Purifying Powdered Metal Or Reducing Powdered Metal Compound To Free Metal Patents (Class 75/369)
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Publication number: 20100294079Abstract: The present invention provides a method and facility for preventing crumbling and powderization of green pellets when producing high strength green pellets using a powder feedstock and using the pellets in a rotary hearth reducing furnace and for efficiently reducing the same. It comprises kneading by a kneader 5 a feedstock of a powder of a fine particle size (20 to 80 wt % having size of not more than 10 ?m) including a metal oxide and carbon-bearing powder fed from a feed storage tank 1 and producing green pellets by a pan type pelletizer 7. The green pellets are screened by a pellet screen 9, then dried by a pellet dryer 11 and reduced by firing in a rotary hearth reducing furnace 13. At that time, the green pellets are continuously conveyed to prevent crumbling.Type: ApplicationFiled: July 29, 2010Publication date: November 25, 2010Applicant: Nippon Steel CorporationInventors: Tetuharu Ibaraki, Hiroshi Oda, Shoji Imura, Masaharu Takahashi
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Publication number: 20100285326Abstract: The disclosure is directed to a process for producing separable iron and titanium oxides from an ore containing titanium oxide and ferric oxide, comprising: (a) forming agglomerates comprising carbon-based materials and the ore, the quantity of carbon of the agglomerates being sufficient for, at an elevated temperature, reducing ferric oxide to ferrous oxide and forming a ferrous oxide-rich molten slag, (b) introducing the agglomerates onto a carbon bed of a moving hearth furnace; (c) heating the agglomerates in the moving hearth furnace to a temperature sufficient for reducing and melting the agglomerates to produce a ferrous oxide-rich molten slag; (d) metallizing the ferrous oxide of the molten slag by reaction of the ferrous oxide and the carbon of the carbon bed at a furnace temperature sufficient for maintaining the slag in a molten state; and (e) solidifying the slag after metallization of the ferrous oxide to form a matrix of titanium oxide-rich slag having a plurality of metallic iron granules distriType: ApplicationFiled: July 19, 2010Publication date: November 11, 2010Applicant: E. I. DU PONT DE NEMOURS AND COMPANYInventors: JOHN JAMES BARNES, Stephen Erwin Lyke, Dat Nguyen, Mitsutaka Hino, Akira Uragami, Isao Kobayashi, Thomas Peter Battle, Joseph M. Shekiro, JR.
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Patent number: 7785390Abstract: Molybdenum metal powder has surface-area-to-mass-ratios in a range of between about 1.0 meters2/gram (m2/g) and about 3.0 m2/g, as determined by BET analysis, in combination with a particle size wherein at least 30% of the particles are larger than a size +100 standard Tyler mesh sieve. A method for producing molybdenum metal powder includes providing a supply of ammonium molybdate and a reducing gas; causing an exothermic reaction between the ammonium molybdate and the reducing gas at a first temperature to produce an intermediate reaction product and a supplemental reducing gas; causing an endothermic reaction between the intermediate reaction product and the reducing gas at a final temperature to produce the molybdenum metal powder.Type: GrantFiled: August 14, 2007Date of Patent: August 31, 2010Assignee: Climax Engineered Materials, LLCInventors: Loyal M. Johnson, Jr., Sunil Chandra Jha, Carl Cox, Patrick Ansel Thompson
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Patent number: 7758668Abstract: A process for synthesizing metal submicron and nano-scale powders for use in articles of manufacture. In a suitable reactor, single metal or multiple metal complexes are heated to a temperature whereby, upon contact with hydrogen gas, an exothermic reaction begins. The further temperature rise in response to the exothermic reaction is minimized by reducing the external heat input, thereby minimizing the agglomeration or sintering of the metal nano-scale particles resulting from the process. Preferably, after drawing a vacuum on the metal complexes in the reactor, the hydrogen is introduced at above, equal to or below ambient pressure and the reaction is purposely made slow to prevent agglomeration or sintering.Type: GrantFiled: April 17, 2007Date of Patent: July 20, 2010Assignee: Chemnano, Inc.Inventor: Wei Wu
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Publication number: 20100147110Abstract: 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: ApplicationFiled: July 8, 2008Publication date: June 17, 2010Applicant: TAIYO NIPPON SANSO CORPORATIONInventors: Hiroshi Igarashi, Takayuki Matsumura, Shinichi Miyake
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Patent number: 7736414Abstract: Rhenium nanoparticle mixtures and methods for making the same are provided. The rhenium nanoparticle mixture can be painted onto a surface to be coated and dried at low temperatures to form a gas-tight elemental rhenium coating. Moreover, the rhenium nanoparticle mixture can be used to join rhenium components and temperatures far lower than traditional welding techniques would require. The low temperature formation of rhenium coatings allows rhenium coatings to be provided on surfaces that would otherwise be uncoatable, whether because of their inability to withstand high temperatures (e.g., carbon/carbon composites, graphite, etc.), or because the high aspect ratio of the surface would prevent other coating methods from being effective (e.g., the inner surfaces of tubes and nozzles).Type: GrantFiled: May 15, 2007Date of Patent: June 15, 2010Assignee: Lockheed Martin CorporationInventor: Alfred A. Zinn
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Patent number: 7704297Abstract: A melt of nickel nitrate hydrate is introduced as droplets or liquid flow into a heated reaction vessel and thermally decomposed in a gas phase at a temperature of 1200° C. or more and at an oxygen partial pressure equal to or below the equilibrium oxygen pressure of nickel-nickel oxide at that temperature to manufacture a highly crystalline fine nickel powder with an extremely narrow particle size distribution. The oxygen partial pressure during the thermal decomposition is preferably 10?2 Pa or less, and a metal other than nickel, a semimetal and/or a compound of these may be added to the nickel nitrate hydrate melt to manufacture a highly crystalline nickel alloy powder or highly crystalline nickel composite powder. The resultant powder is suited in particular to thick film pastes such as conductor pastes for manufacturing ceramic multilayer electronic components.Type: GrantFiled: April 3, 2007Date of Patent: April 27, 2010Assignee: Shoei Chemical Inc.Inventors: Yuji Akimoto, Kazuro Nagashima, Hidenori Ieda, Tetsuya Kimura
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Publication number: 20100024598Abstract: Process and apparatus for the treatment of divided metal residues contaminated by one or more organic compounds, comprising: mixing, inside a chamber, of said metal residues with at least one calcium/magnesium compound capable of reacting exothermically with water; exothermic reaction of said at least one calcium/magnesium compound with the water that the metal residues contain; rise in temperature of the metal residues subject to an exothermic reaction; dehydration of said metal residues during this exothermic reaction; oxidation of the organic compounds during said mixing, by bringing the metal residues contaminated by one or more organic compounds mixed with said at least one calcium/magnesium compound into contact with a gas stream containing at least partly oxygen; and removal from the chamber of a handleable dehydrated treated product having a residual content of organic compounds of less than 1% by weight of said treated product.Type: ApplicationFiled: September 25, 2007Publication date: February 4, 2010Applicant: PAUL WURTH S.A.Inventors: Jean-Luc Roth, Ludivine Piezanowski, Marc Pelletier, Alain Laudet
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Patent number: 7625421Abstract: Novel forms of molybdenum metal. Novel forms of molybdenum metal are characterized by a surface area of substantially about 2.1 m2/g to substantially about 4.1 m2/g. Novel forms of molybdenum metal are also characterized by a relatively uniform size.Type: GrantFiled: November 8, 2006Date of Patent: December 1, 2009Assignee: Cyprus Amax Mineral CompanyInventors: Mohamed H. Kahn, Joel Taube, Loyal M. Johnson, Jr.
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Patent number: 7604679Abstract: An efficient process for producing fine nickel powder, capable of metallizing the powder at low temperature to prevent its sintering, and fine nickel powder produced by the process, composed of particles having a flat shape, diameter of limited variations and uniform thickness, and suitable for internal electrodes for laminate ceramic capacitors of high electric capacity. The process comprises a step for forming a nickel compound coated with gelatin by adsorbing gelatin on preformed nickel compound particles with different size and shape (Step (A)), and another step for converting said nickel compound coated with gelatin into fine particles containing metallic nickel and nickel oxide by heating the nickel compound coated with gelatin produced in Step (A) in an inert gas atmosphere (Step (B)). It may include an additional step (Step (C)), subsequent to Step (B), for completely reducing nickel oxide in said fine particles by heating at temperature lower than that for Step (B) in a reducing gas atmosphere.Type: GrantFiled: November 4, 2005Date of Patent: October 20, 2009Assignee: Sumitomo Metal Mining Co., Ltd.Inventors: Yasumasa Hattori, Egon Matijevic
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Publication number: 20090136770Abstract: To provide a dispersion which is excellent in oxidation resistance and dispersion stability, and which contains metal fine particles capable of forming a metal film excellent in conductivity; a process for producing it; and an article having a metal film excellent in conductivity. A process for producing a dispersion of metal fine particles, which comprises heating a dispersion of metal hydride fine particles, comprising a dispersion medium, metal hydride fine particles dispersed in the medium and having an average particle size of at most 50 nm, and an organic compound with from 4 to 1000 carbon atoms, having an amino group, in an inert atmosphere at a temperature of from 60 to 350° C.; a dispersion containing metal fine particles, obtained by such a process; and an article having a metal film formed by applying the dispersion containing metal fine particles on a substrate and firing it.Type: ApplicationFiled: January 27, 2009Publication date: May 28, 2009Applicant: ASAHI GLASS COMPANY, LIMITEDInventors: Hideyuki HIRAKOSO, Keisuke Abe, Yasuhiro Sanada
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Patent number: 7527752Abstract: A method for surface treatment of nickel nanoparticles using an organic solution, including dispersing nickel nanoparticles in a reductive organic solvent to obtain homogeneity; heating the dispersion of nickel nanoparticles; and separating the solution after treatment, washing and drying. Nickel nanoparticles treated by this method are preferably substantially free of impurities remaining on particle surfaces and thus have smooth surfaces and increased tap density, and the use thereof enables efficient production of a multi-layer ceramic capacitor.Type: GrantFiled: June 24, 2005Date of Patent: May 5, 2009Assignee: Samsung Electro-Mechanics Co., Ltd.Inventors: Seon Mi Yoon, Jae Young Choi, Yong Kyun Lee, Hyun Chul Lee
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Patent number: 7524353Abstract: Densified molybdenum metal powder and method for producing same. Densified molybdenum powder has substantially generally spherical particles, surface area to mass ratio of no more than about 0.5 m2/g as determined by BET analysis, and a flowability greater than about 32 s/50g as determined by a Hall Flowmeter. A method for producing densified molybdenum metal powder includes providing a supply of precursor material of molybdenum metal powder particles reduced from ammonium molybdate; providing a supply of reducing gas; densifying the precursor material in the presence of the reducing gas; and producing the densified molybdenum metal powder.Type: GrantFiled: February 17, 2006Date of Patent: April 28, 2009Assignee: Climax Engineered Materials, LLCInventors: Loyal M. Johnson, Jr., Sunil Chandra Jha, Patrick Ansel Thompson
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Patent number: 7503959Abstract: Metal particles that can be alloyed with rhenium are dispersed as a main component in a gas phase, a rhenium oxide vapor is made to be present around these particles, the rhenium oxide is reduced, and the rhenium precipitated on the surface of the main component metal particles as a result of this reduction is diffused under a high temperature into the main component metal particles, which gives a rhenium-containing alloy powder including the main component metal and rhenium. The powder thus obtained preferably contains 0.01 to 50 wt % rhenium, has an average particle size of 0.01 to 10 ?m, and is made into a conductor paste by being uniformly mixed and dispersed in an organic vehicle along with other additives as needed.Type: GrantFiled: October 16, 2006Date of Patent: March 17, 2009Assignee: Shoei Chemical Inc.Inventors: Yuji Akimoto, Kazuro Nagashima, Masayuki Maekawa, Hidenori Ieda, Yasuhiro Kamahori
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Publication number: 20090053132Abstract: The present invention relates to a process for preparing powders of niobium suboxides or niobium, wherein the process comprising: mixing the niobium oxides as raw material with reducing agent, conducting a reaction at a temperature in the range of 600˜1300° C. in an atmosphere of vacuum or inert gas or hydrogen gas, leaching the reaction product to remove the residual reducing agent and the oxides of the reducing agent and other impurities, heat treating at a temperature of the range of 1000˜1600° C. in an atmosphere of vacuum or inert gas, and screening to obtain the powders of niobium suboxide or niobium of capacitor grade. According to the present invention, the niobium oxides were directly reduced into capacitor grade niobium suboxides or niobium with reducing agents which can be easily removed by mineral acids, wherein the speed of the reaction can be controlled and the reaction can directly reduce the niobium oxides into capacitor grade niobium suboxides or niobium powder.Type: ApplicationFiled: August 22, 2008Publication date: February 26, 2009Inventors: Wenfeng SHI, Xudong XI, Yong LI, Xueqing CHEN, Wei WANG
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Patent number: 7481864Abstract: Processes for producing valve metal are described, in which valve metal oxide is converted to valve metal using a vapor-phase transport agent to form a gaseous valve metal species in the presence of a solid getter material. Also described is the valve metal so produced, and anodes prepared from the valve metal, as well as electrolytic capacitors using the anodes.Type: GrantFiled: January 14, 2005Date of Patent: January 27, 2009Assignee: Cabot CorporationInventor: Robert Mariani
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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: 7431751Abstract: A method of producing a refractory metal powder that includes providing a metal powder containing magnesium tantalate or magnesium niobate; and heating the powder in an inert atmosphere in the presence of magnesium, calcium and/or aluminum to a temperature sufficient to remove magnesium tantalate or magnesium niobate from the powder and/or heating the powder under vacuum to a temperature sufficient to remove magnesium tantalate or magnesium niobate from the powder, the heating steps being performed in any order. The metal powder can be formed into pellets at an appropriate sintering temperature, which can be formed into electrolytic capacitors.Type: GrantFiled: September 29, 2004Date of Patent: October 7, 2008Assignee: H.C. Starck Inc.Inventors: Leonid Natan Shekhter, Leonid Lanin, Anastasis M. Conlon
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Publication number: 20080223175Abstract: There is described a method of making a nanocrystalline tungsten powder that comprises: (a) heating a tungsten-containing material in a reducing atmosphere at an intermediate temperature of from about 600° C. to about 700° C. for an intermediate time period; the tungsten-containing material being selected from ammonium paratungstate, ammonium metatungstate or a tungsten oxide; and (b) increasing the temperature to a final temperature of about 800° C. to about 1000° C. for a final time period.Type: ApplicationFiled: February 25, 2008Publication date: September 18, 2008Applicant: OSRAM SYLVANIA INC.Inventors: Hans-Joachim Lunk, Henry J. Stevens
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Patent number: 7419529Abstract: An object of the present invention is to provide a method of forming fine particles on a substrate in which reoxidization of reduced fine particles is suppressed. Reduced fine particles (FeO fine particles) are formed by embedding metal oxide fine particles (Fe2O3 fine particles) fixed on a p type silicon semiconductor substrate into a silicon oxidized film, and carrying out a heat treatment in a reducing gas atmosphere. Presence of the silicon oxidized film enables suppression of reoxidization of the reduced fine particles (FeO fine particles) due to exposure to the ambient air.Type: GrantFiled: November 23, 2005Date of Patent: September 2, 2008Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Shigeo Yoshii, Michihito Ueda, Nozomu Matsukawa, Ichiro Yamashita
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Patent number: 7419528Abstract: 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: GrantFiled: February 19, 2003Date of Patent: September 2, 2008Assignee: General Electric CompanyInventors: Clifford Earl Shamblen, Andrew Philip Woodfield, Eric Allen Ott, Michael Francis Xavier Gigliotti
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Patent number: 7407526Abstract: The invention concerns an iron powder for fortifying foodstuff. The powder consists of a reduced iron powder having irregularly shaped particles, wherein the iron powder has a ratio AD:PD less than 0.3, wherein AD is the apparent density in g/cm3, and PD is the particle density in g/cm3. The specific surface area of the powder particles is above 300 m2/kg as measured by the BET method and the average particle size is between 5-45 ?m.Type: GrantFiled: November 24, 2004Date of Patent: August 5, 2008Assignee: Höganäs ABInventors: Bo Hu, Fredrik Eklund, Nils Jonsson, Fredrik Persson
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Patent number: 7399335Abstract: A method of preparing primary refractory metals (e.g., primary tantalum metal) by contacting a particulate refractory metal oxide (e.g., tantalum pentoxide) with a heated gas (e.g., a plasma), is described. The heated gas comprises hydrogen gas. The temperature range of the heated gas and the mass ratio of hydrogen gas to refractory metal oxide are each selected such that: (i) the heated gas comprises atomic hydrogen; (ii) the refractory metal oxide feed material is substantially thermodynamically stabilized (i.e., the concurrent formation of suboxides that are not reduced by atomic hydrogen is minimized); and (iii) the refractory metal oxide is reduced by contact with the heated gas, thereby forming primary refractory metal (e.g., primary tantalum metal and/or primary niobium metal).Type: GrantFiled: March 22, 2005Date of Patent: July 15, 2008Assignee: H.C. Starck Inc.Inventors: Leonid Natan Shekhter, Leah F. Simkins, Hugh P. Greville, Leonid Lanin
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Patent number: 7361205Abstract: The invention relates to a method of producing granules made of high purity metal or metal alloy, in particular based on chromium, the method being characterized in that it comprises the steps consisting in: preparing a metal or a metal alloy having non-metallic inclusions essentially comprising oxides of the base metal; pelletizing the metal or the alloy with a reducing agent in order to form the pellets or tablets; treating the pellets or tablets in a vacuum in order to enable the reducing agent to react on the inclusions without substantial sublimation of the metal or the metals of the alloy; and eliminating a surface layer from the pellets or tablets. The invention is applicable to manufacturing mechanical parts out of superalloys.Type: GrantFiled: January 20, 2003Date of Patent: April 22, 2008Assignee: Delachaux S.A.Inventor: Philippe Liebaert
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Patent number: 7354472Abstract: A method of producing a refractory metal powder by (A) combining (i) an oxide particle component and (ii) a reducing agent; (B) forming a substantially uniform mixture of (i) and (ii); (C) continuously feeding the mixture into a furnace; (D) igniting the mixture at a reaction zone and starting a reaction that is sufficiently exothermic to form a high temperature flash; (E) starting a reaction that is sufficiently exothermic to form a high temperature self-sustaining flash; and (F) producing a free-flowing reduced oxide powder.Type: GrantFiled: June 21, 2004Date of Patent: April 8, 2008Assignee: H.C. Starck Inc.Inventors: Leonid Natan Shekhter, Edward V. McCormick, Leah F. Simkins, Edward K. Schiele
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Patent number: 7309374Abstract: In contrast to current industrial practice where alloying powders are added to starting powder metallurgy compositions either as powder mixtures or fully prealloyed powders, the present invention posits a diffusion bonded nickel-copper precursor additive mixture for direct one step addition to the starting powder metallurgy master blend composition. Segregation and dusting are substantially reduced and the mechanical properties of the resultant compact are improved.Type: GrantFiled: April 4, 2005Date of Patent: December 18, 2007Assignee: Inco LimitedInventors: Tajpreet Singh, Scott Thomas Campbell, Thomas Francis Stephenson, Ouan Min Yang
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Patent number: 7300492Abstract: A novel molybdenum compound, ammonium dodecamolybdomolybdate (AMM), is described which may be used in the manufacture of molybdenum metal and molybdenum carbide powders. The molybdenum compound is a dodecaheteropoly acid salt having a Keggin-type structure wherein molybdenum resides in both the hetero as well as peripheral atomic positions. The novel compound has the general formula (NH4)2Mo12MoO40·6H2O. Because of its low solubility, the compound can be crystallized efficiently and at a high purity from ammonium molybdate solutions.Type: GrantFiled: September 1, 2004Date of Patent: November 27, 2007Assignee: Osram Sylvania Inc.Inventors: Raj P. Singh, Thomas A. Wolfe, David L. Houck
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Patent number: 7279024Abstract: High purity cobalt with a very few content of impurities such as copper, a method of manufacturing thereof, and high purity cobalt targets are provided. The cobalt containing impurities such as copper is dissolved in a hydrochloric acid solution, and the concentration of the hydrochloric acid of the aqueous solution of cobalt chloride is adjusted to 0.1 kmol/m3 to 3 kmol/m3. Then, cobalt is added in the aqueous solution of cobalt chloride, and an inert gas is injected into the solution with agitating, in order to convert the divalent copper ions contained in the aqueous solution of cobalt chloride to monovalent copper ions. Then, the aqueous solution of cobalt chloride is fed into a column filled up with the anion exchange resins. Cobalt is not absorbed on the anion exchange resins although the monovalent copper ions are absorbed on the anion exchange resins. Therefore, copper can be separated from the aqueous solution of cobalt chloride.Type: GrantFiled: March 17, 2004Date of Patent: October 9, 2007Assignees: Sony CorporationInventors: Masahito Uchikoshi, Norio Yokoyama, Tamas Kekesi, Minoru Isshiki
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Patent number: 7276102Abstract: Molybdenum metal powder, and method for production thereof. Molybdenum metal powder has surface-area-to-mass-ratios in a range of between about 1.0 meters2/gram (m2/g) and about 3.0 m2/g, as determined by BET analysis, in combination with a particle size wherein at least 30% of the particles have a particle size larger than a size +100 standard Tyler mesh sieve. In addition, molybdenum metal powder 10 may be further distinguished by flowability in a range of between about 29 seconds/50 grams (s/50 g) and about 64 s/50 g, as determined by a Hall Flowmeter. A method of producing molybdenum powder may comprise providing a supply of ammonium molybdate, heating the ammonium molybdate at an initial temperature in the presence of a reducing gas to produce an intermediate product, and heating the intermediate product at a final temperature in the presence of the reducing gas, producing molybdenum metal powder.Type: GrantFiled: October 21, 2004Date of Patent: October 2, 2007Assignee: Climax Engineered Materials, LLCInventors: Loyal M. Johnson, Jr., Sunil Chandra Jha, Carl Cox, Patrick Ansel Thompson
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Patent number: 7273509Abstract: A process of making metal nanoparticles comprising the steps of: providing a precursor composition comprising at least one metallic compound and at least one organic compound; wherein the organic compound is selected from the group consisting of an ethynyl compound, a metal-ethynyl complex, and combinations thereof; wherein the precursor composition is a liquid or a solid at room temperature; and heating the precursor composition under conditions effective to produce metal nanoparticles. A metal nanoparticle composition comprising metal nanoparticles dispersed homogenously in a matrix selected from the group consisting of ethynyl polymer, crosslinked ethynyl polymer, amorphous carbon, carbon nanotubes, carbon nanoparticles, graphite, and combinations thereof.Type: GrantFiled: June 24, 2004Date of Patent: September 25, 2007Assignee: The United States of America as of of America as represented by the Secretary of the NavyInventors: Teddy M. Keller, Syed B. Qadri
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Patent number: 7258722Abstract: Any one of a Ti-containing water-soluble salt, metatitanic acid (TiO(OH)2) slurry and ultra fine titanium oxide powder, and a transition metal containing metal salt are dissolved in water to prepare a raw material mixture. The raw material is spray-dried to obtain precursor powder, which is calcined to form ultra fine Ti/transition metal complex oxide and is then mixed with nano-sized carbon particles and subjected to reduction and carburization in a non-oxidizing atmosphere.Type: GrantFiled: December 30, 2003Date of Patent: August 21, 2007Assignee: Korea Institute of Machinery and MaterialsInventors: Byoung Kee Kim, Seong Hyeon Hong, Yong Won Woo
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Patent number: 7192467Abstract: Novel forms of molybdenum metal, and apparatus and methods for production thereof. Novel forms of molybdenum metal are preferably characterized by a surface area of substantially about 2.1 m2/g to substantially about 4.1 m2/g. Novel forms of molybdenum metal are also preferably characterized by a relatively uniform size.Type: GrantFiled: November 20, 2003Date of Patent: March 20, 2007Assignee: Climax Engineered Materials, LLCInventors: Mohamed Khan, Joel Taube, Loyal M. Johnson, Jr.
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Patent number: 7153340Abstract: Ultra fine TaC-transition metal based complex powder is prepared by: dispersing a mixture of a Ta-containing material and a transition metal-containing water soluble salt into a solvent; stirring the mixture and spray-drying the stirred material to obtain precursor powder; calcining the precursor powder to form ultra fine Ta-transition metal complex oxide powder; mixing the ultra fine Ta-transition metal complex oxide powder with nano-sized carbon particles, followed by drying to obtain complex oxide powder; and subjecting the dried complex oxide powder to reduction/carburization in a non-oxidizing atmosphere.Type: GrantFiled: December 30, 2003Date of Patent: December 26, 2006Assignee: Korean Institute of Machinery and MaterialsInventors: Byong Kee Kim, Seong Hyeon Hong, Yong Won Woo
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Patent number: 7122069Abstract: A Mo—Cu composite powder is provided which is comprised of individual finite particles each having a copper phase and a molybdenum phase wherein the molybdenum phase substantially encapsulates the copper phase. The composite powder may be consolidated by conventional P/M techniques and sintered without copper bleedout according to the method described herein to produce Mo—Cu pseudoalloy articles having very good shape retention, a high sintered density, and a fine microstructure.Type: GrantFiled: March 13, 2001Date of Patent: October 17, 2006Assignee: Osram Sylvania Inc.Inventors: Leonid P Dorfman, Michael J. Scheithauer, David L. Houck, Anna T. Spitsberg, Jeffrey N. Dann
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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: 7066979Abstract: Process for producing a valve metal powder by producing a precursor of desired morphology, converting the precursor into an oxide of the valve metal, stabilizing the structure of the oxide by heat treatment and reducing the stabilized oxide while retaining the morphology. Valve metal powders obtainable in this way, in particular comprising spherical agglomerates with a mean agglomerate size of 10–80 ?m, preferably 20–40 ?m, and use of these valve metal powders to produce solid electrolyte capacitors.Type: GrantFiled: March 7, 2003Date of Patent: June 27, 2006Assignee: H. C. Starck GmbHInventors: Josua Löffelholz, Hady Seyeda, Rüdiger Wolf, Karlheinz Reichert, Christoph Schnitter
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Patent number: 7066980Abstract: A method in which a metal powder is produced by ejecting a thermally decomposable metal compound powder into a reaction vessel through a nozzle together with a carrier gas under the condition V/S>600, where V is the flow rate of the carrier gas per unit time (liter/min), and S is the cross-sectional area of the nozzle opening part (cm2), and heating this metal powder at a temperature which is higher than the decomposition temperature of the metal compound powder and not lower than (Tm?200)° C., where Tm is the melting point of the metal, in a state where the metal compound powder is dispersed in the gas phase at a concentration of 10 g/liter or less. The method provides a fine, spherical, highly-crystallized metal powder which has a high purity, high density, high dispersibility and extremely uniform particle size, at low cost and using a simple process.Type: GrantFiled: September 8, 2003Date of Patent: June 27, 2006Assignee: Shoei Chemical, Inc.Inventors: Yuji Akimoto, Shinichi Ono, Kazuro Nagashima, Masayuki Maekawa, Hidenori Ieda
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Patent number: 7060121Abstract: A method for producing gold nanoparticles is disclosed. When gold salt solution is mixed with an adsorbent, gold in the form of complexes is adsorbed onto the surface of the adsorbent. The gold-loaded adsorbent, after being separated from the solution by screening, filtration, settling or other methods, is ashed to form ashes. The ashes contain gold nanoparticles and impurities such as oxides of sodium, potassium and calcium. The impurities can be removed by dissolution using dilute acids. The relatively pure gold nanoparticles are obtained after the impurities are removed. Activated carbon or gold-adsorbing resin can be used as the adsorbent. Silver or platinum group metal nanoparticles can also be produced by this method.Type: GrantFiled: June 25, 2003Date of Patent: June 13, 2006Inventors: Hsing Kuang Lin, Daniel Edward Walsh
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Patent number: 7001443Abstract: A metallic alloy is prepared from a gaseous mixture of at least two non-oxide precursor compounds, wherein the non-oxide precursor compounds collectively comprise the metallic constituents. The mixture of the non-oxide precursor compounds is oxidized to form a solid mixed metallic oxide. The solid mixed metallic oxide is chemically reduced to produce the metallic alloy.Type: GrantFiled: December 23, 2002Date of Patent: February 21, 2006Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, William Thomas Carter, Jr.
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Patent number: 6989041Abstract: A process for producing titanium sponge includes carrying out a reduction reaction by supplying titanium tetrachloride to a reaction vessel which stores a reduction bath liquid containing an upper layer of a reactant bath liquid layer containing fused magnesium as a main component and a lower layer of a product bath liquid layer containing fused magnesium chloride as a main component, wherein the level of the interface between the reactant bath liquid layer and the product bath liquid layer and the level of the reduction bath liquid surface are controlled in response to an accumulated supply of titanium tetrachloride.Type: GrantFiled: April 3, 2003Date of Patent: January 24, 2006Assignee: Toho Titanium Co., Ltd.Inventors: Nobuaki Ito, Masanori Yamaguchi, Kenichi Kato, Shigeo Ampo
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Patent number: 6939390Abstract: Nickel powder includes, on the basis of the total number of particles, not less than 10% of particles whose particle size is not less than 1.2 times the average particle size, as determined by the SEM observation; and not less than 10% of particles whose particle size is not more than 0.8 times the average particle size, as determined by the SEM observation. The nickel powder can be prepared by, for instance, precipitating nickel particles from an aqueous solution containing a nickel salt and a hydrazine reducing agent, without forming any hydroxide of nickel as an intermediate. A conductive paste containing the nickel powder can be applied onto an internal or external electrode for electronic parts.Type: GrantFiled: July 1, 2003Date of Patent: September 6, 2005Assignee: Mitsui Mining and Smelting Co., Ltd.Inventors: Yoshiharu Toshima, Takao Hayashi, Yasuhide Yamaguchi, Hiroyuki Shimamura
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Patent number: 6932851Abstract: A method of producing metal alloy nanoparticles comprising forming a cyanosol by reacting a mixture of a chlorometallate complex and a cyanometallate complex, spin-coating the mixture onto a substrate to form a film, and sintering the film to form metal alloy nanoparticles.Type: GrantFiled: November 4, 2002Date of Patent: August 23, 2005Assignee: The Trustees of Princeton UniversityInventors: Andrew B. Bocarsly, Shu Zhu
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Patent number: 6929675Abstract: A method for providing an anhydrous route for the synthesis of amine capped coinage-metal (copper, silver, and gold) nanoparticles (NPs) using the coinage-metal mesityl (mesityl=C6H2(CH3)3-2,4,6) derivatives. In this method, a solution of (Cu(C6H2(CH3)3)5, (Ag(C6H2(CH3)3)4, or (Au(C6H2(CH3)3)5 is dissolved in a coordinating solvent, such as a primary, secondary, or tertiary amine; primary, secondary, or tertiary phosphine, or alkyl thiol, to produce a mesityl precursor solution. This solution is subsequently injected into an organic solvent that is heated to a temperature greater than approximately 100° C. After washing with an organic solvent, such as an alcohol (including methanol, ethanol, propanol, and higher molecular-weight alcohols), oxide free coinage NP are prepared that could be extracted with a solvent, such as an aromatic solvent (including, for example, toluene, benzene, and pyridine) or an alkane (including, for example, pentane, hexane, and heptane).Type: GrantFiled: April 24, 2003Date of Patent: August 16, 2005Assignee: Sandia CorporationInventors: Scott D. Bunge, Timothy J. Boyle
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Patent number: 6918946Abstract: A method for the production of a robust, chemically stable, crystalline, passivated nanoparticle and composition containing the same, that emit light with high efficiencies and size-tunable and excitation energy tunable color. The methods include the thermal degradation of a precursor molecule in the presence of a capping agent at high temperature and elevated pressure. A particular composition prepared by the methods is a passivated silicon nanoparticle composition displaying discrete optical transitions.Type: GrantFiled: March 28, 2002Date of Patent: July 19, 2005Assignee: Board of Regents, The University of Texas SystemInventors: Brian A. Korgel, Paul Thurk, Keith P. Johnston
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Patent number: 6918945Abstract: A method for manufacturing sponge iron includes heating iron oxide together with a solid reducing agent to reduce the iron oxide into sponge iron, wherein the iron oxide includes a mixture of powdered hematite and powdered iron ore or a mixture of powdered hematite and powdered mill scale, the powdered hematite has a specific surface area of 2.0 m2/g or more, and the content of the powdered hematite is 5-45% by mass with respect to the total quantity of iron oxide.Type: GrantFiled: February 13, 2002Date of Patent: July 19, 2005Assignee: JFE Steel CorporationInventors: Satoshi Uenosono, Akio Sonobe, Hiroshi Sugihara
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Patent number: 6902601Abstract: A method of producing an elemental material or an alloy thereof from a halide or mixtures of halides is provided. The halide or mixtures thereof are contacted with a reducing gas in the presence of reductant material, preferably in sufficient quantity to convert the halide to the elemental material or alloy and to maintain the temperature of the reactants at a temperature lower than the boiling point of the reductant material at atmospheric pressure or the sintering temperature of the produced elemental material or alloy.Type: GrantFiled: September 12, 2002Date of Patent: June 7, 2005Assignee: Millennium Inorganic Chemicals, Inc.Inventors: Jason X. Nie, Robert Daniels, Dale H. Perkins-Banks, Thomas Messer
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Patent number: 6887297Abstract: The invention relates to methods of making monodisperse nanocrystals comprising the steps of reducing a copper salt with a reducing agent, providing a passivating agent comprising a nitrogen and/or an oxygen donating moitey and isolating the copper nanocrystals. Moreover, the invention relates to methods for making a copper film comprising the steps of applying a solvent comprising copper nanocrystals onto a substrate and heating the substrate to form a film of continuous bulk copper from said nanocrystals. Finally, the invention also relates to methods for filling a feature on a substrate with copper comprising the steps of applying a solvent comprising copper nanocrystals onto the featured substrate and heating the substrate to fill the feature by forming continuous bulk copper in the feature.Type: GrantFiled: November 8, 2002Date of Patent: May 3, 2005Assignee: Wayne State UniversityInventors: Charles H. Winter, Zhengkun Yu, Charles L. Dezelah, IV
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Patent number: 6887296Abstract: A process is described for the preparation of powder mixtures or composite powders from at least one first type of powder from the group consisting of high-melting metals, hard materials and ceramic powders and at least one second type of powder from the group consisting of binder metals, binder-metal mixed crystals and binder-metal alloys, where the second type of powder is formed from precursor compounds in the form of water-soluble salts in an aqueous suspension of the first type of powder by precipitation as oxalate, removal of the mother liquor and reduction to the metal.Type: GrantFiled: December 11, 2000Date of Patent: May 3, 2005Assignee: H.C. Starck GmbHInventors: Bernd Mende, Gerhard Gille, Ines Lamprecht
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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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Patent number: 6881377Abstract: Provided is an ultrafine nickel powder suitable for a laminated ceramic capacitor electrode material. According to the ultrafine nickel powder, cracks and/or delamination are not liable to generate in the process for producing a ceramic capacitor, and its internal electrode can be made into a thinner layer, and the electric risistivity of the capacitor-can be made low. The ultrafine nickel powder has an average particle size of 0.1-1.0 ?m, having the sulfur content of 0.02-1.0% by weight, and particles thereof being spherical, thereby exhibiting excellent properties. They can be produced by vapor phase hydrogen-reducing process using nickel chloride vapor.Type: GrantFiled: May 21, 2003Date of Patent: April 19, 2005Assignee: Kawatetsu Mining Co., Ltd.Inventors: Hideshi Katayama, Kan Saito, Shuetsu Ogasawara, Takao Hamada