Methods Patents (Class 219/121.59)
  • Patent number: 7304263
    Abstract: The footprint of a reactive atom plasma processing tool can be modified using an aperture device. A flow of reactive gas can be injected into the center of an annular plasma. An aperture can be positioned relative to the plasma such that the effective footprint of the plasma can be changed without adjusting the gas flows or swapping out the tool. Once the aperture and tool are in position relative to a workpiece, reactive atom plasma processing can be used to modify the surface of the workpiece, such as to etch, smooth, polish, clean, and/or deposit material onto the workpiece. If necessary, a coolant can be circulated about the aperture. Multiple apertures can also be used to provide a variety of footprint sizes and/or shapes. This description is not intended to be a complete description of, or limit the scope of, the invention. Other features, aspects, and objects of the invention can be obtained from a review of the specification, the figures, and the claims.
    Type: Grant
    Filed: August 5, 2004
    Date of Patent: December 4, 2007
    Assignee: RAPT Industries, Inc.
    Inventors: Andrew Chang, Jeffrey W. Carr, Jude Kelley, Peter S. Fiske
  • Patent number: 7279655
    Abstract: Inductively coupled plasma (ICP) reforming converts carbonaceous compounds into a fuel for use in generating electrical power. Energy rich hydrocarbon fuels, such as coal, marine diesel, oils, and hydrocarbon wastes are employed as a feedstock for the ICP, which transforms the feedstock into a fuel that can be used by fuel cells and gas turbines for the production of electricity. The overall efficiency of an ICP-based electrical power system can be increased by providing partial oxidation within the reaction vessel. The partial oxidation conditions consume a small amount of the reformed fuel gas, thereby liberating sufficient thermal energy to reduce the electrical power requirements of the ICP to maintain desired reactor temperatures, and providing an increase in the overall net electrical power production. The integrated power production system can also adjust to meet an increased requirement for process heat and steam by balancing the effect of partial oxidation.
    Type: Grant
    Filed: June 10, 2004
    Date of Patent: October 9, 2007
    Assignee: Plasmet Corporation
    Inventors: Andreas Blutke, John Vavruska, Mark Henderson, Robert Ferguson
  • Patent number: 7262384
    Abstract: A reaction vessel and a method for efficiently producing and collecting nanoparticles in the reaction vessel using cyclonic gas flow. Gas is injected through an inlet tangentially positioned relative to the axis of the vessel to cause the gas to form an outer helical vortex flow and an inner helical vortex flow within the vessel. A reaction synthesizer is operated within the inner helical vortex to produce nanoparticles and larger byproduct particles from precursor materials. The double helical vortex conveys the byproduct particles to an outlet for collection responsive to the cyclonic flow and gravity and an outlet downstream of the inner helical vortex collects the nanoparticles. The vortices formed in the reaction vessel minimize buildup on walls of the reaction vessel and provide a way to rapidly move the synthesized nanoparticles out of the reaction vessel.
    Type: Grant
    Filed: September 30, 2004
    Date of Patent: August 28, 2007
    Assignee: NovaCentrix, Corp.
    Inventor: Douglas K. Jackson
  • Patent number: 7259350
    Abstract: A method for repairing cracks in a metal part comprising the steps of providing a metal part having a crack, cleaning the crack to remove an oxide layer, depositing a repair alloy via at least one of cathodic arc deposition and low pressure plasma spraying to cover the crack, and heating the part at a temperature and pressure sufficient to close the crack.
    Type: Grant
    Filed: August 26, 2004
    Date of Patent: August 21, 2007
    Assignee: United Technologies Corporation
    Inventors: Michael Minor, Chris Bischof, Herbert Koven, Paul Pellet
  • Patent number: 7241964
    Abstract: Heating head and mask apparatus are provided for producing electrically conductive heated glass panels that may be used to warm objects or insure unobstructed viewing through glass by removing moisture. The heating head and mask apparatus utilizes either a circularly rotating or an inline heating head and mask apparatus, which deposits conductive metal bus bars into electrical contact with electrically conductive-coatings that are-disposed on the glass panels.
    Type: Grant
    Filed: June 28, 2004
    Date of Patent: July 10, 2007
    Inventors: Peter F. Gerhardinger, Randall L. Bauman, Dillon R. Ashton
  • Patent number: 7220936
    Abstract: A method of thermally processing a material includes exposing the material to at least one pulse of infrared light emitted from a directed plasma arc to thermally process the material, the pulse having a duration of no more than 10 s.
    Type: Grant
    Filed: July 30, 2004
    Date of Patent: May 22, 2007
    Assignee: UT-Battelle, LLC
    Inventors: Ronald D. Ott, Craig A. Blue, Nancy J. Dudney, David C. Harper
  • Patent number: 7217903
    Abstract: A method is provided for purifying gases, particularly gases contaminated by environmentally harmful substances, by way of plasma discharge. The gas to be purified is guided through a thermal plasma, which is generated by electrodeless ignition of a process gas, so that, by way of the thermal plasma, the harmful substances contained in the gas to be purified are converted to environmentally neutral, fully oxidized substances.
    Type: Grant
    Filed: November 29, 2002
    Date of Patent: May 15, 2007
    Assignee: MTU Aero Engines GmbH
    Inventors: Erwin Bayer, Joerg Hoeschele, Juergen Steinwandel
  • Patent number: 7214903
    Abstract: An apparatus and method for heating materials or substances in an oven at an oven temperature below their melting and/or vaporization points to either melt and/or vaporize the substance. Substances are inserted into a substantially spherical envelope. The envelope is sealed at a preset pressure. The solid is heated in an oven at an oven temperature substantially below the melting or vaporization temperature of the substance at the preset pressure for a time sufficient to either melt or vaporize the substance.
    Type: Grant
    Filed: November 23, 2005
    Date of Patent: May 8, 2007
    Assignee: CZ Technologies, Inc.
    Inventor: Susana Curatolo
  • Patent number: 7189940
    Abstract: Apparatus and methods for plasma-assisted melting are provided. In one embodiment, a plasma-assisted melting method can include: (1) adding a solid to a melting region, (2) forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall, (3) sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into a liquid, and (4) collecting the liquid. Solids that can be melted consistent with this invention can include metals, such as metal ore and scrap metal. Various plasma catalysts are also provided.
    Type: Grant
    Filed: June 2, 2003
    Date of Patent: March 13, 2007
    Assignee: BTU International Inc.
    Inventors: Satyendra Kumar, Devendra Kumar
  • Patent number: 7176404
    Abstract: A torch cable in which both the electrical connection and the pneumatic connection can be made concurrently in one motion by coupling the end of the torch cable to the exterior of the supply unit. The coupling further includes a quick disconnect feature. The torch cable coupling is simple and inexpensive, using standard off-the-shelf components. The end of the cable comprises various components that are overmolded to form an electrically insulative body, e.g., made of urethane rubber compound. This molded body incorporates strain relief, is water resistant, protects the electrical plug, and stabilizes the electrical contacts. Gas, power and control are combined in one assembly. The pneumatic quick disconnect coupling is used as a latching mechanism for the entire assembly. The torch cable can be disconnected from the supply unit by simply releasing the quick disconnect coupling and then pulling the end of the torch cable away from the supply unit.
    Type: Grant
    Filed: January 22, 2003
    Date of Patent: February 13, 2007
    Assignee: Illinois Tool Works Inc.
    Inventor: Kenneth F. Herres
  • Patent number: 7176402
    Abstract: An electronic part processing method for peeling off a resin coating of an electronic part having a terminal section. The method includes a step of irradiating, with plasma, a coated wire having copper as a principal constituent and a surface coated with a resin.
    Type: Grant
    Filed: October 21, 2004
    Date of Patent: February 13, 2007
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Tomohiro Okumura, Kenichiro Suetsugu, Hiroshi Kawazoe, Mitsuo Saitoh, Akio Furusawa
  • Patent number: 7173211
    Abstract: A device to place an incision into matter with a harmonious plasma cloud. A radiofrequency generator system produces pulsed or continuous electromagnetic waveform which is transmitted by an active transmitter incising electrode tip. This generated electromagnetic wave is utilized to initiate a plasma cloud with processes such as thermal ionization and a photoelectric effect which then trigger an Avalanche Effect for charged atomic particles at the surface of the active transmitter incising electrode tip. This electromagnetic wave is impedance matched, frequency matched, power matched and tuned to the plasma cloud in order to sustain and control a harmonious plasma cloud with reduced atomic particle turbulence and chaos. This harmonious plasma cloud forms a coating over the surface of the active transmitter electrode tip as well as acts to reduce the energy needed from the power amplifier of our plasma cutting device.
    Type: Grant
    Filed: February 1, 2005
    Date of Patent: February 6, 2007
    Assignee: RJF Holdings II, Inc.
    Inventors: Damian Coccio, Richard J. Fugo
  • Patent number: 7166198
    Abstract: A method of treating a fluorocarbon feedstock includes generating, in a high temperature zone, an electrical arc between at least one cathode and at least one anode, generating in the high temperature zone and by means of the electrical arc and a plasma gas, a thermal plasma having a tail flame, allowing a fluorocarbon feedstock comprising at least one fluorocarbon compound to form a reactive thermal mixture with the thermal plasma tail flame, with the fluorocarbon compound dissociating into at least one fluorocarbon precursor or reactive species having fewer carbon atoms than the fluorocarbon compound, and cooling the reactive thermal mixture to form, from the fluorocarbon precursor or reactive species, a fluorocarbon product.
    Type: Grant
    Filed: February 9, 2001
    Date of Patent: January 23, 2007
    Assignees: South African Nuclear Energy Corporation Limited, 3M Innovative Properties Company
    Inventors: Izak Jacobus Van Der Walt, Klaus Hintzer, Werner Schwertfeger, Gerald Lee Bauer
  • Patent number: 7166175
    Abstract: A process and a device for the pulsed plasma strengthening of a metallic component, in which the surface to be strengthened is not acted on in a merely punctiform manner and the roughness of the surfaces is not adversely effected, comprising the steps of: providing a metallic component (1, 8, 18), coating a surface section (7, 7?) of the metallic component (1, 8, 18) with a sublimable material (22), applying a pulsed plasma jet (20) to the surface section (7, 7?) in such a way that the material is sublimed and as a result a shock wave is introduced into the component (1, 8, 18) in order to form residual compressive stresses in a region which extends from the surface section (7, 7?) into the component (1, 8, 18).
    Type: Grant
    Filed: July 21, 2001
    Date of Patent: January 23, 2007
    Assignee: MTU Aero Engines GmbH
    Inventors: Erwin Bayer, Henri Wagner
  • Patent number: 7161110
    Abstract: An apparatus and method for heating materials or substances in an oven at an oven temperature below their melting and/or vaporization points to either melt and/or vaporize the substance. Substances are inserted into a substantially spherical envelope. The envelope is sealed at a preset pressure. The solid is heated in an oven at an oven temperature substantially below the melting or vaporization temperature of the substance at the preset pressure for a time sufficient to either melt or vaporize the substance.
    Type: Grant
    Filed: January 7, 2004
    Date of Patent: January 9, 2007
    Assignee: CZT, Inc.
    Inventor: Susana Curatolo
  • Patent number: 7141755
    Abstract: The present invention provides an accelerated weathering test method, which gives the results having a high correlation with the results of natural exposure and can significantly reduce a test duration. An accelerated weathering test method for a coating film with a remote plasma apparatus, wherein it is possible to bring the interior of the remote plasma apparatus into a reduced pressure and introduce gas, for example oxygen gas, into the apparatus.
    Type: Grant
    Filed: February 26, 2003
    Date of Patent: November 28, 2006
    Assignee: Nippon Paint Co., Ltd.
    Inventors: Masahiko Akahori, Tetsurou Kajino, Minoru Umino, Harunori Gouji, Rie Tomita, Yasuhiro Shibata
  • Patent number: 7138599
    Abstract: An electrical conductor and a gas-filled layer are located at or near the surface of an object being deiced. The conductor carries an AC voltage that generates an alternating electric field in the gas-filled layer. A conductive layer increases the electric field strength in the gas-filled layer between the electrical conductor and the conductive layer. The alternating electric field causes electric breakdown of gas and plasma-formation in the gas-filled layer. The plasma absorbs energy released during electric discharge through the plasma, which heats ice, causing it to melt. The alternating electric field typically has a field strength in a range of about from 1 to 100 kV/cm. The AC voltage typically has an amplitude in a range of about from 10 kV to 1300 kV, and a frequency in a range of about from 50 Hz to 1 MHz. The gas-filled layer includes a plasma-forming gas selected from, among others, air, nitrogen and argon.
    Type: Grant
    Filed: January 9, 2002
    Date of Patent: November 21, 2006
    Assignee: The Trustees of Dartmouth College
    Inventor: Victor F. Petrenko
  • Patent number: 7132621
    Abstract: Methods and apparatus are provided for igniting, modulating, and sustaining a plasma for various plasma processes and treatments. In one embodiment, a plasma is ignited by subjecting a gas in a multi-mode processing cavity to electromagnetic radiation having a frequency between about 1 MHz and about 333 GHz in the presence of a plasma catalyst, which may be passive or active. A passive plasma catalyst may include, for example, any object capable of inducing a plasma by deforming a local electric field. An active plasma catalyst can include any particle or high energy wave packet capable of transferring a sufficient amount of energy to a gaseous atom or molecule to remove at least one electron from the gaseous atom or molecule, in the presence of electromagnetic radiation.
    Type: Grant
    Filed: May 7, 2003
    Date of Patent: November 7, 2006
    Assignee: Dana Corporation
    Inventors: Satyendra Kumar, Devendra Kumar
  • Patent number: 7126081
    Abstract: A system and method for synthesizing nanopowder which provides for precursor material ablation from two opposing electrodes that are spaced apart within a gaseous atmosphere, where a plasma is created by a high power pulsed electrical discharge between the electrodes, such pulse being of short duration to inertially confine the plasma, thereby creating a high temperature and high density plasma having high quench and/or reaction rates with the gaseous atmosphere for improved nanopowder synthesis.
    Type: Grant
    Filed: July 30, 2004
    Date of Patent: October 24, 2006
    Assignee: Nanotechnologies, Inc.
    Inventors: Kurt A. Schroder, Doug K. Jackson
  • Patent number: 7115833
    Abstract: A metering system and associated method for supplying gas to a torch are provided. The metering system includes a controller that is configured to adjust a pressure regulator according to the pressure and flow rate of the gas delivered to the torch. For example, the torch can be a plasma arc torch that has an electrode positioned in a nozzle and operates in a working mode by providing an arc from the electrode to a workpiece. In a first mode of operation, the metering system can provide a gas to the torch by adjusting the pressure regulator according to the pressure downstream of the pressure regulator. In a second mode of operation, the metering system can provide adjust the pressure regulator according to the flow rate of the gas through a flow transducer in series with the pressure regulator.
    Type: Grant
    Filed: November 3, 2004
    Date of Patent: October 3, 2006
    Assignee: The ESAB Group, Inc.
    Inventors: Philip K. Higgins, Wayne Stanley Severance, Jr.
  • Patent number: 7091441
    Abstract: Arc plasma torch generated by a torch module installed on the bottom wall in the narrow section of a tapered S-band rectangular cavity, is used to seed microwave discharge where the microwave electric field is maximum. This tapered cavity is designed to support TE103 mode. With seeding, only low Q cavity and moderate microwave power (time average power of 700 W) are needed. The microwave-enhanced discharge increases the size, cycle energy, and duty cycle of the seeding arc-torch plasma considerably. This torch can be run stably without introducing gas flow or run just using airflow. Adding airflow can increase not only the size of the torch plasma but also its cycle energy, which may reach a plateau of about 12 J/per cycle for the airflow rate exceeding 0.393 l/s. This microwave plasma torch may have a radius of about 1.25 cm or more, a height of about 5 cm, and a peak electron density exceeding 5×1013 cm?3.
    Type: Grant
    Filed: March 19, 2004
    Date of Patent: August 15, 2006
    Assignee: Polytechnic University
    Inventor: Spencer P. Kuo
  • Patent number: 7083763
    Abstract: A feed system for loading waste into a fuel gas generator system where the feed system is made of a walled container wherein the outer container back has an outer back hole and the inner container back has an inner back hole, and wherein the holes are aligned and a piston penetrates the holes, wherein the piston is connected to a plate moveably disposed in the container, wherein the piston is connected to sealable opening locks to apply pressure and retract the plate to a position against the back thereby providing a loading chamber to insert waste, a second piston connected to the door retracts the door for loading waste, at least one inert gas injector mounted to the container for flooding the loading chamber with inert gas, a liquid cooling system disposed in the walls of the container, and a controller for operating the locks, doors and sealable opening.
    Type: Grant
    Filed: September 23, 2002
    Date of Patent: August 1, 2006
    Inventor: Joseph Frank Pierce, Jr.
  • Patent number: 7081598
    Abstract: There is provided by this invention an apparatus and method of supplying to ignite a plasma wherein in the event of an arc a shunt switch is used to divert the power away from the plasma that is incorporated into an over-voltage protection circuit that controls the shunt switch to act as a boost switch when the arc is extinguished such that the stored inductor energy is used to boost the ignition voltage for reigniting the plasma if it is extinguished. When the arc is extinguished, the inductor current is diminished, and the plasma is ignited, then the switch S1 is turned OFF and the inductor energy goes to the plasma and the power supply operates in its normal operating mode.
    Type: Grant
    Filed: August 24, 2004
    Date of Patent: July 25, 2006
    Assignee: Advanced Energy Industries, Inc.
    Inventors: Milan Ilic, Vladislav V. Shilo, Kalyan N. C. Siddabattula
  • Patent number: 7075030
    Abstract: An apparatus includes a plasma generator aligned with a beam generator for producing a plasma to shield an energized beam. An electrode is coaxially aligned with the plasma generator and followed in turn by a vortex generator coaxially aligned with the electrode. A target is spaced from the vortex generator inside a fluid environment. The electrode is electrically biased relative to the electrically grounded target for driving the plasma toward the target inside a vortex shield.
    Type: Grant
    Filed: August 30, 2004
    Date of Patent: July 11, 2006
    Assignee: Brookhaven Science Associates, LLC
    Inventors: Ady Hershcovitch, Rory Dominick Montano
  • Patent number: 7067762
    Abstract: A plasma cutting machine is provided in which a dross adhesion inhibitor is jetted from a plasma torch toward the cutting start position (piercing position) of the object material. A dross adhesion inhibitor supply flow path for feeding the dross adhesion inhibitor is connected to an assist gas feeding line in which an assist gas for assisting cutting of the object material with the plasma arc flows.
    Type: Grant
    Filed: November 25, 2003
    Date of Patent: June 27, 2006
    Assignee: Komatsu Industries Corporation
    Inventors: Yoshihiro Yamaguchi, Tetsuya Kabata, Kazuhiro Kuraoka, Takahiro Iriyama
  • Patent number: 7045737
    Abstract: A glass-processing method adjusts the range of the heating region according to the work piece and processing condition, and a glass-processing apparatus implements the method. The method incorporates the heating of a glass body with a thermal plasma torch comprising (a) a main body provided with a plurality of ports from which a gas issues and (b) a device for applying a high-frequency electric field to the gas fed into the main body. The method comprises the steps of (1) adjusting the plasma flame's size perpendicular to the center axis of the main body by controlling the flow rate of the gas fed into each port according to the size of the glass body, the processing condition, or both and (2) heating the glass body.
    Type: Grant
    Filed: February 19, 2004
    Date of Patent: May 16, 2006
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Masashi Onishi, Masaaki Hirano, Tetsuya Nakanishi
  • Patent number: 7034244
    Abstract: The present invention is directed to a system and method for improved operational feedback from a plasma torch to a plasma-cutting power source. A plasma cutter includes a plasma cutting power source, a plasma torch in communication with the plasma cutting power source, and a serialization circuit disposed within the plasma torch to control transmission of multiple feedback signals from the plasma torch to the plasma cutting power source. The serialization circuit receives the multiple feedback signals and places the feedback in a queue, such that the multiple feedback signals are sent from the queue to a processing unit in the power source via a single communications link.
    Type: Grant
    Filed: September 3, 2003
    Date of Patent: April 25, 2006
    Assignee: Illinois Tool Works Inc.
    Inventor: Tim A. Matus
  • Patent number: 7012214
    Abstract: Nanopowder synthesis systems in which a pulsed magnetic field is applied to electrodes of precursor material, in close proximity to an electrical discharge arc that is formed between the electrodes, to attain increased yields of nanopowder. A magnet insert of a coating precursor material is used to coat the nanopowder and thereby reduce nanoparticle agglomeration.
    Type: Grant
    Filed: September 24, 2003
    Date of Patent: March 14, 2006
    Assignee: Nanotechnologies, Inc.
    Inventors: Kurt A. Schroder, Doug K. Jackson
  • Patent number: 6998565
    Abstract: A plasma processing apparatus includes a first dielectric that is connected to a microwave generating unit, the first dielectric having a section that extends along a surface of a rectangular sample, and that makes an electric field strength distribution of the microwaves generated from the microwave generating unit substantially uniform along the surface of the sample; a slot plate that is provided below the first dielectric and in which a plurality of first slots are formed, the slot plate retaining or further enhancing the uniformity of the electric field strength distribution of the microwaves in the first dielectric; a second dielectric that is provided below the slot plate and that retains or further enhances the uniformity of the electric field strength distribution of the microwaves supplied from the slot plate; and a processing unit that processes the sample using a plasma generated in the reaction vessel by the microwaves.
    Type: Grant
    Filed: January 30, 2004
    Date of Patent: February 14, 2006
    Assignee: Rohm Co., Ltd.
    Inventor: Toshikuni Shinohara
  • Patent number: 6987238
    Abstract: A plasma arc torch and method for improving the life of the consumable parts of the plasma arc torch, including the electrode, the tip and the shield cap. The method includes turbulating gas as it flows over the exposed surfaces of the electrode, tip and shield cap to increase turbulence in the hydrodynamic boundary layer of the gas flow, thereby enhancing convective heat transfer. The result of enhanced cooling is improved consumable parts life. For example, to increase the turbulence of the gas flow over the outer surface of the electrode, the plasma arc torch electrode has a roughened, or textured outer surface formed with dimples, axially extending grooves or spiraling grooves formed in the outer surface of the electrode. The inner and outer surfaces of the tip and the inner surface of the shield cap are similarly textured.
    Type: Grant
    Filed: March 30, 2001
    Date of Patent: January 17, 2006
    Assignee: Thermal Dynamics Corporation
    Inventors: Kevin D. Horner-Richardson, David A. Small, Jesse A. Roberts
  • Patent number: 6987236
    Abstract: A plasma powder welding device in this invention comprises a powder having an identical kind of main component as that of a work piece, a feeder feeding the powder to the work piece, a welding torch generating a plasma between itself and the work piece for focusing the powder fed by the feeder on the work piece and transferring the powder to the work piece, and a power source supplying an electric power to the welding torch, wherein a distance from the welding torch to a focal point to which the powder is focused is set nearly equal to or more than the height of the torch.
    Type: Grant
    Filed: January 5, 2004
    Date of Patent: January 17, 2006
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Tetsu Innami, Hiroyuki Kiso, Hideki Ihara
  • Patent number: 6977359
    Abstract: A vacuum-processing method carries out, in a vacuum-processing vessel (4), a process wherein a condition of an interior of the vacuum processing vessel (4) changes as the number of processed objects (W) increases, such as a film-forming process for forming a thin film on a semiconductor wafer (W) by using a process gas in the vacuum processing vessel (4). The vacuum-processing method controls a controlled parameter directly affecting an effect of the process, such as film thickness, so that the controlled parameter is maintained at a target value (rt). The vacuum-processing method determines a model function obeying a change of the condition of the interior of the processing vessel (4), and calculates the target value (rt) of the controlled parameter every time one or a plurality of objects (W) are processed on the basis of a set value (Dt) of a set parameter representing the effect of the process, and the model function.
    Type: Grant
    Filed: May 17, 2002
    Date of Patent: December 20, 2005
    Assignee: Tokyo Electron Limited
    Inventor: Shigeru Kasai
  • Patent number: 6965629
    Abstract: A nanopowder synthesis system having an autofuser device which obviates the need for external power switches, and which accommodates repeated discharges (of the order of 107) between ablating electrodes of precursor material at a high repetition rate (?1 Hz).
    Type: Grant
    Filed: June 7, 2004
    Date of Patent: November 15, 2005
    Assignee: Nanotechnologies, Inc.
    Inventors: Kurt A. Schroder, Douglas Keith Jackson, Stephen James Schmidt
  • Patent number: 6960737
    Abstract: A system for controlling gas flow from a gas source, through a gas conduit, and to a plasma arc torch during a transition from a cold flow when no arc is present to a hot flow when an arc is provided by the present invention. The system comprises a first solenoid in communication with the gas source, a second solenoid disposed proximate the plasma arc torch, and a bypass circuit in communication with the gas source and the second solenoid. The bypass circuit comprises a bypass solenoid that controls the gas pressure within the gas conduit to reduce gas flow fluctuations when transitioning from cold flow to hot flow. Additional gas control systems and methods are also provided that cause the gas pressure to be higher during cold flow, prior to arc ignition, which overcomes the rapid drop in flow that typically occurs during the transition to hot flow.
    Type: Grant
    Filed: August 29, 2003
    Date of Patent: November 1, 2005
    Assignee: Thermal Dynamics Corporation
    Inventor: David A. Tatham
  • Patent number: 6955612
    Abstract: A manufacturing method for a golf club head. The method includes the steps of: casting a cast body provided with a recession thereon; cutting the cast body to form with at least one cut opening in the recession on the golf club head; adhering a carbon-fiber plate to the recession to seal the cut opening; defining a buffer groove between the carbon-fiber plate and the cast body; and filling with an elastic material into the buffer groove; processing the cast body to an end product.
    Type: Grant
    Filed: May 28, 2003
    Date of Patent: October 18, 2005
    Assignee: Fu Sheng Industrial Co., Ltd.
    Inventor: Yuan-Ping Lu
  • Patent number: 6949716
    Abstract: Process for the surface treatment of an object made of an electrically conductive material, with an atmospheric plasma, including the generation of plasma jets by plasma generators, the application of the plasma jets to a surface of the object to be treated, and the relative displacement of the object relative to the plasma generators. At least one of the plasma jets is a cathodic jet and at least one of the plasma jets is an anodic jet. The anodic jet is applied to a treatment zone on the surface to be treated in the proximity of the cathodic jet.
    Type: Grant
    Filed: November 12, 2001
    Date of Patent: September 27, 2005
    Assignee: APIT Corp. S.A.
    Inventors: Pavel Koulik, Anatolii Saitchenko, Naïl Musin
  • Patent number: 6946616
    Abstract: A cooling system for a plasma arc torch is provided that comprises a coaxial fluid flow that improves cooling of components within the plasma arc torch and that provides a more compact torch design. The coaxial fluid flow, namely, the cooling fluid flow, is distributed circumferentially about the central longitudinal axis of the torch and is flowing in the same direction at any radial location from the central longitudinal axis. The cooling fluid flows distally towards the consumable components, then proximally towards the torch head, then distally again, and then proximally again for recirculation. Additionally, both the plasma gas flow and the secondary gas flow are also flowing coaxially in addition to the cooling fluid flow.
    Type: Grant
    Filed: April 7, 2003
    Date of Patent: September 20, 2005
    Assignee: Thermal Dynamics Corporation
    Inventors: Kevin J. Kinerson, Mark Gugliotta, Christopher J. Conway, Darrin H. MacKenzie
  • Patent number: 6943317
    Abstract: There is provided by this invention a novel apparatus and method of operating a dc plasma process that diverts the power supply current from the plasma at the initiation of an arc, thereby inhibiting energy from flowing from the power supply to the plasma, and then to allow energy to flow again when the power supply re-enables energy flow to the plasma. The diverting means is connected to the output of the power supply to divert current away from the plasma at the initiation of an arc wherein the diverting means is actuated when the arc is detected on the output and diverts the current for a first pre-determined time. The diverting means is released at the end of the first pre-determined time before the current reaches zero wherein current is redirected to the plasma and the diverting means is reactivated at the end of a second pre-determined time in the event the arc is not extinguished.
    Type: Grant
    Filed: July 2, 2004
    Date of Patent: September 13, 2005
    Assignee: Advanced Energy Industries, Inc.
    Inventors: Milan Ilic, Kalyan N. C. Siddabattula, Andrey B. Malinin
  • Patent number: 6936786
    Abstract: A dual mode plasma arc torch is provided that preferably comprises a start cartridge disposed between an electrode and a tip. In one form, the start cartridge comprises an initiator that is in electrical contact with the electrode and that is resiliently biased into contact with the tip, such that when the plasma arc torch is in a contact start mode, the initiator is movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. Further, when the plasma arc torch is in a high frequency start mode, the start cartridge spaces the tip from the electrode such that a pilot arc is established between the electrode and the tip. In other forms, a contact start torch is provided that is operable under high frequency, and conversely, a high frequency start torch is provided that is operable under low voltage.
    Type: Grant
    Filed: November 24, 2003
    Date of Patent: August 30, 2005
    Assignee: Thermal Dynamics Corporation
    Inventors: Roger W. Hewett, Kevin D. Horner-Richardson, Joseph P. Jones, Shiyu Chen, Fred Rogers
  • Patent number: 6933463
    Abstract: A main arc ignition method capable of extending lives of a plasma electrode and a nozzle. For this purpose, before or immediately after starting arc, a plasma torch is supplied with a plasma gas at least either at a lower flow rate or at lower gas pressure; the plasma gas is switched to a gas flow rate and gas pressure of a time of cutting a work, after pilot arc is ignited between an electrode and a nozzle, or after main arc is ignited between the electrode and the work; and when generation of the main arc between the electrode and the work is detected, a pilot current is interrupted promptly by a semiconductor switch which is interposed in series with a resistance, in a pilot current circuit that is connected to the nozzle and supplies the pilot current to the pilot arc.
    Type: Grant
    Filed: January 22, 2003
    Date of Patent: August 23, 2005
    Assignee: Komatsu Industries Corp.
    Inventors: Yoshihiro Yamaguchi, Takahiro Iriyama, Tetsuya Kabata
  • Patent number: 6914210
    Abstract: A stationary shroud of a gas turbine engine made of a base metal is repaired by removing any damaged material from a flow-path region of the stationary shroud to leave an initially exposed base-metal flow-path surface; and applying a base-metal restoration overlying the initially exposed flow-path surface. The base-metal restoration is applied by furnishing a source of a structural material that is compatible with the base metal, and depositing the source of the structural material overlying the initially exposed base-metal flow-path surface of the stationary shroud by plasma transferred arc welding to form a repaired base-metal flow-path surface. An environmentally resistant rub coating may be applied overlying the base-metal restoration.
    Type: Grant
    Filed: October 30, 2002
    Date of Patent: July 5, 2005
    Assignee: General Electric Company
    Inventors: Warren Davis Grossklaus, Jr., Matthew Nicklus Miller
  • Patent number: 6911619
    Abstract: An emissive electrode insert formed from an alloy containing hafnium and zirconium. The insert typically contains at least about 80% hafnium by weight and about 0.1 to about 8% zirconium by weight. The invention also relates to a plasma torch electrode formed from an electrode body with a cavity into which such an emissive insert is fitted, to a plasma torch utilizing such an electrode, and to a plasma cutting process for cutting a steel workpiece, in which such a plasma torch is employed.
    Type: Grant
    Filed: March 10, 2004
    Date of Patent: June 28, 2005
    Assignees: L'Air Liquide, Societe Anonyme pour l'etude et, l'Exploitation des Procedes Georges Claude, LA Soudure Autogene Francaise
    Inventor: Michel Delzenne
  • Patent number: 6911618
    Abstract: An object of the present invention is to provide a producing method by which minute metal balls having a high sphericity or roundness and a uniform diameter. The present invention provides a method of producing minute metal balls, comprising the steps of cutting a wire material having a diameter ? at predetermined distances to provide metal pieces having a cut length L equal to or smaller than 2 mm and a ratio L/? in a range of 0.1?L/??3.0, and introducing the metal pieces into a plasma flame to spheroidize the metal pieces. In the present invention, it is preferable that the metal pieces are made of any metal selected from the group consisting of Cu, Ag, Au and Al, or an alloy as a main of any of these metals. It is also preferable that the metal pieces are made of any metal selected from the group consisting of Fe, Ti, W, Ni and Cr, or an alloy as a main of any of these metals.
    Type: Grant
    Filed: February 3, 2004
    Date of Patent: June 28, 2005
    Assignee: Hitachi Metals, Ltd.
    Inventor: Nobuhiko Chiwata
  • Patent number: 6903301
    Abstract: A contact start plasma arc torch is provided that comprises an electrode, a tip, and an initiator that is resiliently biased into contact with the tip, the initiator being movable against the resilient bias to separate from the tip and establish a pilot arc between the initiator and the tip. The initiator is disposed within a start cartridge, which preferably comprises a coil spring that biases the initiator into contact with the tip. The plasma arc torch further comprises a plurality of head vent holes to vent gas from within the start cartridge during operation of the torch. Additionally, the tip defines a plurality of swirl holes and secondary gas holes to generate and control a plasma stream that is subsequently blown from a central exit orifice in the tip.
    Type: Grant
    Filed: February 26, 2002
    Date of Patent: June 7, 2005
    Assignee: Thermal Dynamics Corporation
    Inventors: Joseph P. Jones, Kevin D. Horner-Richardson, Shiyu Chen, Roger W. Hewett
  • Patent number: 6900408
    Abstract: The invention features a centralized control architecture for a closely-coupled plasma arc system, in which the “intelligence” of the system is integrated into a single controller. The closely-coupled plasma arc system includes a power source, an automatic process controller and a torch-height controller, where each of these components individually has a closed-loop dynamic relationship with the controller.
    Type: Grant
    Filed: June 23, 2004
    Date of Patent: May 31, 2005
    Assignee: Hypertherm, Inc.
    Inventors: Tate S. Picard, Roger E. Young, Gregory S. Wilson, Ronald M. Huppe
  • Patent number: 6888094
    Abstract: A plasma processing method of processing a substrate by controlling the application of a bias to the substrate independently of generation of plasma. The method includes modulating periodically an output value of a high-frequency voltage applied to a substrate base and changing a duty ratio of the periodic modulation for one of each processed substrate and for each of a plurality of processed substrates. The duty ratio is defined as a ratio of a sub-period of a period of the period modulation, during which a large voltage of the output value of the high-frequency voltage is applied, to the period of the periodic modulation.
    Type: Grant
    Filed: February 20, 2004
    Date of Patent: May 3, 2005
    Assignee: Hitachi High-Technologies Corporation
    Inventors: Tetsuo Ono, Katsumi Setoguchi, Hideyuki Yamamoto
  • Patent number: 6841754
    Abstract: A plasma arc torch that includes a torch body having a nozzle mounted relative to a composite electrode in the body to define a plasma chamber. The torch body includes a plasma flow path for directing a plasma gas to the plasma chamber in which a plasma arc is formed. The nozzle includes a hollow, body portion and a substantially solid, head portion defining an exit orifice. The composite electrode can be made of a metallic material (e.g., silver) with high thermal conductivity in the forward portion electrode body adjacent the emitting surface, and the aft portion of the electrode body is made of a second low cost, metallic material with good thermal and electrical conductivity. This composite electrode configuration produces an electrode with reduced electrode wear or pitting comparable to a silver electrode, for a price comparable to that of a copper electrode.
    Type: Grant
    Filed: March 8, 2002
    Date of Patent: January 11, 2005
    Assignee: Hypertherm, Inc.
    Inventors: David J. Cook, Kirk H. Ferland, Charles Hackett, Young Yang, Richard W. Couch, Zhipeng Lu
  • Patent number: 6838636
    Abstract: A method of welding two silicon workpieces (20, 22) together into one member without the formation of cracks along the weld. A first method passes current (34, 36) through one or both of the workpieces to heat them to between 600 and 900° C. Then an electric, laser, or plasma welder (38, 40) passes along the seam (24) between the workpieces to weld them together. A second method passing current (34) through a plate (60), preferably formed of silicon, which either supports the workpieces or is brought into contact with at least one of them, whereby the workpieces are preheated prior to the welding operation.
    Type: Grant
    Filed: June 18, 2003
    Date of Patent: January 4, 2005
    Assignee: Integrated Materials, Inc.
    Inventors: Raanan Y. Zehavi, Robert L. Davis, David B. Ackard, James W. Govorko
  • Publication number: 20040251241
    Abstract: Inductively coupled plasma (ICP) reforming converts carbonaceous compounds into a fuel for use in generating electrical power. Energy rich hydrocarbon fuels, such as coal, marine diesel, oils, and hydrocarbon wastes are employed as a feedstock for the ICP, which transforms the feedstock into a fuel that can be used by fuel cells and gas turbines for the production of electricity. The overall efficiency of an ICP-based electrical power system can be increased by providing partial oxidation within the reaction vessel. The partial oxidation conditions consume a small amount of the reformed fuel gas, thereby liberating sufficient thermal energy to reduce the electrical power requirements of the ICP to maintain desired reactor temperatures, and providing an increase in the overall net electrical power production. The integrated power production system can also adjust to meet an increased requirement for process heat and steam by balancing the effect of partial oxidation.
    Type: Application
    Filed: June 10, 2004
    Publication date: December 16, 2004
    Applicant: Nuvotec, Inc.
    Inventors: Andreas Blutke, John Vavruska, Mark Henderson, Robert Ferguson
  • Patent number: 6815632
    Abstract: A plasma torch comprises: a hollow shaft connected to a first supply pipe for a flow of a first gas and to an electrode which is hollow so that it surrounds part of the shaft and forms a first chamber for cooling the electrode and for outfeed of the first gas; a nozzle surrounding the electrode and forming a second chamber, for receiving the first gas for generating plasma, and a third chamber, for the passage of the first gas arriving from the first, cooling chamber through third pipes, to the second chamber, through second pipes which pass through the nozzle. First sealing parts are inserted between the shaft and the nozzle on both sides of the third pipes, forming a sealed zone close to the third pipes.
    Type: Grant
    Filed: June 30, 2003
    Date of Patent: November 9, 2004
    Assignee: Cebora S.p.A.
    Inventor: Silvano Dallavalle