Abstract: A method for manufacturing a transfer member suitable for use in an image forming system. A liquid polymer is applied to an internal surface of a rotating drum, spun flat, and cured in place. Additional components of the belt are applied to the rotating mold to form a multi-layered transfer member.

Abstract: A silicone-epoxy resin is mixed with a conductivity enhancing agent, such as carbon black, and is cured to control the resistivity of films that may be used as mold release agents in mold processing or mold shaping electrically sensitive energetic compositions, such as rocket fuels, explosives, gas generator fuels and the like. The uncured precursor to the mold release agent is placed as a coating on molds that are used in these processes. Upon curing on the mold, the enhanced conductivity of the film permits dissipation of static electricity from the electrically sensitive energetic compositions.

Abstract: A fuel cell separator made of conductive material and resin wherein the conducive material is recycled from waste of fuel cell separators. The fuel cell separator consisting of conductive material and resin is made by using the waste of fuel cell separator consisting of conductive material and resin. The waste of fuel cell separator is pulverized to powder and is mixed with unused resin and, if necessary, supplemental conductive material, to establish powdered material. The powdered material is molded under the predetermined molding pressure and temperature. The fuel cell separators using the recycled material are comparable to fuel cell separators made solely from new material. In another aspect, a method of producing a fuel cell separator using the recycled material is disclosed.

Abstract: A method for repairing fiber-reinforced composite structures while maintaining original EM and lightning protection using carbon nanotubes, fibers, and thermoset resins is disclosed. According to one embodiment of the invention, the method comprises preparing a damaged area for repair; preparing a repair patch for the damaged area, the repair patch comprising nanotubes; applying the repair patch to the damaged area; and curing the repair patch. A repair patch for a composite structure having a conductive layer is disclosed. According to one embodiment of the present invention, the repair patch includes a binder and nanotubes. A repair resin for repairing a composite structure having a conductive layer is disclosed. According to one embodiment of the present invention, the repair layer includes a resin and nanotubes. A putty for repairing a composite structure having a conductive layer is disclosed.

Abstract: A method of manufacturing material suitable for the construction of a component of a fuel cell, such as a flow field plate or electrode, is provided. Uncured resin impregnated flexible graphite sheet is ground into particles. Without re-expanding the particles, and without adding further resin to the particles, the particles are molded into the form of the desired material. The material is then cured. Additives may be mixed with the particles to improve the properties of the material.

Abstract: A film is made of an insulating matrix resin and an electroconductive material, in which the electroconductive material is dispersed in the insulating matrix resin in such a manner that a surface resistivity of A [&OHgr;] of the film and a volume resistivity of B [&OHgr;·cm] of the film in the direction of a thickness thereof normal to the surface of the film satisfy a relationship of: A>B, and when the film has a thickness of T [cm], the electroconductive material is dispersed in the insulating matrix resin in such a manner that the surface resistivity of A [&OHgr;] of the film and the volume resistivity of B [&OHgr;·cm] of the film satisfy a relationship of: A [&OHgr;]×T [cm]>B [&OHgr;·cm]. This film can be prepared by a centrifugal molding method.

Abstract: A conductive polymer is disclosed which is suitable for use in applications which require corrosion resistance including resistance to corrosion when subjected to acidic flow at temperature ranging from −40 to 140 degrees Fahrenheit and which can be molded such as by compression and/or injection molding techniques, into highly intricate and thin specimens without significant post machining. and which exhibit consistent conductivity, sufficient strength and flexibility, and appropriate surface characteristics. In particular the invention involves molding resin composition, which have high loadings of conductive fillers. Further the compositions may include rheological modifiers such as Group II oxides and hydroxides; carbodiamides; aziridines; polyisocyanates; polytetrafluorethylene (PTFE); perfluoropolyether (PFPE), and polyethylene. In an additional embodiment of the invention, an anti-shrink additive is added to improve the characteristics of the molded fuel cell plate.

Abstract: A flexible graphite sheet exhibiting enhanced isotropy is provided. In addition, an apparatus, system and method for continuously producing a resin-impregnated flexible graphite sheet is also provided.

Abstract: An electrically conductive floor covering made of first particles of a polymer material which are surrounded with electrically conductive second particles and compressed in the intermediate space between the top and bottom sides of the floor covering, with the floor covering having at least one cut surface and the electrically conductive second particles forming conductive paths which connect the upper side and the lower side of the floor covering in an electrically conductive way, in which the first particles comprise at least one granulated elastomer material and form a matrix, in which the second particles form electric conductive paths along the particle boundaries of the first particles.

Abstract: A method for manufacturing a transfer member suitable for use in an image forming system. A liquid polymer is applied to an internal surface of a rotating drum, spun flat, and cured in place. Additional components of the belt are applied to the rotating mold to form a multi-layered transfer member.

Abstract: A compostion having improved fuel vapor barrier properties comprising a blend of about 20 to 80 weight percent of a first fluorointerpolymer with about 80 to 20 weight percent of a second fluorointerpolymer, the first fluorointerpolymer comprising a copolymer, terpolymer or mixture thereof formed by the copolymerization of two or more monomers selected from the group consisting of hexafluoropropylene, vinylidene fluoride and tetrafluoroethylene, and the second fluorointerpolymer comprising a copolymer, terpolymer or mixture thereof formed by the copolymerization of two or more monomers selected from the group consisting of hexafluoropropylene, vinylidene fluoride and tetrafluorotheylene, wherein the first fluorointerpolymer exhibits elastomer characteristics and the second fluorointerpolymer exhibits thermoplstic characteristics.

Abstract: A composite that includes an elastomer matrix into which carbon fibrils are incorporated. The fibrils are characterized as having a morphology consisting of tubes that are free of a continuous thermal carbon overcoat and have graphitic layers that are substantially parallel to the fibril axis, or as having a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along the fibril axis.

Abstract: A magneto-resistive CrO2 polymer composite blend comprising 90-95% by weight of the polymer preferably Low Density Poly Ethylene, 5-10% by weight of magnetic filler preferably CrO2 and 2-4% by weight of an additive, prepared by the process of mixing the said polymer, said CrO2 and said additive in a mortar pestle to obtain a homogenous mixture, the said mixture is heated at a temperature of 95-100° C. to obtain a blended melt, the said blended melt is then casted between two metal plates to obtain sheets by applying the pressure.

Abstract: An electrode for secondary battery made of carbon material is provided, which is light in weight while excellent in charge-discharge properties and in durability in repetitive use. A material for electrode is obtained by intermixing a synthetic resin with vapor-phase growth carbon fibers to make the vapor-phase growth carbon fibers uniformly dispersed in the synthetic resin to obtain a mixture, molding the mixture into a predetermined shape to obtain a molded product, and heating the molded product at high temperature to convert it into a carbon-carbon composite material. The electrode for battery is made of thus obtained carbon-carbon composite material.

Abstract: A process for producing an electrode for an electric double layer capacitor, which comprises extruding a mixture comprising a carbonaceous material, a polytetrafluoroethylene and a processing aid by paste extrusion, and rolling the obtained extruded product by rolling rolls to form it into a sheet shape.

Abstract: A contact key switch formed with two conductive layers molded together on opposite sides of an elastic layer to form a contact sheet. A contact portion is removed from the contact sheet and molded with a main body to form the contact key switch.

Abstract: A method of making a cathode assembly for a metal-air battery includes extruding a composition having a catalyst, a fibrillatable material, and a lubricant, to form an extrudate; calendering the extrudate; connecting the extrudate to a current collector; and heating the extrudate to remove at least a portion of the lubricant to make the cathode assembly. The method can further include laminating a separator to the cathode assembly.

Abstract: A front cover, a rear cover and a base portion are crushed into a crushed material, and further pelletized into a recycled plastic pellet. The recycled plastic pellet is used as a part of a molding material to produce mold plastic parts for a photosensitive material. When the molding material is melt in heat, a thermoplastic resin is deteriorated by heat or modified. Therefore, properties and qualities of recycled plastic mold parts are less than those of new ones. Further, when the thermoplastic resin is deteriorated by heat, the photosensitive material reacts with the thermoplastic resin to decomposed products having an bad influence on photographic characteristics. In order to prevent the deterioration by heat, oxidation inhibiting materials are added, and in order to absorb the decomposed products, carbon blacks are added.

Abstract: A technique for fabricating an improved electronic enclosure. The electronic enclosure is made of graphite fibers dispersed directionally (non-homogeneous) in an absolac/polycarbonate (ABS/PC) resin mix, which the composition is molded to form the plastic enclosure. The graphite concentration is highest along the interior surface of the enclosure to provide improved heat transfer, as well as adequate EMI/RFI shielding. However, the graphite concentration decrease along the thickness, wherein at the outer surface, the graphite concentration level is zero. The directional variation in the graphite loading allows high graphite loading at the interior surface of the enclosure, but retains lower loading at other regions along the thickness so that rigidity and impact resistance are retained for the enclosure.

Abstract: A technique and apparatus are disclosed for injection molding highly filled conductive resin compositions. These compositions include one or more of unsaturated polyester and vinyl ester resin; a copolymer having a terminal ethylene group; and at least about 50 weight percent of an inorganic particulate conductive filler, an initiator, and a rheological modifier to prevent phase separation between said resin and said conductive filler during molding. The method of the present invention allows these compositions to be molded into highly intricate and thin electrically and thermally conductive specimens without significant post process machining. The method involves the use of an injection molding apparatus that has a hopper with an auger having a vertical component in its positioning to feed into the feed throat of an injection molding machine which has a phenolic screw that has been modified to have a constant inner diameter and a constant flight depth.

Abstract: The invention relates to a process for producing a positive electrode, containing an organic polymer as binder, for primary elements with alkaline electrolytes. The process according to the invention is carried out in the following way: manganese dioxide particles are mixed with a graphite dispersion, which contains an organic polymer, and are compressed to form an electrode body.

Abstract: Modified cokes or blacks suitable as alkali metal intercalation electrodes in electrochemical cells are produced by a method comprising boiling the coke or black in concentrated hydrochloric acid, flushing with distilled water, sonicating the coke or black in acetone, and drying the coke or black at a temperature of 150 to 300° C. The modified cokes and blacks produced by this method show Intercalation capacities up to 50% higher than unmodified cokes and blacks, and maintain the high electrolyte compatibility, rate capability and cyclability of the cokes or blacks.

Abstract: The present invention refers to an anode composition comprising as binding agent the sugar cane molasses, mascavo sugar, brown sugar or demerara, VHP, crystal, refined or hard sugar, instead of the conventional electrolytic pitch. The composition may optionally include additives based on lithium, fluorine, aluminum, boron and sulfur, and is used in a process for the manufacture of anodes for the primary aluminum industry. The invention also refers to a process for the manufacture of said anode and the application thereof to the primary aluminum industry.

Abstract: A separator for a fuel cell is manufactured by preparing a raw material powder, uniformly mixing the prepared raw material to be formed into a slurry, and charging the raw material powder derived from granulation into a metal mold for heat press forming. The raw material is obtained by adding to carbon powder a binder containing a mixture of phenolic resin and epoxy resin. Therefore the heat press forming step does not cause the binder to generate gas, thus allowing manufacturing of a separator exhibiting sufficient gas-impermeability.

Abstract: A thermally conductive and electrically insulative polymer composition and a method for creating the same is provided. Thermally conductive filler material is coated with a thermally conductive and electrically insulative coating material and mixed with a base polymer matrix. The mixture is molded into the desired shape. The electrically insulative coating material prevents the transfer of electricity through the filler material thus resulting in an electrically insulative composition.

Abstract: An improved elastomeric mold for use in fabricating microstructures, the mold having first and second surfaces, the first surface including at least one recessed microchannel and the second surface including an access opening or filling member that extends through the mold to the first surface and communicates with the recessed microchannel. The mold is used by placing it onto a substrate with the recessed microchannel facing the substrate. The access opening of the mold is filled with a liquid material which is capable of solidifying. The access opening continuously introduces the liquid material into the space defined between the microchannel and the substrate. After the liquid material solidifies, the mold is removed from the substrate thereby leaving a microstructure formed from the solidified liquid material on the substrate.

Abstract: An electrochemical sensor which is tailored for sensitivity to specific chemical analytes by selecting proper constituents. The electrochemical sensor is comprised of an immiscible polymer blend of at least two polymers in which a conductive filler is dispersed in one of the polymers of the blend through a multiple percolation approach to compounding. When in the presence of a chemical analyte which is in either a liquid or vapor phase, one phase of the dual immiscible polymer blend swells, effecting a decrease in the conductivity, or increase in resistivity, of the polymer blend. The electrochemical sensor is reversible in that when the chemical analyte evaporates or is removed, the polymer blend returns to its original conductivity.

Abstract: Processes and apparatus for melt extrusion of polymeric compositions, particularly conductive polymers, in which a gear pump delivers molten polymeric composition to an extrusion orifice. Overfeeding of the composition due to pressure variations is avoided by means of a polymer relief means, preferably a second, smaller gear pump, which removes a portion of the molten composition when the pressure exceeds a selected level.

Abstract: The invention provides an organic positive temperature coefficient thermistor comprising at least two polymer matrices, a low-molecular organic compound and a conductive particle having spiky protuberances. For the polymer matrices, at least two thermoplastic polymer matrices having varying melting points or at least one thermoplastic polymer matrix and at least one thermosetting polymer matrix are used. It is thus possible to provide an organic positive temperature coefficient thermistor which has sufficiently low room-temperature resistance and a large rate of resistance change between an operating state and a non-operating state, and can operate with a reduced temperature vs. resistance curve hysteresis, ease of control of operating temperature, and high performance stability.

Abstract: A process is described for making a set of precision tweezers (1) which includes a grip (2) with two tines (2′, 2″), to each of which is attached a shaped tip (3′, 3″), characterized by the fact that it includes the following phases:

Abstract: Composition for preparing water-repellent coatings on optical substrates, comprising a porous, electrically conductive molding and an organosilicon compound, obtainable by mixing an electrically conductive or semiconductive support material with a binder and subjecting the mixture to compression molding to form a compression molding, sintering the compression molding at preferably 1100 to 1500° C. in air to form a porous molding, impregnating the molding with the organosilicon compound, and ageing the impregnated molding by storage in air for at least 3 days.

Abstract: Carbon fiber-filled PC-ABS resin compositions which have improved electrical properties at a given level of carbon fibers, and which do not suffer from as significant a decrease in impact strength as would result from the introduction of generic carbon fibers are achieved using carbon fibers treated with a polyamide terpolymer binder. The bundles are dispersed within the PC-ABS blend. The compositions can be used for injection molding of articles for use as components in applications requiring static dissipation and/or EMI shielding. Such articles include, but are not limited to electronic devices, dust handling equipment and notebook computer enclosures.

Abstract: Carbon fiber-filled, thermoplastic resin compositions having improved electrical properties at a given level of carbon fibers are formed from thermoplastic resin and carbon fibers associated into bundles with a binder. The thermoplastic resin and the binder are selected to be incompatible such that the adhesion of the fiber to the resin is poor. An exemplary composition is formed from a thermoplastic polymer selected from among polystyrene, high impact polystyrene, polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyphenylene ether, polyether imide and blends thereof; and carbon fibers associated into bundles with a polyamide terpolymer binder. The bundles are dispersed within the thermoplastic polymer. The compositions can be used for injection molding of articles for use as components in applications requiring static dissipation and/or EMI shielding. Such articles include electronic devices, dust handling equipment and notebook computer enclosures.

Abstract: A highly conductive thermoplastic elastomer (TPE) gap filler having superior durability and EMI shielding properties. According to the preferred embodiment, the TPE comprises graphite fiber having a nickel-copper-nickel coating formed thereabout that is suspended within an elastomer, which preferably comprises polyvinylchloride (PVC). The TPE of the present invention is particularly well-suited for reducing radio frequency electromagnetic radiation reflected by gaps formed between adjacent panels of a structure, and is particularly well-suited for the maintenance and repair of LO aircraft. The TPE of the present invention may further be modified to include carbon black filler.

Abstract: The radiation shielding composition and method of the present invention relate to a conformal coating material composed of a matrix of densely packed radiation shielding particles, which are disbursed within a binder. The shielding composition is applied to objects to be protected such as integrated circuits, or to packages therefor, as well as for protecting animals including humans from unwanted exposure to radiation in outer space or other environments.

Abstract: A process of producing multi-layer cathode structures. In one aspect, the process comprises providing a carbonaceous cathode substrate, and forming at least one layer of a metal boride-containing composite refractory material over the substrate, wherein the surface of the carbonaceous substrate to be coated is roughened prior to the formation of the layer overlying the said surface. The roughening of the surfaces reduces the tendency of the layers to separate in high temperature operating conditions. In another aspect, the process comprises providing a carbonaceous cathode substrate, and forming at least two coating layers of a metal boride-containing composite refractory material successively over the substrate, wherein the content of metal boride in the coating layers increases progressively as the distance of the layer from the substrate increases.

Abstract: A conductive polymer is disclosed which is suitable for use in applications which require corrosion resistance including resistance to corrosion when subjected to acidic flow at temperature ranging from −40 to 140 degrees Fahrenheit and which can be molded into highly intricate and thin specimens which exhibit consistent conductivity, sufficient strength and flexibility, and appropriate surface characteristics. In particular the invention involves molding unsaturated prepolymer resin composition which have high loadings of conductive fillers. Further to enable the necessary characteristics, the compositions include rheological modifiers such as Group II oxides and hydroxides; carbodiamides; aziridines; polyisocyanates; polytetrafluoroethylene (PTFE); perfluoropolyether (PFPE), and polyethylene.

Abstract: Powder mixture is supplied into a die under a state that a center pin is located lower than the top surface of the die, after which the center pin is lifted up to a given molding position where an annular molding space is defined between the center pin and the die. The powder mixture is then compressed from upper and lower sides with an upper plunger and a lower plunger to form a pellet. The center pin and the lower plunger are simultaneously lifted up to remove the pellet out of the die.

Abstract: A method of molding a reinforced article for optimizing heat transfer, electrical conductivity and/or structural integrity is provided. A mold assembly is first provided which is capable of forming an article of a desired configuration. The desired positioning of the filler within the molded article is determined according to the thermal, electrical or structural needs of the article. An input gate and output gate vent is formed in the mold assembly to ensure positioning of the filler as desired. Polymer, loaded with reinforced filler, is introduced into the mold assembly via the input gate. Polymer is positioned in the mold assembly with the reinforcing filler being substantially parallel and aligned with the flow path. Finally, the molded article is ejected from the mold assembly. With the molding method of the present invention, thermal and electrical conductivity and structural integrity of articles may be increased several times over articles molding with conventional molding methods.

Abstract: A method for preparing a conductive thermoplastic resin composition or an electric conductor includes the step of kneading (a) conductive resin master batch pellets of conductive carbon black and a thermoplastic resin in which the conductive carbon black accounts for 5 to 50% by weight relative to the total amount 100 parts by weight of the conductive carbon black and the thermoplastic resin, (b) a thermoplastic resin in a weight ratio: (a+b)/(a) ranging from 1.01 to 1.5. This method permits the production of a conductive carbon black-containing conductive resin composition and an electric conductor which show stable conductivity even within a high resistance region (having a surface resistivity ranging from 10.sup.6 to 10.sup.16 .OMEGA.), wherein the control of the conductivity is difficult.

Abstract: Flexible graphite sheet is made by compressing a mixture of fine particle of intercalated, exfoliated, expanded natural graphite with fine particles of intercalated, unexpanded, expandable particles of natural graphite, the unexpanded particles being more finely sized than the expanded particles. The resulting sheet of flexible graphite exhibits improved fire retardant and sealability properties.

Abstract: A method of molding a thermally conductive article for transferring heat from a heat generating surface is provided. A mold assembly is first provided which is capable of forming an article of a desired configuration. The initial location of contact on the article with the heat generating surface is then determined. An input gate is formed in the mold assembly at the initial location of contact. The optimum heat flow path through the article is determined. A termination location of the heat flow path is determined. Polymer, loaded with conductive filler, is introduced into the mold assembly via the input gate. Venting is provided in the mold assembly at the termination location of the heat flow path. Polymer is positioned in the mold assembly with the conductive filler being substantially parallel and aligned with the heat flow path. Finally, the molded article is ejected from the mold assembly.

Abstract: A self-lubricating plastic center plate assembly bearing liner for placement between a body bolster center plate and a truck bolster center plate of a center plate assembly in a railroad car, wherein the liner is configured to substantially mate with the center plates and includes a body having an integrally formed electrically conductive ring of plastic material which provides electrical continuity between the plates in the center plate assembly.

Abstract: A bottom lining for electrolytic cells formed from steel pots for use in primary production and secondary refining, made from a monolithic stamping of a finely granulated powder having a high alumina content, and a process for producing same. The powder is obtained from aluminum industrial scrap recovery and salt slags and has the following components in the following amounts based on dried weight:______________________________________ Al.sub.2 O.sub.3 40-90% AlN 0.1-25% MgO 4-20% SiO.sub.2 0.5-15% CaO 0.1-15% Al (metallic) 0.1-10% Si (metallic) 0.1-10% Fe.sub.2 O.sub.3 0.1-5% C not more than 5% F not more than 5% Na.sub.2 O 0.1-5% K.sub.2 O 0.1-2% TiO.sub.2 0.1-2% Others not more than 5% Loss on ignition not more than 10%.

Abstract: Flexible graphite sheet having embedded ceramic fibers extending from its surfaces into the sheet to increase the permeability of the sheet to resin.

Abstract: A molded article comprising:(1) 70 to 99.5% by weight of a thermoplastic resin, and(2) 0.5 to 30% by weight of carbon fibers;wherein the carbon fiber comprises,(a) carbon fibers having a length of more than 1.5 mm being contained in an amount of 0.1 to 4.7% by weight,(b) carbon fibers having a length of 0.5 to 1.5 mm being contained in an amount of 0.2 to 10.7% by weight, and(c) carbon fibers having a length of less than 0.5 mm being contained in an amount of 0.2 to 14.6% by weight, wherein the weight % is based on the total amount of the thermoplastic resin and the carbon fibers.

Abstract: An improved elastomeric mold for use in fabricating microstructures, the mold having first and second surfaces, the first surface including at least one recessed microchannel and the second surface including an access opening or filling member that extends through the mold to the first surface and communicates with the recessed microchannel. The mold is used by placing it onto a substrate with the recessed microchannel facing the substrate. The access opening of the mold is filled with a liquid material which is capable of solidifying. The access opening continuously introduces the liquid material into the space defined between the microchannel and the substrate. After the liquid material solidifies, the mold is removed from the substrate thereby leaving a microstructure formed from the solidified liquid material on the substrate.

Abstract: The present invention provides a carbon composite material which is a molded material comprising (a) an expanded graphite powder and (b) a thermoplastic resin or a thermosetting resin or a fired product of the thermosetting resin, and the expanded graphite powder (a) being dispersed in the component (b), wherein the expanded graphite powder has an average particle diameter of 5-12 .mu.m and at least 80% of the total particles of the expanded graphite powder have particle diameters of 0.1-20 .mu.m; and a process for producing a carbon composite material, which comprises mixing and dispersing a thermoplastic or thermosetting resin and the expanded graphite powder as mentioned above, and then pressure-molding the resulting mixture at room temperature to 400.degree. C., or a process for producing a carbon composite material, which comprises mixing and dispersing a thermosetting resin and the expanded graphite powder as mentioned above, pressure-molding the resulting mixture at room temperature to 400.degree. C.

Abstract: An injection molding method for forming an article having a receptacle with a coating on an interior surface includes providing an injection molding tool with at least one cavity in one part and at least one core pin projecting from a second part having an outside surface. The core pin is sized to fit within the cavity with a clearance thereby defining a cavity space. The injection molding tool has an open position wherein the core pin is withdrawn from the cavity and a closed position wherein the core pin is disposed within the cavity for defining the cavity space. The method further sequentially then includes moving the injection molding tool to the open position and applying a coating of a coating material to the outside surface of the core pin. The method further includes moving the injection molding tool to the closed position.

Abstract: A method for producing a highly uniform dispersion of a carbonaceous conductive material for incorporation into a resin to achieve an excellent conductivity by acid-treating fine particles of the carbonaceous conductive material, and then crushing the resultant treated particles in a mill.