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1. 发明授权

US11498128B2 Manufacturing apparatus comprising collocated reduction apparatus, processor and additive-manufacturing apparatus 有权
公开(公告)号：US11498128B2
公开(公告)日：2022-11-15
申请号：US16302419
申请日：2017-05-24
申请人： METALYSIS LIMITED
发明人： Dion Vaughan , Melchiorre Conti
IPC分类号： B33Y10/00 , B33Y30/00 , B33Y40/00 , B33Y70/00 , B23K26/342 , B23K26/00 , C23C4/18 , C25C7/00 , C25C7/08 , C25C7/06 , B22F10/20 , B22F1/065 , B22F9/20 , B33Y50/02 , C23C4/123 , B22D23/00 , B22F3/115 , C22B34/12 , C25C3/28 , C25C5/04 , B22F1/052 , B23K103/14 , C22C1/04 , B22F10/30
摘要： A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.

2. 发明授权

US10066309B2 Method and apparatus for electrochemical reduction of a solid feedstock 有权
公开(公告)号：US10066309B2
公开(公告)日：2018-09-04
申请号：US13983123
申请日：2012-02-02
申请人： Allen Richard Wright
发明人： Allen Richard Wright
IPC分类号： C25C7/00
摘要： The method, apparatus and product relate to the electrochemical reduction of a solid feedstock (20) to produce a product. A container (2) is filled with a fused salt (6), and one or more anodes (14) contact the fused salt. A cathode (18) is loaded with feedstock and engages with a transport apparatus (22, 36, 40) which locates and moves the cathode past the anodes(s), while the cathode and the feedstock contact the fused salt. As the cathode moves past the anodes(s), a voltage applied between the cathode and the anode(s) electrochemically reduces the solid feedstock to form the product.

3. 发明申请

US20120230860A1 PURIFICATION PROCESS 审中-公开
标题翻译：净化过程
公开(公告)号：US20120230860A1
公开(公告)日：2012-09-13
申请号：US13477368
申请日：2012-05-22
申请人： Charles M. WARD-CLOSE , Alastair B. Godfrey , Paul S. Goodwin
发明人： Charles M. WARD-CLOSE , Alastair B. Godfrey , Paul S. Goodwin
IPC分类号： B22F1/00 , B22F9/30 , B22F9/16
CPC分类号： C22B34/1295 , C22B9/14 , C22B34/129
摘要： A method for purifying metal M1 particles manufactured by an electrochemical reduction process, the method comprising the steps of introducing the metal M1 particles into a heat source (13) at a temperature substantially equal to or higher than the melting point of M1 so as to cause vaporisation of some or substantially all of the contaminating impurities present, removing the vaporised impurities from the vicinity of the particles, and cooling the purified metal M1 particles. The purified particles can be used directly in lower temperature powder metallurgy processes and have a fully dense spherical particle morphology, imparting good flowability. The purification process can also be incorporated as an integral stage of sheet or stock production processes based on particle feedstocks that have been produced by electrochemical reduction.
摘要翻译：一种净化通过电化学还原法制造的金属M1颗粒的方法，所述方法包括以大致等于或高于M1的熔点的温度将金属M1颗粒引入热源（13）的步骤，从而导致蒸发一些或基本上所有的污染杂质，从颗粒附近除去蒸发的杂质，并冷却纯化的金属M1颗粒。纯化的颗粒可以直接用于低温粉末冶金工艺中，并具有完全致密的球形颗粒形态，赋予良好的流动性。净化过程也可以作为基于通过电化学还原生产的颗粒原料的片材或原料生产方法的整体阶段。

4. 发明申请

US20110158843A1 Electrolytic reduction of metal oxides such as titanium dioxide and process applications 审中-公开
标题翻译：金属氧化物如二氧化钛的电解还原和工艺应用
公开(公告)号：US20110158843A1
公开(公告)日：2011-06-30
申请号：US12929993
申请日：2011-03-01
申请人： Charles M. Ward-Close , Alastair B. Godfrey
发明人： Charles M. Ward-Close , Alastair B. Godfrey
IPC分类号： C22C14/00 , C25C3/28 , C25B9/00
CPC分类号： C25C5/04 , B22F9/20 , B22F2999/00 , C22B4/06 , C22B5/00 , C22B5/02 , C22B34/1263 , C22B34/129 , C22C47/04 , C22C47/14 , C25C3/00 , C25C3/28
摘要： A method of removing oxygen from a solid metal, metal compound or semi-metal M1O by electrolysis in a fused salt of M2Y or a mixture of salts, which comprises conducting electrolysis under conditions such that reaction of oxygen rather than M2 deposition occurs at an electrode surface and that oxygen dissolves in the electrolyte M2Y and wherein, M1O is in the form of (sintered) granules or is in the form of a powder which is continuously fed into the fused salt. Also disclosed is a method of producing a metal foam comprising the steps of fabricating a foam-like metal oxide perform, removing oxygen from said foam structured metal oxide preform by electrolysis in a fused salt of M2Y or a mixture of salts, which comprises conducting electrolysis under conditions such that reaction of oxygen rather than M2 deposition occurs at an electrode surface. The method is advantageously applied for the production of titanium from Ti-dioxide.
摘要翻译：在M2Y的熔融盐或盐的混合盐中通过电解从固体金属，金属化合物或半金属M1O中除去氧的方法，其包括在氧气反应而不是M2沉积发生在电极的条件下进行电解表面，并且氧气溶解在电解质M2Y中，并且其中M1O为（烧结）颗粒的形式，或呈粉末形式，其连续地供入熔融盐。还公开了一种制造金属泡沫的方法，其包括以下步骤：制造泡沫状金属氧化物，通过在M2Y的熔融盐或盐的混合盐中电解，从所述泡沫结构的金属氧化物预型体中除去氧，其包括进行电解在使电极表面发生氧而不是M2沉积的反应的条件下进行。该方法有利地用于从二氧化钛制备钛。

5. 发明授权

US10590553B2 Method of producing metallic tantalum 有权
公开(公告)号：US10590553B2
公开(公告)日：2020-03-17
申请号：US15321489
申请日：2015-06-25
申请人： METALYSIS LIMITED
发明人： Ian Mellor , Greg Doughty
IPC分类号： C25C3/26 , C22B34/24 , H01G9/00 , H01G9/008 , H01G9/042 , H01G9/04 , H01G9/052 , H01G9/045
摘要： A method of producing metallic tantalum comprises the steps of providing a precursor comprising a tantalate of a first metal, arranging the precursor material in contact with a molten salt in an electrolytic cell, the electrolysis cell further comprising an anode and a cathode arranged in contact with the molten salt, and applying a potential between the anode and the cathode such that the precursor material is reduced to tantalum. The first metal is an alkali metal or an alkaline earth metal. The anode does not comprise a carbon material, which prevents contamination of the tantalum and improves current efficiency of the process.

6. 发明授权

US10066307B2 Electrolytic method, apparatus and product 有权
公开(公告)号：US10066307B2
公开(公告)日：2018-09-04
申请号：US14401462
申请日：2013-05-10
申请人： METALYSIS LIMITED
发明人： Allen Richard Wright , Stephen Holloway
IPC分类号： C25C3/00 , C25C3/02 , C25C3/04 , C25C3/06 , C25C3/26 , C25C3/28 , C25C3/30 , C25C3/32 , C25C3/34
摘要： In a method for removing a substance from a feedstock comprising a solid metal or a solid metal compound, the feedstock is contacted with a fused-salt melt. The fused-salt melt contains a fused salt, a reactive-metal compound, and a reactive metal. The fused salt comprises an anion species which is different from the substance, the reactive-metal compound comprises the reactive metal and the substance, and the reactive metal is capable of reaction to remove at least some of the substance from the feedstock. A cathode and an anode contact the melt, and the feedstock contacts the cathode. An electrical current is applied between the cathode and the anode such that at least a portion of the substance is removed from the feedstock. During the application of the current, a quantity of the reactive metal in the melt is maintained sufficient to prevent oxidation of the anion species of the fused salt at the anode. The method may advantageously be usable for removing the substance from successive batches of the feedstock, where the applied current is controlled such that the fused-salt melt after processing a batch contains the quantity of the reactive metal sufficient to prevent oxidation of the anion species at the anode.

7. 发明授权

US08747644B2 Apparatus and method for reduction of a solid feedstock 有权
标题翻译：用于还原固体原料的装置和方法
公开(公告)号：US08747644B2
公开(公告)日：2014-06-10
申请号：US13320079
申请日：2010-05-12
申请人： Peter G. Dudley , Allen Richard Wright
发明人： Peter G. Dudley , Allen Richard Wright
IPC分类号： C25C3/00 , C25C3/08 , C25C7/08
CPC分类号： C25C7/005 , C22B4/08 , C22B5/02 , C22B34/129 , C25C3/00 , C25C3/28 , C25C7/00
摘要： In a method for reducing a solid feedstock (110), such as a solid metal compound, feedstock is arranged on upper surfaces of elements (60, 80, 81) in a bipolar cell stack contained within a housing (25). A molten salt electrolyte is circulated through the housing so that it contacts the elements of the bipolar stack and the feedstock. A potential is applied to terminal electrodes (50, 60) of the bipolar stack such that the upper surfaces of the elements become cathodic and the lower surfaces of the elements become anodic. The applied potential is sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
摘要翻译：在用于还原固体原料（例如固体金属化合物）的方法中，原料被布置在包含在壳体（25）内的双极电池堆中的元件（60,80,81）的上表面上。熔融盐电解液循环通过壳体，使其与双极堆叠元件和原料接触。将电位施加到双极堆叠的端子电极（50,60），使得元件的上表面变为阴极并且元件的下表面变得阳极。施加的电位足以引起原料的还原。本发明还提供了一种用于实现该方法的装置。

8. 发明申请

US20120138475A1 APPARATUS AND METHOD FOR REDUCTION OF A SOLID FEEDSTOCK 有权
标题翻译：用于减少固体饲料的装置和方法
公开(公告)号：US20120138475A1
公开(公告)日：2012-06-07
申请号：US13320076
申请日：2010-05-12
申请人： Peter G. Dudley , Allen Richard Wright
发明人： Peter G. Dudley , Allen Richard Wright
IPC分类号： C25C7/00 , C25C3/00
CPC分类号： C25C7/005 , C22B4/08 , C22B5/02 , C22B34/129 , C25C3/00 , C25C3/28 , C25C7/00
摘要： In a method for reduction of a solid feedstock, such as a solid metal compound, in an electrolytic apparatus a portion of the feedstock is arranged in each of two or more electrolytic cells (50, 60, 70, 80). A molten salt is provided as an electrolyte in each cell. The molten salt is circulated from a molten salt reservoir (10) such that salt flows through each of the cells. Feedstock is reduced in each cell by applying a potential across electrodes in each cell, the potential being sufficient to cause reduction of the feedstock. The invention also provides an apparatus for implementing the method.
摘要翻译：在固体原料如固体金属化合物的还原方法中，在电解装置中，将一部分原料配置在两个以上的电解槽（50,60,70,80）中。在每个电池中提供作为电解质的熔融盐。熔融盐从熔盐储存器（10）循环使得盐流过每个单元。在每个电池中通过在每个电池中的电极上施加电势来减少原料，其潜力足以引起原料的还原。本发明还提供了一种用于实现该方法的装置。

9. 发明授权

US07758740B2 Electrochemical reduction of metal oxides 有权
标题翻译：电化学还原金属氧化物
公开(公告)号：US07758740B2
公开(公告)日：2010-07-20
申请号：US10561597
申请日：2004-06-21
申请人： Andrew Arthur Shook , Gregory David Rigby , Ivan Ratchev
发明人： Andrew Arthur Shook , Gregory David Rigby , Ivan Ratchev
IPC分类号： C25C3/00 , C25C7/00 , C25C7/02
CPC分类号： C25C7/007 , C22B1/2406 , C22B5/02 , C22B34/129 , C25C3/28 , C25C5/04 , C25C7/025
摘要： An electrolytic cell for electrochemically reducing metal oxide powders and/or pellets is disclosed. The cell includes a cathode (25) in the form of a plate that has an upper surface for supporting metal oxide powders and/or pellets. The plate is horizontally disposed or slightly inclined and has a forward end and a rearward end and is immersed in an electrolyte bath. The plate is supported for movement so as to cause metal oxide powders and/or pellets on the upper surface of the plate to move toward a forward end of the plate. The cell also includes a means for causing metal oxide powders and/or pellets to move over the upper surface of the plate toward the forward end of the cathode while in contact with molten electrolyte whereby electrochemical reduction of the metal oxide to metal can occur. A method of continuously or semi-continuously reducing metal oxide powders and/or pellets in the cell is also disclosed.
摘要翻译：公开了用于电化学还原金属氧化物粉末和/或丸粒的电解池。电池包括板形式的阴极（25），其具有用于支撑金属氧化物粉末和/或颗粒的上表面。该板水平放置或稍微倾斜，并具有前端和后端，并浸入电解液浴中。支撑板移动，以使板的上表面上的金属氧化物粉末和/或颗粒向板的前端移动。电池还包括使金属氧化物粉末和/或丸粒在与熔融电解液接触的同时朝向阴极的前端移动到板的上表面上的装置，由此可以发生金属氧化物到金属的电化学还原。还公开了在电池中连续或半连续还原金属氧化物粉末和/或丸粒的方法。

10. 发明授权

US11072862B2 Methods of making graphene materials 有权
公开(公告)号：US11072862B2
公开(公告)日：2021-07-27
申请号：US16103088
申请日：2018-08-14
申请人： Metalysis Limited
发明人： Ian Mellor , Greg Doughty
IPC分类号： C25B1/135 , C25B1/00 , C01B32/184 , C25C3/28 , C25B11/043 , C25C3/26 , C01B32/196 , C25C1/06 , C25C7/02 , C25B11/02
摘要： A method of making a graphene-containing material comprising the steps of: electrolytically reducing a transition metal oxide to a transition metal in an electrolytic cell using a molten salt electrolyte and a carbon anode; followed by extracting a dry graphene material from the electrolytic cell. Also provided is a graphene-containing material obtainable by the method of the invention.

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