Patents by Inventor Erik G Vaaler
Erik G Vaaler 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: 11788213Abstract: A method of making a multi-composition fiber is provided, which includes providing a precursor laden environment, and forming a fiber in the precursor laden environment using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material. The formed fiber includes a primary fiber material and an elemental additive material, where the elemental additive material has too large an atom size to fit within a single crystalline domain within a crystalline structure of the fiber, and is deposited on grain boundaries between adjacent crystalline domains of the primary fiber material to present an energy barrier to atomic diffusion through the grain boundaries, and to increase creep resistance by slowing down growth between the adjacent crystalline domains of the primary fiber material.Type: GrantFiled: December 23, 2020Date of Patent: October 17, 2023Assignee: FREE FORM FIBERS, LLCInventors: Shay L. Harrison, Joseph Pegna, Erik G. Vaaler, Ram K. Goduguchinta, Kirk L. Williams, John L. Schneiter
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Patent number: 11518719Abstract: Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.Type: GrantFiled: January 27, 2020Date of Patent: December 6, 2022Assignee: Free Form Fibers, LLCInventors: Joseph Pegna, Erik G. Vaaler, Shay L. Harrison, John L. Schneiter, Kirk L. Williams, Ram K. Goduguchinta
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Patent number: 11362256Abstract: A method is provided for growing a fiber structure, where the method includes: obtaining a substrate, growing an array of pedestal fibers on the substrate, growing fibers on the pedestal fibers, and depositing a coating surrounding each of the fibers. In another aspect, a method of fabricating a fiber structure includes obtaining a substrate and growing a plurality of fibers on the substrate according to 1½D printing. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted methods.Type: GrantFiled: June 27, 2018Date of Patent: June 14, 2022Assignee: FREE FORM FIBERS, LLCInventors: Joseph Pegna, Ram K. Goduguchinta, Kirk L. Williams, John L. Schneiter, Shay L. Harrison, Erik G. Vaaler
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Publication number: 20220144711Abstract: A method of forming a high purity ingot for wafer production, such as a silicon carbidewafer. Precursors are added to a reactor; at least part of a fiber is formed in the reactor from the precursors using chemical deposition interacting with the precursors; and granular material is then formed from the fiber. The method further includes forming the ingot from the granular material. In one aspect, the chemical deposition can include laser induced chemical vapor deposition. Further, the method can include separating one or more wafers from the ingot for use in semiconductor fabrication.Type: ApplicationFiled: January 21, 2022Publication date: May 12, 2022Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, John L. SCHNEITER, Joseph PEGNA, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS, Erik G. VAALER
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Publication number: 20210230743Abstract: A method of forming a high purity granular material, such as silicon carbide powder. Precursors are added to a reactor; at least part of a fiber is formed in the reactor from the precursors using chemical deposition interacting with said precursors; and the granular material is then formed from the fiber. In one aspect, the chemical deposition may include laser induced chemical vapor deposition. The granular material may be formed by grinding or milling the fiber into the granular material, e.g., ball milling the fiber. In one example, silicon carbide powder having greater than 90% beta crystalline phase purity and less than 0.25% oxygen contamination can be obtained.Type: ApplicationFiled: January 25, 2021Publication date: July 29, 2021Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, John L. SCHNEITER, Joseph PEGNA, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS, Erik G. VAALER
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Publication number: 20210222332Abstract: A multi-composition fiber is provided including a primary fiber material and an elemental additive material deposited on grain boundaries between adjacent crystalline domains of the primary fiber material. A method of making a multi-composition fiber is also provided, which includes providing a precursor laden environment, and promoting fiber growth using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material.Type: ApplicationFiled: December 23, 2020Publication date: July 22, 2021Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, Joseph PEGNA, Erik G. VAALER, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS, John L. SCHNEITER
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Publication number: 20210087726Abstract: A non-woven fabric is provided which includes a three-dimensional array of fibers. The three-dimensional array of fibers includes an array of standing fibers extending perpendicular to a plane of the non-woven fabric and attached to a base substrate, where the base substrate is one or more of an expendable film substrate, a metal base substrate, or a mandrel substrate. Further, the three-dimensional array of fibers includes multiple layers of non-woven parallel fibers running parallel to the plane of the non-woven fiber in between the array of standing fibers in a defined pattern of fiber layer orientations. In implementation, the array of standing fibers are grown to extend from the base substrate using laser-assisted chemical vapor deposition (LCVD).Type: ApplicationFiled: July 24, 2020Publication date: March 25, 2021Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, Shay L. HARRISON, Erik G. VAALER, John L. SCHNEITER
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Patent number: 10876227Abstract: A multi-composition fiber is provided including a primary fiber material and an elemental additive material deposited on grain boundaries between adjacent crystalline domains of the primary fiber material. A method of making a multi-composition fiber is also provided, which includes providing a precursor laden environment, and promoting fiber growth using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material.Type: GrantFiled: November 29, 2017Date of Patent: December 29, 2020Assignee: FREE FORM FIBERS, LLCInventors: Shay L. Harrison, Joseph Pegna, Erik G. Vaaler, Ram K. Goduguchinta, Kirk L. Williams, John L. Schneiter
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Publication number: 20200203028Abstract: Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.Type: ApplicationFiled: January 27, 2020Publication date: June 25, 2020Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, Erik G. VAALER, Shay L. HARRISON, John L. SCHNEITER, Kirk L. WILLIAMS, Ram K. GODUGUCHINTA
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Patent number: 10676391Abstract: Composite materials are provided which include a glass-ceramic matrix composition that is lightly crystallized, a fiber reinforcement within the glass-ceramic matrix composition which remains stable at temperatures greater than 1400° C., and an interphase coating formed on the fiber reinforcement. A method of making a composite material is also provided, which includes applying heat and pressure to a shape including fiber reinforcements and glass particles. The heat and pressure lightly crystallize a matrix material formed by the heat and pressure on the glass particles, forming a thermally stable composite material.Type: GrantFiled: June 19, 2018Date of Patent: June 9, 2020Assignee: FREE FORM FIBERS, LLCInventors: Shay L. Harrison, Joseph Pegna, John L. Schneiter, Erik G. Vaaler, Marvin Keshner
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Patent number: 10546661Abstract: Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.Type: GrantFiled: June 23, 2015Date of Patent: January 28, 2020Assignee: FREE FORM FIBERS, LLCInventors: Joseph Pegna, Erik G. Vaaler, Shay L. Harrison, John L. Schneiter, Kirk L. Williams, Ram K. Goduguchinta
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Publication number: 20180370846Abstract: Composite materials are provided which include a glass-ceramic matrix composition that is lightly crystallized, a fiber reinforcement within the glass-ceramic matrix composition which remains stable at temperatures greater than 1400° C., and an interphase coating formed on the fiber reinforcement. A method of making a composite material is also provided, which includes applying heat and pressure to a shape including fiber reinforcements and glass particles. The heat and pressure lightly crystallize a matrix material formed by the heat and pressure on the glass particles, forming a thermally stable composite material.Type: ApplicationFiled: June 19, 2018Publication date: December 27, 2018Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, Joseph PEGNA, John L. SCHNEITER, Erik G. VAALER, Marvin KESHNER
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Publication number: 20180370860Abstract: A method is provided for growing a fiber structure, where the method includes: obtaining a substrate, growing an array of pedestal fibers on the substrate, growing fibers on the pedestal fibers, and depositing a coating surrounding each of the fibers. In another aspect, a method of fabricating a fiber structure includes obtaining a substrate and growing a plurality of fibers on the substrate according to 1½D printing. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted methods.Type: ApplicationFiled: June 27, 2018Publication date: December 27, 2018Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS, John L. SCHNEITER, Shay L. HARRISON, Erik G. VAALER
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Publication number: 20180148864Abstract: A multi-composition fiber is provided including a primary fiber material and an elemental additive material deposited on grain boundaries between adjacent crystalline domains of the primary fiber material. A method of making a multi-composition fiber is also provided, which includes providing a precursor laden environment, and promoting fiber growth using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material.Type: ApplicationFiled: November 29, 2017Publication date: May 31, 2018Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, Joseph PEGNA, Erik G. VAALER, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS, John L. SCHNEITER
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Publication number: 20180087214Abstract: A refractory oxide coated fiber is provided including a primary fiber material and a refractory oxide coating over the primary fiber material. Further, a method of making a refractory oxide coated fiber is provided, which includes: providing a first precursor-laden environment, the first precursor-laden environment including a primary precursor; promoting fiber growth within the first precursor-laden environment using laser heating; and providing a second precursor-laden environment to promote coating of the fiber, the second precursor-laden environment comprising a refractory oxide precursor, and the coating producing a refractory oxide coating over the fiber with a hexagonal microstructure.Type: ApplicationFiled: September 28, 2017Publication date: March 29, 2018Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, Marvin KESHNER, Joseph PEGNA, Erik G. VAALER, John L. SCHNEITER, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS
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Publication number: 20180087157Abstract: Multi-composition fibers with one or more refractory additives, and methods of making the fibers, are provided. The method(s) includes providing a precursor-laden environment, and promoting fiber growth using laser heating. The precursor-laden environment includes a primary precursor material and a refractory precursor material. The multi-composition fiber may include a primary fiber material, and a refractory material substantially homogeneously intermixed with the primary fiber material.Type: ApplicationFiled: September 28, 2017Publication date: March 29, 2018Applicant: FREE FORM FIBERS, LLCInventors: Shay L. HARRISON, Joseph PEGNA, Erik G. VAALER, John L. SCHNEITER, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS
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Publication number: 20170369998Abstract: Methods are provided for making a nanofiber-coated fiber. The method(s) include: providing a base fiber; depositing a nanofreckle on the base fiber; and growing a nanofiber at the nanofreckle. In another aspect, nanofiber-coated fibers are provided, produced by the above-noted methods making a nanofiber-coated fiber.Type: ApplicationFiled: June 23, 2017Publication date: December 28, 2017Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, Erik G. VAALER, John L. SCHNEITER, Shay L. HARRISON, Ram K. GODUGUCHINTA, Kirk L. WILLIAMS
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Publication number: 20170331022Abstract: A method is provided for making a multilayer functional fiber, where the method includes: providing a scaffold fiber; disposing a first electrode layer enclosing the scaffold fiber; disposing a functional layer enclosing the first electrode layer, the functional layer having a functional characteristic varying as a function of longitudinal position along the functional layer; disposing a second electrode layer enclosing the functional layer; and disposing a cladding layer enclosing the second electrode layer. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted method.Type: ApplicationFiled: May 11, 2017Publication date: November 16, 2017Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, Erik G. VAALER, John L. SCHNEITER, Shay L. HARRISON
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Publication number: 20170213604Abstract: Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.Type: ApplicationFiled: June 23, 2015Publication date: July 27, 2017Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, Erik G. VAALER, Shay L. HARRISON, John L. SCHNEITER, Kirk L. WILLIAMS, Ram K. GODUGUCHINTA
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Publication number: 20100151680Abstract: A substrate carrier is used in an in-line fabrication such as Plasma Enhanced Chemical Vapor Deposition (PECVD) for application of thin film on substrates. The carrier is in thermal communication with the substrate and thereby provides heat sinking. The carrier further permits movement of the substrate past a deposition apparatus at a deposition station.Type: ApplicationFiled: December 17, 2008Publication date: June 17, 2010Applicant: OPTISOLAR INC.Inventors: Shulin Wang, Gautam Ganguly, Marvin Keshner, Erik G. Vaaler, James Harroun, Paul McClelland