Patents by Inventor Brian John Melody
Brian John Melody has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 6591515Abstract: An apparatus is disclosed for drying materials wet with one or more solvents, particularly hygroscopic materials and materials wet with a high boiling point (low vapor pressure) solvent that are sensitive to heat. Wet material is loaded into a chamber, which is then sealed and caused to oscillate back and forth. Vacuum is enlisted to provide rapid evaporation of solvent at a lower temperature than possible at standard atmospheric pressure. The material is oscillated until a sudden decrease in the residual pressure of the chamber, which indicates completion of the drying cycle. Because vacuum is applied to an oscillating chamber, a rotary vacuum seal is not required to accomplish drying in accordance with the practice of the instant invention.Type: GrantFiled: September 10, 2001Date of Patent: July 15, 2003Assignee: Kemet Electronics CorporationInventors: John Tony Kinard, Michael John Maich, Brian John Melody, Duane Earl Stenzinger, David Alexander Wheeler, Keith Lee Moore
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Publication number: 20030111355Abstract: An electrolyte comprising a polyester condensation product of 2-methyl-1,3-propane diol and boric acid; and further comprising dimethyl amino ethoxy ethanol in an amount to reduce the resistance of the electrolyte. The electrolyte may further comprise ortho-phosphoric acid and at least one substituted pyrrolidone or lactone, such as N-methyl-2-pyrrolidone, N-ethyl-2-pyrrolidone, N-hydroxy ethyl-2-pyrrolidone or 4-butyrolactone. The ortho-phosphoric acid prevents hydration of anodic aluminum oxide in contact with the solution. The pyrrolidone or lactone reduce the resistance of the electrolyte. The electrolyte may also comprise sodium silicate.Type: ApplicationFiled: December 10, 2001Publication date: June 19, 2003Applicant: Kemet Electronics CorporationInventors: Brian John Melody, John Tony Kinard, David Alexander Wheeler
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Patent number: 6548324Abstract: Edges of a slit and cut to length foil having a dielectric oxide film on at least one surface are edge formed by edge forming the foil in an aqueous citrate electrolyte, preferably an aqueous ammonium citrate electrolyte, depolarizing the foil, and then edge forming the foil in an aqueous phosphate electrolyte, preferably an ammonium dihydrogen phosphate electrolyte. Using this formation process, a foil with excellent hydration resistance and capacitance is produced.Type: GrantFiled: June 6, 2001Date of Patent: April 15, 2003Assignee: Kemet Electronics CorporationInventors: Philip Michael Lessner, Albert Kennedy Harrington, Brian John Melody, John Tony Kinard
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Patent number: 6540900Abstract: Disclosed is a process for the continuous anodizing of aluminum foil for use in aluminum electrolytic capacitors. Specifically, etched anode foil is anodized to relatively low voltage in a two-step reel-to-reel process. The process is particularly useful for anodizing highly-etched aluminum foil for use in surface mount aluminum capacitors containing conductive polymer cathode material. The process is economical and provides high foil quality. Specifically, the process for anodizing aluminum foil comprises anodizing the foil in a first electrolyte a solution, passing the foil through an oven, anodizing the foil in a second anodizing solution wherein the first electrolyte solution and second electrolyte solution each comprise about 5 wt % to about 50 wt % glycerine, about 0.01 wt % to about 0.2 wt % ammonium phosphate, and de-ionized water, and wherein the foil is anodized in the first electrolyte solution for at least 3.Type: GrantFiled: October 16, 2001Date of Patent: April 1, 2003Assignee: Kemet Electronics CorporationInventors: John Tony Kinard, Brian John Melody, Philip Michael Lessner, Albert Kennedy Harrington, David Alexander Wheeler, Erik Karlsen Reed, Duane Earl Stenziner
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Publication number: 20030046824Abstract: An apparatus is disclosed for drying materials wet with one or more solvents, particularly hygroscopic materials and materials wet with a high boiling point (low vapor pressure) solvent that are sensitive to heat. Wet material is loaded into a chamber, which is then sealed and caused to oscillate back and forth. Vacuum is enlisted to provide rapid evaporation of solvent at a lower temperature than possible at standard atmospheric pressure. The material is oscillated until a sudden decrease in the residual pressure of the chamber, which indicates completion of the drying cycle. Because vacuum is applied to an oscillating chamber, a rotary vacuum seal is not required to accomplish drying in accordance with the practice of the instant invention.Type: ApplicationFiled: September 10, 2001Publication date: March 13, 2003Inventors: John Tony Kinard, Michael John Maich, Brian John Melody, Duane Earl Stenzinger, David Alexander Wheeler, Keith Lee Moore
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Publication number: 20020195348Abstract: Non-aqueous electrolytic solutions suitable for anodizing valve metal derivative anodes, methods of anodizing using non-aqueous electrolytic solutions, and capacitors prepared with non-aqueous electrolytic solutions. The non-aqueous electrolytic solution comprises glycerine and at least one soluble salt formed by the neutralization of at least one non-halogen-containing organic or inorganic acid anion with at least one alkali metal, ammonium, or protonated amine cation; wherein the acid anion is derived from an acid having a pKa lower than phosphoric acid.Type: ApplicationFiled: June 28, 2002Publication date: December 26, 2002Applicant: KEMET ELECTRONICS CORPORATIONInventors: Brian John Melody, John Tony Kinard, David Alexander Wheeler, Philip Michael Lessner
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Publication number: 20020191371Abstract: A process for edge forming a slit and cut-to-length foil having a dielectric oxide film on its face comprising forming the foil in an aqueous citrate electrolyte, preferably an aqueous ammonium citrate electrolyte, depolarizing the foil, and forming the foil in an aqueous phosphate electrolyte, preferably an ammonium dihydrogen phosphate electrolyte. Using this formation process, a foil with excellent hydration resistance and capacitance is produced.Type: ApplicationFiled: June 6, 2001Publication date: December 19, 2002Inventors: Philip Michael Lessner, Albert Kennedy Harrington, Brian John Melody, John Tony Kinard
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Publication number: 20020186521Abstract: Aluminum surface mount capacitors containing one or more anode foil coupons are initially anodized in an aqueous phosphate solution in order to produce an anodic oxide film having extreme resistance to hydration and attack by corrosive anions for the purpose of producing surface mount capacitors at high yield and of high stability.Type: ApplicationFiled: July 12, 2002Publication date: December 12, 2002Applicant: KEMET ELECTRONICS CORPORATIONInventors: Philip Michael Lessner, Brian John Melody, John Tony Kinard, Erik Karlsen Reed, Albert Kennedy Harrington, Daniel F. Persico, David Alexander Wheeler
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Patent number: 6480371Abstract: Electrolytes containing water, phosphoric acid, at least one organic solvent, and at least one alkanolamine can be used for anodizing valve metals prepared from metal powder having a surface area of least 0.35 m2/g or 35,000 CV/g. The anodizing electrolytes have relatively high conductivity and are capable of being used at high anodizing currents. The anodic film produced by these electrolytes on valve metals is of substantially uniform thickness and has improved electrical parameters.Type: GrantFiled: February 1, 2000Date of Patent: November 12, 2002Assignee: Kemet Electronics CorporationInventors: John Tony Kinard, Brian John Melody, David Alexander Wheeler
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Patent number: 6475368Abstract: A method of anodizing an aluminum substrate comprising heating the substrate to a first temperature of 200° C. to about 380° C.; suspending the substrate into a first electrolyte and applying a first anodizing current to the first electrolyte; rinsing the substrate; heating the substrate to a second temperature of 200° C. to about 380° C.; and suspending the substrate into a second electrolyte and applying a second anodizing current to the second electrolyte, wherein the first electrolyte and second electrolyte each comprise an aqueous solution of at least one salt of alpha-hydroxy acid.Type: GrantFiled: March 7, 2001Date of Patent: November 5, 2002Assignee: Kemet Electronics CorporationInventors: Albert Kennedy Harrington, Brian John Melody, John Tony Kinard, Philip Michael Lessner, David Alexander Wheeler
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Patent number: 6459565Abstract: Aluminum surface mount capacitors containing one or more anode foil coupons are initially anodized in an aqueous phosphate solution in order to produce an anodic oxide film having extreme resistance to hydration and attack by corrosive anions for the purpose of producing surface mount capacitors at high yield and of high stability.Type: GrantFiled: June 26, 2001Date of Patent: October 1, 2002Assignee: Kemet Electronics CorporationInventors: Philip Michael Lessner, Brian John Melody, John Tony Kinard, Erik Karlsen Reed, Albert Kennedy Harrington, Daniel F. Persico, David Alexander Wheeler
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Publication number: 20020125143Abstract: A method of anodizing an aluminum substrate comprising heating the substrate to a first temperature of 200° C. to about 380° C.; suspending the substrate into a first electrolyte and applying a first anodizing current to the first electrolyte; rinsing the substrate; heating the substrate to a second temperature of 200° C. to about 380° C.; and suspending the substrate into a second electrolyte and applying a second anodizing current to the second electrolyte, wherein the first electrolyte and second electrolyte each comprise an aqueous solution of at least one salt of alpha-hydroxy acid.Type: ApplicationFiled: March 7, 2001Publication date: September 12, 2002Inventors: Albert Kennedy Harrington, Brian John Melody, John Tony Kinard, Philip Michael Lessner, David Alexander Wheeler
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Patent number: 6436268Abstract: Non-aqueous electrolytic solutions suitable for anodizing valve metal derivative anodes, methods of anodizing using non-aqueous electrolytic solutions, and capacitors prepared with non-aqueous electrolytic solutions. The non-aqueous electrolytic solution comprises glycerine and at least one soluble salt formed by the neutralization of at least one non-halogen-containing organic or inorganic acid anion with at least one alkali metal, ammonium, or protonated amine cation; wherein the acid anion is derived from an acid having a pKa lower than phosphoric acid.Type: GrantFiled: August 2, 2000Date of Patent: August 20, 2002Assignee: Kemet Electronics CorporationInventors: Brian John Melody, John Tony Kinard, David Alexander Wheeler, Philip Michael Lessner
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Publication number: 20020076484Abstract: A method of preparing a capacitor having at least one porous element comprising applying to the element a masking material with an ink jet printer head. Preferably the masking material is a liquid resin such as an acrylic, a polyurethane, a silicone, or a polyimide.Type: ApplicationFiled: December 14, 2001Publication date: June 20, 2002Applicant: Kemet Electronics CorporationInventors: Philip Michael Lessner, Peter Fernstrom, Brian John Melody, John tony Kinard
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Patent number: 6375710Abstract: Metal powders are pressed into compacts more readily through the addition of a minor percentage of dimethyl sulfone binder. Dimethyl sulfone may be dry-blended with the metal powder by mixing it in the form of a powder, or it may be wet-blended by first dissolving it in a suitable solvent, then adding it to the metal powder and evaporating the solvent. Dimethyl sulfone may be almost completely removed from compacts pressed from tantalum, etc., either by vacuum distillation or by water leaching, to leave compacts uncontaminated by the binder and suitable for further processing into capacitor anodes, etc.Type: GrantFiled: December 21, 2000Date of Patent: April 23, 2002Assignee: Kemet Electronics CorporationInventors: Keith Lee Moore, Brian John Melody, John Tony Kinard, David Alexander Wheeler
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Patent number: 6346185Abstract: A method of anodizing valve metals with a borate polyester solution formed by the combining 2-methyl-1,3-propane diol and boric acid and heating to about 130 to about 160° C. The heating drives off water produced by esterification. A substrate is immersed in the borate polyester electrolyte solution at a temperature of about 25° C. to about 85° C. and an anodizing voltage is applied.Type: GrantFiled: October 23, 2000Date of Patent: February 12, 2002Assignee: Kemet Electronics CorporationInventors: John Tony Kinard, Brian John Melody, David Alexander Wheeler, Philip Michael Lessner
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Patent number: 6334945Abstract: A process for isolating flaw sites in the dielectric of solid electrolytic capacitor comprising immersing a conductive polymer impregnated capacitor in an electrolyte solution, and then alternately subjecting the conductive polymer impregnated capacitor to a high voltage and a low voltage; wherein the high voltage is between about 10 volts and 50 volts, and the low voltage is between about 0 volts and the voltage corresponding to 90% of the anodization voltage for pellets anodized at less than 20 volts, or the voltage at which the current drops to 50% of the peak voltage current for pellets anodized at voltages greater than or equal to 20 volts. The period of time at or above the anodization voltage is relatively short to prevent damaging the dielectric film.Type: GrantFiled: September 7, 2000Date of Patent: January 1, 2002Assignee: Kemet Electronics CorporationInventors: Philip Michael Lessner, Randolph Stephen Hahn, Brian John Melody, Erik Karlsen Reed, John Tony Kinard
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Patent number: 6319459Abstract: Organic acid-based binders are efficiently removed from powder metallurgy compacts, such as tantalum capacitor anode bodies, by immersion in a heated aqueous alkanolamine solution followed by rinsing in warm water. This method results in lower residual carbon and oxygen levels than are found with thermal binder removal methods.Type: GrantFiled: October 18, 1999Date of Patent: November 20, 2001Assignee: Kemet Electronics CorporationInventors: Brian John Melody, John Tony Kinard, Keith Lee Moore, David Alexander Wheeler
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Patent number: 6315808Abstract: Metal powders are pressed into compacts more readily through the addition of a minor percentage of dimethyl sulfone binder. Dimethyl sulfone may be dry-blended with the metal powder by mixing it in the form of a powder, or it may be wet-blended by first dissolving it in a suitable solvent, then adding it to the metal powder and evaporating the solvent. Dimethyl sulfone may be almost completely removed from compacts pressed from tantalum, etc., either by vacuum distillation or by water leaching, to leave compacts uncontaminated by the binder and suitable for further processing into capacitor anodes, etc.Type: GrantFiled: September 16, 1999Date of Patent: November 13, 2001Assignee: Kemet Electronics CorporationInventors: Keith Lee Moore, Brian John Melody, John Tony Kinard, David Alexander Wheeler
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Patent number: 6267861Abstract: A method of non-thickness-limited anodizing for valve metals and alloys which are resistant to the non-thickness-limited growth of anodic oxide, such as niobium and high niobium content alloys. Non-thickness-limited anodic oxide film growth is produced on such valve metals by employing a first glycerine-based electrolyte containing about 1 to about 3 wt % water for the initial production of anodic oxide. After the substrate is anodized using the first electrolyte, it is immersed in a second glycerine-based electrolyte having less than about 0.1 wt % water. The second electrolyte may be produced by allowing water to evaporate from the first electrolyte solution until the solution contains less than about 0.1 wt. % water.Type: GrantFiled: October 2, 2000Date of Patent: July 31, 2001Assignee: Kemet Electronics CorporationInventors: John Tony Kinard, Brian John Melody, David Alexander Wheeler