Patents by Inventor Luke Walker
Luke Walker 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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Publication number: 20260054415Abstract: The invention relates in general to sintering under pressure and with electrical current, often termed spark plasma sintering (SPS). Particular aspects of the invention are directed to a sintering device, a sintering process, a ceramic body product, an assembly comprising the ceramic body and the use of a graphite layer in a sintering process. The invention relates to a device having a sintering chamber, the sintering chamber being bordered by the following device parts: ? i. a first punch surface of a first punch; ? ii. a second punch surface of a second punch; and ? iii. an interior surface of a die; wherein: ? the punches are adapted and arranged to apply a pressure of at least 1 MPa along a compression axis to a target in the sintering chamber; the first punch and the second punch are connected to an electrical power source.Type: ApplicationFiled: August 4, 2023Publication date: February 26, 2026Inventors: Matthew Joseph DONELON, Luke WALKER
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Publication number: 20260042711Abstract: A process for the preparation of a ceramic body, comprising the steps: a. providing a plurality of particles; b. providing a device that comprises a sintering chamber bordered by a die; c. introducing the particles into the sintering chamber; d. applying a pressure P in the range from 1 MPa to 80 MPa to the plurality of particles in the sintering chamber to obtain the ceramic body, wherein a temperature in the sintering chamber, during preparation of the ceramic body, is controlled so that the temperature at a centre of the sintering chamber is lower than the temperature at an interior surface of the die.Type: ApplicationFiled: August 4, 2023Publication date: February 12, 2026Inventors: Luke WALKER, Matthew Joseph DONELON, Devendra VERMA
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Publication number: 20260022074Abstract: Disclosed herein is a method for making a sintered ceramic body comprising at least one layer of 99% or greater by volume of polycrystalline yttrium aluminum garnet (YAG) substantially free of unreacted yttrium oxide and yttrium rich phases. by sintering and in-situ reaction of yttria with alumina including fine and coarse particle sizes.Type: ApplicationFiled: July 14, 2023Publication date: January 22, 2026Inventors: Devendra VERMA, Luke WALKER, Steven Roger KENNEDY, Matthew Joseph DONELON
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Patent number: 12515372Abstract: A spark plasma sintering tool. The tool comprises a die including an inner wall having a diameter that defines an inner volume configured to receive a ceramic powder, and an upper punch and a lower punch operably coupled with the die, wherein each of the upper and lower punches have an outer wall defining a diameter that is less than the diameter of the inner wall of the die thereby creating a gap from 10 ?m to 100 ?m wide between each of the punches and the inner wall of the die when at least one of the punches moves within the inner volume of the die. Also disclosed is a method of using the tool to create a large sintered ceramic body and a computer readable medium storing processor-executable instructions adapted to cause one or more computing devices to operate the tool.Type: GrantFiled: September 30, 2021Date of Patent: January 6, 2026Assignee: Heraeus Covantics North America LLCInventors: Luke Walker, Matthew Joseph Donelon, Lillian Thompson
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Patent number: 12497334Abstract: Disclosed is a ceramic sintered body comprising yttrium oxide and zirconium oxide wherein the ceramic sintered body comprises not less than 75 mol % to not greater than 95 mol % yttrium oxide and not less than 5 mol % to not greater than 25 mol % zirconium oxide, wherein the ceramic sintered body comprises porosity in an amount of less than 2% by volume, wherein a density of the ceramic sintered body does not vary by more than 2% relative to theoretical density across a greatest dimension. The ceramic sintered body has a grain size of from 0.4 to less than 2 um as measured according to ASTM E1 12-2010. The ceramic sintered body may be machined into plasma resistant components for use in plasma processing chambers. Methods of making are also disclosed.Type: GrantFiled: July 1, 2022Date of Patent: December 16, 2025Assignee: Heraeus Covantics North America LLCInventors: Luke Walker, Matthew Joseph Donelon
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Publication number: 20250375812Abstract: One aspect is a process for producing a layered body. A first powder is introduced into an interior volume to obtain a first powder layer. The interior volume has a cross-sectional width of at least 200 mm, and is bordered by a die of carbon. The first powder is a mixture comprising a first constituent powder and a further constituent powder of different chemical compositions. The first powder layer is subjected to a heat, generated by a voltage, and to a pressure to obtain the layered body. The further constituent powder has a particle size distribution D=q(?) of volume density q over particle size ?, such that D has a first local maximum ? at particle size ?? with volume density q?, D has a second local maximum ? at particle size ?? with volume density q?, ??>??, and q?/q? is at least 1.Type: ApplicationFiled: June 3, 2025Publication date: December 11, 2025Applicant: Heraeus Covantics North America LLCInventors: Luke WALKER, Matthew Joseph DONELON, Samantha BAUMANN
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Patent number: 12486202Abstract: Disclosed is a multilayer sintered ceramic body comprising at least one first layer comprising at least one crystalline phase of YAG, wherein the at least one first layer has at least one surface; and at least one second layer comprising alumina and at least one of stabilized zirconia and partially stabilized zirconia, wherein the at least one surface of the at least one first layer comprises pores wherein the pores have a maximum size of from 0.1 to 5 um as measured by SEM, and wherein each of the at least one first layer and the at least one second layer has a coefficient of thermal expansion (CTE), wherein the CTE of the at least one first layer and the CTE of the at least one second layer differ from 0 to 0.6×10?6/° C. as measured in accordance with ASTM E228-17. Methods of making are also disclosed.Type: GrantFiled: October 13, 2021Date of Patent: December 2, 2025Assignee: Heraeus Covantics North America LLCInventors: Luke Walker, Matthew Joseph Donelon, Saurabh Waghmare, Lillian Thompson
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Publication number: 20250346537Abstract: A method of making a sintered ceramic body comprising the steps of disposing a ceramic powder inside an inner volume of a spark plasma sintering tool, wherein the tool comprises: a die comprising a sidewall comprising inner and outer walls, wherein the inner wall has a diameter defining the inner volume; upper and lower punches operably coupled with the die, wherein each of the punches have an outer wall defining a diameter less than the diameter of the die inner wall, thereby creating a gap between the punches and the inner wall when at least one of the punches are moved within the inner volume, and the gap is from 10 ?m to 70 ?m wide; creating vacuum conditions inside the inner volume; moving at least one of the punches to apply pressure to the ceramic powder while heating, and sintering; and lowering the temperature of the sintered body.Type: ApplicationFiled: July 23, 2025Publication date: November 13, 2025Applicant: Heraeus Covantics North America LLCInventors: Luke WALKER, Matthew Joseph DONELON, Lillian THOMPSON
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Publication number: 20250304460Abstract: Disclosed is a ceramic sintered body comprising magnesium aluminate spinel of composition MgAl2O4 having from 90 to 100% by volume of a cubic crystallographic structure and a density of from 3.47 to 3.58 g/cc, wherein the ceramic sintered body is free of sintering aids. A method of making the ceramic sintered body comprising spinel is also disclosed.Type: ApplicationFiled: June 13, 2025Publication date: October 2, 2025Applicant: Heraeus Covantics North America LLCInventors: Luke WALKER, Matthew Joseph DONELON, Steven Roger KENNEDY, Sudip KOIRALA
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Publication number: 20250296884Abstract: Disclosed is a multilayer sintered ceramic body comprising at least one first layer comprising polycrystalline YAG, wherein the at least one first layer has at least one surface; and at least one second layer comprising magnesium aluminate spinel, wherein the at least one surface of the at least one first layer comprises pores wherein the pores have a maximum size of from 0.1 to 5 pm as measured by SEM, and wherein each of the at least one first layer and the at least one second layer has a coefficient of thermal expansion (GTE), wherein the GTE of the at least one first layer and the GTE of the at least one second layer differ from 0 to 0.6×10?6/° C. Methods of making are also disclosed.Type: ApplicationFiled: December 20, 2022Publication date: September 25, 2025Inventors: Steven Roger KENNEDY, Luke WALKER
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Patent number: 12398079Abstract: A method of making a sintered ceramic body comprising the steps of disposing a ceramic powder (5) inside an inner volume of a spark plasma sintering tool (1), wherein the tool comprises: a die (2) comprising a sidewall comprising inner and outer walls, wherein the inner wall has a diameter defining the inner volume; upper and lower punches (4,4?) operably coupled with the die, wherein each of the punches have an outer wall defining a diameter less than the diameter of the die inner wall, thereby creating a gap (3) between the punches and the inner wall when at least one of the punches are moved within the inner volume, and the gap is from 10 ?m to 70 ?m wide; creating vacuum conditions inside the inner volume; moving at least one of the punches to apply pressure to the ceramic powder while heating, and sintering; and lowering the temperature of the sintered body.Type: GrantFiled: September 30, 2021Date of Patent: August 26, 2025Assignee: Heraeus Covantics North America LLCInventors: Luke Walker, Matthew Joseph Donelon, Lillian Thompson
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Patent number: 12358806Abstract: Disclosed is a ceramic sintered body comprising magnesium aluminate spinel of composition MgAl2O4 having from 90 to 100% by volume of a cubic crystallographic structure and a density of from 3.47 to 3.58 g/cc, wherein the ceramic sintered body is free of sintering aids. A method of making the ceramic sintered body comprising spinel is also disclosed.Type: GrantFiled: July 13, 2021Date of Patent: July 15, 2025Assignee: Heraeus Covantics North America LLCInventors: Luke Walker, Matthew Joseph Donelon, Steven Roger Kennedy, Sudip Koirala
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Publication number: 20250222558Abstract: A method of polishing a surface of a polycrystalline sintered ceramic body, the method comprising the steps of: a) providing a sintered ceramic body comprising a polycrystalline material and having a density of from about 99.5% to about 99.999% of the polycrystalline material's theoretical density, wherein the sintered ceramic body has at least one surface; b) grinding the at least one surface until the surface has (I) a flatness of no more than 25 microns on average measured over four quadrants of the at least one surface at angles of 0°, 90°, 180°, and 270° as measured with a spherometer, (ii) an Ra of less than 14 microinches, and (iii) an Rz of less than 160 microinches; c) after the grinding step, lapping the at least one surface with a lapping plate and a lapping media slurry; d) after lapping, successively polishing the at least one surface.Type: ApplicationFiled: March 24, 2023Publication date: July 10, 2025Inventors: Luke WALKER, Matthew Joseph DONELON, Saurabh WAGHMARE
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Publication number: 20240391836Abstract: A sintered ceramic body comprising at least one layer comprising from 90% to 99.8% by volume of polycrystalline yttrium aluminum garnet (YAG) and from 15 ppm to 500 ppm of zirconium, wherein the at least one layer comprises at least one surface, wherein the at least one surface comprises pores having a pore size not exceeding 5 pm and having a maximum pore size of 1.5 pm for at least 95% of the pores, wherein the at least one surface exhibits an L* value of from 50 to 77, and an “a” value of from 6 to 12, wherein the at least one layer has a thickness of from 500 pm to 2 cm, and wherein the values of L* and “a” vary no more than 10% across the at least one surface. Also disclosed are methods of making same.Type: ApplicationFiled: September 2, 2022Publication date: November 28, 2024Inventors: Luke WALKER, Matthew Joseph DONELON, Steven Roger KENNEDY
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Publication number: 20240308918Abstract: Disclosed is a ceramic sintered body comprising yttrium oxide and zirconium oxide wherein the ceramic sintered body comprises not less than 75 mol % to not greater than 95 mol % yttrium oxide and not less than 5 mol % to not greater than 25 mol % zirconium oxide, wherein the ceramic sintered body comprises porosity in an amount of less than 2% by volume, wherein a density of the ceramic sintered body does not vary by more than 2% relative to theoretical density across a greatest dimension. The ceramic sintered body has a grain size of from 0.4 to less than 2 um as measured according to ASTM E1 12-2010. The ceramic sintered body may be machined into plasma resistant components for use in plasma processing chambers. Methods of making are also disclosed.Type: ApplicationFiled: July 1, 2022Publication date: September 19, 2024Inventors: Luke WALKER, Matthew Joseph DONELON
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Publication number: 20240253148Abstract: An example method for joining metals is described herein. The method can include forming an intermediate joint between a light metal member and a metal insert, where the intermediate joint is formed using a solid state welding process. The method can also include forming a primary joint between the light metal member and a high strength steel member, where the primary joint is formed using a welding process that produces coalescence at a temperature above the melting point of the light metal member and/or the high-strength steel member.Type: ApplicationFiled: March 6, 2024Publication date: August 1, 2024Inventors: Wei Zhang, Ying Lu, Luke Walker, Menachem Kimchi
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Patent number: 12048698Abstract: In one aspect, the present invention provides a method for treating or ameliorating the effects of a HER2 positive cancer in a subject. In some embodiments, the method comprises administering a combination therapy comprising an anti-HER2 antibody and tucatinib. In some embodiments, the method further comprises administering a chemotherapeutic agent (e.g., an antimetabolite) to the subject. Pharmaceutical compositions and kits are also provided herein.Type: GrantFiled: April 26, 2023Date of Patent: July 30, 2024Assignee: Seagen Inc.Inventors: Scott Peterson, Luke Walker
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Publication number: 20240158301Abstract: Disclosed is a multilayer sintered ceramic body comprising at least one first layer comprising at least one crystalline phase of YAG, wherein the at least one first layer has at least one surface; and at least one second layer comprising alumina and at least one of stabilized zirconia and partially stabilized zirconia, wherein the at least one surface of the at least one first layer comprises pores wherein the pores have a maximum size of from 0.1 to 5 um as measured by SEM, and wherein each of the at least one first layer and the at least one second layer has a coefficient of thermal expansion (CTE), wherein the CTE of the at least one first layer and the CTE of the at least one second layer differ from 0 to 0.6×10?6/° C. as measured in accordance with ASTM E228-17. Methods of making are also disclosed.Type: ApplicationFiled: October 13, 2021Publication date: May 16, 2024Inventors: Luke WALKER, Matthew Joseph DONELON, Saurabh WAGHMARE, Lillian THOMPSON
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Publication number: 20240101486Abstract: Disclosed herein is a multilayer sintered ceramic body comprising at least one first layer comprising poly crystalline YAG, wherein the at least one first layer comprising poly crystalline YAG comprises pores wherein the pores have a maximum size of from 0.1 to 5 ?m, at least one second layer comprising alumina and zirconia wherein the zirconia comprises at least one of stabilized and partially stabilized zirconia, and at least one third layer comprising at least one of YAG, alumina, and zirconia, wherein an absolute value of the difference in coefficient of thermal expansion (CTE) between the at least one first, second and third layers is from 0 to 0.75×10-6/° C. as measured in accordance with ASTM E228-17, wherein the at least one first, second and third layers form a unitary, multilayer sintered ceramic body. Methods of making are also disclosed.Type: ApplicationFiled: December 17, 2021Publication date: March 28, 2024Inventors: Luke WALKER, Matthew Joseph DONELON, Saurabh WAGHMARE, Lillan THOMPSON
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Publication number: 20240092936Abstract: In one aspect, the present disclosure relates to a method for treating or ameliorating the effects of a HER2 positive breast cancer in a subject by administration of a combination of tucatinib, capecitabine, and trastuzumab. In some embodiments, the methods provided herein are useful for treating or ameliorating the effects of a HER2 positive breast cancer-associated brain metastasis in a subject by administration of a combination of tucatinib, capecitabine, and trastuzumab.Type: ApplicationFiled: October 20, 2020Publication date: March 21, 2024Inventor: Luke Walker