Abstract: A method for forming an electrode for a fuel cell is disclosed. The method comprises combining an electrically conductive material (e.g., graphite) and a solid grindable resole resin binder, the binder being essentially free of nitrogen and nitrogen-containing compounds, and consolidating the electrically conductive material and the binder to form the fuel cell electrode. The use of a solid, grindable, single stage, nitrogen-free resole resin binder serves to increase the operating life of the electrode. One example binder comprises the reaction product of bisphenol A and a molar excess of an aldehyde, such as formaldehyde.

Abstract: A polymer composition that can be used to cure a novolac resin at a lower temperature than conventional curing agents and with reduced emission of volatile compounds is disclosed. The curing agent composition is prepared by mixing and reacting in aqueous solution a phenolic monomer and an aldehyde in the presence of a basic catalyst to form an intermediate resin, and reacting the intermediate resin with an amine to form the curing agent. The aldehyde to phenolic monomer molar ratio in the reaction should be at least about 1.0:1. The preferred amine is hexamethylenetetramine, and it is preferred that the hexamethylenetetramine to phenolic monomer molar ratio is at least about 0.12:1. The curing agent releases minimal volatile compounds when used to cure novolac resins, and unlike conventional resole curing agents, has an indefinite shelf life in both the pure form and when blended with a novolac resin.

Abstract: A thermosetting resin composition which can be used to produce pultruded products with a lustrous surface finish comprises about 60% to about 95% by weight of an uncured, liquid phenolic resin containing about 70-90% solids by weight and about 5 to about 40% of particles of a molding composition comprising an uncured, solid phenolic resin and a suitable filler.

Abstract: A method for preparing a friction element from rod-like particles of friction ingredients includes preheating the particles, which have a diameter of about 3/32" to about 1/4", to a temperature between 150.degree. F. and 375.degree. F., introducing a predetermined amount of the preheated rod-like particles into a friction element mold, and compressing the preheated rod-like particles under heat and pressure to form the friction element. Compositions for forming the rod-like particles are disclosed.

Abstract: A thermosetting resin containing composition can be heated to reduce its viscosity and used as a liquid in a liquid injection molding method. It has a phenolic resin content of about 80% to about 90% solids by weight, and contains about 5% to about 40% of a polyglycol. The composition may also contain resorcinol as a compatibilizing agent and a polyalkylene glycol as the polyglycol agent. In a novel method the resin containing composition is heated to reduce its viscosity and introduced into a heated mold in a liquid injection molding method.

Abstract: A light-weight, corrosion-resistant, multiple engaging ratchet assembly comprising few, easily manufactured parts for simplified operation of pawls and ratchet teeth in a free-wheel drive gear ratchet assembly. An outer wheel includes a cavity to receive an inner wheel with a pawl ring or integral pawls. The pawls ride over ratchet teeth protruding from a circumferential surface on the outer wheel when the inner wheel and the outer wheel rotate in opposite directions. Turning the inner wheel in a second direction the same as the outer wheel direction of rotation brings the pawls into engagement with the ratchet teeth causing the inner wheel to drive the outer wheel.

Abstract: A polymer blend of superior impact resistance comprises an intimate blend of a polyalkylene terephthalate resin, a polyesteramide and an impact resistance booster which is an elastomeric block copolymer. The preferred impact resistance booster is a block copolymer which has been modified with maleic acid anhydride.

Abstract: A polymer blend of superior impact resistance comprises an intimate blend of a polyester resin, a polycarbonate resin and an acid-modified polyolefin. The preferred acid-modified polyolefin is a polyethylene wax which has been modified with maleic acid anhydride.

Abstract: A thermosetting resin containing composition can be heated to reduce its viscosity and used as a liquid in a liquid injection molding method. It has a phenolic resin content of about 80% to about 90% solids by weight, and contains about 5% to about 40% of a polyglycol. The composition may also contain resorcinol as a compatibilizing agent and a polyalkylene gylcol as the polyglycol agent. In a novel method the resin containing composition is heated to reduce its viscosity and introduced into a heated mold in a liquid injection molding method.

Abstract: The mold described herein comprises an upper and a lower portion in which the upper portion comprises an inverted cavity flash land mold section and the lower portion comprises a readily removable steel plate. By having the cavity flash land mold portion inverted and in the upper portion of the mold, the molded product is more easily separable by gravity from this upper mold portion which avoids the necessity to use means for lifting the molded product from the cavity and thereby avoids the distortions and stresses previously caused in the product by such lifting means. To aid in separating the product from the inverted cavity upper portion as the upper portion is separated from the lower flat sheet portion of the mold, releasing means, such as air from poppet valves in the upper area of the cavity mold, may be used to facilitate separation of the product from the upper cavity portion and deposition of this product on the lower flat sheet portion of the mold.

Abstract: The vitreous carbon disclosed herein is prepared from the molded product of a moldable composition produced from co-reacted mixtrues of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The process described herein involves the gradual addition of aqueous formaldehyde, containing 35-60 percent by weight of formaldehyde, to a phenol maintained at a temperature of 60.degree.-100.degree. C., preferably 70.degree.-90.degree. C., and at a reduced pressure of 11-26 inches of mercury in the presence of an alkaline catalyst. The rate of formaldehyde addition is such that the exothermic reaction aids in maintaining the stated temperature range and thereby simultaneously distills approximately all the water added with the formaldehyde and that formed by the condensation so that the volume of the reaction mass is maintained approximately constant. This constant volume allows efficient use of the equipment.

Abstract: The process and product derived therefrom use the moldable composition derived from intimate co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The moldable composition disclosed herein comprises co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The process for producing a vitreous carbon involves the molded product of a moldable composition produced from co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The fast crystallizing polyalkyleneterephthalate resin compositions disclosed herein contain 0.05-4 percent by weight of a sodium salt of a hydrocarbon acid having the formula R.degree.(COO).sub.y Na.sub.z wherein R.degree. is a hydrocarbon group having a valency of y and having 1-25 carbon atoms therein, preferably 1-10 carbon atoms, y is an integer having a value of at least one, advantageously 1-10 and preferably 1-3, and z is an integer having a value of at least one and no greater than the value of y, this sodium salt of the hydrocarbon acid being in the form of a complex with a polymeric compound, which contains at least two recurring units of the formula --CH.sub.2 CH.sub.2 O--, together with reinforcing agents, fillers and/or additives and optionally a flow promoter selected from low molecular weight organic esters or polymers containing a recurring structure of [(CH.sub.2).sub.x O--].sub.

Abstract: The vitreous carbon disclosed herein is prepared from intimate uniform mixtures of powder or otherwise blendable form of 20-80% by weight of a solid phenolic-aldehyde Novolak resin and of 20-80% by weight of a solid phenolic-aldehyde resol resin, the percentages being based on the combined weight of the Novolak and resol resins, and the aldehyde in said Novolak resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde, together with a carbonaceous filler, preferably graphite, in a proportion as high as 76% by weight based on the total composition. Generally the graphite may comprise 30-70%, advantageously 35-65% and preferably 40-60% of the molding composition. The vitreous carbon is improved in electrical properties and in the capability of being shaped into large thin plates which are much more stress-free than otherwise produced.

Abstract: Novel, unsaturated vinylacetylene-terminated polyimides and processes for their preparation are disclosed herein. These new polyimides are derivatives of anhydride-terminated aromatic polyimides from which they can be prepared by amidation to provide new unsaturated amide groups having a terminal group containing the structure --CH.dbd.CH--C.tbd.C-- or --C.tbd.C--CH.dbd.CH--, hereinafter sometimes referred to as "conjugated enynes". These new compositions are more tractable than the original anhydride-terminated polyimides and can be converted at appropriate lower temperatures to crosslinked, insoluble, infusible polymers without by-product formation, thereby extending greatly the applications for which the aromatic polyimides can be employed. Moreover, these new polyimides can undergo the Diels-Alder type of addition with a large number of dienophiles. Certain monomeric materials are also described.

Abstract: The vitreous carbon disclosed herein is prepared from intimate uniform mixtures of powder or otherwise blendable form of 20-80% by weight of a solid phenolic-aldehyde Novolak resin and of 20-80% by weight of a solid phenolic-aldehyde resol resin, the percentages being based on the combined weight of the Novolak and resol resins, and the aldehyde in said Novolak resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde, together with a carbonaceous filler, preferably graphite, in a proportion as high as 76% by weight based on the total composition. Generally the graphite may comprise 30-70%, advantageously 35-65% and preferably 40-60% of the molding condition. The vitreous carbon is improved in electrical properties and in the capability of being shaped into large thin plates which are much more stress-free than otherwise produced.