Patents by Inventor Thomas M. Lucas

Thomas M. Lucas 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: 20240039011
    Abstract: A method of manufacturing a current collector for an electrochemical cell assembly includes providing a base plate including a surface, bend-forming the base plate to create a plurality of open corrugations protruding from the surface, each open corrugation including a first flange and a second flange, and forming a foot between the first flange and the second flange of each open corrugation to close each open corrugation and form a corrugation.
    Type: Application
    Filed: July 27, 2023
    Publication date: February 1, 2024
    Inventors: Thomas M. LUCAS, Ramakrishnan VENKATARAMAN, Abdelkader HILMI, Chao-Yi YUH
  • Patent number: 9642192
    Abstract: A method of manufacturing an electrode for a fuel cell, the method comprising forming a powder bed from a predetermined powder, sintering the powder bed at a first predetermined temperature to form a substrate, and in some embodiments subsequently distributing an electrolyte powder on a surface of the substrate, and impregnating the substrate with electrolyte by heating the substrate with the electrolyte powder thereon to a second predetermined temperature so as to melt and wick the electrolyte into the substrate, thereby forming the electrode for the fuel cell, wherein at least one of the sintering and impregnating is performed by applying induction heating to at least one of said powder bed and said substrate.
    Type: Grant
    Filed: August 4, 2011
    Date of Patent: May 2, 2017
    Assignee: FUELCELL ENERGY, INC.
    Inventors: Thomas M. Lucas, Weizhong Zhu, Thomas Vailionis
  • Publication number: 20170084931
    Abstract: A method of fabricating a fuel cell component for use with or as part of a fuel cell in a fuel cell stack, the method comprising: providing a fuel cell component, providing a deposition assembly for depositing loading material particles onto the fuel cell component, and actuating the deposition assembly to cause the deposition assembly to deposit said loading material particles onto said fuel cell component.
    Type: Application
    Filed: November 29, 2016
    Publication date: March 23, 2017
    Inventors: Salvador E. CORREA, Thomas M. LUCAS, Lawrence J. NOVACCO
  • Patent number: 9548510
    Abstract: A method of fabricating a fuel cell component for use with or as part of a fuel cell in a fuel cell stack, the method comprising: providing a fuel cell component, providing a deposition assembly for depositing loading material particles onto the fuel cell component, and actuating the deposition assembly to cause the deposition assembly to deposit said loading material particles onto said fuel cell component.
    Type: Grant
    Filed: July 9, 2014
    Date of Patent: January 17, 2017
    Assignee: FUELCELL ENERGY, INC.
    Inventors: Salvador E. Correa, Thomas M. Lucas, Lawrence J. Novacco
  • Publication number: 20140356752
    Abstract: A method of fabricating a fuel cell component for use with or as part of a fuel cell in a fuel cell stack, the method comprising: providing a fuel cell component, providing a deposition assembly for depositing loading material particles onto the fuel cell component, and actuating the deposition assembly to cause the deposition assembly to deposit said loading material particles onto said fuel cell component.
    Type: Application
    Filed: July 9, 2014
    Publication date: December 4, 2014
    Inventors: Salvador E. Correa, Thomas M. Lucas, Lawrence J. Novacco
  • Patent number: 8802332
    Abstract: A system for fabricating a fuel cell component in which a deposition mechanism deposits loading material particles onto the fuel cell component and an actuation mechanism actuates the deposition mechanism. A unit provides a tape fixing agent to the fuel cell component and loaded material particles so as to retain the particles on the fuel cell component. Other fuel components are retained to the fuel cell component also using a tape fixing agent.
    Type: Grant
    Filed: March 19, 2012
    Date of Patent: August 12, 2014
    Assignee: FuelCell Energy, Inc.
    Inventors: Salvador E. Correa, Thomas M. Lucas, Lawrence J. Novacco
  • Publication number: 20130032973
    Abstract: A method of manufacturing an electrode for a fuel cell, the method comprising forming a powder bed from a predetermined powder, sintering the powder bed at a first predetermined temperature to form a substrate, and in some embodiments subsequently distributing an electrolyte powder on a surface of the substrate, and impregnating the substrate with electrolyte by heating the substrate with the electrolyte powder thereon to a second predetermined temperature so as to melt and wick the electrolyte into the substrate, thereby forming the electrode for the fuel cell, wherein at least one of the sintering and impregnating is performed by applying induction heating to at least one of said powder bed and said substrate.
    Type: Application
    Filed: August 4, 2011
    Publication date: February 7, 2013
    Inventors: Thomas M. Lucas, Weizhong Zhu, Thomas Vailionis
  • Publication number: 20120231371
    Abstract: A system for fabricating a fuel cell component in which a deposition mechanism deposits loading material particles onto the fuel cell component and an actuation mechanism actuates the deposition mechanism. A unit provides a tape fixing agent to the fuel cell component and loaded material particles so as to retain the particles on the fuel cell component. Other fuel components are retained to the fuel cell component also using a tape fixing agent.
    Type: Application
    Filed: March 19, 2012
    Publication date: September 13, 2012
    Inventors: Salvador E. Correa, Thomas M. Lucas, Lawrence J. Novacco
  • Patent number: 8137741
    Abstract: A system for fabricating a fuel cell component in which a deposition mechanism deposits loading material particles onto the fuel cell component and an actuation mechanism actuates the deposition mechanism. A unit provides a tape fixing agent to the fuel cell component and loaded material particles so as to retain the particles on the fuel cell component. Other fuel components are retained to the fuel cell component also using a tape fixing agent.
    Type: Grant
    Filed: May 10, 2007
    Date of Patent: March 20, 2012
    Assignee: FuelCell Energy, Inc.
    Inventors: Salvador E. Correa, Thomas M. Lucas, Lawrence J. Novacco
  • Publication number: 20080280180
    Abstract: A system for fabricating a fuel cell component in which a deposition mechanism deposits loading material particles onto the fuel cell component and an actuation mechanism actuates the deposition mechanism. A unit provides a tape fixing agent to the fuel cell component and loaded material particles so as to retain the particles on the fuel cell component. Other fuel components are retained to the fuel cell component also using a tape fixing agent.
    Type: Application
    Filed: May 10, 2007
    Publication date: November 13, 2008
    Inventors: Salvador E. Correa, Thomas M. Lucas, Lawrence J. Novacco
  • Patent number: 7060219
    Abstract: A method and apparatus for continuous fabrication of homogeneous thin flake or powder electrolyte material from inorganic salt, metallic or similar materials or from mixtures of such materials for use in Carbonate Fuel Cell (“CFC”) power plants. Electrolyte precursor powders are fed to a continuous blender type mixer using precision metering equipment that controls material feed rates. The homogenous mixture of blended powders is then fed into a high temperature melting tank in which the mixture is melted, forming the desired molten eutectic composition. The liquid eutectic melt drips from the melting tank through ceramic or metallic nozzles and splat-cools on a rotating, water-cooled metal cylinder to produce uniform size, thin flake material. The thin flake electrolyte material can be used as-is, or it may be further processed using continuous grinding and powder fabrication equipment.
    Type: Grant
    Filed: April 30, 2004
    Date of Patent: June 13, 2006
    Assignee: FuelCell Energy, Inc.
    Inventors: Thomas M. Lucas, Jody Doyon
  • Patent number: 6884269
    Abstract: A method and apparatus for continuous fabrication of homogeneous thin flake or powder electrolyte material from inorganic salt, metallic or similar materials or from mixtures of such materials for use in Carbonate Fuel Cell (“CFC”) power plants. Electrolyte precursor powders are fed to a continuous blender type mixer using precision metering equipment that controls material feed rates. The homogenous mixture of blended powders is then fed into a high temperature melting tank in which the mixture is melted, forming the desired molten eutectic composition. The liquid eutectic melt drips from the melting tank through ceramic or metallic nozzles and splat-cools on a rotating, water-cooled metal cylinder to produce uniform size, thin flake material. The thin flake electrolyte material can be used as-is, or it may be further processed using continuous grinding and powder fabrication equipment.
    Type: Grant
    Filed: June 13, 2002
    Date of Patent: April 26, 2005
    Assignee: FuelCell Energy, Inc.
    Inventors: Thomas M. Lucas, Jody Doyon
  • Publication number: 20040195738
    Abstract: A method and apparatus for continuous fabrication of homogeneous thin flake or powder electrolyte material from inorganic salt, metallic or similar materials or from mixtures of such materials for use in Carbonate Fuel Cell (“CFC”) power plants. Electrolyte precursor powders are fed to a continuous blender type mixer using precision metering equipment that controls material feed rates. The homogenous mixture of blended powders is then fed into a high temperature melting tank in which the mixture is melted, forming the desired molten eutectic composition. The liquid eutectic melt drips from the melting tank through ceramic or metallic nozzles and splat-cools on a rotating, water-cooled metal cylinder to produce uniform size, thin flake material. The thin flake electrolyte material can be used as-is, or it may be further processed using continuous grinding and powder fabrication equipment.
    Type: Application
    Filed: April 30, 2004
    Publication date: October 7, 2004
    Inventors: Thomas M. Lucas, Joel D. Doyon
  • Publication number: 20030232000
    Abstract: A method and apparatus for continuous fabrication of homogeneous thin flake or powder electrolyte material from inorganic salt, metallic or similar materials or from mixtures of such materials for use in Carbonate Fuel Cell (“CFC”) power plants. Electrolyte precursor powders are fed to a continuous blender type mixer using precision metering equipment that controls material feed rates. The homogenous mixture of blended powders is then fed into a high temperature melting tank in which the mixture is melted, forming the desired molten eutectic composition. The liquid eutectic melt drips from the melting tank through ceramic or metallic nozzles and splat-cools on a rotating, water-cooled metal cylinder to produce uniform size, thin flake material. The thin flake electrolyte material can be used as-is, or it may be further processed using continuous grinding and powder fabrication equipment.
    Type: Application
    Filed: June 13, 2002
    Publication date: December 18, 2003
    Inventors: Thomas M. Lucas, Joel D. Doyon
  • Patent number: 4433870
    Abstract: A stool which is fully collapsible and adjustable to four different positions. It is particularly suitable for the sportsman, such as the hunter and fisherman. While spot hunting deer it will give the same high view as if standing and, at the same time, support the backside and legs and lower back of the sportsman. The fisherman can use it while "spinning" in a stream without sinking in the creek's soft bottom in view of a platform shaped base. It is also useful around the house to support the housewife while ironing, doing dishes or working around a work bench. It may be carried by a strap around the shoulder or by a belt.
    Type: Grant
    Filed: May 29, 1981
    Date of Patent: February 28, 1984
    Inventors: Donald J. Bairen, Thomas M. Lucas