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).

  • Publication number: 20260054415
    Abstract: 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: Application
    Filed: August 4, 2023
    Publication date: February 26, 2026
    Inventors: Matthew Joseph DONELON, Luke WALKER
  • Publication number: 20260042711
    Abstract: 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: Application
    Filed: August 4, 2023
    Publication date: February 12, 2026
    Inventors: Luke WALKER, Matthew Joseph DONELON, Devendra VERMA
  • Publication number: 20260022074
    Abstract: 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: Application
    Filed: July 14, 2023
    Publication date: January 22, 2026
    Inventors: Devendra VERMA, Luke WALKER, Steven Roger KENNEDY, Matthew Joseph DONELON
  • Patent number: 12515372
    Abstract: 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: Grant
    Filed: September 30, 2021
    Date of Patent: January 6, 2026
    Assignee: Heraeus Covantics North America LLC
    Inventors: Luke Walker, Matthew Joseph Donelon, Lillian Thompson
  • Patent number: 12497334
    Abstract: 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: Grant
    Filed: July 1, 2022
    Date of Patent: December 16, 2025
    Assignee: Heraeus Covantics North America LLC
    Inventors: Luke Walker, Matthew Joseph Donelon
  • Publication number: 20250375812
    Abstract: 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: Application
    Filed: June 3, 2025
    Publication date: December 11, 2025
    Applicant: Heraeus Covantics North America LLC
    Inventors: Luke WALKER, Matthew Joseph DONELON, Samantha BAUMANN
  • Patent number: 12486202
    Abstract: 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: Grant
    Filed: October 13, 2021
    Date of Patent: December 2, 2025
    Assignee: Heraeus Covantics North America LLC
    Inventors: Luke Walker, Matthew Joseph Donelon, Saurabh Waghmare, Lillian Thompson
  • Publication number: 20250346537
    Abstract: 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: Application
    Filed: July 23, 2025
    Publication date: November 13, 2025
    Applicant: Heraeus Covantics North America LLC
    Inventors: Luke WALKER, Matthew Joseph DONELON, Lillian THOMPSON
  • Publication number: 20250304460
    Abstract: 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: Application
    Filed: June 13, 2025
    Publication date: October 2, 2025
    Applicant: Heraeus Covantics North America LLC
    Inventors: Luke WALKER, Matthew Joseph DONELON, Steven Roger KENNEDY, Sudip KOIRALA
  • Publication number: 20250296884
    Abstract: 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: Application
    Filed: December 20, 2022
    Publication date: September 25, 2025
    Inventors: Steven Roger KENNEDY, Luke WALKER
  • Patent number: 12398079
    Abstract: 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: Grant
    Filed: September 30, 2021
    Date of Patent: August 26, 2025
    Assignee: Heraeus Covantics North America LLC
    Inventors: Luke Walker, Matthew Joseph Donelon, Lillian Thompson
  • Patent number: 12358806
    Abstract: 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: Grant
    Filed: July 13, 2021
    Date of Patent: July 15, 2025
    Assignee: Heraeus Covantics North America LLC
    Inventors: Luke Walker, Matthew Joseph Donelon, Steven Roger Kennedy, Sudip Koirala
  • Publication number: 20250222558
    Abstract: 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: Application
    Filed: March 24, 2023
    Publication date: July 10, 2025
    Inventors: Luke WALKER, Matthew Joseph DONELON, Saurabh WAGHMARE
  • Publication number: 20240391836
    Abstract: 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: Application
    Filed: September 2, 2022
    Publication date: November 28, 2024
    Inventors: Luke WALKER, Matthew Joseph DONELON, Steven Roger KENNEDY
  • Publication number: 20240308918
    Abstract: 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: Application
    Filed: July 1, 2022
    Publication date: September 19, 2024
    Inventors: Luke WALKER, Matthew Joseph DONELON
  • Publication number: 20240253148
    Abstract: 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: Application
    Filed: March 6, 2024
    Publication date: August 1, 2024
    Inventors: Wei Zhang, Ying Lu, Luke Walker, Menachem Kimchi
  • Patent number: 12048698
    Abstract: 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: Grant
    Filed: April 26, 2023
    Date of Patent: July 30, 2024
    Assignee: Seagen Inc.
    Inventors: Scott Peterson, Luke Walker
  • Publication number: 20240158301
    Abstract: 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: Application
    Filed: October 13, 2021
    Publication date: May 16, 2024
    Inventors: Luke WALKER, Matthew Joseph DONELON, Saurabh WAGHMARE, Lillian THOMPSON
  • Publication number: 20240101486
    Abstract: 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: Application
    Filed: December 17, 2021
    Publication date: March 28, 2024
    Inventors: Luke WALKER, Matthew Joseph DONELON, Saurabh WAGHMARE, Lillan THOMPSON
  • Publication number: 20240092936
    Abstract: 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: Application
    Filed: October 20, 2020
    Publication date: March 21, 2024
    Inventor: Luke Walker