Abstract: The method of preparing cold mill work rolls for forming a surface finish on a metal substrate includes the steps of placing a work roll on a grinder, truing the work roll, roughening the work roll, and performing at least one finishing pass on the work roll. The method may further include the step of sanding the work roll. The finished work roll may be inserted into a cold mill and the metal substrate cold rolled with the work rolls to achieve the desired surface finish.

Abstract: A method for cost-effectively producing thermoelectric elements and thermoelectric modules with a multitude of thermoelectric couples is disclosed. This method makes the fabrication of very small size thermoelectric elements and miniaturized, compact, powerful thermoelectric modules possible. Methods of the present invention can be also used to fabricate integrated thermoelectric modules in electrical or other devices. The invented method is based on an additive technology using thermoelectric pastes and a patternable insulator layer. Layers of conductive traces are first fabricated on the two insulating planes. A patternable insulator layer is formed and filled with P- and N-type thermoelectric pastes. The thermoelectric elements are formed during the curing or sintering of the thermoelectric pastes. Sizes and positions of the thermoelectric elements are defined by the patterned insulator layer.

Abstract: Methods for the production of insulated, conductive through-features in conductive core materials for electronics packaging are disclosed. Invention methods employ protective mask technology in order to facilitate the selective removal of material from planar conductive core material that has been encapsulated in electrically insulated materials. By filling the cavity in the conductive core material with an electrically insulated material, the through-feature is electrically isolated from the remainder of the core material. In this manner, a conductive through-feature that completely transverses the core of the substrate board is created. Also provided are planar substrates for multilayer printed circuit boards, or chip carriers, comprising the conductive through-features produced by invention methods.

Abstract: A method of fabricating individual, embedded capacitors in multilayer printed circuit boards is disclosed. The method is compatible with standard printed circuit board fabrication. The capacitor fabrication is based on a sequential build-up technology employing a first patternable insulator. After patterning of the insulator, pattern grooves are filled with a high dielectric constant material, typically a polymer/ceramic composite. Capacitance values are defined by the pattern size, thickness and dielectric constant of the composite. Capacitor electrodes and other electrical circuitry can be created either by etching laminated copper, by metal evaporation or by depositing conductive ink.

Abstract: In accordance with the present invention, there are provided novel metal-containing compositions useful for the preparation of electrical resistance devices (e.g., resistors and thermistor elements). Compositions according to the invention comprise at least one low melting point metal material, and optionally a higher melting point metal material, with the further presence of a binder system also being optional. Compositions according to the invention exhibit a wide range of resistivity and a wide range of values for temperature coefficient of resistance (TCR). Compositions with low values for TCR are useful for resistor applications while compositions with large values for TCR are useful for thermistor applications. Resistor or thermistor elements can be produced by applying compositions according to the invention onto suitable substrates and subsequently alloying (i.e., curing and/or sintering) the compositions.

Abstract: An ultrasonic inspection apparatus and method tests elongated, cylindrical aluminum billets. The apparatus includes a frame supporting a movable carriage having at least one ultrasonic detector assembly mounted thereon. Each ultrasonic detector assembly includes a bracket detachably mounted to the carriage, at least one holder movably coupled to the bracket, a spring-biasing mechanism to bias the holder from the bracket, a transducer shoe attached to the holder and a transducer attached to the shoe. The shoe is configured to conform to the outer surface of the billet and to be flooded with fluid to assist in testing.

Abstract: In accordance with the present invention, there are provided novel vertically interconnected assemblies and compositions useful therefore. Invention assemblies comprise substrate boards with multiple layer electronic assemblies. The multiple layers comprise individual layers of circuitry separated and adhered by dielectric materials selectively coated and/or filled with a transient liquid phase sintered (TLPS) material. The TLPS is formulated to be electrically conductive, and thereby serves to convey current between the layers of circuitry. In addition, the TLPS is easily workable so that it is amenable to automated, stepwise construction of multilayer circuitry without the need for labor intensive drilling and filling of conductive vias.

Abstract: In accordance with the present invention, it has been discovered that conductive traces made from transient liquid phase sintering (TLPS) pastes, plated by electroless or electrolytic means, result in improved solderability, adhesion and conductivity of the circuitry. Transient liquid phase sintering pastes employed in the practice of the present invention differ from conventional metal loaded polymer thick film (PTF) inks in that they contain, in addition to a binder, they also contain both a relatively high melting metal powder and a relatively low melting solder powder capable of forming a continuous intermetallic/metallic phase after sintering. The present invention is particularly useful, for example, for the fabrication of single and multi-layer printed circuit boards, providing horizontal and vertical conductive interconnects, metallized through-holes, and conductive pads for electronic component attachment.

Abstract: A method and apparatus for the removal of total cyanide from aqueous solution. The method includes the steps of placing the aqueous solution into a reaction tank, adding lime, ferrous sulfate, and acid to the solution in the reaction tank and agitating the resultant mixture for a reaction time of about one hour. The agitated mixture is transferred from the reaction tank to a clarifier tank and polyelectrolyte solution is added to induce iron-cyanide complex precipitate coagulation. The apparatus includes a reaction tank to hold the aqueous solution and a lime slurry tank, ferrous sulfate tank and acid tank in flow communication with the reaction tank. A pH control assembly controls the flow of acid from the acid tank into the reaction tank and a reaction tank agitation assembly extends into the interior of the reaction tank. The clarifier feed conduit extends between the reaction tank and a clarifier tank.

Abstract: An inventive method for electrical and thermal electronic component attachment is disclosed. The combination of transient liquid phase sintering (TLPS) and a permanent adhesive flux binder provides the advantages of both conventional soldering technology and conductive adhesives. This hybrid approach delivers electrical and thermal conduction through sintered metal joints and mechanical properties based on a tailorable polymer matrix. These transient liquid phase sintering conductive adhesives can utilize conventional dispensing, placement, and processing equipment. During the reflow process, metal powders in the composition undergo interparticle sintering as well as alloying to the contact pads. This process produces a strong mechanical, thermal, and electrical interconnect which ensures good conductivity that is also resistant to humidity and temperature cycling.

Abstract: A method and apparatus are disclosed for cleaning filter elements, such as filter bags in a plurality of baghouses and for predicting the useful life of such filter elements in individual baghouses. The volumetric flow rate of air from each baghouse is continually calculated using actual impact and static pressure measurements and compared with a flow rate set point. The set point is continually adjusted for density correction based on the actual air stream temperature. The bags are pulsed for cleaning when the flow rate is less than the adjusted set point. Pulsing is then halted when the flow rate reaches or exceeds the adjusted set point. Total daily cleaning times are accumulated over time and graphically displayed to indicate when a critical level is reached indicating that filter bag change out is needed. Each baghouse is monitored in this manner to reflect the unique operating conditions of each baghouse.

Abstract: A method and apparatus for the removal of total cyanide from aqueous solution. The method includes the steps of placing the aqueous solution into a reaction tank, adding lime, ferrous sulfate, and acid to the solution in the reaction tank and agitating the resultant mixture for a reaction time of about one hour. The agitated mixture is transferred from the reaction tank to a clarifier tank and polyelectrolyte solution is added to induce iron-cyanide complex precipitate coagulation. The apparatus includes a reaction tank to hold the aqueous solution and a lime slurry tank, ferrous sulfate tank and acid tank in flow communication with the reaction tank. A pH control assembly controls the flow of acid from the acid tank into the reaction tank and a reaction tank agitation assembly extends into the interior of the reaction tank. The clarifier feed conduit extends between the reaction tank and a clarifier tank.

Abstract: Red mud bauxite residue produced in the Bayer Process is treated in a plurality of centrifuges and repulp tanks to successively wash and dewater the red mud. A final centrate liquor is obtained in a first upstream centrifuge stage which is rich in alumina and caustic values for respective recovery and reuse. The concentrated red mud cake produced in the final downstream washing/centrifuge step is low in caustic and alumina concentration permitting environmentally friendly disposal. The concentrated red mud cake is reslurried and mixed with bauxite sand for disposal in a dry stacking impoundment area.

Abstract: An apparatus for removing residue deposits on filtration elements is disclosed which significantly reduces the time necessary for cleaning the filters. This apparatus utilizes an improved arrangement of spray nozzles so as to effectively clean the filter leaf assemblies and the housing which encloses the filter leaves. The apparatus can incorporate semiautomatic and automatic control mechanisms to reduce or eliminate human error in the cleaning of the filters. The apparatus increases production time in the filtering process and thus increases the capacity of the filters.

Abstract: A method for sampling and controlling the addition of suspended gases, liquids and solids in a control stream to a process stream is disclosed wherein the surface area of the suspended material acts as the determining feature for control of the process. The measured surface area is compared with a preselected surface area to control the addition of the suspended material. This method is particularly useful for the control of particulate seed material to the process stream in the Bayer process for the production of alumina. The method is also broadly applicable to physical and/or chemical control means in an analytical scheme for controlling and monitoring any process.