Patents by Inventor Paul A. Menchhofer

Paul A. Menchhofer 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: 10239046
    Abstract: A fluffy nano-material and method of manufacture are described. At 2000× magnification the fluffy nanomaterial has the appearance of raw, uncarded wool, with individual fiber lengths ranging from approximately four microns to twenty microns. Powder-based nanocatalysts are dispersed in the fluffy nanomaterial. The production of fluffy nanomaterial typically involves flowing about 125 cc/min of organic vapor at a pressure of about 400 torr over powder-based nano-catalysts for a period of time that may range from approximately thirty minutes to twenty-four hours.
    Type: Grant
    Filed: November 21, 2014
    Date of Patent: March 26, 2019
    Assignees: Consolidated Nuclear Security, LLC, UT-Battelle, LLC
    Inventors: Paul A. Menchhofer, Roland D. Seals, Jane Y. Howe, Wei Wang
  • Publication number: 20180154435
    Abstract: Disclosed herein are structures comprising a titanium, zirconium, or hafnium powder particle with titanium carbide, zirconium carbide, or hafnium carbide (respectively) nano-whiskers grown directly from and anchored to the powder particle. Also disclosed are methods for fabrication of such structures, involving heating the powder particles and exposing the particles to an organic gas.
    Type: Application
    Filed: January 30, 2018
    Publication date: June 7, 2018
    Inventors: Paul A. Menchhofer, Roland D. Seals, James O. Kiggans, JR.
  • Patent number: 9878307
    Abstract: Methods of fabricating nano-catalysts are described. In some embodiments the nano-catalyst is formed from a powder-based substrate material and is some embodiments the nano-catalyst is formed from a solid-based substrate material. In some embodiments the substrate material may include metal, ceramic, or silicon or another metalloid. The nano-catalysts typically have metal nanoparticles disposed adjacent the surface of the substrate material. The methods typically include functionalizing the surface of the substrate material with a chelating agent, such as a chemical having dissociated carboxyl functional groups (—COO), that provides an enhanced affinity for metal ions. The functionalized substrate surface may then be exposed to a chemical solution that contains metal ions. The metal ions are then bound to the substrate material and may then be reduced, such as by a stream of gas that includes hydrogen, to form metal nanoparticles adjacent the surface of the substrate.
    Type: Grant
    Filed: January 14, 2013
    Date of Patent: January 30, 2018
    Assignee: Consolidated Nuclear Security, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Patent number: 9732445
    Abstract: A method for producing a carbon fiber, the method comprising: (i) subjecting a continuous carbon fiber precursor having a polymeric matrix in which strength-enhancing particles are incorporated to a stabilization process during which the carbon fiber precursor is heated to within a temperature range ranging from the glass transition temperature to no less than 20° C. below the glass transition temperature of the polymeric matrix, wherein the maximum temperature employed in the stabilization process is below 400° C., for a processing time within said temperature range of at least 1 hour in the presence of oxygen and in the presence of a magnetic field of at least 1 Tesla, while said carbon fiber precursor is held under an applied axial tension; and (ii) subjecting the stabilized carbon fiber precursor, following step (i), to a carbonization process. The stabilized carbon fiber precursor, resulting carbon fiber, and articles made thereof are also described.
    Type: Grant
    Filed: March 6, 2015
    Date of Patent: August 15, 2017
    Assignee: UT-BATTELLE, LLC
    Inventors: Orlando Rios, Michael Alan McGuire, Karren Leslie More, Wyatt Evan Tenhaeff, Paul A. Menchhofer, Felix Leonard Paulauskas
  • Publication number: 20160258082
    Abstract: A method for producing a carbon fiber, the method comprising: (i) subjecting a continuous carbon fiber precursor having a polymeric matrix in which strength-enhancing particles are incorporated to a stabilization process during which the carbon fiber precursor is heated to within a temperature range ranging from the glass transition temperature to no less than 20° C. below the glass transition temperature of the polymeric matrix, wherein the maximum temperature employed in the stabilization process is below 400° C., for a processing time within said temperature range of at least 1 hour in the presence of oxygen and in the presence of a magnetic field of at least 1 Tesla, while said carbon fiber precursor is held under an applied axial tension; and (ii) subjecting the stabilized carbon fiber precursor, following step (i), to a carbonization process. The stabilized carbon fiber precursor, resulting carbon fiber, and articles made thereof are also described.
    Type: Application
    Filed: March 6, 2015
    Publication date: September 8, 2016
    Inventors: Orlando Rios, Michael Alan McGuire, Karren Leslie More, Wyatt Evan Tenhaeff, Paul A. Menchhofer, Felix Leonard Paulauskas
  • Patent number: 9017598
    Abstract: A metal-bonded graphite foam composite includes a ductile metal continuous phase and a dispersed phase that includes graphite foam particles.
    Type: Grant
    Filed: June 21, 2012
    Date of Patent: April 28, 2015
    Assignee: UT-Battelle, LLC
    Inventors: Paul A. Menchhofer, James W. Klett
  • Publication number: 20150104646
    Abstract: A fluffy nano-material and method of manufacture are described. At 2000× magnification the fluffy nanomaterial has the appearance of raw, uncarded wool, with individual fiber lengths ranging from approximately four microns to twenty microns. Powder-based nanocatalysts are dispersed in the fluffy nanomaterial. The production of fluffy nanomaterial typically involves flowing about 125 cc/min of organic vapor at a pressure of about 400 torr over powder-based nano-catalysts for a period of time that may range from approximately thirty minutes to twenty-four hours.
    Type: Application
    Filed: November 21, 2014
    Publication date: April 16, 2015
    Inventors: Paul A. Menchhofer, Roland D. Seals, Jane Y. Howe, Wei Wang
  • Patent number: 8974719
    Abstract: A method of forming nano-structure composite materials that have a binder material and a nanostructure fiber material is described. A precursor material may be formed using a mixture of at least one metal powder and anchored nanostructure materials. The metal powder mixture may be (a) Ni powder and (b) NiAl powder. The anchored nanostructure materials may comprise (i) NiAl powder as a support material and (ii) carbon nanotubes attached to nanoparticles adjacent to a surface of the support material. The process of forming nano-structure composite materials typically involves sintering the mixture under vacuum in a die. When Ni and NiAl are used in the metal powder mixture Ni3Al may form as the binder material after sintering. The mixture is sintered until it consolidates to form the nano-structure composite material.
    Type: Grant
    Filed: February 12, 2010
    Date of Patent: March 10, 2015
    Assignee: Consolidated Nuclear Security, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Patent number: 8945691
    Abstract: A fluffy nano-material and method of manufacture are described. At 2000× magnification the fluffy nanomaterial has the appearance of raw, uncarded wool, with individual fiber lengths ranging from approximately four microns to twenty microns. Powder-based nanocatalysts are dispersed in the fluffy nanomaterial. The production of fluffy nanomaterial typically involves flowing about 125 cc/min of organic vapor at a pressure of about 400 torr over powder-based nano-catalysts for a period of time that may range from approximately thirty minutes to twenty-four hours.
    Type: Grant
    Filed: February 12, 2010
    Date of Patent: February 3, 2015
    Assignee: Consolidated Nuclear Security, LLC
    Inventors: Paul A. Menchhofer, Roland D. Seals, Jane Y. Howe, Wei Wang
  • Publication number: 20140037978
    Abstract: Anchored nanostructure materials and methods for their fabrication are described. The anchored nanostructure materials may utilize nano-catalysts that include powder-based or solid-based support materials. The support material may comprise metal, such as NiAl, ceramic, a cermet, or silicon or other metalloid. Typically, nanoparticles are disposed adjacent a surface of the support material. Nanostructures may be formed as anchored to nanoparticles that are adjacent the surface of the support material by heating the nano-catalysts and then exposing the nano-catalysts to an organic vapor. The nanostructures are typically single wall or multi-wall carbon nanotubes.
    Type: Application
    Filed: October 17, 2013
    Publication date: February 6, 2014
    Applicant: Babcock & Wilcox Technical Services Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Patent number: 8591988
    Abstract: Methods for fabricating anchored nanostructure materials are described. The methods include heating a nano-catalyst under a protective atmosphere to a temperature ranging from about 450° C. to about 1500° C. and contacting the heated nano-catalysts with an organic vapor to affix carbon nanostructures to the nano-catalysts and form the anchored nanostructure material.
    Type: Grant
    Filed: October 16, 2012
    Date of Patent: November 26, 2013
    Assignee: Babcock & Wilcox Technical Services Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Publication number: 20130195708
    Abstract: A metal-bonded graphite foam composite includes a ductile metal continuous phase and a dispersed phase that includes graphite foam particles.
    Type: Application
    Filed: June 21, 2012
    Publication date: August 1, 2013
    Applicant: UT-Battelle, LLC
    Inventors: James W. Klett, Paul A. Menchhofer, James A. Hunter
  • Patent number: 8377840
    Abstract: Methods of fabricating nano-catalysts are described. In some embodiments the nano-catalyst is formed from a powder-based substrate material and is some embodiments the nano-catalyst is formed from a solid-based substrate material. In some embodiments the substrate material may include metal, ceramic, or silicon or another metalloid. The nano-catalysts typically have metal nanoparticles disposed adjacent the surface of the substrate material. The methods typically include functionalizing the surface of the substrate material with a chelating agent, such as a chemical having dissociated carboxyl functional groups (—COO), that provides an enhanced affinity for metal ions. The functionalized substrate surface may then be exposed to a chemical solution that contains metal ions. The metal ions are then bound to the substrate material and may then be reduced, such as by a stream of gas that includes hydrogen, to form metal nanoparticles adjacent the surface of the substrate.
    Type: Grant
    Filed: February 13, 2009
    Date of Patent: February 19, 2013
    Assignee: Babcock & Wilcox Technical Services Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Publication number: 20130029836
    Abstract: A method of forming nano-structure composite materials that have a binder material and a nanostructure fiber material is described. A precursor material may be formed using a mixture of at least one metal powder and anchored nanostructure materials. The metal powder mixture may be (a) Ni powder and (b) NiAl powder. The anchored nanostructure materials may comprise (i) NiAl powder as a support material and (ii) carbon nanotubes attached to nanoparticles adjacent to a surface of the support material. The process of forming nano-structure composite materials typically involves sintering the mixture under vacuum in a die. When Ni and NiAl are used in the metal powder mixture Ni3Al may form as the binder material after sintering. The mixture is sintered until it consolidates to form the nano-structure composite material.
    Type: Application
    Filed: February 12, 2010
    Publication date: January 31, 2013
    Applicant: BABCOCK & WILCOX TECHNICAL SERVICES Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Publication number: 20120321892
    Abstract: Disclosed herein are structures comprising a titanium, zirconium, or hafnium powder particle with titanium carbide, zirconium carbide, or hafnium carbide (respectively) nano-whiskers disposed adjacent and anchored to the powder particle. Also disclosed are methods for fabrication of such structures, involving heating the powder particles and exposing the particles to an organic gas.
    Type: Application
    Filed: June 17, 2011
    Publication date: December 20, 2012
    Applicant: BABCOCK & WILCOX TECHNICAL SERVICES Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, James O. Kiggins, JR.
  • Patent number: 8318250
    Abstract: Anchored nanostructure materials and methods for their fabrication are described. The anchored nanostructure materials may utilize nano-catalysts that include powder-based or solid-based support materials. The support material may comprise metal, such as NiAl, ceramic, a cermet, or silicon or other metalloid. Typically, nanoparticles are disposed adjacent a surface of the support material. Nanostructures may be formed as anchored to nanoparticles that are adjacent the surface of the support material by heating the nano-catalysts and then exposing the nano-catalysts to an organic vapor. The nanostructures are typically single wall or multi-wall carbon nanotubes.
    Type: Grant
    Filed: February 13, 2009
    Date of Patent: November 27, 2012
    Assignee: Babcock & Wilcox Technical Services Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Publication number: 20110285049
    Abstract: A precursor for carbon fiber production comprises a continuous lignin fiber including carbon nanotubes dispersed therein at a concentration of about 10 wt. % or less. A method of melt-spinning a continuous lignin fiber includes preparing a melt comprising molten lignin and a plurality of carbon nanotubes, and extruding the melt through a spinneret to form a continuous lignin fiber having the carbon nanotubes dispersed therein.
    Type: Application
    Filed: May 19, 2010
    Publication date: November 24, 2011
    Inventors: Frederick S. Baker, Darren A. Baker, Paul A. Menchhofer
  • Patent number: 8052951
    Abstract: Disclosed are structures formed as bulk support media having carbon nanotubes formed therewith. The bulk support media may comprise fibers or particles and the fibers or particles may be formed from such materials as quartz, carbon, or activated carbon. Metal catalyst species are formed adjacent the surfaces of the bulk support material, and carbon nanotubes are grown adjacent the surfaces of the metal catalyst species. Methods employ metal salt solutions that may comprise iron salts such as iron chloride, aluminum salts such as aluminum chloride, or nickel salts such as nickel chloride. Carbon nanotubes may be separated from the carbon-based bulk support media and the metal catalyst species by using concentrated acids to oxidize the carbon-based bulk support media and the metal catalyst species.
    Type: Grant
    Filed: April 3, 2009
    Date of Patent: November 8, 2011
    Assignee: UT-Battelle, LLC
    Inventors: Paul A. Menchhofer, Frederick C. Montgomery, Frederick S. Baker
  • Publication number: 20100254885
    Abstract: Disclosed are structures formed as bulk support media having carbon nanotubes formed therewith. The bulk support media may comprise fibers or particles and the fibers or particles may be formed from such materials as quartz, carbon, or activated carbon. Metal catalyst species are formed adjacent the surfaces of the bulk support material, and carbon nanotubes are grown adjacent the surfaces of the metal catalyst species. Methods employ metal salt solutions that may comprise iron salts such as iron chloride, aluminum salts such as aluminum chloride, or nickel salts such as nickel chloride. Carbon nanotubes may be separated from the carbon-based bulk support media and the metal catalyst species by using concentrated acids to oxidize the carbon-based bulk support media and the metal catalyst species.
    Type: Application
    Filed: April 3, 2009
    Publication date: October 7, 2010
    Inventors: Paul A. Menchhofer, Frederick C. Montgomery, Frederick S. Baker
  • Publication number: 20100210456
    Abstract: Nano-catalysts that have utility for forming nanostructures and manufacturing nanomaterials are described. In some embodiments the nano-catalyst is formed from a powder-based substrate material and is some embodiments the nano-catalyst is formed from a solid-based substrate material. In some embodiments the substrate material may include metal, ceramic, or silicon or another metalloid. The nano-catalysts typically have metal nanoparticles disposed adjacent the surface of the substrate material. Methods of forming the nano-catalysts are disclosed. The methods typically include functionalizing the surface of the substrate material with a chelating agent, such as a chemical having dissociated carboxyl functional groups (—COO), that provides an enhanced affinity for metal ions. The functionalized substrate surface may then be exposed to a chemical solution that contains metal ions.
    Type: Application
    Filed: February 13, 2009
    Publication date: August 19, 2010
    Applicant: BABCOCK & WILCOX TECHNICAL SERVICES Y-12, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang