Patents Examined by Danielle M. Carda
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Patent number: 12091733Abstract: A control process of inclusions in ultra-clean rare earth steel, wherein the content of rare earth elements REM in the ultra-clean rare earth steel, the total oxygen content T[O]m, the total sulfur content T[S]m in the steel, and the total oxygen content T[O]r in a rare earth metal or alloy added to the steel are controlled to satisfy the following formula: ?500<REM?(m*T[O]m+n*T[O]r+k*T[S]m)<?30, where REM is the content of rare earth elements in the steel, in ppm; T[O]m is the total oxygen content in the steel, in ppm; T[O]r is the total oxygen content in a rare earth metal or alloy added to the steel, in ppm; T[S]m is the total sulfur content in the steel, in ppm; m is a first correction coefficient, with a value of 2-4.5;n is a second correction coefficient; and k is a third correction coefficient.Type: GrantFiled: May 2, 2023Date of Patent: September 17, 2024Assignee: INSTITUTE OF METAL RESEARCH CHINESE ACADEMY OF SCIENCESInventors: Dianzhong Li, Yikun Luan, Hongwei Liu, Paixian Fu, Xiaoqiang Hu, Pei Wang, Lijun Xia, Chaoyun Yang, Hanghang Liu, Yang Liu, Peng Liu, Yiyi Li
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Patent number: 12071677Abstract: The inventions described herein provide methods and systems for recycling lithium iron phosphate batteries, including: adding an oxidizing agent to a recycling stream of lithium iron phosphate (LiFePO4) batteries to form a leach solution; filtering the leach solution to remove a residue and obtain a lithium rich solution; modifying pH of the lithium rich solution for filtering impurities and obtaining a purified Li solution; and adding a precipitant to the purified Li solution thereby precipitating a lithium compound.Type: GrantFiled: August 2, 2022Date of Patent: August 27, 2024Assignee: Ascend Elements, Inc.Inventors: Eric Gratz, Kee-Chan Kim
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Patent number: 12018345Abstract: A pyro-metallurgical process for producing a non-ferrous metal or a compound thereof, wherein a metal raw material is fed into a rotary kiln, the metal being one of arsenic (As), antimony (Sb), lead (Pb), cadmium (Cd), mercury (Hg), silver (Ag), tin (Sn), nickel (Ni), or zinc (Zn). The raw material is heated to produce a volatized material, in which the non-ferrous metal or compound thereof is produced from the volatized material. A magnesium-based additive is additionally fed to the rotary kiln in an amount of between 0.5 wt. % and 9.5 wt. % relative to the total weight of the raw material. The magnesium-based additive is heated together with the raw material to produce the volatized material and a solid product while also counteracting ring formation in the rotary kiln.Type: GrantFiled: December 1, 2021Date of Patent: June 25, 2024Assignee: S.A. LHOIST RECHERCHE ET DEVELOPPEMENTInventors: Ian Saratovsky, Wliiiam Edward Johnson, Jr.
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Patent number: 11999088Abstract: By using a forming die having a fixed die and a movable die moving along a parting surface on the fixed die and by moving the movable die along the parting surface, to press and hold a sintered part between the movable die and the fixed die, to form a cavity around the sintered part except parts which abut on the fixed die and the movable die by the forming die, and to fill the cavity with melted material which becomes an exterior part, so that the sintered part and the exterior part are integrated by insert molding.Type: GrantFiled: January 25, 2021Date of Patent: June 4, 2024Assignee: DIAMET CORPORATIONInventors: Shinichi Takezoe, Tsuneo Maruyama, Hideo Sakai
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Patent number: 11976343Abstract: An aluminium based alloy, and a method for production of components by additive manufacturing (AM) or other rapid solidification process with the alloy, is based on the alloy having a composition with from 2.01 wt % to 15.0 wt % manganese, from 0.3 wt % to 2.0 wt % scandium, with a balance apart from minor alloy elements and incidental impurities of aluminium.Type: GrantFiled: July 28, 2023Date of Patent: May 7, 2024Assignee: MONASH UNIVERSITYInventors: Paul Rometsch, Xinhua Wu, Qingbo Jia
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Patent number: 11970753Abstract: A method for producing an ultra-high-strength hot-rolled structural steel includes producing a steel alloy with a carbon content not greater than 0.2%, avoiding a diffusive transformation of the austenite by achieving a transformation delay through the addition of manganese, chromium, and boron, and casting the steel alloy. The cast steel alloy is heated and hot rolled to form a steel strip which is then immediately hardened and mechanically straightened to produce mobile dislocations, wherein the boron, manganese and chromium delay diffusive transformation from an austenite structure to achieve formation of a martensite structure during the hardening. The steel strip is then annealed at a temperature between 100 and 200° C.Type: GrantFiled: September 17, 2019Date of Patent: April 30, 2024Assignee: voestalpine Stahl GmbHInventors: Markus Sonnleitner, Martin Klein, Gerhard Hubmer, Helmut Spindler
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Patent number: 11946108Abstract: Foundry coke products, and associated methods and systems for melting iron in a cupola furnace with the coke products are disclosed herein. A representative method can include receiving a population of coke products and iron in a cupola furnace, and melting the iron in the cupola furnace to form molten iron having a carbon content higher than a carbon content of the received iron. The coke products can comprise (i) an elongate shape including a length:width dimension of at least 1.5:1, (ii) an ash fusion temperature of no more than 2400° F., and/or (iii) a coke reactivity index (CRI) of at least 30%.Type: GrantFiled: November 4, 2022Date of Patent: April 2, 2024Assignee: SUNCOKE TECHNOLOGY AND DEVELOPMENT LLCInventors: John Francis Quanci, John Michael Richardson, Jonathan Hale Perkins
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Patent number: 11920213Abstract: Disclosed is an incomplete extraction method for recycling batteries, which may include: introducing a pretreatment gas into a device loaded with a waste battery powder, and bringing a gas outlet into communication with absorption liquid A and absorption liquid B in order; raising the temperature and introducing the pretreatment gas; reducing the temperature and introducing a reaction gas; raising the temperature, introducing the reaction gas, and then introducing the pretreatment gas; and reducing the temperature, and turning off the pretreatment gas; adding an extractant to absorption liquid A, mixing the mixture, taking organic phase A, adding a stripping agent, and taking aqueous phase A; and adjusting the pH to acidity, then adding an extractant, taking organic phase B, adding a stripping agent to obtain a stock solution enriched in Li, Mn, Ni and Co.Type: GrantFiled: April 30, 2021Date of Patent: March 5, 2024Assignees: GUANGDONG BRUNP RECYCLING TECHNOLOGY CO., LTD., HUNAN BRUNP RECYCLING TECHNOLOGY CO., LTD., HUNAN BRUNP EV RECYCLING CO., LTD.Inventors: Haijun Yu, Ting Peng, Yinghao Xie, Xuemei Zhang
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Patent number: 11920205Abstract: The present invention provides a casting method and cast product of spherical graphite cast iron, in which, even with a small modulus, there is no chill, the spherical graphite in the tissue is further made ultrafine, the dispersion of the particle diameter is small, and the number of the particles is several times that of the conventional one in the as cast state where heat treatment is not carried out. A casting method of a spherical graphite cast iron includes a melting process, a spheroidizing treatment process, an inoculation process, and a casting process, in which the original molten metal after the inoculation process is poured and filled up to a product space through a gate of a metal mold; where the original molten metal is controlled to a semi-solidification temperature range, before being filled up to the product space.Type: GrantFiled: May 23, 2022Date of Patent: March 5, 2024Inventors: Masayuki Itamura, Haruki Itofuji, Mitsuru Adachi
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Patent number: 11913095Abstract: In various embodiments, metallic alloy powders are utilized as feedstock, or to fabricate feedstock, utilized in additive manufacturing processes to form three-dimensional metallic parts. Such feedstock includes composite particles each comprising a mixture and/or alloy of a first constituent metal and one or more second constituent metals, where each of the particles comprises a plurality of grains each surrounded by a matrix, the grains comprising the first constituent metal, and the matrix comprising the one or more second constituent metals.Type: GrantFiled: October 19, 2021Date of Patent: February 27, 2024Assignee: H.C. STARCK SOLUTIONS EUCLID, LLCInventors: Michael T. Stawovy, Scott D. Ohm, Fahrron C. Fill
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Patent number: 11913090Abstract: A method for extracting rare earth elements and critical minerals including adding an acid to a mixture comprising organically bound rare earth elements. The mixture is maintained at a pH of 0.25 to 4 for a period of time, resulting in a liquor and a leached mixture. The liquor is removed from the leached mixture to form a dewatered cake. The dewatered cake is washed to form a washing liquid. The washing liquid is recycled to create a second slurry comprising organically bound rare earth elements.Type: GrantFiled: November 4, 2021Date of Patent: February 27, 2024Assignee: University of North DakotaInventors: Nolan Theaker, Daniel Laudal
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Patent number: 11887760Abstract: There is provided a soft magnetic alloy comprising a composition expressed by a formula of (Fe(1-?)A?)(1-m-x-y)MmXxYy, in which M represents at least one selected from the group consisting of Zr and Hf, X represents at least one selected from the group consisting of Ni, Mn, Cu, Co, Al, and Ge, Y represents at least one selected from the group consisting of B, P, and Si, A represents at least one selected from the group consisting of Ti, V, Cr, Zn, Mg, Sn, Bi, O, N, S, and a rare earth element, m, x, y, and ? satisfy relationships of 0.070?m?0.120, 0.001?x?0.030, 0?y?0.010, and 0???0.100, and the alloy contains Fe-based nanocrystals having an average crystal grain size of 30 nm or less.Type: GrantFiled: November 5, 2021Date of Patent: January 30, 2024Assignee: TDK CORPORATIONInventors: Kensuke Ara, Hajime Amano
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Patent number: 11859263Abstract: This application pertains to methods of recovering metals from metal sulfides that involve contacting the metal sulfide with an acidic sulfate solution containing ferric sulfate and a reagent that has a thiocarbonyl functional group, wherein the concentration of reagent in the acidic sulfate solution is sufficient to increase the rate of metal ion extraction relative to an acidic sulfate solution that does not contain the reagent, to produce a pregnant solution containing the metal ions.Type: GrantFiled: October 19, 2017Date of Patent: January 2, 2024Assignee: Jetti Resources, LLCInventors: David Dixon, Edouard Asselin, Zihe Ren, Nelson Mora Huertas
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Patent number: 11839917Abstract: Embodiments disclosed herein relate to polycrystalline diamond compacts that have a substrate including a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having and at least one alloying element, wherein the at least one alloying element constitutes less than 12 wt % of the substrate and wherein the cobalt constitutes less than 12 wt % of the substrate; and methods of making the same.Type: GrantFiled: September 11, 2019Date of Patent: December 12, 2023Assignee: US SYNTHETIC CORPORATIONInventor: Debkumar Mukhopadhyay
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Patent number: 11833590Abstract: An additive manufacturing product is provided. The additive manufacturing product includes an embedded electronic, a transition zone, and a base material. The transition zone encases the embedded electronic. The transition zone includes transition material. The base material encases the transition zone. The transition material includes an intermediate melting point that is lower than a melting point of the base material.Type: GrantFiled: May 13, 2021Date of Patent: December 5, 2023Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Diana Giulietti, Alexander Madinger
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Patent number: 11827953Abstract: A disclosed process produces at least one concentrated copper product together with at least one crude solder product, starting from a black copper composition with at least 50% of copper together with at least 1.0% wt of tin and at least 1.0% wt of lead The process includes the step of partially oxidizing the black copper thereby forming a first copper refining slag, followed by partially reducing the first copper refining slag to form a first lead-tin based metal composition and a first spent slag. The total feed to the reducing step includes an amount of copper that is at least 1.5 times as high as the sum of the amounts of Sn plus Pb present, and the first spent slag includes at most 20% wt total of copper, tin and lead together.Type: GrantFiled: December 11, 2018Date of Patent: November 28, 2023Assignee: METALLO BELGIUMInventors: Bert Coletti, Jan Dirk A. Goris, Yves De Visscher, Charles Geenen, Walter Guns, Niko Mollen, Steven Smets, Andy Breugelmans
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Patent number: 11807914Abstract: The present invention provides a method which is capable of more strictly controlling the oxygen partial pressure required during the melting of a starting material, thereby being capable of recovering a valuable metal more efficiently. A method for recovering valuable metals (Cu, Ni, Co), said method comprising the following steps: a step for preparing, as a starting material, a charge that contains at least phosphorus (P), iron (Fe) and valuable metals; a step for heating and melting the starting material into a melt, and subsequently forming the melt into a molten material that contains an alloy and slag; and a step for recovering the alloy that contains valuable metals by separating the slag from the molten material. With respect to this method for recovering valuable metals, the oxygen partial pressure in the melt is directly measured with use of an oxygen analyzer when the starting material is heated and melted.Type: GrantFiled: June 21, 2021Date of Patent: November 7, 2023Assignee: SUMITOMO METAL MINING CO., LTD.Inventor: Yu Yamashita
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Patent number: 11788158Abstract: The present disclosure relates, according to some embodiments to a method for steel production, the method comprising forming a hydrogen and a carbon from a natural gas using thermal plasma electrolysis; reducing iron ore fines with the H2 to form an iron briquette; melting the briquette iron from the furnace to form a melted iron and melted non-metallic slag; separating the non-metallic slag from the melted iron in the furnace; combining the carbon and the melted iron in a furnace to form a carbon black and iron mixture; and alloying the melted iron with the carbon black to form a steel.Type: GrantFiled: February 14, 2023Date of Patent: October 17, 2023Assignee: PATHFINDER HOLDINGS CORP.Inventor: James Maurice Small
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Patent number: 11773467Abstract: Provided are a method and a system for processing a rare earth concentrate ore. The method comprises (1) mixing the rare earth concentrate ore and concentrated sulfuric acid, thereby obtaining a mixed slurry and a first fluorine-containing gas; (2) mixing the mixed slurry and an initiator liquid for acidolysis, thereby obtaining a clinker and a second fluorine-containing gas; (3) subjecting the clinker to leaching with water, thereby obtaining a leached slurry; (4) subjecting the leached slurry to a solid-liquid separation, thereby obtaining a filtrate and a leached slag, and recycling the leached slag to step (2) for acidolysis again.Type: GrantFiled: October 25, 2019Date of Patent: October 3, 2023Assignee: CHINA ENFI ENGINEERING CORPORATIONInventors: Jianwen Tang, Guoshan Du, Pengfei Xian, Shuang Qiu, Wenlong Zhou, Bo Qin
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Patent number: 11746396Abstract: An aluminium based alloy, and a method for production of components by additive manufacturing (AM) or other rapid solidification process with the alloy, is based on the alloy having a composition with from 2.01 wt % to 15.0 wt % manganese, from 0.3 wt % to 2.0 wt % scandium, with a balance apart from minor alloy elements and incidental impurities of aluminium.Type: GrantFiled: December 3, 2018Date of Patent: September 5, 2023Assignee: MONASH UNIVERSITYInventors: Paul Rometsch, Xinhua Wu, Qingbo Jia