Some embodiments herein are directed to devices and methods for automatically starting a plasma utilizing a wand. In some embodiments, the wand may be used to start a plasma in a plasma torch such as, for example, a microwave plasma torch or an induction plasma torch, as discussed below. The wand may comprise an elongate, hollow wand member comprising a closed distal end, a proximal end, and one or more apertures extending from a hollow interior of the wand member to an exterior surface of the wand member; and an elongate wire member positioned within the hollow interior of the wand member and extending along at least a portion of a length of the wand member, wherein the wire member is configured to be placed in operable communication through the aperture with a power source, such that the power source can be activated to in turn start the plasma within the plasma torch. The plasma torches discussed herein may be used in various applications including, for example, high volume synthesis of advanced materials such as nano-materials, micro-powders, coatings, alloy compositions for additive manufacturing.
Embodiments disclosed herein relate to a systems, methods, and apparatus for the production of solid carbon materials and carbon containing gasses. The embodiments disclosed herein may facilitate the conversion of carbon-containing gases into carbon monoxide gas and/or solid carbon materials, such as, for example graphene, carbon nanocages, and carbon nanotubes. The process is cost efficient, energy efficient, and environmentally friendly with the ability to use or recycle carbon-containing gasses to produce solid carbon products.
C23C 16/511 - 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 using electric discharges using microwave discharges
3.
MICROWAVE APPARATUS AND METHOD FOR PRODUCTION OF CARBON MATERIALS
Embodiments disclosed herein relate to a systems, methods, and apparatus for the production of solid carbon materials and carbon containing gasses. The embodiments disclosed herein may facilitate the conversion of carbon-containing gases into carbon monoxide gas and/or solid carbon materials, such as, for example graphene, carbon nanocages, and carbon nanotubes. The process is cost efficient, energy efficient, and environmentally friendly with the ability to use or recycle carbon-containing gasses to produce solid carbon products.
Disclosed herein are systems, methods, and devices processing feed material utilizing an upstream swirl module and composite gas flows. Some embodiments are directed to a microwave plasma apparatus for processing a material, comprising: a first flow module, a second flow module, and a liner.
A pulsed control vibratory particle hopper includes a particle hopper, a vibrating tray, a mechanical vibrator, and a controller. The particle hopper includes a hopper outlet, and the vibrating tray receives particles from the hopper outlet. The mechanical vibrator is mechanically connected to the vibrating tray to generate a baseline vibration, as well as a periodic vibration amplitude spike or pulse. The controller is in communication with the mechanical vibrator to control the mechanical vibrator and generate the periodic vibration amplitude spike with a duration Tp, a maximum amplitude Ap, and a frequency Fp. The pulse duration, pulse amplitude, and pulse frequency are determined based on the size or a type of the material being dispensed from the particle hopper.
Disclosed herein are systems, methods, and devices for rapid synthesis of materials. In some embodiments, a system may comprise a material processing apparatus for processing a material, the material processing apparatus comprising a material passage structure in communication with a material feeding inlet, the material passage structure located within a reaction chamber, and the material feeding inlet configured to receive a material and transfer the material to the material passage structure; and a heat source in communication with the reaction chamber, the heat source comprising one or more of: plasma, flame, combustion sources, resistive heaters, heated liquid baths, electromagnetic radiation, and/or induction heaters, wherein the material passage structure is located within, surrounding, or adjacent to the heat source, such that the material passage structure is heated by the heat source and the material is converted to a product within the material passage structure.
Disclosed herein are systems, methods, and devices for rapid synthesis of materials. In some embodiments, a system may comprise a material processing apparatus for processing a material, the material processing apparatus comprising a material passage structure in communication with a material feeding inlet, the material passage structure located within a reaction chamber, and the material feeding inlet configured to receive a material and transfer the material to the material passage structure; and a heat source in communication with the reaction chamber, the heat source comprising one or more of: plasma, flame, combustion sources, resistive heaters, heated liquid baths, electromagnetic radiation, and/or induction heaters, wherein the material passage structure is located within, surrounding, or adjacent to the heat source, such that the material passage structure is heated by the heat source and the material is converted to a product within the material passage structure.
A method of real time optimization of a microwave plasma includes adjusting in real time an injection angle of a swirl gas flow of the microwave plasma, the magnitude of the swirl gas flow of the microwave plasma, or the microwave power applied to the microwave plasma.
Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.
B22F 1/05 - Metallic powder characterised by the size or surface area of the particles
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
10.
SPHEROIDAL DEHYDROGENATED METALS AND METAL ALLOY PARTICLES
Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.
B22F 9/30 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
The embodiments disclosed herein are directed to systems, methods, and compositions of lithium oxides. In various embodiments of the present disclosure, the systems, methods, and compositions are directed to micron-sized lithium oxide particles that are optimally dense and spherical for use in lithium battery applications.
44) into a liner, the liner in communication with a microwave waveguide; propagating microwaves through the microwave waveguide, the microwaves generated using a microwave generator; and generating a microwave plasma by contacting the plasma gas with the microwaves.
4) into a liner, the liner in communication with a microwave waveguide; propagating microwaves through the microwave waveguide, the microwaves generated using a microwave generator; and generating a microwave plasma by contacting the plasma gas with the microwaves.
Disclosed herein are embodiments of strain tolerant particles, methods of manufacturing such structures, and feedstock to form said structures. In some embodiments, the structures can include alternating regions of an energy storage structure and a reinforcing structure. Advantageously, when the strain tolerant particles are used within an anode of a lithium ion battery, the reinforcing structure may provide mechanical stability to the particles and thus increase cycle life.
Methods are disclosed for producing product particles having a uniform size using a microwave plasma process. More particularly, methods of the present technology are used to manufacture product particles having a core at least partially surrounded by a shell. The core and shell of the product particles are chemically distinct. Methods of the present technology occur within a plasma chamber of a microwave plasma reactor and a microwave formed plasma is utilized to vaporize core precursor material.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/16 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes
B82B 3/00 - Manufacture or treatment of nanostructures by manipulation of individual atoms or molecules, or limited collections of atoms or molecules as discrete units
Disclosed herein are systems, methods, and devices processing feed material utilizing a microwave plasma apparatus comprising a powder ingress preventor (PIP). In some embodiments, the microwave plasma apparatus comprises a core plasma tube and a liner; and a ring structure comprising: a bearing surface, the bearing surface contacting an interior diameter of the core plasma tube; and an opening, the opening contacting an outer diameter of the liner.
Disclosed herein are systems, methods, and devices processing feed material utilizing a microwave plasma apparatus comprising a powder ingress preventor (PIP). In some embodiments, the microwave plasma apparatus comprises a core plasma tube and a liner; and a ring structure comprising: a bearing surface, the bearing surface contacting an interior diameter of the core plasma tube; and an opening, the opening contacting an outer diameter of the liner.
The embodiments disclosed herein are directed to systems and devices which utilize multiple microwave plasmas can be used to increase the efficiency of traditional single microwave plasma systems. Disclosed herein is a microwave plasma apparatus for processing materials which includes a reaction chamber, a plurality of microwave plasma applicators in communication with the reaction chamber, one or more microwave radiation sources, at least one waveguide for guiding microwave radiation from the one or more microwave radiations sources to multiple plasma applicators, and a material feeding system in communication with the reaction chamber.
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B33Y 70/00 - Materials specially adapted for additive manufacturing
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C04B 35/58 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
C04B 35/626 - Preparing or treating the powders individually or as batches
20.
Plasma apparatus and methods for processing feed material utilizing an upstream swirl module and composite gas flows
Disclosed herein are systems, methods, and devices processing feed material utilizing an upstream swirl module and composite gas flows. Some embodiments are directed to a microwave plasma apparatus for processing a material, comprising: a first flow module, a second flow module, and a liner.
Disclosed herein are systems, methods, and devices processing feed material utilizing an upstream swirl module and composite gas flows. Some embodiments are directed to a microwave plasma apparatus for processing a material, comprising: a first flow module, a second flow module, and a liner; a first swirl module in communication the second flow module, the first swirl module comprising one or more first gas inlets, the one or more first gas inlets configured to generate a first swirl gas flow towards the second swirl module; the second swirl module comprising one or more second gas inlets, the one or more second gas inlets configured to generate a second swirl gas flow towards the liner, wherein the first swirl module and the second swirl module are configured such that the first swirl gas flow and the second swirl gas flow are combined into a composite gas flow prior to entering the liner.
C23C 16/511 - 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 using electric discharges using microwave discharges
The embodiments disclosed herein are directed to systems, methods, and devices for processing a material using a microwave plasma apparatus with an interior liner. In some embodiments, the liner comprises a reduction resistant material layer in direct contact with a hydrogen-containing plasma of a plasma processing apparatus. In some embodiments, the liner may comprise a sleeve disposed between a plasma and one or more concentric tubes of a plasma processing apparatus. In some embodiments, the liner may comprise a coating of material applied to the one or more concentric tubes. In some embodiments, the liner may comprise a flexible ceramic material, such as a ceramic ribbon that is coiled or wrapped in a helix shape spiraling around the interior of the one or more concentric tubes.
The embodiments disclosed herein are directed to systems, methods, and devices for processing a material using a microwave plasma apparatus with an interior liner. In some embodiments, the liner comprises a reduction resistant material layer in direct contact with a hydrogen-containing plasma of a plasma processing apparatus. In some embodiments, the liner may comprise a sleeve disposed between a plasma and one or more concentric tubes of a plasma processing apparatus. In some embodiments, the liner may comprise a coating of material applied to the one or more concentric tubes. In some embodiments, the liner may comprise a flexible ceramic material, such as a ceramic ribbon that is coiled or wrapped in a helix shape spiraling around the interior of the one or more concentric tubes.
An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
The embodiments disclosed herein are directed to systems and devices which utilize multiple microwave plasmas can be used to increase the efficiency of traditional single microwave plasma systems. Disclosed herein is a microwave plasma apparatus for processing materials which includes a reaction chamber, a plurality of microwave plasma applicators in communication with the reaction chamber, one or more microwave radiation sources, at least one waveguide for guiding microwave radiation from the one or more microwave radiations sources to multiple plasma applicators, and a material feeding system in communication with the reaction chamber.
The embodiments disclosed herein are directed to systems and devices which utilize multiple microwave plasmas can be used to increase the efficiency of traditional single microwave plasma systems. Disclosed herein is a microwave plasma apparatus for processing materials which includes a reaction chamber, a plurality of microwave plasma applicators in communication with the reaction chamber, one or more microwave radiation sources, at least one waveguide for guiding microwave radiation from the one or more microwave radiations sources to multiple plasma applicators, and a material feeding system in communication with the reaction chamber.
The embodiments disclosed herein are directed to systems and methods for manufacturing recycled copper alloy powder particles from used or deficient copper alloy powder particles. In some embodiments, used copper alloy powder particles comprising near-surface oxygen are introduced into a microwave plasma torch. In some embodiments, the used copper alloy powder particles are heated within the microwave plasma torch to at least partially remove the oxygen and form recycled copper alloy powder particles, without melting the used copper alloy powder particles.
C23C 16/511 - 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 using electric discharges using microwave discharges
C23C 16/513 - 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 using electric discharges using plasma jets
C23C 16/50 - 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 using electric discharges
31.
SYSTEMS AND METHODS FOR REJUVENATION OF COPPER ALLOY
The embodiments disclosed herein are directed to systems and methods for manufacturing recycled copper alloy powder particles from used or deficient copper alloy powder particles. In some embodiments, used copper alloy powder particles comprising near-surface oxygen are introduced into a microwave plasma torch. In some embodiments, the used copper alloy powder particles are heated within the microwave plasma torch to at least partially remove the oxygen and form recycled copper alloy powder particles, without melting the used copper alloy powder particles.
B22F 1/142 - Thermal or thermo-mechanical treatment
B22F 1/05 - Metallic powder characterised by the size or surface area of the particles
B22F 9/22 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with reduction of metal compounds starting from solid metal compounds using gaseous reductors
Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/30 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/142 - Thermal or thermo-mechanical treatment
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
01 - Chemical and biological materials for industrial, scientific and agricultural use
Goods & Services
Electrochemical energy storage materials, namely,cathode active materials in the nature of metal oxide powders for industrial purposes, anode active materials in the nature of graphite and silicon for industrial purposes, solid battery electrolytes, metal oxide powders for industrial purposes, metal sulfides, alkaline metals and metal phosphate powders.
35.
PROCESS FOR PRODUCING SPHEROIDIZED POWDER FROM FEEDSTOCK MATERIALS
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/142 - Thermal or thermo-mechanical treatment
B22F 1/052 - Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
A pulsed control vibratory particle hopper includes a particle hopper, a vibrating tray, a mechanical vibrator, and a controller. The particle hopper includes a hopper outlet, and the vibrating tray receives particles from the hopper outlet. The mechanical vibrator is mechanically connected to the vibrating tray to generate a baseline vibration, as well as a periodic vibration amplitude spike or pulse. The controller is in communication with the mechanical vibrator to control the mechanical vibrator and generate the periodic vibration amplitude spike with a duration Tp, a maximum amplitude Ap, and a frequency Fp. The pulse duration, pulse amplitude, and pulse frequency are determined based on the size or a type of the material being dispensed from the particle hopper.
B65B 1/08 - Methods of, or means for, filling the material into the containers or receptacles by vibratory feeders
B65G 27/32 - Applications of devices for generating or transmitting jigging movements with means for controlling direction, frequency, or amplitude of vibration or shaking movement
A pulsed control vibratory particle hopper includes a particle hopper, a vibrating tray, a mechanical vibrator, and a controller. The particle hopper includes a hopper outlet, and the vibrating tray receives particles from the hopper outlet. The mechanical vibrator is mechanically connected to the vibrating tray to generate a baseline vibration, as well as a periodic vibration amplitude spike or pulse. The controller is in communication with the mechanical vibrator to control the mechanical vibrator and generate the periodic vibration amplitude spike with a duration Tp, a maximum amplitude Ap, and a frequency Fp. The pulse duration, pulse amplitude, and pulse frequency are determined based on the size or a type of the material being dispensed from the particle hopper.
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B65B 1/08 - Methods of, or means for, filling the material into the containers or receptacles by vibratory feeders
B65G 27/32 - Applications of devices for generating or transmitting jigging movements with means for controlling direction, frequency, or amplitude of vibration or shaking movement
06 - Common metals and ores; objects made of metal
Goods & Services
Metallic material being common metal powders, metal alloys of common metal and other material, specifically, common metal powders, all for use in manufacturing, industry and science
39.
METHOD AND APPARATUS FOR REAL TIME OPTIMIZATION OF A MICROWAVE PLASMA
A method of real time optimization of a microwave plasma includes adjusting in real time an injection angle of a swirl gas flow of the microwave plasma, the magnitude of the swirl gas flow of the microwave plasma, or the microwave power applied to the microwave plasma. An optimization scheme can be created for a particular process requirement or to address time-varying drift in a system. For example, as the output temperature of the torch drifts as the system reaches steady-state operation, the tuning algorithm can adjust the inputs in order to regain the desired output temperature.
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
B05B 7/08 - Spray pistols; Apparatus for discharge with separate outlet orifices, e.g. to form parallel jets, to form intersecting jets
B05B 7/24 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas with means, e.g. a container, for supplying liquid or other fluent material to a discharge device
A method of real time optimization of a microwave plasma includes adjusting in real time an injection angle of a swirl gas flow of the microwave plasma, the magnitude of the swirl gas flow of the microwave plasma, or the microwave power applied to the microwave plasma. An optimization scheme can be created for a particular process requirement or to address time-varying drift in a system. For example, as the output temperature of the torch drifts as the system reaches steady-state operation, the tuning algorithm can adjust the inputs in order to regain the desired output temperature.
H05H 1/46 - Generating plasma using applied electromagnetic fields, e.g. high frequency or microwave energy
H05H 1/34 - Plasma torches using an arc - Details, e.g. electrodes, nozzles
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
B05B 7/24 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas with means, e.g. a container, for supplying liquid or other fluent material to a discharge device
A system for processing fine powders includes a hopper for dispensing powder material through a hopper outlet, and a feeding chamber positioned downstream of the hopper outlet to receive the powder material and convey the powder material to a plasma torch. The system also includes an auger positioned at the hopper outlet, a mechanical vibrator and a mesh screen attached to a flange of the feeding chamber, and a pneumatic system providing a gas flow sufficient to propel the powder material without extinguishing a plasma of the plasma torch.
B05B 7/14 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
B65G 53/08 - Gas pressure systems operating without fluidisation of the materials with mechanical injection of the materials, e.g. by screw
2277 in the presence of hydrogen gas at a temperature below the melting point of the lithium carbonate, such that at least a portion of the lithium carbonate decomposes to form lithium oxide. In some embodiments, the lithium oxide is heated to a temperature sufficient to crystallize the lithium oxide to form the solid electrolyte material comprising lithium lanthanum zirconium oxide (LLZO) particles.
A system for processing fine powders includes a hopper for dispensing powder material through a hopper outlet, and a feeding chamber positioned downstream of the hopper outlet to receive the powder material and convey the powder material to a plasma torch. The system also includes an auger positioned at the hopper outlet, a mechanical vibrator and a mesh screen attached to a flange of the feeding chamber, and a pneumatic system providing a gas flow sufficient to propel the powder material without extinguishing a plasma of the plasma torch.
H05H 1/42 - Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder, liquid
B05B 7/14 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B41F 23/06 - Powdering devices, e.g. for preventing set-off
G01F 11/18 - Apparatus requiring external operation adapted at each repeated and identical operation to measure and separate a predetermined volume of fluid or fluent solid material from a supply or container, without regard to weight, and to deliver it with measuring chambers moved during operation of the valve type, i.e. the separating being effected by fluid-tight or powder-tight movements wherein the measuring chamber reciprocates for fluent solid material
Disclosed herein are materials and processes for production of lithium oxide materials, such as lithium lanthanum zirconium oxide (LLZO), having a small particle size and high density for use in lithium-ion batteries. Some embodiments are directed to forming and then heating a multiphase material comprising lithium carbonate and La2Zr2O7 in the presence of hydrogen gas at a temperature below the melting point of the lithium carbonate, such that at least a portion of the lithium carbonate decomposes to form lithium oxide. In some embodiments, the lithium oxide is heated to a temperature sufficient to crystallize the lithium oxide to form the solid electrolyte material comprising lithium lanthanum zirconium oxide (LLZO) particles.
A system for processing fine powders includes a hopper for dispensing powder material through a hopper outlet, and a feeding chamber positioned downstream of the hopper outlet to receive the powder material and convey the powder material to a plasma torch. The system also includes an auger positioned at the hopper outlet, a mechanical vibrator and a mesh screen attached to a flange of the feeding chamber, and a pneumatic system providing a gas flow sufficient to propel the powder material without extinguishing a plasma of the plasma torch.
H05H 1/42 - Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder, liquid
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B41F 23/06 - Powdering devices, e.g. for preventing set-off
G01F 11/18 - Apparatus requiring external operation adapted at each repeated and identical operation to measure and separate a predetermined volume of fluid or fluent solid material from a supply or container, without regard to weight, and to deliver it with measuring chambers moved during operation of the valve type, i.e. the separating being effected by fluid-tight or powder-tight movements wherein the measuring chamber reciprocates for fluent solid material
Disclosed herein are materials and processes for production of lithium oxide materials, such as lithium lanthanum zirconium oxide (LLZO), having a small particle size and high density for use in lithium-ion batteries. Some embodiments are directed to forming and then heating a multiphase material comprising lithium carbonate and La2Zr2O7 in the presence of hydrogen gas at a temperature below the melting point of the lithium carbonate, such that at least a portion of the lithium carbonate decomposes to form lithium oxide. In some embodiments, the lithium oxide is heated to a temperature sufficient to crystallize the lithium oxide to form the solid electrolyte material comprising lithium lanthanum zirconium oxide (LLZO) particles.
The embodiments disclosed herein are directed to systems, methods, and devices for producing materials having desired characteristics using microwave plasma. In some embodiments, performing an iterative process may be used to produce a material having desired characteristics, the process comprising forming a microwave plasma within the reaction chamber, analyzing the plasma to determine if properties of the plasma are within a range expected to produce the desired characteristics of the material; and adjusting, based on the analysis of the plasma, one or more parameters. In some embodiments, an extension tube is provided within a microwave plasma apparatus to extend the length of a microwave plasma.
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
48.
SYSTEMS, METHODS, AND DEVICES FOR PRODUCING A MATERIAL WITH DESIRED CHARACTERISTICS USING MICROWAVE PLASMA
The embodiments disclosed herein are directed to systems, methods, and devices for producing materials having desired characteristics using microwave plasma. In some embodiments, performing an iterative process may be used to produce a material having desired characteristics, the process comprising forming a microwave plasma within the reaction chamber, analyzing the plasma to determine if properties of the plasma are within a range expected to produce the desired characteristics of the material; and adjusting, based on the analysis of the plasma, one or more parameters. In some embodiments, an extension tube is provided within a microwave plasma apparatus to extend the length of a microwave plasma.
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
B22F 10/34 - Process control of powder characteristics, e.g. density, oxidation or flowability
The embodiments disclosed herein are directed to systems, methods, and devices for producing materials having desired characteristics using microwave plasma. In some embodiments, performing an iterative process may be used to produce a material having desired characteristics, the process comprising forming a microwave plasma within the reaction chamber, analyzing the plasma to determine if properties of the plasma are within a range expected to produce the desired characteristics of the material; and adjusting, based on the analysis of the plasma, one or more parameters. In some embodiments, an extension tube is provided within a microwave plasma apparatus to extend the length of a microwave plasma.
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
50.
SYSTEMS, METHODS, AND DEVICES FOR PRODUCING A MATERIAL WITH DESIRED CHARACTERISTICS USING MICROWAVE PLASMA
The embodiments disclosed herein are directed to systems, methods, and devices for producing materials having desired characteristics using microwave plasma. In some embodiments, performing an iterative process may be used to produce a material having desired characteristics, the process comprising forming a microwave plasma within the reaction chamber, analyzing the plasma to determine if properties of the plasma are within a range expected to produce the desired characteristics of the material; and adjusting, based on the analysis of the plasma, one or more parameters. In some embodiments, an extension tube is provided within a microwave plasma apparatus to extend the length of a microwave plasma.
H05H 1/30 - Plasma torches using applied electromagnetic fields, e.g. high-frequency or microwave energy
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
09 - Scientific and electric apparatus and instruments
Goods & Services
(1) Production apparatus and instruments, namely, high-power microwave-based plasma system for creating and modifying advanced powder and particle materials and parts and accessories therefor, for use in processing materials and compounds, namely, powders, metals, metal alloys, metal alloy powders, metal powders, particles, cathode materials, anode materials, electrolyte materials, ceramics, ceramic powders, phosphors, quantum dots, oxides, carbides, nitrides, oxynitrides, borides, composite materials, paint pigment materials, abrasive materials, transparent ceramics in the nature of treatment of materials by means of high temperature plasma process
(2) Scientific production apparatus and instruments, namely, high power microwave-based plasma system for scientific or laboratory use comprising a high voltage microwave generator, plasma torch, treatment chamber, and controls, parts and accessories therefor, used for research of composition, change in composition, and creation of compounds as a result of exposure to and treatment to high temperature plasma processes; electrical production apparatus and instruments, namely, high power microwave-based plasma systems comprising wave guides for high power beam delivery
52.
MICROWAVE PLASMA PROCESSING OF SPHEROIDIZED COPPER OR OTHER METALLIC POWDERS
Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus. In some embodiments, plasma processing of the pre-processed feedstock material may synthesize pure, spheroidized metal or metal alloy particles, with substantially no contamination of the volatile material ion the final product.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
53.
Systems and methods for additive manufacturing of metal nitride ceramics
Described herein are embodiments directed to additive manufacturing (AM), including three-dimensional (3D) printing, of metal nitride ceramics. In some embodiments herein, AM may comprise powder bed fusion (PBF) techniques. Also described herein are metal nitride ceramic components formed by AM techniques and methods for forming metal nitrides capable of being used in AM processes.
Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus.
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
55.
SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING OF METAL NITRIDE CERAMICS
Described herein are embodiments directed to additive manufacturing (AM), including three-dimensional (3D) printing, of metal nitride ceramics. In some embodiments herein, AM may comprise powder bed fusion (PBF) techniques. Also described herein are metal nitride ceramic components formed by AM techniques.
H01B 1/02 - Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus.
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
57.
SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING OF METAL NITRIDE CERAMICS
Described herein are embodiments directed to additive manufacturing (AM), including three-dimensional (3D) printing, of metal nitride ceramics. In some embodiments herein, AM may comprise powder bed fusion (PBF) techniques. Also described herein are metal nitride ceramic components formed by AM techniques.
B33Y 80/00 - Products made by additive manufacturing
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
C04B 35/58 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
H01B 1/02 - Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
Disclosed herein are systems and methods for synthesis of polymer derived ceramic materials, including silicon oxycarbide comprising silicon metal. In some embodiments, the silicon metal is formed by carbothermal reduction during thermal processing. In some embodiments, the thermal processing comprises microwave plasma processing. In some embodiments, the silicon metal forms nanodomains within a structure of the silicon oxycarbide ceramic material.
C04B 35/00 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
C04B 35/56 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
C04B 35/571 - Fine ceramics obtained from polymer precursors
C23C 16/511 - 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 using electric discharges using microwave discharges
C23C 16/513 - 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 using electric discharges using plasma jets
60.
SYSTEMS AND METHODS FOR SILICON OXYCARBIDE CERAMIC MATERIALS COMPRISING SILICON METAL
Disclosed herein are systems and methods for synthesis of polymer derived ceramic materials, including silicon oxycarbide comprising silicon metal. In some embodiments, the silicon metal is formed by carbothermal reduction during thermal processing. In some embodiments, the thermal processing comprises microwave plasma processing. In some embodiments, the silicon metal forms nanodomains within a structure of the silicon oxycarbide ceramic material.
C04B 35/00 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
C04B 35/571 - Fine ceramics obtained from polymer precursors
C04B 35/56 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
C23C 16/511 - 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 using electric discharges using microwave discharges
C23C 16/513 - 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 using electric discharges using plasma jets
Disclosed herein are systems and methods for synthesis of polymer derived ceramic materials, including silicon oxycarbide comprising silicon metal. In some embodiments, the silicon metal is formed by carbothermal reduction during thermal processing. In some embodiments, the thermal processing comprises microwave plasma processing. In some embodiments, the silicon metal forms nanodomains within a structure of the silicon oxycarbide ceramic material.
C04B 35/56 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on carbides
C04B 35/571 - Fine ceramics obtained from polymer precursors
Disclosed herein are systems and methods for synthesis of submicron-scale or micron-scale single crystal cathode (SCC) material, such as NMC, using a feedstock and microwave plasma processing. Microwave plasma processing of these SCC materials provides a low cost, scalable approach. In some embodiments, advanced SCC materials may be synthesized through microwave plasma processing of feedstock materials, wherein the SCC materials may comprise at least 80% nickel. In some embodiments, the microwave plasma processing may enable synthesis of SCC materials with very short calcination.
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
H01M 4/131 - Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
Disclosed herein are systems and methods for synthesis of submicron-scale or micron-scale single crystal cathode (SCC) material, such as NMC, using a feedstock and microwave plasma processing. Microwave plasma processing of these SCC materials provides a low cost, scalable approach. In some embodiments, advanced SCC materials may be synthesized through microwave plasma processing of feedstock materials, wherein the SCC materials may comprise at least 80% nickel. In some embodiments, the microwave plasma processing may enable synthesis of SCC materials with very short calcination.
B01J 19/12 - Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electromagnetic waves
Disclosed herein are systems and methods for synthesis of submicron-scale or micron-scale single crystal cathode (SCC) material, such as NMC, using a feedstock and microwave plasma processing. Microwave plasma processing of these SCC materials provides a low cost, scalable approach. In some embodiments, advanced SCC materials may be synthesized through microwave plasma processing of feedstock materials, wherein the SCC materials may comprise at least 80% nickel. In some embodiments, the microwave plasma processing may enable synthesis of SCC materials with very short calcination.
H01M 4/525 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
H01M 4/505 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
65.
METHODS AND SYSTEMS FOR RECLAMATION OF LI-ION CATHODE MATERIALS USING MICROWAVE PLASMA PROCESSING
Disclosed herein are embodiments of systems and methods for recycling used solid feedstocks containing lithium powders for use in lithium-ion batteries. The used solid feedstocks may be Lithium Nickel Manganese Cobalt Oxide (NMC) materials. In some embodiments, the used solid feedstock can undergo a microwave plasma process to produce a newly usable, lithium supplemented solid precursor with augmented chemistries and physical properties.
Disclosed herein are embodiments of systems and methods for recycling used solid feedstocks containing lithium powders for use in lithium-ion batteries. The used solid feedstocks may be Lithium Nickel Manganese Cobalt Oxide (NMC) materials. In some embodiments, the used solid feedstock can undergo a microwave plasma process to produce a newly usable, lithium supplemented solid precursor with augmented chemistries and physical properties.
Disclosed herein are embodiments of systems and methods for recycling used solid feedstocks containing lithium powders for use in lithium-ion batteries. The used solid feedstocks may be Lithium Nickel Manganese Cobalt Oxide (NMC) materials. In some embodiments, the used solid feedstock can undergo a microwave plasma process to produce a newly usable, lithium supplemented solid precursor with augmented chemistries and physical properties.
Methods are disclosed for producing core-shell particles having a uniform size using a microwave plasma process. More particularly, methods of the present technology are used to manufacture core-shell particles having a core at least partially surrounded by a shell. The core and shell of the core-shell particles are chemically distinct. Methods of the present technology occur within a plasma chamber of a microwave plasma reactor and a microwave formed plasma is utilized to vaporize core precursor material.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B82B 3/00 - Manufacture or treatment of nanostructures by manipulation of individual atoms or molecules, or limited collections of atoms or molecules as discrete units
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/16 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes
Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 1/05 - Metallic powder characterised by the size or surface area of the particles
70.
SYSTEMS AND METHODS FOR SYNTHESIS OF SPHEROIDIZED METAL POWDERS
Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/02 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes
B22F 9/22 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with reduction of metal compounds starting from solid metal compounds using gaseous reductors
71.
SYSTEMS AND METHODS FOR SYNTHESIS OF SPHEROIDIZED METAL POWDERS
Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/22 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with reduction of metal compounds starting from solid metal compounds using gaseous reductors
72.
Spheroidal dehydrogenated metals and metal alloy particles
Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/30 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
H05H 1/42 - Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder, liquid
H05H 1/30 - Plasma torches using applied electromagnetic fields, e.g. high-frequency or microwave energy
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
Some embodiments herein are directed to devices and methods for automatically starting a plasma utilizing a wand. In some embodiments, the wand may be used to start a plasma in a plasma torch such as, for example, a microwave plasma torch or an induction plasma torch. The plasma torches discussed herein may be used in various applications including, for example, high volume synthesis of advanced materials such as nano-materials, micro-powders, coatings, alloy compositions for additive manufacturing.
An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.
An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.
Some embodiments herein are directed to devices and methods for automatically starting a plasma utilizing a wand. In some embodiments, the wand may be used to start a plasma in a plasma torch such as, for example, a microwave plasma torch or an induction plasma torch. The plasma torches discussed herein may be used in various applications including, for example, high volume synthesis of advanced materials such as nano-materials, micro-powders, coatings, alloy compositions for additive manufacturing.
An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.
Some embodiments herein are directed to devices and methods for automatically starting a plasma utilizing a wand. In some embodiments, the wand may be used to start a plasma in a plasma torch such as, for example, a microwave plasma torch or an induction plasma torch, as discussed below. The wand may comprise an elongate, hollow wand member comprising a closed distal end, a proximal end, and one or more apertures extending from a hollow interior of the wand member to an exterior surface of the wand member; and an elongate wire member positioned within the hollow interior of the wand member and extending along at least a portion of a length of the wand member, wherein the wire member is configured to be placed in operable communication through the aperture with a power source, such that the power source can be activated to in turn start the plasma within the plasma torch. The plasma torches discussed herein may be used in various applications including, for example, high volume synthesis of advanced materials such as nano-materials, micro-powders, coatings, alloy compositions for additive manufacturing.
Disclosed herein are embodiments of producing Si or SiOx from inexpensive silica sources. In some embodiments, plasma processing can be used to covert the silica sources to the silicon products. Unique morphologies can be formed in some embodiments. In some embodiments, reducing agents, catalysts, and/or salts can be used to provide advantageous properties.
Disclosed herein are embodiments of producing Si or SiOx from inexpensive silica sources. In some embodiments, plasma processing can be used to covert the silica sources to the silicon products. Unique morphologies can be formed in some embodiments. In some embodiments, reducing agents, catalysts, and/or salts can be used to provide advantageous properties.
C01B 33/023 - Preparation by reduction of silica or silica-containing material
C01B 33/025 - Preparation by reduction of silica or silica-containing material with carbon or a solid carbonaceous material, i.e. carbo-thermal process
xx from inexpensive silica sources. In some embodiments, plasma processing can be used to covert the silica sources to the silicon products. Unique morphologies can be formed in some embodiments. In some embodiments, reducing agents, catalysts, and/or salts can be used to provide advantageous properties.
C01B 33/023 - Preparation by reduction of silica or silica-containing material
C01B 33/025 - Preparation by reduction of silica or silica-containing material with carbon or a solid carbonaceous material, i.e. carbo-thermal process
C01B 33/18 - Preparation of finely divided silica neither in sol nor in gel form; After-treatment thereof
Disclosed herein are embodiments of strain tolerant particles, methods of manufacturing such structures, and feedstock to form said structures. In some embodiments, the structures can include alternating regions of an energy storage structure and a reinforcing structure. Advantageously, when the strain tolerant particles are used within an anode of a lithium ion battery, the reinforcing structure may provide mechanical stability to the particles and thus increase cycle life.
Disclosed herein are embodiments of strain tolerant particles, methods of manufacturing such structures, and feedstock to form said structures. In some embodiments, the structures can include alternating regions of an energy storage structure and a reinforcing structure. Advantageously, when the strain tolerant particles are used within an anode of a lithium ion battery, the reinforcing structure may provide mechanical stability to the particles and thus increase cycle life.
Disclosed herein are embodiments of strain tolerant particles, methods of manufacturing such structures, and feedstock to form said structures. In some embodiments, the structures can include alternating regions of an energy storage structure and a reinforcing structure. Advantageously, when the strain tolerant particles are used within an anode of a lithium ion battery, the reinforcing structure may provide mechanical stability to the particles and thus increase cycle life.
The present disclosure relates to methodologies, systems and apparatus for generating lithium ion battery materials. Starting materials are combined to form a homogeneous precursor solution including lithium, and a droplet maker is used to generate droplets of the precursor solution having controlled size. These droplets are introduced into a microwave generated plasma, where micron or sub-micron scale lithium-containing particles are formed. These lithium-containing particles are collected and formed into a slurry to form lithium ion battery materials.
H01M 4/505 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
H01M 4/525 - Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
Disclosed herein are embodiments of doped and undoped spherical or spheroidal lithium lanthanum zirconium oxide (LLZO) powder products, and methods of production using microwave plasma processing, which can be incorporated into solid state lithium ion batteries. Advantageously, embodiments of the disclosed LLZO powder display a high quality, high purity stoichiometry, small particle size, narrow size distribution, spherical morphology, and customizable crystalline structure.
Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/30 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes with decomposition of metal compounds, e.g. by pyrolysis
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
40 - Treatment of materials; recycling, air and water treatment,
Goods & Services
(1) Materials treatment, namely, processing, reprocessing, treatment and custom manufacturing of materials, compounds and parts via high powered microwave-based plasma, via chemical and mechanical processing of metals, metal alloys, ceramics, turnings, custom and commercial off the shelf parts, components and assemblies for the aerospace, medical, battery, and automotive industries
89.
PROCESS FOR PRODUCING SPHEROIDIZED POWDER FROM FEEDSTOCK MATERIALS
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/142 - Thermal or thermo-mechanical treatment
B22F 1/052 - Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B33Y 70/00 - Materials specially adapted for additive manufacturing
92.
UNIQUE FEEDSTOCKS FOR SPHERICAL POWDERS AND METHODS OF MANUFACTURING
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
C04B 35/48 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C04B 35/58 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
C04B 35/626 - Preparing or treating the powders individually or as batches
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B05B 7/22 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating the material to be sprayed electrically, e.g. by arc
93.
UNIQUE FEEDSTOCKS FOR SPHERICAL POWDERS AND METHODS OF MANUFACTURING
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B05B 7/22 - Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating the material to be sprayed electrically, e.g. by arc
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
C04B 35/48 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxides based on zirconium or hafnium oxides or zirconates or hafnates
C04B 35/58 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
C04B 35/626 - Preparing or treating the powders individually or as batches
94.
Unique feedstocks for spherical powders and methods of manufacturing
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B33Y 70/00 - Materials specially adapted for additive manufacturing
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C04B 35/58 - Shaped ceramic products characterised by their composition; Ceramic compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxides based on borides, nitrides or silicides
C04B 35/626 - Preparing or treating the powders individually or as batches
95.
Process for producing spheroidized powder from feedstock materials
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
B22F 1/142 - Thermal or thermo-mechanical treatment
96.
Process for producing spheroidized powder from feedstock materials
Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
B22F 1/142 - Thermal or thermo-mechanical treatment
97.
STRAIN TOLERANT PARTICLE STRUCTURES FOR HIGH ENERGY ANODE MATERIALS AND SYTHESIS METHODS THEREOF
Disclosed herein are embodiments of strain tolerant particle structures, methods of manufacturing such structures, and precursors to form said structures. In some embodiments, the structures can be formed of a network of nano-scale walls. The structures can be incorporated into powders, which can then be used for any number of applications, such as microwave plasma processing.
Disclosed herein are embodiments of strain tolerant particle structures, methods of manufacturing such structures, and precursors to form said structures. In some embodiments, the structures can be formed of a network of nano-scale walls. The structures can be incorporated into powders, which can then be used for any number of applications, such as microwave plasma processing.
Disclosed herein are embodiments of strain tolerant particle structures, methods of manufacturing such structures, and precursors to form said structures. In some embodiments, the structures can be formed of a network of nano-scale walls. The structures can be incorporated into powders, which can then be used for any number of applications, such as microwave plasma processing.
Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
