Abstract: Surfaces of structural components of metal or the like are protected by depositing a wear-resistant dispersion coating of a matrix metal and hard-material particles embedded in the metal matrix. The depositing is accomplished by a sequential plasma spraying and particle blasting, whereby the hard-material particles are applied separately from the plasma stream to inject the particles into the plastically still deformable matrix metal. The coating steps are performed in an evacuated chamber or in an inert gas environment. These coatings are especially suitable on the blade tips of gas turbine engines, on the sealing fins of labyrinth seals or as "rub" coatings on circumferential rotor surfaces or the like.

Abstract: An electrode is attached to a solid electrolyte material by: (1) mixing a metallic nickel component and 1 wt% to 10 wt% of yttria stabilized zirconia having particle diameters up to 3 micrometers with an organic binder solution to form a slurry, (2) applying the slurry to a solid zirconia electrolyte material, (3) heating the slurry to drive off the organic binder and form a porous layer of metallic nickel substantially surrounded and separated by the zirconia particles, and (4) electro-chemical vapor depositing a skeletal structure between and around the metallic nickel and the zirconia particles where the metallic nickel components do not substantially sinter to each other, yet the layer remains porous.

Abstract: An apparatus for layering powder onto particles has a vessel in which a rotor is mounted rotatable therein around a vertical axis. The rotor is a disc with a supporting surface for supporting particles. The apparatus also has a feeder with a substantially horizontal introducing member protruding slightly into the vessel above the disc. The introducing member limits a liquid outlet and an annular powder outlet encompassing the liquid outlet. During a layering operation, the introducing member protrudes into a bed of particles lying on the rotating disc and moved by the latter. There can then be sprayed liquid and powder simultaneously onto the particles passing in proximity of the outlets. This enables layering powder onto particles to produce thereby pellets having sizes lying in a narrow range.

Abstract: A process for making an electrically conductive pattern on a substrate including forming a patterned adhesive layer on the substrate, applying a conductive metal powder to the adhesive layer, and in a second coating pass, applying a powder containing supplementary elements to the pattern. The patterned substrate is fired to volatilize theadhesive layer and sinter the powders. This process can be used to make printed circuits on ceramic substrates which are useful in hybrid circuits, for example.

Abstract: A method of applying a multicolor finish to an elongated channel member, particularly a ball channel for a pinball machine. A first fusible color coating is applied to a first portion of the channel member. A second fusible color coating is applied to a second portion of the channel member, while also applying the second color coating to a part of the first portion. The part of the first portion is adjacent the second portion, and the first and second color coatings are of different colors. Upon fusion of the color coatings the part of the first portion of the channel member assumes a third color that is a blend of the first and second colors, to provide a pleasing ball channel of at least three colors.

Abstract: An electrochemical device, containing a solid oxide electrolyte material and an electrically conductive composite layer, has the composite layer attached by: (A) applying a layer of LaCrO.sub.3, YCrO.sub.3 or LaMnO.sub.3 particles (32), on a portion of a porous ceramic substrate (30), (B) heating to sinter bond the particles to the substrate, (C) depositing a dense filler structure (34) between the doped particles (32), (D) shaving off the top of the particles, and (E) applying an electronically conductive layer over the particles (32) as a contact.

Abstract: A friction member which is suitable for use as a friction facing member in a transmission is provided. the friction member includes a uniform density heat resistant paper, a first layer of thermoset polymeric binder coated over and at least partially impregnated into one major surface of the paper, granular carbon friction particles uniformly distributed over and partially imbedded in the exposed surface of the first layer and a second layer of thermoset binder over the first layer and partially imbedded granular friction particles which coats without obscuring the granular friction particles.

Abstract: A dense coating of a calcium phosphate compound is formed on the surface of a bioadaptable ceramic substrate by applying to the ceramic calcium metaphosphate alone or a mixture of calcium metaphosphate with calcium pyrophosphate, heat-treating the applied layer thereby fusing the applied layer to the surface of the ceramic, then applying to the fused layer a slurry resulting from the mixture of calcium metaphosphate with tetracalcium phosphate, and subsequently heat-treating the applied layer of the slurry thereby inducing reaction of the slurry.

Abstract: An electrode is deposited on a support by providing a porous ceramic support tube (10) having an open end (14) and closed end (16); masking at least one circumferential interior band (18 and 18') inside the tube; evacuating air from the tube by an evacuation system (30), to provide a permeability gradient between the masked part (18 and 18') and unmasked part (20) of the tube; applying a liquid dispersion of solid electrode particles to the outside surface of the support tube, where liquid flows through the wall, forming a uniform coating (42) over the unmasked support part (20) and a tapered coating over the masked part (18 and 18').

Abstract: A process for making a carbon-carbon composite having a combination of high crystallinity, high strength, high modulus and high thermal and electrical conductivity. High-modulus/high-strength mesophase derived carbon fibers are woven into a suitable cloth. Layers of this easily graphitizable woven cloth are covered with petroleum or coal tar pitch and pressed at a temperature a few degrees above the softening point of the pitch to form a green laminated composite. The green composite is restrained in a suitable fixture and heated slowly to carbonize the pitch binder. The carbonized composite is then impregnated several times with pitch by covering the composite with hot pitch under pressure. The composites are given a heat treatment between each impregnation step to crack up the infiltrated carbon and allow additional pitch to enter the microstructure during the next impregnation cycle. The impregnated composites are then given a final heat treatment in the range 2500.degree. to 3000.degree. C.

Abstract: A flocked polyurethane foam fabric and method for manufacturing the same for which flock fibers imbedded in an adhesive on the foam are permanently flattened and entangled. Dry ink is transferred onto the flock fibers at the same time that flattening of the fibers is taking place. The flock fibers are thermally set into their flattened state along an outer surface of a polyurethane foam base of the fabric. Flattening the flock fibers causes the entanglement of the flock, thereby improving the hand, appearance, drapeability, abrasion resistance, water repellency and heat insulation qualities for apparel items over that of unflattened flock fibers.

Abstract: A fiber-reinforced thermoplastic composite comprising a fiber reinforcement, a first thermoplastic polymer about said fiber reinforcement, and a second thermoplastic polymer interposed between said fiber reinforcement and said first thermoplastic polymer; said second thermoplastic polymer being different from and compatible with said first thermoplastic polymer and capable of wetting said fiber reinforcement; and to the process of making such composite.

Abstract: A process for the manufacture of a prophylactic device having contained therein at least one pharmaceutically active substance, comprising:forming a first layer of elastomeric material into the desired shape of the prophylactic device;prevulcanizing the first layer;applying to one side of the first layer a layer of microcapsules having at least one pharmaceutically active substance encapsulated therein;depositing on the coating of microcapsules a second layer of elastomeric material; andvulcanizing the first and second layers of elastomeric material. The device may be in the form of a contraceptive sheath, finger stall or glove, and protects the user from contamination by various germs, viruses, fungi and other pathogens in the whole area of the body covered by the device.

Abstract: The present invention relates to a method for preparing a surface for bonding with a synthetic resin. In the method, a layer is applied onto a substrate surface by sand blasting with a composition comprising (A) 0.01 to 90% by weight of an optionally silanized material having a particle size less than 5 .mu.m and having a hardness greater than that of the substrate surface, and/or (B) 20 to 100% by weight of a silanized siliceous material having an average particle size of 2 to 200 .mu.m, and (C) the remainder of the sand blasting composition having an average particle size greater than 5 .mu.m, and optionally the layer is thereafter silanized. The invention is further directed to the above-mentioned composition.

Abstract: A layer or coating bonded to a substrate is encapsulated to prevent portions of the layer from becoming detached and randomly distributed. This is accomplished by applying a first layer of an adhesive to the exposed surface of the layer to be encapsulated. A second layer composed of a fibrous material is placed in contact with the first layer of adhesive and then an additional layer of adhesive is applied by a suitable technique such as brushing or coating. The additional layer of adhesive penetrates the fibrous material forming a stratified layer composed of an outer layer primarily of the adhesive, an intermediate layer composed primarily of a mixture of adhesive and fibrous material and an inner layer including the exposed surface layer and portions of the adhesive. The method is useful for encapsulating potentially hazardous materials such as lead based paints and asbestos.

Abstract: Composite or assembled gemstones are usually made by laminating together several layers of rock or mineral substances. Established lapidary processes used in making these stones are very effective when the gem-material part of the composite stone is of stable composition. Such material can then be easily cut and ground into the smooth flat layers necessary for laminating. These same methods, however, prove much less effective when applied to poorly-consolidated gem material: material that because of its friable nature tends to chip and flake when attempts are made to cut it into layers. My process is designed specifically for use on this latter type of gem material and is especially suited to processing gem-quality fossil ammonite shell. This process differs from the traditional methods in that it eliminates the need for cutting and grinding the gem material into smooth, flat layers. Instead, the gem material is simply shredded or fragmented into a mass of small, thin flakes.

Abstract: An apparatus for and method of coating an article by the use of electro-static attraction of ionized particles which are subsequently cured. The apparatus includes a first foraminous conveyor for carrying the article through a powder coating zone and a second conveyor for carrying the article through a curing zone. The surface of the article which rests on the foraminous conveyor is cleaned of particles as the article is transferred from the first foraminous conveyor to the second conveyor. The first foraminous conveyor is also cleaned of particles after the article has been transferred. After the articles have been cured to form a coating on the article, the article is put through the coating system again except that the article is supported on the conveyor so that the surface which was not coated in the first pass through the system is out of contact with the conveyor.

Abstract: To produce a layer in a multi-layer circuit structure, a "green ceramic tape" (16) comprising a sheet of particles of ceramic, glass ceramic, or a glass/ceramic composite in an organic binder is applied to a ceramic substrate (12) on which conductive paths (14) have been deposited. A slurry of hollow microspheres (20) is then deposited onto the green ceramic tape (16), and pressure is applied to drive the spheres into the tape. A further tape layer (22) is then applied, and the resultant structure is fired.

Abstract: The invention is a method of making an ion permeable membrane, electrode and current collector assembly comprising the steps of:(a) forming a foundation layer comprising a porous electrically conductive material;(b) at least partially coating a fluoropolymer binder on at least one surface of the conductive foundation layer;(c) applying a particulate and finely divided catalyst material over the fluoropolymer binder on the foundation layer;(d) dispersing a suitable polymeric material over the catalyst material in a manner to obtain penetration of the polymeric material into the porous foundation layer to form a substantially continuous coating on the catalyst material and the at least partially coated foundation layer; and(e) applying sufficient heat and/or pressure to enhance the flow of polymeric material into the foundation layer and around the catalyst material to obtain adherence thereto and to sinter the polymer material into a substantially nonporous layer around the catalyst material.

Abstract: An improved process for the flame spray coating of an object with a polymeric material comprising a linear alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon, optionally blended with ethylene/.alpha.,.beta.-ethylenically unsaturated carboxylic acid copolymer, includes coating the object with a first coating of the polymeric material, thermally degrading at least the surface of the first coat, and subsequently supplying a second coating of the polymeric material.

Abstract: The process for hardening ballasts and other heaped structures calls for an adhesive, which is pourable at ambient temperatures, to first be transformed into the solid state by means of cooling. Then, the application of the liquid adhesive onto the heaped structure is time-dosed by the thawing of the cooled adhesive.

Abstract: A process for fabricating cermet electrodes for solid oxide electrochemical cells by sintering is disclosed. First, a porous metal electrode is fabricated on a solid oxide cell, such as a fuel cell by, for example, sintering, and is then infiltrated with a high volume fraction stabilized zirconia suspension. A second sintering step is used to sinter the infiltrated zirconia to a high density in order to more securely attach the electrode to the solid oxide electrolyte of the cell. High performance fuel electrodes can be obtained with this process. Further electrode performance enhancement may be achieved if stabilized zirconia doped with cerium oxide, chromium oxide, titanium oxide, and/or praseodymium oxide for electronic conduction is used.

Abstract: A sensor element useful in making fluorescence-optical measurements includes a substrate having a carrier surface, particles having a large specific surface are which are glued, melted or sintered onto the carrier surface so as to provide small elevations of a regular distribution on the carrier surface, and an indicator substance immobilized on the particles. Additional substances can be applied to the particles to reduce undesirable influences of properties of the sample on the indicator substance.

Abstract: A method of manufacture for producing a decorative laminate which exhibits through-color printing is provided in which a layer of absorptive PVC resin particles of substantially only one particle thickness is printed with, for example, three differently colored vinyl plastisol printing inks. The decorative article is useful as a floor covering.

Abstract: A lacquer system which essentially comprises a silicic acid heteropolyconsate, a flake-shaped or lamellar filler, a solvent and, if appropriate a conventional synthetic resin for lacquers is suitable for producing anti-corrosion coatings, especially on glass surfaces.

Abstract: A flocked polyurethane foam fabric and method for manufacturing the same for which flock fibers imbedded in an adhesive on the foam are permanently flattened and entangled. Dry ink is transferred onto the flock fibers at the same time that flattening of the fibers is taking place. The flock fibers are thermally set into their flattened state along an outer surface of a polyurethane foam base of the fabric. Flattening the flock fibers causes the entanglement of the flock, thereby improving the hand, appearance, drapeability, abrasion resistance, water repellency and heat insulation qualities for apparel items over that of unflattened flock fibers.

Abstract: A composite and a process for forming it are provided, said process comprising providing a substrate bearing crystalline and preferably single crystal filaments as growths on the substrate and forming a solid matrix encompassing the filaments. The composites are useful for aircraft, boat and auto skins and structural members.

Abstract: A porous substrate is formed from an agglomeration of fibers preferably has a carbonaceous composition and a binder is applied to the substrate. The binder may illustratively be an acrylic or beeswax to vaporize during pyrolysis or may illustratively be a phenolic resin, a furfural resin or pitch to retain pyrolyzed carbon on the fibers after pyrolysis. A mixture of particles having the same approximate size as the diameter of the fibers is then applied to the fibers to become mechanically locked in the substrate pores.

Abstract: In a process for thermally spraying molten metal onto an uncured resin, to prevent some of the sprayed metal particles from being engulfed in the still wet or uncured resin layer, the resin layer is filled with micron sized beads, filler and/or spheres. The spheres or beads or other filling of the resin prevents the impacting metal particles from being engulfed but still allows the metal particles to imbed in the uncured resin surface to achieve a strong mechanical bond when the resin cures.

Abstract: An apparatus and method for coating a substrate with plastisol and depositing pebbles into the ungelled coated plastisol is presented. A powder containing fusible particles compatible with the coated substrate and the pebbles is then deposited by at least one rotary silk-screen printing frame and thereafter a heat treatment is carried out in an oven or with infrared lamps at a temperature below the distortion temperature of the substrate in order to set the deposited materials.

Abstract: Gilding or relief-marking process which starts with any typographic, offset or other impression and converts it into relief of variable thickness, by the known thermography principle, but employing a hot-melt powder endowing the film forming the relief with adhesive properties capable, after it has solidified, of transferring and retaining on its surface a marking material.

Abstract: The present invention relates to a waterproofing complex for the deck of a road structure, which is intended to receive a surfacing course, the said complex comprising:a bottom layer consisting of a mortar containing about 10 to about 15% of aggregate with a diameter of less than 80 .mu.m, and from about 7.5 to about 9.5% of a bituminous binder based on elastomers, the percentages being expressed by weight relative to the dry aggregate, anda top layer consisting of a bitumen rich in elastomers.It further relates to a process for the waterproof road lining of the deck of a structure.

Abstract: A cured emulsion of a polymerizable silicone compound and an inert paste such as petroleum jelly, liquid soap solution, or combination thereof forms a tough, elastic material that simulates the characteristics of connective tissue when used to join an outer skin layer to an understructure, and is useable in the production of models and prostheses. The silicone compound is preferably a mixture of a room temperature vulcanizable silicone rubber and a low viscosity silicone fluid. A high viscosity plasticizer, such as high viscosity silicone fluid, can be added to the emulsion to better simulate the characteristics of connective tissue. The emulsion is preferably joined to the outer skin layer by adhering fiber to the emulsion and coating the emulsion and fibers with the outer layer.

Abstract: A method for making seamless, porous metal articles comprising:(a) rotating a mold containing a stabilized suspension of a metal particulate at a rate and for a time such that the particulate is separated from the suspension and distributed on the interior wall of the mold, thereby forming a structure conforming to the interior wall of the mold, the rate of rotation being sufficiently high that at least about 100 Gs of centrifugal acceleration is achieved at the interior wall of the structure,(b) drying the formed structure to provide a structure having green or unsintered strength, and(c) sintering the dried structure to remove volatile material and fuse the individual particles of the particulate to each other to form the seamless, porous metal article.Metal articles in accordance with the invention have substantially uniform diameters, thicknesses and pore structures, have Bubble Point ratios of 1.5 or less, and find particular use as filters.

Abstract: To alter the surface qualities of nonreactive materials, such as polypropylene and polyethylene in order to provide a means for bonding the plastic to metal, hard granular materials of oxides or carbides are partially impregnated into the surface of the plastic by application of heat and pressure so that granular edges remain exposed. Thereafter, a silver coating is applied over the impregnated plastic to interlock with the granules. The composite layered plastic then provides a means for soldering or bonding the plastic to a metallic coupling using either a bonding cement or a low temperature solder such as bismuth, lead, or tin based solder. Abrasion-resistant qualities also are improved by impregnating the internal surfaces of a plastic tube in order to improve its wear-resistance during transporting abrasive slurries of sand, coal, and the like.

Abstract: A method of building a dental appliance and a kit for use in the method are provided. In the method, metal copings are coated with an opague ceramic paste, and a coarse ceramic powder, having structural stability under the conditions needed to fire the ceramic paste, is dusted on the coating of ceramic paste, and the coping is fired. A coated metal coping with a rough, sandpaper like surface is produced, and subsequent layers of ceramic paste are applied to the rough surface to build up the dental appliance. The kit of the invention provides at least one preformed opaque ceramic paste, dusting powders, and other ingredients needed to build a dental appliance.

Abstract: A method and composite produced by depositing particulate material on a planular surface, contacting the surface and the particulate material with a gas-curable resin and curing the resin to adhere the particulate matter to the surface.

Abstract: An open-topped casting mold and a matching mold are hingedly connected and are electrostatically coated with a powder screen; casting material is then poured into the molds without disturbing the powder by holding the powder in position with static electricity. The molds are pivoted together to provide a composite body of the hardened casting material formed by the bonding of the material from the two molds.

Abstract: An open-topped casting mold and a mating cover are electrostatically coated with a powder screen and casting material is poured into the mold without disturbing the powder by holding the powder in position with static electricity. The casting material is permitted to harden and a screen of powdery or fatty material placed on the upper surface of the hardened material and protective film applied over the screen.

Abstract: A coating for polystyrene foam products is set forth. The coating has the preferred form of a first latex layer of copolymer of butadiene with either styrene or vinylidene chloride or both mixed with a fine aggregate such as silica flour or fly ash and a top layer made of one or more strata of a thermosetting resin. This resin is a thermosetting mixture of ethylenically unsaturated monomers and/or one or more of:1. unsaturated polyester or polyesteramide resins,2. norbornyl modified unsaturated polyester or polyesteramide resins,3. hydrocarbon modified unsaturated polyester or polyesteramide resins,4. vinyl ester resins, or5. mixtures of the foregoing resins.The resin is mixed with an aggregate of particle size ranging from about 10 microns to larger as required and having a color pigment therein as required. The latex and resin with aggregate is applied over the polystyrene article to form a and protected composite structure.

Abstract: A retroreflective sheeting utilizing a particular polymer as the bead bond layer is disclosed. The polymeric bead bond comprises urethane and urea linkages, and has a stage prior to thermosetting in which it may be softened by the application of heat and in which it has a relatively nontacky character. The retroreflective sheeting disclosed possesses the unique combination of high reflectance and superior exterior durability.

Abstract: A process is provided for conducting or catalyzing a chemical reaction on a surface by depositing on the surface an adherent monolayer of positively charged polymer particles containing an active agent distributed throughout the polymer and contacting the deposited adherent monolayer with a suitable reactant. The positively charged polymer particles have diameters of less than about 3 micrometers and preferably less than 1 micrometer. The polymer particles are suspended in water to form an aqueous colloidal dispersion. The dispersion is useful as a stable catalyst system and particularly useful for complete electroless deposition of a conductive metal on printed circuit board surfaces and the walls of through-holes formed therein.

Abstract: A method of making a pressure sensitive adhesive stock material for tags or labels is provided which eliminates the need for a self-supporting paper, cardboard, or plastic substrate. A layer of pressure sensitive adhesive is provided, preferably on a release liner. The upper surface of the adhesive is then treated to render it substantially tack free and suitable for printing directly thereon.

Abstract: A developer carrier to be formed is provided with an electrode layer which includes a plurality of electrode particles embedded in a dielectric material as electrically isolated from one another and exposed at an outer surface at least partly. In one aspect of the present invention, an underlying layer is first formed on a support and then an electrode layer is formed on the underlying layer. In forming the electrode layer, a first layer of first dielectric, adhesive layer is formed on the underlying layer and, after application of a plurality of electrode particles on the first layer, a second layer of second dielectric, adhesive layer is formed on the first layer and the electrode particles to define a to-be-formed electrode layer, whose outer surface is processed to have said electrode particles exposed at the processed outer surface thereby defining the electrode layer. In another aspect, there is provided a developer carrier having the underlying layer which includes an elastomer and a magnetic material.

Abstract: There is described a method for lining the one surface from a base with a continuous granulate layer, which comprises relieving the granulates from foreign materials, raising said granulates to a higher level than said base, spreading said granulates to form said layer, coating the granulates during the fall thereof with a material causing same to adhere to said base, moving the fall location relative to said base along a direction in parallel relationship with the one base side, at a pre-determined speed, and letting said material coating the granulates laid down on the base, harden.

Abstract: Metal coated ceramic particles are bonded to a metallic substrate in a high temperature sintering process. A low viscosity binder solution containing fine metallic particulates is first applied to the substrate surface. Then, the coated ceramic particles are disposed upon the substrate surface, and the binder solution and the metal particulates therein are attracted by capillarity into regions of point contact between the ceramic particles and the substrate surface. During a subsequent high temperature sintering operation, the metal coating on the ceramic particles diffuses into the metal substrate, and the metallic particulates melt and solidify to bridge the gap between the substrate and ceramic particles.

Abstract: A process for modifying the surface condition of materials comprises applying simultaneously to the surface of a material a plurality of typo-offset, silk screen printing or offset inks or varnishes having different polymerization temperatures and polymerization speeds, predrying at an appropriate temperature and for a length of time sufficient for polymerizing a certain type of ink(s), applying to the treated surface at least one batch of particles which adhere exclusively to not yet polymerized inks, removing the excess particles of a batch by suction and/or blowing and finishing the drying at a temperature and for a length of time appropriate for completing the polymerization of all the types of ink.

Abstract: An exhaust device whose inner surface is coated with a heat-insulating layer and a refractory layer. Each layer is formed by conducting at least one cycle of the steps of: (a) coating the inner surface with an inorganic binder solution, (b) immediately adhering a coating powder to the binder solution layer so that the powder is fully and uniformly impregnated with the binder solution, and (c) drying and solidifying it by heat treatment. The coating layer does not suffer from cracking, peeling and breakage.

Abstract: Multiple layered plastic sheets is produced by sequentially disposing at least two powdered flowable materials onto a melted layer of plastic being conveyed in a given direction. Each material corresponds to a separate layer of the resulting multilayer sheet.

Abstract: An improved capillary action wicking structure and method with a method for its making and with application of the wicking structure to a high temperature electrical battery cell of the sodium/sulfur type. The wicking structure includes finely-divided metal particles of nickel, for example, that are attached to the solid electrolyte structure in the electrical battery cell by an organic binder and sintering combination.