Patents by Inventor Kenneth Scott Weil

Kenneth Scott Weil 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: 10934605
    Abstract: Methods are provided for synthesizing high purity niobium or rhenium powders by a combustion reaction. The methods can include: forming a combustion synthesis solution by dissolving in water an oxidizer, a fuel, and at least one base-soluble, ammonium salt of niobium or rhenium in amounts that yield a stoichiometric burn when combusted; and heating the combustion synthesis solution to a temperature sufficient to substantially remove the water and to initiate a self-sustaining combustion reaction.
    Type: Grant
    Filed: October 17, 2017
    Date of Patent: March 2, 2021
    Assignee: Battelle Memorial Institute
    Inventors: John G. Frye, Kenneth Scott Weil, Curt A. Lavender, Jin Yong Kim
  • Patent number: 10378094
    Abstract: Reactive coating processes are provided that can include providing a coating material, reacting the coating material to form a shell about the coating material, contacting the shelled coating material with a substrate to be coated, depositing the coating material from within the shelled coating material on the substrate, and removing the shells from the substrate. Coating materials may be deposited upon a substrate to be coated and reacted to form a shell about the coating material. The coating materials can be particles and a shell can be formed about each of the individual particles.
    Type: Grant
    Filed: July 1, 2016
    Date of Patent: August 13, 2019
    Assignee: Battelle Memorial Institute
    Inventors: Jung-Pyung Choi, Jeffrey W. Stevenson, Kenneth Scott Weil, Yeong-Shyung Matt Chou, Jens T. Darsell, Vineet V. Joshi
  • Publication number: 20180037975
    Abstract: Nanocrystalline metal powders comprising tungsten, molybdenum, rhenium or niobium can be synthesized using a combustion reaction. Methods for synthesizing the nanocrystalline metal powders are characterized by forming a combustion synthesis solution by dissolving in water an oxidizer, a fuel, and a base-soluble, ammonium precursor of tungsten, molybdenum, rhenium, or niobium in amounts that yield a soichiometric burn when combusted. The combustion synthesis solution is then heated to a temperature sufficient to substantially remove water and to initiate a self-sustaining combustion reaction. The resulting powder can be subsequently reduced to metal form by heating in a reducing gas environment.
    Type: Application
    Filed: October 17, 2017
    Publication date: February 8, 2018
    Inventors: John G. Frye, Kenneth Scott Weil, Curt A. Lavender, Jin Yong Kim
  • Patent number: 9802834
    Abstract: Nanocrystalline metal powders comprising tungsten, molybdenum, rhenium and/or niobium can be synthesized using a combustion reaction. Methods for synthesizing the nanocrystalline metal powders are characterized by forming a combustion synthesis solution by dissolving in water an oxidizer, a fuel, and a base-soluble, ammonium precursor of tungsten, molybdenum, rhenium, or niobium in amounts that yield a stoichiometric burn when combusted. The combustion synthesis solution is then heated to a temperature sufficient to substantially remove water and to initiate a self-sustaining combustion reaction. The resulting powder can be subsequently reduced to metal form by heating in a reducing gas environment.
    Type: Grant
    Filed: February 5, 2010
    Date of Patent: October 31, 2017
    Assignee: Battelle Memorial Institute
    Inventors: John G. Frye, Kenneth Scott Weil, Curt A. Lavender, Jin Yong Kim
  • Patent number: 9481923
    Abstract: Methods of aluminizing the surface of a metal substrate. The methods of the present invention do not require establishment of a vacuum or a reducing atmosphere, as is typically necessary. Accordingly, aluminization can occur in the presence of oxygen, which greatly simplifies and reduces processing costs by allowing deposition of the aluminum coating to be performed, for example, in air. Embodiments of the present invention can be characterized by applying a slurry that includes a binder and powder granules containing aluminum to the metal substrate surface. Then, in a combined step, a portion of the aluminum is diffused into the substrate and a portion of the aluminum is oxidized by heating the slurry to a temperature greater than the melting point of the aluminum in an oxygen-containing atmosphere.
    Type: Grant
    Filed: May 21, 2009
    Date of Patent: November 1, 2016
    Assignee: Battelle Memorial Institute
    Inventors: Jung-Pyung Choi, Kenneth Scott Weil
  • Publication number: 20160312358
    Abstract: Reactive coating processes are provided that can include providing a coating material, reacting the coating material to form a shell about the coating material, contacting the shelled coating material with a substrate to be coated, depositing the coating material from within the shelled coating material on the substrate, and removing the shells from the substrate. Coating materials may be deposited upon a substrate to be coated and reacted to form a shell about the coating material. The coating materials can be particles and a shell can be formed about each of the individual particles.
    Type: Application
    Filed: July 1, 2016
    Publication date: October 27, 2016
    Applicant: Battelle Memorial Institute
    Inventors: Jung-Pyung Choi, Jeffrey W. Stevenson, Kenneth Scott Weil, Yeong-Shyung Matt Chou, Jens T. Darsell, Vineet V. Joshi
  • Patent number: 9283637
    Abstract: Tools for friction stir welding can be made with fewer process steps, lower cost techniques, and/or lower cost ingredients than other state-of-the-art processes by utilizing improved compositions and processes of fabrication. Furthermore, the tools resulting from the improved compositions and processes of fabrication can exhibit better distribution and homogeneity of chemical constituents, greater strength, and/or increased durability. In one example, a friction stir weld tool includes tungsten and rhenium and is characterized by carbide and oxide dispersoids, by carbide particulates, and by grains that comprise a solid solution of the tungsten and rhenium. The grains do not exceed 10 micrometers in diameter.
    Type: Grant
    Filed: January 22, 2013
    Date of Patent: March 15, 2016
    Assignee: Battelle Memorial Institute
    Inventors: Glenn J. Grant, John G. Frye, Jin Yong Kim, Curt A. Lavender, Kenneth Scott Weil
  • Patent number: 8424747
    Abstract: A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.
    Type: Grant
    Filed: April 5, 2010
    Date of Patent: April 23, 2013
    Assignee: Battelle Memorial Institute
    Inventors: Kenneth Scott Weil, John S. Hardy, Jin Yong Kim, Jung-Pyung Choi
  • Patent number: 8048587
    Abstract: An electrically-conductive mesh spacer incorporated into the hydrogen and air gas flow spaces between each anode and cathode and its adjacent interconnect in a fuel cell stack. The mesh is formed of metal strands and is formed into a predetermined three-dimensional pattern to make contact at a plurality of points on the surfaces of the electrode and the interconnect element. The formed mesh spacer is secured as by brazing to the interconnect element at a plurality of locations to form an interconnect, which preserves the pattern during assembly of a fuel cell stack. The height of the formed pattern is greater than the height of a gas flow space after fuel cell assembly, such that the mesh spacer is slightly compressed during assembly of a fuel cell stack. Because the metal mesh is both compliant and resilient, the compressed spacer is continuously urged into mechanical and electrical contact with its electrode over all temperatures and pressures to which the fuel cell assembly may be subjected during use.
    Type: Grant
    Filed: November 27, 2002
    Date of Patent: November 1, 2011
    Assignees: Delphi Technologies, Inc., Batelle Memorial Institute
    Inventors: Haskell Simpkins, Karl J. Haltiner, Jr., Subhasish Mukerjee, Kenneth Scott Weil, Dean Paxton
  • Publication number: 20110194970
    Abstract: Nanocrystalline metal powders comprising tungsten, molybdenum, rhenium or niobium can be synthesized using a combustion reaction. Methods for synthesizing the nanocrystalline metal powders are characterized by forming a combustion synthesis solution by dissolving in water an oxidizer, a fuel, and a base-soluble, ammonium precursor of tungsten, molybdenum, rhenium, or niobium in amounts that yield a soichiometric burn when combusted. The combustion synthesis solution is then heated to a temperature sufficient to substantially remove water and to initiate a self-sustaining combustion reaction. The resulting powder can be subsequently reduced to metal form by heating in a reducing gas environment.
    Type: Application
    Filed: February 5, 2010
    Publication date: August 11, 2011
    Applicant: BATTELLE MEMORIAL INSTITUTE
    Inventors: John G. Frye, Kenneth Scott Weil, Curt A. Lavender, Jin Yong Kim
  • Publication number: 20100297341
    Abstract: Methods of aluminizing the surface of a metal substrate. The methods of the present invention do not require establishment of a vacuum or a reducing atmosphere, as is typically necessary. Accordingly, aluminization can occur in the presence of oxygen, which greatly simplifies and reduces processing costs by allowing deposition of the aluminum coating to be performed, for example, in air. Embodiments of the present invention can be characterized by applying a slurry that includes a binder and powder granules containing aluminum to the metal substrate surface. Then, in a combined step, a portion of the aluminum is diffused into the substrate and a portion of the aluminum is oxidized by heating the slurry to a temperature greater than the melting point of the aluminum in an oxygen-containing atmosphere.
    Type: Application
    Filed: May 21, 2009
    Publication date: November 25, 2010
    Applicant: BATTELLE MEMORIAL INSTITUTE
    Inventors: Jung-Pyung Choi, Kenneth Scott Weil
  • Publication number: 20100218875
    Abstract: A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.
    Type: Application
    Filed: April 5, 2010
    Publication date: September 2, 2010
    Applicant: BATTELLE MEMORIAL INSTITUTE
    Inventors: Kenneth Scott Weil, John S. Hardy, Jin Yong Kim, Jung-Pyung Choi
  • Patent number: 7754367
    Abstract: An interconnect system including: a separator plate to provide an anode gas flow space; a first metal interconnect disposed between the separator plate and an anode surface; a nickel oxide paste applied in a pattern over the surface of the anode and adjacent surface of the separator plate which when sintered results in a first conductive layer bonded to the anode and the first interconnect, and a second conductive layer bonded to the first interconnect and the separator plate; a second metal interconnect disposed between a cathode surface of the cell and the separator plate of an adjacent cell cassette; and a silver-containing paste applied over the surface of the cathode and the separator plate which when sintered results in a third conductive layer bonded to the cathode and the second interconnect, and a fourth conductive layer bonded to the second interconnect and the separator plate.
    Type: Grant
    Filed: June 28, 2007
    Date of Patent: July 13, 2010
    Assignees: Delphi Technologies, Inc., Battelle Memorial Institute
    Inventors: Karl J. Haltiner, Jr., Subhasish Mukerjee, Lawrence A. Chick, Kerry D. Meinhardt, Vincent L. Sprenkle, Kenneth Scott Weil, Jin Yong Kim
  • Patent number: 7691174
    Abstract: A feedstock composition and a method of forming metal articles using powder metallurgy techniques comprise mixing metal powders and a novel aromatic binder system. The composition of the novel feedstock comprises an aromatic binder system and a metal powder. The aromatic binder system comprises an aromatic species and can further comprise lubricants, surfactants, and polymers as additives. The metal powder comprises elemental metals, metal compounds, and metal alloys, particularly for highly-reactive metals. The method of forming metal articles comprises the steps of providing and mixing the metal powder and the aromatic binder system to produce a novel feedstock. The method further comprises processing the novel feedstock into a metal article using a powder metallurgy forming technique. Metal articles formed using the present invention have an increase in carbon and oxygen contents each less than or equal to 0.2 wt % relative to the metal powder used to fabricate the article.
    Type: Grant
    Filed: March 8, 2004
    Date of Patent: April 6, 2010
    Assignee: Battelle Memorial Institute
    Inventors: Eric A. Nyberg, Kenneth Scott Weil, Kevin L. Simmons
  • Patent number: 7691488
    Abstract: A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.
    Type: Grant
    Filed: June 11, 2007
    Date of Patent: April 6, 2010
    Assignee: Battelle Memorial Institute
    Inventors: Kenneth Scott Weil, John S. Hardy, Jin Yong Kim, Jung-Pyung Choi
  • Patent number: 7585348
    Abstract: A feedstock composition and a method of forming metal articles using powder metallurgy techniques comprise mixing metal powders and a novel aromatic binder system. The composition of the novel feedstock comprises an aromatic binder system and a metal powder. The aromatic binder system comprises an aromatic species and can further comprise lubricants, surfactants, and polymers as additives. The metal powder comprises elemental metals, metal compounds, and metal alloys, particularly for highly-reactive metals. The method of forming metal articles comprises the steps of providing and mixing the metal powder and the aromatic binder system to produce a novel feedstock. The method further comprises processing the novel feedstock into a metal article using a powder metallurgy forming technique. Metal articles formed using the present invention have an increase in carbon and oxygen contents each less than or equal to 0.2 wt % relative to the metal powder used to fabricate the article.
    Type: Grant
    Filed: November 17, 2006
    Date of Patent: September 8, 2009
    Assignee: Battelle Memorial Institute
    Inventors: Eric A. Nyberg, Kenneth Scott Weil, Kevin L. Simmons
  • Patent number: 7585458
    Abstract: A feedstock composition and a method of forming metal articles using powder metallurgy techniques comprise mixing metal powders and a novel aromatic binder system. The composition of the novel feedstock comprises an aromatic binder system and a metal powder. The aromatic binder system comprises an aromatic species and can further comprise lubricants, surfactants, and polymers as additives. The metal powder comprises elemental metals, metal compounds, and metal alloys, particularly for highly-reactive metals. The method of forming metal articles comprises the steps of providing and mixing the metal powder and the aromatic binder system to produce a novel feedstock. The method further comprises processing the novel feedstock into a metal article using a powder metallurgy forming technique. Metal articles formed using the present invention have an increase in carbon and oxygen contents each less than or equal to 0.2 wt % relative to the metal powder used to fabricate the article.
    Type: Grant
    Filed: November 17, 2006
    Date of Patent: September 8, 2009
    Assignee: Battelle Memorial Institute
    Inventors: Eric A. Nyberg, Kenneth Scott Weil, Kevin L. Simmons
  • Publication number: 20090016953
    Abstract: High-temperature air braze filler materials composed of various ternary metal alloys are described. Noble metals (M) are added as a ternary constituent to a silver-copper oxide (Ag—CuOx) system. The silver (Ag) component is directly substituted with the noble metal to form a series of alloys. Addition of the noble metal increases the solidus and liquidus temperatures of the resulting air braze filler metals and increases temperatures under which seals and other sealing components formed from these filler metals can be employed.
    Type: Application
    Filed: July 10, 2008
    Publication date: January 15, 2009
    Inventors: Kenneth Scott Weil, John S. Hardy, Jin Yong Kim
  • Publication number: 20090004545
    Abstract: An interconnect system for connecting adjacent fuel cells in a fuel cell stack. The system comprises five elements: a separator plate to provide an anode gas flow space when joined to a mating cell frame; a first metal interconnect disposed between the separator plate and the anode surface; a nickel oxide paste applied in a pattern over the surface of the anode and adjacent surface of the separator plate which when sintered results in a conductive layer bonded to the anode and to the separator plate; a second metal interconnect disposed between the cathode surface of the cell and the separator plate of the adjacent cell cassette; and a silver-containing paste applied over the surface of the cathode and the separator plate which when sintered results in a conductive layer bonded to the cathode and to the separator plate.
    Type: Application
    Filed: June 28, 2007
    Publication date: January 1, 2009
    Inventors: Karl J. Haltiner, JR., Subhasish Mukerjee, Lawrence A. Chick, Kerry D. Meinhardt, Vincent L. Sprenkle, Kenneth Scott Weil, Jin Yong Kim
  • Publication number: 20080305356
    Abstract: A method for joining two ceramic parts, or a ceramic part and a metal part, and the joint formed thereby. The method provides two or more parts, a braze consisting of a mixture of copper oxide and silver, a diffusion barrier, and then heats the braze for a time and at a temperature sufficient to form the braze into a bond holding the two or more parts together. The diffusion barrier is an oxidizable metal that forms either a homogeneous component of the braze, a heterogeneous component of the braze, a separate layer bordering the braze, or combinations thereof. The oxidizable metal is selected from the group Al, Mg, Cr, Si, Ni, Co, Mn, Ti, Zr, Hf, Pt, Pd, Au, lanthanides, and combinations thereof.
    Type: Application
    Filed: June 11, 2007
    Publication date: December 11, 2008
    Inventors: Kenneth Scott Weil, John S. Hardy, Jin Yong Kim, Jung-Pyung Choi