim 38  wherein the particulate material comprises spheroidal particles.  
   
   
       43 . The collimator of  claim 38  wherein the particulate material comprises more than one size of particles.  
   
   
       44 . The collimator of  claim 38  wherein the binder comprises an epoxy resin.  
   
   
       45 . The collimator of  claim 38  wherein the particulate material has a specific gravity SG P  and the binder has specific gravity SG B  wherein the ratio of SG P :SG B  is approximately 8.  
   
   
       46 . The collimator of  claim 38  further comprising a surfactant.  
   
   
       47 . The collimator of  claim 38  wherein the composite has a density greater than about 11.4 grams per cubic centimeters.  
   
   
       48 . The collimator of  claim 38  wherein the composite has a density that is at least the tap density of the particulate material.

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