Patents by Inventor John L. Schneiter
John L. Schneiter 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: 11761085Abstract: A composite tape and method of fabrication are provided which includes multiple layers and a laser-driven chemical vapor deposition (LCVD)-formed additive material in at least one layer of the multiple layers to enhance one or more properties of the composite tape. The LCVD-formed additive material is a single crystalline material and can include LCVD-formed granular material and/or LCVD-formed fiber material in the same or different layers of the composite tape to enhance, for instance, fracture strength and/or wear resistance of the composite tape.Type: GrantFiled: August 23, 2021Date of Patent: September 19, 2023Assignee: FREE FORM FIBERS, LLCInventors: John L. Schneiter, John Novalis, Shay L. Harrison
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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: 20220064798Abstract: A composite tape and method of fabrication are provided which includes multiple layers and a laser-driven chemical vapor deposition (LCVD)-formed additive material in at least one layer of the multiple layers to enhance one or more properties of the composite tape. The LCVD-formed additive material is a single crystalline material and can include LCVD-formed granular material and/or LCVD-formed fiber material in the same or different layers of the composite tape to enhance, for instance, fracture strength and/or wear resistance of the composite tape.Type: ApplicationFiled: August 23, 2021Publication date: March 3, 2022Applicant: FREE FORM FIBERS, LLCInventors: John L. SCHNEITER, John NOVALIS, Shay L. HARRISON
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Publication number: 20210253434Abstract: A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers.Type: ApplicationFiled: November 2, 2020Publication date: August 19, 2021Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, John L. SCHNEITER, Kirk L. WILLIAMS, Ramkiran GODUGUCHINTA
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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: 10882749Abstract: A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers.Type: GrantFiled: August 13, 2018Date of Patent: January 5, 2021Assignee: FREE FORM FIBERS, LLCInventors: Joseph Pegna, John L. Schneiter, Kirk L. Williams, Ramkiran Goduguchinta
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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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Patent number: 10822240Abstract: A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers.Type: GrantFiled: August 13, 2018Date of Patent: November 3, 2020Assignee: FREE FORM FIBERS, LLCInventors: Joseph Pegna, John L. Schneiter, Kirk L. Williams, Ramkiran Goduguchinta
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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: 20190062222Abstract: A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers.Type: ApplicationFiled: August 13, 2018Publication date: February 28, 2019Applicant: FREE FORM FIBERS, LLCInventors: Joseph PEGNA, John L. SCHNEITER, Kirk L. WILLIAMS, Ramkiran GODUGUCHINTA
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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: 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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Patent number: 10047015Abstract: A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers.Type: GrantFiled: January 18, 2013Date of Patent: August 14, 2018Assignee: FREE FORM FIBERS, LLCInventors: Joseph Pegna, John L. Schneiter, Kirk L. Williams, Ramkiran Goduguchinta