Abstract: A porous membrane is provided by biaxially stretching a film of high density polyethylene (HDPE), including particles of an incompatible material. This film has a meshed network of HDPE fibers and striations of layers coplanar with the plane of the film. This film is porous in a direction perpendicular to the plane of the film and has a void content of at least 20%. The porous membrane may have one or more nonporous backing layers. The membrane may be used as filter or battery separator.

Abstract: The invention relates to foam composites having improved properties. These polymeric foams are prepared by polymerization of certain water-in-oil emulsions having a relatively high ratio of water phase to oil phase, commonly known in the art as high internal phase emulsions, or “HIPEs.” The HIPE-derived foam materials used in the present invention comprise a generally hydrophobic, flexible, semi-flexible, or rigid nonionic polymeric foam structure of interconnected open-cells. These foam structures have a density of less than about 100 mg/cc, a glass transition temperature (Tg) of between about −40° and 90° C., and at least about 1% by weight compatible fibers incorporated into the foam. The foam composites have improved tensile properties compared to foams having no incorporated fibers or foams having noncompatible fibers incorporated therein.

Abstract: A friction material for brake including reinforcing fibers, a friction modifier, a lubricant, and a binder, characterized by containing, as a part of the component of the friction modifier, 2 to 5 wt % zeolite, 0.8 to 2 wt % antimony oxide and 0.2 to 1 wt % fluorine based polymer.

Abstract: A process for manufacturing wet-felted and thermally bonded porous structures is provided to produce formed porous media for use in filters with improved filtration performance. The process includes the steps of forming a slurry with a primary media consisting of natural or synthetic fibers, a wet strength agent consisting of fibrillated fibers, and a binding agent; vacuum forming the slurry to produce a formed media; drying the formed media using a gas at a temperature below the melting temperature of the binding agent; bonding the formed media using a gas at a temperature above the melting temperature of the binding agent; and cooling the formed media using a gas at ambient temperature. The process produces a formed porous media with improved bonding which results in improved filtration performance.

Abstract: A microporous membrane is described comprising at least two layers, wherein each layer is characterized by nodes interconnected by fibrils, the layers are bonded by means of plastic flow at temperatures below the melting point of either membrane material, and the pore architecture is formed in situ by an expansion process. A stratified microporous membrane is produced wherein the pore architecture of each layer may be discretely controlled. The article is useful for filtration and medical applications where a pore size gradient is required.

Abstract: A low to near-zero metal matrix composite material featuring high modulus carbon fibers reinforcing a lightweight metal or semimetal. The fibers have a negative coefficient of thermal expansion in the axial direction. Laminates featuring parallel arrays of fibers may be cross-plied to produce quasi-isotropic properties in the composite body. The CTE of the composite body depends not only upon the relative CTE's of the fibers and matrix, and their relative amounts (e.g., loadings), but also upon the relative elastic moduli of the fibers and matrix. By intentionally introducing porosity into the matrix, the elastic modulus of the matrix is reduced, and thus the CTE of the composite body is influenced more by the CTE contribution of the fibers. In effect, the composite CTE is shifted toward that of the fibers, which shifting represents a reduction in composite CTE. Hydrogen outgassing upon solidification of the metallic matrix is one technique for producing such porosity.

Abstract: A fuel cell comprising at least one composite membrane which includes a porous support impregnated with ion exchange resin to make the pores of the support occlusive, wherein the thickness of the composite membrane is less than 0.025 mm. The membrane is strong and has good ionic conductivity. Methods of making the composite membrane are also disclosed.

Abstract: A method of producing a polytetrafluoroethylene (PTFE) material including the steps of extruding a first material to form a first extrudate, and extruding a second PTFE material to form a second extrudate, wherein the first PTFE material is more expandable than the second PTFE material. A stack is formed from at least one layer of the first extrudate and at least one layer of the second extrudate, and the stack is expanded and sintered to form the article.

Abstract: A novel polytetrafluoroethylene (PTFE) material includes a plurality of aggregates connected together by a plurality of relatively long fibrils. Each of the aggregates are formed of PTFE nodes that are connected together by relatively short fibrils. Preferably, the long fibrils have lengths of 500 to 1000 microns and the short fibrils have a lengths of 10 to 30 microns. The aggregates have densities of less than 2.0 grams per cubic centimeter which is lower than the densities of the solid PTFE nodes which have densities of about 2.0 to 2.2 grams per cubic centimeter.

Abstract: An apparatus and method for metabolic cooling and insulation of a user in a cold environment. In its preferred embodiment the apparatus is a highly flexible composite material having a flexible matrix containing a phase change thermal storage material. The apparatus can be made to heat or cool the body or to act as a thermal buffer to protect the wearer from changing environmental conditions. The apparatus may also include an external thermal insulation layer and/or an internal thermal control layer to regulate the rate of heat exchange between the composite and the skin of the wearer.

Abstract: A three dimensional porous elastomeric polymeric material is described that has a morphology primarily of polymeric fibers fused randomly along portions of their length, with a cross-section of a network of irregular polymeric areas that are interconnected to define interconnected voids; where the bulk density of the material is at least 0.35 grams/cc. The material is useful in garment and other protective covering applications where it can be adhered to various substrates to provide improved abrasion resistance. Composites of the material are described also.

Abstract: The invention relates to a wood wool construction element and a method for its manufacture.

Abstract: A composite membrane is provided which includes a base material and an ion exchange resin. The base material has a microstructure characterized by nodes interconnected by fibrils, or a microstructure characterized by fibrils with no nodes present. The ion exchange resin substantially impregnates the membrane such that the membrane is essentially air impermeable.