Abstract: Provided are methods to fabricate bulk quantities at relatively low-cost of isotropic homogeneous nanostructured materials with high interfacial area whose properties are controlled and optimized by tailored interfaces between discrete dissimilar materials. In a preferred embodiment, the material is formed by uniformly and intimately mixing nanoparticles of different composition and then compacting and consolidating them to near theoretical density by a process that minimizes grain growth and controls the structure of the interfacial film-like region. One preferred application of these materials is a fast ion conducting material that can be used as a solid electrolyte in gas electrolyzers, electrochemical pumps, gas sensors, catalytic reactors, and most importantly in fuel cells.

Abstract: This present invention describes interface-defined nanolaminates (IDnLs), which are novel nanolaminate materials fabricated from metals and ceramics, and new methods for fabricating these IDnL materials, including new methods for manufacturing high aspect ratio parts comprising IDnL materials according to the present invention. IDnLs are fundamentally different from ordinary laminates in that their properties are defined by the interfaces between the layers rather by the properties of the bulk materials comprising the individual layers. In contrast to superlattice materials, IDnLs may be made thermally stable due to the wide selection of interface-defining materials, which allows judicial use of equilibrium phase diagrams. The degree of interface coherency in IDnLs may be varied to optimize material properties. In addition, IDnLs may be manufactured inexpensively in bulk, industrial quantities and large sizes by the techniques disclosed in this invention.

Abstract: A method of modifying the apparent wettability (the area contacted by a liquid) of solids with liquids by controlling the surface geometry or the capillary geometry. This modification is possible by understanding the geometric relationship between the contact angle and the included angle of surface features. This same geometric relationship can be used to enhance two-phase fluid separation during phase transformation as well as measure dynamic contact angles.

Abstract: This invention describes a novel type of materials named by the inventors as Interface-Defined nano-Laminates (IDnL), and a new method for fabricating these materials from ceramic, metallic, and other powders. The laminate layer thickness in IDnL is smaller than that of ordinary laminates, but greater than that of superlattices. IDnL are fundamentally different from ordinary laminates in that their properties are defined by interfaces, and not by the properties of the bulk materials comprising individual layers. In contrast to superlattice materials, IDnL can be made thermally stable, due to the wide selection of interface-defining materials, which allows judicial use of equilibrium phase diagrams, and the “entropic stabilization” approach discovered by the authors; and in addition IDnL can be manufactured inexpensively in bulk, industrial quantities and large sizes by the techniques revealed in this invention. The degree of interface coherency in an IDnLs can be varied to optimize material properties.

Abstract: This invention describes a unique of class of nano-scale materials for use as protective coatings or barriers against heat as well as material loss due to processes such as corrosion, ablation, erosion, or oxidation. These nano-scale laminated materials are also useful as free-standing components and as substrates, especially for high temperature oxidation-resistant applications. The novel materials of this invention are known as interface-defined nano-laminates (IDnLs), and are fabricated by a new method from ceramic, metallic, and other powders. The laminate layer thickness in an IDnL is smaller than that of ordinary laminates but greater than that of superlattices. Interface-defined nano-laminates are fundamentally different from ordinary laminates in that their properties are defined by interfaces, and not by the properties of the bulk materials comprising individual layers.

Abstract: New fluid separation devices and absorption materials are disclosed. Hollow fibers with an axial capillary slit act as very high efficiency absorption materials, as well as high-surface-area fluid separation devices. The hollow fibers with an axial capillary slit are constructed to preferentially absorb or repel different fluids and arranged to maximize that action over a plurality of fibers to separate different fluids. These separation devices can also function as injection devices and very effective micro-reactors.

Abstract: In the present invention, a technique is described for manufacturing microtube devices which have peripheral geometries that are not uniform along the tube or device axis. These geometries may exist in only one location on the periphery of the microtube device or geometries may be repeated either uniformly or non-uniformly with micron or sub-micron precision along the tube or device axis. The preferred manufacturing process involves forming a complex mandrel, ie., (one, for example, that can not be formed by extrusion or pultrusion under constant processing conditions) and giving it at least one metallic and/or nonmetallic coating by any of a variety of techniques. The complex mandrel can then be removed by appropriate chemical or physical means that do not adversely affect the coating(s) desired for the wall. The result is a microtube structure having an axial profile duplicating that on the mandrel from which it was formed.

Abstract: Provided are methods for fabricating fluid separation devices with precisely-sized, shaped microscopic capillaries that can separate one immiscible fluid from another on the basis of different separation characteristics. In particular, the method comprises the steps of fabricating a first set of capillaries having a first separation characteristic and a second set of capillaries having a second separation characteristic, incorporating one end of all of the capillaries into an inlet face, incorporating the second end of the first set of capillaries into a first outlet face, and incorporating the second end of the second set of capillaries into a second outlet face. Preferably, the first set of capillaries is hydrophillic and the second set of capillaries is hydrophobic.

Abstract: There are provided methods for fabricating devices for admitting air to a closed container while preventing passage of a water-based fluid therethrough. These devices comprise a plurality of hydrophobic capillaries or a hydrophobic reticulated microporous material. The devices comprising hydrophobic capillaries are fabricated by a variety of techniques, such as those employing extrusion, pultrusion, fugitive mandrel removal or a combination of these techniques. The devices comprising hydrophobic reticulated microporous material are fabricated by techniques such as foaming, sintering, template replication, incorporation of sacrificial particles or a combination of these techniques.

Abstract: The present invention relates, generally, to a method and apparatus for electrowinning metals, and more particularly to a method and apparatus for copper electrowinning using the ferrous/ferric anode reaction and a flow-through anode, such as, for example, a dimensionally stable carbon, carbon composite, metal-graphite, or stainless steel anode. In general, the use of a flow-through anode—coupled with an effective electrolyte circulation system—enables the efficient and cost-effective operation of a copper electrowinning system employing the ferrous/ferric anode reaction at a total cell voltage of less than about 1.5 V and at current densities of greater than about 26 Amps per square foot (about 280 A/m2), and reduces acid mist generation. Furthermore, the use of such a system permits the use of low ferrous iron concentrations and optimized electrolyte flow rates as compared to prior art systems while producing high quality, commercially saleable product (i.e.

Abstract: A method of modifying the apparent wettability (the area contacted by a liquid) of solids with liquids by controlling the surface geometry or the capillary geometry. This modification is possible by understanding the geometric relationship between the contact angle and the included angle of surface features. This same geometric relationship can be used to control entrance of a liquid into a capillary and the flow of more than one fluid in distinct streams through a capillary device.

Abstract: In the present invention, a technique is described for manufacturing microtube devices which have peripheral geometries that are not uniform along the tube or device axis. These geometries may exist in only one location on the periphery of the microtube device or geometries may be repeated either uniformly or non-uniformly with micron or sub-micron precision along the tube or device axis. The preferred manufacturing process involves forming a complex mandrel, ie., (one, for example, that can not be formed by extrusion or pultrusion under constant processing conditions) and giving it at least one metallic and/or nonmetallic coating by any of a variety of techniques. The complex mandrel can then be removed by appropriate chemical or physical means that do not adversely affect the coating(s) desired for the wall. The result is a microtube structure having an axial profile duplicating that on the mandrel from which it was formed.

Abstract: A liquid to solid material surface contact angle measurement system operating by way of detecting a transition in the behavior of a liquid sample with the solid material in a changing angular confinement environment along with use of a mathematical algorithm to then determine contact angle. Measurement of the angle at which the tested liquid transitions between apparent wetting and apparent non-wetting behavior, regardless of whether the liquid and solid material are truly classified as wetting or non-wetting, provides a measurement from which disclosed mathematical algorithms can predict the surface wetting characteristics of the liquid on the solid material. Automated performance of the confinement environment measurement and examples are included.

Abstract: There are provided methods for fabricating baby bottle nipples which mimic the function of the human breast nipple. In the human breast nipple, milk is delivered to the baby through 15-25 fluid-delivery capillaries called lactiferous ducts. These ducts are 2-4 centimeters in length and 500-900 microns in diameter. Baby bottle nipples fabricated in accordance with the methods of this invention have the common feature of at least one hydrophilic fluid delivery passage. In one embodiment, the fluid delivery passage is a microtube. In another embodiment, the fluid delivery passage is a microchannel. In yet another embodiment, the fluid delivery passage comprises a porous reticulated foam with interconnected pores. In each of these embodiments, the fluid delivery passage has at least one dimension in the range of 1-2000 microns.

Abstract: A high-temperature fiber-reinforced carbon-carbon composite material of essentially uniform density, is fabricated by the following sequence of steps: (a) selecting a fiber/matrix material combination; (b) providing a fiber preform of desired shape and fiber placement; (c) selecting at least one low-viscosity pre-carbon monomer material that wets the surfaces of the fiber preform; (d) impregnating the fiber preform with the monomer; (e) polymerizing the monomer material in-situ in a single phase process into a pre-carbon polymer of desired molecular weight; (f) pryolyzing the pre-carbon polymer to form a carbon matrix material; and (g) repeating steps (d)-(f) to further densify the preform.

Abstract: This invention is a rapid low-cost technique for manufacturing thick high-performance carbon and ceramic composites in the form of uniformly densified near-net shaped structures. This is accomplished by impregnating composite preforms with low-viscosity wetting monomers which undergo polymerization followed by pyrolysis reactions in the preform ultimately creating ceramic and/or carbon matrices. Since the monomers possess low-molecular-weight they have low viscosities. Thus, if they wet the fiber and partially-densified preform they can easily impregnate even the smallest pores. Once inside the preforms, polymerization of the monomers is then initiated, resulting in a liquid matrix-precursor of the high molecular weight needed to produce a superior matrix (upon pyrolysis) with high efficiency.

Abstract: Baby bottle nipples which mimic the function of the human breast nipple are provided. In the human breast nipple, milk is delivered to the baby through 15-25 fluid-delivery capillaries called lactiferous ducts. These ducts are 2-4 centimeters in length and 500-900 microns in diameter. Baby bottle nipples fabricated in accordance with the methods of this invention have the common feature of at least one hydrophilic fluid delivery passage. In one embodiment, the fluid delivery passage is a microtube. In another embodiment, the fluid delivery passage is a microchannel. In yet another embodiment, the fluid delivery passage comprises a porous reticulated foam with interconnected pores. In each of these embodiments, the fluid delivery passage has at least one dimension in the range of 1-2000 microns.

Abstract: In the present invention, a technique is described for manufacturing microtube devices which have peripheral geometries that are not uniform along the tube or device axis. These geometries may exist in only one location on the periphery of the microtube device or geometries may be repeated either uniformly or non-uniformly with micron or sub-micron precision along the tube or device axis. The preferred manufacturing process involves forming a complex mandrel, ie., (one, for example, that can not be formed by extrusion or pultrusion under constant processing conditions) and giving it at least one metallic and/or nonmetallic coating by any of a variety of techniques. The complex mandrel can then be removed by appropriate chemical or physical means that do not adversely affect the coating(s) desired for the wall. The result is a microtube structure having an axial profile duplicating that on the mandrel from which it was formed.

Abstract: Nanoscale aluminum alloy powder is synthesized by mechanical alloying/milling techniques without significant oxidation, nitridation, or contamination with foreign materials. These powders are consolidated into a very dense billet form without a high temperature sintering step. The desired microstructure and properties were obtained by post hot isostatic pressing, extrusion, and/or forging of the nanoscale material billet made from the powders.

Abstract: This invention is a rapid low-cost technique for manufacturing thick high-performance carbon and ceramic composites in the form of uniformly densified near-net shaped structures. This is accomplished by impregnating composite preforms with low-viscosity wetting monomers which undergo polymerization followed by pyrolysis reactions in the preform ultimately creating ceramic and/or carbon matrices. Since the monomers possess low-molecular-weight they have low viscosities. Thus, if they wet the fiber and partially-densified preform they can easily impregnate even the smallest pores. Once inside the preforms, polymerization of the monomers is then initiated, resulting in a liquid matrix-precursor of the high molecular weight needed to produce a superior matrix (upon pyrolysis) with high efficiency.