Patents by Inventor Karel Hajmrle

Karel Hajmrle 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: 8114821
    Abstract: The production of solid lubricant agglomerates by combining solid lubricant powder, an inorganic binder, other fillers if optionally desired, and a liquid to form a mixture, and driving off the liquid to form dry agglomerates which are subsequently classified by size or milled and classified by size to yield agglomerates of a desired size range. These agglomerates are then treated to stabilize the binder, thereby strengthening the binder and rendering it nondispersible in the liquid. The undesired size ranges can be readily recycled because the agglomerates with untreated binder can be reprocessed, thereby promoting high recovery rates.
    Type: Grant
    Filed: December 5, 2003
    Date of Patent: February 14, 2012
    Assignee: Zulzer Metco (Canada) Inc.
    Inventors: Karel Hajmrle, William Walkhouse
  • Patent number: 7763573
    Abstract: The production of solid lubricant agglomerates by combining solid lubricant powder, an inorganic binder, other fillers if optionally desired, and a liquid to form a mixture, and driving off the liquid to form dry agglomerates which are subsequently classified by size or milled and classified by size to yield agglomerates of a desired size range. These agglomerates are then treated to stabilize the binder, thereby strengthening the binder and rendering it nondispersible in the liquid. The treated agglomerates are then blended or clad with a metal, metal alloy or a metallic composition, to produce a composition suitable for thermal spray applications.
    Type: Grant
    Filed: June 9, 2006
    Date of Patent: July 27, 2010
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Karel Hajmrle, William Walkhouse, Petr Fiala
  • Patent number: 7582362
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Grant
    Filed: January 30, 2007
    Date of Patent: September 1, 2009
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
  • Patent number: 7291577
    Abstract: A process for the production of a supported catalyst. The process comprises heating a slurry that comprises a catalyst support and at least one active catalytic ingredient precursor. Gas is introduced to the slurry at a sufficient pressure to reduce the at least one active catalytic ingredient precursor and deposit at least one active catalytic ingredient onto a surface of the catalyst support to form the supported catalyst. The supported catalyst has a large active catalytic surface area.
    Type: Grant
    Filed: June 10, 2003
    Date of Patent: November 6, 2007
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Karel Hajmrle, Syed Hussain, Paul Albert Laplante
  • Publication number: 20070218309
    Abstract: The present invention provides a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron, and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The present invention further provides an abradable coating formed on a metal substrate according to a method comprising the step of depositing a bond coat on the metal substrate by thermal spraying of a bond coat composition comprising nickel, chromium and optionally aluminum and yttrium on the metal substrate and depositing the abradable coating on the bond coat by thermal spraying of a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire.
    Type: Application
    Filed: January 5, 2007
    Publication date: September 20, 2007
    Inventors: Karel Hajmrle, Anthony Chilkowich, Petr Fiala
  • Patent number: 7267889
    Abstract: The present invention provides a sprayable composition comprising a ceramic particulate including albite, illite, and quart, and a metallic composition, including nickel, chromium, iron, and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The present invention further provides an abradable coating formed on a metal substrate according to a method comprising the step of depositing the abradable coating on the metal substrate by thermal spraying of a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The abradable coating may be applied to a metal substrate such as steel, nickel-based alloys, and titanium.
    Type: Grant
    Filed: October 1, 2002
    Date of Patent: September 11, 2007
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Karel Hajmrle, Anthony Peter Chilkowich
  • Publication number: 20070122639
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Application
    Filed: January 30, 2007
    Publication date: May 31, 2007
    Inventors: Petr Fiala, Anthony Chilkowich, Karel Hajmrle
  • Patent number: 7179507
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Grant
    Filed: April 28, 2005
    Date of Patent: February 20, 2007
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
  • Publication number: 20060293194
    Abstract: The production of solid lubricant agglomerates by combining solid lubricant powder, an inorganic binder, other fillers if optionally desired, and a liquid to form a mixture, and driving off the liquid to form dry agglomerates which are subsequently classified by size or milled and classified by size to yield agglomerates of a desired size range. These agglomerates are then treated to stabilize the binder, thereby strengthening the binder and rendering it nondispersible in the liquid. The treated agglomerates are then blended or clad with a metal, metal alloy or a metallic composition, to produce a composition suitable for thermal spray applications.
    Type: Application
    Filed: June 9, 2006
    Publication date: December 28, 2006
    Inventors: Karel Hajmrle, William Walkhouse, Petr Fiala
  • Patent number: 7135240
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Grant
    Filed: December 16, 2004
    Date of Patent: November 14, 2006
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
  • Patent number: 7052527
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition comprises a mixture of metal-clad solid lubricant particles and unclad solid lubricants particles for producing an abradable seal used in the compressor section of gas engines, aircraft engines, radial compressors and the like. The metal is selected from alloys of Ni, Co, Cu, Fe and Al, preferably Ni alloys, and the solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride and molybdenum disulphide, preferably hexagonal boron nitride or hexagonal boron nitride and graphite.
    Type: Grant
    Filed: April 29, 2004
    Date of Patent: May 30, 2006
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Karel Hajmrle, Petr Fiala
  • Patent number: 7008462
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Grant
    Filed: December 16, 2004
    Date of Patent: March 7, 2006
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
  • Publication number: 20050287390
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition comprises a mixture of metal-clad solid lubricant particles and unclad solid lubricants particles for producing an abradable seal used in the compressor section of gas engines, aircraft engines, radial compressors and the like. The metal is selected from alloys of Ni, Co, Cu, Fe and Al, preferably Ni alloys, and the solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride and molybdenum disulphide, preferably hexagonal boron nitride or hexagonal boron nitride and graphite.
    Type: Application
    Filed: April 29, 2004
    Publication date: December 29, 2005
    Inventors: Karel Hajmrle, Petr Fiala
  • Publication number: 20050233160
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Application
    Filed: April 28, 2005
    Publication date: October 20, 2005
    Inventors: Petr Fiala, Anthony Chilkowich, Karel Hajmrle
  • Publication number: 20050155454
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Application
    Filed: December 16, 2004
    Publication date: July 21, 2005
    Inventors: Petr Fiala, Anthony Chilkowich, Karel Hajmrle
  • Publication number: 20050158572
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Application
    Filed: December 16, 2004
    Publication date: July 21, 2005
    Inventors: Petr Fiala, Anthony Chilkowich, Karel Hajmrle
  • Publication number: 20050124505
    Abstract: The production of solid lubricant agglomerates by combining solid lubricant powder, an inorganic binder, other fillers if optionally desired, and a liquid to form a mixture, and driving off the liquid to form dry agglomerates which are subsequently classified by size or milled and classified by size to yield agglomerates of a desired size range. These agglomerates are then treated to stabilize the binder, thereby strengthening the binder and rendering it nondispersible in the liquid. The undesired size ranges can be readily recycled because the agglomerates with untreated binder can be reprocessed, thereby promoting high recovery rates.
    Type: Application
    Filed: December 5, 2003
    Publication date: June 9, 2005
    Inventors: Karel Hajmrle, William Walkhouse
  • Patent number: 6887530
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
    Type: Grant
    Filed: June 7, 2002
    Date of Patent: May 3, 2005
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
  • Publication number: 20040247923
    Abstract: The present invention provides a sprayable composition comprising a ceramic particulate including albite, illite, and quart, and a metallic composition, including nickel, chromium, iron, and silicon. The sprayable composition maybe a composite particle, a blend, or a cored wire. The present invention further provides an abradable coating formed on a metal substrate according to a method comprising the step of depositing the abradable coating on the metal substrate by thermal spraying of a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The abradable coating may be applied to a metal substrate such as steel, nickel-based alloys, and titanium.
    Type: Application
    Filed: April 8, 2004
    Publication date: December 9, 2004
    Inventors: Karel Hajmrle, Anthony Peter Chilkowich
  • Patent number: 6808756
    Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition comprises a mixture of metal-clad solid lubricant particles and unclad solid lubricants particles for producing an abradable seal used in the compressor section of gas engines, aircraft engines, radial compressors and the like. The metal is selected from alloys of Ni, Co, Cu, Fe and Al, preferably Ni alloys, and the solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride and molybdenum disulphide, preferably hexagonal boron nitride or hexagonal boron nitride and graphite.
    Type: Grant
    Filed: January 17, 2003
    Date of Patent: October 26, 2004
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Karel Hajmrle, Petr Fiala