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).
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Patent number: 9771659Abstract: 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: GrantFiled: March 12, 2014Date of Patent: September 26, 2017Assignee: Alcoa USA Corp.Inventors: Xinghua Liu, Douglas A. Weirauch, Jr., Frankie E. Phelps, Joseph M. Dynys, Jonell Kerkhoff, Robert A. DiMilia
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Publication number: 20150075975Abstract: 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: ApplicationFiled: November 21, 2014Publication date: March 19, 2015Inventors: Douglas A. Weirauch, JR., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
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Publication number: 20140262807Abstract: 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: ApplicationFiled: March 12, 2014Publication date: September 18, 2014Inventors: Xinghua Liu, Douglas A. Weirauch, JR., Frankie E. Phelps, Joseph M. Dynys, Jonell Kerkhoff, Robert A. DiMilia
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Publication number: 20120222964Abstract: 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: ApplicationFiled: May 15, 2012Publication date: September 6, 2012Applicant: ALCOA INC.Inventors: Douglas A. Weirauch, JR., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
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Patent number: 8211278Abstract: 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: GrantFiled: July 28, 2010Date of Patent: July 3, 2012Assignee: Alcoa Inc.Inventors: Douglas A. Weirauch, Jr., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
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Publication number: 20110024304Abstract: 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: ApplicationFiled: July 28, 2010Publication date: February 3, 2011Applicant: Alcoa Inc.Inventors: Douglas A. Weirauch, JR., Lance M. Sworts, Brian J. Tielsch, Robert A. DiMilia
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Patent number: 7507322Abstract: 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: GrantFiled: June 23, 2006Date of Patent: March 24, 2009Assignee: Alcoa Inc.Inventors: Robert DiMilia, Xinghua Liu, Douglas Weirauch, Jr.
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Patent number: 7235161Abstract: 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: GrantFiled: November 19, 2003Date of Patent: June 26, 2007Assignee: Alcoa Inc.Inventors: Robert A. DiMilia, Xinghua Liu, Douglas A. Weirauch, Jr.
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Patent number: 7033469Abstract: 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: GrantFiled: November 8, 2002Date of Patent: April 25, 2006Assignee: Alcoa Inc.Inventors: Douglas A. Weirauch, Jr., Joseph M. Dynys, Robert A. DiMilia, Siba P. Ray, Xinghua Liu, Frankie E. Phelps
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Patent number: 6821312Abstract: 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: GrantFiled: April 1, 2002Date of Patent: November 23, 2004Assignee: Alcoa Inc.Inventors: Siba P. Ray, Xinghua Liu, Frankie E. Phelps, Joseph M. Dynys, Douglas A. Weirauch, Jr.
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Patent number: 6758991Abstract: 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: GrantFiled: November 8, 2002Date of Patent: July 6, 2004Assignee: Alcoa Inc.Inventors: Robert A. DiMilia, Joseph M. Dynys, Douglas A. Weirauch, Jr., Siba P. Ray, Xinghua Liu, Frankie E. Phelps
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Patent number: 6423195Abstract: 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: GrantFiled: April 4, 2000Date of Patent: July 23, 2002Assignee: Alcoa Inc.Inventors: Siba P. Ray, Douglas A. Weirauch, Jr., Xinghua Liu
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Patent number: 6372119Abstract: 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: GrantFiled: April 4, 2000Date of Patent: April 16, 2002Assignee: Alcoa Inc.Inventors: Siba P. Ray, Xinghua Liu, Douglas A. Weirauch, Jr.
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Patent number: 6217739Abstract: 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: GrantFiled: November 1, 1999Date of Patent: April 17, 2001Assignee: Alcoa Inc.Inventors: Siba P. Ray, Xinghua Liu, Douglas A. Weirauch, Jr.
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Patent number: 5219800Abstract: 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: GrantFiled: July 18, 1991Date of Patent: June 15, 1993Assignee: Aluminum Company of AmericaInventors: John F. Kelso, Karen L. Bowersox, G. Edward Graddy, Jr., Douglas A. Weirauch, Jr.
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Patent number: 4628038Abstract: 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: GrantFiled: June 27, 1985Date of Patent: December 9, 1986Assignee: Owens-Corning Fiberglas CorporationInventor: Douglas A. Weirauch, Jr.