Patents Assigned to Advanced Ceramics Research, Inc.
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Patent number: 7704594Abstract: Fibrous monolith processing techniques to fabricate multifunctional structures capable of performing more than one discrete function such as structures capable of bearing structural loads and mechanical stresses in service and also capable of performing at least one additional non-structural function.Type: GrantFiled: August 11, 2004Date of Patent: April 27, 2010Assignee: Advanced Ceramics Research, Inc.Inventors: Anthony C. Mulligan, John Halloran, Dragan Popovich, Mark J. Rigali, Manish P. Sutaria, K. Ranji Vaidyanathan, Michael L. Fulcher, Kenneth L. Knittel
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Patent number: 7517580Abstract: Fibrous monolith composites having architectures that provide increased flaw insensitivity, improved hardness, wear resistance and damage tolerance and methods of manufacture thereof are provided for use in dynamic environments to mitigate impact damage and increase wear resistance.Type: GrantFiled: December 9, 2005Date of Patent: April 14, 2009Assignee: Advanced Ceramics Research, Inc.Inventors: Anthony C. Mulligan, Mark J. Rigali, Manish P. Sutaria, Dragan Popovich, Joseph P. Halloran, Michael L. Fulcher, Randy C. Cook
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Publication number: 20090075088Abstract: A method for manufacturing a composite material utilizes a tooling material having a desired shape. The surface of the tooling material is coated with a composite film that includes a conductive filler material. A composite composition is introduced into contact with the surface of the tooling material to form a desired shape. The composite composition is processed to produce the composite material, and the composite material has a conductive composite surface layer that includes the conductive filler material.Type: ApplicationFiled: July 21, 2008Publication date: March 19, 2009Applicant: Advanced Ceramics Research, Inc.Inventors: K. Ranji Vaidyanathan, Jeffrey Campbell
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Publication number: 20080237922Abstract: Methods and compositions for fabricating composite parts including at least one structural material and at least one protective material that are integrally bonded without the use of secondary bonding operations. One or more of the materials forming the layers of the composite parts may be a ceramic composition with or without porosity and one or more of the materials may be a polymer composition. Methods including co-injection processes also are provided for fabricating multi-layered structures in which each layer serves a desired function while still being integrated into the overall structure.Type: ApplicationFiled: July 15, 2005Publication date: October 2, 2008Applicant: Advanced Ceramics Research, Inc.Inventors: K. Ranji Vaidyanathan, Catherine Green, John W. Gillespie, Shridhar Yarlagadda, Gregory J. Artz
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Patent number: 7387757Abstract: Processes for mechanically fabricating two and three-dimensional fibrous monolith composites include preparing a fibrous monolith filament from a core composition of a first powder material and a boundary material of a second powder material. The filament includes a first portion of the core composition surrounded by a second portion of the boundary composition. One or more filaments are extruded through a mechanically-controlled deposition nozzle onto a working surface to create a fibrous monolith composite object. The objects may be formed directly from computer models and have complex geometries.Type: GrantFiled: June 29, 2004Date of Patent: June 17, 2008Assignee: Advanced Ceramics Research, Inc.Inventors: Anthony C. Mulligan, Mark J. Rigali, Manish P. Sutaria, Gregory J. Artz, Felix H. Gafner, K. Ranji Vaidyanathan
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Patent number: 7360309Abstract: A heat exchanger device includes an extruded body that includes one or more layers of channels for coolant flow therethrough, the channels generally having inner diameters of between about 50 microns to about 2000 microns. The device is formed of a material having a high thermal conductivity to facilitate transfer of heat from the heating components present in the subject cooling application to the coolant passing through the heat exchanger and to be compatible with materials of the heating components. The device material is selected from the group consisting of ceramic oxides, ceramic carbides, ceramic nitrides, ceramic borides, ceramic silicides, metals, and intermetallics, and combinations thereof. The heat exchanger device is formed from an extruded filament that is arranged to give the desired channel configuration. The filament includes a central, removable material and an outer material that forms the channel walls upon removal of the central material.Type: GrantFiled: January 28, 2004Date of Patent: April 22, 2008Assignee: Advanced Ceramics Research, Inc.Inventors: K. Ranji Vaidyanathan, Alfonso Ortega, Marlene Platero, Prathib Skandakumaran, Chad Bower
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Patent number: 7299130Abstract: Methods and apparatuses provide surveillance of a convoy. At least one unmanned aerial vehicle (UAV) obtains images around the convoy's position to provide information about potential hostile activity while the UAV follows a generally curvilinear path around the convoy as instructed by one of the convoy vehicles. Path planner algorithm software is executed by the controlling convoy vehicle in which position and velocity information regarding the unmanned aerial vehicle and the convoy are processed to determine values of control variables. The determined values are sent to the unmanned aerial vehicle over a wireless communications channel. The path of the surveillance vehicle may be changed in order to provide evasive measures to avoid an attack on the surveillance vehicle by an adversary.Type: GrantFiled: December 13, 2004Date of Patent: November 20, 2007Assignee: Advanced Ceramic Research, Inc.Inventors: Anthony C. Mulligan, Christopher D. Troudt, Jason Michael K. Douglas
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Publication number: 20070243393Abstract: Sandwich composite constructions with superior thermal and acoustic insulation properties are provided. In addition, the sandwich composite constructions are lightweight and have a mechanical integrity that may allow them to withstand an impact force of five pounds per square inch or more. One aspect of the present invention relates to the composition of the sandwich constructions, while another relates to methods of fabricating the sandwich composite constructions. Materials incorporated into the constructions include fibrous material, aerogel, resin, separation material, and insulating material, such as a foam. A vacuum assisted resin transfer method (VARTM) may be used to manufacture the sandwich composites by infusing resin into a composite preform such that the resin is received into at least a portion of the fibrous material pores. Water soluble tooling materials may be used as the substrate for the preform to fabricate sandwich composite panels having either simple or complex geometries.Type: ApplicationFiled: October 25, 2006Publication date: October 18, 2007Applicant: ADVANCED CERAMICS RESEARCH, INC.Inventors: K. Vaidyanathan, Jeffrey Campbell, Arthur Studley, Christina Bisch, John Gillespie, Stephen Andersen, Ahmad Obaid
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Publication number: 20060220280Abstract: Methods for consolidation and densification of fibrous monolith composite structures are provided. Consolidation and densification of two- and three-dimensional fibrous monolith components having complex geometries can be achieved by pressureless sintering. The fibrous monolith composites are formed from filaments having at least a first material composition generally surrounded by a second material composition. The composites are sintered at a pressure of no more than about 30 psi to provide consolidated and densified fibrous monolith composites.Type: ApplicationFiled: June 16, 2006Publication date: October 5, 2006Applicant: Advanced Ceramics Research, Inc.Inventors: Manish Sutaria, Mark Rigali, Ronald Cipriani, Gregory Artz, Anthony Mulligan
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Publication number: 20060135344Abstract: Fibrous monolith composites suitable for use in high temperature environments and/or harsh chemical environments are provided, along with methods of preparation thereof. The fibrous monolith composites exhibit such beneficial properties as enhanced strength, corrosion resistance, thermal shock resistance and thermal cycling tolerance.Type: ApplicationFiled: January 18, 2005Publication date: June 22, 2006Applicant: Advanced Ceramics Research, Inc.Inventors: Mark Rigali, Manish Sutaria, Greg Hilmas, Anthony Mulligan, Marlene Platero-AllRunner, Mark Opeka
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Patent number: 7063812Abstract: Methods for consolidation and densification of fibrous monolith composite structures are provided. Consolidation and densification of two- and three-dimensional fibrous monolith components having complex geometries can be achieved by pressureless sintering. The fibrous monolith composites are formed from filaments having at least a first material composition generally surrounded by a second material composition. The composites are sintered at a pressure of no more than about 30 psi to provide consolidated and densified fibrous monolith composites.Type: GrantFiled: May 24, 2004Date of Patent: June 20, 2006Assignee: Advanced Ceramics Research, Inc.Inventors: Manish P. Sutaria, Mark J. Rigali, Ronald A. Cipriani, Gregory J. Artz, Anthony C. Mulligan
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Publication number: 20060091580Abstract: Fibrous monolith composites having architectures that provide increased flaw insensitivity, improved hardness, wear resistance and damage tolerance and methods of manufacture thereof are provided for use in dynamic environments to mitigate impact damage and increase wear resistance.Type: ApplicationFiled: December 9, 2005Publication date: May 4, 2006Applicant: Advanced Ceramics Research, Inc.Inventors: Anthony Mulligan, Mark Rigali, Manish Sutaria, Dragan Popovich, Joseph Halloran, Michael Fulcher, Randy Cook
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Publication number: 20060074557Abstract: Methods and apparatuses provide surveillance of a convoy. At least one unmanned aerial vehicle (UAV) obtains images around the convoy's position to provide information about potential hostile activity while the UAV follows a generally curvilinear path around the convoy as instructed by one of the convoy vehicles. Path planner algorithm software is executed by the controlling convoy vehicle in which position and velocity information regarding the unmanned aerial vehicle and the convoy are processed to determine values of control variables. The determined values are sent to the unmanned aerial vehicle over a wireless communications channel. The path of the surveillance vehicle may be changed in order to provide evasive measures to avoid an attack on the surveillance vehicle by an adversary.Type: ApplicationFiled: December 13, 2004Publication date: April 6, 2006Applicant: Advanced Ceramics Research, Inc.Inventors: Anthony Mulligan, Christopher Troudt, Jason Michael Douglas
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Publication number: 20060008549Abstract: Methods for preparing fibrous monolith composite materials include continuously extruding cell and boundary material compositions. A filament is formed from a cell material composition and passed through a chamber of an extrusion assembly. A boundary material composition is extruded generally about the cell material composition filament and the two material compositions are co-extruded to form an extruded coated filament.Type: ApplicationFiled: September 10, 2004Publication date: January 12, 2006Applicant: Advanced Ceramics Research, Inc.Inventors: Mark Rigali, Manish Sutaria, Felix Gafner, Ronald Cipriani, Randy Egner, Randy Cook
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Patent number: 6974624Abstract: Fibrous monolith composites having architectures that provide increased flaw insensitivity, improved hardness, wear resistance and damage tolerance and methods of manufacture thereof are provided for use in dynamic environments to mitigate impact damage and increase wear resistance.Type: GrantFiled: December 4, 2002Date of Patent: December 13, 2005Assignee: Advanced Ceramics Research, Inc.Inventors: Anthony C. Mulligan, Mark J. Rigali, Manish P. Sutaria, Dragan Popovich, Joseph P. Halloran, Michael L. Fulcher, Randy C. Cook
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Publication number: 20050260093Abstract: The present invention relates to the fabrication of low cost, in situ, porous metallic, ceramic and cermet foam structures having improved mechanical properties such as energy absorption and specific stiffness. Methods of fabricating the structures from compositions including ceramic and/or metallic powders are provided. The flowable compositions also include an immiscible phase that results in pores within the final structure. Furthermore, the structures may be shaped to have external porosity, such as with mesh-like structures.Type: ApplicationFiled: January 28, 2005Publication date: November 24, 2005Applicant: Advanced Ceramics Research, Inc.Inventors: Gregory Artz, K. Vaidyanathan, Michael Fulcher, Mark Rigali, John Lombardi, Joseph Walish, Ronald Cipriani
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Publication number: 20050230029Abstract: A process for continuous composite coextrusion comprising: (a) forming first a material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate in a manner such that the composition has a substantially cylindrical geometry and thus can be used as a substantially cylindrical feed rod; (b) forming a hole down the symmetrical axis of the feed rod; (c) inserting the start of a continuous spool of ceramic fiber, metal fiber or carbon fiber through the hole in the feed rod; (d) extruding the feed rod and spool simultaneously to form a continuous filament consisting of a green matrix material completely surrounding a dense fiber reinforcement and said filament having an average diameter that is less than the average diameter of the feed rod; and (e) depositing the continuous filament into a desired architecture which preferably is determined from specific loading conditions of the desired object and CAD design of the object to provide a green fiber reiType: ApplicationFiled: May 17, 2005Publication date: October 20, 2005Applicant: Advanced Ceramics Research, Inc.Inventors: K. Vaidyanathan, Joseph Walish, Mark Fox, John Gillespie, Shridhar Yarlagadda, Michael Effinger, Anthony Mulligan, Mark Rigali
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Patent number: 6935594Abstract: Methods and compositions for fabricating composite parts including at least one structural material and at least one protective material that are integrally bonded without the use of secondary bonding operations. One or more of the materials forming the layers of the composite parts may be a ceramic composition with or without porosity and one or more of the materials may be a polymer composition. Methods including co-injection processes also are provided for fabricating multi-layered structures in which each layer serves a desired function while still being integrated into the overall structure.Type: GrantFiled: November 12, 2002Date of Patent: August 30, 2005Assignee: Advanced Ceramics Research, Inc.Inventors: K. Ranji Vaidyanathan, Catherine Green, John W. Gillespie, Shridhar Yarlagadda, Gregory J. Artz
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Publication number: 20050116136Abstract: The present invention relates to a low density, water-soluble coring and tooling material used for the fabrication of composite parts. One aspect of the present invention relates to a lightweight, strong composite coring material that can be easily shaped and removed from cured composite parts. Another aspect of the present invention relates to a lightweight, strong composite tooling material that is easily tailored to provide a specific coefficient of thermal expansion and thermal conductivity, thus providing a tooling material that can be matched to the composite structure and material being fabricated.Type: ApplicationFiled: October 14, 2004Publication date: June 2, 2005Applicant: Advanced Ceramics Research, Inc.Inventors: Gregory Artz, John Lombardi, K. Vaidyanathan, Joseph Walish
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Patent number: 6899777Abstract: A process for continuous composite coextrusion comprising: (a) forming first a material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate in a manner such that the composition has a substantially cylindrical geometry and thus can be used as a substantially cylindrical feed rod; (b) forming a hole down the symmetrical axis of the feed rod; (c) inserting the start of a continuous spool of ceramic fiber, metal fiber or carbon fiber through the hole in the feed rod; (d) extruding the feed rod and spool simultaneously to form a continuous filament consisting of a green matrix material completely surrounding a dense fiber reinforcement and said filament having an average diameter that is less than the average diameter of the feed rod; and (e) depositing the continuous filament into a desired architecture which preferably is determined from specific loading conditions of the desired object and CAD design of the object to provide a green fiber reiType: GrantFiled: January 2, 2002Date of Patent: May 31, 2005Assignee: Advanced Ceramics Research, Inc.Inventors: K. Ranji Vaidyanathan, Joseph Walish, Mark Fox, John W. Gillespie, Jr., Shridhar Yarlagadda, Michael R. Effinger, Anthony C. Mulligan, Mark J. Rigali