Abstract: Disclosed herein is a method to produce a semi-crystalline fluoro-polymer film. A semi-crystalline fluoro-polymer material is used. The material is compressed to produce the film. During compression, the material is maintained at a temperature below the melting point of the material. The compression step can be cycled to allow cooling of the material between compression stages. Alternative methods are provided for compressing the material with a co-extrusion substrate, extruding the material and utilizing mandrel expansion for the material.

Abstract: Fibers and yarns of polyethylene terephthalate (PET) and PET copolymers with a sheath/filamentous core microstructure are formed from unoriented and non crystalline "as spun" source fibers and yarns by drawing to high draw ratios in one step. Fibers and yarns with the sheath/filamentous core microstructure are stiffer than commercial PET fibers. Fibers and yarns with the sheath/filamentous core microstructure may be annealed and relaxed to increase their dimensional stability without loss of the sheath/filamentous core microstructure.

Abstract: Injection moldable, highly filled polymer composites are provided which exhibit high dimensional stability at temperatures above the glass transition temperature of the matrix polymer. The heat distortion temperature of the composites approaches that of the crystal melting temperature of the matrix polymer. The composite includes a polyaryletherketone matrix and at least two types of fillers each providing unique properties. The first filler is a reinforcing fiber filler which provides high strength and stiffness. The second filler is an non-thermoplastic immobilizing filler to immobilize the amorphous portion of the partially crystalline polyaryletherketone polymer and provide resistance to high temperature distortion. Notwithstanding its improved mechanical and heat resistant properties, the composite remains injection moldable and thus capable of low cost manufacturing.

Abstract: Provided is an injection moldable composition suitable for forming ceramic or metallic greenbodies. The composition comprises in combination an inorganic or metallic filler in an amount of from about 63 volume percent to about 92 volume percent, a binding organic matrix resin, and an organosilane processing reagent represented by the general formula:SiX.sub.1 X.sub.2 X.sub.3 X.sub.4wherein at least one of X.sub.1, X.sub.2, X.sub.3 or X.sub.4 is an unfunctionalized alkyl or alkenyl group having 10 to 35 carbon atoms and at least one of X.sub.1, X.sub.2, X.sub.3 or X.sub.4 is an alkoxy group or halide, such that the moldable composition exhibits a low initial mixing torque upon mechanical agitation. These compositions offer excellent advantage in processibility using conventional mixing and molding equipment.Also provided is a process for preparing the moldable compositions.

Abstract: A polymeric composition containing internal lubricants is suitable for low friction applications. The composition contains from about 65 to about 85 weight percent of a polymeric blend and from about 15 to about 35 weight percent of internal lubricants, wherein said blend consists essentially of from about 35 to about 100 weight percent of polybenzimidazole and from about 0 to about 65 weight percent of poly(aryletherketone), and said lubricants consist essentially of graphite and boron nitride in a weight ratio of about 1:10 to about 10:1, respectively. The composition is useful for preparing shaped articles such as bearings, bearing sleeves, rings, etc.

Abstract: A compactible polybenzimidazole composition contains from about 95 to about 5 weight percent of solid lubricant particles which are uniformly dispersed and encapsulated in from about 55 to about 95 weight percent of polybenzimidazole. The solid lubricant comprises graphite and boron nitride in a weight ratio of about 10:1 to about 1:10. The composition is useful for preparing self lubricating, shaped articles such as bearings, bearing sleeves, rings, seals, etc. which exhibit low friction properties.

Abstract: A moldable hollow glass filled PBI composition. The composition may be prepared by making a well-mixed slurry of glass microspheres in a solution of PBI in a suitable solvent, and then spinning the slurry through a jet or die under pressure and into a water bath where the particles coagulate. The solvent dissolves in the water, allowing solvent-free PBI-glass composite particles to be isolated.

Abstract: A process for preparing shaped polybenzimidazole sintered products having increased resistance to dimensional modification by absorption of water and the products prepared therefrom.

Abstract: A cold compactible polymeric powder capable of being compressed into a shaped article includes a polybenzimidazole containing powder having an apparent density ranging from about 0.14 to about 0.300 gm/cm.sup.3, a compaction constant ranging from about 0.100 to about 0.500 MPa.sup.-1, and a plasticizer content ranging from about 1 to about 25 weight percent The highly porous polymeric powders are preferably formed by dissolving polymeric resins in a suitable solvent to form a polymeric solution, and atomizing the solution into a droplet atmosphere of a non-solvent.

Abstract: Fine, porous polybenzimidazole-containing particles prepared by spray-atomizing/quenching a polybenzimidazole-containing polymer solution into porous polybenzimidazole-containing particles, and fluidized bed, oppose jet milling the particles into fine, porous polybenzimidazole-containing particles. The milled particles exhibit a narrow particle size distribution centered at about a 5 .mu.m mean particle size, a surface area of about 35 m.sup.2 /g, and an open porosity of about 1.2 cm.sup.2 /gm which is at pore radius of less than about 100 nm.

Abstract: A process for forming polymer powders by dissolving one or more polymers in a suitable solvent, followed by atomizing the solution into a droplet atmosphere of a non-solvent to precipitate polymer particles. The particles are separated from the non-solvent, washed and dried to produce a powder with a rounded particle morphology, high internal porosity and surface area, and high apparent density.Polymer powders with these properties can be pressed to dense shaped articles suitable for sintering in automated presses because the powders have good low and compressibility characteristics. The process if particularly useful when applied to soluble polymers that are not readily shaped by melt processing means.

Abstract: A process for forming polymer powders by dissolving one or more polymers in a suitable solvent, followed by atomizing the solution into a droplet atmosphere of a non-solvent to precipitate polymer particles. The particles are separated from the non-solvent, washed and dried to produce a powder with a rounded particle morphology, high internal porosity and surface area, and high apparent density.Polymer powders with these properties can be pressed to dense shaped articles suitable for sintering in automated presses because the powders have good low and compressibility characteristics. The process if particularly useful when applied to soluble polymners that are not readily shaped by melt processing means.

Abstract: An injection moldable ceramic composition is prepared by mixing a sinterable powder, a polyacetal binding agent and silicon carbide whiskers which have been coated with a polyacetal resin.

Abstract: Greenbodies are produced by a RIM injection molding process wherein a homogeneous mixture of finely divided ceramic or metallic material and a polymerizable monomeric binder is injected into a mold and held at an elevated temperature for a sufficient time to polymerize the binder and form the greenbody. A preferred monomeric binder includes di- and tri-acrylate or -methacrylate esters of polyols. The low viscosity of the monomeric binder allows a loading of ceramic material of greater than 50 vol. % without adversely affecting the ability to injection mold the mixture.

Abstract: Cubelets are made from a piezoelectrically active ceramic material having holes therein which may be cross-cored. The holes are selectively filled with a liquid curable resin, such as an epoxy. The cubelets may also be formed from bonded or sintered "half-shapes" containing half cores, wherein a face bisects one hole or an array of holes or cross-cored holes to form one or an array of semicircular grooves or crossed semicircular grooves. The cubelets, whether filled with resin or having unfilled internal volume, are arranged in a precision array within the snug-fitting cavities of a lattice, whereby the holes are sealed off, to form a cubelet/lattice assembly which is then electroded and poled in an electric field and encapsulated in polymer to form a part of a hydrophone assembly, for example.

Abstract: This invention provides a process for producing a carboxylate ester from a monoolefin and a carboxylic acid, in the presence of a solid catalyst comprising a composite of 5-sulfoisophthalic acid and a carrier substrate having a surface area between about 1-1000 m.sup.2 /gram.A carboxylate ester such as ethyl propionate is produced with a STY efficiency of at least 100 grams/liter hour.

Abstract: This invention provides a process for producing a carboxylate ester from a monoolefin and a carboxylic acid, in the presence of a solid catalyst comprising a composite of 5-sulfoisophthalic acid and a carrier substrate having a surface area between about 1-1000 m.sup.2 /gram.A carboxylate ester such as ethyl propionate is produced with a STY efficiency of at least 100 grams/liter hour.

Abstract: This invention provides a catalyst and process for achieving highly selective straight chain aldehyde formation from alpha-olefins under hydroformylation conditions. The improved hydroformylation results are obtained under mild conditions of temperature and pressure in the presence of a stabilized catalyst complex of rhodium metal, bidentate ligand and monodentate ligand represented by the formula: ##STR1## Illustrative of a preferred bidentate ligand is trans 1,2-bis(diphenylphosphinomethyl)cyclobutane. Illustrative of a preferred monodentate ligand is diphenylethylphosphine. It is an essential feature of the invention process that the monodentate ligand is provided in a molar excess with respect to the rhodium metal in the stabilized catalyst complex.

Abstract: This invention provides a catalyst and process for achieving highly selective straight chain aldehyde formation from alpha-olefins under hydroformylation conditions. The improved hydroformylation results are obtained under mild conditions of temperature and pressure in the presence of a stabilized catalyst complex of rhodium metal, bidentate ligand and monodentate ligand represented by the formula: ##STR1## Illustrative of a preferred bidentate ligand is trans 1,2-bis-(diphenylphosphinomethyl)cyclobutane. Illustrative of a preferred monodentate ligand is diphenylethylphosphine. It is an essential feature of the invention process that the monodentate ligand is provided in a molar excess with respect to the rhodium metal in the stabilized catalyst complex.

Abstract: This invention provides a process for achieving straight chain aldehyde formation from alpha-olefins with improved selectivity efficiency under hydroformylation conditions. The improved hydroformylation results are obtained under mild conditions of temperature and pressure in the presence of a stabilized catalyst complex of rhodium metal, bidentate ligand and monodentate ligand represented by the formula: ##STR1## Illustrative of a preferred bidentate ligand L is 1,1'-bis-(diphenylphosphino)ferrocene. Illustrative of a preferred monodentate ligand L' is diphenylethylphosphine. It is an essential feature of the invention process that the monodentate ligand is provided in a molar excess with respect to the rhodium metal in the stabilized catalyst complex.