Patents by Inventor Christopher HALLMARK
Christopher HALLMARK has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240055707Abstract: A method of forming a brazed joint is described. The method includes pressing a non-molybdenum component, such as a cross pin of a battery case assembly, against a molybdenum component, such as a terminal pin of the battery case assembly, and applying one or more electrical pulses to form an interface liquid layer between the components that cools to form the brazed joint. At least one of the electrical pulses has a constant voltage over a pulse time. A contact resistance between the components can decrease during the pulse time, and thus, the constant voltage can cause an uncontrolled electrical current of the electrical pulse to increase. The increasing electrical current heats the components sufficiently to form the interface liquid layer having a predetermined thickness that provides a required bend strength. Removal of surface oxides provide consistent mechanical strength for this joint. Other embodiments are also described and claimed.Type: ApplicationFiled: October 26, 2023Publication date: February 15, 2024Inventors: Shichan Chiang, Christopher Hallmark, Michael Erickson, Kurt Erickson, Nicholas Hamor, Jeffrey Armstrong, Philip Edward Poole, Nathan Messerich
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Patent number: 11831030Abstract: A method of forming a brazed joint is described. The method includes pressing a non-molybdenum component, such as a cross pin of a battery case assembly, against a molybdenum component, such as a terminal pin of the battery case assembly, and applying one or more electrical pulses to form an interface liquid layer between the components that cools to form the brazed joint. At least one of the electrical pulses has a constant voltage over a pulse time. A contact resistance between the components can decrease during the pulse time, and thus, the constant voltage can cause an uncontrolled electrical current of the electrical pulse to increase. The increasing electrical current heats the components sufficiently to form the interface liquid layer having a predetermined thickness that provides a required bend strength. Removal of surface oxides provide consistent mechanical strength for this joint. Other embodiments are also described and claimed.Type: GrantFiled: May 20, 2019Date of Patent: November 28, 2023Assignee: PACESETTER, INC.Inventors: Shichan Chiang, Christopher Hallmark, Michael Erickson, Kurt Erickson, Nicholas Hamor, Jeffrey Armstrong, Philip Edward Poole, Nathan Messerich
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Patent number: 11735711Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.Type: GrantFiled: February 19, 2021Date of Patent: August 22, 2023Assignee: Pacesetter, Inc.Inventors: Russell Bruch, Joseph Beauvais, Jeffrey Armstrong, Del Charles Brooks, III, Christopher Hallmark, John Duggan
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Publication number: 20210184320Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.Type: ApplicationFiled: February 19, 2021Publication date: June 17, 2021Applicant: Pacesetter, Inc.Inventors: Russell Bruch, Joseph Beauvais, Jeffrey Armstrong, Del Charles Brooks III, Christopher Hallmark, John Duggan
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Publication number: 20210098772Abstract: Fabricating the electrode blank includes baking a blank precursor. The blank precursor contains the components of an electrode active medium including an active material. Fabricating the electrode blank also includes performing one or more post-bake calender operations on the blank precursor after baking the blank precursor. Each post-bake calender operation includes calendering the blank precursor.Type: ApplicationFiled: September 24, 2020Publication date: April 1, 2021Inventors: Diana McMillan, Christopher Hallmark
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Patent number: 10964922Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.Type: GrantFiled: December 27, 2018Date of Patent: March 30, 2021Assignee: Pacesetter, Inc.Inventors: Del Charles Brooks, III, Christopher Hallmark, John Duggan, Jeffrey Armstrong
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Patent number: 10727454Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.Type: GrantFiled: November 16, 2017Date of Patent: July 28, 2020Assignee: Pacesetter, Inc.Inventors: Russell Bruch, Joseph Beauvais, Jeffrey Armstrong, Del Charles Brooks, III, Christopher Hallmark, John Duggan
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Publication number: 20190363313Abstract: A method of forming a brazed joint is described. The method includes pressing a non-molybdenum component, such as a cross pin of a battery case assembly, against a molybdenum component, such as a terminal pin of the battery case assembly, and applying one or more electrical pulses to form an interface liquid layer between the components that cools to form the brazed joint. At least one of the electrical pulses has a constant voltage over a pulse time. A contact resistance between the components can decrease during the pulse time, and thus, the constant voltage can cause an uncontrolled electrical current of the electrical pulse to increase. The increasing electrical current heats the components sufficiently to form the interface liquid layer having a predetermined thickness that provides a required bend strength. Removal of surface oxides provide consistent mechanical strength for this joint. Other embodiments are also described and claimed.Type: ApplicationFiled: May 20, 2019Publication date: November 28, 2019Inventors: Shichan Chiang, Christopher Hallmark, Michael Erickson, Kurt Erickson, Nicholas Hamor, Jeffrey Armstrong, Philip Edward Poole, Nathan Messerich
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Publication number: 20190131593Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.Type: ApplicationFiled: December 27, 2018Publication date: May 2, 2019Applicant: Pacesetter, Inc.Inventors: Del Charles Brooks, III, Christopher Hallmark, John Duggan, Jeffrey Armstrong
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Publication number: 20180138463Abstract: A battery includes a case having a feedthrough port, a feedthrough assembly disposed in the feedthrough port, and a cell stack disposed within the case. The feedthrough port includes an inner conductor and an insulator core separating the inner conductor from the case. The cell stack includes an anode, a cathode, and a separator insulating the anode from the cathode, wherein the anode and cathode are offset from one another. An insulating boot surrounding the cell stack insulates the cell stack from the case. The insulating boot has an opening configured to receive therein the feedthrough assembly, which may include overmolded insulation. The interior surfaces and interior walls of the battery case may be thermal spray-coated with a dielectric material to prevent lithium dendrite formation between cathode and anode surfaces.Type: ApplicationFiled: November 16, 2017Publication date: May 17, 2018Applicant: Pacesetter, Inc.Inventors: Russell Bruch, Joseph Beauvais, Jeffrey Armstrong, Del Charles Brooks, III, Christopher Hallmark, John Duggan
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Publication number: 20120276435Abstract: A method of forming an encapsulated solid electrochemical component includes stacking a first separator, a solid electrochemical component, and a second separator on an upper surface of a vacuum plate to form an electrochemical component assembly, applying a vacuum to the electrochemical component assembly, and applying a first laser beam around at least part of a circumference of the solid electrochemical component in the electrochemical component assembly while applying the vacuum to melt and bond the first and second separators together. The method also includes applying a second laser beam around the circumference of the solid electrochemical component in the electrochemical component assembly while applying the vacuum. The second laser beam has a second relatively high power compared to the power of the first laser beam such that the first and second separators around the circumference of the solid electrochemical component are cut.Type: ApplicationFiled: April 23, 2012Publication date: November 1, 2012Applicant: EAGLEPICHER TECHNOLOGIES, LLCInventor: Christopher HALLMARK