Patents by Inventor Seyed Mohammad Sajadi
Seyed Mohammad Sajadi 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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Patent number: 11858039Abstract: Methods for fabricating a multi-material composite structure are described. Methods for fabricating a multi-material composite structure include forming a first colloidal ink solution with a first material matrix, water, and a rheology modifying agent; forming a second colloidal ink solution with a second material matrix, water, and a rheology modifying agent; printing a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution; printing a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution; forming a 3D structure by printing a plurality of layers including the first layer and the second layer printed in an alternating pattern; and sintering the 3D structure to form the multi-material composite structure.Type: GrantFiled: January 13, 2022Date of Patent: January 2, 2024Assignees: Saudi Arabian Oil Company, William Marsh Rice UniversityInventors: Seyed Mohammad Sajadi, Peter Boul, Chandra Sekhar Tiwary, Muhammad M. Rahman, Pulickel M. Ajayan, Carl Thaemltiz
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Publication number: 20230330923Abstract: A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.Type: ApplicationFiled: June 20, 2023Publication date: October 19, 2023Applicants: SAUDI ARABIAN OIL COMPANY, WILLIAM MARSH RICE UNIVERSITYInventors: Seyed Mohammad SAJADI, Ashok Kumar MEIYAZHAGAN, Peter BOUL, Muhammad RAHMAN, Carl THAEMLITZ, Pulickel AJAYAN
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Publication number: 20230330922Abstract: A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.Type: ApplicationFiled: June 20, 2023Publication date: October 19, 2023Applicants: SAUDI ARABIAN OIL COMPANY, WILLIAM MARSH RICE UNIVERSITYInventors: Seyed Mohammad SAJADI, Ashok Kumar MEIYAZHAGAN, Peter BOUL, Muhammad RAHMAN, Carl THAEMLITZ, Pulickel AJAYAN
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Publication number: 20230330921Abstract: A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.Type: ApplicationFiled: June 20, 2023Publication date: October 19, 2023Applicants: SAUDI ARABIAN OIL COMPANY, WILLIAM MARSH RICE UNIVERSITYInventors: Seyed Mohammad SAJADI, Ashok Kumar MEIYAZHAGAN, Peter BOUL, Muhammad RAHMAN, Carl THAEMLITZ, Pulickel AJAYAN
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Publication number: 20230330936Abstract: A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.Type: ApplicationFiled: June 20, 2023Publication date: October 19, 2023Applicants: SAUDI ARABIAN OIL COMPANY, WILLIAM MARSH RICE UNIVERSITYInventors: Seyed Mohammad SAJADI, Ashok Kumar MEIYAZHAGAN, Peter BOUL, Muhammad RAHMAN, Carl THAEMLITZ, Pulickel AJAYAN
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Patent number: 11724443Abstract: A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.Type: GrantFiled: May 14, 2020Date of Patent: August 15, 2023Assignees: SAUDI ARABIAN OIL COMPANY, WILLIAM MARSH RICE UNIVERSITYInventors: Seyed Mohammad Sajadi, AshokKumar Meiyazhagan, Peter Boul, Muhammad Rahman, Carl Thaemlitz, Pulickel Ajayan
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Publication number: 20230226746Abstract: An improved method and apparatus for adding a new layer to a stack of previously processed layers. In an example, a method is provided for mounting the previously processed layer on a build platform, mounting the new layer on a substrate, aligning the new layer with the previously processed layer, moving the new layer and the previously processed into contact with one another, and applying energy to the new layer from an energy source through the substrate to simultaneously process the new layer and bond the new layer to the previously processed layer to form a bonded processed multilayer stack on the build platform. A flexible compliant pressure conveyance media is moved into contact with the substrate to apply pressure to the new layer while the energy is being applied.Type: ApplicationFiled: January 13, 2023Publication date: July 20, 2023Applicant: Sakuu CorporationInventors: Morteza VATANI, Seyed Mohammad SAJADI
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Publication number: 20230226727Abstract: The present disclosure pertains to an improved method and apparatus for compacting a powder layer. An exemplary method comprises placing the substrate on a first plate, placing a second plate over the powder layer so that the substrate and the powder layer are sandwiched between the first plate and the second plate to form a multilayered structure comprising the first plate, the substrate, the powder layer and the second plate, and calendering the multilayered structure between a top calendering roller and a bottom calendering roller.Type: ApplicationFiled: December 19, 2022Publication date: July 20, 2023Applicant: Sakuu CorporationInventors: Seyed Mohammad SAJADI, Morteza VATANI, Siamak AZIZI
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Publication number: 20230226762Abstract: Improved carrier plates and methods of use thereof are provided to secure and transport individual layers of a multilayer structure during manufacture of the multilayer structure. In one implementation a carrier plate is provided including a lower portion and a raised portion to support a flexible substrate holding an individual layer laid on an upper surface of the raised portion. Clamping mechanisms, such as rollers, are formed on extended regions adjacent to side walls of the raised portion. The clamping mechanisms are configured to move from open positions, where the clamping mechanisms are spaced apart from the sidewalls of the raised portion, to closed positions, where the clamping mechanisms secure opposite edge portions of the flexible substrate between the clamping mechanisms and the first and sidewalls of the raised portion.Type: ApplicationFiled: December 2, 2022Publication date: July 20, 2023Applicant: Sakuu CorporationInventors: Morteza VATANI, Seyed Mohammad SAJADI, Timothy BYMAN, Tom HAYS, Peter BRUSS, Don AMBLI, Justin CARROLL, Lawrence NGUYEN
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Publication number: 20230226756Abstract: A method and system for 3D printing for creating at least two discrete sections of powder on a substrate, segmenting the substrate to isolate the at least two discrete sections of powder, compacting the powder on a segment of the substrate, removing loose/non-compacted powder from the segment of the substrate, create a printed/processed layer by performing one or more of a printing process or a processing operation on the segment of substrate, and transferring the printed/processed layers from the segment of substrate to a build platform.Type: ApplicationFiled: January 13, 2023Publication date: July 20, 2023Applicant: Sakuu CorporationInventors: Morteza VATANI, Seyed Mohammad SAJADI, Steven Zhichao SHI, David Paul WANAMAKER, Siamak AZIZI, Karl LITTAU
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Publication number: 20230226764Abstract: An improved apparatus and method provide conditioning to a powder deposited on a substrate (e.g., a web), for example, by wetting the powder in a 3D printing apparatus. To achieve this in an exemplary implementation, a wetting apparatus is located between a powder dispenser and at least one top calendering roller in a direction of movement of the substrate, wherein the wetting apparatus is configured to apply a wetting agent to the powder on the substrate before the powder passes through the calendering roller. The wetting agent is comprised of a material which increases cohesiveness of the powder to prevent the powder from adhering to the top roller. In a particular implementation, the wetting agent is steam confined to an area of the substrate where the powder passes through the wetting apparatus, without wetting other areas of the substrate which are not in the wetting apparatus.Type: ApplicationFiled: December 2, 2022Publication date: July 20, 2023Applicant: Sakuu CorporationInventors: Morteza VATANI, Seyed Mohammad SAJADI, David Paul WANAMAKER, Kevin NESDAHL, Tim DEBRUIN, Brian LINDAHL, Justin CARROLL
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Publication number: 20230219138Abstract: Methods for fabricating a multi-material composite structure are described. Methods for fabricating a multi-material composite structure include forming a first colloidal ink solution with a first material matrix, water, and a rheology modifying agent; forming a second colloidal ink solution with a second material matrix, water, and a rheology modifying agent; printing a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution; printing a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution; forming a 3D structure by printing a plurality of layers including the first layer and the second layer printed in an alternating pattern; and sintering the 3D structure to form the multi-material composite structure.Type: ApplicationFiled: January 13, 2022Publication date: July 13, 2023Inventors: Seyed Mohammad Sajadi, Peter Boul, Chandra Sekhar Tiwary, Muhammad M. Rahman, Pulickel M. Ajayan, Carl Thaemltiz
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Publication number: 20230016497Abstract: A three-dimensional (ā3Dā) printing system for printing on a substrate, the printing system including a powder distribution device dispensing powder on the substrate and including a blade-shaped end, the blade-shaped end disposed at a height above the substrate; a powder uniformization device located at a distance from the powder distribution device along a direction substantially parallel to a longitudinal axis of the substrate; one or more sensors disposed upstream from the powder uniformization device and configured to determine one or more parameters of a thickness of the dispensed powder at one or more locations; and a control apparatus configured to determine whether the one or more parameters of the thickness is above a predetermined threshold value, and if the one or more parameters is determined to be above the predetermined threshold value, to adjust the powder distribution device.Type: ApplicationFiled: June 16, 2022Publication date: January 19, 2023Applicant: Sakuu CorporationInventors: Morteza VATANI, Siamak AZIZI, Seyed Mohammad SAJADI, Steven Zhichao SHI
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Publication number: 20230020717Abstract: Examples relate to a print station of a three-dimensional (ā3Dā) printing apparatus, and method of 3D printing, the print station including a substrate configured to hold a printed object, the substrate having a longitudinal axis, and a print system over the substrate, the print system including a powder distribution device including a blade-shaped end, and a powder uniformization device located at a distance from the powder distribution device along a direction parallel to the longitudinal axis.Type: ApplicationFiled: July 14, 2021Publication date: January 19, 2023Applicant: Sakuu CorporationInventors: Morteza VATANI, Siamak AZIZI, Seyed Mohammad SAJADI, Steven Z. SHI
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Publication number: 20210354366Abstract: A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.Type: ApplicationFiled: May 14, 2020Publication date: November 18, 2021Applicants: SAUDI ARABIAN OIL COMPANY, WILLIAM MARSH RICE UNIVERSITYInventors: Seyed Mohammad SAJADI, AshokKumar MEIYAZHAGAN, Peter BOUL, Muhammad RAHMAN, Carl THAEMLITZ, Pulickel AJAYAN
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Patent number: 10913683Abstract: Provide is a cement ink for a cement ink for 3D printing (which also includes additive manufacturing) of 3D cement structures and materials. The cement ink includes an American Petroleum Institute (API) Class G cement, a nano-clay, a superplasticizer, a hydroxyethyl cellulose, and a defoamer. The nano-clay may be hydrophilic bentonite. The superplasticizer may be a polycarboxylate ether. The defoamer may be 2-ethyl-1-hexanol. Processes for forming the cement ink and printing 3D cement structures using the cement ink are also provided.Type: GrantFiled: October 8, 2019Date of Patent: February 9, 2021Assignees: Saudi Arabian Oil Company, William Marsh Rice UniversityInventors: Muhammad M Rahman, Seyed Mohammad Sajadi, Ashok Kumar, Peter J Boul, Carl Thaemlitz, Pulickel M Ajayan
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Publication number: 20200181014Abstract: Provide is a cement ink for a cement ink for 3D printing (which also includes additive manufacturing) of 3D cement structures and materials. The cement ink includes an American Petroleum Institute (API) Class G cement, a nano-clay, a superplasticizer, a hydroxyethyl cellulose, and a defoamer. The nano-clay may be hydrophilic bentonite. The superplasticizer may be a polycarboxylate ether. The defoamer may be 2-ethyl-1-hexanol. Processes for forming the cement ink and printing 3D cement structures using the cement ink are also provided.Type: ApplicationFiled: October 8, 2019Publication date: June 11, 2020Inventors: Muhammad M. Rahman, Seyed Mohammad Sajadi, Ashok Kumar, Peter J. Boul, Carl Thaemlitz, Pulickel M. Ajayan