Patents by Inventor Felix L. Paulauskas
Felix L. Paulauskas 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).
-
Publication number: 20240076808Abstract: An apparatus and method for the low temperature carbonization of a continuous tow of polymeric material fiber, such as PAN or other carbon fiber precursor materials at atmospheric pressure in an inert gas (usually nitrogen or argon) is disclosed. A pair of antennas are arranged within an electromagnetic cavity and face each other in an edgewise fashion for direct electromagnetic heating of the fiber tow as it passes between them. Supplemental background heating increases the dielectric loss of the fiber tow in order to improve absorption of electromagnetic energy and prevent arcing. The invention produces a higher density low temperature carbonized fiber in a shorter residence time compared to conventional low temperature carbonization.Type: ApplicationFiled: September 3, 2022Publication date: March 7, 2024Inventors: William W. Wallace, Hippolyte A. Grappe, Felix L. Paulauskas, H. Felix Wu, Truman Bonds
-
Publication number: 20240076807Abstract: An apparatus is disclosed for electromagnetically and thermally treating polymeric materials, including PAN and other carbon fiber precursors at large scale at atmospheric pressure, while measuring the temperature in the closed environment of the process chamber. The apparatus is designed for continuous processing, and to be compatible with other stages of existing carbon fiber production lines. It provides direct electromagnetic coupling to the fiber tow(s) in the near-field region of one or more microwave waveguide launchers and also provides direct radiative or IR heating from susceptor plates located on the opposite side of the tow from the waveguide opening for processing a band of multiple tows of fiber. It produces low-temperature-carbonized (LTC) fiber with shorter residence time and higher density compared to the conventional process. Its design is inherently scalable to larger production. A related method is also disclosed.Type: ApplicationFiled: September 3, 2022Publication date: March 7, 2024Inventors: Hippolyte A. Grappe, William W. Wallace, Felix L. Paulauskas, H. Felix Wu, Joshua T. Brady
-
Patent number: 10207427Abstract: A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.Type: GrantFiled: October 13, 2017Date of Patent: February 19, 2019Assignee: UT-Battelle, LLCInventors: Soydan Ozcan, Felix L. Paulauskas
-
Patent number: 10138305Abstract: A plasma treatment method that includes providing treatment chamber including an intermediate heating volume and an interior treatment volume. The interior treatment volume contains an electrode assembly for generating a plasma and the intermediate heating volume heats the interior treatment volume. A work piece is traversed through the treatment chamber. A process gas is introduced to the interior treatment volume of the treatment chamber. A plasma is formed with the electrode assembly from the process gas, wherein a reactive species of the plasma is accelerated towards the fiber tow by flow vortices produced in the interior treatment volume by the electrode assembly.Type: GrantFiled: August 17, 2016Date of Patent: November 27, 2018Assignees: UT-Battelle, LLC, REMAXCO TECHNOLOGIESInventors: Felix L. Paulauskas, Truman Bonds
-
Publication number: 20180071958Abstract: A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.Type: ApplicationFiled: October 13, 2017Publication date: March 15, 2018Inventors: Soydan Ozcan, Felix L. Paulauskas
-
Patent number: 9815224Abstract: A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.Type: GrantFiled: March 30, 2015Date of Patent: November 14, 2017Assignee: UT-Battelle, LLCInventors: Soydan Ozcan, Felix L. Paulauskas
-
Publication number: 20160355614Abstract: A plasma treatment method that includes providing treatment chamber including an intermediate heating volume and an interior treatment volume. The interior treatment volume contains an electrode assembly for generating a plasma and the intermediate heating volume heats the interior treatment volume. A work piece is traversed through the treatment chamber. A process gas is introduced to the interior treatment volume of the treatment chamber. A plasma is formed with the electrode assembly from the process gas, wherein a reactive species of the plasma is accelerated towards the fiber tow by flow vortices produced in the interior treatment volume by the electrode assembly.Type: ApplicationFiled: August 17, 2016Publication date: December 8, 2016Applicants: UT-Battelle, LLC, REMAXCO TECHNOLOGIESInventors: Felix L. Paulauskas, Truman Bonds
-
Publication number: 20160288371Abstract: A method of processing a carbon fiber tow includes the steps of providing a carbon fiber tow made of a plurality of carbon filaments, depositing a sizing composition at spaced-apart sizing sites along a length of the tow, leaving unsized interstitial regions of the tow, and cross-cutting the tow into a plurality of segments. Each segment includes at least a portion of one of the sizing sites and at least a portion of at least one of the unsized regions of the tow, the unsized region including and end portion of the segment.Type: ApplicationFiled: March 30, 2015Publication date: October 6, 2016Inventors: Soydan Ozcan, Felix L. Paulauskas
-
Patent number: 9447205Abstract: A plasma treatment method that includes providing treatment chamber including an intermediate heating volume and an interior treatment volume. The interior treatment volume contains an electrode assembly for generating a plasma and the intermediate heating volume heats the interior treatment volume. A work piece is traversed through the treatment chamber. A process gas is introduced to the interior treatment volume of the treatment chamber. A plasma is formed with the electrode assembly from the process gas, wherein a reactive species of the plasma is accelerated towards the fiber tow by flow vortices produced in the interior treatment volume by the electrode assembly.Type: GrantFiled: November 19, 2012Date of Patent: September 20, 2016Assignees: UT-BATTELLE, LLC, REMAXCO TECHNOLOGIESInventors: Felix L. Paulauskas, Truman Bonds
-
Patent number: 9427720Abstract: A method for continuously processing carbon fiber including establishing a microwave plasma in a selected atmosphere contained in an elongated chamber having a microwave power gradient along its length defined by a lower microwave power at one end and a higher microwave power at the opposite end of the elongated chamber. The elongated chamber having an opening in each of the ends of the chamber that are adapted to allow the passage of the fiber tow while limiting incidental gas flow into or out of said chamber. A continuous fiber tow is introduced into the end of the chamber having the lower microwave power. The fiber tow is withdrawn from the opposite end of the chamber having the higher microwave power. The fiber to is subjected to progressively higher microwave energy as the fiber is being traversed through the elongated chamber.Type: GrantFiled: March 24, 2014Date of Patent: August 30, 2016Assignee: UT-BATELLE, LLCInventors: Terry L. White, Felix L. Paulauskas, Timothy S. Bigelow
-
Publication number: 20140225051Abstract: Disclosed herein is a flame retardant composition comprising sulfonated polyolefin and a SO2-scavenging material and/or a flame retardant material that is not a sulfonated polyolefin. Also disclosed is a flame-resistant composite comprising a host material in which is incorporated sulfonated polyolefin as a flame retardant composition. Further disclosed are methods for producing the flame retardant composition and flame-resistant composites.Type: ApplicationFiled: February 7, 2014Publication date: August 14, 2014Applicant: UT-Battelle, LLCInventors: Amit K. Naskar, Felix L. Paulauskas, Charles David Warren, Christopher J. Janke
-
Publication number: 20140205511Abstract: A method for continuously processing carbon fiber including establishing a microwave plasma in a selected atmosphere contained in an elongated chamber having a microwave power gradient along its length defined by a lower microwave power at one end and a higher microwave power at the opposite end of the elongated chamber. The elongated chamber having an opening in each of the ends of the chamber that are adapted to allow the passage of the fiber tow while limiting incidental gas flow into or out of said chamber. A continuous fiber tow is introduced into the end of the chamber having the lower microwave power. The fiber tow is withdrawn from the opposite end of the chamber having the higher microwave power. The fiber to is subjected to progressively higher microwave energy as the fiber is being traversed through the elongated chamber.Type: ApplicationFiled: March 24, 2014Publication date: July 24, 2014Applicant: UT-Battelle, LLCInventors: Terry L. White, Felix L. Paulauskas, Timothy S. Bigelow
-
Patent number: 8741395Abstract: An apparatus and method for enhancing the surface energy and/or surface chemistry of carbon fibers involves exposing the fibers to direct or indirect contact with atmospheric pressure plasma generated using a background gas containing at least some oxygen or other reactive species. The fiber may be exposed directly to the plasma, provided that the plasma is nonfilamentary, or the fiber may be exposed indirectly through contact with gases exhausting from a plasma discharge maintained in a separate volume. In either case, the process is carried out at or near atmospheric pressure, thereby eliminating the need for vacuum equipment. The process may be further modified by moistening the fibers with selected oxygen-containing liquids before exposure to the plasma.Type: GrantFiled: July 23, 2012Date of Patent: June 3, 2014Assignees: UT-Battelle, LLC, Remaxco Technologies, LLCInventors: Felix L. Paulauskas, Daniel M. Sherman
-
Publication number: 20140142255Abstract: A plasma treatment method that includes providing treatment chamber including an intermediate heating volume and an interior treatment volume. The interior treatment volume contains an electrode assembly for generating a plasma and the intermediate heating volume heats the interior treatment volume. A work piece is traversed through the treatment chamber. A process gas is introduced to the interior treatment volume of the treatment chamber. A plasma is formed with the electrode assembly from the process gas, wherein a reactive species of the plasma is accelerated towards the fiber tow by flow vortices produced in the interior treatment volume by the electrode assembly.Type: ApplicationFiled: November 19, 2012Publication date: May 22, 2014Applicant: UT-BATTELLE, LLCInventors: Felix L. Paulauskas, Truman Bonds
-
Patent number: 8679592Abstract: A method for continuously processing carbon fiber including establishing a microwave plasma in a selected atmosphere contained in an elongated chamber having a microwave power gradient along its length defined by a lower microwave power at one end and a higher microwave power at the opposite end of the elongated chamber. The elongated chamber having an opening in each of the ends of the chamber that are adapted to allow the passage of the fiber tow while limiting incidental gas flow into or out of said chamber. A continuous fiber tow is introduced into the end of the chamber having the lower microwave power. The fiber tow is withdrawn from the opposite end of the chamber having the higher microwave power. The fiber to is subjected to progressively higher microwave energy as the fiber is being traversed through the elongated chamber.Type: GrantFiled: October 4, 2010Date of Patent: March 25, 2014Assignee: UT-Battelle, LLCInventors: Terry L. White, Felix L. Paulauskas, Timothy S. Bigelow
-
Publication number: 20130048485Abstract: An apparatus and method for enhancing the surface energy and/or surface chemistry of carbon fibers involves exposing the fibers to direct or indirect contact with atmospheric pressure plasma generated using a background gas containing at least some oxygen or other reactive species. The fiber may be exposed directly to the plasma, provided that the plasma is nonfilamentary, or the fiber may be exposed indirectly through contact with gases exhausting from a plasma discharge maintained in a separate volume. In either case, the process is carried out at or near atmospheric pressure, thereby eliminating the need for vacuum equipment. The process may be further modified by moistening the fibers with selected oxygen-containing liquids before exposure to the plasma.Type: ApplicationFiled: July 23, 2012Publication date: February 28, 2013Applicant: UT-BATTELLE, LLCInventors: Felix L. Paulauskas, Daniel M. Sherman
-
Patent number: 8227051Abstract: An apparatus and method for enhancing the surface energy and/or surface chemistry of carbon fibers involves exposing the fibers to direct or indirect contact with atmospheric pressure plasma generated using a background gas containing at least some oxygen or other reactive species. The fiber may be exposed directly to the plasma, provided that the plasma is nonfilamentary, or the fiber may be exposed indirectly through contact with gases exhausting from a plasma discharge maintained in a separate volume. In either case, the process is carried out at or near atmospheric pressure, thereby eliminating the need for vacuum equipment. The process may be further modified by moistening the fibers with selected oxygen-containing liquids before exposure to the plasma.Type: GrantFiled: June 22, 2005Date of Patent: July 24, 2012Assignee: UT-Battle, LLCInventors: Felix L. Paulauskas, Daniel M. Sherman
-
Publication number: 20110079505Abstract: A method for continuously processing carbon fiber including establishing a microwave plasma in a selected atmosphere contained in an elongated chamber having a microwave power gradient along its length defined by a lower microwave power at one end and a higher microwave power at the opposite end of the elongated chamber. The elongated chamber having an opening in each of the ends of the chamber that are adapted to allow the passage of the fiber tow while limiting incidental gas flow into or out of said chamber. A continuous fiber tow is introduced into the end of the chamber having the lower microwave power. The fiber tow is withdrawn from the opposite end of the chamber having the higher microwave power. The fiber to is subjected to progressively higher microwave energy as the fiber is being traversed through the elongated chamber.Type: ApplicationFiled: October 4, 2010Publication date: April 7, 2011Applicant: UT-BATTELLE,LLCInventors: Terry L. White, Felix L. Paulauskas, Timothy S. Bigelow
-
Patent number: 7824495Abstract: A system to continuously produce fully carbonized or graphitized carbon fibers using microwave-assisted plasma (MAP) processing comprises an elongated chamber in which a microwave plasma is excited in a selected gas atmosphere. Fiber is drawn continuously through the chamber, entering and exiting through openings designed to minimize in-leakage of air. There is a gradient of microwave power within the chamber with generally higher power near where the fiber exits and lower power near where the fiber enters. Polyacrylonitrile (PAN), pitch, or any other suitable organic/polymeric precursor fibers can be used as a feedstock for the inventive system. Oxidized or partially oxidized PAN or pitch or other polymeric fiber precursors are run continuously through a MAP reactor in an inert, non-oxidizing atmosphere to heat the fibers, drive off the unwanted elements such as oxygen, nitrogen, and hydrogen, and produce carbon or graphite fibers faster than conventionally produced carbon fibers.Type: GrantFiled: November 9, 2005Date of Patent: November 2, 2010Assignee: UT-Battelle, LLCInventors: Terry L. White, Felix L. Paulauskas, Timothy S. Bigelow
-
Patent number: 7786253Abstract: An apparatus for treating polymeric materials comprises a treatment chamber adapted to maintain a selected atmosphere; a means for supporting the polymeric material within the chamber; and, a source of plasma-derived gas containing at least one reactive oxidative species whereby the polymer is stabilized and cross linked through exposure to the oxidative species in the chamber at a selected temperature. The polymer may be directly exposed to the plasma, or alternatively, the plasma may be established in a separate volume from which the reactive species may be extracted and introduced into the vicinity of the polymer. The apparatus may be configured for either batch-type or continuous-type processing. The apparatus and method are especially useful for preparing polymer fibers, particularly PAN fibers, for later carbonization treatments.Type: GrantFiled: May 14, 2009Date of Patent: August 31, 2010Assignees: Ut-Battelle, LLC, Sentech, Inc.Inventors: Felix L. Paulauskas, Terry L. White, Daniel M. Sherman