Free Form Fibers, LLC

United States of America

Back to Profile

1-39 of 39 for Free Form Fibers, LLC Sort by
Query
Aggregations
Jurisdiction
        United States 20
        World 16
        Canada 3
Date
2024 1
2023 1
2022 5
2021 5
2020 2
See more
IPC Class
C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation 12
C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide 11
D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material 11
C04B 35/628 - Coating the powders 9
C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like 8
See more
Status
Pending 6
Registered / In Force 33
Found results for  patents

1.

NON-WOVEN MICRO-TRELLIS FABRICS AND COMPOSITE OR HYBRID-COMPOSITE MATERIALS REINFORCED THEREWITH

      
Application Number 18652980
Status Pending
Filing Date 2024-05-02
First Publication Date 2024-09-12
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Harrison, Shay L.
  • Vaaler, Erik G.
  • Schneiter, John L.

Abstract

A non-woven fabric is provided which includes a three-dimensional array of fibers. The three-dimensional array of fibers includes an array of standing fibers extending perpendicular to a plane of the non-woven fabric and attached to a base substrate, where the base substrate is one or more of an expendable film substrate, a metal base substrate, or a mandrel substrate. Further, the three-dimensional array of fibers includes multiple layers of non-woven parallel fibers running parallel to the plane of the non-woven fiber in between the array of standing fibers in a defined pattern of fiber layer orientations. In implementation, the array of standing fibers are grown to extend from the base substrate using laser-assisted chemical vapor deposition (LCVD).

IPC Classes  ?

  • D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
  • D04H 1/4234 - Metal fibres
  • D04H 1/4374 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
  • D04H 1/4382 - Stretched reticular film fibresComposite fibresMixed fibresUltrafine fibresFibres for artificial leather

2.

EMBEDDED WIRE CHEMICAL VAPOR DEPOSITION (EWCVD)

      
Application Number US2022071965
Publication Number 2023/278905
Status In Force
Filing Date 2022-04-28
Publication Date 2023-01-05
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Williams, Kirk L.
  • Harrison, Shay L.

Abstract

Methods of forming a ceramic matrix, as well as fiber preforms and methods of forming fiber preforms to facilitate formation of a ceramic matrix are provided. The method includes obtaining a fiber preform to facilitate forming the ceramic matrix. The fiber preform includes a fiber layer with a plurality of fibers and a heating element embedded within the fiber preform. The method also includes heating the fiber preform via the heating element embedded within the fiber preform, and depositing matrix material into the fiber preform by embedded wire chemical vapor deposition (EWCVD) of the matrix material during the heating of the fiber preform by the heating element. The chemical vapor deposition of the matrix material within the fiber preform facilitates formation of the ceramic matrix.

IPC Classes  ?

  • C23C 16/30 - Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
  • C23C 16/22 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like

3.

EMBEDDED WIRE CHEMICAL VAPOR DEPOSITION (EWCVD)

      
Application Number 17661059
Status Pending
Filing Date 2022-04-28
First Publication Date 2022-12-29
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Williams, Kirk L.
  • Harrison, Shay L.

Abstract

Methods of forming a ceramic matrix, as well as fiber preforms and methods of forming fiber preforms to facilitate formation of a ceramic matrix are provided. The method includes obtaining a fiber preform to facilitate forming the ceramic matrix. The fiber preform includes a fiber layer with a plurality of fibers and a heating element embedded within the fiber preform. The method also includes heating the fiber preform via the heating element embedded within the fiber preform, and depositing matrix material into the fiber preform by embedded wire chemical vapor deposition (EWCVD) of the matrix material during the heating of the fiber preform by the heating element. The chemical vapor deposition of the matrix material within the fiber preform facilitates formation of the ceramic matrix.

IPC Classes  ?

  • C23C 16/44 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
  • H05B 3/34 - Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs

4.

FIBER STRUCTURES WITH EMBEDDED SENSORS

      
Application Number US2022071655
Publication Number 2022/272192
Status In Force
Filing Date 2022-04-11
Publication Date 2022-12-29
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Budka, Thomas Philip

Abstract

Methods of fabricating fiber structures with embedded sensors are provided. The method includes obtaining a scaffold fiber and forming, by 1½-D printing using laser induced chemical vapor deposition, circuitry on the scaffold fiber to provide a fiber structure with embedded sensor. The forming includes printing a solid state oscillator about the scaffold fiber, and printing a sensing device about the scaffold fiber electrically coupled to the solid state oscillator to effect, at least in part, oscillations of the solid state oscillator. The forming further includes printing an antenna about the scaffold fiber electrically connected to the solid state oscillator to facilitate in operation wireless transmitting of a signal from the fiber structure with embedded sensor.

IPC Classes  ?

  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/583 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on boron nitride
  • C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like
  • H01L 35/04 - Structural details of the junction; Connections of leads

5.

FIBER STRUCTURES WITH EMBEDDED SENSORS

      
Application Number 17658665
Status Pending
Filing Date 2022-04-11
First Publication Date 2022-12-22
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Budka, Thomas Philip

Abstract

Methods of fabricating fiber structures with embedded sensors are provided. The method includes obtaining a scaffold fiber and forming, by 1½-D printing using laser induced chemical vapor deposition, circuitry on the scaffold fiber to provide a fiber structure with embedded sensor. The forming includes printing a solid state oscillator about the scaffold fiber, and printing a sensing device about the scaffold fiber electrically coupled to the solid state oscillator to effect, at least in part, oscillations of the solid state oscillator. The forming further includes printing an antenna about the scaffold fiber electrically connected to the solid state oscillator to facilitate in operation wireless transmitting of a signal from the fiber structure with embedded sensor.

IPC Classes  ?

  • G01K 3/14 - Thermometers giving results other than momentary value of temperature giving differences of valuesThermometers giving results other than momentary value of temperature giving differentiated values in respect of space
  • G01K 17/00 - Measuring quantity of heat
  • G01K 7/02 - Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat using thermoelectric elements, e.g. thermocouples
  • B33Y 10/00 - Processes of additive manufacturing
  • B33Y 80/00 - Products made by additive manufacturing
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation

6.

HIGH PURITY INGOT FOR WAFER PRODUCTION

      
Application Number 17580990
Status Pending
Filing Date 2022-01-21
First Publication Date 2022-05-12
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Schneiter, John L.
  • Pegna, Joseph
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Vaaler, Erik G.

Abstract

A method of forming a high purity ingot for wafer production, such as a silicon carbidewafer. Precursors are added to a reactor; at least part of a fiber is formed in the reactor from the precursors using chemical deposition interacting with the precursors; and granular material is then formed from the fiber. The method further includes forming the ingot from the granular material. In one aspect, the chemical deposition can include laser induced chemical vapor deposition. Further, the method can include separating one or more wafers from the ingot for use in semiconductor fabrication.

IPC Classes  ?

  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • G21C 3/58 - Solid reactor fuel
  • C23C 16/32 - Carbides
  • C01B 32/963 - Preparation from compounds containing silicon

7.

Composite tape with LCVD-formed additive material in constituent layer(s)

      
Application Number 17408922
Grant Number 11761085
Status In Force
Filing Date 2021-08-23
First Publication Date 2022-03-03
Grant Date 2023-09-19
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Schneiter, John L.
  • Novalis, John
  • Harrison, Shay L.

Abstract

A composite tape and method of fabrication are provided which includes multiple layers and a laser-driven chemical vapor deposition (LCVD)-formed additive material in at least one layer of the multiple layers to enhance one or more properties of the composite tape. The LCVD-formed additive material is a single crystalline material and can include LCVD-formed granular material and/or LCVD-formed fiber material in the same or different layers of the composite tape to enhance, for instance, fracture strength and/or wear resistance of the composite tape.

IPC Classes  ?

  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • C23C 16/32 - Carbides
  • B32B 27/18 - Layered products essentially comprising synthetic resin characterised by the use of special additives
  • B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments

8.

HIGH PURITY FIBER FEEDSTOCK FOR LOOSE GRAIN PRODUCTION

      
Application Number US2021014857
Publication Number 2021/154630
Status In Force
Filing Date 2021-01-25
Publication Date 2021-08-05
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Schneiter, John L.
  • Pegna, Joseph
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Vaaler, Erik G.

Abstract

A method of forming a high purity granular material, such as silicon carbide powder. Precursors are added to a reactor; at least part of a fiber is formed in the reactor from the precursors using chemical deposition interacting with said precursors; and the granular material is then formed from the fiber. In one aspect, the chemical deposition may include laser induced chemical vapor deposition. The granular material may be formed by grinding or milling the fiber into the granular material, e.g., ball milling the fiber. In one example, silicon carbide powder having greater than 90% beta crystalline phase purity and less than 0.25% oxygen contamination can be obtained.

IPC Classes  ?

9.

HIGH PURITY FIBER FEEDSTOCK FOR LOOSE GRAIN PRODUCTION

      
Application Number 17156746
Status Pending
Filing Date 2021-01-25
First Publication Date 2021-07-29
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Schneiter, John L.
  • Pegna, Joseph
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Vaaler, Erik G.

Abstract

A method of forming a high purity granular material, such as silicon carbide powder. Precursors are added to a reactor; at least part of a fiber is formed in the reactor from the precursors using chemical deposition interacting with said precursors; and the granular material is then formed from the fiber. In one aspect, the chemical deposition may include laser induced chemical vapor deposition. The granular material may be formed by grinding or milling the fiber into the granular material, e.g., ball milling the fiber. In one example, silicon carbide powder having greater than 90% beta crystalline phase purity and less than 0.25% oxygen contamination can be obtained.

IPC Classes  ?

  • C23C 16/32 - Carbides
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • C23C 16/56 - After-treatment
  • C01B 32/963 - Preparation from compounds containing silicon
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/626 - Preparing or treating the powders individually or as batches
  • G21C 3/26 - Fuel elements with fissile or breeder material in powder form within a non-active casing

10.

Method of making a multi-composition fiber

      
Application Number 17132205
Grant Number 11788213
Status In Force
Filing Date 2020-12-23
First Publication Date 2021-07-22
Grant Date 2023-10-17
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Schneiter, John L.

Abstract

A method of making a multi-composition fiber is provided, which includes providing a precursor laden environment, and forming a fiber in the precursor laden environment using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material. The formed fiber includes a primary fiber material and an elemental additive material, where the elemental additive material has too large an atom size to fit within a single crystalline domain within a crystalline structure of the fiber, and is deposited on grain boundaries between adjacent crystalline domains of the primary fiber material to present an energy barrier to atomic diffusion through the grain boundaries, and to increase creep resistance by slowing down growth between the adjacent crystalline domains of the primary fiber material.

IPC Classes  ?

  • C23C 16/44 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
  • D01F 11/12 - Chemical after-treatment of man-made filaments or the like during manufacture of carbon with inorganic substances
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • D01D 5/20 - Formation of filaments, threads, or the like with varying denier along their length
  • C01B 32/956 - Silicon carbide
  • D01F 1/10 - Other agents for modifying properties
  • C23C 16/52 - Controlling or regulating the coating process
  • C01B 32/914 - Carbides of single elements
  • C01B 21/076 - Binary compounds of nitrogen with metals, with silicon, or with boron with titanium or zirconium
  • C01B 35/04 - Metal borides
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • H01S 3/067 - Fibre lasers

11.

NON-WOVEN MICRO-TRELLIS FABRICS AND COMPOSITE OR HYBRID-COMPOSITE MATERIALS REINFORCED THEREWITH

      
Application Number US2020043378
Publication Number 2021/061268
Status In Force
Filing Date 2020-07-24
Publication Date 2021-04-01
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Harrison, Shay L.
  • Vaaler, Erik G.
  • Schneiter, John L.

Abstract

A non-woven fabric is provided which includes a three-dimensional array of fibers. The three-dimensional array of fibers includes an array of standing fibers extending perpendicular to a plane of the non-woven fabric and attached to a base substrate, where the base substrate is one or more of an expendable film substrate, a metal base substrate, or a mandrel substrate. Further, the three-dimensional array of fibers includes multiple layers of non-woven parallel fibers running parallel to the plane of the non-woven fiber in between the array of standing fibers in a defined pattern of fiber layer orientations.

IPC Classes  ?

  • A61F 13/15 - Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the bodySupporting or fastening means thereforTampon applicators
  • A61F 13/539 - Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the bodySupporting or fastening means thereforTampon applicators characterised by the absorbing medium characterised by the connection of absorbent layers with each other or with the outer layers
  • A61L 15/24 - Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bondsDerivatives thereof

12.

Non-woven micro-trellis fabrics and composite or hybrid-composite materials reinforced therewith

      
Application Number 16938072
Grant Number 12006605
Status In Force
Filing Date 2020-07-24
First Publication Date 2021-03-25
Grant Date 2024-06-11
Owner Free Form Fibers, LLC (USA)
Inventor
  • Pegna, Joseph
  • Harrison, Shay L.
  • Vaaler, Erik G.
  • Schneiter, John L.

Abstract

A non-woven fabric is provided which includes a three-dimensional array of fibers. The three-dimensional array of fibers includes an array of standing fibers extending perpendicular to a plane of the non-woven fabric and attached to a base substrate, where the base substrate is one or more of an expendable film substrate, a metal base substrate, or a mandrel substrate. Further, the three-dimensional array of fibers includes multiple layers of non-woven parallel fibers running parallel to the plane of the non-woven fiber in between the array of standing fibers in a defined pattern of fiber layer orientations. In implementation, the array of standing fibers are grown to extend from the base substrate using laser-assisted chemical vapor deposition (LCVD).

IPC Classes  ?

  • D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
  • D04H 1/4234 - Metal fibres
  • D04H 1/4374 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
  • D04H 1/4382 - Stretched reticular film fibresComposite fibresMixed fibresUltrafine fibresFibres for artificial leather

13.

Fibers fabricated with metals incorporated into grain boundaries for high temperature applications

      
Application Number 17000858
Grant Number 11473220
Status In Force
Filing Date 2020-08-24
First Publication Date 2020-12-17
Grant Date 2022-10-18
Owner Free Form Fibers LLC (USA)
Inventor
  • Vaaler, Erik Garth
  • Keshner, Marvin S
  • Harrison, Shay

Abstract

A fiber comprises a bulk material comprising: one or more of carbon, silicon, boron, silicon carbide, and boron nitride; and a metal or metal alloy whose affinity for oxygen is greater than that of the bulk material. At least a first portion of the metal or metal alloy is present at the entrance to grain boundaries at the surface of the fiber and within the fiber to a depth of at least 1 micron from the fiber surface. A method of improving a fiber comprises heating a fiber in an inert atmosphere to 900-1300 C for sufficient time to allow at least some of a metal or metal alloy, placed on the fiber, to diffuse and/or flow into and along grain boundaries to a depth of at least 1 micron. The metal or metal alloy has a greater affinity for oxygen than that of the fiber bulk material.

IPC Classes  ?

  • B32B 9/00 - Layered products essentially comprising a particular substance not covered by groups
  • D01F 11/12 - Chemical after-treatment of man-made filaments or the like during manufacture of carbon with inorganic substances
  • D01F 9/12 - Carbon filamentsApparatus specially adapted for the manufacture thereof
  • D01F 11/16 - Chemical after-treatment of man-made filaments or the like during manufacture of carbon by physicochemical methods
  • C04B 35/628 - Coating the powders
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/583 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on boron nitride
  • D01F 9/127 - Carbon filamentsApparatus specially adapted for the manufacture thereof by thermal decomposition of hydrocarbon gases or vapours
  • D02G 3/00 - Yarns or threads, e.g. fancy yarnsProcesses or apparatus for the production thereof, not otherwise provided for

14.

Additive manufacturing technique for placing nuclear reactor fuel within fibers

      
Application Number 16752736
Grant Number 11518719
Status In Force
Filing Date 2020-01-27
First Publication Date 2020-06-25
Grant Date 2022-12-06
Owner Free Form Fibers, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Harrison, Shay L.
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ram K.

Abstract

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.

IPC Classes  ?

  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
  • C04B 35/628 - Coating the powders
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/83 - Carbon fibres in a carbon matrix
  • C23C 16/08 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material from metal halides
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • G21C 21/02 - Manufacture of fuel elements or breeder elements contained in non-active casings
  • G21C 3/07 - CasingsJackets characterised by their material, e.g. alloys
  • G21C 3/04 - Constructional details
  • G21C 3/42 - Selection of substances for use as reactor fuel
  • G21C 3/18 - Internal spacers or other non-active material within the casing, e.g. compensating for expansion of fuel rods or for compensating excess reactivity
  • G21C 3/20 - Details of the construction within the casing with coating on fuel or on inside of casingDetails of the construction within the casing with non-active interlayer between casing and active material
  • G21C 3/28 - Fuel elements with fissile or breeder material in solid form within a non-active casing
  • G21C 3/62 - Ceramic fuel

15.

High strength ceramic fibers and methods of fabrication

      
Application Number 16101730
Grant Number 10882749
Status In Force
Filing Date 2018-08-13
First Publication Date 2019-02-28
Grant Date 2021-01-05
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ramkiran

Abstract

A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers. A method of forming an interphase in a ceramic matrix composite material having a plurality of SiC fibers, which maximizes toughness by minimizing fiber to fiber bridging, including arranging a plurality of SiC fibers into a preform; selectively removing (e.g., etching) silicon out of the surface of the fibers resulting in a porous carbon layer on the fibers; and replacing the porous carbon layer with an interphase layer (e.g., Boron Nitride), which coats the fibers to thereby minimize fiber to fiber bridging in the preform.

IPC Classes  ?

  • C01B 32/956 - Silicon carbide
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/628 - Coating the powders
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like

16.

FUNCTIONAL HIGH-PERFORMANCE FIBER STRUCTURE

      
Application Number US2018039675
Publication Number 2019/005911
Status In Force
Filing Date 2018-06-27
Publication Date 2019-01-03
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Schneiter, John L.
  • Harrison, Shay L.
  • Vaaler, Erik G.

Abstract

A method is provided for growing a fiber structure, where the method includes: obtaining a substrate, growing an array of pedestal fibers on the substrate, growing fibers on the pedestal fibers, and depositing a coating surrounding each of the fibers. In another aspect, a method of fabricating a fiber structure includes obtaining a substrate and growing a plurality of fibers on the substrate according to 1 ½ D printing. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted methods.

IPC Classes  ?

  • B32B 19/06 - Layered products essentially comprising natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
  • B81C 1/00 - Manufacture or treatment of devices or systems in or on a substrate
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation

17.

HIGH TEMPERATURE GLASS-CERAMIC MATRIX WITH EMBEDDED REINFORCEMENT FIBERS

      
Application Number US2018038155
Publication Number 2019/005525
Status In Force
Filing Date 2018-06-19
Publication Date 2019-01-03
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay, L.
  • Pegna, Joseph
  • Schneiter, John, L.
  • Vaaler, Erik, G.
  • Keshner, Marvin

Abstract

Composite materials are provided which include a glass-ceramic matrix composition that is lightly crystallized, a fiber reinforcement within the glass-ceramic matrix composition which remains stable at temperatures greater than 1400°C, and an interphase coating formed on the fiber reinforcement. A method of making a composite material is also provided, which includes applying heat and pressure to a shape including fiber reinforcements and glass particles. The heat and pressure lightly crystallize a matrix material formed by the heat and pressure on the glass particles, forming a thermally stable composite material.

IPC Classes  ?

  • C04B 35/71 - Ceramic products containing macroscopic reinforcing agents
  • C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • D01F 9/10 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material by decomposition of organic substances

18.

High temperature glass-ceramic matrix with embedded reinforcement fibers

      
Application Number 16011698
Grant Number 10676391
Status In Force
Filing Date 2018-06-19
First Publication Date 2018-12-27
Grant Date 2020-06-09
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Pegna, Joseph
  • Schneiter, John L.
  • Vaaler, Erik G.
  • Keshner, Marvin

Abstract

Composite materials are provided which include a glass-ceramic matrix composition that is lightly crystallized, a fiber reinforcement within the glass-ceramic matrix composition which remains stable at temperatures greater than 1400° C., and an interphase coating formed on the fiber reinforcement. A method of making a composite material is also provided, which includes applying heat and pressure to a shape including fiber reinforcements and glass particles. The heat and pressure lightly crystallize a matrix material formed by the heat and pressure on the glass particles, forming a thermally stable composite material.

IPC Classes  ?

  • C03C 10/00 - Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
  • C03C 14/00 - Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • C23C 16/32 - Carbides
  • C23C 16/40 - Oxides
  • C23C 16/04 - Coating on selected surface areas, e.g. using masks
  • C23C 16/54 - Apparatus specially adapted for continuous coating
  • C03C 25/52 - Coatings containing inorganic materials only
  • C23C 16/06 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
  • C03C 25/42 - Coatings containing inorganic materials
  • C03C 25/44 - Carbon, e.g. graphite
  • C03B 32/02 - Thermal crystallisation, e.g. for crystallising glass bodies into glass-ceramic articles
  • C03B 19/06 - Other methods of shaping glass by sintering

19.

Functional high-performance fiber structure

      
Application Number 16019839
Grant Number 11362256
Status In Force
Filing Date 2018-06-27
First Publication Date 2018-12-27
Grant Date 2022-06-14
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Schneiter, John L.
  • Harrison, Shay L.
  • Vaaler, Erik G.

Abstract

A method is provided for growing a fiber structure, where the method includes: obtaining a substrate, growing an array of pedestal fibers on the substrate, growing fibers on the pedestal fibers, and depositing a coating surrounding each of the fibers. In another aspect, a method of fabricating a fiber structure includes obtaining a substrate and growing a plurality of fibers on the substrate according to 1½D printing. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted methods.

IPC Classes  ?

  • H01L 35/34 - Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • D01F 8/18 - Conjugated, i.e. bi- or multicomponent, man-made filaments or the likeManufacture thereof from other substances
  • H01L 35/04 - Structural details of the junction; Connections of leads
  • H01L 35/28 - SEMICONDUCTOR DEVICES; ELECTRIC SOLID STATE DEVICES NOT OTHERWISE PROVIDED FOR - Details thereof operating with Peltier or Seebeck effect only
  • C23C 16/54 - Apparatus specially adapted for continuous coating
  • H01L 41/047 - Electrodes
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • C04B 35/628 - Coating the powders
  • B32B 19/06 - Layered products essentially comprising natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
  • C04B 35/515 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides
  • C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C23C 16/30 - Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
  • C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
  • C23C 16/04 - Coating on selected surface areas, e.g. using masks
  • H01L 41/08 - Piezo-electric or electrostrictive elements
  • H01L 41/087 - Piezo-electric or electrostrictive elements formed as coaxial cables

20.

Fibers fabricated to incorporate metals for high temperature applications

      
Application Number 15612251
Grant Number 10815588
Status In Force
Filing Date 2017-06-02
First Publication Date 2018-12-06
Grant Date 2020-10-27
Owner Free Form Fibers LLC (USA)
Inventor
  • Vaaler, Erik Garth
  • Keshner, Marvin S
  • Harrison, Shay

Abstract

A fiber comprises a bulk material comprising one or more materials selected from the group consisting of carbon, silicon, boron, silicon carbide, and boron nitride; and a metal whose affinity for oxygen is greater than the affinity for oxygen of any of the one or more materials. The metal may be selected from the group consisting of beryllium, titanium, hafnium and zirconium. At least a first portion of the metal may be present in un-oxidized form at the entrance to and/or within grain boundaries within the fiber. A method of improving at least one of the strength, creep resistance, and toughness of a fiber comprises adding to a fiber, initially comprising a bulk material having a first affinity for oxygen, a metal that has a second affinity for oxygen higher than the first affinity. The metal may be selected from the group consisting of beryllium, titanium, hafnium and zirconium.

IPC Classes  ?

  • D01F 9/127 - Carbon filamentsApparatus specially adapted for the manufacture thereof by thermal decomposition of hydrocarbon gases or vapours
  • D01F 11/12 - Chemical after-treatment of man-made filaments or the like during manufacture of carbon with inorganic substances
  • C04B 35/628 - Coating the powders
  • C04B 41/52 - Multiple coating or impregnating
  • C04B 41/45 - Coating or impregnating
  • C04B 41/00 - After-treatment of mortars, concrete, artificial stone or ceramicsTreatment of natural stone
  • C09D 163/00 - Coating compositions based on epoxy resinsCoating compositions based on derivatives of epoxy resins
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like

21.

FIBER WITH ELEMENTAL ADDITIVE(S) AND METHOD OF MAKING

      
Document Number 03044401
Status In Force
Filing Date 2017-11-29
Open to Public Date 2018-06-07
Grant Date 2023-09-19
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Schneiter, John L.

Abstract

A multi-composition fiber is provided including a primary fiber material and an elemental additive material deposited on grain boundaries between adjacent crystalline domains of the primary fiber material. A method of making a multi-composition fiber is also provided, which includes providing a precursor laden environment, and promoting fiber growth using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material.

IPC Classes  ?

  • C04B 35/628 - Coating the powders
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
  • C04B 35/581 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on aluminium nitride

22.

FIBER WITH ELEMENTAL ADDITIVE(S) AND METHOD OF MAKING

      
Application Number US2017063607
Publication Number 2018/102352
Status In Force
Filing Date 2017-11-29
Publication Date 2018-06-07
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Schneiter, John L.

Abstract

A multi-composition fiber is provided including a primary fiber material and an elemental additive material deposited on grain boundaries between adjacent crystalline domains of the primary fiber material. A method of making a multi-composition fiber is also provided, which includes providing a precursor laden environment, and promoting fiber growth using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material.

IPC Classes  ?

  • C04B 35/628 - Coating the powders
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
  • C04B 35/581 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on aluminium nitride

23.

Fiber with elemental additive(s) and method of making

      
Application Number 15825664
Grant Number 10876227
Status In Force
Filing Date 2017-11-29
First Publication Date 2018-05-31
Grant Date 2020-12-29
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.
  • Schneiter, John L.

Abstract

A multi-composition fiber is provided including a primary fiber material and an elemental additive material deposited on grain boundaries between adjacent crystalline domains of the primary fiber material. A method of making a multi-composition fiber is also provided, which includes providing a precursor laden environment, and promoting fiber growth using laser heating. The precursor laden environment includes a primary precursor material and an elemental precursor material.

IPC Classes  ?

  • D01F 9/00 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments
  • D01F 11/12 - Chemical after-treatment of man-made filaments or the like during manufacture of carbon with inorganic substances
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • D01D 5/20 - Formation of filaments, threads, or the like with varying denier along their length
  • C01B 32/956 - Silicon carbide
  • D01F 1/10 - Other agents for modifying properties
  • C23C 16/44 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
  • C01B 32/914 - Carbides of single elements
  • C01B 21/076 - Binary compounds of nitrogen with metals, with silicon, or with boron with titanium or zirconium
  • C01B 35/04 - Metal borides
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • H01S 3/067 - Fibre lasers

24.

MULTI-COMPOSITION FIBER WITH REFRACTORY ADDITIVE(S) AND METHOD OF MAKING

      
Application Number US2017053890
Publication Number 2018/064261
Status In Force
Filing Date 2017-09-28
Publication Date 2018-04-05
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Schneiter, John L.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.

Abstract

Multi-composition fibers with one or more refractory additives, and methods of making the fibers, are provided. The method(s) includes providing a precursor-laden environment, and promoting fiber growth using laser heating. The precursor-laden environment includes a primary precursor material and a refractory precursor material. The multi-composition fiber may include a primary fiber material, and a refractory material substantially homogeneously intermixed with the primary fiber material.

IPC Classes  ?

  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/81 - Whiskers
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • G21C 3/18 - Internal spacers or other non-active material within the casing, e.g. compensating for expansion of fuel rods or for compensating excess reactivity
  • G21C 3/20 - Details of the construction within the casing with coating on fuel or on inside of casingDetails of the construction within the casing with non-active interlayer between casing and active material

25.

REFRACTORY OXIDE COATED FIBER AND METHOD OF MAKING

      
Application Number US2017053900
Publication Number 2018/064269
Status In Force
Filing Date 2017-09-28
Publication Date 2018-04-05
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay L.
  • Keshner, Marvin
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Schneiter, John L.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.

Abstract

A refractory oxide coated fiber is provided including a primary fiber material and a refractory oxide coating over the primary fiber material. Further, a method of making a refractory oxide coated fiber is provided, which includes: providing a first precursor-laden environment, the first precursor-laden environment including a primary precursor; promoting fiber growth within the first precursor-laden environment using laser heating; and providing a second precursor-laden environment to promote coating of the fiber, the second precursor-laden environment comprising a refractory oxide precursor, and the coating producing a refractory oxide coating over the fiber with a hexagonal microstructure.

IPC Classes  ?

  • C04B 35/00 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B 35/01 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides
  • C04B 35/08 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on beryllium oxide
  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products

26.

NANOFIBER-COATED FIBER AND METHODS OF MAKING

      
Application Number US2017038930
Publication Number 2017/223399
Status In Force
Filing Date 2017-06-23
Publication Date 2017-12-28
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Schneiter, John L.
  • Harrison, Shay L.
  • Goduguchinta, Ram K.
  • Williams, Kirk L.

Abstract

Methods are provided for making a nanofiber-coated fiber.The method(s) include: providing a base fiber; depositing a nanofreckle on the base fiber; and growing a nanofiber at the nanofreckle.In another aspect, nanofiber-coated fibers are provided, produced by the above-noted methods making a nanofiber-coated fiber.

IPC Classes  ?

  • C09K 3/00 - Materials not provided for elsewhere
  • B05D 1/36 - Successively applying liquids or other fluent materials, e.g. without intermediate treatment

27.

FIBER DELIVERY ASSEMBLY AND METHOD OF MAKING

      
Application Number US2017032103
Publication Number 2017/197082
Status In Force
Filing Date 2017-05-11
Publication Date 2017-11-16
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ram K.
  • Harrison, Shay L.

Abstract

In one aspect, a fiber delivery assembly is provided including a backing tape and a single-filament fiber coupled to the backing tape. In another aspect, a method of making a fiber delivery assembly is provided, which includes: providing a backing tape; providing a single-filament fiber; and coupling the single-filament fiber to the backing tape.

IPC Classes  ?

  • C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like
  • C09J 7/02 - on carriers
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material

28.

MULTILAYER FUNCTIONAL FIBER AND METHOD OF MAKING

      
Application Number US2017032149
Publication Number 2017/197105
Status In Force
Filing Date 2017-05-11
Publication Date 2017-11-16
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik, G.
  • Schneiter, John, L.
  • Harrison, Shay, L.

Abstract

A method is provided for making a multilayer functional fiber, where the method includes: providing a scaffold fiber; disposing a first electrode layer enclosing the scaffold fiber; disposing a functional layer enclosing the first electrode layer, the functional layer having a functional characteristic varying as a function of longitudinal position along the functional layer; disposing a second electrode layer enclosing the functional layer; and disposing a cladding layer enclosing the second electrode layer. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted method.

IPC Classes  ?

  • B32B 5/00 - Layered products characterised by the non-homogeneity or physical structure of a layer
  • C04B 35/583 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on boron nitride
  • C04B 41/50 - Coating or impregnating with inorganic materials
  • C08K 3/38 - Boron-containing compounds

29.

Multilayer functional fiber and method of making

      
Application Number 15592726
Grant Number 12133465
Status In Force
Filing Date 2017-05-11
First Publication Date 2017-11-16
Grant Date 2024-10-29
Owner Free Form Fibers, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Schneiter, John L.
  • Harrison, Shay L.

Abstract

A method is provided for making a multilayer functional fiber, where the method includes: providing a scaffold fiber; disposing a first electrode layer enclosing the scaffold fiber; disposing a functional layer enclosing the first electrode layer, the functional layer having a functional characteristic varying as a function of longitudinal position along the functional layer; disposing a second electrode layer enclosing the functional layer; and disposing a cladding layer enclosing the second electrode layer. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted method.

IPC Classes  ?

  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • H10N 10/01 - Manufacture or treatment
  • H10N 10/81 - Structural details of the junction
  • H10N 30/00 - Piezoelectric or electrostrictive devices
  • H10N 30/06 - Forming electrodes or interconnections, e.g. leads or terminals
  • H10N 30/87 - Electrodes or interconnections, e.g. leads or terminals
  • H10N 10/10 - Thermoelectric devices comprising a junction of dissimilar materials, i.e. devices exhibiting Seebeck or Peltier effects operating with only the Peltier or Seebeck effects

30.

Additive manufacturing technique for placing nuclear reactor fuel within fibers

      
Application Number 15320800
Grant Number 10546661
Status In Force
Filing Date 2015-06-23
First Publication Date 2017-07-27
Grant Date 2020-01-28
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Harrison, Shay L.
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ram K.

Abstract

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.

IPC Classes  ?

  • G21C 3/20 - Details of the construction within the casing with coating on fuel or on inside of casingDetails of the construction within the casing with non-active interlayer between casing and active material
  • G21C 21/02 - Manufacture of fuel elements or breeder elements contained in non-active casings
  • G21C 3/07 - CasingsJackets characterised by their material, e.g. alloys
  • C23C 16/08 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material from metal halides
  • C23C 16/48 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating by irradiation, e.g. photolysis, radiolysis, particle radiation
  • G21C 3/18 - Internal spacers or other non-active material within the casing, e.g. compensating for expansion of fuel rods or for compensating excess reactivity
  • G21C 3/28 - Fuel elements with fissile or breeder material in solid form within a non-active casing
  • G21C 3/62 - Ceramic fuel

31.

Contiguously blended nano-scaled multi-phase fibers

      
Application Number 15114504
Grant Number 09896385
Status In Force
Filing Date 2015-01-26
First Publication Date 2016-12-01
Grant Date 2018-02-20
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay Llewellyn
  • Pegna, Joseph
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ramkiran

Abstract

A multi-component or ‘composite’ inorganic fiber comprising a nano-scale contiguous collection of a plurality of packed unique phases of material randomly interspersed throughout the fiber body, without unwanted impurities, and a method for producing same. Said phases include three or more foundational chemical elements from the Periodic Table mixed together during fiber production, producing distinct material phases interspersed throughout the fiber volume.

IPC Classes  ?

  • C04B 35/628 - Coating the powders
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • D01F 8/18 - Conjugated, i.e. bi- or multicomponent, man-made filaments or the likeManufacture thereof from other substances
  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B 35/56 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/58 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
  • C04B 35/581 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on aluminium nitride
  • C04B 35/583 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides based on boron nitride

32.

RADIALLY GRADED FULLY DENSE INORGANIC FILAMENTS FOR ENHANCED STRENGTH AND CREEP RESISTANCE

      
Application Number US2016014432
Publication Number 2016/153587
Status In Force
Filing Date 2016-01-22
Publication Date 2016-09-29
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Schneiter, John L.
  • Pegna, Joseph
  • Goduguchinta, Ramkiran
  • Williams, Kirk L.
  • Harrison, Shay Llewellyn

Abstract

A fully dense ceramic and/or other inorganic fiber containing elongated crystal grains in and around the fiber center and oriented along the fiber axis, with a smooth transition to more equiaxed grains towards the radial periphery of the fiber, and method for producing such.

IPC Classes  ?

33.

Radially graded fully dense inorganic filaments for enhanced strength and creep resistance

      
Application Number 15003915
Grant Number 09938393
Status In Force
Filing Date 2016-01-22
First Publication Date 2016-07-28
Grant Date 2018-04-10
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Schneiter, John L.
  • Pegna, Joseph
  • Goduguchinta, Ramkiran
  • Williams, Kirk L.
  • Harrison, Shay Llewellyn

Abstract

A fully dense ceramic and/or other inorganic fiber containing elongated crystal grains in and around the fiber center and oriented along the fiber axis, with a smooth transition to more equiaxed grains towards the radial periphery of the fiber, and method for producing such.

IPC Classes  ?

  • C23C 16/00 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
  • C08K 3/38 - Boron-containing compounds
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
  • C08K 3/02 - Elements
  • C08K 3/14 - Carbides
  • C08K 3/34 - Silicon-containing compounds
  • C04B 35/622 - Forming processesProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products

34.

AN ADDITIVE MANUFACTURING TECHNOLOGY FOR THE FABRICATION AND CHARACTERIZATION OF NUCLEAR REACTOR FUEL

      
Document Number 02952471
Status Pending
Filing Date 2015-06-23
Open to Public Date 2015-12-30
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Harrison, Shay L.
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ram K.

Abstract

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.

IPC Classes  ?

  • G21C 21/02 - Manufacture of fuel elements or breeder elements contained in non-active casings
  • G21C 3/07 - CasingsJackets characterised by their material, e.g. alloys
  • G21C 3/28 - Fuel elements with fissile or breeder material in solid form within a non-active casing
  • G21C 3/42 - Selection of substances for use as reactor fuel

35.

AN ADDITIVE MANUFACTURING TECHNOLOGY FOR THE FABRICATION AND CHARACTERIZATION OF NUCLEAR REACTOR FUEL

      
Application Number US2015037080
Publication Number 2015/200257
Status In Force
Filing Date 2015-06-23
Publication Date 2015-12-30
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Vaaler, Erik G.
  • Harrison, Shay L.
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ram K.

Abstract

Nuclear fuel structures and methods for fabricating are disclosed herein. The nuclear fuel structure includes a plurality of fibers arranged in the structure and a multilayer fuel region within at least one fiber of the plurality of fibers. The multilayer fuel region includes an inner layer region made of a nuclear fuel material, and an outer layer region encasing the nuclear fuel material. A plurality of discrete multilayer fuel regions may be formed over a core region along the at least one fiber, the plurality of discrete multilayer fuel regions having a respective inner layer region of nuclear fuel material and a respective outer layer region encasing the nuclear fuel material. The plurality of fibers may be wrapped around an inner rod or tube structure or inside an outer tube structure of the nuclear fuel structure, providing both structural support and the nuclear fuel material of the nuclear fuel structure.

IPC Classes  ?

  • G21C 3/02 - Fuel elements
  • G21C 3/04 - Constructional details
  • G21C 3/42 - Selection of substances for use as reactor fuel
  • G21C 21/02 - Manufacture of fuel elements or breeder elements contained in non-active casings
  • B23B 19/00 - HeadstocksEquivalent parts of any machine tools

36.

CONTIGUOUSLY BLENDED NANO-SCALED MULTI-PHASE FIBERS

      
Document Number 02938112
Status In Force
Filing Date 2015-01-26
Open to Public Date 2015-07-30
Grant Date 2022-05-03
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay Llewellyn
  • Pegna, Joseph
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ramkiran

Abstract

A multi-component or 'composite' inorganic fiber comprising a nano-scale contiguous collection of a plurality of packed unique phases of material randomly interspersed throughout the fiber body, without unwanted impurities, and a method for producing same. Said phases include three or more foundational chemical elements from the Periodic Table mixed together during fiber production, producing distinct material phases interspersed throughout the fiber volume.

IPC Classes  ?

  • D01F 1/10 - Other agents for modifying properties
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material

37.

CONTIGUOUSLY BLENDED NANO-SCALED MULTI-PHASE FIBERS

      
Application Number US2015012822
Publication Number 2015/112935
Status In Force
Filing Date 2015-01-26
Publication Date 2015-07-30
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Harrison, Shay Llewellyn
  • Pegna, Joseph
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ramkiran

Abstract

A multi-component or 'composite' inorganic fiber comprising a nano-scale contiguous collection of a plurality of packed unique phases of material randomly interspersed throughout the fiber body, without unwanted impurities, and a method for producing same. Said phases include three or more foundational chemical elements from the Periodic Table mixed together during fiber production, producing distinct material phases interspersed throughout the fiber volume.

IPC Classes  ?

  • D01F 1/10 - Other agents for modifying properties
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material

38.

High strength ceramic fibers and methods of fabrication

      
Application Number 14372085
Grant Number 10047015
Status In Force
Filing Date 2013-01-18
First Publication Date 2015-01-01
Grant Date 2018-08-14
Owner FREE FORM FIBERS, LLC (USA)
Inventor
  • Pegna, Joseph
  • Schneiter, John L.
  • Williams, Kirk L.
  • Goduguchinta, Ramkiran

Abstract

A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers. A method of forming an interphase in a ceramic matrix composite material having a plurality of SiC fibers, which maximizes toughness by minimizing fiber to fiber bridging, including arranging a plurality of SiC fibers into a preform; selectively removing (e.g., etching) silicon out of the surface of the fibers resulting in a porous carbon layer on the fibers; and replacing the porous carbon layer with an interphase layer (e.g., Boron Nitride), which coats the fibers to thereby minimize fiber to fiber bridging in the preform.

IPC Classes  ?

  • C04B 35/76 - Fibres, filaments, whiskers, platelets, or the like
  • C04B 35/628 - Coating the powders
  • C04B 35/565 - Shaped ceramic products characterised by their compositionCeramic compositionsProcessing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides based on silicon carbide
  • C04B 35/80 - Fibres, filaments, whiskers, platelets, or the like
  • C01B 32/956 - Silicon carbide
  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material

39.

HIGH STRENGTH CERAMIC FIBERS AND METHODS OF FABRICATION

      
Application Number US2013022053
Publication Number 2013/180764
Status In Force
Filing Date 2013-01-18
Publication Date 2013-12-05
Owner FREE FORM FIBERS LLC (USA)
Inventor
  • Pegna, Joseph
  • Schneiter, John
  • Williams, Kirk
  • Goduguchinta, Ramkiran

Abstract

A method and apparatus for forming a plurality of fibers from (e.g., CVD) precursors, including a reactor adapted to grow a plurality of individual fibers; and a plurality of independently controllable lasers, each laser of the plurality of lasers growing a respective fiber. A high performance fiber (HPF) structure, including a plurality of fibers arranged in the structure; a matrix disposed between the fibers; wherein a multilayer coating is provided along the surfaces of at least some of the fibers with an inner layer region having a sheet-like strength; and an outer layer region, having a particle-like strength, such that any cracks propagating toward the outer layer from the matrix propagate along the outer layer and back into the matrix, thereby preventing the cracks from approaching the fibers. A method of forming an interphase in a ceramic matrix composite material having a plurality of SiC fibers, which maximizes toughness by minimizing fiber to fiber bridging, including arranging a plurality of SiC fibers into a preform; selectively removing (e.g., etching) silicon out of the surface of the fibers resulting in a porous carbon layer on the fibers; and replacing the porous carbon layer with an interphase layer (e.g., Boron Nitride), which coats the fibers to thereby minimize fiber to fiber bridging in the preform.

IPC Classes  ?

  • D01F 9/08 - Man-made filaments or the like of other substancesManufacture thereofApparatus specially adapted for the manufacture of carbon filaments of inorganic material
  • D06M 11/74 - Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon or graphiteTreating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbidesTreating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereofSuch treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with graphitic acids or their salts