Abstract: A method for thermally activating photocatalytic generation of hydrogen from water, comprising: mixing a catalyst comprising a plurality of nanoparticles into a volume of water, wherein H2O molecules adsorb onto the surface of the plurality of nanoparticles to form OH complexes, wherein the diameters of the plurality of nanoparticles are less than 35 nanometers; exposing the solution to sunlight, wherein the temperature of the solution is increased to be within the range of 110 to 140 degrees Fahrenheit; and generating a plurality of electron hole pairs in the plurality of nanoparticles of the catalyst, wherein the electron hole pairs assist in the weakening of OH complexes on the surface of the plurality of nanoparticles to cause hydrogen atoms to thermally desorb from the OH complexes.

Abstract: Disclosed is a process for applying a kinetic spray coating of powder particles onto a substrate covered in a plastic-type material without first removing the plastic-type material. In one use of the process a mask is used to enable a single kinetic spray pass to both remove the plastic covering and bind particles having average nominal diameters of from 60 to 250 microns to the underlying substrate. In another use of the process the particles have an average nominal diameter of from 250 to 1400 microns and the use of a mask is optional because the particles can penetrate the plastic material and bind directly to the substrate. The process finds special use in forming electrical connections or solderable pads anywhere along the length of a flexible circuit.

Abstract: A process for physically bonding two parts to each other is disclosed. In addition, a process for forming electrical connections have a low resistance is disclosed. The process is generally applicable to the joining of two parts each formed from a metal, an alloy, or a combination thereof. The process finds special use in the formation of multi-celled batteries. The process involves placing two parts or electrical conductors in contact with each other and then bonding them to each other using a kinetic spray process and powder particles. In formation of a multi-celled battery the particles are preferably electrically conductive. The process enables for rapid and cost effective formation of a physical connection. In addition, the connection can have an electrical resistance of less than about 0.5 milli Ohms and strength equal or greater than ultrasonic welding.

Abstract: A converging diverging supersonic nozzle for a kinetic spray system is disclosed. In one embodiment, the supersonic nozzle has a first end opposite an exit end and a diverging region adjacent the exit end. A removable throat insert has an entrance cone and a throat and is received in the first end with the throat positioned adjacent the diverging region. In another embodiment, the removable throat insert has an entrance cone, a diverging region and a throat positioned between the entrance cone and the diverging region. The disclosed replaceable throat inserts address the problem of excessive wear in the throat relative to the rest of the supersonic nozzle which has plagued other kinetic spray systems. With the disclosed inserts a worn throat can rapidly and economically be replaced while saving the rest of the supersonic nozzle.

Abstract: A method for deposition of a metal layer onto plastic materials is disclosed. The method allows for formation of long length strain gauges and deposition of high melting temperature metals onto plastic materials. The method comprises initially depositing a pattern of powder particles onto the plastic material using a kinetic spray process. Then the high melting temperature metal layer is deposited using a thermal spray process. The metal layer only adheres to the pattern of the powder particles and not to the plastic substrate. To form a stain gauge the powder particles are deposited in a discontinuous non-electrically conductive density on the plastic material. Then a metal layer is deposited using a thermal spray process and a metal having a variable resistance. The metal forms a continuous and electrically conductive pathway having a resistance that changes as stress is applied to the substrate.

Abstract: An improved nozzle for use in kinetic spray systems is disclosed. The nozzle includes a supersonic portion comprising a tubular section and a flow regulator. A portion of the flow regulator is received in the tubular portion. The flow regulator includes a biconical flow concentrator that allows one to create very small dimension coatings on substrates. Using the present nozzle enables one to create spot coatings and very narrow width line coatings that find use in electrical components.

Abstract: Disclosed is a method for forming a heat sink laminate and a heat sink laminate formed by the method. In the method a particle mixture is formed from a metal, an alloy or mixtures thereof with a ceramic or mixture of ceramics. The mixture is kinetically sprayed onto a first side of a dielectric material to form a metal matrix composite layer. The second side of the dielectric material is thermally coupled to a heat sink baseplate, thereby forming the heat sink laminate.

Abstract: Disclosed is a process for applying a kinetic spray coating of powder particles onto a substrate covered in a plastic-type material without first removing the plastic-type material. In one use of the process a mask is used to enable a single kinetic spray pass to both remove the plastic covering and bind particles having average nominal diameters of from 60 to 250 microns to the underlying substrate. In another use of the process the particles have an average nominal diameter of from 250 to 1400 microns and the use of a mask is optional because the particles can penetrate the plastic material and bind directly to the substrate. The process finds special use in forming electrical connections or solderable pads anywhere along the length of a flexible circuit.