Abstract: A metallized composite includes a thermoplastic sheet and at least one discontinuous layer of metal within the thermoplastic sheet. The discontinuous metal layer can be disposed between two thermoplastic layers that are bound together, such as by melting the layers together, pressing, or by use of an adhesive. The metallized composites of the invention can be employed as reflective surfaces, such as are used as mirrors or substitutes for chrome trim on automobiles. A particularly preferred metal as a component of the discontinuous layer of the composite is indium.

Abstract: A resin composition including from about 1 to about 100 weight percent of a thermoplastic oxazolidone ring-containing compound having a molecular weight of at least 5000, which is the reaction product of: a) from about 20 to about 43 weight percent, based on the polyepoxide and polyisocyanate reactants, of a polyisocyanate having an isocyanate-functionality of from about 1.8 to about 2.2; b) from about 80 to about 57 weight percent, based on the polyepoxide and polyisocyanate reactants, of a polyepoxide having an epoxide functionality of from about 1.8 to about 2.2; and optionally, c) a chain extender. The resin composition is used as an adhesive to adhere a copper foil to a prepreg or a laminate, with improved peel strength and Tg.

Abstract: An optical device module, for example, an LED array module or photosensor module, includes a plurality of optical devices electrically attached to contact lands on a substrate by a plurality of electrically conductive hard particles and mechanically attached by a non-electrically conductive bonding adhesive. The optical device module may further include a cover that is transparent to the light emitted or detected by the optical devices and that has electrically conductive contact pads on an inner surface thereof, which are bonded to bond pads on a face surface of the optical devices. A process for fabricating an optical device module includes electrically connecting the optical device to the electrical contact land on the substrate by attaching a plurality of electrically conductive hard particles to either the base surface of the optical device or to the electrical contact lands.

Abstract: A semiconductor chip module uses a silicone adhesive between the semiconductor chip and a cap, said adhesive having sufficient bond strength to secure said cap to said chip without additional mechanical constraint while providing a direct thermally conductive path and permitting sufficient heat flow from said chip to said cap to maintain steady state operation of said semiconductor chip. The preferred silicone adhesive comprises a primerless, two-part polysiloxane-based adhesive made by reacting polydimethyl siloxane, an organosilicon compound, a polysiloxane, and a silane, in the presence of a catalyst.

Abstract: An optical device having at least two optically transparent optical parts which are bonded together with an optically transparent adhesive layer. The adhesive layer is formed from a matrix containing silicon, titanium, zirconium, aluminum or germianium, and oxygen atoms. At least part of the atoms is bonded to other atom(s) through a polyvalent hydrocarbon group and directly bonded a monovalent hydrocarbon group. The refractive index value of the adhesive layer approximates to the refractive index values of the at least two optically transparent optical parts. An adhesive composition for bonding optical parts and a method of bonding optical parts are also proposed.

Abstract: Resin soaked fiberglass strands are applied to abrasively cleaned steel pipe to increase the hoop stress. Steel pipe that is abrasively cleaned is preheated and a primer coat is applied. Fiberglass strands that are soaked with heated resin are then applied in a helical method to the pipe to induce an accelerated cure of the resin. Followed by a polyethylene wrap to protect the ouside of the composite. Allowing the coated pipe to be driven over a conveyor line. This process is continuous in which the steel pipe is wrapped from end to end, on pipe that is connected with a come-along (steel or plastic).

Abstract: A method for forming a saturating paper comprising the steps of selecting a sheet of paper, creating an embossed pattern of polygons on the sheet to increase the absorption capacity of the sheet, and causing a resin to contact the sheet such that the sheet absorbs at least a portion of the resin. The invention also includes a method for forming a decorative laminate including the steps of providing an overlay sheet, embossing the overlay sheet to increase the absorption capacity of the overlay sheet, and causing a resin to contact the overlay sheet such that the overlay sheet absorbs at least a portion of the resin. The method also includes the steps of locating the overlay sheet onto a decor sheet, and heating the overlay sheet and the decor sheet under pressure to bond the overlay sheet to the decor sheet.

Abstract: A laminate film has a composite structure and a bonding surface that eliminates the formation of air bubbles during the lamination process. A process for forming the laminate film includes spreading a PET film with an adhesive, drying the adhesive, and spreading a PE film, which is in a melted phase, on the dried adhesive, to form a composite film. An EVA fluid is spread on the PE film of the composite film, and the composite film with the EVA fluid is passed between first and second rollers. The first roller has a pockmarked surface and contacts the EVA fluid, thereby forming a pockmarked surface on the EVA fluid.

Abstract: A method and apparatus for fabricating a three-dimensional object from porous solid preform layers and at least a pore-filling material.

Abstract: A method of fabricating a passive integrated circuit. The integrated circuitry is fabricated in a single plane, the circuitry including passive components such as capacitors, resistors, and inductors. The method features the steps of forming on a substrate a first pattern of conductive material and a first set of passive component elements, and depositing a patterned dielectric layer onto the substrate. The first pattern of conductive material provides electrical connectivity to the first set of passive component elements.

Abstract: The bonding of steel locating hinge washers to a hinge assembly to facilitate doors-off/door-on processing through an automotive trim shop. The adhesive bonding system cures during the cathodic electro-cost primer bake cycle. The adhesive maintains an intimate, positive contact with both metal surfaces ensuring adequate bonding performance and maximized bonding surface area during a defined heat or bake cycle.

Abstract: A method for coating cloth especially fiberglass sheets with a thermosetting resin and resulting structure is provided. The coating is performed in two steps. In the first step, essentially all of the strands of the fiberglass are coated with the resin/solvent mixture while maintaining at least some of the interstices or openings essentially free of the solvent mixture. This first coating is then partially cured to between about 70% and 90% of full cure. The coated fiberglass with partially cured resin thereon is then given a second coating of either the same or different thermosetting resin mixture which coats the first coating and fills in the interstices between the fibers. This second coating is then partially cured, which advances the cure of the first coating past 80% full cure and results in an impregnated fiberglass cloth structure for use as sticker sheets.

Abstract: A textile composition for use in constructing useful garments, the textile composition comprising united superimposed layers of a plastisol composition, a primer and a pliant, stretchable fabric.

Abstract: One-component, heat-curing reactive compositions based on liquid rubbers containing reactive olefinic double bonds and optionally solid rubbers and vulcanization systems based on sulfur have high maxima of the acoustic loss factor over a broad in-use temperature range of around +10° C. to +40° C. in their vulcanized state. These compositions optionally contain fine-particle thermoplastic polymers as an additional component. The compositions are suitable for use as acoustically damping adhesives, sealing compounds or coating compositions.

Abstract: Disclosed is a polyol/polyisocyanate adhesive system having an isocyanate component and a catalyzed component which form a heat-cured composition when admixed and heated above a threshold temperature. The catalyzed component has a hydroxyl-functional component catalyzed with a catalyst combination of a heat-activatable amine or amine-like catalyst which is activated at temperatures above the threshold temperature, and an activatable complexed metal catalyst comprising the reaction product of tin or bismuth catalysts, or a mixture thereof, and a molar excess of a mercapto compound complexing agent. The catalyst combination is effective to maintain the processibility of the system at ambient temperatures while promoting the rapid cure of the system when heated above the threshold temperature.

Abstract: A process for the manufacturing of floor elements, which floor elements comprises an upper decorative surface a lower surface, edges intended for joining and a core forming a carrying structure. At least a first surface web or a number of first surface webs and possibly a second surface web or a number of second surface webs is fed between the belts of a continuous belt press. A mixture of polyols, such as polyester or polyether, crude methylene diphenyl diisocyanate and possibly a small amount of blowing agent in a ratio forming a polymeric resin with a density in the range 600-1400kg/m3 is then applied between the first surface web and the optional second surface web while being fed in between the belts of the continuous belt press. The belts are arranged to allow a mainly uniform and specified material thickness to form, whereby a slightly porous or solid polyurethane core is formed and possibly bonded to the first surface web and possibly the optional second web.

Abstract: An orthotic device developed and customized to control the desired movement of the patient's defective lower limb. The device incorporates a footplate made of a rubber-like elastomeric material and a proximal segment that encompasses the foot at the metatarsophalangeal joints and the shin portion of the leg. This proximal segment is made of a rubber-like elastomeric material laminated into multiple layers of fabric throughout the proximal segment. Additional strips of fabric are positioned within the proximal segment of the device to limit or promote certain motions within the foot and ankle. This device incorporates a continuous closure from the foot to the proximal segment, creating total contact and hydrostatic containment of the foot and lower leg.

Abstract: A processes for adhering a vulcanized rubber to a vulcanized rubber or an unvulcanized rubber. Adhesion of vulcanized rubbers to each other is conducted by using at least one of the vulcanized rubbers before vulcanization thereof according to steps of: (1) laminating a sheet material which can easily be peeled from a surface of a rubber after vulcanization to a rough surface of the rubber before vulcanization, (2) vulcanizing a resultant laminate, (3) removing the sheet material from the vulcanized laminate immediately before adhesion of the vulcanized rubber in the laminate to another vulcanized rubber, and (4) adhering the vulcanized rubbers to each other according to a method of adhesion. The adhering of the vulcanized rubbers to each other is also conducted by using a rubber composition for adhesion inserted between the vulcanized rubbers without procedures using the sheet material.

Abstract: A pressure-sensitive adhesive based on a dimethylpolysiloxane gum for adhering porous and semi-porous substrates. The adhesive has thixotropic properties which permits the viscosity of the adhesive to breakdown when pressure from one substrate is exerted on another substrate which is in a horizontal position in order to allow a temporary adhesion. The adhesive is transparent, has a consistency of a gel, and a viscosity range that controls the flow of the adhesive and provides a bond that can be broken by physical separation of the two substrates.

Abstract: A laminated panel having an abrasion resistant surface is provided. The laminated panel includes a web being impregnated with a thermo-set resin, a bottom coat and an abrasion resistant top coat; a substrate; and thermo-fusing a bottom sheet to a second surface of the substrate opposite the first surface. The web is thermo-fused to one surface of the substrate, and the bottom sheet is simultaneously thermo-fused to the opposite surface of the substrate. A process for making an abrasion resistant laminated panel is also provided. The process includes the steps of partially impregnating a paper sheet or web with a thermosetting resin, drying it, coating the top side of the partially impregnated paper sheet or web with an abrasion resistant coat, simultaneously coating the bottom side of the paper sheet or web with a thermosetting resin composition, thermo-fusing the coated paper sheet or web to a first surface of a substrate and a bottom sheet to produce the laminated panel.

Abstract: A method for producing integral capacitance components for inclusion within printed circuit boards. Hydrothermally prepared nanopowders permit the fabrication of a very thin dielectric layers that offer increased dielectric constants and are readily penetrated by microvias. Disclosed is a method of preparing a slurry or suspension of a hydrothermally prepared nanopowder and solvent. A suitable bonding material, such as a polymer is mixed with the nanopowder slurry, to generate a composite mixture which is formed into a dielectric layer. The dielectric layer may be placed upon a conductive layer prior to curing, or conductive layers may be applied upon a cured dielectric layer, either by lamination or by metallization processes, such as vapor deposition or sputtering.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A fiber reinforced composite wood board is designed particularly for use in the flooring of truck trailers which experience adverse operating conditions such as from heavy loads of lift trucks on the top side and water spray during rainy periods on the bottom side. The composite wood board comprises an edge-glued laminated wood member composed of wood segments with end joints. The wood member is underlaid with a thin layer of fiber reinforced plastic. The top surface of the composite wood board is the same as that of the laminated wood. The fiber reinforced plastic underlay is composed of glass and/or carbon fibers embedded in a polymeric resin such as epoxy, phenolic, vinyl ester, polyester, polypropylene or polyamide resin. Further, the fiber reinforced plastic underlay is substantially bonded to the wood member with a reactive hotmelt adhesive.

Abstract: A method of producing a vibration isolation mount assembly comprising at least one metal bracket member bonded to a volume of a resilient elastomeric material. The bonding of the elastomeric material to the metal bracket is improved by electrostatically spraying the metal brackets with an epoxy coating prior to adhering the rubber to the metal bracket members, but after vulcanization of the rubber material.

Abstract: A contact adhering method comprising the steps of: (1) applying a layer of a moisture curable adhesive to at least one of two adherends; (2) maintaning the two adherends in non-contact with each other for a period of time until the surface of the layer of moisture curable adhesive develops tack as a result of exposure to atmospheric moisture; and (3) bringing the two adherends into contact with each other in a tack range.

Abstract: A process for producing an improved three-dimensional polymeric adhesive material comprises: (1) reacting a starting polymer containing an active hydrogen or hydroxy function with a polyfunctional nucleophile to form an adduct product; and (2) reacting the adduct product with a polyelectrophile to generate a three-dimensional polymeric adhesive material. Preferably, the starting polymer is a high molecular weight polyester, the polyfunctional nucleophile is a polyisocyanate, and the polyelectrophile is at least one polyepoxide. The present invention also encompasses processes for bonding at least two substrates by generating the adhesive material between them, as well as the adhesive material itself. The invention is particularly suitable for bonding electronic components such as printed circuit boards.

Abstract: Methods for forming a lined brake shoe having a curved brake lining attached to a table of the lined brake shoe. The curved brake lining is manufactured by molding a flat sheet of brake lining material in a partially polymerized state. This flat sheet is allowed to cool prior to be positioned within a press having warmed dies. The warm dies of the press form the curved brake lining while holding the curved brake lining in its desired shape. The warm dies restart the polymerization process. When further polymerization has been completed the curved lining is removed from the press. One embodiment places the table of the lined brake shoe in the press. Then, by adding a bonding material, the completed lined brake shoe can be manufactured while the polymerization process continues in the press.

Abstract: A low-stress interface between materials having different thermal coefficients of expansion and method for fabricating same includes using a laminated composite layer having a lateral thermal coefficient of expansion (TCE) that is matched to the TCE of another layer of material that is joined thereto. Using a laminate material having a lateral TCE similar to the TCE of the material to which it is joined equalizes the lateral thermal expansion of the two materials at the interface therebetween and minimizes the stress placed on the material that joins the two materials. Furthermore, the layer of material to which the laminate is joined can also be a laminate.

Abstract: The invention relates to a process for applying coating films to three-dimensionally curved substrates, and to a process for producing coating films. In order to apply the coating film, which has at least a coating layer and an adhesive layer, the radiation-curable coating layer of the coating film is partially cured so as to be free from tack before being applied to the substrate. Following application, the coating film is subjected to electromagnetic radiation at below the wavelength of the visible spectrum and is fully cured. To produce a coating film, the coating layer is partially cured so as to be free from tack and in this state is stored until it is applied to a substrate. The coating layer can be attached at least indirectly to a smooth support base in conjunction with an adhesive layer. The coating layer and/or the coating film can be detached from a roller in applying the coating film to a substrate.

Abstract: Relatively low molecular weight olefin/CO polymers are graft copolymerized. The graft copolymers provide the basis for waterborne adhesives that are particularly useful for making wood composites.

Abstract: Adhesive coating film consisting of a) a radiation-cured coat which comprises from 40 to 90% by weight, preferably from 50 to 60% by weight, of urethane acrylate, from 0 to 20% by weight, preferably from 10 to 15% by weight, of polyether acrylate, from 10 to 50% by weight, preferably from 25 to 40% by weight, of reactive diluent, from 0 to 30% by weight of pigments from 0 to 10% by weight, preferably from 2 to 5% by weight, of a carboxy-functional (meth)acrylic esther [sic], from 0 to 10% by weight of other customary coatings fillers, and in the case of curing with UV radiation, from 0 to 10% by weight, preferably from 3 to 6% by weight, of photoinitiator, and b) which carries on one side an adhesive composition which has free NCO groups in the freshly applied adhesive composition, can be plastified thermally, especially under the intended processing conditions, and has a markedly weak surface tack.

Abstract: A batt of acoustical/thermal insulation for use in insulating appliances, compressors, machines and the like is disclosed. The batt comprises a fiberglass blanket and a release liner assembly. The liner assembly features a carrier sheet for supporting layers or coatings of adhesive on opposite broad surfaces thereof. One adhesive coated surface of the carrier sheet is releasably adhesively attached to a conventional release liner which is coated with an adhesive release agent. The other adhesively coated surface is joined to exposed fibers of a surface portion of the fiberglass blanket while the adhesive coating is in a heated, uncured, liquid state so as to immerse surface fibbers of the blanket in the adhesive. The carrier sheet adds stability to the resulting laminate structure and prevents surface fibers from being torn from the blanket when the release liner is removed from the carrier at the time of placement of the batt in service. A method for forming the batt is also disclosed.

Abstract: A method for bonding heat sinks to packaged electronic components comprises the steps of: (a) exposing to a plasma a surface of a molded polymer formed on a substrate; (b) allowing the plasma to at least partially convert silicon-containing residue on the surface to silica; and (c) bonding an article to the surface by applying an adherent material between the article and the surface. Often, the silicon-containing residue is silicone oil, a mold release compound, which may prevent the formation of a bond when using conventional bonding methods and materials. The silica layer formed on the surface of the molded polymer assists in formation of a proper bond. The plasma may be an oxygen plasma and the adherent material may be selected from either a heat cured silicone-based paste adhesive with a metal oxide filler or a heat cured porous polymer film impregnated with adhesive.

Abstract: A method of preparing a beta titanium-composite laminate comprising providing a first layer of beta titanium alloy having a yield strength to modulus of elasticity ratio and adhering a first layer of composite having a strength to modulus of elasticity ratio to the layer of beta titanium alloy, thereby forming a beta titanium-composite laminate, where the yield strength to modulus of elasticity ratio of the first layer of beta titanium alloy matches the strength to modulus of elasticity ratio of the first layer of composite such that the first layer of beta titanium alloy will reach its stress limit and the first layer of composite will reach its stress limits at about the same total strain.