Abstract: A screw and method for processing metal, metallic alloys, and metal matrix composites in a plastic injection molding machine is disclosed. The screw includes shank with a screw shaft extending from the shank. The screw shaft includes a rear portion proximate to the shank, a middle portion proximate the rear portion, and a front portion proximate the middle portion. Flights extend from the rear portion of the screw shaft for advancing material through the plastic injection molding machine into the middle portion of the screw shaft. Flights may optionally be included in the front portion of the screw.

Abstract: An injection moldable, thermally conductive polymer composition that has ultra low CTE properties is provided. The composition is suitable both for substrate applications in high precision electronics assemblies as well as over molding applications in conjunction with ceramic substrates. The composition includes a base polymer matrix material loaded with thermally conductive filler, which imparts thermal conductivity to the polymer matrix while also maintaining or enhancing the dielectric properties of the base polymer. The resultant composition exhibits CTE properties in the range of between 9 ppm/° C. and 2 ppm/° C., exhibits an optical anisotropy of below 1.5, and a thermal conductivity of greater than 2 W/m° K. The composition is suitable for use in over molding applications in conjunction with virtually any suitable electronics substrate material without the introduction of mechanical stresses produced by large CTE differentials.

Abstract: An injection moldable, thermally conductive polymer composition that has ultra low CTE properties is provided. The composition is suitable both for substrate applications in high precision electronics assemblies as well as over molding applications in conjunction with ceramic substrates. The composition includes a base polymer matrix material loaded with thermally conductive filler, which imparts thermal conductivity to the polymer matrix while also maintaining or enhancing the dielectric properties of the base polymer. The resultant composition exhibits CTE properties in the range of between 9 ppm/° C. and 2 ppm/° C., exhibits an optical anisotropy of below 1.5, and a thermal conductivity of greater than 2W/m° K. The composition is suitable for use in over molding applications in conjunction with virtually any suitable electronics substrate material without the introduction of mechanical stresses produced by large CTE differentials.

Abstract: A method of processing metal, metallic alloys, and metal matrix composites in a plastics injection molding machine is disclosed. The method includes the steps of providing a plastics injection molding machine having a screw. A step of removing the screw is included in the method. A step of replacing the screw with a modified screw configured and arranged for processing metals is also included. Alternatively, a step of removing the flights from the middle portion of the original screw shaft may be included.

Abstract: An injection moldable, thermally conductive polymer composition that has ultra low CTE properties is provided. The composition is suitable both for substrate applications in high precision electronics assemblies as well as over molding applications in conjunction with ceramic substrates. The composition includes a base polymer matrix material loaded with thermally conductive filler, which imparts thermal conductivity to the polymer matrix while also maintaining or enhancing the dielectric properties of the base polymer. The resultant composition exhibits CTE properties in the range of between 9 ppm/° C. and 2 ppm/° C., exhibits an optical anisotropy of below 1.5, and a thermal conductivity of greater than 2 W/m° K. The composition is suitable for use in over molding applications in conjunction with virtually any suitable electronics substrate material without the introduction of mechanical stresses produced by large CTE differentials.

Abstract: A method is provided for forming a feedstock material for use in net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The feedstock includes a carefully matched mixture of polymer resin and a metallic alloy that is suitable for use in a molding method that includes melting and injecting the material into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof.

Abstract: A method of processing metal, metallic alloys, and metal matrix composites in a plastics injection molding machine is disclosed. The method includes the steps of providing a plastics injection molding machine having a screw. A step of removing the screw is included in the method. A step of replacing the screw with a modified screw configured and arranged for processing metals is also included. Alternatively, a step of removing the flights from the middle portion of the original screw shaft may be included.

Abstract: A thermally conductive polymer composition having enhanced mechanical properties is provided. The polymer composition consists of a base polymer matrix loaded with fillers that results in a thermal conductivity that is greater than 1.5 W/m° K and a tensile modulus within an acceptable range making the composition suitable for structural plastic applications, such as between 1,700 to 12,000 Mpa and more preferably between approximately 2,700 to 10,000 Mpa and even more preferably in the range of between approximately 4,000 to 9,000 Mpa. In addition to a tensile modulus within the identified range the composition also includes an elongation to break value that is at least above 1.0% and more preferably in the range of about 1.2% to 10%.

Abstract: The present invention provides a novel method whereby a thermally conductive belt is manufactured through net shape molding. Specifically the method of the present invention is for manufacturing a power transfer belt that is of a highly thermally conductive polymer composition, in contrast to the typical rubber material used to fabricate the belts of the prior art. The new and unique belt of the present invention is manufactured of a thermally conductive polymer material that is easily injection moldable into any desired shape and configuration. Further, the polymer composition is very thermally conductive, which assists in dissipating heat that is generated by the friction created during normal operation of the device. The new belt material and its construction allow heat to be conducted directly through the surface of the belt thus preventing heat buildup within the belt itself, thereby preserving and extending its life.

Abstract: A polymer composition having high thermal conductivity and dielectric strength is provided. The polymer composition comprises a base polymer matrix and a thermally-conductive, electrically-insulating material. A reinforcing material such as glass can be added to the composition. The polymer composition can be molded into packaging assemblies for electronic devices such as capacitors, transistors, and resistors.

Abstract: A screw and method for processing metal, metallic alloys, and metal matrix composites in a plastic injection molding machine is disclosed. The screw includes shank with a screw shaft extending from the shank. The screw shaft includes a rear portion proximate to the shank, a middle portion proximate the rear portion, and a front portion proximate the middle portion. Flights extend from the rear portion of the screw shaft for advancing material through the plastic injection molding machine into the middle portion of the screw shaft. Flights may optionally be included in the front portion of the screw.

Abstract: A method is provided for forming a net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The method includes injecting a carefully matched mixture of a molten polymer resin and a molten metallic alloy into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof. Further, the present invention provides for the compounding of a feedstock suitable for use in conjunction with the method described above.

Abstract: A net-shape molded heat sink is provided which includes a thermally conductive main body and a number of thermally conductive fins integrally connected to and emanating from the main body. The heat sink is formed by overmolding a carbon-carbon matrix core plate with a thermally conductive polymer composition that is filled with thermally conductive filler material. The molded heat sink is freely connecting through the part which makes it more efficient and has an optimal thermal configuration.

Abstract: A method is provided for forming a feedstock material for use in net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The feedstock includes a carefully matched mixture of polymer resin and a metallic alloy that is suitable for use in a molding method that includes melting and injecting the material into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof.

Abstract: A thermally-conductive polymer composition suitable for making molded reflector articles having light-reflecting surfaces is provided. The composition comprises: a) about 20% to about 80% by weight of a base polymer matrix such as polycarbonate; and b) about 20% to about 80% by weight of a thermally-conductive carbon material such as graphite. The composition can be used to make reflector articles such as housings for automotive tail lamps, head lamps, and other lighting fixtures. A method for manufacturing reflector articles is also provided.

Abstract: A thermally conductive grout for geothermal heat pump systems is disclosed. Preferably, the grout includes graphite and/or natural graphite as a thermally conductive additive in a cementitious base to achieve a composition having a thermal conductivity greater than 4 W/mK.

Abstract: A method of making a net-shape molded article for use with food processing and food contact is disclosed. The article is made from a molten resin including a polypropylene base matrix loaded with a thermally conductive filler such that the molten resin has a thermal conductivity between about 1.0 W/mK and about 20 W/mK when fully set. The molten resin is formed into an article, such as a food tray, using injection molding techniques. Preferably, the thermally conductive material includes hexagonal boron nitride and natural graphite.

Abstract: A composition and method for die-level packaging of microelectronics is disclosed. The composition includes about 20% to about 80% of a thermoplastic base matrix; about 20% to about 70% of a non-metallic, thermally conductive material such that the composition has a coefficient of thermal expansion of less than 20 ppm/C and a thermal conductivity of greater than 1.0 W/mK. Using injection molding techniques, the composition can be molten and then injected into a die containing the microelectronics to encapsulate the microelectronics therein.

Abstract: A method of molding reinforced polymer compositions using a molding machine with a tapered bore is provided. The method has particular application in molding polymer that is reinforced with particles having an aspect ratio that is greater than 1:1. The plunger machine used in the method includes a barrel housing with a smooth walled barrel with longitudinal fins projecting inwardly towards the center of the bore that defines a main melt chamber. A plunger housing, having a plunger bore, defines an initial melt chamber and is in communication with the main melt chamber. A plunger resides in the plunger bore and is reciprocatable therein. The barrel bore is continuously inwardly tapered and cooperates with the longitudinal fins to provide a shortened melt period and a smooth transition and alignment of reinforcing members within the polymer mixture during the melt process.

Abstract: A method for making a stator assembly having a thermally-conductive, plastic housing for a high speed motor is provided. A thermally-conductive, high-density polymer composition is used to make the housing, and the stator is uniformly encapsulated therein. The polymer composition comprises a base polymer matrix such as polyphenylene sulfide, and a thermally-conductive, high-density filler material such as zinc oxide.