Abstract: A polymeric coating material is provided for coating powdered materials, and more particularly, for coating powdered metals which are compression molded to form magnetic cores. The preferred polymeric materials are polybenzimidazole, an aromatic polyamide such as polyphthalamide, and appropriate polyimides which, when properly applied to metal particles to form a magnetic core, are characterized as having a sufficiently high heat deflection temperature of at least about 270.degree. C., so as to prevent the degradation of the mechanical and magnetic properties of the magnetic core at exposure at elevated temperatures. Each of these preferred coating materials is characterized by excellent mechanical properties, chemical resistance and dielectric characteristics within this temperature range.

Abstract: A method of making a bipolar battery comprising a plurality of framed, bipolar electrodes stacked together and embedded in a housing molded in situ thereabout. The housing will preferably comprise a polymeric foam.

Abstract: A process for pneumatically isostatically compacting a sintered compact to densify the compact wherein the surface of the compact is oxidized to form a gas impervious oxide barrier on said surface before the compact is subjected to the pneumatic isostatic compaction process. Oxidation of the compact surface is preferably accomplished by steaming the compact before or after sintering.

Abstract: A pressure casting system including a core having self-cleaning core prints. The core prints are spaced from the bottom wall of the pockets with which they mate, and include channels for admitting molten metal into the print-pocket space so provided.

Abstract: A cylinder liner for an internal combustion engine is held onto a detachable mandrel portion of a die by a plurality of split-ring-type compression springs. A sliplock on the ends of the split-ring spring limits the extent to which the spring can open or close.

Abstract: A flash-proof RIM mold and method of making same. The mold has a thermosetting resin squeezed and cured between the mold portions at the edge of the parting line exposed to the mold cavity. The resin fills any gaps between the mold portions resulting from mismatched surfaces. The resin adheres to one mold portion and is readily spaceable from the other. A strip of uncured resin is applied to one of the mold portions, the mold closed at its operating temperature, and the resin allowed to cure to a semi-cured state. The mold is opened and any resin exuding into the mold cavity removed. After the resin has fully cured the mold is ready for use.

Abstract: A bipolar battery comprising a plurality of framed, bipolar electrodes stacked together and embedded in a housing molded in situ thereabout. The housing will preferably comprise a polymeric foam.

Abstract: A "lost foam" method of making a casting having a preform embedded at a selective location therein including the steps of: engulfing a porous preform in a fugitive pattern; embedding the pattern in a loose sand mold in a vessel; pouring molten metal into the mold cavity via a sprue and runner system formed in the sand bed so as to destroy the pattern and fill the mold cavity with metal; pressurizing the vessel to force molten metal from the cavity into the porous preform; replacing metal lost from the cavity with make-up metal from the sprue and runner system; allowing the casting to solidify; and removing the casting from the sand bed.

Abstract: A preform for impregnation of a metal or ceramic matrix material comprising a multiplicity of reinforcement particles bonded together so as to define a three-dimensional, open-cell reticulum comprising a plurality of randomly oriented thread-like portions interconnected one to the next via a plurality of nodes. A reinforced composite made from such preform and method of making the preform is disclosed/claimed wherein the reinforcement particles are mixed with prepolymers used to produce a fugitive binder for the particles comprising a foamed polymer, and the particles align themselves with the polymer portions of the resulting foam.

Abstract: The invention provides an electrode for a lead-acid battery, formed in an essentially continuous process without the need for curing under controlled temperature and humidity conditions. This is accomplished by using a relatively high metallic lead content precursor powder intermingled with a leady-oxide powder. Another aspect of the invention is the use of relatively high surface area leady-oxide powder which contributes to performance. Another important aspect of the invention is that the active material paste is prepared without the use of an acid in a water based process which provides a simpler pasting chemistry. The process eliminates the complex basic lead sulfate reactions found in present methods.

Abstract: A valve-regulated, deep-cycling, gas-recombinant, high energy, lead-acid battery operating at superambient temperatures and internal pressures wherein the sidewalls of the battery container (i.e., intersected by the intercell partitions) are abnormally thin and reinforced against bulging by ribs which project from the container and extend in a direction transverse the intercell partitions. The ribs will preferably have a sinuous shape for optimal strength and heat transfer from the battery.

Abstract: Method and apparatus for quickly, and substantially uniformly, heating and cooling a bed of polymeric fibers having high melting point and low melting point fibers therein for softening the low melting point fibers and bonding them to the high melting point fibers to form a seat cushion. Hot and cool gases are flowed through the bed of fibers to effect the heating/cooling.

Abstract: Method of distributing and retaining insoluble additive particles uniformly throughout a mass of moldable metal particles. The additive particles are suspended in a solution of a polymeric binder and spray-coated onto the metal particles. When the solvent evaporates, the additives remain glued to the metal particles by the binder.

Abstract: An electrical connector for a battery terminal having a known minimum diameter, comprising an electric contact of electrically conductive material having a substantially U-shaped cross-section defined by a base portion and a pair of resilient legs extending away from the base portion, the free end of each leg being bent inwardly to form an arm which is directed back towards the base portion, the pair of arms being resilient, spaced apart to define a longitudinally extending slot therebetween, and converging such that the slot has a predetermined inner width which is less than a predetermined outer width, the predetermined outer width of the slot being greater than the minimum diameter of the battery terminal, and the predetermined inner width of the slot being less than the minimum diameter of the battery terminal; and a housing of electrically insulating material which surrounds the electric contact and which has an opening adjacent the slot through which the battery terminal can pass.

Abstract: Apparatus for molding expanded polymer beads by the steam-fusion technique including mold segments having perforate walls, steam chests confronting the mold segments, and thermal insulation located at the junction between the mold segments and the steam chests to reduce conductive heat transfer therebetween.

Abstract: Non destructive adhesion testing of coatings to substrates. A supersonic jet of water is impinged against the coating. The impingement intensity of the jet is set at a predetermined "failure intensity" determined by testing of a sample having a minimum acceptable level of adhesion. Parts passing through the supersonic jet unscratched pass the test. Parts whose coatings debond when impacted by the jet fail the test.

Abstract: A solid material is bonded to a metal cast thereagainst by means of a metallurgical diffusion bond. The solid material is coated with a latent exoergic coating which coating reacts exothermically to produce intermetallic phases at the surface of the solid when the metal is cast thereagainst. The heat generated by the intermetallic-phase-formation reaction promotes the diffusion bond.

Abstract: Method of making a cast-to-size mold for molding class A finishes on molded plastic articles including the steps of filling any pores in the molding surface with a conductive thermosetting resin and thereafter electroplating the surface.

Abstract: A metallized epoxy die formed by depositing boron nitride and iron oxide particle layers on the pattern used to form the die and spraying molten metal onto the particle layers followed by casting the epoxy against the exposed surface of the sprayed metal.

Abstract: A gas-shielded siphonic valve for controlling the flow of molten metal from one vessel to another. The valve includes a hollow conduit extending between the vessels above the surfaces of the metal therein with opposite ends thereof immersed in the metal in both vessels. An exhaust port permits evacuation of the inside of the conduit sufficiently to draw enough metal up into the conduit to effect a siphoning action between the vessels. A housing surrounding the conduit defining a chamber about the conduit for holding an inert gas. Any leaks in the system will neither break the siphoning action nor contaminate the metal. Varying the amount of vacuum applied to the system can be used to control the rate of flow of metal therethrough.