Granted Patent
B2
US 12,403,516 · App. 17/035,597 · Granted Sep 2, 2025
Shape processes, feedstock materials, conductive materials and/or assemblies
Inventors:
Glenn J. Grant (Benton City, WA); Keerti S. Kappagantula (Richland, WA); Xiao Li (Richland, WA)
Assignee:
Battelle Memorial Institute
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Abstract
Shear assisted extrusion processes (ShAPE) for forming Metal-NCCF extrusions are provided. The processes can include: using a die tool, applying a rotational shearing force and an axial extrusion force to a feedstock material comprising a metal and NCCF (NanoCrystalline Carbon Films); and extruding a mixture comprising the metal and NCCF through an opening in the die tool to form the Metal-NCCF extrusion. ShAPE feedstock materials are provided that can include a metal and NCCF. Conductive solid material mixtures are provided that can include a metal and a NCCF. Portions of the metals and NCCF of the material mixtures can have an isotropic crystallographic orientation. Assemblies relying in part on conductivity can include: a conductive solid material mixture that includes: a metal; and a NCCF.
Claims (29)
1. A shear-assisted extrusion process for forming Metal-NCCF extrusions, the process comprising:
using a die tool, applying a rotational shearing force and an axial extrusion force at an interface of a scroll face of the die tool and a face of a feedstock material, the scroll face of the die tool oriented in a direction generally perpendicular to the axial extrusion force, and comprising spiral grooves to direct plasticized feedstock material toward openings in the scroll face of the die tool;
wherein the feedstock material comprises a metal and a NCCF (NanoCrystalline Carbon Forms), wherein:
the metal comprises one or more of Cu, Mg, Al, Fe, Ti, and/or Ni; and the NCCF is deposited on the metal; and
wherein the process comprises extruding a mixture comprising the metal and the NCCF through the openings in the die tool to form a Metal-NCCF extrusion comprising a homogeneous distribution of NCCF particles throughout the metal-NCCF extrusion; and
wherein the scroll face of the die comprises a member extending from a center of the scroll face of the die tool.
2. The process of claim 1 wherein the NCCF comprises chemical vapor deposited (CVD) graphene or reduced graphene oxide.
3. The process of claim 2 wherein the NCCF is at least 1 ppb by weight of the feedstock material.
4. The process of claim 1 wherein the applying the rotational shearing force and the axial extrusion force to the feedstock material deforms at least a portion of the feedstock material and mixes the deformed at least a portion of the feedstock material.
5. The process of claim 1 wherein the feedstock defines a billet.
6. The process of claim 5 wherein metal portions with deposited NCCF are located in openings within surrounding metal of the feedstock.
7. The process of claim 5 wherein the feedstock comprises particles, films, discs, nuggets, chips, foils, or powders of the metal upon which the NCCF is deposited.
8. The process of claim 1 wherein the Metal-NCCF extrusion is a conductive solid material mixture comprising the metal and the NCCF.
9. The process of claim 1 wherein the mixture is extruded along a mandrel to form a hollow Metal-NCCF extrusion.
10. The process of claim 9 wherein the openings are configured to convey plasticized feedstock material to the mandrel.
11. The process of claim 1 , wherein the mixture is extruded to form the Metal-NCCF extrusion including establishing a specified crystallographic orientation based on an extrusion process parameter comprising at least one of a specified rotational velocity or a specified axial force.
12. The process of claim 11 , wherein the specified crystallographic orientation comprises an isotropic crystallographic orientation.
13. The process of claim 11 , wherein the shear-assisted extrusion process results in a crystallographic orientation with increased isotropy versus that of the feedstock material.
14. The process of claim 1 , wherein the scroll face comprises a plurality of grooves in a circular formation terminating at respective openings.
15. The process of claim 14 , wherein the plurality of grooves are configured to direct plasticized material from a first location on the interface between the feedstock material and the scroll face, through the openings defined within the scroll face, and to a second location upon a die bearing surface of the die tool.
16. The process of claim 1 , wherein the metal is one of Ni, Cu, Al, or Mg.
17. The process of claim 1 , wherein the NCCF is incorporated into the feedstock material in a cavity of the feedstock material.
18. The process of claim 10 , wherein the cavity of the feedstock material comprises Cu foil.
19. The process of claim 18 , wherein the Cu foil includes a chemical vapor deposited (CVD) graphene monolayer.
20. The process of claim 1 , wherein the NCCF is incorporated into the feedstock material on portions of Cu metal in a cavity of the feedstock material.
21. The process of claim 20 , wherein the portions of Cu metal in the cavity include a chemical vapor deposited (CVD) graphene monolayer.
22. The process of claim 1 , wherein a portion of the feedstock metal does not include a graphene deposit.
23. The process of claim 1 , wherein the feedstock material comprises a copper puck.
24. The process of claim 23 , wherein the feedstock material is surrounded by a feedstock material ring.
Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST
Recorded May 7, 2021
From: GRANT, GLENN J.; KAPPAGANTULA, KEERTI S.; LI, XIAO
To: BATTELLE MEMORIAL INSTITUTE
Reel/Frame 056178/0369 →
CONFIRMATORY LICENSE
Recorded Jan 11, 2021
From: BATTELLE MEMORIAL INSTITUTE, PACIFIC NORTHWEST DIVISION
To: U.S. DEPARTMENT OF ENERGY
Reel/Frame 054872/0605 →
Continuity (10)
Provisional Application
62906911
· Sep 27, 2019
Provisional Application
62460227
· Feb 17, 2017
Provisional Application
62313500
· Mar 25, 2016
Provisional Application
61804560
· Mar 22, 2013
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