IP Library Granted Patent US 6,921,497
Granted Patent B2
US 6,921,497 · App. 10/123,028 · Granted Jul 26, 2005

Composition of matter tailoring: system I

Assignee: Electromagnetics Corporation
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Quick Facts
Patent No.
US 6,921,497
App. No.
10/123,028
Granted
Jul 26, 2005
Kind
B2
Abstract

The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Claims (80)

1. A manufactured copper characterized by the x-ray fluorescence spectrometry plot of FIG. 6A , 6 B, 7 , or 26 .

2. A manufactured nickel characterized by the x-ray fluorescence spectrometry plot of FIG. 27A , 27 B, 28 A, 28 B, 29 , or 30 .

3. A manufactured nickel characterized by the x-ray fluorescence spectrometry plot of FIG. 27A or 27 B.

4. A manufactured cobalt characterized by the x-ray fluorescence spectrometry plot of FIG. 31A , 31 B, 32 A, 32 B, 33 A, 33 B, or 34 .

5. A manufactured cobalt characterized by the x-ray fluorescence spectrometry plot of FIG. 31A or 31 B.

6. A manufactured silicon characterized by the x-ray fluorescence spectrometry plot of FIG. 45A , 45 B, 46 A, 46 B, 47 A, 47 B, 48 A, or 48 B.

7. A manufactured silicon characterized by the x-ray fluorescence spectrometry plot of FIG. 45A or 45 B.

8. An manufactured iron characterized by the x-ray fluorescence spectrometry plot of FIG. 49A , 49 B, 50 A, 50 B, 51 A, or 51 B.

9. An manufactured iron characterized by the x-ray fluorescence spectrometry plot of FIG. 49A or 49 B.

10. An manufactured alloy comprised of copper, gold, and silver characterized by the x-ray fluorescence spectrometry plot of FIG. 35 , 36 , or 37 .

11. An manufactured alloy comprised of tin, lead, and zinc characterized by the x-ray fluorescence spectrometry plot of FIG. 38 , 39 , or 40 .

12. An manufactured alloy comprised of tin, sodium, magnesium, and potassium characterized by the x-ray fluorescence spectrometry plot of FIG. 41 , 42 , 43 , or 44 .

13. An alloy comprised of iron, vanadium, chromium, and manganese characterized by the x-ray fluorescence spectrometry plot of FIG. 52 , 53 , 54 , or 55 .

14. An manufactured alloy comprised of nickel, tantalum, hafnium, and tungsten characterized by the x-ray fluorescence spectrometry plot of FIG. 56 , 57 , 58 , 59 , 60 , or 61 .

15. A method of processing a metal or an alloy of metals, comprising the steps of:

(A.) adding the metal or alloy to a reactor in or more steps and melting said metal or alloy;

(B.) adding a carbon source to the molten metal or alloy and dissolving carbon in said molten metal or alloy, followed by removing the undissolved carbon source;

(C.) increasing the temperature of the molten metal or alloy;

(D.) varying the temperature of the molten metal or alloy between two temperatures over one or more cycles;

(E.) adding a flow of an inert gas through the molten metal or alloy;

(F.) varying the temperature of the molten metal or alloy between two temperatures over one or more cycles;

(G.) adding a carbon source to the molten metal or alloy and dissolving carbon in said molten metal or alloy, followed by removing the undissolved carbon source;

(H.) varying the temperature of the molten metal or alloy between two temperatures over one or more cycles, wherein the molten metal or alloy has a greater degree of saturation with carbon than in Step (F.);

(I.) stopping the flow of the inert gas;

(J.) varying the temperature of the molten metal or alloy between two temperatures over one or more cycles, wherein the molten metal or alloy has a greater degree of saturation with carbon than in Step (H.) and wherein an inert gas is added as the temperature is lowered and an inert gas, chosen independently, is added as the temperature is raised;

(K.) varying the temperature of the molten metal or alloy between two temperatures over one or more cycles, wherein the molten metal or alloy has a greater degree of saturation with carbon than in Step (J.) and wherein an inert gas is added as the temperature is lowered and an inert gas, chosen independently, is added as the temperature is raised;

(L.) stopping the flow of the inert gases;

(M.) varying the temperature of the molten metal or alloy between two temperatures over one or more cycles, wherein the molten metal or alloy has an equal or greater degree of saturation with carbon than in Step (K.); and

(N.) cooling the molten metal or alloy to room temperature, thereby obtaining a solidified manufactured metal or alloy.

16. The method of claim 15 , wherein the metal is a transition metal.

17. The method of claim 16 , wherein the transition metal is chromium, manganese, iron, cobalt, nickel, copper, zinc, or alloys thereof.

18. The method of claim 15 , wherein the metal is an alkali metal or an alkaline earth metal.

19. The method of claim 15 , wherein the metal is silicon.

20. The method of claim 15 , wherein the metal is aluminum.

21. The method of claim 15 , wherein the alloy of metals comprises copper, gold, and silver.

22. The method of claim 15 , wherein the alloy of metals comprises tin, zinc, and lead.

23. The method of claim 15 , wherein the alloy of metals comprises tin, sodium, magnesium, and potassium.

24. The method of claim 15 , wherein the alloy of metals comprises iron, vanadium, chromium, and manganese.

25. The method of claim 15 , wherein the alloy of metals comprises nickel, tantalum, hafnium, and tungsten.

26. The method of claim 15 , wherein the carbon source of Steps (B.) and (G.), independently, is a graphite rod, graphite powder, graphite flakes, diamond, fullerenes, natural gas, methane, ethane, propane, butane, pentane, cast iron, iron comprising carbon, or steel comprising carbon.

27. The method of claim 15 , wherein each cycle of Steps (D.), (F.), (H.), (J.), (K.), and (L.) comprises, in any order, a period of increasing metal or alloy temperature and a period of decreasing metal or alloy temperature and wherein a cycle has a duration of 3 to 67 minutes.

28. The method of claim 27 , wherein each cycle of Steps (D.), (F.), (H.), (J.), (K.), and (L.) comprises, in any order, a period of increasing metal or alloy temperature and a period of decreasing metal or alloy temperature and wherein a cycle has a duration of 8 to 30 minutes.

29. The method of claim 15 , wherein the period of increasing metal or alloy temperature in Steps (D.), (F.), (H.), (J.), (K.), and/or (L.), independently, is different than the period of decreasing metal or alloy temperature.

30. The method of claim 15 , wherein the period of increasing metal or alloy temperature in Steps (D.), (F.), (H.), (J.), (K.), and/or (L.), independently, is equal to the period of decreasing metal or alloy temperature.

31. The method of claim 15 , wherein the inert gas of Steps (E.), (J.), and (K.), independently, is argon, nitrogen, helium, neon, xenon, hydrogen, krypton, and mixtures thereof.

32. The method of claim 15 , wherein the molten metal or alloy of Step (N.) is cooled to room temperature by heat exchange with inert gas over 1 to 72 hours.

33. The method of claim 15 , wherein the molten metal or alloy of Step (N.) is cooled to room temperature by quenching in a bath comprising tap water, distilled water, deionized water, other forms of water, inert gases, liquid nitrogen or other suitable liquified gases, a thermally-stable oil or organic coolant, and combinations thereof.

34. The method of claim 15 , wherein the reactor is an induction furnace.

35. A method of processing a metal or an alloy of metals, comprising the steps of:

(A.) adding the metal or alloy to a reactor in one or more steps and melting said metal or alloy;

(B.) adding a carbon source to the molten metal or alloy and dissolving carbon in said molten metal or alloy, followed by removing the undissolved carbon source;

(C.) varying the temperature of the molten metal or alloy between two temperatures over two or more cycles;

(D.) adding a carbon source to the molten metal or alloy and further dissolving carbon in said molten metal or alloy, followed by removing the undissolved carbon source;

(E.) varying the temperature of the molten metal or alloy between two temperatures over two or more cycles, wherein the molten metal or alloy has a greater degree of saturation with carbon than in Step (D.); and

(F.) cooling the molten metal or alloy to room temperature, thereby obtaining a solidified manufactured metal or alloy;

further characterized by adding a flow of inert gas before, during, or after Steps (B.) through (E.).

36. The method of claim 35 , wherein the metal is a transition metal.

37. The method of claim 36 , wherein the transition metal is chromium, manganese, iron, cobalt, nickel, copper, zinc, or alloys thereof.

38. The method of claim 35 , wherein the metal is an alkali metal or an alkaline earth metal.

39. The method of claim 35 , wherein the metal is silicon.

40. The method of claim 35 , wherein the metal is aluminum.

41. A method of processing copper, comprising the steps of:

(A.) adding copper to a reactor in one or more steps and melting copper;

(B.) adding a carbon source to the molten copper and dissolving carbon in the molten copper, followed by removing the undissolved carbon source;

(C.) increasing the temperature of the copper;

(D.) varying the temperature of the molten copper between two temperatures over 15 cycles;

(E.) adding a flow of an inert gas through the molten copper;

(F.) varying the temperature of the molten copper between two temperatures over 5 cycles;

(G.) adding a carbon source to the molten copper and dissolving carbon in the molten copper, followed by removing the undissolved carbon source;

(H.) varying the temperature of the molten copper between two temperatures over 20 cycles;

(I.) stopping the flow of the inert gas;

(J.) varying the temperature of the molten copper between two temperatures over 4.5 cycles, wherein an inert gas is added as the temperature is lowered and an inert gas, chosen independently, is added as the temperature is raised;

(K.) varying the temperature of the molten copper between two temperatures over 15.5 cycles, wherein an inert gas is added as the temperature is lowered and an inert gas, chosen independently, is added as the temperature is raised;

(L.) stopping the flow of the inert gases;

(M.) varying the temperature of the molten copper between two temperatures over 1 cycle; and

(N.) cooling the molten copper to room temperature, thereby obtaining a solidified manufactured copper.

42. A method of processing copper of claim 1 , comprising:

(1.) contacting molten copper with a carbon source;

(2.) an iterative cycling process, wherein relative saturation of copper with carbon remains the same or increases independently with each cycle; and

(3.) cooling the molten copper to room temperature, thereby obtaining a solidified manufactured copper.

Assignments (7)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 18, 2018
From: ELECTROMAGNETICS CORPORATION
To: CONTINUUM ENERGY TECHNOLOGIES, LLC
Reel/Frame 046894/0847 →
SECURITY INTEREST Recorded May 1, 2018
From: CONTINUUM ENERGY TECHNOLOGIES LLC
To: IRON OAK LLC
Reel/Frame 045679/0818 →
RELEASE OF SECURITY INTEREST Recorded Apr 30, 2018
From: IRON OAK LLC
To: CONTINUUM ENERGY TECHNOLOGIES LLC
Reel/Frame 045666/0873 →
CHANGE OF NAME Recorded Nov 22, 2016
From: ATOMIC ORDERED MATERIALS, LLC
To: CONTINUUM ENERGY TECHNOLOGIES, LLC
Reel/Frame 040673/0815 →
SECURITY INTEREST Recorded Oct 14, 2016
From: CONTINUUM ENERGY TECHNOLOGIES LLC
To: IRON OAK LLC
Reel/Frame 040021/0785 →
CORRECTIVE DOCUMENT REEL 013025 FRAMES 0079-0081 Recorded May 9, 2003
From: NAGEL, CHRISTOPHER J.
To: ELECTROMAGNETICS CORPORATION
Reel/Frame 014046/0355 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 25, 2002
From: NAGEL, CHRISTOPHER J.
To: ATOMIC ORDERED MATERIALS, L.L.C.
Reel/Frame 013025/0079 →
Continuity (3)
Continuation In Part 0941672000 · Oct 13, 1999
Continuation In Part PCTUS002854900 · Oct 13, 2000
Related Publication 20040119053A1 · Jun 24, 2004