Patent
US 11,268,042ABRADABLE COATING hBN FILLER MATERIAL AND METHOD OF MANUFACTURE
Christopher W. Strock
US
Copyright © 2026 Matter42. All rights reserved.
Patent
Atlas literature
Patent
US 11,268,042Patent drawings and their descriptions. Click a drawing to enlarge it.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for solid lubricant filler powder used in abradable coating manufacture comprising: mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and said hexagonal boron nitride powder; consolidating the bentonite clay and the hexagonal boron nitride powder utilizing tape casting to form a composite material; heat treating the composite material to at least 500 degrees centigrade; breaking up the composite material into a variety of sizes; and segregating the composite material to produce a final product of low dust powder of composite hexagonal boron nitride and calcined bentonite. Currently amended
The process according to claim 1, further comprising: recycling said composite material that is deemed to be too coarse and too fine. Original
The process according to claim 1, wherein said step of breaking up the composite material into a variety of sizes comprises crushing said composite material. Original
The process according to claim 1, further comprising: adding a binder with said hexagonal boron nitride and said bentonite clay prior to said mixing step. Original
The process according to claim 1, wherein said hexagonal boron nitride is crushed prior to mixing with the bentonite clay. Original
The process according to claim 1, wherein said step of segregating the composite material comprises segregating said composite material based on size selected from the group consisting of a coarse size, a fine size and a desired fraction size. Original
The process according to claim 1, prior to said step of mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and a hexagonal boron nitride powder, further comprising: combining said bentonite clay with water and a dispersant; and ball milling the bentonite clay, the water and the dispersant. Original
The process according to claim 1, wherein said step of heat treating comprises calcine heat treatment. Original
The process according to claim 1, further comprising: bindering the composite material; and de-bindering the composite material. Original
The process according to claim 1 wherein said heat treating can include a minimum temperature of 500 degrees Centigrade and range as high as 1000 degrees Centigrade. Original
Canceled
The process according to claim [[4]] 1, further comprising: applying a calcine heat treatment to said mixture of said bentonite clay and said hexagonal boron nitride powder after drying the composite material. Currently amended
The process according to claim [[4]] 1, wherein said step of pressing comprises at least one of: roll pressing said mixture of said bentonite clay and said hexagonal boron nitride powder, and extruding said mixture of said bentonite clay and said hexagonal boron nitride powder. Currently amended
Canceled
Embodiments described in the patent, grouped by the materials and process steps they use.
3 materials1 process step
Bentonite clay and hBN powders are mixed (optionally with fugitive solvents and binders such as wax, acrylic, or PVA); consolidated by bulk pressing, tape casting, or extruding; dried, de-bound, and calcine heat treated at minimum 500°C (desirably 750°C, up to 1000°C) in air; crushed into angular particles; optionally tumbled to improve flow; sized and segregated to produce free-flowing, low-dust (<5 wt% at ≤11 micron) powder of composite hBN and calcined bentonite with desired fraction of 10–150 microns.
3 materials1 process step
Bentonite clay, water, and dispersant are combined and optionally ball milled; crushed hBN is added and mixed in a disperser mixer; the slurry is tape cast (wet thickness ~3x desired calcined particle size, e.g. 150 µm wet for 50 µm calcined particle); dried; calcine heat treated; crushed; segregated by size; oversized/undersized fractions recycled; desired fraction sent as final product.
3 materials1 process step
Crushed hBN, bentonite clay, and optional organic binder (wax, stearate, or polymer) are combined and mixed; composition is pressed, roll pressed, or extruded; subsequently heat treated.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Particle Size Range | 10–150 microns | composite hexagonal boron nitride and calcined bentonite powder |
Dust Content Specification | ≤ 5 wt% |
Patent
Atlas literature
Patent
US 11,268,042Patent drawings and their descriptions. Click a drawing to enlarge it.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for solid lubricant filler powder used in abradable coating manufacture comprising: mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and said hexagonal boron nitride powder; consolidating the bentonite clay and the hexagonal boron nitride powder utilizing tape casting to form a composite material; heat treating the composite material to at least 500 degrees centigrade; breaking up the composite material into a variety of sizes; and segregating the composite material to produce a final product of low dust powder of composite hexagonal boron nitride and calcined bentonite. Currently amended
The process according to claim 1, further comprising: recycling said composite material that is deemed to be too coarse and too fine. Original
The process according to claim 1, wherein said step of breaking up the composite material into a variety of sizes comprises crushing said composite material. Original
The process according to claim 1, further comprising: adding a binder with said hexagonal boron nitride and said bentonite clay prior to said mixing step. Original
The process according to claim 1, wherein said hexagonal boron nitride is crushed prior to mixing with the bentonite clay. Original
The process according to claim 1, wherein said step of segregating the composite material comprises segregating said composite material based on size selected from the group consisting of a coarse size, a fine size and a desired fraction size. Original
The process according to claim 1, prior to said step of mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and a hexagonal boron nitride powder, further comprising: combining said bentonite clay with water and a dispersant; and ball milling the bentonite clay, the water and the dispersant. Original
The process according to claim 1, wherein said step of heat treating comprises calcine heat treatment. Original
The process according to claim 1, further comprising: bindering the composite material; and de-bindering the composite material. Original
The process according to claim 1 wherein said heat treating can include a minimum temperature of 500 degrees Centigrade and range as high as 1000 degrees Centigrade. Original
Canceled
The process according to claim [[4]] 1, further comprising: applying a calcine heat treatment to said mixture of said bentonite clay and said hexagonal boron nitride powder after drying the composite material. Currently amended
The process according to claim [[4]] 1, wherein said step of pressing comprises at least one of: roll pressing said mixture of said bentonite clay and said hexagonal boron nitride powder, and extruding said mixture of said bentonite clay and said hexagonal boron nitride powder. Currently amended
Canceled
Embodiments described in the patent, grouped by the materials and process steps they use.
3 materials1 process step
Bentonite clay and hBN powders are mixed (optionally with fugitive solvents and binders such as wax, acrylic, or PVA); consolidated by bulk pressing, tape casting, or extruding; dried, de-bound, and calcine heat treated at minimum 500°C (desirably 750°C, up to 1000°C) in air; crushed into angular particles; optionally tumbled to improve flow; sized and segregated to produce free-flowing, low-dust (<5 wt% at ≤11 micron) powder of composite hBN and calcined bentonite with desired fraction of 10–150 microns.
3 materials1 process step
Bentonite clay, water, and dispersant are combined and optionally ball milled; crushed hBN is added and mixed in a disperser mixer; the slurry is tape cast (wet thickness ~3x desired calcined particle size, e.g. 150 µm wet for 50 µm calcined particle); dried; calcine heat treated; crushed; segregated by size; oversized/undersized fractions recycled; desired fraction sent as final product.
3 materials1 process step
Crushed hBN, bentonite clay, and optional organic binder (wax, stearate, or polymer) are combined and mixed; composition is pressed, roll pressed, or extruded; subsequently heat treated.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Particle Size Range | 10–150 microns | composite hexagonal boron nitride and calcined bentonite powder |
Dust Content Specification | ≤ 5 wt% |
Patent
Atlas literature
Patent
US 11,268,042Patent drawings and their descriptions. Click a drawing to enlarge it.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for solid lubricant filler powder used in abradable coating manufacture comprising: mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and said hexagonal boron nitride powder; consolidating the bentonite clay and the hexagonal boron nitride powder utilizing tape casting to form a composite material; heat treating the composite material to at least 500 degrees centigrade; breaking up the composite material into a variety of sizes; and segregating the composite material to produce a final product of low dust powder of composite hexagonal boron nitride and calcined bentonite. Currently amended
The process according to claim 1, further comprising: recycling said composite material that is deemed to be too coarse and too fine. Original
The process according to claim 1, wherein said step of breaking up the composite material into a variety of sizes comprises crushing said composite material. Original
The process according to claim 1, further comprising: adding a binder with said hexagonal boron nitride and said bentonite clay prior to said mixing step. Original
The process according to claim 1, wherein said hexagonal boron nitride is crushed prior to mixing with the bentonite clay. Original
The process according to claim 1, wherein said step of segregating the composite material comprises segregating said composite material based on size selected from the group consisting of a coarse size, a fine size and a desired fraction size. Original
The process according to claim 1, prior to said step of mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and a hexagonal boron nitride powder, further comprising: combining said bentonite clay with water and a dispersant; and ball milling the bentonite clay, the water and the dispersant. Original
The process according to claim 1, wherein said step of heat treating comprises calcine heat treatment. Original
The process according to claim 1, further comprising: bindering the composite material; and de-bindering the composite material. Original
The process according to claim 1 wherein said heat treating can include a minimum temperature of 500 degrees Centigrade and range as high as 1000 degrees Centigrade. Original
Canceled
The process according to claim [[4]] 1, further comprising: applying a calcine heat treatment to said mixture of said bentonite clay and said hexagonal boron nitride powder after drying the composite material. Currently amended
The process according to claim [[4]] 1, wherein said step of pressing comprises at least one of: roll pressing said mixture of said bentonite clay and said hexagonal boron nitride powder, and extruding said mixture of said bentonite clay and said hexagonal boron nitride powder. Currently amended
Canceled
Embodiments described in the patent, grouped by the materials and process steps they use.
3 materials1 process step
Bentonite clay and hBN powders are mixed (optionally with fugitive solvents and binders such as wax, acrylic, or PVA); consolidated by bulk pressing, tape casting, or extruding; dried, de-bound, and calcine heat treated at minimum 500°C (desirably 750°C, up to 1000°C) in air; crushed into angular particles; optionally tumbled to improve flow; sized and segregated to produce free-flowing, low-dust (<5 wt% at ≤11 micron) powder of composite hBN and calcined bentonite with desired fraction of 10–150 microns.
3 materials1 process step
Bentonite clay, water, and dispersant are combined and optionally ball milled; crushed hBN is added and mixed in a disperser mixer; the slurry is tape cast (wet thickness ~3x desired calcined particle size, e.g. 150 µm wet for 50 µm calcined particle); dried; calcine heat treated; crushed; segregated by size; oversized/undersized fractions recycled; desired fraction sent as final product.
3 materials1 process step
Crushed hBN, bentonite clay, and optional organic binder (wax, stearate, or polymer) are combined and mixed; composition is pressed, roll pressed, or extruded; subsequently heat treated.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Particle Size Range | 10–150 microns | composite hexagonal boron nitride and calcined bentonite powder |
Dust Content Specification | ≤ 5 wt% |
Patent
Atlas literature
Patent
US 11,268,042Patent drawings and their descriptions. Click a drawing to enlarge it.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for solid lubricant filler powder used in abradable coating manufacture comprising: mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and said hexagonal boron nitride powder; consolidating the bentonite clay and the hexagonal boron nitride powder utilizing tape casting to form a composite material; heat treating the composite material to at least 500 degrees centigrade; breaking up the composite material into a variety of sizes; and segregating the composite material to produce a final product of low dust powder of composite hexagonal boron nitride and calcined bentonite. Currently amended
The process according to claim 1, further comprising: recycling said composite material that is deemed to be too coarse and too fine. Original
The process according to claim 1, wherein said step of breaking up the composite material into a variety of sizes comprises crushing said composite material. Original
The process according to claim 1, further comprising: adding a binder with said hexagonal boron nitride and said bentonite clay prior to said mixing step. Original
The process according to claim 1, wherein said hexagonal boron nitride is crushed prior to mixing with the bentonite clay. Original
The process according to claim 1, wherein said step of segregating the composite material comprises segregating said composite material based on size selected from the group consisting of a coarse size, a fine size and a desired fraction size. Original
The process according to claim 1, prior to said step of mixing a bentonite clay and a hexagonal boron nitride powder to form a mixture of said bentonite clay and a hexagonal boron nitride powder, further comprising: combining said bentonite clay with water and a dispersant; and ball milling the bentonite clay, the water and the dispersant. Original
The process according to claim 1, wherein said step of heat treating comprises calcine heat treatment. Original
The process according to claim 1, further comprising: bindering the composite material; and de-bindering the composite material. Original
The process according to claim 1 wherein said heat treating can include a minimum temperature of 500 degrees Centigrade and range as high as 1000 degrees Centigrade. Original
Canceled
The process according to claim [[4]] 1, further comprising: applying a calcine heat treatment to said mixture of said bentonite clay and said hexagonal boron nitride powder after drying the composite material. Currently amended
The process according to claim [[4]] 1, wherein said step of pressing comprises at least one of: roll pressing said mixture of said bentonite clay and said hexagonal boron nitride powder, and extruding said mixture of said bentonite clay and said hexagonal boron nitride powder. Currently amended
Canceled
Embodiments described in the patent, grouped by the materials and process steps they use.
3 materials1 process step
Bentonite clay and hBN powders are mixed (optionally with fugitive solvents and binders such as wax, acrylic, or PVA); consolidated by bulk pressing, tape casting, or extruding; dried, de-bound, and calcine heat treated at minimum 500°C (desirably 750°C, up to 1000°C) in air; crushed into angular particles; optionally tumbled to improve flow; sized and segregated to produce free-flowing, low-dust (<5 wt% at ≤11 micron) powder of composite hBN and calcined bentonite with desired fraction of 10–150 microns.
3 materials1 process step
Bentonite clay, water, and dispersant are combined and optionally ball milled; crushed hBN is added and mixed in a disperser mixer; the slurry is tape cast (wet thickness ~3x desired calcined particle size, e.g. 150 µm wet for 50 µm calcined particle); dried; calcine heat treated; crushed; segregated by size; oversized/undersized fractions recycled; desired fraction sent as final product.
3 materials1 process step
Crushed hBN, bentonite clay, and optional organic binder (wax, stearate, or polymer) are combined and mixed; composition is pressed, roll pressed, or extruded; subsequently heat treated.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Particle Size Range | 10–150 microns | composite hexagonal boron nitride and calcined bentonite powder |
Dust Content Specification | ≤ 5 wt% |
composite hexagonal boron nitride and calcined bentonite powder |
Particle Size D50 | 20–75 microns | composite hexagonal boron nitride and calcined bentonite powder |
Thickness | 10–150 µm | — |
Thickness | 12–100 µm | — |
Thickness | 16–75 µm | — |
Thickness | 20–75 µm | — |
Thickness | 22–50 µm | — |
Thickness | 25–35 µm | — |
Thickness | ≤ 11 µm | — |
composite hexagonal boron nitride and calcined bentonite powder |
Particle Size D50 | 20–75 microns | composite hexagonal boron nitride and calcined bentonite powder |
Thickness | 10–150 µm | — |
Thickness | 12–100 µm | — |
Thickness | 16–75 µm | — |
Thickness | 20–75 µm | — |
Thickness | 22–50 µm | — |
Thickness | 25–35 µm | — |
Thickness | ≤ 11 µm | — |
composite hexagonal boron nitride and calcined bentonite powder |
Particle Size D50 | 20–75 microns | composite hexagonal boron nitride and calcined bentonite powder |
Thickness | 10–150 µm | — |
Thickness | 12–100 µm | — |
Thickness | 16–75 µm | — |
Thickness | 20–75 µm | — |
Thickness | 22–50 µm | — |
Thickness | 25–35 µm | — |
Thickness | ≤ 11 µm | — |
composite hexagonal boron nitride and calcined bentonite powder |
Particle Size D50 | 20–75 microns | composite hexagonal boron nitride and calcined bentonite powder |
Thickness | 10–150 µm | — |
Thickness | 12–100 µm | — |
Thickness | 16–75 µm | — |
Thickness | 20–75 µm | — |
Thickness | 22–50 µm | — |
Thickness | 25–35 µm | — |
Thickness | ≤ 11 µm | — |