公开(公告)号：US11673840B2

公开(公告)日：2023-06-13

申请号：US16337482

申请日：2017-10-26

Applicant: Dynamic Material Systems LLC

Inventor： Arnold Hill ,  William Easter ,  Walter Sherwood

IPC: C04B35/571 ,  C04B35/56 ,  C04B35/622 ,  C04B41/00 ,  C04B41/50 ,  C09K8/80

CPC classification number: C04B35/571 ,  C04B35/5603 ,  C04B35/62222 ,  C04B41/0072 ,  C04B41/5059 ,  C09K8/805 ,  C04B2235/3895

Abstract: A complex composite particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant or in a composite structure.

公开(公告)号：US20190292441A1

公开(公告)日：2019-09-26

申请号：US16345577

申请日：2017-10-26

Applicant: Dynamic Material Systems LLC

Inventor： Arnold Hill ,  William Easter

IPC: C09K8/80 ,  C04B35/528 ,  C04B35/622 ,  C04B35/626 ,  C04B35/628

Abstract: A composite article is comprised of coal dust, as defined herein, and a polymer derived ceramic material that is pyrolyzed in a substantially non-oxidizing atmosphere. For example, the composite article may be made of a mixture of the coal dust and polymer derived ceramic, from particles formed of a mixture of coal dust and polymer derived ceramic or from complex particle composites comprising a plurality of particles formed of a mixture of coal dust and polymer derived ceramic.

公开(公告)号：US10392311B2

公开(公告)日：2019-08-27

申请号：US15704727

申请日：2017-09-14

Applicant: Dynamic Material Systems, LLC

Inventor： Arnold Hill ,  William Easter

IPC: C04B35/597 ,  C04B35/565 ,  C04B38/00 ,  C10M159/00 ,  C04B35/626 ,  C04B35/583 ,  C04B38/06 ,  C04B35/56 ,  C04B35/58 ,  C04B35/589 ,  C04B35/571 ,  C04B35/00 ,  C04B35/584 ,  C09K8/80

Abstract: Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 μm to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. Nano-sized ceramic particles are formed from the green body produced by methods for making bulk, dense composite ceramics. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

公开(公告)号：US20180022652A1

公开(公告)日：2018-01-25

申请号：US15704727

申请日：2017-09-14

Applicant: Dynamic Material Systems, LLC

Inventor： Arnold Hill ,  William Easter

IPC: C04B35/597 ,  C04B35/565 ,  C04B38/00 ,  C10M159/00 ,  C04B35/626 ,  C04B35/583 ,  C04B38/06 ,  C04B35/56 ,  C04B35/58 ,  C04B35/589 ,  C04B35/571 ,  C04B35/00 ,  C04B35/584 ,  C09K8/80

CPC classification number: C04B35/597 ,  C04B35/5603 ,  C04B35/565 ,  C04B35/571 ,  C04B35/58 ,  C04B35/583 ,  C04B35/584 ,  C04B35/589 ,  C04B35/6269 ,  C04B35/62695 ,  C04B38/008 ,  C04B2235/483 ,  C04B2235/602 ,  C04B2235/6028 ,  C04B2235/77 ,  C04B2235/95 ,  C09K8/805 ,  C10M159/00 ,  C04B35/00 ,  C04B38/0074 ,  C04B38/0615

Abstract: Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 μm to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. Nano-sized ceramic particles are formed from the green body produced by methods for making bulk, dense composite ceramics. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

公开(公告)号：US11407687B2

公开(公告)日：2022-08-09

申请号：US16894638

申请日：2020-06-05

Applicant: Dynamic Material Systems LLC

Inventor： Arnold Hill ,  William Easter

IPC: B28B1/00 ,  B33Y80/00 ,  C04B35/56 ,  C04B35/571 ,  C04B35/622 ,  C04B35/626 ,  C04B35/628 ,  C04B35/64 ,  B33Y10/00 ,  B33Y70/00

Abstract: A complex ceramic particle and ceramic composite material may be made of a pretreated coal dust and a polymer derived ceramic that is mixed together and pyrolyzed in a nonoxidizing atmosphere. Constituent portions of the particle mixture chemically react causing particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for a plurality of uses including composite articles and proppants.

公开(公告)号：US20210002178A1

公开(公告)日：2021-01-07

申请号：US16980544

申请日：2019-03-19

Applicant: Dynamic Material Systems LLC

Inventor： Walter Sherwood ,  Arnold Hill ,  Gordon Nameni ,  William Easter

IPC: C04B35/532 ,  C04B35/64 ,  C04B35/638 ,  C04B35/628 ,  C04B41/00 ,  C04B41/50 ,  C04B41/86

Abstract: A composite tile is comprised of coal dust and a pre-ceramic polymer that are mixed together and pyrolyzed to form a ceramic composite. For example, a chemical reaction during pyrolysis chemically converts at least a portion of the coal dust and pre-ceramic polymer to a fire proof ceramic composite suitable for use as a roofing tile either as pyrolyzed or as post-treated to seal cracks and pores formed during pyrolysis.

公开(公告)号：US09764987B2

公开(公告)日：2017-09-19

申请号：US14858096

申请日：2015-09-18

Applicant: Dynamic Material Systems, LLC

Inventor： Arnold Hill ,  William Easter

IPC: C04B35/597 ,  C04B35/584 ,  C10M159/00 ,  C04B35/583 ,  C09K8/80 ,  C04B35/56 ,  C04B35/565 ,  C04B35/571 ,  C04B35/589 ,  C04B35/626 ,  C04B38/00 ,  C04B35/58

CPC classification number: C04B35/597 ,  C04B35/5603 ,  C04B35/565 ,  C04B35/571 ,  C04B35/58 ,  C04B35/583 ,  C04B35/584 ,  C04B35/589 ,  C04B35/6269 ,  C04B35/62695 ,  C04B38/008 ,  C04B2235/483 ,  C04B2235/602 ,  C04B2235/6028 ,  C04B2235/77 ,  C04B2235/95 ,  C09K8/805 ,  C10M159/00 ,  C04B35/00 ,  C04B38/0074 ,  C04B38/0615

Abstract: Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 μm to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

公开(公告)号：US20170008236A1

公开(公告)日：2017-01-12

申请号：US15274899

申请日：2016-09-23

Applicant: Dynamic Material Systems, LLC

Inventor： William Easter ,  Arnold Hill

IPC: B29C67/00 ,  B23K26/00 ,  B28B1/00 ,  B23K26/342 ,  B33Y10/00 ,  B33Y70/00

CPC classification number: B29C64/165 ,  B22F3/1055 ,  B23K26/0006 ,  B23K26/342 ,  B23K2103/02 ,  B23K2103/08 ,  B23K2103/16 ,  B23K2103/18 ,  B23K2103/42 ,  B23K2103/52 ,  B28B1/001 ,  B29C64/106 ,  B29C64/153 ,  B33Y10/00 ,  C04B35/01 ,  C04B35/522 ,  C04B35/532 ,  C04B35/56 ,  C04B35/5603 ,  C04B35/571 ,  C04B35/58 ,  C04B35/58085 ,  C04B35/589 ,  C04B35/6269 ,  C04B35/62695 ,  C04B35/634 ,  C04B38/008 ,  C04B2111/00181 ,  C04B2235/32 ,  C04B2235/3817 ,  C04B2235/3852 ,  C04B2235/3891 ,  C04B2235/425 ,  C04B2235/427 ,  C04B2235/483 ,  C04B2235/5248 ,  C04B2235/5264 ,  C04B2235/5288 ,  C04B2235/602 ,  C04B2235/6026 ,  C04B2235/6028 ,  C04B2235/95 ,  C10M159/00 ,  C22C29/00 ,  Y02P10/295 ,  C04B35/00 ,  C04B38/0074 ,  C04B38/0615

Abstract: Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of novel ceramic composites. Additive manufacture or 3D printing of bulk ceramic and ceramic composite components occurs at considerably lower temperatures and shorter manufacturing intervals than the current state of the art. The methods, processes, systems, devices and apparatus and selection of precursor resins produce ceramic and ceramic composite material systems which have not been produced before by 3D printing.

Abstract translation: 提供了用于添加剂制造的方法，工艺，系统，装置和装置，从而导致新型陶瓷复合材料的3D印刷。 散装陶瓷和陶瓷复合材料部件的添加制造或3D印刷在比现有技术水平低得多的温度和更短的制造间隔下发生。 前体树脂的方法，工艺，系统，装置和设备以及选择产生的陶瓷和陶瓷复合材料体系在3D印刷之前尚未生产。

公开(公告)号：US11148320B1

公开(公告)日：2021-10-19

申请号：US15964551

申请日：2018-04-27

Applicant: Dynamic Material Systems, LLC

Inventor： Walter Sherwood ,  Matthew Stephens ,  Arnold Hill ,  William Easter

IPC: B28B1/00 ,  C08L83/16 ,  C04B35/565 ,  C04B35/01 ,  C04B35/632 ,  C04B40/02 ,  C09C1/00 ,  C09C1/48 ,  C09C1/64 ,  C08L83/04 ,  B33Y10/00 ,  B33Y70/00 ,  C04B35/58 ,  C04B35/74

Abstract: Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of ceramic materials and components with a thickness greater than three millimeters (3 mm). A sulfur-free 3D printable formulation comprises a liquid inorganic polymer resin using Stereolithograpy (SLA) printers and Digital Light Processing (DLP) curing of the polymer resin via the chemical bonding of the materials rather than sintering. Thus, the process has shorter manufacturing intervals, significantly lower energy use and produces larger scale ceramic components having less linear shrinkage, less mass loss and high ceramic yield with no corrosive sulfur compounds present in the ceramic component.

公开(公告)号：US11104841B2

公开(公告)日：2021-08-31

申请号：US16324843

申请日：2017-08-11

Applicant: Dynamic Material Systems LLC

Inventor： Arnold Hill ,  William Easter

IPC: C09K8/80 ,  E21B43/267 ,  C04B35/622 ,  C04B35/626 ,  C04B35/528

Abstract: A material useful as a proppant comprises a core chemically reacted in situ from coal dust and a polymer derived ceramic material, such that at least a portion of the coal dust is chemically converted to a ceramic, nanoparticles, graphene, nanofibers or combinations of any of these.