Abstract: A polymer matrix composite comprising a porous polymeric network; and a plurality of dielectric particles distributed within the polymeric network structure; wherein the dielectric particles are present in a range from 5 to 98 weight percent, based on the total weight of the dielectric particles and the polymer (excluding the solvent); and wherein the polymer matrix composite has a dielectric constant in a range from 1.05 to 80; and methods for making the same. Polymer matrix composites comprising dielectric particles are useful, for example, as electric field insulators.

Abstract: A powder-rubbing apparatus comprises: a rotatable rubbing roll having a rotational axis; a substrate path; an oscillating mechanism for oscillating the rotatable rubbing roll along the rotational axis; and a powder coating die comprising an inlet port in fluid communication with an outlet port disposed adjacent to the substrate path. The substrate frictionally contacts the rotatable rubbing roll within a rubbing zone. A dispenser for dispensing gas-borne powder is in fluid communication with the inlet port of the powder coating die. The dispenser is aligned such that at least a portion of a gas-borne powder dispensed from the powder coating die is deposited directly onto at least one of the rotatable rubbing roll or the substrate and conveyed into the rubbing zone. A method of using the powder-rubbing apparatus and a powder-rubbed web preparable thereby are also disclosed.

Abstract: Laminated articles are provided including a porous fibrous nonwoven matrix and guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix. The laminated articles further include a first substrate and a second substrate sealed to the first substrate. Methods of making laminated articles and methods of using laminated articles are also provided.

Abstract: Polymer matrix composite comprising a porous polymeric network; and a plurality of intumescent particles distributed within the polymeric network structure; wherein the intumescent particles are present in a range from 15 to 99 weight percent, based on the total weight of the intumescent particles and the polymer (excluding the solvent); and wherein the polymer matrix composite volumetrically expands at least 2 times its initial volume when exposed to at least one temperature greater than 135° C.; and methods for making the same. The polymer matrix composites are useful, for example, as fillers, thermally initiated fuses, and fire stop devices.

Abstract: A polymer matrix composite comprising a porous polymeric network; and a plurality of indicator particles distributed within the polymeric network structure; wherein the indicator particles are present in a range from 1 to 99 weight percent, based on the total weight of the indicator particles and the polymer (excluding the solvent); and wherein the polymer matrix composite has a density of at least 0.05 g/cm3; and methods for making the same. The polymer matrix composites are useful, for example, as sensors.

Abstract: Injection molding parts onto a carrier web located between mold halves, each mold half having a cavity, resulting in molded articles having parts on both sides of the carrier web. Polymer flow into the cavities is assisted by application of ultrasonic energy to the mold. After the molding operation, mold halves are separated, and the carrier web is advanced, or indexed, to a next position for another molding sequence. Articles produced include lenses with part of the carrier web between lens halves, and a carrier web bearing an array of molded parts.

Abstract: Laminated articles are provided including a porous fibrous nonwoven matrix and guanidine-functionalized metal silicate particles enmeshed within the porous fibrous nonwoven matrix. The laminated articles further include a first substrate and a second substrate sealed to the first substrate. Methods of making laminated articles and methods of using laminated articles are also provided.

Abstract: An ultrasonic-assisted injection molding system and method for making precisely-shaped articles. A source of ultrasonic energy is positioned to apply vibrational energy to a mold cavity connected to at least one gate in flow communication with a source of molten (co)polymer. The mold is heated to a temperature of 104-116° C., and the molten (co)polymer is injected into the mold cavity. After cooling the mold until the molten (co)polymer within the gate has solidified, ultrasonic energy is applied to the mold without remelting the solidified (co)polymer within the gate until the temperature increases to 116-122° C., thereby substantially relieving flow induced stresses. The mold is then cooled until the temperature decreases to 101-107° C., and is thereafter heated until the temperature increases to 116-122° C., thereby substantially relieving any thermally induced stresses. The mold is cooled until the molten (co)polymer has solidified, thereby forming a precision molded plastic optical element.

Abstract: There is provided a method for making hollow microspheres by means of dispensing the feed using vibratory energy, preferably ultrasonic energy, hollow microspheres made using the method, and an apparatus for making hollow microspheres.

Abstract: Injection molding parts onto a carrier web located between mold halves, each mold half having a cavity, resulting in molded articles having parts on both sides of the carrier web. Polymer flow into the cavities is assisted by application of ultrasonic energy to the mold. After the molding operation, mold halves are separated, and the carrier web is advanced, or indexed, to a next position for another molding sequence. Articles produced include lenses with part of the carrier web between lens halves, and a carrier web bearing an array of molded parts.

Abstract: Injection molding parts onto a carrier web located between mold halves, each mold half having a cavity, resulting in molded articles having parts on both sides of the carrier web. Polymer flow into the cavities is assisted by application of ultrasonic energy to the mold. After the molding operation, mold halves are separated, and the carrier web is advanced, or indexed, to a next position for another molding sequence. Articles produced include lenses with part of the carrier web between lens halves, and a carrier web bearing an array of molded parts.

Abstract: A method of molding a microneedle including providing a mold apparatus having a mold insert having the negative image of at least one microneedle, a compression core, a mold housing configured to allow a reciprocal motion between the mold insert and the compression core. The method includes placing the mold apparatus in a closed position, injecting polymeric material into the closed mold apparatus, compressing the injected polymeric material between the mold insert and the compression core by a reciprocal motion between the compression core and the mold insert, opening the mold, and removing a molded microneedle from the mold. The mold insert has a mold insert height and the molded microneedle has a height that is from about 90% of the mold insert height to about 115% of the mold insert height.

Abstract: Microneedle arrays made by an injection molding process that uses ultrasonic energy to assist flow of polymer melt into a mold cavity, said microneedles having a high proportion (at least 60%) of fill, i.e., completely formed microneedles across the array. Microneedle array can be on a base or land no more than 250 ?m thick.

Abstract: Articles enabled by an injection molding process that molds parts on a carrier web located between mold halves and uses ultrasonic energy to assist flow of polymer melt into the mold cavity. One such article is a carrier web having a high density of molded parts, i.e., bearing an array of molded articles adhered to the web in rows and columns, the articles being spaced closer (center-to-center or edge-to-edge) than the diagonal spacing between articles in the next adjacent row and next adjacent column. Another such article is a microneedle array on a land no more than 250 ?m thick on which at least 60% of the microneedles across the array are filled (i.e., completely formed).

Abstract: An ultrasonic-assisted injection molding system and method for making precisely-shaped articles. A source of ultrasonic energy is positioned to apply vibrational energy to a mold cavity connected to at least one gate in flow communication with a source of molten (co)polymer. The mold is heated to a temperature of 104-116° C., and the molten (co)polymer is injected into the mold cavity. After cooling the mold until the molten (co)polymer within the gate has solidified, ultrasonic energy is applied to the mold without remelting the solidified (co)polymer within the gate until the temperature increases to 116-122° C., thereby substantially relieving flow induced stresses. The mold is then cooled until the temperature decreases to 101-107° C., and is thereafter heated until the temperature increases to 116-122° C., thereby substantially relieving any thermally induced stresses. The mold is cooled until the molten (co)polymer has solidified, thereby forming a precision molded plastic optical element.

Abstract: There is provided a method for making hollow microspheres by means of dispensing the feed using vibratory energy, preferably ultrasonic energy, hollow microspheres made using the method, and an apparatus for making hollow microspheres.

Abstract: Injection molding parts onto a carrier web located between mold halves, each mold half having a cavity, resulting in molded articles having parts on both sides of the carrier web. Polymer flow into the cavities is assisted by application of ultrasonic energy to the mold. After the molding operation, mold halves are separated, and the carrier web is advanced, or indexed, to a next position for another molding sequence. Articles produced include lenses with part of the carrier web between lens halves, and a carrier web bearing an array of molded parts.

Abstract: Injection molding parts onto a carrier web located between mold halves, each mold half having a cavity, resulting in molded articles having parts on both sides of the carrier web. Polymer flow into the cavities is assisted by application of ultrasonic energy to the mold. After the molding operation, mold halves are separated, and the carrier web is advanced, or indexed, to a next position for another molding sequence. Articles produced include lenses with part of the carrier web between lens halves, and a carrier web bearing an array of molded parts.

Abstract: A method of molding a microneedle including providing a mold apparatus having a mold insert having the negative image of at least one microneedle, a compression core, a mold housing configured to allow a reciprocal motion between the mold insert and the compression core. The method includes placing the mold apparatus in a closed position, injecting polymeric material into the closed mold apparatus, compressing the injected polymeric material between the mold insert and the compression core by a reciprocal motion between the compression core and the mold insert, opening the mold, and removing a molded microneedle from the mold. The mold insert has a mold insert height and the molded microneedle has a height that is from about 90% of the mold insert height to about 115% of the mold insert height.

Abstract: Articles enabled by an injection molding process that molds parts on a carrier web located between mold halves and uses ultrasonic energy to assist flow of polymer melt into the mold cavity. One such article is a carrier web having a high density of molded parts, i.e., bearing an array of molded articles adhered to the web in rows and columns, the articles being spaced closer (center-to-center or edge-to-edge) than the diagonal spacing between articles in the next adjacent row and next adjacent column. Another such article is a microneedle array on a land no more than 250 ?m thick on which at least 60% of the microneedles across the array are filled (i.e., completely formed).