Patents by Inventor Scott N. Roberts

Scott N. Roberts 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: 20220212254
    Abstract: Systems and methods for developing tough hypoeutectic amorphous metal-based materials for additive manufacturing, and methods of additive manufacturing using such materials are provided. The methods use 3D printing of discrete thin layers during the assembly of bulk parts from metallic glass alloys with compositions selected to improve toughness at the expense of glass forming ability. The metallic glass alloy used in manufacturing of a bulk part is selected to have minimal glass forming ability for the per layer cooling rate afforded by the manufacturing process, and may be specially composed for high toughness.
    Type: Application
    Filed: November 29, 2021
    Publication date: July 7, 2022
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Andre M. Pate, Scott N. Roberts
  • Publication number: 20220136779
    Abstract: Systems and methods for thermal management using separable heat pipes and methods of manufacture thereof. Various embodiments provide a porous insert that can be used to join or connect heat pipes. Further embodiments provide thermal management systems that are modular, expandable, reparable, by allowing for joining of evaporators, condensers, and adiabatic sections via porous inserts. Various embodiments allow for two-phase thermal management systems, where liquid and gaseous phases can be transported simultaneously. Certain embodiments incorporate heat generating components with embedded evaporators and/or condensers. Many embodiments are additively manufactured, including via 3D printing.
    Type: Application
    Filed: November 2, 2021
    Publication date: May 5, 2022
    Applicant: California Institute of Technology
    Inventors: Weibo Chen, Benjamin I. Furst, Scott N. Roberts
  • Patent number: 11185921
    Abstract: Systems and methods for developing tough hypoeutectic amorphous metal-based materials for additive manufacturing, and methods of additive manufacturing using such materials are provided. The methods use 3D printing of discrete thin layers during the assembly of bulk parts from metallic glass alloys with compositions selected to improve toughness at the expense of glass forming ability. The metallic glass alloy used in manufacturing of a bulk part is selected to have minimal glass forming ability for the per layer cooling rate afforded by the manufacturing process, and may be specially composed for high toughness.
    Type: Grant
    Filed: May 24, 2018
    Date of Patent: November 30, 2021
    Assignee: California Institute of Technology
    Inventors: Douglas C. Hofmann, Andre M. Pate, Scott N. Roberts
  • Patent number: 11155907
    Abstract: Systems and methods in accordance with embodiments of the invention advantageously shape sheet materials that include metallic glass-based materials. In one embodiment, a method of shaping a sheet of material including a metallic glass-based material includes: heating a metallic glass-based material within a first region within a sheet of material to a temperature greater than the glass transition temperature of the metallic glass-based material; where the sheet of material has a thickness of between 0.
    Type: Grant
    Filed: December 28, 2017
    Date of Patent: October 26, 2021
    Assignee: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Patent number: 11114713
    Abstract: Thermal management systems for battery cells and methods for their additive manufacture are provided. The thermal management systems include at least one heat pipe that physically contacts the battery cell and conforms to its geometry. Each battery cell is deposited within a separate heat pipe, and each heat pipe is disposed on a base plate, which itself connects to a heat sink. In many embodiments, the heat pipe is a two-phase heat exchanger having three major components: liquid channels, wick elements, and vapor channels. In such embodiments, the wick component comprises a porous body configured to be disposed between the liquid channels and vapor channels. The wick component may be made using a stochastic additive manufacturing process such that the wick component may take any configuration and/or such that the wick component may be directly integrated into the body of the heat pipe as a unitary piece thereof.
    Type: Grant
    Filed: June 20, 2019
    Date of Patent: September 7, 2021
    Assignee: California Institute of Technology
    Inventors: Eric T. Sunada, Scott N. Roberts, Benjamin I. Furst, Ratnakumar V. Bugga
  • Publication number: 20210207281
    Abstract: Systems and method for fabricating a metal core truss pan& with seamlessly embedded features in accordance with embodiments of the invention are illustrated. One embodiment includes a method for producing a metal core truss pan& composite, the method including fabricating a sacrificial core truss panel including a plurality of interconnected truss members and at least one embedded feature, and plating the sacrificial core truss panel with a layer of metal forming a metal core truss panel including a plurality of interconnected metal truss members and at least one seamlessly embedded metal feature.
    Type: Application
    Filed: March 3, 2021
    Publication date: July 8, 2021
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Patent number: 10968527
    Abstract: Systems and method for fabricating a metal core truss panel with seamlessly embedded features in accordance with embodiments of the invention are illustrated. One embodiment includes a method for producing a metal core truss panel composite, the method including fabricating a sacrificial core truss panel including a plurality of interconnected truss members and at least one embedded feature, and plating the sacrificial core truss panel with a layer of metal forming a metal core truss panel including a plurality of interconnected metal truss members and at least one seamlessly embedded metal feature.
    Type: Grant
    Filed: November 8, 2016
    Date of Patent: April 6, 2021
    Assignee: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Publication number: 20200378687
    Abstract: Multi-phase thermal control systems, evaporators, variable porous wick elements, heat transfer structures, and methods for their production are provided. Two-phase evaporators for use in such multi-phase thermal control systems are also provided. Two-phase evaporators incorporate a vapor plate body having there three major layers: a vapor channel network, a wick, and a liquid channel. The vapor channel network comprises a plurality of extrusions (e.g., vapor pillars) and associated channels (e.g., vapor channels) configured to allow a vapor to flow therethrough. The wick comprises a porous body configured to be disposed between the vapor channel network of and the liquid flow reservoir.
    Type: Application
    Filed: August 17, 2020
    Publication date: December 3, 2020
    Applicant: California Institute of Technology
    Inventors: Scott N. Roberts, Arthur J. Mastropietro, Benjamin I. Furst, Eric T. Sunada, Jordan Mizerak, Hiroki Nagai, Stefano Cappucci
  • Publication number: 20200278017
    Abstract: Harmonic drives are used widely in robotics as a method for achieving high gear reductions and for driving force transmissions. The harmonic drive is made a three components: a wave generator, a flexspline, and a circular spline. Embodiments described flexsplines for a metal strain wave gearing. The cup of the flexspline is free from sharp edges and with a rounded bottom with a curvature maximized based on the geometry of the flexspline. Compared to a steel flexspline, implementations of flexsplines will have the same outer diameter, the same number of teeth and profile, the same input shaft/base, the same wall thickness near the teeth, but comprise a rounded bottom where the input shaft/base transitions to the straight wall of the flexspline, providing improved performance of BMG flexsplines by reducing low cycle fatigue failures due to stress concentrations.
    Type: Application
    Filed: February 26, 2020
    Publication date: September 3, 2020
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Robert P. Dillon, Scott N. Roberts
  • Patent number: 10746475
    Abstract: Multi-phase thermal control systems, evaporators, variable porous wick elements, heat transfer structures, and methods for their production are provided. Two-phase evaporators for use in such multi-phase thermal control systems are also provided. Two-phase evaporators incorporate a vapor plate body having there three major layers: a vapor channel network, a wick, and a liquid channel. The vapor channel network comprises a plurality of extrusions (e.g., vapor pillars) and associated channels (e.g., vapor channels) configured to allow a vapor to flow therethrough. The wick comprises a porous body configured to be disposed between the vapor channel network of and the liquid flow reservoir.
    Type: Grant
    Filed: August 1, 2017
    Date of Patent: August 18, 2020
    Assignee: California Institute of Technology
    Inventors: Scott N. Roberts, Arthur J. Mastropietro, Benjamin I. Furst, Eric T. Sunada, Jordan Mizerak, Hiroki Nagai, Stefano Cappucci
  • Publication number: 20200108443
    Abstract: Systems and methods for additive manufacturing systems implementing adaptive optics in accordance with various embodiments of the invention are illustrated. One embodiment includes an additive manufacturing system including a laser source configured to form an output beam, a scanning mirror disposed in an optical path of the output beam, wherein the scanning mirror is configured to reflect and scan the output beam at a range of scan angles, a deformable mirror disposed in the optical path of the output beam, wherein the deformable mirror has a plurality of configurations for reflecting and altering a wavefront of the output beam, wherein the configuration of the deformable mirror is based on the scan angle of the scanning mirror, and a print bed configured to hold a print material, wherein the output beam is configured to fuse the print material to form a build object.
    Type: Application
    Filed: October 8, 2019
    Publication date: April 9, 2020
    Applicant: California Institute of Technology
    Inventors: John B. Steeves, Scott N. Roberts, Samuel C. Bradford, Christine A. Gebara, Christina J. Naify
  • Publication number: 20190393576
    Abstract: Thermal management systems for battery cells and methods for their additive manufacture are provided. The thermal management systems include at least one heat pipe that physically contacts the battery cell and conforms to its geometry. Each battery cell is deposited within a separate heat pipe, and each heat pipe is disposed on a base plate, which itself connects to a heat sink. In many embodiments, the heat pipe is a two-phase heat exchanger having three major components: liquid channels, wick elements, and vapor channels. In such embodiments, the wick component comprises a porous body configured to be disposed between the liquid channels and vapor channels. The wick component may be made using a stochastic additive manufacturing process such that the wick component may take any configuration and/or such that the wick component may be directly integrated into the body of the heat pipe as a unitary piece thereof.
    Type: Application
    Filed: June 20, 2019
    Publication date: December 26, 2019
    Applicant: California Institute of Technology
    Inventors: Eric T. Sunada, Scott N. Roberts, Benjamin I. Furst, Ratnakumar V. Bugga
  • Publication number: 20180339338
    Abstract: Systems and methods for developing tough hypoeutectic amorphous metal-based materials for additive manufacturing, and methods of additive manufacturing using such materials are provided. The methods use 3D printing of discrete thin layers during the assembly of bulk parts from metallic glass alloys with compositions selected to improve toughness at the expense of glass forming ability. The metallic glass alloy used in manufacturing of a bulk part is selected to have minimal glass forming ability for the per layer cooling rate afforded by the manufacturing process, and may be specially composed for high toughness.
    Type: Application
    Filed: May 24, 2018
    Publication date: November 29, 2018
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Andre M. Pate, Scott N. Roberts
  • Publication number: 20180119259
    Abstract: Systems and methods in accordance with embodiments of the invention advantageously shape sheet materials that include metallic glass-based materials. In one embodiment, a method of shaping a sheet of material including a metallic glass-based material includes: heating a metallic glass-based material within a first region within a sheet of material to a temperature greater than the glass transition temperature of the metallic glass-based material; where the sheet of material has a thickness of between 0.
    Type: Application
    Filed: December 28, 2017
    Publication date: May 3, 2018
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Publication number: 20180031330
    Abstract: Multi-phase thermal control systems, evaporators, variable porous wick elements, heat transfer structures, and methods for their production are provided. Two-phase evaporators for use in such multi-phase thermal control systems are also provided. Two-phase evaporators incorporate a vapor plate body having there three major layers: a vapor channel network, a wick, and a liquid channel. The vapor channel network comprises a plurality of extrusions (e.g., vapor pillars) and associated channels (e.g., vapor channels) configured to allow a vapor to flow therethrough. The wick comprises a porous body configured to be disposed between the vapor channel network of and the liquid flow reservoir.
    Type: Application
    Filed: August 1, 2017
    Publication date: February 1, 2018
    Applicant: California Institute of Technology
    Inventors: Scott N. Roberts, Arthur J. Mastropietro, Benjamin I. Furst, Eric T. Sunada
  • Publication number: 20170137955
    Abstract: Systems and method for fabricating a metal core truss panel with seamlessly embedded features in accordance with embodiments of the invention are illustrated. One embodiment includes a method for producing a metal core truss panel composite, the method including fabricating a sacrificial core truss panel including a plurality of interconnected truss members and at least one embedded feature, and plating the sacrificial core truss panel with a layer of metal forming a metal core truss panel including a plurality of interconnected metal truss members and at least one seamlessly embedded metal feature.
    Type: Application
    Filed: November 8, 2016
    Publication date: May 18, 2017
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Patent number: 9610650
    Abstract: Systems and methods in accordance with embodiments of the invention fabricate objects including metallic glass-based materials using ultrasonic welding. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: ultrasonically welding at least one ribbon to a surface; where at least one ribbon that is ultrasonically welded to a surface has a thickness of less than approximately 150 ?m; and where at least one ribbon that is ultrasonically welded to a surface includes a metallic glass-based material.
    Type: Grant
    Filed: April 23, 2014
    Date of Patent: April 4, 2017
    Assignee: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Patent number: 9187812
    Abstract: Systems and methods for joining BMG Composites are disclosed. Specifically, the joining of BMG Composites is implemented so as to preserve the amorphicity of their matrix phase and the microstructure of their particulate phase. Implementation of the joining method with respect to the construction of modular cellular structures that comprise BMG Composites is also discussed.
    Type: Grant
    Filed: March 12, 2012
    Date of Patent: November 17, 2015
    Assignee: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts, Henry Kozachkov, Marios D. Demetriou, Joseph P. Schramm, William L. Johnson
  • Publication number: 20140342179
    Abstract: Systems and methods in accordance with embodiments of the invention advantageously shape sheet materials that include metallic glass-based materials. In one embodiment, a method of shaping a sheet of material including a metallic glass-based material includes: heating a metallic glass-based material within a first region within a sheet of material to a temperature greater than the glass transition temperature of the metallic glass-based material; where the sheet of material has a thickness of between 0.
    Type: Application
    Filed: April 14, 2014
    Publication date: November 20, 2014
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts
  • Publication number: 20140312098
    Abstract: Systems and methods in accordance with embodiments of the invention fabricate objects including metallic glass-based materials using ultrasonic welding. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: ultrasonically welding at least one ribbon to a surface; where at least one ribbon that is ultrasonically welded to a surface has a thickness of less than approximately 150 ?m; and where at least one ribbon that is ultrasonically welded to a surface includes a metallic glass-based material.
    Type: Application
    Filed: April 23, 2014
    Publication date: October 23, 2014
    Applicant: California Institute of Technology
    Inventors: Douglas C. Hofmann, Scott N. Roberts