Patents Assigned to Utility Global, Inc.
  • Patent number: 11453618
    Abstract: Herein discussed is a method of sintering a ceramic comprising (a) providing an electromagnetic radiation (EMR) source; (b) (i) providing a layer of intermixed ceramic particles and absorber particles, wherein the absorber particles have a volume fraction in the intermixed particles in the range of no less than 3%; or (ii) providing a first layer comprising ceramic particles and a second layer comprising absorber particles in contact with at least a portion of the first layer, wherein the second layer is farther from the EMR source than the first layer; (c) heating (i) the layer of intermixed particles or (ii) the first layer using EMR; and (d) controlling the EMR such that at least a portion of the ceramic particles are sintered wherein (i) the layer of intermixed particles becomes impermeable or (ii) the first layer becomes impermeable, wherein the absorber particles have greater EMR absorption than the ceramic particles.
    Type: Grant
    Filed: September 23, 2020
    Date of Patent: September 27, 2022
    Assignee: Utility Global, Inc.
    Inventors: Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20210121978
    Abstract: Herein discussed is a method of heating a material having a surface comprising exposing the surface to an electromagnetic radiation source emitting a first wavelength spectrum; receiving a second wavelength spectrum from the surface using a detector at a sampling frequency; wherein the first wavelength spectrum and the second wavelength spectrum have no greater than 10% of overlap, wherein the overlap is the integral of intensity with respect to wavelength. In an embodiment, the first wavelength spectrum and the second wavelength spectrum have no greater than 5% of overlap or no greater than 3% of overlap or no greater than 1% of overlap or no greater than 0.5% of overlap. In an embodiment, exposing the surface to the radiation source causes the material to sinter at least partially.
    Type: Application
    Filed: October 23, 2020
    Publication date: April 29, 2021
    Applicant: Utility Global, Inc.
    Inventors: Matthew Dawson, Nicholas Farandos, Jin Dawson, Chris Matson
  • Publication number: 20210069786
    Abstract: Herein disclosed is a method of manufacturing comprises depositing a composition on a substrate slice by slice to form an object; heating in situ the object using electromagnetic radiation (EMR); wherein said composition comprises a first material and a second material, wherein the second material has a higher absorption of the radiation than the first material. In an embodiment, the EMR has a wavelength ranging from 10 to 1500 nm and the EMR has a minimum energy density of 0.1 Joule/cm2. In an embodiment, the EMR comprises UV light, near ultraviolet light, near infrared light, infrared light, visible light, laser, electron beam. In an embodiment, said object comprises a catalyst, a catalyst support, a catalyst composite, an anode, a cathode, an electrolyte, an electrode, an interconnect, a seal, a fuel cell, an electrochemical gas producer, an electrolyser, an electrochemical compressor, a reactor, a heat exchanger, a vessel, or combinations thereof.
    Type: Application
    Filed: November 5, 2019
    Publication date: March 11, 2021
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20210024425
    Abstract: Herein discussed is a method of sintering a ceramic comprising (a) providing an electromagnetic radiation (EMR) source; (b) (i) providing a layer of intermixed ceramic particles and absorber particles, wherein the absorber particles have a volume fraction in the intermixed particles in the range of no less than 3%; or (ii) providing a first layer comprising ceramic particles and a second layer comprising absorber particles in contact with at least a portion of the first layer, wherein the second layer is farther from the EMR source than the first layer; (c) heating (i) the layer of intermixed particles or (ii) the first layer using EMR; and (d) controlling the EMR such that at least a portion of the ceramic particles are sintered wherein (i) the layer of intermixed particles becomes impermeable or (ii) the first layer becomes impermeable, wherein the absorber particles have greater EMR absorption than the ceramic particles.
    Type: Application
    Filed: September 23, 2020
    Publication date: January 28, 2021
    Applicant: Utility Global, Inc.
    Inventors: Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200303749
    Abstract: Herein discussed is an electrode comprising a copper or copper oxide phase and a ceramic phase, wherein the copper or copper oxide phase and the ceramic phase are sintered and are inter-dispersed with one another. Further discussed herein is a method of making a copper-containing electrode comprising: (a) forming a dispersion comprising ceramic particles and copper or copper oxide particles; (b) depositing the dispersion onto a substrate to form a slice; and (c) sintering the slice using electromagnetic radiation.
    Type: Application
    Filed: May 14, 2020
    Publication date: September 24, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200255959
    Abstract: A method of producing hydrogen includes providing a device, introducing a first stream including a fuel to the device, introducing a second stream comprising water to the device, reducing the water in the second stream to hydrogen, and extracting hydrogen from the device. The first stream and the second stream do not come in contact with each other in the device.
    Type: Application
    Filed: January 10, 2020
    Publication date: August 13, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200259186
    Abstract: A method of making a gas producer includes providing a first tubular electrode; coating the inner or outer surface of the first tubular electrode with an electrolyte material; coating the electrolyte material with a second electrode material; and sintering the second electrode material using electromagnetic radiation to form a second tubular electrode.
    Type: Application
    Filed: January 10, 2020
    Publication date: August 13, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200255962
    Abstract: A hydrogen production system comprising: a fuel source; a water source; and a hydrogen producer; where the fuel source and the water source are in fluid communication with the hydrogen producer; and where fuel enters the hydrogen producer from the fuel source and water enters the hydrogen producer from the water source and the fuel and the water do not come in contact with each other in the hydrogen producer.
    Type: Application
    Filed: January 10, 2020
    Publication date: August 13, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200255963
    Abstract: A device includes a first electrode, a second electrode, and an electrolyte between the electrodes. The first electrode and the second electrode may comprise a metallic phase that does not contain a platinum group metal when the device is in use, and where the electrolyte is solid state and is oxide ion conducting.
    Type: Application
    Filed: January 10, 2020
    Publication date: August 13, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200235409
    Abstract: Methods are disclosed to provide balance of plant for an electrochemical reactor. The methods include forming a vessel, wherein the vessel has at least a wall and an internal space configured to contain the reactor; forming fluid channels in or attached to at least a portion of the wall of the vessel, and where the fluid channels are configured to be in fluid communication with the reactor.
    Type: Application
    Filed: December 9, 2019
    Publication date: July 23, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200235410
    Abstract: An electrochemical reactor includes a first electrode, a second electrode, an electrolyte between the first and second electrodes, and a first heat exchanger. The first heat exchanger may be in fluid communication with the first electrode and where the minimum distance between the first electrode and the first heat exchanger is no greater than 10 cm.
    Type: Application
    Filed: December 9, 2019
    Publication date: July 23, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200227763
    Abstract: A system comprising an electrochemical reactor chamber, an integrated chiller, and optionally a reformer chamber, wherein the reactor chamber, integrated chiller, and optional reformer chamber are of unitary construction.
    Type: Application
    Filed: January 28, 2020
    Publication date: July 16, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200182549
    Abstract: A multi-fluid heat exchanger includes at least three fluid inlets and at least three fluid channels. Each of the at least three fluid channels have a minimum dimension of no greater than 30 mm.
    Type: Application
    Filed: December 9, 2019
    Publication date: June 11, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200176803
    Abstract: Herein discussed is a method of making a fuel cell comprising (a) producing an anode using an additive manufacturing machine (AMM); (b) creating an electrolyte using the additive manufacturing machine; and (c) making a cathode using the additive manufacturing machine. In an embodiment, the anode, the electrolyte, and the cathode are assembled into a fuel cell utilizing the additive manufacturing machine. In an embodiment, the fuel cell is formed using only the additive manufacturing machine.
    Type: Application
    Filed: November 5, 2019
    Publication date: June 4, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Jin Dawson
  • Publication number: 20200156104
    Abstract: Herein discussed is a method of making an object comprising mixing particles with a liquid to form a dispersion; depositing the dispersion on a substrate to form a layer; and treating the layer to cause at least a portion of the particles to sinter, wherein the particles have a size distribution that has at least one of the following characteristics: (a) said size distribution comprises D10 and D90, wherein 10% of the particles have a diameter no greater than D10 and 90% of the particles have a diameter no greater than D90, wherein D90/D10 is in the range of from 1.5 to 100; or (b) said size distribution is bimodal such that the average particle size in the first mode is at least 5 times the average particle size in the second mode; or (c) said size distribution comprises D50, wherein 50% of the particles have a diameter no greater than D50, wherein D50 is no greater than 100 nm.
    Type: Application
    Filed: November 12, 2019
    Publication date: May 21, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200144627
    Abstract: There is disclosed a method of making an electrode for an electrochemical reactor. The method includes the steps of (a) depositing an electrode material in segments on a substrate; (b) sintering the electrode material to form electrode segments; and (c) depositing a filler material between the electrode segments. Preferably, the method also includes the steps of (d) depositing additional material to cover the filler; and (e) sintering the additional material. Preferably, the additional material comprises electrode material, electrolyte material, or interconnect material.
    Type: Application
    Filed: November 23, 2019
    Publication date: May 7, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200144635
    Abstract: The present invention is a method of making an interconnect containing at least one microchannel for an electrochemical reactor. The method includes providing a template then depositing an interconnect material where the interconnect material is in contact with the template. The template is in a form that produces at least one microchannel in the interconnect material when at least a portion of the template is removed.
    Type: Application
    Filed: November 29, 2019
    Publication date: May 7, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200144633
    Abstract: The present invention is an interconnect for an electrochemical reactor that includes at least one microchannel. The at least one microchannel has a cross-sectional area orthogonal to a flow path and where the cross-sectional area is no greater than 1 mm2. Preferably, the microchannel has a planar projection area PPAc and the interconnect has a planar projection area PPAi, wherein the ratio of PPAc/PPAi is in the range of 0.2-0.8, or 0.3-0.7, or 0.4-0.6, or 0.45-0.55.
    Type: Application
    Filed: November 29, 2019
    Publication date: May 7, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200144648
    Abstract: Herein disclosed is a method of making an electrochemical reactor comprising a) depositing a composition on a substrate to form a slice; b) drying the slice using a non-contact dryer; c) sintering the slice using electromagnetic radiation (EMR), wherein the electrochemical reactor comprises an anode, a cathode, and an electrolyte between the anode and the cathode. In an embodiment, the electrochemical reactor comprises at least one unit, wherein the unit comprises the anode, the cathode, the electrolyte and an interconnect and wherein the unit has a thickness of no greater than 1 mm. In an embodiment, the anode is no greater than 50 microns in thickness, the cathode is no greater than 50 microns in thickness, and the electrolyte is no greater than 10 microns in thickness.
    Type: Application
    Filed: November 15, 2019
    Publication date: May 7, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson
  • Publication number: 20200144628
    Abstract: The invention is an electrode for use in an electrochemical reactor and a method of making it. The electrode has an electrode porosity and includes an electrode material with channels formed therein. The porosity of the electrode material is less than the porosity of the electrode. In the method, an electrode is made by depositing a first composition including a first electrode material and a first pore former, wherein the first pore former is a first volume fraction VFp1 of the first composition. A second composition is deposited with includes a second electrode material and a second pore former. In this aspect, the second pore former is a second volume fraction VFp2. The first composition and second composition form a first layer of the electrode. This first layer is heated such that at least a portion of the first pore former and at least a portion of the second pore former become empty spaces in the electrode.
    Type: Application
    Filed: November 23, 2019
    Publication date: May 7, 2020
    Applicant: Utility Global, Inc.
    Inventors: David R. Hall, Matthew Dawson, Nicholas Farandos, Jin Dawson