Abstract: An improved process for making a structural foamed polymer, a multilayer polymer film, sheet or tube, a pultrusion polymer profile, a compression molded extruded fiber reinforced polymer pre-form, a strand foamed polymer and a SCORIM formed polymer article. The improvement includes the step of dispersing a multi-layered silicate material with the polymer so that the polymer has dispersed therein single layers of silicate material, double layers of silicate material, triple layers of silicate material, four layers of silicate material, five layers of silicate material and more than five layers of silicate material, the volume percent of the one, two, three, four and five layers of silicate material greater than the volume percent of the more then five layers of silicate material. In each of the above embodiments an important benefit of the instant invention is the orientation of the plane of the layers of silicate material.

Abstract: A method for manufacturing a compound construction element, in an extrusion process wherein a composite material is pressed through an extrusion die, which composite material includes a matrix of thermoplastic synthetic material including wood particles or other, cellulose containing particles in a content on the order of 50% by weight or more, wherein also one or more elongated additional elements are passed through the extrusion die, which additional elements are brought into tight engagement with the composite material, after which the compound element is shaped and preferably cooled in a die.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

Abstract: Techniques for generating a stable, force-resisting positive or negative representation of a shape. A state-changeable mixture includes uniform, generally ordered, closely-spaced solid bodies and a liquid carrier medium of relatively similar density, with the liquid medium filling any voids or interstices between the bodies and excluding air or gas bubbles from the mixture. Within the mixture, the solid bodies can be caused to transition from a near-liquid or fluent condition of mobility to a stable, force-resisting condition through introduction and then extraction of a slight excess quantity of the carrier medium. To create mobility, this excess quantity or transition liquid is introduced to create a fluent condition by providing a slight clearance between the bodies which permits the gently-forced introduction of at least two simultaneous slip planes between ordered bulk masses of the bodies at any point in the mixture.

Abstract: Fiber spinning of two polymer compositions wherein one of the compositions contains carbon nanotubes produces structures such as fibers, ribbons, yarns and films of carbon nanotubes. The polymers are removed and stabilization of the carbon nanotube material is achieved by post-spinning processes. The advances disclosed herein enable the carbon nanotube composites to be used in actuators, supercapacitors, friction materials and in devices for electrical energy harvesting.

Abstract: A method of manufacturing to increase the thermal and electrical conductivity of polymers includes layering a filled polymer with an unfilled polymer to produce a multi-layered system of alternating filled and unfilled polymer layers. The filler material comprises thermally and/or electrically conductive material. A preferred polymer is a shape memory polymer. A method of manufacturing magnetic multi-layered polymer systems is described. Articles formed from such multi-layered systems are also disclosed.

Abstract: A system for improving wood strand orientation in a wood strand orienter having a plurality of orienter disks. The system includes a plurality of axially-spaced, parallel pre-orienting shafts positioned in a second plane above and substantially parallel to the orienter disks, each one of the pre-orienting shafts having a plurality of wheels mounted thereon. Each of the wheels has a hub and a plurality of outwardly-extending finger members. When the pre-orienting shafts are positioned over the disks, each one of the finger members passes, in turn, through a portion of the volume defined between the two adjacent orienter disks the wheel sits between. This permits bridged wood strands to be turned and straightened, reducing the “% overs”, the percentage of strands bridging the orienter disks and carried across the top of the orienter without falling through the orienter.

Abstract: A method for fabricating of macroscopic two or three dimensionally ordered arrays of single wall nanotubes (SWNTs) comprising the following steps: chemically treating purified SWNTs using the sol gel process to add chemically reactive groups to either the tube ends or tube bodies in order to functionalize the SWNTs; suspending the functionalized SWNTs in an appropriate liquid medium such that a colloid is produced; treating the colloid with a chemical or heat to promote coupling of the individual functionalized SWNTs to each other; and heating the coupled SWNTs to evaporate any excess liquid so as to provide a final product comprising an array of covalently bound functionalized SWNTs.

Abstract: A method of making a composite article of a graphite-filled polymer mixture that is robust during high shear mixing and compounding, and that exhibits relatively low electrical resistivity after molding. The mixture is formed by shear mixing a liquid polymeric material, graphitized carbon fibers having diameters of less than one micrometer, and glass fibers longer than the carbon fibers. The carbon and glass fibers constitute up to about 25 volume percent and up to about 50 weight percent, respectively, of the mixture, though the addition of as little as about 1 weight percent of the glass fibers has been shown to dramatically reduce resistivity. The mixture is then introduced into a mold so that the glass fibers are substantially oriented parallel to the direction of flow.

Abstract: Magnetizable fibers dispersed in a viscous body, particularly reinforcing metal fibers dispersed in a wet cementitious material, is carried out by providing a fiber aligning member (15) having a nonmagnetic wall (17) including a first wall portion (17A) and a second wall portion (17B), moving the aligning member (15) relative to the viscous body with the first wall portion (17A) leading and the second portion (17B) trailing it and with the first and second wall portions (17A, 17B) contacting the viscous body, and directing a magnetic field into the viscous body through the first wall portion (17A) to subject the fibers (F) to a moving magnetic field.

Abstract: A carbonaceous composite material molded from a carbonaceous composite compound composed mainly of graphite, a thermosetting resin, and a fibrous base material, wherein molding is carried out in such a way that said fibrous base material is oriented in said carbonaceous composite material; a process for producing said carbonaceous composite material; a fuel cell separator having said carbonaceous composite material as a component; and a polymer electrolyte fuel cell. The carbonaceous composite material can be produced by injection molding, transfer molding or extrusion molding without difficulties encountered in the past. It has high strength, with a minimum amount of warpage. It contributes to productivity.

Abstract: Decorative surface material having a decorative pattern in which a combination of domains of varying sizes and colors are defined by shading variations at the interfaces of adjoining domains, the decorative pattern being provided by a process in which a flowable thermosettable molding formulation having orientable particles mixed therein is divided into fragments which are mixed together, the mixture is fed into a hot mold and pressure is applied to form the solid surface material.

Abstract: A method of manufacturing a magnetic rubber ring comprises: providing an unvulcanized rubber containing rubber materials and magnetic powers; using an extruding machine to extrude the unvulcanized rubber into a rubber band having a nearly round cross section; cutting the rubber band into a strip of rubber band of a predetermined length; forming a rubber band ring by joining opposite ends of the strip of rubber band together, wherein the opposite ends of the strip of rubber band have respective meeting slanted faces cut at a predetermined angle such that a joint of the rubber band ring obtained by joining the opposite ends of the strip of rubber band become thinner in a direction of compression when the rubber band ring is compressed in a direction of its center line; and compressing the rubber band ring under applied heating in the direction of the center line.

Abstract: Fine particles (23) are oriented and dispersed in a polymer medium to obtain a composite material (24), which is high-density compression molded to such a size that a photonic band gap develops, thereby obtaining a photonic crystal element (26). The orientation of the fine particles (23) in the polymer medium can be carried out on a scale (tens of micrometers to several millimeters) where required manipulations can be done with ease.

Abstract: An initial process for preparing material to use in manufacturing fiber-reinforced structures. One embodiment envisions a method of manufacturing a cement board. The initial process includes providing an open mat of recycled carpet fibers in a container, placing a mortar mixture directly over the fiber mat, distributing the mortar through the fiber mat by moving a comb having bent tines through the mortar-fiber mixture, and vibrating the mortar-fiber mixture substantially simultaneously with the distribution of mortar through the fiber. Also provided is a method for making the final product.

Abstract: Molding material consisting of resin coated reinforcing fibers in a molten mass of resin and fibers is prepared at a molding site for controlled supply to a molding machine. A conveying device, such as a pair of pinch rollers, serves to pull fibers from supply spools through guide orifices of a coating die having a chamber within which the fiber is coated with molten resin. Further impregnation of the fibers with resin takes place in the conveying device, which also develops pressure on its output side serving to push the mass of hot resin and fiber into a receiving device for movement to a molding machine. The receiving device may be the feed screw for an injection molding machine or simply a plate movable to and from a compression molding machine. The fibers may be cut into predetermined lengths by a cutting device positioned downstream of the aforesaid conveying device.

Abstract: A solution containing randomized nanotubes is introduced into a channelized mold and the solution is dried resulting in a number of parallel nanotubes stretched across the walls of the channel. In one embodiment, the channels are open along their longitudinal axis and that opening is covered with a material, such as silicon. The solution is allowed to dry, preferably at room temperature, and as it recedes from the channel the receding solution tends to stretch certain of the nanotubes across the channel so that they become attached to the opposite walls of the channel. By varying the shapes and width of the channel sides various controlled nanotube lengths can be achieved. The mold, with the constructed nanotubes, can be positioned to mate with another structure for the transfer of the nanotubes to the second structure.

Abstract: A method of forming an interconnection component with integral conductive elastomeric sheet material, comprising providing a connector frame defining an opening, casting uncured elastomeric conductive polymer interface (ECPI) material onto the connector frame spanning the opening, and curing the ECPI in the presence of a magnetic field, to integrally couple the ECPI to the connector frame, and create a series of spaced conductive columns through the ECPI thickness.

Abstract: In a method of manufacturing a friction member used for a vibration wave driving apparatus including a vibration member, a contact member which is brought into frictional contact with the vibration member and relatively moved by vibrations produced in the vibration member, and the friction member formed on one of friction portions of the vibration member and contact member, a molded member is formed by compression molding of a plastic powder and an additive, a sintered member is formed by sintering the molded member, a sheet is formed by cutting the sintered member in the form of a sheet, and a modified layer formed by cutting is removed from the friction surface of the sheet.

Abstract: A film is made of an insulating matrix resin and an electroconductive material, in which the electroconductive material is dispersed in the insulating matrix resin in such a manner that a surface resistivity of A [&OHgr;] of the film and a volume resistivity of B [&OHgr;·cm] of the film in the direction of a thickness thereof normal to the surface of the film satisfy a relationship of: A>B, and when the film has a thickness of T [cm], the electroconductive material is dispersed in the insulating matrix resin in such a manner that the surface resistivity of A [&OHgr;] of the film and the volume resistivity of B [&OHgr;·cm] of the film satisfy a relationship of; A[&OHgr;]'T [cm]>B [&OHgr;·cm]. This film can be prepared by a centrifugal molding method.

Abstract: A shoe outsole (1) is formed of a polymer, e.g. rubber, composition including a short fiber. The amount of the short fiber to be blended is 2 to 40 parts by weight for 100 parts by weight of a base polymer, e.g. rubber. The short fiber has an orientation in an almost horizontal direction. An orientation angle to the horizontal direction of the short fiber is 30 degrees or less. The short fiber may have an orientation in almost horizontal and lateral directions. Moreover, the short fiber may have an orientation in almost horizontal and longitudinal directions. The outsole (1) is excellent in a strength.

Abstract: A modified polymer material is discloses, including a polymer base and boehmite particles provided in the polymer base. the boehmite particles are made up of mainly anisotropically shaped particles.

Abstract: A solar control light transmitting thermoplastic polymer sheet is provided which contains flakes of metal pigment that are aligned coplanar with the upper face of the sheet. The sheet transmits a controlled amount of light while reflecting a significant amount and absorbing the rest. In an alternative, the sheet has a co-extruded second layer of UV-protective thermoplastic polymer formed on top of the first layer.

Abstract: A method of manufacturing a fiber assembly, the method comprising: (a) providing a plurality of layers, each layer comprising sintered fibers of piezoelectric material aligned substantially parallel; (b) laminating the plurality of layers; and (c) applying a matrix material to the laminated layers to affix the layers and form a fiber assembly.

Abstract: A method is provided for manufacturing a holder which has a holding part and a connector part. The holding part has an elastic body holding a built-in electronic part in a position. The method steps include pouring a liquid polymer mixed with a magnetic electric conductor into a mold for forming the holder. A magnetic force is applied to a desired position in the mold to orient the magnetic electric conductor to form a connector pattern of the connector part with the magnetic force. A holding part is molded integrally with the connector part to provide a one piece integral structure by crosslinking the liquid polymer. The magnetic electric conductor may be linked together by a force of a magnetic field. This defines a conductive passage in the connector part.

Abstract: This invention includes a method of producing a thin, oriented layer of polymer material. The material is preferably produced by the method of introducing a shearing flow to a free surface in a predominantly monomeric solution of the self-assembling polymer sub-units, and inducing polymerization or growth of the monomer while in this shearing flow. The system for forming the oriented layer of material provides relative movement between a delivery system and the substrate on or over which the material is deposited. The rate of flow of the material from the delivery system and the relative velocity between the deposition surface and the material as it is delivered to the surface are controlled to properly orient the material at the desired thickness. These rates can be adjusted to vary the properties of the film in a controlled manner. Preferred embodiments include either angular or linear relative movement between the delivery system and the substrate.

Abstract: A multi-layer thermoplastic packaging, the outer layer containing at least one filler having particles of different particle size and of a diameter ≧50 &mgr;m, to give a natural stone external appearance and a process for the preparation thereof which includes coextrusion and blowing of the inner and outer layers, to provide the packaging which can be in the form of a flask, bottle, pot or other desired shape.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

Abstract: A method and apparatus for fabricating toroidal rings having a magnetization that alternates or changes direction along its azimuthal axis. Such a toroidal ring is made by first placing an unmagnetized toroidal ring into a first magnetization fixture. The first magnetization fixture is operable to magnetize only given regions of the toroidal ring, where the magnetization in those regions is in the same radial direction along its azimuthal axis. The toroidal ring is then placed in a second magnetization fixture that is operable to magnetize only the regions of the toroidal ring the were substantially unmagnetized by the first magnetization fixture. The direction of magnetization by the second fixture is opposite that of the first fixture. The result is a toroidal ring having a magnetization that alternates direction along its azimuthal axis.

Abstract: A method for manufacturing bodies containing reinforcing fibers includes mixing fibers, fiber bundles, or fiber agglomerates with at least one binder that can be carbonized to form a molding material; and compressing the molding material to form bodies containing reinforcing fibers with a mold having inserts. The resulting bodies have recesses with lateral edges corresponding to the inserts such that the reinforcing fibers are oriented approximately parallel to the lateral edges of the recesses.

Abstract: Decorative surface material having a decorative pattern in which a combination of domains of varying sizes and colors are defined by shading variations at the interfaces of adjoining domains, the decorative pattern being provided by a process in which a flowable thermosettable molding formulation having orientable particles mixed therein is divided into fragments which are mixed together, the mixture is fed into a hot mold and pressure is applied to form the solid surface material.

Abstract: A method of manufacturing a strip of unvulcanized rubber compound including short fibers oriented towards specific directions is disclosed, and the method comprises: extruding a mixture of unvulcanized rubber and short fibers to form a strip of the mixture and to orient the short fibers towards the extruding direction; and piercing the strip with needles in a thickness direction of the strip to orient the short fibers towards the piercing direction.

Abstract: A reinforced polymer is formed by combining a quantity of nano-fibers, preferably carbon nanotubes, with powders of the polymer. The mixture is heated to cause the polymer to fuse to the fibers, forming a feedstock. The feedstock is heated and forced through a die that has channels that change in direction a number of times. Each change in direction results in a high shear stress applied to the feedstock. The shear stress causes the twisted ropes of carbon nanotubes to elongate and align with each other. Rather than a die, sheet rollers may be employed to apply the shear stress.

Abstract: This patent application describes the use of molecular imprinting as a means for preparation of anti-idiotypic imprint matrices. With this technique, imprints of artificial or natural molecules including their recognition sites, such as of molecularly imprinted polymers or biological receptors, antibodies or enzymes, can be prepared. In the former case, using the original imprints as casts or molds in a subsequent polymerisation step, utilising preferentially functionally complementary monomers, the formation of imprint materials containing recognition sites complementary in shape and functionality with the original imprint can be obtained but being of different composition. Alternatively, imprints or images of the artificial or biological species can be obtained directly. The so formed preparations can be used in a vast variety of applications, e.g. as new drugs, inhibitors or new affinity materials.

Abstract: A film is made of an insulating matrix resin and an electroconductive material, in which the electroconductive material is dispersed in the insulating matrix resin in such a manner that a surface resistivity of A [&OHgr;] of the film and a volume resistivity of B [&OHgr;·cm] of the film in the direction of a thickness thereof normal to the surface of the film satisfy a relationship of: A>B, and when the film has a thickness of T [cm], the electroconductive material is dispersed in the insulating matrix resin in such a manner that the surface resistivity of A [&OHgr;] of the film and the volume resistivity of B [&OHgr;·cm] of the film satisfy a relationship of: A [&OHgr;]×T [cm]>B [&OHgr;·cm]. This film can be prepared by a centrifugal molding method.

Abstract: A polymer heat pipe with a carbon core and a method of forming such a heat pipe is disclosed. The heat pipe includes a substantially pure carbon fiber core and an outer jacket of substantially pure polymer material. The heat pipe is formed by extruding a mixture of a base of polymer material and a plurality of carbon fibers through an extrusion die. The extrusion die is heated into a range of approximately 250-400° F. to cause the carbon fiber to migrate to the center of the extrudate and the polymer to migrate outwardly. As a result, a jacket of polymer material is formed around a core of carbon fibers to form a highly thermally conductive heat pipe.

Abstract: Magnetic, conformable articles for use with traffic bearing surfaces are disclosed which comprise an organic binder having magnetic particles distributed therein. The articles may be employed in intelligent vehicle guidance systems, and in systems to guide other mobile objects such as farm animals, pets, or visually impaired pedestrians. Methods of making the articles and methods of using the systems to control and/or guide a mobile object using the magnetic field generated from the articles are also described.

Abstract: Fine circumferential skin cracking in extruded thin-walled cordierite honeycombs having channel wall thicknesses not exceeding about 0.004 inches (100 &mgr;m) but skin layers of substantially higher thickness is prevented by extruding the honeycombs under conditions that enhance cordierite crystal alignment in the skin; thin-walled honeycomb products having skins free of fine cracks that are well-matched in thermal expansion to the honeycomb cores are provided.

Abstract: A method for producing shaped bodies of particulate material by introducing an easily flowable slurry of water and particulate material into a mold with perforated walls and by applying a sufficiently high pressure to the slurry in the mold so as to express a sufficient proportion of the liquid to allow physical contact and interengagement between the particles. The method may be carried out continuously in an extrusion process including introducing the slurry under high pressure into a extruder and conveying the slurry through a shaping section of the extruder to a draining and consolidation section of the extruder with drain holes and slits whereby a non-flowable, consolidated, shaped body leaves the extruder through an exit section.

Abstract: A method, process and apparatus for generating a stable, force-resisting positive or negative representation of a shape. A state-changeable mixture includes uniform, generally ordered, closely-spaced solid bodies and a liquid carrier medium of relatively similar density, with the liquid medium filling any voids or interstices between the bodies and excluding air or gas bubbles from the mixture. Within the mixture, the solid bodies can be caused to transition from a near-liquid or fluent condition of mobility to a stable, force-resisting condition through introduction and then extraction of a slight excess quantity of the carrier medium. To create mobility, this excess quantity or transition liquid is introduced to create a fluent condition by providing a slight clearance between the bodies which permits the gently-forced introduction of at least two simultaneous slip planes between ordered bulk masses of the bodies at any point in the mixture.

Abstract: A template is placed over a mold cavity, with the template including a series of orifices which extend over substantially the entire surface of the mold cavity. Molten plastic is passed through the orifices in a pattern corresponding to the shape of the article to be molded, and the molten plastic is formed into a molded article having the shape of the mold cavity.

Abstract: The invention relates to a process for the preparation of molecularly imprinted polymers useful for separation of enzymes, which comprises the steps of reacting a complex of enzyme and affinity monomer, a comonomer and a crosslinker, with a polymerization initiator and a polymerization accelerator at ambient temperature and pressure for a period ranging between 2 to 24 hrs, thereby obtaining a crosslinked polymer, crushing the cross linked polymer obtained to fine particles, adding a solvent and extracting imprinted enzyme from the polymer, obtaining the molecularly imprinted polymer, contacting the imprinted polymer with aqueous solution containing imprinted enzyme or a mixture of imprinted enzyme and other enzymes and isolating the enzyme-adsorbed polymer.

Abstract: A technique for fabricating an improved electronic enclosure. The electronic enclosure is made of graphite fibers dispersed directionally (non-homogeneous) in an absolac/polycarbonate (ABS/PC) resin mix, which the composition is molded to form the plastic enclosure. The graphite concentration is highest along the interior surface of the enclosure to provide improved heat transfer, as well as adequate EMI/RFI shielding. However, the graphite concentration decrease along the thickness, wherein at the outer surface, the graphite concentration level is zero. The directional variation in the graphite loading allows high graphite loading at the interior surface of the enclosure, but retains lower loading at other regions along the thickness so that rigidity and impact resistance are retained for the enclosure.

Abstract: Superconductor containing filaments having embedments of superconducting material surrounded by a rayon matrix are formed by preparing a liquid suspension which contains at least 10 weight percent superconducting material; forming a multicomponent filament having a core of the suspension and a viscose sheath which contains cellulose xanthate; and thereafter, regenerating cellulose from the cellulose xanthate to form a rayon matrix.

Abstract: A process for centrifugal slip casting a textured hollow tube. A slip made up of a carrier fluid and a suspended powder is introduced into a porous mold which is rotated at a speed sufficient to create a centrifugal force that forces the slip radially outward toward the inner surface of the mold. The suspended powder, which is formed of particles having large dimensional aspect ratios such as particles of superconductive BSCCO, settles in a textured fashion radially outward toward the mold surface. The carrier fluid of the slip passes by capillary action radially outward around the settled particles and into the absorbent mold. A layer of mold release material is preferably centrifugally slip cast to cover the mold inner surface prior to the introduction of the BSCCO slip, and the mold release layer facilitates removal of the BSCCO greenbody from the mold without fracturing.

Abstract: A master tool for a reception station on a press for shaping sheets of paper or cardboard, comprising a moving slide and a number of bars (1) adapted to form a grid for non-stop reception of blanks and a bottom separating tool comprising two boards (4, 5) adjustable on two transverse beams (9, 10) of the moving slide, the beams having top edges having the same profile, the profile of the top edge comprising a number of serrated recesses in shape matching the cross-section of the bars (1), the serrated recesses being adjusted to correspond to the transverse positions of the openings in the bottom blank-separating tool.

Abstract: Fine particles (23) are oriented and dispersed in a polymer medium to obtain a composite material (24), which is high-density compression molded to such a size that a photonic band gap develops, thereby obtaining a photonic crystal element (26). The orientation of the fine particles (23) in the polymer medium can be carried out on a scale (tens of micrometers to several millimeters) where required manipulations can be done with ease.

Abstract: A support element for a wiper strip belonging to a wiper blade for motor vehicle windows is proposed, which assures proper contact of a wiper strip, belonging to the wiper blade, with the window to be wiped. The support element is embodied as elongated in bandlike fashion, and it comprises an elastic plastic. The rubber-elastic wiper strip, elongated in bandlike fashion, can be secured to the support element longitudinally axially parallel. An especially durably operationally reliable support element is obtained if the support element is made from a fiber-reinforced thermoplastic plastic, and the fibers are admixed with the plastic.

Abstract: The present application is directed to a new class of composite materials, called field-structured composite (FSC) materials, which comprise a oriented aggregate structure made of magnetic particles suspended in a nonmagnetic medium, and to a new class of processes for their manufacture. FSC materials have much potential for application, including use in chemical, optical, environmental, and mechanical sensors.

Abstract: The present invention is directed to a method for making a molded roofing unit formed of a fiber-reinforced plastic composition. In a preferred embodiment, the method comprises forming a camber in the roofing unit. The method of the present invention provides consistent results in the molding process, low material and production costs, and produces a roofing product with high rigidity and strength, impact resistance, stability in high wind conditions, and which is easy to install.