Patents by Inventor Darren Kenneth Rogers

Darren Kenneth Rogers 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).

  • Patent number: 7588608
    Abstract: According to the present invention there is provided a porous coal-based material having a density of between about 0.1 g/cm3 and about 0.6 g/cm3 that is produced by the controlled heating of small coal particulate in a “mold” and under a non-oxidizing atmosphere. The coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 4.0 and about 4.5. The porous product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc. Such porous products, without further treatment exhibit compressive strengths of up to about 6000 psi. Further treatment by carbonization or graphitization yields products that can be used as electrical or heat conductors. Methods for the production of these coal-based cellular products are also described.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: September 15, 2009
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventor: Darren Kenneth Rogers
  • Patent number: 7578860
    Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell Index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, beat or electrical insulator etc.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: August 25, 2009
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventor: Darren Kenneth Rogers
  • Patent number: 7544222
    Abstract: An ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the “dirty” and friable particulate activated carbon foam materials of the prior art.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: June 9, 2009
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 7481855
    Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: January 27, 2009
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 7452389
    Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: November 18, 2008
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 7449035
    Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: November 11, 2008
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 7247368
    Abstract: Carbon foams exhibiting a dielectric constant of from about 2 to about 6 and simultaneously an electrical resistivity in the range of between about 1.E+00 ohm-cm and about 1.E+06 ohm-cm, demonstrate excellent radar emission absorptivity in the megahertz and gigahertz ranges.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: July 24, 2007
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventor: Darren Kenneth Rogers
  • Patent number: 6869455
    Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.
    Type: Grant
    Filed: February 5, 2002
    Date of Patent: March 22, 2005
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 6861151
    Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.
    Type: Grant
    Filed: July 14, 2001
    Date of Patent: March 1, 2005
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 6860910
    Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: March 1, 2005
    Assignee: Touchstone Research Laboratories, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 6849098
    Abstract: Carbonaceous, composite tooling fabricated from pitch-based or coal-based cellular or porous products, “carbonaceous foams” having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 that are produced by: 1) conventional pitch foaming processes or; 2) the controlled beating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. According to a specifically preferred embodiment, the starting material coal has a free swell index as determined by ASTM test D720 of between about 3.5 and about 5.0.
    Type: Grant
    Filed: August 29, 2001
    Date of Patent: February 1, 2005
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Brian E. Joseph, Darren Kenneth Rogers
  • Publication number: 20040258605
    Abstract: Carbonaceous, composite tooling fabricated from pitch-based or coal-based cellular or porous products, “carbonaceous foams” having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 that are produced by: 1) conventional pitch foaming processes or; 2) the controlled heating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. According to a specifically preferred embodiment, the starting material coal has a free swell index as determined by ASTM test D720 of between about 3.5 and about 5.0.
    Type: Application
    Filed: July 22, 2004
    Publication date: December 23, 2004
    Inventors: Brian E. Joseph, Darren Kenneth Rogers
  • Patent number: 6833011
    Abstract: An ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the “dirty” and friable particulate activated carbon foam materials of the prior art.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: December 21, 2004
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 6833012
    Abstract: Petroleum or coal tar pitch-based cellular or porous products having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 are produced by the controlled heating of mesophase carbon materials derived from coal tar or petroleum pitch having a softening point in excess of about 300° C. and preferably between about 300 and about 400° C. in a “mold” and under a non-oxidizing atmosphere. The porous product thereby produced, preferably as a net shape or near net shape, can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: December 21, 2004
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventor: Darren Kenneth Rogers
  • Publication number: 20040247850
    Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.
    Type: Application
    Filed: March 29, 2004
    Publication date: December 9, 2004
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Patent number: 6814765
    Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc.
    Type: Grant
    Filed: January 14, 2002
    Date of Patent: November 9, 2004
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventor: Darren Kenneth Rogers
  • Publication number: 20040180187
    Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell Index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, beat or electrical insulator etc.
    Type: Application
    Filed: March 29, 2004
    Publication date: September 16, 2004
    Inventor: Darren Kenneth Rogers
  • Publication number: 20040177550
    Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.
    Type: Application
    Filed: March 29, 2004
    Publication date: September 16, 2004
    Inventors: Darren Kenneth Rogers, Janusz Wladyslaw Plucinski
  • Publication number: 20040177549
    Abstract: According to the present invention there is provided a porous coal-based material having a density of between about 0.1 g/cm3 and about 0.6 g/cm3 that is produced by the controlled heating of small coal particulate in a “mold” and under a non-oxidizing atmosphere. The coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 4.0 and about 4.5. The porous product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc. Such porous products, without further treatment exhibit compressive strengths of up to about 6000 psi. Further treatment by carbonization or graphitization yields products that can be used as electrical or heat conductors. Methods for the production of these coal-based cellular products are also described.
    Type: Application
    Filed: March 29, 2004
    Publication date: September 16, 2004
    Inventor: Darren Kenneth Rogers
  • Publication number: 20040177548
    Abstract: Petroleum or coal tar pitch-based cellular or porous products having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 are produced by the controlled heating of mesophase carbon materials derived from coal tar or petroleum pitch having a softening point in excess of about 300° C. and preferably between about 300 and about 400° C. in a “mold” and under a non-oxidizing atmosphere. The porous product thereby produced, preferably as a net shape or near net shape, can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products.
    Type: Application
    Filed: March 29, 2004
    Publication date: September 16, 2004
    Inventor: Darren Kenneth Rogers