Abstract: A method for forming a balloon for a dilatation catheter involving the steps of extruding a segment of thermoplastic material, maintaining the center portion at a temperature below the glass transition of the thermoplastic material, drawing the segment to a predetermined length, wherein after the drawing the wall thickness of the center portion does not appreciably change, and expanding the segment in a mold to produce the balloon.

Abstract: Methods and apparatus for forming a film of a liquid material and for employing the film as a test sample for determining properties of the material in a suitable analytical instrument such as a spectrophotometer.

Abstract: A machine for crystallizing a thermoplastic preform or container is constructed from modular subassemblies and utilizes a preheated plug to provide the sole upright support for a workpiece in the crystallizing process. The first modular subassembly includes the workpiece in-feed and plug preheat structures and incorporates the drive apparatus for the entire machine. The opposed end of the crystallizing machine is constructed of a subassembly which operates to provide the turnaround and tensioning takeup for the carrier mechanism transporting the workpieces. Positioned between the first subassembly and the opposed end subassembly are heating and cooling processing modules which can be provided in any number depending on the size constraints and workpiece quantity restraints desired. The processing modules provide the heating and crystallizing processes for the desired area of the workpiece and the cooling process of the workpiece prior to unloading.

Abstract: This invention relates to rigid porous carbon structures and to methods of making same. The rigid porous structures have a high surface area which are substantially free of micropores. Methods for improving the rigidity of the carbon structures include causing the nanofibers to form bonds or become glued with other nanofibers at the fiber intersections. The bonding can be induced by chemical modification of the surface of the nanofibers to promote bonding, by adding "gluing" agents and/or by pyrolyzing the nanofibers to cause fusion or bonding at the interconnect points.

Abstract: Porous fluoropolymer films, such as PTFE films, formed by a method including the steps of (a) forming a fluoropolymer (e.g., PTFE) paste, (b) extruding, calendaring, or otherwise processing the paste to form a film extrudate, (c) causing the film extrudate to be calendared in a first directional axis, (d) subsequently calendaring the film extrudate in a second directional axis which is different from the first directional axis, (e) subsequently calendaring the film extrudate in at least one additional directional axis which is different from said first and second directional axes, thereby forming a multiaxially calendared film extrudate, (f) drying the multiaxially calendared film extrudate, and (g) radially expanding the multiaxially calendared film extrudate to form a radially oriented fluoropolymer (e.g., PTFE) film. The porous fluoropolymer films formed by this method are multiaxially oriented and exhibit isotropic strength properties.

Abstract: A process for producing graphite materials for a negative electrode used in a lithium secondary battery which process includes the steps of packing carbon materials having an average particle diameter of 5 to 50 .mu.m in a plurality of boxes, placing the boxes in a graphitization furnace, subjecting the graphite materials to graphitization treatment, and thereafter subjecting the resultant graphite materials to uniformization treatment by mixing and agitation. The above process is capable of decreasing the influence on the qualitative variation of graphite materials ascribed to packing operation into boxes for graphitization, to the position of the materials in a graphitization furnace, and to bubbling phenomenon or the like through graphitization treatment, and is also capable of stabilizing the qualities of the resulting graphite materials and increasing the productivity.

Abstract: A polyester resin composition is calendered to produce a film or a sheet. The polyester resin composition is a polyester having a crystallization half time from a molten state of at least 5 minutes combined with an additive for preventing sticking of the polyester to calendering rolls.

Abstract: A method of thermoforming a thin flexible film comprising a series of steps. A thin flexible film capable of being thermoformed is heated until it is pliable. A mold having first and second surfaces on different planes forms a thermoformed article having a contoured surface. A first portion of the pliable film is contacted with the first surface. A first vacuum is applied through the first surface to draw the first portion against the first surface. After the first portion of the film is drawn against the first surface, a second portion of the film contacts the second surface. A second vacuum is applied through the second surface to draw the second portion of the film against the second surface. Air trapped between the mold and the film is first removed between the first surface and the first portion of the film and then removed from between the second surface and the second portion of said film so that the thermoformed article is substantially defect-free.

Abstract: A process for preparing high strength carbon fiber from PAN-fiber wherein the time of the oxidation step is reduced from 30-90 minutes to about 8-15 minutes and product prepared therefrom.

Abstract: A carbon composite structure, for example, an automotive engine piston, is made by preparing a matrix including of a mixture of non crystalline carbon particulate soluble in an organic solvent and a binder that has a liquid phase. The non crystalline particulate also contains residual carbon hydrogen bonding. An uncured structure is formed by combining the matrix mixture, for example, carbon fibers such as graphite dispersed in the mixture and/or graphite cloth imbedded in the mixture. The uncured structure is cured by pyrolyzing it in an inert atmosphere such as argon. Advantageously, the graphite reinforcement material is whiskered prior to combining it with the matrix mixture by a novel method involving passing a gaseous metal suboxide over the graphite surface.

Abstract: A Process is described in which the polymer is passed over a former under hydro-static pressure, which may involve passing the material over a die or series of dies for the purpose of imposing multi-axial expansion to the workpiece. Some of the advantages are increased stiffness and reduction in creep. Improved wear is also found.

Abstract: The graphitized composite article of the present invention is formed by embedding carbon fiber felt in a matrix of a carbon filler; a thermosetting resin and a solvent; curing the composite article; then, carbonizing and graphitizing the cured composite article to form the graphitized composite article for use as a separator plate capable of substantially inhibiting mixing of hydrogen and oxygen and/or the loss of electrolyte within a fuel cell stack. The graphitized composite article may be a graphitized laminate.

Abstract: Direct thermal syntheses in the absence of catalyst, of poly(borazylenes) and of oligomers of borazine with polyhedral boranes, carboranes or heteroboranes are disclosed. The products of these syntheses are precursors to BN or other boron-containing ceramics.

Abstract: Producing of near net shape carbon (optionally carbon--carbon composite) pistons and other artifacts by sintering (with or without carbon fibers, preferably pitch-based carbon fibers and most preferably blends of vapor grown carbon fibers(VGCF)) homogeneous powders derived from petroleum pitch. The powders preferably exhibit properties equal to or exceeding those of POCO AXF-5Q. Preferred specific technical steps are substantially as follows:1. Individually prepare, by evaporation, heat treating and/or oxidizing of carbon-containing pitches, followed by oxidizing, comminuting and/or spray drying, to produce sinterable pitch powders (and optionally create uniform dryblends of pitch powder with various fractions of vapor-grown or other carbon fiber.)2. Produce near net shape carbon--carbon artifacts, such as cup shapes which are convertible to internal-combustion (i-c) pistons with minimal machining, by pressing or injecting into molds, then sintering and carbonizing. Both uniaxially (e.g.

Abstract: Cellulosic single fibers such as cotton are prepared without any resins or pitches to a mass or bulk such as a lap which is self-shaped and retains its form by a force of cohesive intertanglement of fibers. The mass as prepared is heated for carbonization or graphitization, if desired, to obtain unique shaped carbides of porous and stable structures in which the cohesion of fibers is made more dense on account of the total shrinkage of the mass by carbonization.

Abstract: Stretch-formable metal-plastic composite laminate, for example for the production of containers, the laminate having a metal layer and a plastic layer on both sides of the metal layer, the metal layer having a thickness x and the plastic layers each having a thickness of 0.7 x to 1.4 x, and x being a thickness of 30 to 70 .mu.m, and the plastic layers containing thermoplastics based on olefin, for example polypropylene, or consisting of them.

Abstract: A mesophase pitch-based carbon fiber for use as a material for a negative electrode of a secondary battery, and a process for producing the same. The mesophase pitch-based carbon fiber comprises a columnar core part having a texture composed of a plurality of graphite layers extending along an axial direction and extending with minute flexures in a plane perpendicular to the axis and an outer-shell part surrounding the core part. The outer-shell part has a texture composed of a laminate of a plurality of graphite layers extending along an axial direction. The graphite layers are oriented in a plane perpendicular to the axis in a fashion such that the graphite layers extend along a circumferential direction with minute flexures while gradually receding from a center of the core part.

Abstract: An improved process is disclosed for producing a unique metals-containing anisotropic pitch suitable for carbon fiber manufacture. Soluble, aromatic-organometallic compounds are added to a carbonaceous feedstock which is substantially free of mesophase pitch and the resulting composition is heat soaked to produce an isotropic pitch product containing mesogens and soluble, aromatic-organometallic compounds. Next, the pitch product is solvent fractionated to separate mesogens which contain metals from the organometallic compounds. The metals-containing mesogens are heated to a temperature sufficient to cause fusion to produce a metals-containing mesophase pitch.In another method, the carbonaceous feedstock is heat soaked to produce an isotropic pitch product containing mesogens and high molecular weight, soluble, aromatic-organometallic compounds are added to the mesogen containing isotropic pitch product prior to solvent fractionation.

Abstract: A composite film is described which has at least one base layer which predominantly comprises polypropylene, and at least one top layer. The top layer is sealable and comprises a homopolymer of an olefin. A process for producing the composite film, the top layer olefin homopolymer and packaging material made from the film also are described.

Abstract: A method of making a one-piece steering wheel insert includes the steps of extruding material into an elongated continuous extrusion having a shape including an outer rim portion, a central hub portion and at least one spoke portion extending between the hub portion and the rim portion, cutting the extrusion into a plurality of blanks, and forming each of the blanks into a final shape of the steering wheel insert.

Abstract: A composition which is a blend of at least two different polyetheramide copolymers, one having predominantly hard polyamide segments and one having predominantly soft polyether segments. When formed into a film and attached to a textile fabric, forms a laminate which is suitable for the production of surgical gowns, and the like. Such films are strong, have good moisture barrier properties while allowing the transmission of air therethrough and have a softness to which provides a clothlike feel.

Abstract: Method and apparatus for forming thick wall plastic components laminated with formable decorative film layers. A thermoformable thick wall plastic sheet in the range of 0.065 to about 0.300 inches thick over at least half its area is provided having a thermoformable decorative dry film coating on one side forming an outer surface of the laminated sheet. The sheet is peripherally supported in an open center rack, heated in one or more ovens to forming temperature and formed by a combination of compression and, preferably, vacuum forming with subsequent trimming of excess material to form a finished component with a high quality finish suitable for automotive body use. The compression and vacuum forming steps may be interchangeably performed in order and provide for high quality finish on the outer surface with shaping of reentrant wall portions on the inner side. Any suitable form of laminated sheet may be formed by the apparatus and method.

Abstract: Process for manufacturing cold formed shaped forms of packaging having at least one recess from a metal-plastic laminate. Examples of such shaped forms of packaging are the base parts of push-through packs or blister packs. The process is such that the laminate is held between a retaining tool and a die. The die exhibits at least one opening and a stamp is driven into the die opening causing the laminate to be shape-formed into a packaging, correspondingly exhibiting one or more recesses. The die and the retaining tool exhibit facing edge regions and the die, within the edge region, exhibits a shoulder region that surrounds the die opening or openings. The surface of the shoulder region lies 0.

Abstract: Disclosed is a process for preparing milled graphite fibers in which the amount of metallic components contained in the milled carbon fibers before graphitizing is limited to not more than 100/1,000,000 in terms of a ratio by weight. Also disclosed is a process for preparing milled graphite fibers in which the amount of metallic components contained in the milled carbon fibers before graphitizing except metallic components originally contained in the fibers themselves is limited to not more than 50/1,000,000 in terms of a ratio by weight. According to these processes, there can be obtained milled graphite fibers whose surfaces are inert, which suffer few longitudinal crackings and which are almost free from occurrence of particulate substances comprising agglomerated or bonded fibers.

Abstract: An aluminum matrix composite is provided comprising a preform formed from interwoven mats of graphitized vapor grown carbon fibers. The mats comprise semi-aligned, semi-continuous vapor grown carbon fibers which have been interwoven in situ during growth. The preferred method of producing the composite includes the steps of providing a vapor grown carbon preform and infiltrating molten aluminum into the interstices of the preform by a pressure casting process. The resulting aluminum matrix composite has a thermal conductivity of between about 600 W/m-K and 700 W/m-K and is useful as a component in electronic devices, aircraft, spacecraft, and other thermal management applications.

Abstract: A process for preparing high strength carbon fiber from PAN-fiber wherein the time of the oxidation step is reduced from 30-90 minutes to about 8-15 minutes and product prepared therefrom.

Abstract: A tape as unwound from a roll is passed through a preheater where it is preheated, and then heated to the softening temperature of the tape material by a main heater. The tape having ceased to retain its flat configuration due to being softened will drape over and come into close contact with generally the entire side surfaces of convex molds except for those portions of the tape located between adjacent convex molds. The tape thus generally brought into close contact with the convex molds continues to be moved with a rotating drum and is exposed to vacuum drawn through the slits formed at the roots of the opposed side walls of the convex molds while it is urged against a drum by the hold-down roller whereby those portions of the tape remote from the convex molds and located between adjacent convex molds are drawn into close contact with the front and back surfaces of the convex molds.

Abstract: The present invention is to improve a laminate molding method and a laminate-molding apparatus for manufacturing molded products that have an external appearance of excellent quality. For this purpose, according to a molding method, by which a mold clamping device (3) laminates sheet of skin material (Mm) and a core resin (200), the tension of the sheet of skin material Mm, which is inserted into a cavity (9) between a clamped fixed metal mold (11) and a clamped movable metal mold (12) and is laminated by the movable metal mold (12), is varied, continuously or in a stepped manner, in consonance with the insertion amount of the sheet of skin material (Mm).

Abstract: Method for producing a shaped part made of a graphitized carbon/carbon composite material in which a compound of carbon fibers is prepared impregnated with a solution of carbon precursors and then cut into sections placed in a mould subjected to a carbonization stage by means of hot unidirectional pressing, wherein, so as to prepare the compound, the fiber is subjected to a heat deoxidation and oil removal treatment followed by a softening in a bath for increasing wettability and hooking and then impregnation in a bath formed of an aqueous solution containing pitch mesophase, high-yield pitch and a binder, the required sufficient calculated amount of compound being placed in bulk in a hot constant volume pressing mould so as to accurately fill the mould at the end of pressing before carrying out said carbonization, the moulded part finally being graphitized at a high temperature. Applications include the aeronautic and spatial fields.

Abstract: The present invention provides a blow spinning die particularly suited for spinning solvated pitch into fibers having a random cross-sectional structure. Additionally, the present invention provides a process for blow spinning fibers from solvated pitches. The present invention also provides pitch fibers having a high energy internal molecular structure. Finally, the present invention provides carbon fibers which have a non-radial internal structure.

Abstract: A novel flexible biregional carbonaceous fiber is disclosed comprising an inner core region of a thermoplastic polymeric material and an outer region of a carbonaceous sheath. The flexible biregional carbonaceous fibers are particularly characterized by having a ratio of the radius of the core region with respect to the total radius of the fiber (r:R) of from about 1:4 to about 1:1.05, a density of from about 1.45 to about 1.87 g/cm.sup.3, and a bending strain value of from greater than 0.01 to less than 50%. In a further embodiment of the invention, a biregional precursor fiber is disclosed having an inner core region of a thermoplastic polymeric material and an outer sheath region of a oxidation stabilized, thermoset polymeric material. The oxidation stabilized precursor fiber is characterized by having a density of from about 1.20 to about 1.32 g/cm.sup.3. The invention further resides in methods of making the biregional fibers.

Abstract: A method for manufacturing a carbon preform comprising the steps of charging a container with pitch fibers obtained by melt spinning a carbonaceous pitch to fill therein during spinning, infusibilizing the thus filled pitch fibers, and calcining and molding the infusibilized pitch fibers under a uniaxial pressure, and a method for manufacturing a carbon/carbon composite material comprising densifying the carbon preform.

Abstract: Rigid-rod and segmented rigid-rod polymers, methods for preparing the polymers and useful articles incorporating the polymers are provided. The polymers incorporate rigid-rod backbones with pendant solubilizing groups attached thereto for rendering the polymers soluble.

Abstract: An improved process is disclosed for producing a unique metals-containing anisotropic pitch suitable for carbon fiber manufacture. Soluble, aromatic-organometallic compounds are added to a carbonaceous feedstock which is substantially free of mesophase pitch and the resulting composition is heat soaked to produce an isotropic pitch product containing mesogens and soluble, aromatic-organometallic compounds. Next, the pitch product is solvent fractionated to separate mesogens which contain metals from the organometallic compounds. The metals-containing mesogens are heated to a temperature sufficient to cause fusion to produce a metals-containing mesophase pitch.In another method, the carbonaceous feedstock is heat soaked to produce an isotropic pitch product containing mesogens and high molecular weight, soluble, aromatic-organometallic compounds are added to the mesogen containing isotropic pitch product prior to solvent fractionation.

Abstract: A process for the preparation of substantially polycrystalline silicon carbide fibers is provided. The fibers may be fabricated to have a small diameter and are thermally stable at high temperatures. The process is carried out by initially forming fibers from a preceramic polymeric precursor comprising methylpolysilane resins. The fibers are then infusibilized to render them nonmelting followed by a pyrolysis step in which the fibers are heated to a temperature in excess of 1600.degree. C. in a nonoxidizing atmosphere to form substantially polycrystalline silicon carbide fibers. The substantially polycrystalline silicon carbide fibers which are formed by the process of the present invention have at least 75% crystallinity and have a density of at least about 2.9 gm/cm.sup.3. The polymeric precursor or the fibers contain, or have incorporated therein, at least about 0.2% by weight boron.

Abstract: A volume of carbon fibrils that includes a multiplicity of fibrils having a morphology consisting of vermicular tubes that are free of a continuous thermal carbon overcoat and have graphite layers that are substantially parallel to the fibril axis and a process for preparing such fibrils.

Abstract: The graphite fiber-reinforced fluororesin composite including 99 to 40 parts by weight of a fluororesin, e.g. polytetrafluoroethylene, and 1 to 60 parts by weight of a graphite fiber. The graphite fiber has a specific surface area of 0.6 to 25 m.sup.2 /g and, as determined by X-ray photoelectron spectroscopic analysis, (1) a surface atomic oxygen/atomic carbon ratio of 0.10 to 0.20, (2) a surface atomic halogen/atomic carbon ratio of 0.05 to 1.8 or (3) a surface atomic oxygen/atomic carbon ratio of 0.10 to 0.20 and a surface atomic halogen/atomic carbon ratio of 0.05 to 1.8. Such fiber may, for example, be obtained by subjecting a graphite fiber to oxidizing treatment, halogenating treatment, or oxidizing and halogenating treatments. The graphite fiber imparts high mechanical strength characteristics and wear resistance to the composite.

Abstract: The invention relates to a heat-insulating structural carbon material and the process for producing thereof. This heat-insulating structural material is prepared from a suspension of discrete carbon fibers in a viscoplastic liquid such as polyglycol, glycerine and petroleum oils, by molding a preform and orienting discrete filaments, followed by baking the preform and depositing pyrolytic carbon in the porous structure thereof. This heat-insulating material comprises a coke matrix, discrete carbon filaments, the coke matrix as a porous film-like structure of coke residue on said filaments, and pyrolytic carbon.

Abstract: An improved method and apparatus for the production of a strand of reinforced graphite-foil yarn which is the basis of the braided graphite-foil yarns. To produce the reinforced graphite-foil strands what is needed is apparatus for a tapered, cone shaped circular die having a specific geometry suitable for curling the fiber and adhesive coated surface inward upon itself, so that the curled ribbon will adhere to itself when compressed into the final protrusion die forming a finished fiber reinforced composite strand of expanded graphite flake having suitable tensile strength, flexibility, and toughness to permit braiding, weaving and other processing making it commercially useful wherever a dry, lubricous, strong, flexible material is desirable.

Abstract: This invention relates to a process for forming metal or non-metal carbide fiber from the corresponding metal or non-metal.

Abstract: Tubular workpieces of oriented polymers such as polyethylene polyester and PVC are formed by drawing a workpiece over an expanding former in the absence of any force perpendicular to the axis of the workpiece. The processes do not require the use of any liquid lubricant. They enable greater degrees of expansion and hence orientation in the direction perpendicular to the axis to be achieved and result in products of improved appearance and strength.

Abstract: A method for producing a squeezable, thin-walled tube container of orientable plastic material in which the container includes a mouth portion, a squeezable thin-walled tubular container body having an open bottom-forming portion and a connecting portion located between the mouth portion and the container body and in which the mouth portion and the connecting portion consists of non-oriented material includes forcing the non-oriented material in the tube portion, by mechanical means, through a gap with a gap width at most amounting to approximately half the wall thickness of the material in the tube portion for orientation of the material passing through the gap, thereby obtaining substantially monoaxial orientation of the material which forms the container body and the open bottom-forming portion of the thin-walled squeezable tube container.

Abstract: Tubular workpieces of oriented polymers such as polyethylene polyester and PVC are formed by drawing a workpiece over an expanding former in the absence of any force perpendicular to the axis of the workpiece. The processes do not require the use of any liquid lubricant. They enable greater degrees of expansion and hence orientation in the direction perpendicular to the axis to be achieved and result in products of improved appearance and strength.

Abstract: An apparatus and method for continuously stretching a web of thermoplastic sheet into an arcuate form of desired curvature for the manufacture of laminated windshields. The apparatus includes conventional heating rolls, but employs at least two adjustable multispoke pyramids, one hot setting pyramid and one cooling pyramid which are separated by a wall incorporating a folding bar. The method relates to the manufacture of cut shaped blanks wherein hot setting and cooling steps are physically separated. Residual snap back after hot setting is released prior to the cooling step.

Abstract: Fabrication of conductive solid porous carbon electrodes for use in batteries, double layer capacitors, fuel cells, capacitive dionization, and waste treatment. Electrodes fabricated from low surface area (<50 m.sup.2 /gm) graphite and cokes exhibit excellent reversible lithium intercalation characteristics, making them ideal for use as anodes in high voltage lithium insertion (lithium-ion) batteries. Electrodes having a higher surface area, fabricated from powdered carbon blacks, such as carbon aerogel powder, carbon aerogel microspheres, activated carbons, etc. yield high conductivity carbon compositives with excellent double layer capacity, and can be used in double layer capacitors, or for capacitive deionization and/or waste treatment of liquid streams. By adding metallic catalysts to be high surface area carbons, fuel cell electrodes can be produced.

Abstract: An apparatus with pivoting blades and closable surfaces for forming a sheet of material into a flower pot or flower pot cover having fins. In an embodiment for forming outwardly extending fins, the apparatus includes a male mold and a plurality of plates arranged in pairs to define a forming opening. The male mold has a plurality of fingers which are laterally extendable from the outer periphery of the male mold. A pneumatic or hydraulic piston and cylinder is provided to move the male mold between a storage position spaced from the forming opening and a forming position within the forming opening. Each pair of plates is movable between an open position and a closed position. In operation, the fingers are extended to push folded portions of a sheet of material between the pairs of plates, which are closed to press the folded portions into fins. In an alternate embodiment for forming outwardly extending fins, pairs of movable plates are positioned between stationary segments.

Abstract: A hose assembly, an internally threaded member therefor and methods of making the same are provided, the hose assembly comprising a flexible hose having opposite ends, an internally threaded member mounted on one of the opposite ends in a manner to swivel thereon to permit the internally threaded member to be finger coupled to an externally threaded part of a liquid dispensing spigot, the internally threaded member having an outer peripheral surface, and an annular member disposed around the internally threaded member in a manner to engage the outer peripheral surface thereof and having an external peripheral surface to be finger engaged for turning the internally threaded member in unison therewith relative to the hose, the annular member comprising a SANTOPRENE material.

Abstract: A process for producing a process for producing a two- or three-dimensional carbon fabric, which process includes melt-spinning (a) an optically anisotropic carbonaceous pitch having an optically anisotropic phase content of 60 to 100%, subjecting the thus- infusibilized fibers to a primary heat treatment at a temperature greater than 1000.degree. and not higher than 2500.degree. C. to produce primary heat treated fibers having a tensile strength not lower than 300 kg/mm.sup.2 and a breaking elongation in the range of 0.4% to 10%, preparing a two- or three-dimensional fabric from the primary heat treated fibers and then subjecting the two- or three-dimensional fabric to a secondary heat treatment at a temperature which is at least 50.degree. higher than the temperature used in the primary heat treatment, the temperature in the secondary heat treatment being higher than 1050.degree. C. and no higher than 3300.degree. C.

Abstract: A fiber blend for use in friction materials. The fiber contains a blend of a highly fibrillated fiber, such as a fibrillated polyacrylonitrile fiber and a fiber with a high carbon content, such as an oxidized carbon fiber precursor.

Abstract: A sheet-like sandwich molding having two outer rigid covering layers and, as the core, at least one sheet-like structure of fiber material, which has been deformed by deep-drawing and been provided with synthetic resin. The sheet-like structure of fiber material, constituting the core, can, for example, be a knitted fabric provided with a curable condensation resin.