Patents Assigned to Ceramatec, Inc.
  • Patent number: 8012621
    Abstract: A nickel-metal hydride storage battery comprising a positive electrode containing nickel hydroxide, a negative electrode containing a hydrogen absorbing alloy, an alkaline electrolyte, and an alkali conducting separator provided between the positive electrode and the negative electrode. The alkali conducting separator may be a solid alkali metal ion super ion conducting material, wherein the alkali metal is Na, K, or Li.
    Type: Grant
    Filed: November 26, 2007
    Date of Patent: September 6, 2011
    Assignee: Ceramatec, Inc.
    Inventors: Ashok V. Joshi, John Howard Gordon, Sai Bhavaraju
  • Patent number: 8003042
    Abstract: Pressureless sintering of silicon carbide with fracture toughness in excess of about 4 MPa-m1/2 as measured by the single-edge precracked beam (SEPB) technique while maintaining a density greater than 3.1 g/cc for compositions with SiC greater than about 94 wt. % is made possible through the use of metallic Al to promote sintering and grain growth. Boron and carbon may be used as traditional sintering aids, with nitrogen to suppress grain growth, and additions of yttrium and/or lanthanide elements to promote intergranular fracture.
    Type: Grant
    Filed: August 31, 2006
    Date of Patent: August 23, 2011
    Assignee: Ceramatec, Inc.
    Inventors: Raymond Ashton Cutler, Roger Marc Flinders, Darin Ray
  • Patent number: 7976686
    Abstract: An electrolyzer cell is disclosed which includes a cathode to reduce an oxygen-containing molecule, such as H2O, CO2, or a combination thereof, to produce an oxygen ion and a fuel molecule, such as H2, CO, or a combination thereof. An electrolyte is coupled to the cathode to transport the oxygen ion to an anode. The anode is coupled to the electrolyte to receive the oxygen ion and produce oxygen gas therewith. In one embodiment, the anode may be fabricated to include an electron-conducting phase having a perovskite crystalline structure or structure similar thereto. This perovskite may have a chemical formula of substantially (Pr(1-x)Lax)(z-y)A?yBO(3-?), wherein 0?x?0.5, 0?y?0.5, and 0.8?z?1.1. In another embodiment, the cathode includes an electron-conducting phase that contains nickel oxide intermixed with magnesium oxide.
    Type: Grant
    Filed: July 23, 2007
    Date of Patent: July 12, 2011
    Assignee: Ceramatec, Inc.
    Inventors: Singaravelu Elangovan, Joseph J. Hartvigsen
  • Patent number: 7959784
    Abstract: Disclosed are processes of making solutions of metal alcoholates in their corresponding alcohols using an electrolytic process. In one embodiment, sodium methylate in methanol is made from methanol and sodium hydroxide solution. The sodium hydroxide solution is placed in the anolyte compartment and the methanol is placed in the catholyte compartment, and the two compartments are separated by a ceramic membrane that selectively transports sodium under the influence of current. In preferred embodiments, the process is cost-effective and not environmentally harmful.
    Type: Grant
    Filed: March 31, 2006
    Date of Patent: June 14, 2011
    Assignee: Ceramatec, Inc.
    Inventors: Shekar Balagopal, Vinod K. Malhotra
  • Patent number: 7918986
    Abstract: Disclosed are processes of making solutions of metal alcoholates in their corresponding alcohols using an electrolytic process. In a preferred embodiment, sodium methylate in methanol is made from methanol and sodium hydroxide solution. The sodium hydroxide solution is placed in the anolyte compartment and the methanol is placed in the catholyte compartment, and the two compartments are separated by a ceramic membrane that selectively transports sodium under the influence of current. In preferred embodiments, the process is cost-effective and not environmentally harmful.
    Type: Grant
    Filed: December 13, 2004
    Date of Patent: April 5, 2011
    Assignee: Ceramatec, Inc.
    Inventors: Shekar Balagopal, Vinod K. Malhotra
  • Patent number: 7897028
    Abstract: Disclosed herein is an improved method for regenerating materials from a desulfurization/demetallation reaction. The desulfurization/demetallation reaction preferably has products including one or more of an alkali sulfide, polysulfide or hydrosulfide, or alkali earth sulfide, polysulfide, or hydrosulfide. The method includes the steps of reacting the desulfurization/demetallation products with a halogen, liberating and removing sulfur from the product, and then electrolyzing the halogenated products to separate the halogen from the alkali metal or alkali earth metal.
    Type: Grant
    Filed: January 20, 2005
    Date of Patent: March 1, 2011
    Assignee: Ceramatec, Inc.
    Inventors: John H. Gordon, Ashok V. Joshi
  • Patent number: 7824536
    Abstract: Disclosed are processes of making solutions of alkali alkoxides in their corresponding alcohols using an electrolytic process. In one embodiment, sodium methoxide in methanol is made from methanol and aqueous sodium hydroxide solution, where the aqueous sodium hydroxide solution is present in the anolyte compartment and a solution of sodium methoxide in methanol is present in the catholyte compartment, the two compartments are separated by a ceramic membrane that selectively transports sodium ions under the influence of an electric potential, and wherein the composition of the solution of sodium methoxide in methanol in the catholyte compartment of the electrolytic cell comprises between at least about 2% by weight sodium methoxide and at most about 20% by weight sodium methoxide.
    Type: Grant
    Filed: June 9, 2006
    Date of Patent: November 2, 2010
    Assignee: Ceramatec, Inc.
    Inventors: Shekar Balagopal, Justin Pendleton, Robin Richards
  • Patent number: 7708966
    Abstract: A selective catalytic reduction (SCR) system includes an on-board ammonia generation system that produces nitrogen from air and hydrogen from a source of a hydrogen-containing compound, and generates an ammonia product from the nitrogen and hydrogen to provide the ammonia product into an exhaust from a NOx generator to reduce the NOx in the exhaust. Oxygen from one or both of the nitrogen generator and the hydrogen generation cell can be supplied to the NOx generator for cleaner combustion or to a particulate filter for cleaning the filter. H2O from the NOx generator can at least partially provide a water source for the hydrogen generation cell.
    Type: Grant
    Filed: February 4, 2008
    Date of Patent: May 4, 2010
    Assignee: Ceramatec, Inc.
    Inventor: Ashok V. Joshi
  • Patent number: 7695580
    Abstract: A method of joining at least two sintered bodies to form a composite structure, includes: providing a joint material between joining surfaces of first and second sintered bodies; applying pressure from 1 kP to less than 5 MPa to provide an assembly; heating the assembly to a conforming temperature sufficient to allow the joint material to conform to the joining surfaces; and further heating the assembly to a joining temperature below a minimum sintering temperature of the first and second sintered bodies. The joint material includes organic component(s) and ceramic particles. The ceramic particles constitute 40-75 vol. % of the joint material, and include at least one element of the first and/or second sintered bodies. Composite structures produced by the method are also disclosed.
    Type: Grant
    Filed: January 17, 2006
    Date of Patent: April 13, 2010
    Assignees: Air Products and Chemicals, Inc., Ceramatec, Inc.
    Inventors: Raymond Ashton Cutler, Kent Neal Hutchings, Brian Paul Kleinlein, Michael Francis Carolan
  • Patent number: 7666812
    Abstract: An improved gas diffusion electrode composed of a perovskite-type oxide dispersed in a mixture of carbon black and a hydrophobic binder polymer. An improved catalyst for use in the electrochemical reduction of oxygen comprising a perovskite-type compound having alpha and beta sites, and having a greater molar ratio of cations at the beta site. A particularly good reduction catalyst is a neodymium calcium manganite. An improved method of dispersing the catalysts with carbon in a reaction layer of the electrode improves performance of the electrode and the oxygen reduction process. This is provided by adding carbon black to an aqueous solution of metal salts before it is heated to a gel and then to a char and then calcined. Optionally, a quantity of the desired oxide catalyst can be premixed with a portion the carbon before adding the carbon to an aqueous solution of the metal salts to be heated.
    Type: Grant
    Filed: August 10, 2007
    Date of Patent: February 23, 2010
    Assignee: Ceramatec, Inc.
    Inventors: John Howard Gordon, Hachiya Toshinori, Shekar Balagopal, Sai Bhavaraju
  • Patent number: 7655202
    Abstract: A process for treating flue gas containing fly ash and carbon dioxide is disclosed. In the process, carbon dioxide and fly ash are contacted with an aqueous metal hydroxide solution to convert carbon dioxide into a metal carbonate, and wherein the metal carbonate and the metal hydroxide cause the fly ash to undergo a geopolymerization reaction and form a geopolymerized fly ash. The geopolymerized fly ash is recovered for disposal or for further use, such as a concrete additive.
    Type: Grant
    Filed: October 9, 2007
    Date of Patent: February 2, 2010
    Assignee: Ceramatec, Inc.
    Inventors: Ashok V. Joshi, Chett Boxley
  • Patent number: 7628951
    Abstract: A method is provided for producing insulation materials and insulation for high temperature applications using novel castable and powder-based ceramics. The ceramic components produced using the proposed process offers (i) a fine porosity (from nano-to micro scale); (ii) a superior strength-to-weight ratio; and (iii) flexibility in designing multilayered features offering multifunctionality which will increase the service lifetime of insulation and refractory components used in the solid oxide fuel cell, direct carbon fuel cell, furnace, metal melting, glass, chemical, paper/pulp, automobile, industrial heating, coal, and power generation industries. Further, the ceramic components made using this method may have net-shape and/or net-size advantages with minimum post machining requirements.
    Type: Grant
    Filed: August 14, 2006
    Date of Patent: December 8, 2009
    Assignee: Ceramatec, Inc.
    Inventors: Akash Akash, Nair Balakrishnan G.
  • Patent number: 7611612
    Abstract: A mixed potential NOx sensor apparatus for measuring the total NOx concentration in a gas stream is disclosed. The NOx sensing apparatus comprises a multilayer ceramic structure with electrodes for sensing both oxygen and NOx gas concentrations and includes screen-printed metalized patterns that function to heat the ceramic sensing element to the proper temperature for optimum performance. This design may provide advantages over the existing technology by miniaturizing the sensing element to provide potentially faster sensor light off times and thereby reduce undesired exhaust gas emissions. By incorporating the heating source within the ceramic sensing structure, the time to reach the temperature of operation is shortened, and thermal gradients and stresses are minimized. These improvements may provide increased sensor performance, reliability, and lifetime.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: November 3, 2009
    Assignee: Ceramatec, Inc.
    Inventors: Balakrishnan G. Nair, Jesse Nachlas
  • Patent number: 7517489
    Abstract: A method is provided for synthesizing beads using starting ceramic, metal, or mineral powders. Typical size of these round beads can range from about 0.1 mm to about 10 mm based on the processing variables. In the method, a slip is obtained which contains a metal, ceramic, and/or mineral powder dispersed in a solvent and an organic binder, such as a grain flour. Droplets of the slip are contacted with heated oil for a sufficient time to form beads. The beads are separated from the oil and dried to remove entrained water. The beads are fired at a temperature sufficient to produce beads possessing desired physical or chemical characteristics. The beads have useful biomedical applications as bone filler materials for bone fixation and bone growth. The beads may be coated with chemical catalyst agents and function as catalyst supports in chemical processes.
    Type: Grant
    Filed: November 3, 2006
    Date of Patent: April 14, 2009
    Assignee: Ceramatec, Inc.
    Inventor: Akash Akash
  • Publication number: 20090038297
    Abstract: Ceramic catalytic compositions, systems, and methods for oxidizing, converting and/or removing NOxgas species present in gas streams such as exhaust gases are provided. The catalysts of the invention oxidize the nitrogen monoxide (NO) in gas streams to nitrogen dioxide (NO2), which may be adsorbed by a metal oxide or other NO2 adsorber. Catalysts suitable for use in systems of the present invention include ceramic oxides, mixtures of ceramic oxides, complex ceramic oxides, and mixtures of complex ceramic oxides. Such catalysts are shown herein to successfully achieve an NO-NO2 equilibrium gas composition at temperatures as low as 275° C. In addition, by using the catalyst with an NO2 adsorber, greater than 95% removal of combined NO and NO2 from the gas stream has been successfully demonstrated. Further, specific strategies have been identified to regenerate the catalyst system and restore performance after prolonged exposure to species such as sulfur dioxide (SO2).
    Type: Application
    Filed: September 1, 2005
    Publication date: February 12, 2009
    Applicant: CERAMATEC , Inc.
    Inventors: Balakrishnan Nair, Sai Bhavaraju, Jesse Nachlas, James Steppan
  • Patent number: 7459594
    Abstract: The process and the device of assistance by electric discharge plasma for a partial oxidization of various liquids or gas, has for object the gas rich production of CO and H2 (syngas) can contain the CH4 and C2H4 also, this without soot formation. Carbonaceous matters considered here are fossil origin (as the diesel oil, gas, the kerosene, the naphtha, the heavy oil, the natural gas, etc.) or renewable (as the rape oil, the ethanol, the glycerol, the biooil, the molasses, the biogas, etc.). Products conversion is obtained in a device by electric discharge plasma GlidArc-I, installed in a superior compartment of the device and communicating directly with its full lower compartment by a refractory porous containing oxides of nickel. The GlidArc-I first of all serves to light the electro-reinforced total combustion of a flux reduce a carbonaceous (fuel) mixed with a gas combustive base of oxygen (for example air).
    Type: Grant
    Filed: June 27, 2005
    Date of Patent: December 2, 2008
    Assignee: Ceramatec, Inc.
    Inventors: Albin Czernichowski, Krystyna Wesolowska, Jan Czernichowski
  • Patent number: 7417385
    Abstract: Systems and methods for ignition and reignition of unstable electrical discharges wherein a secondary electrode positioned is between a set of primary electrodes and a high voltage is applied between the secondary electrode and successive ones of the primary electrodes to produce pilot discharges that ionize a gas there between and thereby reduce the voltage necessary to ignite a primary discharge between the primary electrodes. Power is provided to the secondary electrode by a circuit which is independent of the circuit that supplies power to the primary electrodes and generates voltage pulses which are substantially higher than the voltage between the primary electrodes.
    Type: Grant
    Filed: July 21, 2005
    Date of Patent: August 26, 2008
    Assignee: Ceramatec, Inc.
    Inventors: Albin Czernichowski, Bogdan Hnatiuc, Peter Pastva, Albert Ranaivosoloarimanana
  • Patent number: 7259126
    Abstract: An improved gas diffusion electrode composed of a perovskite-type oxide dispersed in a mixture of carbon black and a hydrophobic binder polymer. An improved catalyst for use in the electrochemical reduction of oxygen comprising a perovskite-type compound having alpha and beta sites, and having a greater molar ratio of cations at the beta site. A particularly good reduction catalyst is a neodymium calcium manganite. An improved method of dispersing the catalysts with carbon in a reaction layer of the electrode improves performance of the electrode and the oxygen reduction process. This is provided by adding carbon black to an aqueous solution of metal salts before it is heated to a gel and then to a char and then calcined. Optionally, a quantity of the desired oxide catalyst can be premixed with a portion the carbon before adding the carbon to an aqueous solution of the metal salts to be heated.
    Type: Grant
    Filed: March 11, 2004
    Date of Patent: August 21, 2007
    Assignee: Ceramatec, Inc.
    Inventors: John H. Gordon, Hachiya Toshinori, Shekar H. Balagopal, Sai V. Bhavaraju
  • Patent number: 7258820
    Abstract: A multi-phase mixed protonic/electronic conducting material comprising a proton-conducting ceramic phase and an electron conductive ceramic phase. Under the presence of a partial pressure gradient of hydrogen across the membrane, a membrane fabricated with this material selectively transports hydrogen ions through the protonically conductive ceramic phase and electrons through the electronically conducting ceramic phase, which results in ultrahigh purity hydrogen permeation through the membrane. The material has a high electronic conductivity and hydrogen gas transport is rate-limited by the protonic conductivity of the material.
    Type: Grant
    Filed: March 5, 2004
    Date of Patent: August 21, 2007
    Assignee: Ceramatec, Inc.
    Inventors: Singaravelu Elangovan, Balakrishnan G. Nair, Troy A. Small
  • Patent number: 7217355
    Abstract: The present invention is a method and apparatus for measuring the total NOx concentration in a gas stream utilizing the principles of a NOx sensor, i.e., mixed potential sensor. The exhaust gas is first conditioned by a catalyst assembly that converts the various species of nitrogen oxide gases present to a fixed steady state concentration ratio of NO2/NO, where NO2 is approximately 0–10% of the total NOx concentration present in the gas exhaust, thereby enabling the NOx sensor to generate a meaningful and reproducible determination of the concentration of total NOx present in the gas being measured. The catalyst assembly also functions to oxidize any unburned combustibles such as CH4, CO, etc., and remove potential contaminants such as SO2.
    Type: Grant
    Filed: May 25, 2005
    Date of Patent: May 15, 2007
    Assignee: Ceramatec, Inc.
    Inventors: Balakrishnan G. Nair, Jesse A. Nachlas, Michael Middlemas