Patents by Inventor Scott A. Whalen
Scott A. Whalen 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: 20210402471Abstract: A method for preparing a shear-assisted extruded material from a powder billet is provided, the method comprising providing a billet of material in substantially powder form; applying both axial and rotational pressure to the material to deform at least some of the contacted material; and extruding the material to form an extruded material. A method for preparing shear-assisted extruded material is provided, the method comprising applying both axial and rotational pressure to stock material to form an extruded material at a rate between 2 and 13 m/min. A method for preparing shear-assisted extruded material is provided. The method comprises applying both axial and rotational pressure to stock material to form an extruded material; and aging the extruded material for less than 3 hours. A method for preparing shear-assisted extruded material is provided.Type: ApplicationFiled: September 13, 2021Publication date: December 30, 2021Inventors: Scott A. Whalen, Jens T. Darsell, MD. Reza-E-Rabby, Brandon Scott Taysom, Tianhao Wang, Darrell R. Herling, Xiao Li
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Publication number: 20210379638Abstract: The present disclosure provides methods for preparing an extruded product from a solid billet. The methods can include providing an as-cast billet for extrusion; applying a simultaneous rotational shear and axial extrusion force to the as-cast billet to plasticize the as-cast billet; and extruding the plasticized as-cast billet with an extrusion die to form an extruded product. Methods for preparing extruded products from billets can also include: providing a billet for extrusion; while maintaining a majority of the billet below 100° C., applying a simultaneous rotational shear and axial extrusion force to one end of the billet to plasticize the one end of the billet; and extruding the plasticized one end of the billet with an extrusion die to form an extruded product.Type: ApplicationFiled: April 27, 2021Publication date: December 9, 2021Inventors: Scott A. Whalen, Darrell R. Herling, Xiao Li, MD. Reza-E-Rabby, Brandon Scott Taysom, Glenn J. Grant, Vineet V. Joshi, Rajib Kalsar, Tianhao Wang
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Publication number: 20210316350Abstract: A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.Type: ApplicationFiled: February 12, 2021Publication date: October 14, 2021Applicant: Battelle Memorial InstituteInventors: Vineet V. Joshi, Scott A. Whalen, Curt A. Lavender, Glenn J. Grant, MD. Reza-E-Rabby, Aashish Rohatgi, Jens T. Darsell
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Patent number: 11045851Abstract: A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.Type: GrantFiled: July 5, 2018Date of Patent: June 29, 2021Assignee: Battelle Memorial InstituteInventors: Vineet V. Joshi, Scott A. Whalen, Curt A. Lavender, Glenn J. Grant, MD. Reza-E-Rabby, Aashish Rohatgi, Jens T. Darsell
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Publication number: 20210053100Abstract: Shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can include applying a rotational shearing force and an axial extrusion to the same location on the feedstock material. Devices for this can include a die tool defined by a die face extending from a rim of the die face inwardly at an angle greater than zero in relation to a sidewall of the die tool in at least one cross section; and/or a die tool defining an opening configured to receive feedstock material for extrusion and further defining a die face defining a recess within the die face and contiguous with the opening. Shear-assisted extrusion processes are also provided that can mix different portions of the feedstock material within a recess about the opening prior to feedstock material entering the opening; and extruding the mixed portions.Type: ApplicationFiled: September 27, 2020Publication date: February 25, 2021Inventors: Scott A. Whalen, Darrell R. Herling, Xiao Li, MD. Reza-E-Rabby, Brandon Scott Taysom, Glenn J. Grant
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Publication number: 20210023596Abstract: A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.Type: ApplicationFiled: June 30, 2020Publication date: January 28, 2021Applicant: Battelle Memorial InstituteInventors: Vineet V. Joshi, Glenn J. Grant, Curt A. Lavender, Scott A. Whalen, Saumyadeep Jana, David Catalini, Jens T. Darsell
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Patent number: 10695811Abstract: A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.Type: GrantFiled: February 17, 2018Date of Patent: June 30, 2020Assignee: Battelle Memorial InstituteInventors: Vineet V. Joshi, Glenn J. Grant, Curt A. Lavender, Scott A. Whalen, Saumyadeep Jana, David Catalini, Jens T. Darsell
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Publication number: 20200016687Abstract: Methods are provided for connecting two dissimilar materials. The methods can include: placing a first material within a groove of a second material, the first material leaving at least a portion of the groove vacant; and placing a third material upon the first material and over the groove; heating the second and third materials to a temperature sufficient to plasticize the second and third materials within the groove and form a mixture of the second and third materials within the groove. Friction stir welding tools are also provided that can include a frusta conical tip having an upper portion defining smooth sidewalls and a lower portion defining a roughened structure.Type: ApplicationFiled: September 9, 2019Publication date: January 16, 2020Applicant: Battelle Memorial InstituteInventors: Scott A. Whalen, M.D. Reza-E-Rabby, Kenneth A. Ross, Martin McDonnell, Yuri Hovanski
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Publication number: 20200009626Abstract: Devices and methods for performing shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can use a device having a scroll face having an inner diameter portion bounded by an outer diameter portion, and a member extending from the inner diameter portion beyond a surface of the outer diameter portion. Extrusion feedstocks and extrusion processes are provided for forming extrusions of a desired composition from a feedstock. The processes can include providing a feedstock having at least two different materials and engaging the materials with one another within a feedstock container. Methods for preparing metal sheets are provided that can include preparing a metal tube via shear assisted processing and extrusion; opening the metal tube to form a sheet having a first thickness; and rolling the sheet to a second thickness that is less than the first thickness.Type: ApplicationFiled: September 5, 2019Publication date: January 9, 2020Applicant: Battelle Memorial InstituteInventors: Scott A. Whalen, Vineet V. Joshi, MD. Reza-E-Rabby, Jens T. Darsell, Mageshwari Komarasamy, Curt A. Lavender, Glenn J. Grant, Aashish Rohatgi, William E. Frazier, III
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Publication number: 20190283335Abstract: A method for solid state joining of dissimilar materials using a friction stir welding device wherein a pin is inserted through an aperture defined in a first material and a second material to hold the materials together and then held in place by friction stir welding a portion of the pin to a material adjacent said pin, or by friction stir welding a cap or plug that holds the pin in place to the adjacent material. The result is a connection or join wherein the central portion of the pin is not friction stir welded but the portions holding the pin in place (the ends or caps) generally are.Type: ApplicationFiled: March 26, 2019Publication date: September 19, 2019Applicant: BATTELLE MEMORIAL INSTITUTEInventors: Scott A. Whalen, MD. Reza-E-Rabby, Kenneth A. Ross, Aashish Rohatgi
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Patent number: 10369748Abstract: A method for solid state joining of dissimilar materials using a friction stir welding device wherein a pin is inserted through an aperture defined in a first material and a second material to hold the materials together and then held in place by friction stir welding a portion of the pin to a material adjacent said pin, or by friction stir welding a cap or plug that holds the pin in place to the adjacent material. The result is a connection or join wherein the central portion of the pin is not friction stir welded but the portions holding the pin in place (the ends or caps) generally are.Type: GrantFiled: October 26, 2017Date of Patent: August 6, 2019Assignee: BATTELLE MEMORIAL INSTITUTEInventors: Scott A. Whalen, Md. Reza-E-Rabby, Kenneth A. Ross, Aashish Rohatgi
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Publication number: 20190126561Abstract: A method for solid state joining of dissimilar materials using a friction stir welding device wherein a pin is inserted through an aperture defined in a first material and a second material to hold the materials together and then held in place by friction stir welding a portion of the pin to a material adjacent said pin, or by friction stir welding a cap or plug that holds the pin in place to the adjacent material. The result is a connection or join wherein the central portion of the pin is not friction stir welded but the portions holding the pin in place (the ends or caps) generally are.Type: ApplicationFiled: October 26, 2017Publication date: May 2, 2019Applicant: BATTELLE MEMORIAL INSTITUTEInventors: Scott A. Whalen, MD. Reza-E-Rabby, Kenneth A. Ross, Aashish Rohatgi
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Patent number: 10189063Abstract: Devices and processes for performing shear-assisted extrusion include a rotatable extrusion die with a scroll face configured to draw plasticized material from an outer edge of a billet generally perpendicularly toward an extrusion orifice while the extrusion die assembly simultaneously applies a rotational shear and axial extrusion force to the billet.Type: GrantFiled: November 14, 2016Date of Patent: January 29, 2019Assignee: BATTELLE MEMORIAL INSTITUTEInventors: Curtis A. Lavender, Vineet V. Joshi, Glenn J. Grant, Saumyadeep Jana, Scott A. Whalen, Jens T. Darsell, Nicole R. Overman
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Publication number: 20180311713Abstract: A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.Type: ApplicationFiled: July 5, 2018Publication date: November 1, 2018Applicant: BATTELLE MEMORIAL INSTITUTEInventors: Vineet V. Joshi, Scott A. Whalen, Curt A. Lavender, Glenn J. Grant, MD. Reza-E-Rabby, Aashish Rohatgi, Jens T. Darsell
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Publication number: 20180250727Abstract: A shear assisted extrusion process for producing cladded materials wherein a cladding material and a material to be cladded are placed in sequence with the cladded material positioned to contact a rotating scroll face first and the material to be cladded second. The two materials are fed through a shear assisted extrusion device at a preselected feed rate and impacted by a rotating scroll face to generate a cladded extrusion product. This process allows for increased through wall strength and decreases the brittleness in formed structures as compared to the prior art.Type: ApplicationFiled: February 17, 2018Publication date: September 6, 2018Applicant: BATTELLE MEMORIAL INSTITUTEInventors: Vineet V. Joshi, Glenn J. Grant, Curt A. Lavender, Scott A. Whalen, Saumyadeep Jana, David Catalini, Jens T. Darsell
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Publication number: 20180073532Abstract: A method for connecting two dissimilar materials having different melting points is described wherein a the materials are heated together to obtain plasticization of the lower melting point material within a prefigured geometry within a first material in such a way so as to form intermetallic features within a solid state joint.Type: ApplicationFiled: September 1, 2017Publication date: March 15, 2018Applicant: BATTELLE MEMORIAL INSTITUTEInventors: Scott A. Whalen, Kenneth A. Ross, M. D. Reza-E-Rabby, Yuri Hovanski
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Publication number: 20170056947Abstract: Devices and processes for performing shear-assisted extrusion include a rotatable extrusion die with a scroll face configured to draw plasticized material from an outer edge of a billet generally perpendicularly toward an extrusion orifice while the extrusion die assembly simultaneously applies a rotational shear and axial extrusion force to the billet.Type: ApplicationFiled: November 14, 2016Publication date: March 2, 2017Applicant: BATTELLE MEMORIAL INSTITUTEInventors: Curtis A. Lavender, Vineet V. Joshi, Glenn J. Grant, Saumyadeep Jana, Scott A. Whalen, Jens T. Darsell, Nicole R. Overman
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Patent number: 7419716Abstract: Methods for providing surface coverings with differential gloss, and surface coverings prepared by the method, are disclosed. The methods involve screen printing or rotogravure printing a relatively low gloss primer onto portions of a substrate surface covering. The primer-coated substrate is then coated with a relatively higher gloss coating composition, and the coating compositions are cured, advantageously in a single curing step. The result is a surface covering including a top coat having a lower gloss level overlying the primer and a higher gloss level in the regions not overlying the primer.Type: GrantFiled: May 30, 2003Date of Patent: September 2, 2008Assignee: AWI Licensing CompanyInventors: Dong Tian, Ralph W. Wright, Jr., Scott Whalen
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Publication number: 20070031785Abstract: An oral care device for use in an oral cavity is provided. The oral care device comprises a handle having proximal and distal ends and an acoustic emitter disposed at the distal end of the handle. An emitting surface is acoustically coupled to the acoustic emitter. The emitting surface is sized for insertion to the oral cavity.Type: ApplicationFiled: October 16, 2006Publication date: February 8, 2007Inventor: Scott Whalen
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Publication number: 20060008767Abstract: An oral care device for use in an oral cavity is provided. The oral care device comprises a handle having proximal and distal ends and an acoustic emitter disposed at the distal end of the handle. An emitting surface is acoustically coupled to the acoustic emitter. The emitting surface is sized for insertion to the oral cavity.Type: ApplicationFiled: April 6, 2005Publication date: January 12, 2006Applicant: The Procter & Gamble CompanyInventor: Scott Whalen