Vaporizing Or Condensing Free Metal Patents (Class 75/367)
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Patent number: 12042774Abstract: Provided are an apparatus for producing inorganic powder, and a method of producing inorganic powder by using such. The apparatus includes a vaporization part where a condensed-phase precursor is vaporized to obtain a gas-phase precursor, a partial precipitation part where the gas-phase precursor obtained in the vaporization part is partially precipitated to a condensed phase, and a reaction part where the gas-phase precursor remaining after being partially precipitated to a condensed phase in the partial precipitation part reacts with a reaction gas to obtain inorganic powder. An equilibrium vapor pressure of the gas-phase precursor in the partial precipitation part is lower than a vapor pressure of the gas-phase precursor obtained in the vaporization part, and an equilibrium vapor pressure of the precursor in the reaction part is equal to or higher than a vapor pressure of the gas-phase precursor partially precipitated to a condensed phase in the partial precipitation part.Type: GrantFiled: September 18, 2023Date of Patent: July 23, 2024Assignee: KOREA INSTITUTE OF INDUSTRIAL TECHNOLOGYInventors: Seung Min Yang, Kyung Hoon Kim, Gun Hee Kim, Young Kyu Jeong, O Hyung Kwon, Chan Bin Mo, Yong Su Jo, Hye Min Park, Gwang Hwa Jin
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Patent number: 12048081Abstract: The invention relates to an EIGA coil (10) for partial melting an electrode (40). The EIGA coil (10) comprises a plurality of windings (12A, 12B, 12C) which are coaxially arranged with respect to a center axis (M) and axially spaced from each other, wherein each of the plurality of windings (12A, 12B, 12C) is formed in the shape of a ring interrupted by a gap (14A, 14B, 14C) and equidistant with respect to the center axis (M) and extending in a plane perpendicular to the center axis (M). Adjacent windings (12A, 12B; 12B, 12C) of the plurality of windings (12A, 12B, 12C) are respectively connected to each other via a connecting portion (20AB, 20BC; 120AB, 120BC).Type: GrantFiled: August 12, 2020Date of Patent: July 23, 2024Assignee: ALD VACUUM TECHNOLOGIES GMBHInventors: Sergejs Spitans, Markus Winton, Franz Pfahls, Henrik Franz, Hans-Jürgen Radtke
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Patent number: 11794248Abstract: A multi-stage gas atomization preparation method of titanium alloy spherical powder for a 3D printing technology includes the following steps: bar preparation and machining step, multi-stage gas atomization powder preparation step through vacuum induction, and powder screening step. The collision probability of the metal droplets at the gas atomization stage is reduced by controlling the gas atomization pressure and the feeding speed of the titanium alloy electrode bar in a hierarchical manner, so that the collaborative control of the particle size and the surface quality of the titanium alloy 3D printing powder in the gas atomization preparation process is realized.Type: GrantFiled: January 23, 2023Date of Patent: October 24, 2023Assignee: SHENYANG UNIVERSITY OF TECHNOLOGYInventors: Ge Zhou, Zhipeng Zhang, Haoyu Zhang, Yaqian Chen, Nannan Zhang, Xiaojiao Zuo, Xin Wang, Siqian Zhang, Lijia Chen
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Patent number: 9567227Abstract: A process for producing silicon which comprises: bringing molten silicon containing an impurity into contact with molten salt in a vessel to react the impurity contained in the molten silicon with the molten salt; removing the impurity from the system.Type: GrantFiled: January 3, 2012Date of Patent: February 14, 2017Assignee: MITSUBISHI CHEMICAL CORPORATIONInventors: Yoji Arita, Takashi Yoneda
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Patent number: 9162288Abstract: Fine, highly-crystallized metal powder is produced at low cost and high efficiency by a method involving: ejecting raw material powder composed of one or more kinds of thermally decomposable metal compound powders into a reaction vessel through a nozzle together with a carrier gas and producing a metal powder by heating the raw material powder at a temperature T2 which is higher than the decomposition temperature of the raw material powder and not lower than (Tm?200°) C. where Tm is the melting point (° C.) of the metal to be produced, while allowing the raw material powder to pass through the reaction vessel in a state where the raw material powder is dispersed in a gas phase at a concentration of 10 g/liter or less, wherein an ambient temperature T1 of a nozzle opening part is set to a temperature of 400° C. or higher and lower than (Tm?200°) C.Type: GrantFiled: August 31, 2012Date of Patent: October 20, 2015Assignee: SHOEI CHEMICAL INC.Inventors: Yuji Akimoto, Kazuro Nagashima, Hidenori Ieda, Masayuki Maekawa
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Patent number: 8882878Abstract: A method of producing ultra-fine metal particles of the present invention includes: blowing metal powders of raw materials into reducing flame formed by a burner 3 in a furnace 5, wherein the metal powders are melted in the flame and allowed to be in an evaporated state, to thereby obtain the spherical ultra-fine metal particles. In the present invention, the atmosphere in the furnace 5 is preferably prepared such that the CO/CO2 ratio is within a range from 0.15 to 1.2. Also, a spiral flow-forming gas is preferably blown into the furnace 5, and the oxygen ratio of the burner 3 is preferably within a range from 0.4 to 0.8. As raw materials, a metal oxide and/or a metal hydroxide which contain the same metal as the metal powders may be used together with the metal powders.Type: GrantFiled: July 8, 2008Date of Patent: November 11, 2014Assignee: Taiyo Nippon Sanso CorporationInventors: Hiroshi Igarashi, Takayuki Matsumura, Shinichi Miyake
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Patent number: 8840701Abstract: Disclosed are methods of making multi-element, finely divided, metal powders containing one or more reactive metals and one or more non-reactive metals. Reactive metals include metals or mixtures thereof from titanium (Ti), zirconium (Zr), hafnium (Hf), tantalum (Ta), niobium (Nb), vanadium (V), nickel (Ni), cobalt (Co), molybdenum (Mo), manganese (Mn), and iron (Fe). Non-reactive metals include metals or mixtures such as silver (Ag), tin (Sn), bismuth (Bi), lead (Pb), antimony (Sb), zinc (Zn), germanium (Ge), phosphorus (P), gold (Au), cadmium (Cd), berrylium (Be), tellurium (Te).Type: GrantFiled: August 12, 2009Date of Patent: September 23, 2014Assignee: E I du Pont de Nemours and CompanyInventors: William J. Borland, Howard David Glicksman
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Patent number: 8821611Abstract: A titanium metal or a titanium alloy having submicron titanium boride substantially uniformly dispersed therein and a method of making same is disclosed. Ti power of Ti alloy powder has dispersed within the particles forming the powder titanum boride which is other than whisker-shaped or spherical substantially uniformly dispersed therein.Type: GrantFiled: December 6, 2012Date of Patent: September 2, 2014Assignee: Cristal Metals Inc.Inventors: Lance Jacobsen, Adam Benish
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Patent number: 8801829Abstract: Process for the production of valve metal powders, in particular niobium and tantalum powder, by reduction of corresponding valve metal oxide powders by means of vaporous reducing metals and/or hydrides thereof, preferably in the presence of an inert carrier gas, wherein the reduction is performed at a vapor partial pressure of the reducing metal/metal hydride of 5 to 110 hPa and an overall pressure of less than 1000 hPa, and tantalum powder obtainable in this way having a high stability of the powder agglomerate particles.Type: GrantFiled: October 22, 2010Date of Patent: August 12, 2014Assignee: H. C. Starck GmbH & Co. KGInventors: Helmut Haas, Ulrich Bartmann, Tadashi Komeya, Nobuyuki Sato
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Patent number: 8734563Abstract: A method of production of Zinc dust, which includes melting Zinc products in a melting furnace on a semi-continuous basis, transferring at least a part of the molten Zinc products to a vaporizing furnace, vaporizing the molten Zinc in the vaporizing furnace into Zinc vapor on a substantially continuous basis, transferring Zinc vapor from the vaporizing furnace to a condenser, and condensing the Zinc vapor to form Zinc dust.Type: GrantFiled: August 6, 2009Date of Patent: May 27, 2014Assignee: Zinchem, a division of Zimco Group (Pty) Ltd.Inventors: Michael Hanneman, Roy William Heslop
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Publication number: 20130340894Abstract: The present technology provides an illustrative method for preparing shaped nanoparticles. The method includes passing a metal vapor to a shaping apparatus and condensing the metal vapor within the shaping apparatus to form selectively-shaped metal nanoparticles. The method may also include forming the metal vapor by heating a bulk metal. In an embodiment, the shaping apparatus comprises a mesh separator that include a plurality of nano-sized, square-shaped pores or a plurality of shaping cups that includes a plurality of recesses.Type: ApplicationFiled: March 7, 2013Publication date: December 26, 2013Applicant: Empire Technology Development LLCInventor: David Max ROUNDHILL
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Publication number: 20130255443Abstract: A titanium metal production apparatus is provided with (a) a first flow channel that supplies magnesium in a state of gas, (b) a second flow channel that supplies titanium tetrachloride in a state of gas, (c) a gas mixing section in which the magnesium and titanium tetrachloride in a state of gas are mixed and the temperature is controlled to be 1600° C. or more, (d) a titanium metal deposition section in which particles for deposition are arranged so as to be movable, the temperature is in the range of 715 to 1500° C., and the absolute pressure is 50 kPa to 500 kPa, and (e) a mixed gas discharge section which is in communication with the titanium metal deposition section.Type: ApplicationFiled: November 16, 2011Publication date: October 3, 2013Applicants: TEKNA PLASMA SYSTEMS INC., HITACHI METALS, LTD.Inventors: Gang Han, Tatsuya Shoji, Shujiroh Uesaka, Mariko Fukumaru, Maher I. Boulos, Jiayin Guo, Jerzy Jurewicz
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Patent number: 8480784Abstract: The various embodiments herein provide a method of producing silver nanoparticles using an electromagnetic levitation melting process. The method comprises levitating and melting a silver sample using a suitable levitation coil and stabilizing a droplet of molten silver. The silver droplet is heated and levitated simultaneously by an induction furnace as a generator. Argon gas is used to provide the inert atmosphere and also applied to cool and condense the silver vapor into a silver nano powder to obtain a silver nano particle. The synthesized silver nanoparticles are collected by brushing them off the brass cylinder using inert gas and are kept in pure Hexane. The size of the nanoparticles is controlled by rate of cooling and heating temperature. The electromagnetic levitation melting method is applied to provide the high purity of silver nano particles with no vacuum equipments.Type: GrantFiled: September 15, 2010Date of Patent: July 9, 2013Inventors: Mahdieh Malekzadeh, Mohammad Halali
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Patent number: 8449646Abstract: Disclosed is a method for preparing low-oxygen titanium powders. The method includes (a) separately placing titanium base powders and calcium in a deoxidation container, (b) deoxidizing the titanium base powders by heating an inner part of the deoxidation container at a temperature of 850° C. to 1050° C. so that the calcium is evaporated to make contact with the titanium base powders, (c) removing calcium oxide from surfaces of titanium powders, which are obtained by deoxidizing the titanium base powders in step (b), by washing the titanium powders, and (d) drying the titanium powders subject to the removing of the calcium oxide in step (c).Type: GrantFiled: July 17, 2012Date of Patent: May 28, 2013Assignee: Korea Institute of Geoscience and Mineral ResourcesInventors: Jae-Won Lim, Jung-Min Oh, Back-Kyu Lee, Chang-Youl Suh, Sung-Wook Cho
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Patent number: 8343668Abstract: A porous tin particle and its preparation method are provided in the present invention. The method includes steps of: (a) performing a reductive (or reductive electrochemical) reaction on a tin particle which simultaneously reacts with lithium ions to form a tin-lithium (Sn—Li) alloy; and (b) performing an oxidative (or oxidative electrochemical) reaction on Sn—Li alloy to release the lithium ions therefrom, and the porous tin particle is formed. The porous tin particle could be further applied in manufacturing the electrochemical electrode for lithium-ion battery with longer cycle life and higher reversibility.Type: GrantFiled: November 1, 2010Date of Patent: January 1, 2013Assignee: National Taiwan UniversityInventors: Nae-Lih Wu, Sung-Chieh Chao
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Patent number: 8333820Abstract: Provided is an aerosol method, and accompanying apparatus, for preparing powdered products of a variety of materials involving the use of an ultrasonic aerosol generator including a plurality of ultrasonic transducers underlying and ultrasonically energizing a reservoir of liquid feed which forms droplets of the aerosol. Carrier gas is delivered to different portions of the reservoir by a plurality of gas delivery ports delivering gas from a gas delivery system. The aerosol is pyrolyzed to form particles, which are then cooled and collected. The invention also provides powders made by the method and devices made using the powders.Type: GrantFiled: March 3, 2011Date of Patent: December 18, 2012Assignee: Cabot CorporationInventors: Mark J. Hampden-Smith, Toivo T. Kodas, Quint H. Powell, Daniel J. Skamser, James Caruso, Clive D. Chandler
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Publication number: 20120272789Abstract: By means of the invention, nanoparticles, which can be pure metal, alloys of two or more metals, a mixture of agglomerates, or particles possessing a shell structure, are manufactured in a gas phase. Due to the low temperature of the gas exiting from the apparatus, metallic nanoparticles can also be mixed with temperature-sensitive materials, such as polymers. The method is economical and is suitable for industrial-scale production. A first embodiment of the invention is the manufacture of metallic nanoparticles for ink used in printed electronics.Type: ApplicationFiled: November 10, 2010Publication date: November 1, 2012Applicant: TEKNOLOGIAN TUTKIMUSKESKUS VTTInventors: Ari Auvinen, Jorma Jokiniemi, Unto Tapper, Johanna Forsman, Johannes Roine
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Patent number: 8287617Abstract: A method for producing an alloy fine particle colloid by heating and evaporating a raw material binary alloy which is in a solid state in an ambient temperature and pressure environment in a reduced-pressure environment, cooling a generated vapor for condensation and solidification and collecting a formed alloy fine particle in a liquid medium, wherein (1) when an atomic fraction of a component element in the raw material alloy is defined as X, a component ratio of each of the elements of the raw material alloy is regulated such that a fraction of a vapor pressure of the component element to the total vapor pressure of the raw material alloy falls within the range of from (X?0.1) to (X+0.1); and (2) the raw material binary alloy is an alloy species which forms a homogeneous alloy phase in an alloy ingot. Thus, an alloy fine particle colloid is rationally and efficiently produced.Type: GrantFiled: April 25, 2007Date of Patent: October 16, 2012Assignee: National Institute for Materials ScienceInventor: Isao Nakatani
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Patent number: 8277892Abstract: A method is disclosed for manufacturing one or more oxygen scavenging particles, wherein the particle(s) comprises an oxidizable metal particle, such as elemental iron; an acidifying electrolyte such as sodium or potassium bisulfate and optionally a water hydrolysable Lewis acid, such as aluminum chloride. The method comprises the step of coating the oxidizable particle with a first compound and then reacting the first compound with a second compound to form a third compound, wherein the third compound promotes the reaction of the oxidizable particle with oxygen.Type: GrantFiled: February 23, 2007Date of Patent: October 2, 2012Assignee: Multisorb Technologies, Inc.Inventor: Kevin L. Rollick
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Patent number: 8216508Abstract: A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.Type: GrantFiled: August 7, 2008Date of Patent: July 10, 2012Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen, Michael Francis Xavier Gigliotti
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Patent number: 8012273Abstract: A metallic article is produced by furnishing one or more nonmetallic precursor compound comprising the metallic constituent element(s), and chemically reducing the nonmetallic precursor compound(s) to produce an initial metallic particle, preferably having a size of no greater than about 0.070 inch, without melting the initial metallic particle. The initial metallic particle is thereafter melted and solidified to produce the metallic article. By this approach, the incidence of chemical defects in the metal article is minimized. The melted-and-solidified metal may be used in the as-cast form, or it may be converted to billet and further worked to the final form.Type: GrantFiled: June 28, 2010Date of Patent: September 6, 2011Assignee: General Electric CompanyInventors: Andrew P. Woodfield, Clifford E. Shamblen, Eric A. Ott
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Publication number: 20100282023Abstract: A system and method of producing an elemental material or an alloy from a halide of the elemental material or halide mixtures. The vapor halide of an elemental material or halide mixtures are introduced into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in excess of the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal. Particulates of the elemental material or alloy and particulates of the halide salt of the reducing metal are produced along with sufficient heat to vaporize substantially all the excess reducing metal. Thereafter, the vapor of the reducing metal is separated from the particulates of the elemental material or alloy and the particulates of the halide salt of the reducing metal before the particulate reaction products are separated from each other.Type: ApplicationFiled: November 3, 2009Publication date: November 11, 2010Inventors: Richard P. Anderson, Donn Armstrong, Jacobsen Lance
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Patent number: 7781018Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapor phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.Type: GrantFiled: November 23, 2009Date of Patent: August 24, 2010Assignee: M&G USA CorporationInventor: Kevin L. Rollick
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Patent number: 7780869Abstract: An efficient oxygen scavenging composition for use in film forming polymers is disclosed wherein the oxygen scavenging composition comprises an oxidizable metal particle, such as elemental iron; a water hydrolysable Lewis acid, such as aluminum chloride; and an acidifying electrolyte such as sodium or potassium bisulfate.Type: GrantFiled: February 27, 2006Date of Patent: August 24, 2010Assignee: M&G USA CorporationInventors: Kevin L. Rollick, Guliz Arf Elliott
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Patent number: 7753989Abstract: A method of producing passivated Ti or Ti alloy particles with oxygen concentrations of less than about 900 parts per million (ppm), which includes introducing a halide vapor of Ti or the metal constituents of the alloy at sonic velocity or greater into a stream of liquid alkali or liquid alkaline earth metal or mixtures thereof forming a reaction zone in which the halide is reduced by the liquid metal present in sufficient excess of stoichiometric such that Ti or Ti alloy powder from the reduction of the halide by the liquid metal is friable. After filtration and distillation excess liquid metal is removed from the Ti or Ti alloy powder that is then maintained at elevated temperature for a time sufficient to grow the particles to average diameters calculated from BET surface area measurement greater than about one micron. After cooling the Ti or Ti alloy powder to temperature of about 80° C.Type: GrantFiled: December 22, 2006Date of Patent: July 13, 2010Assignee: Cristal US, Inc.Inventors: William Ernst, Lance Jacobsen
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Publication number: 20100151267Abstract: A powder batch is described comprising single crystal metal-containing particles having a crystal size of less than 50 nm as measured by X-ray diffraction and having a weight average particle size of from about 10 nanometers to less than 100 nanometers as measured by transmission electron microscopy and including a continuous or non-continuous coating of a ceramic material. The powder batch is preferably produced by flame spraying.Type: ApplicationFiled: June 19, 2007Publication date: June 17, 2010Applicant: Cabot CorporationInventors: Toivo T. Kodas, Miodrag Oljaca, Mark J. Hampden-Smith, George P. Fotou, Ralph E. Kornbrekke, Jian-Ping Shen
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Patent number: 7632331Abstract: Provided is an aerosol method, and accompanying apparatus, for preparing powdered products of a variety of materials involving the use of an ultrasonic aerosol generator (106) including a plurality of ultrasonic transducers (120) underlying and ultrasonically energizing a reservoir of liquid feed (102) which forms droplets of the aerosol. Carrier gas (104) is delivered to different portions of the reservoir by a plurality of gas delivery ports (136) delivering gas from a gas delivery system. The aerosol is pyrolyzed to form particles, which are then cooled and collected. The invention also provides powders made by the method and devices made using the powders.Type: GrantFiled: February 19, 2007Date of Patent: December 15, 2009Assignee: Cabot CorporationInventors: Mark J. Hampden-Smith, Toivo T. Kodas, Quint H. Powell, Daniel J. Skamser, James Caruso, Clive D. Chandler
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Patent number: 7621977Abstract: A system and method of producing an elemental material or an alloy from a halide of the elemental material or halide mixtures. The vapor halide of an elemental material or halide mixtures are introduced into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in excess of the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal. Particulates of the elemental material or alloy and particulates of the halide salt of the reducing metal are produced along with sufficient heat to vaporize substantially all the excess reducing metal. Thereafter, the vapor of the reducing metal is separated from the particulates of the elemental material or alloy and the particulates of the halide salt of the reducing metal before the particulate reaction products are separated from each other.Type: GrantFiled: September 3, 2003Date of Patent: November 24, 2009Assignee: Cristal US, Inc.Inventors: Richard P. Anderson, Donn Armstrong, Jacobsen Lance
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Patent number: 7622153Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapour phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.Type: GrantFiled: August 3, 2005Date of Patent: November 24, 2009Assignee: M&G USA CorporationInventor: Kevin L. Rollick
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Patent number: 7615097Abstract: Ultra fine and nanometer powders and a method of producing same are provided, preferably refractory metal and ceramic nanopowders. When certain precursors are injected into the plasma flame in a reactor chamber, the materials are heated, melted and vaporized and the chemical reaction is induced in the vapor phase. The vapor phase is quenched rapidly to solid phase to yield the ultra pure, ultra fine and nano product. With this technique, powders have been made 20 nanometers in size in a system capable of a bulk production rate of more than 10 lbs/hr. The process is particularly applicable to tungsten, molybdenum, rhenium, tungsten carbide, molybdenum carbide and other related materials.Type: GrantFiled: October 6, 2006Date of Patent: November 10, 2009Assignee: Plasma Processes, Inc.Inventors: Timothy N. McKechnie, Leo V. M. Antony, Scott O'Dell, Chris Power, Terry Tabor
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Patent number: 7559969Abstract: The present invention is generally directed towards a method for producing a solid metallic composition by reacting a gaseous metal halide with a reducing agent are described. In one embodiment, the method includes reacting a gaseous metal halide with a reducing agent in a manner effective to form a nonsolid reaction product, wherein the metal halide has the formula MXi, in which M is a metal selected from a transition metal of the periodic table, aluminum, silicon, boron, and combinations thereof, X is a halogen, i is greater than 0, and the reducing agent is a gaseous reducing agent selected from hydrogen and a compound that releases hydrogen, and combinations thereof; and solidifying the reaction product, thereby forming a metallic composition comprising M that is substantially free from halides. The invention may be used to produce high-purity metallic compositions, particularly titanium particles and alloys thereof for use in powder metallurgy applications.Type: GrantFiled: August 6, 2004Date of Patent: July 14, 2009Assignee: SRI InternationalInventors: Angel Sanjurjo, Eugene Thiers, Kai-Hung Lau, Don L. Hildenbrand, Gopala N. Krishnan, Esperanza Alvarez
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Patent number: 7501007Abstract: A system and method of separating metal powder from a slurry of liquid metal and metal powder and salt is disclosed in which the slurry is introduced into a first vessel operated in an inert environment when liquid metal is separated from the metal powder and salt leaving principally salt and metal powder substantially free of liquid metal. The salt and metal powder is transferred to a second vessel operated in an inert environment with both environments being protected from contamination. Then the salt and metal powder are treated to produce passivated powder substantially free of salt and liquid metal. The method is particularly applicable for use in the production of Ti and its alloys.Type: GrantFiled: September 3, 2003Date of Patent: March 10, 2009Assignee: Cristal US, Inc.Inventors: Richard P. Anderson, Lance Jacobsen
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Patent number: 7449044Abstract: An object of the present invention is to provide a method for production of metallic powder in which aggregation of particles and growth to secondary particle after reducing process of the metallic powder particle can be prevented, to reliably obtain metallic particles containing few coarse particles and to meet requirements of thinner layer and greater number of layers in recent capacitors, and a production device therefor. The present invention includes a reducing process in which metal chloride gas and reducing gas are contacted to continuously reduce the metal chloride, and a cooling process in which a gas containing metallic powder generated in the reducing process is continuously cooled by inert gas. In the cooling process, a vortex flow is generated by blowing out the inert gas from at least one part around the flowing passage of the metallic powder.Type: GrantFiled: September 12, 2003Date of Patent: November 11, 2008Assignee: Toho Titanium Co., Ltd.Inventors: Tsuyoshi Asai, Takuya Miyagi
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Patent number: 7416697Abstract: A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.Type: GrantFiled: May 17, 2004Date of Patent: August 26, 2008Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen, Michael Francis Xavier Gigliotti
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Patent number: 7367999Abstract: A method of producing ultrafine particles by vaporization comprising: vaporizing a target by sputtering; causing particles that fly from the target by vaporization to be deposited on an oil surface; and recovering the oil on which the flown particles have deposited to obtain individually dispersed ultrafine particles.Type: GrantFiled: November 23, 2004Date of Patent: May 6, 2008Assignee: Fujifilm CorporationInventor: Hiroshi Fujimoto
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Patent number: 7351272Abstract: A method of controlling the size and morphology of powder made by the subsurface injection of a halide vapor into a liquid metal is disclosed. A reaction zone is established and the temperature thereof or the time the powder remains therein is controlled to change powder characteristics.Type: GrantFiled: September 3, 2003Date of Patent: April 1, 2008Assignee: International Titanium Powder, LLCInventors: Donn Reynolds Armstrong, Richard Paul Anderson, Lance E. Jacobsen
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Patent number: 7344584Abstract: A process for the production of extra fine spherical metal powders by chemical vapor deposition and dissolution techniques, including metal carbonyls, wherein the metal containing process gas is propelled upwardly through a heated reactor. By employing an upward gas flow as opposed to the conventional downward gas flow, a closer approximation of theoretical plug-flow velocity profiles are achieved thusly resulting in a desirably narrower size particle distribution obviating or reducing the need for subsequent classification techniques.Type: GrantFiled: September 3, 2004Date of Patent: March 18, 2008Assignee: Inco LimitedInventors: Kenneth Stark Coley, Armen Markarian, Shadi Saberi, Randy Shaubel, Rinaldo A. Stefan, Lloyd Matt Timberg, Eric Bain Wasmund
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Patent number: 7314499Abstract: Produce high-function water useful for consumption as healthy drinking water or in the production of health supplements, cosmetic products, food preservatives, freshness-keeping agents for food, insect repellents or deodorizers, wherein such water contains micro-dispersed ultra-fine gold particles and a small amount of dissolved gold and is produced by constructing in the upper section of a high-pressure water tank a combustion chamber equipped with an injector nozzle for oxygen-hydrogen mixture gas, an ignition device and a gold-rod or gold-wire feeder, igniting the injector nozzle for oxygen-hydrogen mixture gas using the ignition device in the combustion chamber to melt and evaporate the gold rod or wire supplied from the feeder or water in which gold foil was dispersed beforehand and to allow the produced gold vapor to contact high-pressure water, and thereby causing the produced ultra-fine gold particles to float and disperse in water.Type: GrantFiled: February 26, 2002Date of Patent: January 1, 2008Assignee: Phild Co., Ltd.Inventors: Yoshihiro Hirata, Yoshio Ueda, Hiroaki Takase, Kazuaki Suzuki
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Patent number: 7208028Abstract: W powder is produced by: preparing a precursor containing tungsten; producing gas by vaporizing or sublimating the precursor; separating the tungsten component by placing the gas in an inert atmosphere while maintaining pressure below atmospheric pressure; and condensing the tungsten component at pressure below atmospheric pressure.Type: GrantFiled: December 30, 2003Date of Patent: April 24, 2007Assignee: Korean Institute of Machinery and MaterialsInventors: Byung Kee Kim, Jin Chun Kim
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Patent number: 7097686Abstract: Nickel powder batches and methods for producing nickel powder batches. The powder batches include particles having a small particle size, narrow size distribution and a spherical morphology. The present invention is also directed to devices incorporating the nickel metal powders.Type: GrantFiled: November 9, 2001Date of Patent: August 29, 2006Assignee: Cabot CorporationInventors: Clive D. Chandler, Daniel J. Skamser, Toivo T. Kodas, Mark J. Hampden-Smith, James Caruso, Quint H. Powell
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Patent number: 7066976Abstract: Electrocatalyst powders and methods for producing electrocatalyst powders, such as carbon composite electrocatalyst powders. The powders have a well-controlled microstructure and morphology. The method includes forming the particles from an aerosol of precursors by heating the aerosol to a relatively low temperature, such as not greater than about 400° C.Type: GrantFiled: August 1, 2002Date of Patent: June 27, 2006Assignee: Cabot CorporationInventors: Mark J. Hampden-Smith, Toivo T. Kodas, Plamen Atanassov, Paolina Atanassova, Klaus Kunze, Paul Napolitano, David Dericotte
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Patent number: 7041150Abstract: A method and apparatus for making alloys or ceramics by the subsurface injection of an equilibrium vapor of a boiling liquid of the ceramic or alloys constituents is disclosed. Various powders and products are disclosed.Type: GrantFiled: September 3, 2003Date of Patent: May 9, 2006Assignee: The University of ChicagoInventors: Donn Reynolds Armstrong, Richard Paul Anderson, Lance E. Jacobsen
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Patent number: 6932852Abstract: A 99.99% pure indium feed is charged into a crucible and heated to 1250 ° C. by an upper heater in a vacuum atmosphere at 1×10?4 Torr, whereupon indium evaporates, condenses on the inner surfaces of an inner tube and drips to be recovered into a liquid reservoir in the lower part of a tubular member, whereas impurity elements having a lower vapor pressure than indium stay within the crucible. The recovered indium mass in the liquid reservoir is heated to 1100° C. by a lower heater and the resulting vapors of impurity elements having a higher vapor pressure than indium pass through diffuser plates in an upper part of the tubular member to be discharged from the system, whereas the indium vapor recondenses upon contact with the diffuser plates and returns to the liquid reservoir, yielding 99.9999% pure indium, while preventing the loss of indium.Type: GrantFiled: July 2, 2003Date of Patent: August 23, 2005Assignee: Dowa Mining Co., Ltd.Inventors: Kishio Tayama, Toshiaki Hodozuka
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Patent number: 6893481Abstract: In a method for manufacturing Ni—Al alloy powders for electrode materials of fuel cells, in which, using aluminum chloride (AlCl3) as a catalyst, powders of Ni and Al, that have been used as electrode materials, are chemically reacted with each other to diffuse the Al into the Ni powders, so that Ni—Al alloy powders can be manufactured at a low temperature below fusion points of Ni and Al while maintaining a shape and a size of the existing Ni powders as they are, thus providing a manufacturing process of Ni—Al alloy powders that is simple, economical, compatible in working, and ready for scale-up, and in which a conventional manufacturing process of electrode based on Ni is used as it is, so that large sized electrode is manufactured.Type: GrantFiled: October 29, 2003Date of Patent: May 17, 2005Assignee: Korea Institute of Science and TechnologyInventors: Suk Woo Nam, Anatoli Maganiouk, Seong-Ahn Hong, In-Hwan Oh, Tae Hoon Lim, Heung Yong Ha, Sung Pil Yoon, Jonghee Han, Eun Ae Cho
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Patent number: 6884279Abstract: A metallic article is produced by furnishing one or more nonmetallic precursor compound comprising the metallic constituent element(s), and chemically reducing the nonmetallic precursor compound(s) to produce an initial metallic particle, preferably having a size of no greater than about 0.070 inch, without melting the initial metallic particle. The initial metallic particle is thereafter melted and solidified to produce the metallic article. By this approach, the incidence of chemical defects in the metal article is minimized. The melted-and-solidified metal may be used in the as-cast form, or it may be converted to billet and further worked to the final form.Type: GrantFiled: July 25, 2002Date of Patent: April 26, 2005Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott
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Publication number: 20040211294Abstract: W powder is produced by: preparing a precursor containing tungsten; producing gas by vaporizing or sublimating the precursor; separating the tungsten component by placing the gas in an inert atmosphere while maintaining pressure below atmospheric pressure; and condensing the tungsten component at pressure below atmospheric pressure.Type: ApplicationFiled: December 30, 2003Publication date: October 28, 2004Inventors: Byung Kee Kim, Jin Chun Kim
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Publication number: 20040159185Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds contains more of a base-metal element, such as nickel, cobalt, iron, iron-nickel, and iron-nickel-cobalt than any other metallic element. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic superalloy material, without melting the metallic superalloy material. The metallic superalloy material is consolidated to produce a consolidated metallic article, without melting the metallic superalloy material and without melting the consolidated metallic article.Type: ApplicationFiled: February 19, 2003Publication date: August 19, 2004Inventors: Clifford Earl Shamblen, Andrew Philip Woodfield, Eric Allen Ott, Michael Francis Xavier Gigliotti
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Patent number: 6755886Abstract: Method for producing metallic particles. The method converts metallic nanoparticles into larger, spherical metallic particles. An aerosol of solid metallic nanoparticles and a non-oxidizing plasma having a portion sufficiently hot to melt the nanoparticles are generated. The aerosol is directed into the plasma where the metallic nanoparticles melt, collide, join, and spheroidize. The molten spherical metallic particles are directed away from the plasma and enter the afterglow where they cool and solidify.Type: GrantFiled: April 18, 2002Date of Patent: June 29, 2004Assignee: The Regents of the University of CaliforniaInventors: Jonathan Phillips, William L. Perry, William J. Kroenke
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Publication number: 20040093986Abstract: A process for preparing a pure PGM (platinum group metal) from a material containing a plurality of PGM compounds, wherein the PGM is selected from the group consisting of Pt, Pd, Os, Ir, Ru, Rh and Re, and the process includes initially forming the PGM in activated form by reduction of PGM ions in aqueous solution at pH 6-8 by a reducing agent, preferably, hydrogen.Type: ApplicationFiled: November 7, 2003Publication date: May 20, 2004Inventors: Kamran M. Khozan, Dmitri S. Terekhov, Victor E. Nanthakumar, Sergiy Kovtun
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Publication number: 20040079196Abstract: A method of controlling the size and morphology of powder made by the subsurface injection of a halide vapor into a liquid metal is disclosed. A reaction zone is established and the temperature thereof or the time the powder remains therein is controlled to change powder characteristics.Type: ApplicationFiled: September 3, 2003Publication date: April 29, 2004Applicant: International Titanium Powder, LLCInventors: Donn Reynolds Armstrong, Richard Paul Anderson, Lance E. Jacobsen