Abstract: A high shear method for making a conductive coating composition includes (a) adding with high shear agitation particles of one or more white metals having a melting point below 650° C. into a fluid with or without a reducing agent; and (b) adding with agitation silver particles into the fluid containing the particles of metals of step (a), wherein a polymer resin has been combined with the fluid.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A method for making a pressure actuated switching device includes applying a conductive coating to the release surface of a transfer substrate to form a conductive electrode film. The conductive film is brought into contact with a surface of a first substrate under conditions of heat and pressure sufficient to cause the conductive film to transfer from the release surface of the transfer substrate to the first surface of the first substrate. The first substrate is then positioned in juxtaposition with a second substrate having a conductive layer film of the first substrate. Also provided herein is a method for spring loading a terminal plug to the pressure actuated switching device.

Abstract: A pressure actuated switching device is made by applying at least a first layer of fluid conductive polymeric coating material to a surface of a sheet of green rubber material. The conductive polymeric coating is solidified to form an electrode, and the sheet of green rubber material is vulcanized. Two strips of green rubber may be simultaneously processed and then joined such that the respective layers of conductive coating are in spaced apart opposing relationship. The conductive polymeric coating may optionally be formulated with green rubber. Optionally, a blowing agent may be included in the conductive coating formulation so as to provide a cellular polymeric foam piezoresistive material from which the electrode is constructed. The green rubber sheets may be processed by a continuous rotary method or by a linear method using a clamping press having opening and closing dies for heating and joining the strips of green rubber.

Abstract: A seamless elongate pressure actuated switch includes a seamless tubular sheath fabricated from a resiliently flexible polymeric resin, and two separate and spaced apart conductive coatings disposed lengthwise along the inside surface of the tubular sheath. The sheath is deformable in response to pressure applied thereto to move the conductive coatings into contact with each other. The conductive coatings are the only means of conducting electricity lengthwise along the inside of the sheath. The thickness of the coatings ranges from about 0.00001 inches to about 0.01 inches. The elongated pressure actuated switch can be made by coating the inside wall of the tubular sheath with a conductive coating and then dividing the conductive coating into two spaced apart portions, or by coextrusion of the spaced apart conductive coatings with the sheath material.

Abstract: A method for making a pressure actuated switching device includes applying a conductive coating to the release surface of a transfer substrate to form a conductive electrode film. The conductive film is brought into contact with a surface of a first substrate under conditions of heat and pressure sufficient to cause the conductive film to transfer from the release surface of the transfer substrate to the first surface of the first substrate. The first substrate is then positioned in juxtaposition with a second substrate having a conductive layer film of the first substrate. Also provided herein is a method for spring loading a terminal plug to the pressure actuated switching device.

Abstract: A pressure actuated switching device for free hanging from a horizontal support, such as a drape sensor, includes an outer electrically non-conductive cover having an exterior surface, an interior surface, and a bottom edge portion. A plurality of weep holes are disposed along the bottom edge for drainage of moisture which may condense in the interior of the device. The device also includes a first electrically conductive coating deposited on the interior surface of the cover sheet, an interior sheet having at least a first surface with a second electrically conductive coating deposited thereon, and an electrically non-conductive spacer disposed between the first electrically conductive coating and the second electrically conductive coating. The non-conductive spacer preferably possesses a plurality of zig-zag shaped ribs. The pressure actuated switching device includes a sensitizing bracket to laterally direct forces applied to its side, and tolerates extreme conditions of moisture, heat and cold.

Abstract: A pressure activated switching device includes a first conductive layer, a second conductive layer spaced apart from the first conductive layer so as to define a planar space therebetween, and a standoff layer of electrically insulative material positioned between the first and second conductive layers. The standoff layer includes at least one opening for permitting movement therethrough of one or the other of said first and second conductive layers for the purpose of making electrical contact between them. The opening is defined by an interior edge of the standoff which laterally circumscribes an interior space, the opening including at least one linear, finger-like projection extending laterally from the interior edge into the interior space. Optionally, the switching device can include a piezoresistive material positioned between a conductive layer and the standoff. The pressure activated switching device can be used, for example, in a safety sensing edge system for a movable door.

Abstract: An electrolytic tilt sensor and a method of assembling the tilt sensor. The tilt sensor includes a metallic envelope comprising a metal container and a metal header welded to the enclosure, hermetically sealing the envelope. The envelope defines a chamber that contains an electrolytic solution and a plurality of electrodes. The electrodes extending through the header from outside of the envelope into the chamber. Each electrode is located in a separate aperture within the header and is insulated from the envelope by an insulator located between the electrode and the header. The method of assembling the tilt sensor includes the steps of placing the electrolytic solution into the container through an opening, engaging the header with the opening and welding the container and header to one another to hermetically seal the envelope.

Abstract: A pressure activated switching device includes an electrically insulative standoff positioned between two conductive layers. The standoff is preferably a polymeric or rubber foam configured in the form of contoured shapes having interdigitated lateral projections. Optionally, the switching device can include a piezoresistive material positioned between a conductive layer and the standoff. The pressure activated switching device can be used, for example, in a safety sensing edge system for a movable door.

Abstract: A pressure actuated switching apparatus includes first and second conductive layers and a plurality of discrete spaced apart dots between the first and second conductive layers. The dots serve as a standoff for separating the conductive layers and are fabricated from an insulative, elastomeric polymer foam which can collapse under the application of compressive force applied to the apparatus to allow contact between the conductive layers with minimized dead space. Alternatively, the standoff can include strips of electrically insulative elastomeric polymer foam.

Abstract: A pressure sensitive sparkless switching device includes a layer of piezoresistive cellular polymer foam, at least two conductive layers, and an insulative spacer element having at least one opening. When pressure is applied to the device the piezoresistive foam disposes itself through the opening of the spacer element and makes electrical contact between the conductive layers. The resistance of the piezoresistive foam varies with the amount of pressure applied to provide an analog as well as on-off function. The device may also provide multiple switching, and shear detection capabilities.

Abstract: A pressure sensitive sparkless switching device includes a layer of piezoresistive cellular polymer foam, at least two conductive layers, and an insulative spacer element having at least one opening. When pressure is applied to the device the piezoresistive foam disposes itself through the opening of the spacer element and makes electrical contact between the conductive layers. The resistance of the piezoresistive foam varies with the amount of pressure applied to provide an analog as well as on-off function. The device may also provide multiple switching, and shear detection capabilities.

Abstract: A pressure sensitive sparkless switching device includes a layer of piezoresistive cellular polymer foam, at least two conductive layers, and an insulative spacer element having at least one opening. When pressure is applied to the device the piezoresistive foam disposes itself through the opening of the spacer element and makes electrical contact between the conductive layers. The resistance of the piezoresistive foam varies with the amount of pressure applied to provide an analog as well as on-off function. The device may also provide multiple switching, and shear detection capabilities.