Abstract: The invention provides a multilayer intumescent mat or sheet that is useful as a mounting for a pollution control device or as a firestop. In one aspect, the multilayer intumescent sheet of the invention comprises a non-moldable flexible non-intumescent layer and a non-moldable flexible intumescent layer comprising an intumescent material wherein the layers form a single sheet without the use of auxiliary bonding means. In another aspect, the multilayer intumescent sheet of the invention comprises a first non-moldable intumescent layer comprising a first intumescent material and a second non-moldable intumescent layer comprising a second intumescent material, the first and second intumescent materials being different, wherein the layers form a single sheet without the use of auxiliary bonding means. The invention also provides a pollution control device comprising a multilayer sheet of the invention disposed between a monolith and a housing.

Abstract: A process for continuous composite coextrusion comprising: (a) forming first a material-laden composition comprising a thermoplastic polymer and at least about 40 volume % of a ceramic or metallic particulate in a manner such that the composition has a substantially cylindrical geometry and thus can be used as a substantially cylindrical feed rod; (b) forming a hole down the symmetrical axis of the feed rod; (c) inserting the start of a continuous spool of ceramic fiber, metal fiber or carbon fiber through the hole in the feed rod; (d) extruding the feed rod and spool simultaneously to form a continuous filament consisting of a green matrix material completely surrounding a dense fiber reinforcement and said filament having an average diameter that is less than the average diameter of the feed rod; and (e) arranging the continuous filament into a desired architecture to provide a green fiber reinforced composite.

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 flexible composite comprising a high tensile strength fibrous component dispersed within a flexible or resilient polymeric matrix, the matrix and fibrous component being essentially unbonded to each other so that the composite retains essentially the flexibility of the polymeric matrix.

Abstract: Method of making wire comprising polycrystalline &agr;-Al2O3 fibers within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper.

Abstract: Disclosed is a structural material excelling in lightness of weight, strength, flexural modulus and other properties, being made from polyamide resin reinforced with continuous fiber and/or long filament reinforcing material. This structural material can be fabricated by a monomer casting method by arranging said fiber reinforcing material preliminarily in a desired shape, putting it into a mold, pouring molten &ohgr;-lactams containing a polymerization catalyst and an initiator into said mold, and heating to obtain polyamide resin.

Abstract: The present invention provides a moisture-retentive cooling gel, a laminate thereof, and a moisture-retentive cooling plaster, which offer moisture-retaining and cooling effects for a controlled duration and have superior functionality, e.g., capability of delivering and transporting an effective ingredient such as a pharmacological active ingredient, a perfume or a deodorant. The moisture-retentive cooling gel comprises: a water-retentive matrix (a1) of a water-soluble polymer having a water content of not lower than 40 wt %; and fibers (f) dispersed in the water-retentive matrix, the fibers (f) having a hydrophilic property at least at surfaces thereof, some of the fibers (f) being exposed on a surface of the water-retentive matrix (a1). The gel has a higher water content and a higher water vaporization rate. An endothermally water-dissolvable compound may be retained in the water-retentive matrix and/or the fibers for enhancement of the cooling capacity of the gel.

Abstract: Provided is a method for the production of a reinforced polymer, which method comprises: (a) introducing carbon nanotubes into a polymer to provide a mixture of the polymer and the nanotubes; (b) stretching the mixture at or above the melting temperature (Tm) of the polymer to orient the carbon nanotubes; and (c) stretching the mixture in the solid state to further orient the carbon nanotubes.

Abstract: Panels and elements for vehicle interiors are obtained by co-extrusion or co-lamination of a layer (10a) of themoplastic support material containing a reinforcement filler with a layer (9a) of thermoplastic covering material containing an amorphous thermoplastic and by thermoforming the resulting sheets in a press.

Abstract: Fiber reinforced brittle matrix composites are disclosed with improved mechanical properties. The composites comprise extensible, somewhat elastic fibers and hardened brittle matrix materials. The fibers are positioned to support the composite in a three dimensional manner. Temporary tension forces are applied to some of the fibers before the matrix has completely hardened. The resulting three dimensional array of aligned fibers acts to improve the properties of the composite by providing self-compression. Self-compression is enabled by the alignment and stored elastic energy resulting from the temporary tension and from other deformations acting with the fiber network. The composites have improved response to challenges such as matrix shrinkage during hardening or bending forces and impacts. The invention is particularly useful with brittle, high modulus matrixes, such as cementitious materials and elastic fibers such as polymeric fibers.

Abstract: A ceiling tile contains a plurality of shells made of a thin membrane and filled with fire retardant materials. When the shells are subjected to high temperatures, as when a fire is present in the room, the shells burst and release the fire retardant materials to extinguish the fire.

Abstract: A carbon--carbon composite clutch friction material for use with a wet lubricant under severe operating conditions is disclosed, the material comprising a woven carbon fabric mesh (suitably a satin weave mesh) infiltrated with pyrolytic carbon to an unusually high density in the range of at least 1.3 g/cc to about 1.5 g/cc. By infiltrating the woven carbon fabric with carbon to such high density, a wear-resistant friction material is provided that still retains enough surface texture for lubricant transport.

Abstract: A fiber resin composite member manufacturing method includes the steps of: selectively distinguishing waste rubber and synthetic resins containing waste tires and waste PET bottles, waste fibers, waste timbers, waste paper, waste plant straws, waste shells from shellfish or clams and so on from industrial waste materials in accordance with their physical chemical features; disintegrating the waste rubber and synthetic resins containing the waste tires and the waste PET bottles in a super low temperature cooling method, disintegrating the waste fibers in an appropriate size by using a scutcher, and distintegrating the other waste materials by means of a general crusher; pouring the disintegrated waste materials into a molding machine in a predetermined composition ratio and melting-molding them in a desired type at a high temperature of about 150 to 300.degree. C. and a high pressure of about 150 to 3,000 ton; and cooling the molded fiber resin composite member at a temperature of about 40 to 70.degree. C.

Abstract: Composite materials formed from bone bioactive glass or ceramic fibers and structural fibers are disclosed. In preferred embodiments, a braid or mesh of interwoven bone bioactive glass or ceramic fibers and structural fibers is impregnated with a polymeric material to provide a composite of suitable biocompatibility and structural integrity. Most preferably, the mesh or braid is designed so that the bioactive fibers are concentrated at the surface of the implant to create a surface comprised of at least 30% bioactive material, thereby providing enhanced bone ingrowth. The interweaving between the bone bioactive glass or ceramic fibers and the core of structural fibers overcomes the problems found in prior composite systems where the bioactive material delaminates from the polymer. Preferred bioactive materials include calcium phosphate ceramics and preferred structural fibers include carbon fibers. Further preferred bioactive materials include aluminum oxide at greater than 0.2%, by mole.

Abstract: This invention concerns a composition comprising a blend of polyolefin with the reaction of a functionalized polyolefin and polyetheramine in which the polyetheramine is grafted into the functionalized polyolefin in a customary mixing apparatus. A process for producing the reaction product of functionalized polypropylene and polyetheramine by melting with polypropylene in a customary mixing apparatus is also disclosed. Blends of the present invention are advantageously useful to prepare paintable automotive body parts. This invention further includes dyeable polyolefin compositions containing the reaction product of functionalized polyolefin and polyetheramine. Dyeable polyolefin fibers, including polypropylene fibers, are disclosed, which may be made by melt spinning, and which may be employed to make woven and non-woven fabric. The polyolefin employed in the practice of this invention may be a flexible polyolefin.

Abstract: In the manufacture of a structural member comprising a thermoplastic composite core with an exterior reinforcing layer, the core member is initially extruded in the shape of a profile. The profile is then contacted with reinforcing fiber and resin to form the exterior reinforcing layer. The exterior thermosetting layer is cured to form a reinforcing layer. The structural member is preferably manufactured using a pultrusion method in which a tractor device is used to provide linear movement of the profile from the extrusion head to the exterior coating operation. The fiber-reinforced thermoset is coated on the entirety of the exterior of the profile or is applied only on a portion of the profile requiring reinforcement in a defined load-bearing direction. The preferred thermoplastic core comprises a polymer-fiber composite material.

Abstract: A method of making a reinforced laminate, including the steps of placing a reinforcing grid on a first outer sheet of thermoplastic, preparing an elastomeric material capable of forming a tie layer between two sheets of thermoplastic, and laminating a second outer sheet of thermoplastic to the first sheet of thermoplastic and the reinforcing grid with the tie layer of elastomeric material therebetween, whereby the reinforcing grid is held by the elastomeric tie layer in between the first outer sheet of thermoplastic and the second outer sheet of thermoplastic, and the reinforcing grid being displaceable within the elastomeric tie layer.

Abstract: An athletic guard shaped to fit against a body part is provided for protecting the body part from injury. The athletic guard includes an energy absorbing laminate structure. The laminate structure includes a first array of high performance, unidirectionally-oriented fiber bundles. A second array of high performance, unidirectionally-oriented fiber bundles are cross-plied at an angle with respect to the first array of fiber bundles, and laminated to the first array of fiber bundles in the absence of adhesives or bonding agents. First and second polymeric films are bonded to outer surfaces of the laminated first and second arrays of unidirectional fiber bundles without penetration of the films into the fiber bundles or through the laminate from one side to the other. A sufficient amount of film resides between the laminated first and second arrays of unidirectional fiber bundles to adhere the first and second arrays of fiber bundles together to form the laminate structure.

Abstract: A protective, impact resistant material and method, the material comprising a fabric of thermoplastic polymeric fibers having a strength of at least 0.4 GPa and an elastic modulus of at least 5 GPa and a matrix of polymeric material disposed in the interstices between the fibers, the matrix having an elastic modulus in the range 0.2 to 3.times.10.sup.6 psi. The polymeric fibers can be gel spun polyethylene, polypropylene, nylon, polyvinyl alcohol and polyethylene terephthalate. In a second embodiment, the matrix is derived from the fabric.

Abstract: A ballistic laminate structure in sheet form includes first and second arrays of high performance, unidirectionally-oriented fiber bundles having a tensile strength greater than 7 grams per denier. The second array of fiber bundles is cross-plied at an angle to the first array of fiber bundles. A polymeric film resides between the first and second cross-plied arrays of fiber bundles to adhere the first and second arrays of fiber bundles together without substantial penetration of the film into the fiber bundles or through the laminate structure from one side to the other.