Patents by Inventor Thomas Dale Ketcham

Thomas Dale Ketcham 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: 10967539
    Abstract: A manufacturing line includes a tape of green material that is directed through a furnace so that the furnace burns off organic binder material and then partially sinters the tape without the use of a setter board. Sintered articles resulting from the manufacturing line may be thin with relatively large surface areas; and, while substantially unpolished, have few sintering-induced surface defects. Tension may be applied to the partially sintered tape as it passes through a second furnace on the manufacturing line to shape resulting sintered articles.
    Type: Grant
    Filed: October 21, 2020
    Date of Patent: April 6, 2021
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
  • Publication number: 20210047243
    Abstract: Ceramic assembly can comprise a ceramic article comprising a thickness defined between a first major surface and a second major surface. The thickness can be about 100 micrometers or less. The ceramic assembly can comprise a polymer coating deposited over at least an outer peripheral portion of the first major surface of the ceramic article. The polymer coating can comprise a thickness of about 30 micrometers or less. An edge strength of the ceramic assembly can be greater than an edge strength of the ceramic article by about 50 MegaPascals or more. Methods of forming a ceramic assembly can comprise depositing a polymer coating on an outer peripheral portion of a first major surface of a ceramic article. Methods can further comprise curing the polymer coating.
    Type: Application
    Filed: October 27, 2020
    Publication date: February 18, 2021
    Inventors: Michael Edward Badding, Francis Martin Behan, Seo-Yeong Cho, Benedict Yorke Johnson, Thomas Dale Ketcham, Robert George Manley, Seongho Seok, Nikolay Zhelev Zhelev, Cheng-Gang Zhuang
  • Publication number: 20210031406
    Abstract: A manufacturing line includes a tape of green material that is directed through a furnace so that the furnace burns off organic binder material and then partially sinters the tape without the use of a setter board. Sintered articles resulting from the manufacturing line may be thin with relatively large surface areas; and, while substantially unpolished, have few sintering-induced surface defects. Tension may be applied to the partially sintered tape as it passes through a second furnace on the manufacturing line to shape resulting sintered articles.
    Type: Application
    Filed: October 21, 2020
    Publication date: February 4, 2021
    Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
  • Patent number: 10875212
    Abstract: A manufacturing line includes a tape of green material that is directed through a furnace so that the furnace burns off organic binder material and then partially sinters the tape without the use of a setter board. Sintered articles resulting from the manufacturing line may be thin with relatively large surface areas; and, while substantially unpolished, have few sintering-induced surface defects. Tension may be applied to the partially sintered tape as it passes through a second furnace on the manufacturing line to shape resulting sintered articles.
    Type: Grant
    Filed: July 16, 2020
    Date of Patent: December 29, 2020
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
  • Publication number: 20200346367
    Abstract: A manufacturing line includes a tape of green material that is directed through a furnace so that the furnace burns off organic binder material and then partially sinters the tape without the use of a setter board. Sintered articles resulting from the manufacturing line may be thin with relatively large surface areas; and, while substantially unpolished, have few sintering-induced surface defects. Tension may be applied to the partially sintered tape as it passes through a second furnace on the manufacturing line to shape resulting sintered articles.
    Type: Application
    Filed: July 16, 2020
    Publication date: November 5, 2020
    Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
  • Patent number: 10766165
    Abstract: A manufacturing line includes a tape of green material that is directed through a furnace so that the furnace burns off organic binder material and then partially sinters the tape without the use of a setter board. Sintered articles resulting from the manufacturing line may be thin with relatively large surface areas; and, while substantially unpolished, have few sintering-induced surface defects. Tension may be applied to the partially sintered tape as it passes through a second furnace on the manufacturing line to shape resulting sintered articles.
    Type: Grant
    Filed: July 25, 2016
    Date of Patent: September 8, 2020
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
  • Publication number: 20200152268
    Abstract: A method of manufacturing a doped polycrystalline ceramic optical device includes mixing a plurality of transition metal complexes and a plurality of rare-earth metal complexes to form a metal salt solution, heating the metal salt solution to form a heated metal salt solution, mixing the heated metal salt solution and an organic precursor to induce a chemical reaction between the heated metal salt solution and the organic precursor to produce a plurality of rare-earth doped crystalline nanoparticles, and sintering the plurality of rare-earth doped nanoparticles to form a doped polycrystalline ceramic optical device having a rare-earth element dopant that is uniformly distributed within a crystal lattice of the doped polycrystalline ceramic optical device.
    Type: Application
    Filed: January 17, 2020
    Publication date: May 14, 2020
    Inventors: Jason Allen Brown, Stuart Gray, Thomas Dale Ketcham, Daniel Aloysius Nolan, Wageesha Senaratne, Jun Yang, Haitao Zhang
  • Patent number: 10604451
    Abstract: A method of treating a ceramic body in a glass making process includes delivering a molten glass to a heated ceramic body, the ceramic body including a ceramic phase and an intergranular glass phase, the molten glass being in contact with a surface of the ceramic body. The method further includes contacting the ceramic body with a first electrode and contacting the molten glass with a second electrode. The method further includes applying an electric field between the first electrode and the second electrode to create an electric potential difference across the ceramic body between the first and second electrodes, the electric potential difference being less than an electrolysis threshold of the ceramic phase and the intergranular glass phase. The intergranular glass phase demixes under driven diffusion in the applied electric field and mobile cations in the intergranular glass phase enrich proximate one of the first and second electrode.
    Type: Grant
    Filed: December 8, 2015
    Date of Patent: March 31, 2020
    Assignee: Corning Incorporated
    Inventors: Monika Backhaus-Ricoult, Thomas Dale Ketcham
  • Patent number: 10581115
    Abstract: Electrolyte for a solid-state battery includes a body having grains of inorganic material sintered to one another, where the grains include lithium. The body is thin, has little porosity by volume, and has high ionic conductivity.
    Type: Grant
    Filed: March 7, 2019
    Date of Patent: March 3, 2020
    Assignee: CORNING INCORPORATED
    Inventors: Michael Edward Badding, Jacqueline Leslie Brown, Jennifer Anella Heine, Thomas Dale Ketcham, Gary Edward Merz, Eric Lee Miller, Zhen Song, Cameron Wayne Tanner, Conor James Walsh
  • Patent number: 10553280
    Abstract: A method of manufacturing a doped polycrystalline ceramic optical device includes mixing a plurality of transition metal complexes and a plurality of rare-earth metal complexes to form a metal salt solution, heating the metal salt solution to form a heated metal salt solution, mixing the heated metal salt solution and an organic precursor to induce a chemical reaction between the heated metal salt solution and the organic precursor to produce a plurality of rare-earth doped crystalline nanoparticles, and sintering the plurality of rare-earth doped nanoparticles to form a doped polycrystalline ceramic optical device having a rare-earth element dopant that is uniformly distributed within a crystal lattice of the doped polycrystalline ceramic optical device.
    Type: Grant
    Filed: February 27, 2018
    Date of Patent: February 4, 2020
    Assignee: Corning Incorporated
    Inventors: Jason Allen Brown, Stuart Gray, Thomas Dale Ketcham, Daniel Aloysius Nolan, Wageesha Senaratne, Jun Yang, Haitao Zhang
  • Publication number: 20200031014
    Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.
    Type: Application
    Filed: October 2, 2019
    Publication date: January 30, 2020
    Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
  • Patent number: 10486332
    Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.
    Type: Grant
    Filed: December 19, 2017
    Date of Patent: November 26, 2019
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
  • Patent number: 10435323
    Abstract: A method of making a glass sheet includes exposing a refractory block material comprising at least one multivalent component to a reducing atmosphere for a time and at a temperature sufficient to substantially reduce the at least one multivalent component of the refractory block material. The method also includes flowing molten glass over the refractory block material that has been exposed to the reducing atmosphere while preventing substantial re-oxidation of the at least one multivalent component.
    Type: Grant
    Filed: January 12, 2015
    Date of Patent: October 8, 2019
    Assignee: Corning Incorporated
    Inventors: Matthew John Dejneka, Benjamin Zain Hanson, Thomas Dale Ketcham, James Robert Rustad, Susan Lee Schiefelbein, Kochuparambil Deenamma Vargheese
  • Patent number: 10399905
    Abstract: A housing for a portable electronic device includes a radio frequency transparent polycrystalline ceramic portion comprising a first surface and a second surface parallel to the first surface. The radio frequency transparent polycrystalline ceramic portion comprises a macro-texture on at least a portion of the first surface, and a predetermined micro-texture is disposed on at least a portion of the macro-texture. A method for manufacturing a housing for a portable electronic device includes forming a green ceramic article comprising a first surface and a second surface parallel to the first surface, embossing at least a portion of the first surface of the green ceramic article with a macro-texture, and sintering the green ceramic article comprising the macro-texture to form a sintered ceramic article. A predetermined micro-texture is disposed on at least a portion of the macro-texture.
    Type: Grant
    Filed: August 30, 2018
    Date of Patent: September 3, 2019
    Assignee: CORNING INCORPORATED
    Inventors: Thomas Dale Ketcham, Weiguo Miao, Eric James Nichols
  • Publication number: 20190207252
    Abstract: Electrolyte for a solid-state battery includes a body having grains of inorganic material sintered to one another, where the grains include lithium. The body is thin, has little porosity by volume, and has high ionic conductivity.
    Type: Application
    Filed: March 7, 2019
    Publication date: July 4, 2019
    Inventors: Michael Edward Badding, Jacqueline Leslie Brown, Jennifer Anella Heine, Thomas Dale Ketcham, Gary Edward Merz, Eric Lee Miller, Zhen Song, Cameron Wayne Tanner, Conor James Walsh
  • Publication number: 20190169073
    Abstract: Disclosed herein are ceramic materials comprising a ceramic phase and a glass phase and at least one of a reduced alkali content or a reduced iron content. Ceramic materials having relatively low creep rates are also disclosed herein, as well as glass forming bodies comprising such materials, and methods for making glass articles using such forming bodies. Refractory bricks for constructing glass manufacturing vessels are also disclosed. Methods for treating ceramic materials to reduce at least one of the alkali or iron content are further disclosed herein.
    Type: Application
    Filed: May 19, 2017
    Publication date: June 6, 2019
    Inventors: Monika Backhaus-Ricoult, Dana Craig Bookbinder, Richard Fiacco, Thomas Dale Ketcham, Paul Maynard Schermerhorn
  • Patent number: 10304536
    Abstract: A quantum memory system includes a doped polycrystalline ceramic, a magnetic field generation unit, and one or more pump lasers. The doped polycrystalline ceramic is positioned within a magnetic field of the magnetic field generation unit when the magnetic field generation unit generates the magnetic field, the one or more pump lasers are optically coupled to the doped polycrystalline ceramic, and the doped polycrystalline ceramic is doped with a rare-earth element dopant that is uniformly distributed within a crystal lattice of the doped polycrystalline ceramic.
    Type: Grant
    Filed: July 16, 2018
    Date of Patent: May 28, 2019
    Assignee: CORNING INCORPORATED
    Inventors: Jason Allen Brown, Thomas Dale Ketcham, Daniel Aloysius Nolan, Wageesha Senaratne, Jun Yang, Haitao Zhang
  • Publication number: 20190077674
    Abstract: A system, process and related sintered article are provided. The process includes supporting a piece of inorganic material with a pressurized gas and sintering the piece of inorganic material while supported by the pressurized gas by heating the piece of inorganic material to a temperature at or above a sintering temperature of the inorganic material such that the inorganic material is at least partially sintered forming the sintered article. The inorganic material is not in contact with a solid support during sintering. The sintered article, such as a ceramic article, is thin, has high surface quality, and/or has large surface areas.
    Type: Application
    Filed: November 14, 2018
    Publication date: March 14, 2019
    Inventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
  • Publication number: 20190062219
    Abstract: A housing for a portable electronic device includes a radio frequency transparent polycrystalline ceramic portion comprising a first surface and a second surface parallel to the first surface. The radio frequency transparent polycrystalline ceramic portion comprises a macro-texture on at least a portion of the first surface, and a predetermined micro-texture is disposed on at least a portion of the macro-texture. A method for manufacturing a housing for a portable electronic device includes forming a green ceramic article comprising a first surface and a second surface parallel to the first surface, embossing at least a portion of the first surface of the green ceramic article with a macro-texture, and sintering the green ceramic article comprising the macro-texture to form a sintered ceramic article. A predetermined micro-texture is disposed on at least a portion of the macro-texture.
    Type: Application
    Filed: August 30, 2018
    Publication date: February 28, 2019
    Inventors: Thomas Dale Ketcham, Weiguo Miao, Eric James Nichols
  • Patent number: 10155667
    Abstract: A system, process and related sintered article are provided. The process includes supporting a piece of inorganic material with a pressurized gas and sintering the piece of inorganic material while supported by the pressurized gas by heating the piece of inorganic material to a temperature at or above a sintering temperature of the inorganic material such that the inorganic material is at least partially sintered forming the sintered article. The inorganic material is not in contact with a solid support during sintering. The sintered article, such as a ceramic article, is thin, has high surface quality, and/or has large surface areas.
    Type: Grant
    Filed: January 24, 2017
    Date of Patent: December 18, 2018
    Assignee: CORNING INCORPORATED
    Inventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann