Abstract: A process for producing a low-cost water-reactive metal sulfide material includes dissolving a substantially anhydrous alkali metal salt and a substantially anhydrous sulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility alkali metal sulfide and a substantially low solubility by-product, and forming a mixture of the high solubility alkali metal sulfide and the low solubility by-product; separating the low solubility by-product from the mixture to isolate the supernatant including the alkali metal sulfide, and separating the polar solvent from the alkali metal sulfide to produce the alkali metal sulfide. The present invention provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired by-products.

Abstract: A process for producing a low-cost water-reactive sulfide material includes reacting a substantially anhydrous first alkali metal salt, a substantially anhydrous first sulfide compound, and a substantially anhydrous first alkali metal hydrosulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility second sulfide and a substantially low solubility second alkali metal salt, and forming a mixture of the high solubility second sulfide, a second alkali metal hydrosulfide, and the low solubility second alkali metal salt; removing the low solubility second alkali metal salt to isolate the supernatant including the second sulfide, and separating the polar solvent from the second sulfide and the second alkali metal hydrosulfide followed by heating to produce the second sulfide. The present disclosure provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired contaminants.

Abstract: A process for producing a low-cost water-reactive sulfide material includes reacting a substantially anhydrous first alkali metal salt, a substantially anhydrous first sulfide compound, and a substantially anhydrous first alkali metal hydrosulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility second sulfide and a substantially low solubility second alkali metal salt, and forming a mixture of the high solubility second sulfide, a second alkali metal hydrosulfide, and the low solubility second alkali metal salt; removing the low solubility second alkali metal salt to isolate the supernatant including the second sulfide, and separating the polar solvent from the second sulfide and the second alkali metal hydrosulfide followed by heating to produce the second sulfide. The present disclosure provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired contaminants.

Abstract: A process for producing a low-cost water-reactive sulfide material includes reacting a substantially anhydrous first alkali metal salt, a substantially anhydrous first sulfide compound, and a substantially anhydrous first alkali metal hydrosulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility second sulfide and a substantially low solubility second alkali metal salt, and forming a mixture of the high solubility second sulfide, a second alkali metal hydrosulfide, and the low solubility second alkali metal salt; removing the low solubility second alkali metal salt to isolate the supernatant including the second sulfide, and separating the polar solvent from the second sulfide and the second alkali metal hydrosulfide followed by heating to produce the second sulfide. The present disclosure provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired contaminants.

Abstract: A process for producing a low-cost water-reactive metal sulfide material includes dissolving a substantially anhydrous alkali metal salt and a substantially anhydrous sulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility alkali metal sulfide and a substantially low solubility by-product, and forming a mixture of the high solubility alkali metal sulfide and the low solubility by-product; separating the low solubility by-product from the mixture to isolate the supernatant including the alkali metal sulfide, and separating the polar solvent from the alkali metal sulfide to produce the alkali metal sulfide. The present invention provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired by-products.

Abstract: A process for producing a low-cost water-reactive metal sulfide material includes dissolving a substantially anhydrous alkali metal salt and a substantially anhydrous sulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility alkali metal sulfide and a substantially low solubility by-product, and forming a mixture of the high solubility alkali metal sulfide and the low solubility by-product; separating the low solubility by-product from the mixture to isolate the supernatant including the alkali metal sulfide, and separating the polar solvent from the alkali metal sulfide to produce the alkali metal sulfide. The present invention provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired by-products.

Abstract: A device for applying compressive force to electrochemical cells or batteries with superior pressure distribution, which includes first and second external plates; a first internal plate positionable adjacent to the first external plate, and comprising an external dimension corresponding to an external dimension of the first external plate and an internal dimension defining a first aperture corresponding to the exterior dimensions of an electrochemical cell or battery; a second internal plate positionable adjacent to the second external plate, and comprising external dimension corresponding to an external dimension of the second external plate and an internal dimension defining a second aperture corresponding to the exterior dimensions of the electrochemical cell or battery; and a plurality of fasteners configured to extend through the first and second external plates and the first and second internal plates to apply pressure to the electrochemical cell or battery positioned between the first and second inter

Abstract: A process for producing a low-cost water-reactive metal sulfide material includes dissolving a substantially anhydrous alkali metal salt and a substantially anhydrous sulfide compound in a substantially anhydrous polar solvent, providing differential solubility for a substantially high solubility alkali metal sulfide and a substantially low solubility by-product, and forming a mixture of the high solubility alkali metal sulfide and the low solubility by-product; separating the low solubility by-product from the mixture to isolate the supernatant including the alkali metal sulfide, and separating the polar solvent from the alkali metal sulfide to produce the alkali metal sulfide. The present invention provides a scalable process for production of a high purity alkali metal sulfide that is essentially free of undesired by-products.

Abstract: A controlled damper assembly includes a controlled-damper-assembly piston, a controlled-damper-assembly piston rod attached to the piston, an insulated wire, and an electrical connector. The insulated wire is positioned in the piston rod, has a first end operatively connected to the piston, and has a second end. The electrical connector has a first connection terminal electrically connected to the second end of the insulated wire and has a second connection terminal electrically connected to the piston rod. An example, without limitation, of a controlled damper assembly is a magnetorheological damper assembly.

Abstract: A suspension damper including a tube and a damping piston assembly disposed within the tube and slidably mounted therein for reciprocal movement in the tube. The suspension damper also includes a piston rod extending through the tube and connected to the damping piston assembly, a rod guide assembly closing a bottom end of the tube, and a rebound cut-off disk and spring suspended in the tube between the rod guide assembly and the damping piston assembly and cooperating with the damping piston assembly to provide a rebound cut-off effect between the rebound cut-off disk and the damping piston assembly. The rebound cut-off disk and spring have specific gravities that are greater than the specific gravity of the fluid in the tube, such that the disk and the spring sink in the fluid.

Abstract: A controlled damper assembly includes a controlled-damper-assembly piston, a controlled-damper-assembly piston rod attached to the piston, an insulated wire, and an electrical connector. The insulated wire is positioned in the piston rod, has a first end operatively connected to the piston, and has a second end. The electrical connector has a first connection terminal electrically connected to the second end of the insulated wire and has a second connection terminal electrically connected to the piston rod. An example, without limitation, of a controlled damper assembly is a magnetorheological damper assembly.

Abstract: The invention provides a magnetorheological piston and damper assembly. The piston includes a piston body including at least one bypass port and an annular gap formed therein. The bypass port is in fluid communication with the annular gap. The bypass port includes a longitudinal portion extending substantially parallel to a piston longitudinal axis, and a bend portion extending substantially away from the longitudinal axis. The annular gap is spaced apart from the longitudinal portion and extends substantially parallel to the piston longitudinal axis. During operation, fluid flows through the bypass port and annular gap. The damper assembly includes a rod and a housing including the fluid carried therein. The piston is slidably carried in the housing and operably attached to the rod.

Abstract: A piston plate for use with a magneto-rheological (“MR”) fluid damper. The piston plate comprises an inner hub and outer rim. The hub has simple geometry and is made from easily machineable material, permitting it to be fabricated using low-cost processes. The rim, which is secured over the hub, is made from a high strength, ferrous metal. The rim may be heat treated for greater strength and reduced magnetic permeability. In one embodiment of the present invention, the rim may be made from powdered metal. A magnetic insulator may be included on an interior face of the piston plate to reduce magnetic coupling between the rim and a piston core in a piston assembly. In another embodiment of the present invention, the piston plate may be made as a single piece from compressed powdered metal.

Abstract: A magnetorheological piston includes a body having a substantially magnetically energizable passageway and a substantially magnetically non-energizable passageway. The substantially magnetically non-energizable passageway has a valveless passageway throat and has a flow cross-sectional area which has a minimum at the passageway throat and which is larger away from the passageway throat. A magnetorheological damper includes a cylinder and the above-described magnetorheological piston, wherein the piston is positioned in, and slideably engages, the cylinder.

Abstract: A suspension damper including a tube and a damping piston assembly disposed within the tube and slidably mounted therein for reciprocal movement in the tube. The suspension damper also includes a piston rod extending through the tube and connected to the damping piston assembly, a rod guide assembly closing a bottom end of the tube, and a rebound cut-off disk and spring suspended in the tube between the rod guide assembly and the damping piston assembly and cooperating with the damping piston assembly to provide a rebound cut-off effect between the rebound cut-off disk and the damping piston assembly. The rebound cut-off disk and spring have specific gravities that are greater than the specific gravity of the fluid in the tube, such that the disk and the spring sink in the fluid.

Abstract: The invention provides a magnetorheological piston and damper assembly. The piston includes a piston body including at least one bypass port and an annular gap formed therein. The bypass port is in fluid communication with the annular gap. The bypass port includes a longitudinal portion extending substantially parallel to a piston longitudinal axis, and a bend portion extending substantially away from the longitudinal axis. The annular gap is spaced apart from the longitudinal portion and extends substantially parallel to the piston longitudinal axis. During operation, fluid flows through the bypass port and annular gap. The damper assembly includes a rod and a housing including the fluid carried therein. The piston is slidably carried in the housing and operably attached to the rod.

Abstract: A hydraulic vehicle damper is provided for limiting the extent and/or speed of extension of the damper on the rebound stroke with a variety of working fluids including magneto-rheological (MR) fluids, through the use of buoyant sleeve in the working chamber of the damper, rather than having rebound limiting elements attached to the damper piston or damper cylinder tube as in prior vehicle dampers.

Abstract: A suspension damper including a tube and a damping piston assembly disposed within the tube and slidably mounted therein for reciprocal movement in the tube. The suspension damper also includes a piston rod extending through the tube and connected to the damping piston assembly, a rod guide assembly closing a top end of the tube, and a rebound cut-off disk and spring suspended in the tube between the rod guide assembly and the damping piston assembly and cooperating with the damping piston assembly to provide a rebound cut-off effect between the rebound cut-off disk and the damping piston assembly. The rebound cut-off disk and spring have specific gravities that are less than the specific gravity of the fluid in the tube, such that the disk and the spring are floatable in the fluid.

Abstract: A magnetorheological piston includes a magnetorheological-piston coil and a magnetorheological-piston core. The magnetorheological-piston coil has a longitudinal axis. In one expression, the magnetorheological-piston core includes at least two separate core pieces, wherein each of the core pieces is a powder-metal core piece, and wherein the coil is positioned to circumferentially surround at least a portion of at least one of the core pieces. In another expression, the magnetorheological-piston core includes separate upper core, center core, and lower core pieces. The center core piece is located longitudinally between the upper core and lower core pieces and has a circumferential surface positioned radially inward from the inner-diameter portion of the coil. The coil is longitudinally positioned between the upper core and lower core pieces. In one example, each of the upper core, center core, and lower core pieces is a powder-metal core piece.

Abstract: A magnetorheological piston includes a body having a substantially magnetically energizable passageway and a substantially magnetically non-energizable passageway. The substantially magnetically non-energizable passageway has a valveless passageway throat and has a flow cross-sectional area which has a minimum at the passageway throat and which is larger away from the passageway throat. A magnetorheological damper includes a cylinder and the above-described magnetorheological piston, wherein the piston is positioned in, and slideably engages, the cylinder.