Abstract: A simple, inexpensive, drillable, reduced CTE laminate and circuitized structures comprising the reduced CTE laminate, is provided. The reduced CTE laminate comprises: from about 40% to 75%, preferably from about 55% to 65%, by weight resin; from about 0.05% to 0.3%, preferably from about 0.08% to 0.10%, by weight curing agent; from about 25% to 60%, preferably from about 30% to 40%, by weight, woven cloth; from about 1% to 15%, preferably from about 5% to 10%, by volume, non-woven quartz mat. The present invention also generally relates to a method for reducing the CTE of circuitized structures, and to methods for making reduced CTE laminate and circuitized structures comprising reduced CTE laminate.

Abstract: The present invention provides non-heat cleaned glass fiber fabrics comprising resin compatible coatings that offer higher tensile strengths than corresponding fabrics that have been heat cleaned and silane finished. These fabrics can be used in a wide variety of applications, such as reinforcements for composites such as printed circuit boards.

Abstract: In a wiring board, predetermined wiring patterns which are formed on both sides of an insulation substrate are electrically connected by an electrically conductive material provided in through holes formed through the insulation substrate. The insulation substrate is composed of a resin impregnated fibrous sheet and a heat resistant film. The present invention solves the problems of the wiring board which are caused by irregularities on the surface of the resin impregnated fibrous sheet. The problems include insufficient adhesion strength between the wiring pattern and the insulation substrate or the limitation of fineness of the wiring pattern due to the irregularities on the surface of the printed wiring board which are formed upon the thermocompression bonding process.

Abstract: A nonwoven fabric of chemically bonded non-cellulose fibers having improved wet tensile properties. The fabric includes a random arrangement of non-cellulose fibers and an essentially formaldehyde free latex binder. The latex binder contains at least about 6.7 wt. % vinyl cyanide monomer to bond the non-cellulose fibers and form a nonwoven fabric having at least a 10% improvement in wet tensile strength over a comparable nonwoven fabric having a latex binder essentially free of formaldehyde and free of vinyl cyanide monomer in the monomeric mixture.

Abstract: An insulation blanket is disclosed that contains fire-blocking materials for preventing rapid penetration of fire into an aircraft fuselage in case of a fire outside the aircraft. The insulation blanket contains at least one layer of fiberglass or other thermal-acoustic insulation material without fire-blocking properties, and one or more layers of fire-blocking material. The fire blocking material is wider than the thermal-acoustic insulation so that it may be folded against and attached to adjacent structural frame members of the fuselage. In the alternative, a thermal-acoustic insulation material is used that has fire-blocking properties instead of the separate layers of fire-blocking and thermal-acoustic insulation materials. A method for installing insulation blankets according to the present invention is disclosed, whereby a fire-blocking insulation portion of the blanket is folded against and attached to frame members of the aircraft using attachment posts or spring clips.

Abstract: A joint and method for forming a joint between two spaced apart materials having dissimilar coefficients of thermal expansion wherein the space is filled with a blended composite of twisted fibrils of the two materials, preferably quartz and carbon, and an adhesive, preferably an epoxy based adhesive.

Abstract: The invention relates to a composite comprising a thermoplastic resin and a glass fabric that can be used in the form of a linear extrudate as a structural member or as a repair unit. The resin glass fiber composite structural member can be manufactured in an extrusion process. The linear extrudate can have a cross-section of any arbitrary shape or can be a regular geometric shape. The profile is made by first preforming the glass fabric into a useful shape, combining the preform fabric with melt resin and extruding the resin and glass fiber in a useful shape. When contacted with melt resin, the glass fiber becomes intimately contacted with and substantially coated with the melt resin.

Abstract: Intumescent laminate with high heat transfer resistance composed of a glass-fiber web or glass-fiber fabric each of which has been coated with a four-component intumescent composition comprising a) a phosphate compound, b) a melamine compound, c) a polyol and d) an inorganic framework-forming compound.

Abstract: This invention concerns lasable bond-ply materials comprising a nonwoven reinforcing material and at least one resin material. The present invention also includes methods for using the bond-ply of this invention to manufacture high density multilayer printed wiring boards.

Abstract: An elastic ground plane (50) has an environmental coating (58) attached to a surface of a fabric (54) having a plurality of fibers. A conductive substance (56) is applied to the fabric (54) to coat the fabric (54).

Abstract: The present invention provides a flame-retardant or nonflammable decorative sheet which is a one-piece laminate of the following materials: one layer or two or more layers of a sheet material for a core layer, obtained by impregnating a base sheet material made of an inorganic fiber, with a composition comprising a phenolic resin and/or a melamine resin and aluminum hydroxide and/or magnesium hydroxide, the proportions of the former and the latter in the composition being 4-15% by weight and 96-85% by weight, respectively, and a sheet material for a decorative layer, placed on at least one side of the sheet material for the core layer. When the sheet material for the core layer consists of two or more layers, there can be interposed, between the layers of the sheet material for the core layer, a sheet material for a reinforcing layer obtained by impregnating a base sheet material made of an inorganic fiber, with a thermosetting resin.

Abstract: Electronic equipment provided with a shell element (2), said shell element (2) being a structural part of an outer casing of the electronic equipment. The shell element (2) comprises a fibre weave reinforced thermoplastics laminate comprising a fibre weave with continuous fibres impregnated with a transparent thermoplastics material so that the shell element (2) has a true three-dimensional appearance.

Abstract: An expansion joint patch apparatus for repairing failed or torn expansion joint belting having a substantially flat, woven substrate material, and a cured solution of suspended elastomer, coating the substrate material. The substrate material is selected from the group consisting of aramid, fiberglass, corrosion resistant alloy wire, polyester, ceramic and kevlar fabrics. The elastomer material is selected from the group consisting of chloroprene, chlorosulfonated polyethylene, ethylene propylene, chloronated isobutylene isoprene, fluoroelastomers and silicone rubbers. The invention further includes a method for forming a fluoroelastomer patch for repairing fabric expansion joints.

Abstract: A single membrane insulation material including a nonwoven insulation mat, a fluoropolymer dispersion surface coated to one side of the mat and a fluoropolymer film component laminated to the thus coated side of the mat under conditions of elevated temperature and pressure. The coating has a depth of penetration which is less than the total thickness of said mat.

Abstract: An electrical substrate material is presented comprising a resin matrix which includes a thermosetting polybutadiene or polyisoprene resin, an ethylene propylene rubber, and optionally a thermoplastic unsaturated butadiene- or isoprene-containing polymer; a particulate filler, a flame retardant additive, a curing agent, and a woven or unwoven fabric. The presence of the ethylene propylene rubber enhances the heat age properties of the substrate material, particularly the dielectric strength and the mechanical properties, while other electrical, chemical, and mechanical properties of the material are not adversely effected.

Abstract: Novel boron-free glass compositions are described which are particularly suited for making fine diameter glass fibers for HEPA electronic clean-room filtration media using flame-attenuation or rotary glass processing.

Abstract: An insulation material for a rocket motor is described, which is composed of a glass fabric, a resin binder, and a fire retardant. The resin binder preferably is composed of a phenolic resin and a Buna-N rubber, and the fire retardant is preferably alumina trihydrate. A method of manufacturing the insulation material is also described.

Abstract: A reinforcing grid which advantageously includes fibers of both a first type and a second type is provided. The first type of fibers have a strength sufficient to reinforce the hardenable structural material, such as concrete, after hardening. The first type of fibers also have a higher resistance to degradation in the hardenable material than the second type of fibers. As such, the first type of fibers will continue to reinforce the hardened material in the event the fibers of the second type become corroded in the hardened material. Consequently, a less expensive type of fiber can be used as the second type of fiber and can corrode in the hardenable material without concern for the strength of the hardened structural product. According to one embodiment, the first type of fibers comprises carbon fibers and the second type of fibers comprises glass fibers.

Abstract: One may obtain an excellent protective coating for a fabric made of heat-resistant fibers, in particular a fabric made of glass fibers like those used for the manufacture of filters in the metallurgical industry, when use is made, as a starting material, of a composition comprising an organic part made of sugar and a mineral part comprising colloidal silica and wollastonite. This composition allows thermoforming of the fabric and gives to the same a very strong protection and a rigidity. This is particularly interesting when the fabric is used for making a filter like those used during the casting of a liquid metal, especially liquid aluminum.

Abstract: This invention concerns lasable bond-ply materials comprising a nonwoven reinforcing material and at least one resin material. The present invention also includes methods for using the bond-ply of this invention to manufacture high density multilayer printed wiring boards.

Abstract: A matrix for use in a method of photocatalytically decomposing organic compounds in a fluid includes a fiber glass mat substrate carrying a photocatalytic material. The fiber glass mat is made of randomly oriented glass fibers that have been substantially filamentized and needled whereby the filaments are interlocked. Adhesion of the photocatalytic material to the substrate is provided without requiring heat cleaning of the fiber glass by controlling the organic content of the fiber glass mat to be less than 1.0 percent by weight as measured by loss on ignition. This is achieved by using sizing compositions that preferably have little or no film forming polymer content.

Abstract: An electrical circuit board fluoropolymer substrate and method of manufacture thereof, comprising a fluoropolymer matrix that includes a mixture of a granular first fluoropolymer resin and a dispersion second fluoropolymer resin. Preferably, the first and second fluoropolymer is polytetrafluoroethylene (PTFE). This mixture is suitable for forming unfilled or filled casting compositions to form thick films, or for dip-coating glass webs.

Abstract: A fabric material and method of its manufacture suitable for use in electronic packages including chip carriers. High insulation resistance is exhibited when subjected to high temperatures and humidity stress conditions.

Abstract: An injection molded fiber-impregnated thermoplastic composite material comprising a plastic polymer matrix wherein the fibers are sufficiently interwoven and entangled in said polymer matrix to provide improved resistance to mechanical loading, and wherein said composite material is particularly suited for the preparation of an injection molded toe cap for a protective shoe.

Abstract: Glass fiber non-woven fabric for base material of laminate comprising binder binding glass fibers to each other and having glass transition temperature of higher than 120.degree. C.

Abstract: In one embodiment, this invention relates to a bitumen-based built-up roofing system comprising a structural deck covered with a membrane comprising;(A) at least two plied layers of reinforcement, the bottom layer being attached to said structural deck,(B) a separately applied bitumen-based waterproofing adhesive between each layer wherein each ply is firmly adhered to the bitumen-based adhesive applied between the plies,(C) a bitumen based flood coat over the plied layers, and(D) a protective layer of inert mineral aggregate material embedded in the flood coat, wherein the bitumen in at least the flood coat comprises a coal tar composition prepared from a blend comprising:(1) from about 80 parts to about 98 parts by weight of coal tar having an overall float test of from about 50 seconds to about 220 seconds,(2) from about 2 parts to about 20 parts by weight of coal tar pitch having a softening point of from about 140 to about 160.degree. C.

Abstract: A laminated board comprising an intermediate layer and two surface layers formed thereon, in which board the intermediate layer comprises a central layer made of a nonwoven glass fiber fabric impregnated with a resin composition containing a thermosetting resin and an inorganic filler and upper and lower layers formed on the central layer, each being made of said resin composition containing a thermosetting resin and an inorganic filler, and the two surface layers formed on the intermediate layer are made of a thermosetting resin-impregnated fiber substrate; and a process for production of the laminated board.

Abstract: The present invention is embodied in ceramic matrix composites with porous interfacial coatings and the methods and processes for fabricating such coatings integral with the ceramic matrix composites. Each ceramic matrix composite of the present invention includes a fibrous substrate or fabric material with a porous interfacial coating. The coating, prior to processing, is comprised of a coating solution made of a carbon precursor and a ceramic precursor resin dissolved directly within a solvent or solvents. Fabrication is achieved by first desizing the fibrous substrate, second immersing the desized fibrous substrate in the mixed coating solution, third evaporating the solvent and curing the precursor and resin via a low temperature cure, and fourth pyrolyzing the coating via a high temperature pyrolysis, preferably in an inert atmosphere. Next, the coated fibrous substrate is combined with a ceramic matrix composite (CMC).

Abstract: A thermally-conductive, electrically insulative interface for conductively cooling a heat-generating source, such as an electronic component, having an associated thermal dissipation member such as a heat sink. The interface is provided as a cured sheet of a curable material formulated as a blend of a curable silicone binder, and a particulate alumina, i.e., aluminum oxide (Al.sub.2 O.sub.3), filler. The interface is observed to exhibit a thermal conductivity of at least about 0.8 W/m-K and a wet dielectric breakdown strength of at least about 475 Vac/mil.

Abstract: A fiber glass mat especially useful for bonding to foam contains glass fibers and a "B" staged acrylic resin having a glass transition temperature above 45 degrees C., the method of making the mat, a precursor for a foam laminate, a method for making a foam laminate, and the product produced by the latter method are disclosed. The mat conforms well to any curvature on the foam layer and stiffens the foam layer resulting in a superior foam laminate for making automotive parts like headliners.

Abstract: A non-porous sheet for bonding to honeycomb-type core structures to be machined on a vacuum chuck includes a woven fiberglass fabric impregnated with a nonporous epoxy-thermoplastic resin having a low melting temperature. The epoxy-thermoplastic resin comprises a blend of bisphenol-A based epoxy and phenoxy thermoplastic. The nonporous sheet is exposed to a relatively low temperature for about five minutes to soften the epoxy-thermoplastic resin. A core structure is placed on the softened sheet and the sheet is allowed to cool to ambient temperature to adhere the non-porous sheet to the core. The core and sheet assembly can then be placed on the surface of a vacuum chuck associated with a machine tool for a subsequent machining operation of the core structure. When the machining operation is finished, the nonporous sheet is easily removed from the core structure by heating the core and sheet assembly slightly above ambient temperature and then peeling off the sheet from the core for reuse.

Abstract: A method for manufacturing a cured resin impregnated substrate comprising placing a substrate into a impregnation zone including a solvent containing curable resin to produce a resin impregnated substrate and at least partially curing the resin impregnated substrate to produce a cured resin impregnated substrate, wherein the number of voids in the cured resin impregnated substrate are reduced by processing the substrate in at least one processing step that reduces the number of voids in the cured resin impregnated substrate product.

Abstract: An aqueous binder composition containing a urea-formaldehyde resin modified with a water-soluble styrene-maleic anhydride copolymer is used in the preparation of fiber mats.

Abstract: An electrical substrate material is presented comprising a thermosetting matrix of polybutadiene or polyisoprene in an amount of about 15 to about 50 volume %; a fabric reinforcement in an amount of 0 to about 40 volume %; a particulate filler, preferably ceramic, in an amount of from 0 to about 60 volume %; microballoons in an amount from 0 to about 60 volume %; and optionally a flame retardant. A peroxide cure initiator and/or crosslinking agent may optionally be added. The presence of a very high surface area particulate filler, preferably fumed silica, is also preferred, in that its presence results in a prepreg which has very little tackiness and can therefore be easily handled by operators. This low tackiness feature allows for the use of conventional automated layup processing, including foil cladding, using one or more known roll laminators.

Abstract: A glass fiber mat for a stampable sheet includes long fibers and short fibers which will not separate even during forming and which are distributed uniformly to make the features of the respective fibers effective. A production system includes a double belt press type laminator which stacks the glass fiber mat, a thermoplastic resin melt and a film which is taken up and applies heat and pressure for impregnation, and cools while maintaining a pressure condition. A supply supplies the glass fiber mat into the laminator. A pair of pressure shearing rollers are arranged between the supply and an endless belt of the laminator for partially cutting the glass fibers into short fibers. The rollers are made of steel to apply line pressure to the glass fiber mat to shear the continuous fibers to uniformly distribute the short fibers in long fibers.

Abstract: An electrical substrate material is presented comprising a thermosetting matrix which includes a polybutadiene or polyisoprene resin, an unsaturated butadiene- or isoprene-containing polymer and an ethylene propylene rubber; a particulate filler and, a fabric. Preferred ethylene propylene rubbers are ethylene propylene copolymers and ethylene propylene diene terpolymer rubbers wherein the diene is dicyclopentadiene. The ethylene propylene rubber is present in an amount of up to about 20 wt % with respect to the resin, preferably in an amount of about 1 to about 7 wt %, more preferably about 5 wt %. The presence of the ethylene propylene rubber enhances the dielectric strength of the resulting electrical substrate material, while other electrical, chemical, and mechanical properties of the material are not adversely effected.

Abstract: A method of making a fibrous, nonwoven electrically conductive mat particularly suited for use in making a glass fiber reinforced product is disclosed. The mat contains a majority of glass fibers with a majority of the glass fibers having a conductive material like an aluminum coating on at least a part of the surface of the glass fibers. The fibers are bonded together with a stretchable resin binder when the mat is to be used to mold a part having a complex curved surface, and a conventional binder when the mat is intended for flat or simple curved parts. The mats of the invention have a surface resistivity of less than about one million ohms/Sq. and usually less than 500 ohms/Sq. and are particularly useful in the manufacture of satellite antenna dishes.

Abstract: Thermoformable multi-layer sheet products are manufactured by pressure laminating one or more molten polymeric films and superposed layers of glass cloth material such that the molten polymer impregnates the glass cloth layers.

Abstract: The subject of the invention is a process for manufacturing a glass strand mat, in which a binder is deposited continuously on a wad of glass strands. The strands are distributed on a moving conveyor, and then the wad is subjected to an oven treatment and possibly to calendering. The process consists of depositing on the wad of strands a liquid binder whose viscosity during deposition is less than approximately 40 millipascal seconds, the binder being formed by an aqueous solution of polyvinyl alcohol(s).

Abstract: A method and apparatus for aligning discontinuous fibers (F 101, 212) is described. A feeder apparatus (20, 120, 220, 220A) is used to align the fibers in a horizontal plane for feeding to the aligning apparatus (40, 140, 240, 240A) providing an electrical (E) field to orient the fibers in one preselected direction. A support or conveyor (70, 170, 270) receives the aligned fibers. The method and apparatus provides composite products having improved physical properties because of the alignment. The fibers can be of different lengths and a mixture of different types to make composites with controlled microstructure and properties. The composite materials can be in the form of non-woven, discontinuous fiber reinforced thermoplastic stampable sheets with controlled fiber orientation distribution. The composites are useful for a variety of goods.

Abstract: A fiber glass mat especially useful for bonding to foam contains glass fibers and a "B" staged acrylic resin having a glass transition temperature above 45 degrees C., the method of making the mat, a precursor for a foam laminate, a method for making a foam laminate, and the product produced by the latter method are disclosed. The mat conforms well to any curvature on the foam layer and stiffens the foam layer resulting in a superior foam laminate for making automotive parts like headliners.

Abstract: An electrical substrate material is presented comprising a thermosetting matrix of polybutadiene or polyisoprene and a co-curable second resin distinct from the first resin. A peroxide cure initiator and/or crosslinking agent may optionally be added. The presence of a very high surface area particulate filler, preferably fumed silica, is also preferred, in that its presence results in a prepreg which has very little tackiness and can therefore be easily handled by operators. This low tackiness feature allows for the use of conventional automated layup processing, including foil cladding, using one or more known roll laminators. While the prepreg of this invention is tack-free enough to be handled relatively easily by hand, it is also tacky enough to be tacked to itself using a roll laminator (e.g., nip roller) at room temperature.

Abstract: There are described a self-adhesive prepreg on the basis of a resin-impregnated fibrous supporting material carrying on at least one surface a layer with an increased ratio of resin to supporting material, and the use thereof for the production of sandwich structures.

Abstract: A structural mat matrix comprises (a) a substrate which consists essentially of from 80% to 99% by weight fiberglass fibers and from 20% to 1% by weight wood pulp and (b) a binder which consists essentially of from 80% to 95% by weight urea formaldehyde and from 20% to 5% by weight acrylic copolymer. The binder bonds the substrate fiberglass fibers and wood pulp together and comprises from 5% to 15% by weight of said matrix, preferably 10% by weight of the matrix.

Abstract: An environmental cover (50) for a reinforced elastomer panel (70) has a knit fabric (82) covered with an electrically conductive material. An environmental calendared sheet (84) is attached to a first surface of the knit fabric (82) and an elastomer calendared sheet (80) is applied to a second surface of the knit fabric (82).

Abstract: A flexible mat is provided having a nonwoven fabric having first and second major surfaces; and a coating of metal oxide on only a portion of at least one of the major surfaces.

Abstract: The invention relates to a composite comprising a thermoplastic resin and a glass fabric that can be used in the form of a linear extrudate as a structural member or as a repair unit. The resin glass fiber composite structural member can be manufactured in an extrusion process. The linear extrudate can have a cross-section of any arbitrary shape or can be a regular geometric shape. The profile is made by first preforming the glass fabric into a useful shape, combining the preform fabric with melt resin and extruding the resin and glass fiber in a useful shape. When contacted with melt resin, the glass fiber becomes intimately contacted with and substantially coated with the melt resin.

Abstract: This invention relates to an electrically conductive shaped article made from thermoplastic materials which are reinforced with glass and steel fibers wherein said fibers are incorporated into the thermoplastic material by pultrusion. The amount of glass fibers incorporated into the thermoplastic material is such that the specific conductivity is at least 10% greater than in a shaped article in which the glass fibers are replaced by thermoplastic material. The shaped article can be used for shielding an article from electromagnetic radiation.

Abstract: A woven fabric to be used in formation of a composite material includes multifilament warp and weft threads. Each of the warp threads and the weft threads have a total weight less than 80% of the weight of the fabric. The woven warp and weft threads have O twist/m and a torsion no greater than an original torsion of the threads before weaving. Each woven warp and weft thread has a width over the entire length thereof that is greater than or equal to an original width before weaving. The fabric is woven to have a given weight per unit area and a fiber volume ratio that is approximately constant throughout the fabric and that is satisfactory for use of the fabric in a composite material. The warp and weft threads of a yarn count that is greater than a yarn count traditionally used to achieve the fiber volume ratio for the given weight per unit area.

Abstract: Semifinished material consisting of symmetrically-needled glass-fiber mat impregnated with a thermoplastic polymer. The glass mat can be made by, for instance, needling continuous filament web from above and below at the same time with a double needling machine.