Patents by Inventor Douglas A. Weirauch, Jr.

Douglas A. Weirauch, Jr. 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: 9771659
    Abstract: A system is provided including an electrolysis cell configured to retain a molten electrolyte bath, the bath including at least one bath component, the electrolysis cell including: a bottom, and a sidewall consisting essentially of the at least one bath component; and a feeder system, configured to provide a feed material including the least one bath component to the molten electrolyte bath such that the at least one bath component is within 2% of saturation, wherein, via the feed material, the sidewall is stable in the molten electrolyte bath.
    Type: Grant
    Filed: March 12, 2014
    Date of Patent: September 26, 2017
    Assignee: Alcoa USA Corp.
    Inventors: Xinghua Liu, Douglas A. Weirauch, Jr., Frankie E. Phelps, Joseph M. Dynys, Jonell Kerkhoff, Robert A. DiMilia
  • Publication number: 20150075975
    Abstract: Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB2) and metal additives, The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity, The electrodes may be durable and used in aluminum electrolysis cells.
    Type: Application
    Filed: November 21, 2014
    Publication date: March 19, 2015
    Inventors: Douglas A. Weirauch, JR., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
  • Publication number: 20140262807
    Abstract: A system is provided including an electrolysis cell configured to retain a molten electrolyte bath, the bath including at least one bath component, the electrolysis cell including: a bottom, and a sidewall consisting essentially of the at least one bath component; and a feeder system, configured to provide a feed material including the least one bath component to the molten electrolyte bath such that the at least one bath component is within 2% of saturation, wherein, via the feed material, the sidewall is stable in the molten electrolyte bath.
    Type: Application
    Filed: March 12, 2014
    Publication date: September 18, 2014
    Inventors: Xinghua Liu, Douglas A. Weirauch, JR., Frankie E. Phelps, Joseph M. Dynys, Jonell Kerkhoff, Robert A. DiMilia
  • Publication number: 20120222964
    Abstract: Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB2) and metal additives. The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity. The electrodes may be durable and used in aluminum electrolysis cells.
    Type: Application
    Filed: May 15, 2012
    Publication date: September 6, 2012
    Applicant: ALCOA INC.
    Inventors: Douglas A. Weirauch, JR., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
  • Patent number: 8211278
    Abstract: Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB2) and metal additives. The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity. The electrodes may be durable and used in aluminum electrolysis cells.
    Type: Grant
    Filed: July 28, 2010
    Date of Patent: July 3, 2012
    Assignee: Alcoa Inc.
    Inventors: Douglas A. Weirauch, Jr., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
  • Publication number: 20110024304
    Abstract: Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB2) and metal additives. The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity. The electrodes may be durable and used in aluminum electrolysis cells.
    Type: Application
    Filed: July 28, 2010
    Publication date: February 3, 2011
    Applicant: Alcoa Inc.
    Inventors: Douglas A. Weirauch, JR., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
  • Patent number: 7507322
    Abstract: Stable anodes comprising iron oxide useful for the electrolytic production of metal such as aluminum are disclosed. The iron oxide may comprise Fe3O4, Fe2O3, FeO or a combination thereof. During the electrolytic aluminum production process, the anodes remain stable at a controlled bath temperature of the aluminum production cell and current density through the anodes is controlled. The iron oxide-containing anodes may be used to produce commercial purity aluminum.
    Type: Grant
    Filed: June 23, 2006
    Date of Patent: March 24, 2009
    Assignee: Alcoa Inc.
    Inventors: Robert DiMilia, Xinghua Liu, Douglas Weirauch, Jr.
  • Patent number: 7235161
    Abstract: Stable anodes comprising iron oxide useful for the electrolytic production of metal such as aluminum are disclosed. The iron oxide may comprise Fe3O4, Fe2O3, FeO or a combination thereof. During the electrolytic aluminum production process, the anodes remain stable at a controlled bath temperature of the aluminum production cell and current density through the anodes is controlled. The iron oxide-containing anodes may be used to produce commercial purity aluminum.
    Type: Grant
    Filed: November 19, 2003
    Date of Patent: June 26, 2007
    Assignee: Alcoa Inc.
    Inventors: Robert A. DiMilia, Xinghua Liu, Douglas A. Weirauch, Jr.
  • Patent number: 7033469
    Abstract: Ceramic inert anodes useful for the electrolytic production of aluminum are disclosed. The inert anodes comprise oxides of Ni, Fe and Al. The Ni—Fe—Al oxide inert anode materials have sufficient electrical conductivity at operation temperatures of aluminum production cells, and also possess good mechanical stability. The Ni—Fe—Al oxide inert anodes may be used to produce commercial purity aluminum.
    Type: Grant
    Filed: November 8, 2002
    Date of Patent: April 25, 2006
    Assignee: Alcoa Inc.
    Inventors: Douglas A. Weirauch, Jr., Joseph M. Dynys, Robert A. DiMilia, Siba P. Ray, Xinghua Liu, Frankie E. Phelps
  • Patent number: 6821312
    Abstract: A method of making cermet inert anodes for the electrolytic production of metals such as aluminum is disclosed. The method includes the step of spray drying a slurry comprising ceramic phase particles and metal phase particles. The resultant spray dried powder, which comprises agglomerates of both the ceramic phase and metal phase particles, may then be consolidated by techniques such as pressing and sintering to produce a cermet inert anode material. The ceramic phase may comprise oxides of Ni, Fe and at least one additional metal selected from Zn, Co, Al, Li, Cu, Ti, V, Cr, Zr, Nb, Ta, W, Mo, Hf and rare earths. The metal phase may comprise Cu, Ag, Pd, Pt, Au, Rh, Ru, Ir and/or Os. The consolidated cermet inert anode material exhibits improved properties such as reduced porosity. The cermet inert anodes may be used in electrolytic reduction cells for the production of commercial purity aluminum as well as other metals.
    Type: Grant
    Filed: April 1, 2002
    Date of Patent: November 23, 2004
    Assignee: Alcoa Inc.
    Inventors: Siba P. Ray, Xinghua Liu, Frankie E. Phelps, Joseph M. Dynys, Douglas A. Weirauch, Jr.
  • Patent number: 6758991
    Abstract: Ceramic inert anodes useful for the electrolytic production of aluminum are disclosed. The inert anodes comprise an oxide of Ni and Fe having a controlled Ni/(Ni+Fe) mole ratio which results in a single-phase structure at the operation temperatures of aluminum production cells. The Ni and Fe oxide material may also have a single-phase structure at the sintering temperature of the material. The single-phase inert anode materials maintain sufficient electrical conductivity at the operating temperatures of the cell, and also possess good mechanical stability.
    Type: Grant
    Filed: November 8, 2002
    Date of Patent: July 6, 2004
    Assignee: Alcoa Inc.
    Inventors: Robert A. DiMilia, Joseph M. Dynys, Douglas A. Weirauch, Jr., Siba P. Ray, Xinghua Liu, Frankie E. Phelps
  • Patent number: 6423195
    Abstract: An inert anode for the electrolytic production of metals such as aluminum is disclosed. The inert anode includes a ceramic oxide material preferably made from NiO, Fe2O3 and ZnO. The inert anode composition may comprise the following mole fractions of NiO, Fe2O3 and ZnO: 0.2 to 0.99 NiO; 0.0001 to 0.8 Fe2O3; and 0.0001 to 0.3 ZnO. The inert anode may optionally include other oxides and/or at least one metal phase, such as Cu, Ag, Pd, Pt, Au, Rh, Ru, Ir and/or Os. The Ni—Fe—Co—O ceramic material exhibits very low solubility in Hall cell baths used to produce aluminum.
    Type: Grant
    Filed: April 4, 2000
    Date of Patent: July 23, 2002
    Assignee: Alcoa Inc.
    Inventors: Siba P. Ray, Douglas A. Weirauch, Jr., Xinghua Liu
  • Patent number: 6372119
    Abstract: An inert anode for the electrolytic production of metals such as aluminum is disclosed. The inert anode includes a ceramic oxide material preferably made from NiO, Fe2O3 and CoO. The inert anode composition may comprise the following mole fractions of NiO, Fe2O3 and CoO: 0.15 to 0.99 NiO; 0.0001 to 0.85 Fe2O3; and 0.0001 to 0.45 CoO. The inert anode may optionally include other oxides and/or at least one metal phase, such as Cu, Ag, Pd, Pt, Au, Rh, Ru, Ir and/or Os. The Ni—Fe—Co—O ceramic material exhibits very low solubility in Hall cell baths used to produce aluminum.
    Type: Grant
    Filed: April 4, 2000
    Date of Patent: April 16, 2002
    Assignee: Alcoa Inc.
    Inventors: Siba P. Ray, Xinghua Liu, Douglas A. Weirauch, Jr.
  • Patent number: 6217739
    Abstract: A method of producing commercial purity aluminum in an electrolytic reduction cell comprising inert anodes is disclosed. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The inert anodes used in the process preferably comprise a cermet material comprising ceramic oxide phase portions and metal phase portions.
    Type: Grant
    Filed: November 1, 1999
    Date of Patent: April 17, 2001
    Assignee: Alcoa Inc.
    Inventors: Siba P. Ray, Xinghua Liu, Douglas A. Weirauch, Jr.
  • Patent number: 5219800
    Abstract: A process for increasing the colorizing effect of known colorizing oxides in an alumina body. The process includes the steps of (a) forming a glass frit containing colorants; (b) mixing the frit and alumina to form a green mixture; and (c) firing the mixture to form a fired ceramic body.
    Type: Grant
    Filed: July 18, 1991
    Date of Patent: June 15, 1993
    Assignee: Aluminum Company of America
    Inventors: John F. Kelso, Karen L. Bowersox, G. Edward Graddy, Jr., Douglas A. Weirauch, Jr.
  • Patent number: 4628038
    Abstract: A water resistant, devitrification resistant glass fiber consisting essentially of SiO.sub.2, Al.sub.2 O.sub.3, CaO, MgO, B.sub.2 O.sub.3, Na.sub.2 O, and F.sub.2 and/or Fe.sub.2 O.sub.3 and/or TiO.sub.2 and/or K.sub.2 O and/or SO.sub.3 in trace amounts, said glass fiber having a delta T of at least about 365.degree. F. and a durability (% fiber weight loss at 96.degree. C.) in water for 24 hours of less than about 0.9%.
    Type: Grant
    Filed: June 27, 1985
    Date of Patent: December 9, 1986
    Assignee: Owens-Corning Fiberglas Corporation
    Inventor: Douglas A. Weirauch, Jr.