Free Form Fibers, LLC

Other

Hewlett-packard Development Company, L.p.

Advanced Materials Corporation

Hewlett-packard Company

Novasolar Holdings Limited

Erik Garth Vaaler

Shay Llewellyn Harrison

John L Schneiter

Joseph Pegna

Marvin S Keshner

Kirk L Williams

Ram K Goduguchinta

Steven W Trovinger

Ross R Allen

Yang T Shieh

Jose J A Rodal

Richard D Barndt

Amir Torkaman

George Panotopoulos

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.

High purity ingot for wafer production

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.

High purity fiber feedstock for loose grain production

A chemical processing method includes decomposing a metal carbonate in a first tube by exposure to a first quantity of heat, producing a metal oxide and carbon dioxide; and hydrating the metal oxide in a second tube concentric with the first, by exposure to steam, producing a metal hydroxide and a second quantity of heat. The partial pressure of the steam and/or of the carbon dioxide is controlled so that the hydration reaction occurs at a second temperature above a first temperature at which the decomposition reaction occurs. The inner one of the concentric tubes has an inner tube wall. At least some of the second quantity of heat flows from the second tube through the inner tube wall to the first tube, providing at least a part of the first quantity of heat.

High-efficiency method for converting limestone to slaked lime

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.

Multilayer functional fiber and method of making

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).

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

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.

Method of making a multi-composition fiber

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.

Additive manufacturing technique for placing nuclear reactor fuel within fibers

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.

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

A lithium battery includes a solid cathode and a solid electrolyte (SSE), wherein a structurally continuous block of material comprises the solid cathode and the SSE. The structurally continuous solid block of material has a first chemical composition in the solid cathode and a second chemical composition, different from the first chemical composition, in the SSE. The SSE overlies the solid cathode, without any physical separation or interface therebetween. A method for fabricating a lithium battery includes placing a first layer of particles of an electrolyte material of a first composition on top of a second layer of particles of a cathode material of a second composition, forming a stack; and compressing and heating the stack of first and second layers to form a continuous solid material. The formed material has a solid electrolyte (SSE) characterized by the first composition and a solid cathode characterized by the second composition.

Solid-state rechargeable lithium battery with solid-state electrolyte

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&#xbd;D printing. In another aspect, a multilayer functional fiber is provided produced by, for instance, the above-noted methods.

Functional high-performance fiber structure

A system for large scale capture of atmospheric carbon dioxide while exposed to air and weather in an outdoor environment, includes a large flat slab with a perimeter wall projecting above its surface; one or more rotary fans, providing uniform, high volume, low velocity, turbulent air flow over the entire slab surface; a transport system transferring powder&#x2014;a particulate material mixed with air&#x2014;to and from all locations on the slab or on an overlying mesh screen, a kiln, closed to outside air, and a compressor. The transport system includes either a vacuum/deposition system or a conveyor system with one or more conveyors. The kiln heats the particulate material, delivered by the transport system from the slab, to output released carbon dioxide, previously absorbed by the particulate material in the powder, to the compressor for compression, and either the heated particulate material, or a processed version of it.

Direct capture of carbon dioxide from air

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.

Fiber with elemental additive(s) and method of making

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.

Fibers fabricated to incorporate metals for high temperature applications

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&#xb0; 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.

High temperature glass-ceramic matrix with embedded reinforcement fibers

An apparatus comprises a separator, a compressor, a mixer and a pump. The separator operates on an input gas mixture comprising carbon dioxide gas and one or more other gases, providing a separated carbon dioxide gas output. A compressor compresses the separated carbon dioxide gas output, providing a second output comprising at least one of gaseous carbon dioxide and liquid carbon dioxide. A mixer mixes the second output with liquid water under pressure to provide a third output comprising: at least one of liquid carbon dioxide and gaseous carbon dioxide; and water with dissolved carbon dioxide. A pump pumps the third output into an underground structure such that components of the third output react with available rock surfaces to form stable carbonates.

Growing community of inventors

Redwood City, CA, United States of America

Erik Garth Vaaler