Abstract: A frequency selective plate which is produced by coating an Ag layer dispersed with Ag particles on a transparent substrate. The Ag layer is formed by depositing an Ag continuous layer on the substrate and heating the Ag continuous layer to varying into Ag particles or by depositing an Ag continuous layer on the heated substrate. The frequency selective plate performs high transparency of radio waves and visible rays while sufficiently reflecting near-infrared rays of solar radiation.

Abstract: The invention discloses a material and an efficient method for the formation of a thermal-spray coating layer of a rare earth fluoride by a process of thermal-spray coating by using a unique thermal spray powder consisting of granules of the rare earth fluoride having a specified average particle diameter. The thermal-spray granules are prepared by granulating primary particles of the rare earth fluoride having a specified average particle diameter from an aqueous slurry containing a binder resin and subjecting the granules to a calcination treatment at a temperature not higher than 600° C.

Abstract: It is disclosed a wateborne composition comprising styrene-acrylic latex having a glass transition temperature (Tg) of from about 0° C. to about 30° C., vinylidene chloride-containing polymer latex and at least one filler. The composition exhibits sound damping property at both low and high frequencies as well as chip resistance and abrasion resistance. The composition is effective for use in the transportation industry, the building industry, the aerospace industry and the appliance industry.

Abstract: Powders of oxidized polyarylene sulfide and powders comprising from 1 to 99% by weight of oxidized polyarylene sulfide and from 1 to 99% by weight of a metal, carbide, ceramic or high temperature polyimide, polyamide imide, polyester imide and aromatic polyester plastic, or a mixture thereof are very suitable for use in thermal spraying and thereby form coatings having a strong chemical and mechanical resistance and high dimensional stability when exposed to high and low temperatures. Such coatings are advantageous for use as abradable seal clearance control coating in the compressor section of gas turbine engines, motor vehicle turbochargers and superchargers, and for use as a coating of reaction vessels, kitchen ware, sealings or bearings.

Abstract: This invention relates to articles made of polyester, preferably polyethylene terephthalate (PET), having coated directly to at least one of the surfaces thereof one or more layers of thermoplastic material with good gas-barrier characteristics, and novel methods of making such articles. Preferably the barrier-coated articles take the form of preforms coated by at least one layer of barrier material and the containers blow-molded therefrom. Such barrier-coated containers are preferably of the type to hold beverages such as soft drinks, beer or juice. The preferred barrier materials have a lower permeability to oxygen and carbon dioxide than PET as well as key physical properties similar to PET. The materials and methods provide that the barrier layers have good adherence to PET, even during and after the blow molding process to form containers from preforms. Preferred barrier coating materials include poly(hydroxyamino ethers).

Abstract: Methods of high speed coating a pigment-containing liquid coating material onto a substrate so as to avoid visible pigment separation in the coating material in its as coated state. In the method, a pigment-containing liquid coating material is applied to a substrate, while the substrate is moving at a high line speed of at least about 15.24 m/min., to form a coated layer. The coating material is applied to the substrate along a substantially straight, dynamic wetting line where the coating material first contacts the moving substrate. The coating material is of the type that will exhibit visible pigment separation on its interface surface when the coating material is coated onto the fast moving substrate, without the use of a substantially straight wetting line. The wetting line is substantially straight when a significant amount of visible pigment separation does not occur at the chosen high line speed.

Abstract: A coating material is deposited on a substrate by vacuum or low-pressure pulsed detonation coating. A detonation chamber receives a detonable mixture containing a coating precursor. The detonable mixture is ignited to produce detonation products laden with the coating precursor. The detonation products are accelerated in a low-pressure or vacuum chamber and discharged through a nozzle into contact with a substrate situated in low pressure to produce a high quality coating.

Abstract: A method for controlling etch bias of carbon doped oxide films comprising performing the etch in a cyclic two step process i.e., a carbon doped oxide (CDO) removal process, said CDO removal process comprises a first gas to etch a trench in the CDO layer. The CDO removal process is followed by a polymer deposition process. The polymer deposition process comprises introducing a second gas in the reactor to deposit a polymer in the trench of the CDO layer. The first gas comprises a first molecule having a first ratio of carbon atoms to fluorine atoms, and the second gas comprises a second molecule having a second ratio of carbon atoms to fluorine atoms, such that the second ratio of carbon atoms to fluorine atoms is greater than the first ratio of carbon atoms to fluorine atoms. The above process may be repeated to etch the final structure.

Abstract: Tanned leather is dry dressed by plasma deposition at atmospheric pressure of a matrix material such as ITO, a silicone, or polyurethane, upon the protein fibers of the surface of the leather and the collagen fiber skeleton below the surface protein fibers. The leather retains its toughness, elasticity, breathability and softness or hand.

Abstract: A grain aggregate is formed by bonding a plurality of cross-linking polymeric grains via a substance (binder) having a reactive functional group, and alternatively, the grain aggregate is formed by bonding at least two different types of a plurality of grains, thus providing the grain aggregate having the improved heat resistance, solvent resistance, strength and light-diffusing properties. Further, a light-diffusing agent made up of the grain aggregate has the improved light-diffusing properties. Therefore, when applying a light-diffusing mold article including the light-diffusing agent to, for example, a backlight of a liquid crystal display device, high brightness and a wide angle of visibility can be attained. Further, by spray drying of a dispersion liquid containing the grain aggregate, the grain aggregate can be produced with ease.

Abstract: Plasma spraying a substrate using particles having a ceramic coating on a combustible core, which may optionally be burned out before spraying, gives a potential for a thicker more conformable protective coat.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: This invention relates to methods whereby nanoparticle liquid suspensions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. Ultrasound is used for disintegration of the as-synthesized particle agglomerates, nanoparticle dispersion in liquid media, and liquid precursor atomization.

Abstract: A method and device of treating an irregularly shaped article to prepare the article for painting is provided. The device includes a burner which can produce an adjustable flame tongue which can fit into crevices, openings and other irregular topographical features of an item to be painted or otherwise coated. The burner device further provides means to apply a grafting chemical on a freshly oxidized surface. Further, the invention provides means to colorize treated objects so that they may be recognized as having been treated. In another embodiment, the grafting chemicals may be enhanced with electrolytic solutions such that electrostatic methods of painting may be subsequently employed on the item. In an alternate embodiment, the burner is adapted to spray a powder inside of a generally enclosed flame, and is used in conjunction with chop guns to manufacture glass or carbon fiber preforms.

Abstract: A method for making an aluminum substrate that is subjected to repeated impaction more wear resistant. The method comprises applying at least about 0.005 inch thick coating of an amorphous composition directly to only portions of this substrate, preferably after it is shaped into a product for transporting consumable materials. The coating composition to which steel, aluminum, PTFE and/or polyethylene may be added, can be thermally sprayed to the substrate surface.

Abstract: A laminate includes a metal layer which is formed on and covers a surface of an insulating substrate activated by a plasma treatment by any method selected from a sputtering method, a vacuum depositing method and an ion plating method. The substrate is obtained by molding a resin composition containing 20 to 150 parts by mass of a fibrous filler having an average fiber diameter of 0.1 to 5 &mgr;m and an average fiber length of 10 to 50 &mgr;m relative to 100 parts by mass of a base resin comprising a thermoplastic resin and a thermosetting resin.

Abstract: A flow tube has a metal outer tube and is lined with an ETFE fluoropolymer that is resistant to corrosive chemicals and mechanical damage even at high temperatures. The inner surface of the metal tube is coated with a bonding metal that can be securely bonded to the outer metal tube and also forms a strong bond with ETFE fluoropolymer. After the bonding metal has been applied, a layer of a desired thickness of the ETFE fluoropolymer is molded in place to form an inner liner for the flow tube.

Abstract: A curable composition is placed on a candle, and then the composition is exposed to curing conditions such as ultraviolet light, to thereby cure the coating composition and provide a candle having a cured coating. The curable composition may be the reaction product of TMPTA (trimethylolpropanetriacrylate), itself the reaction product of trimethylolpropane and acrylic acid) and oleyl amine (an unsaturated primary amine having eighteen carbons). The candle may be made of wax or a gelled solvent, i.e., a mixture of gellant and solvent, particularly a hydrocarbon or other low polarity solvent. The undiluted coating may be applied by spraying on the oily surface of the candle. Ultraviolet cure of the coating occurs in 1-2 seconds.

Abstract: A process for removing contaminants from the surface of a substrate comprises contacting the substrate with a cleaning composition comprising at least one mono-, di-, or trialkoxy-substituted perfluoroalkane, perfluorocycloalkane, perfluorocycloalkyl-containing perfluoroalkane, or perfluorocycloalkylene-containing perfluoroalkane compound, the compound optionally containing additional catenary heteroatoms. The compounds exhibit good solvency properties while being environmentally acceptable.

Abstract: The invention relates to a novel thermal spray process for the deposition of coatings with a graded or layered composition and the coated articles produced thereby. More particularly, the invention relates to feeding mixtures of coating materials to a thermal spray device and continuously or intermittently changing the composition of the deposited coatings by changing the thermal spray operating parameters. The continuous or intermittent change in the composition of the coating material during deposition creates a graded or layered coating structure.

Abstract: The rubber-reinforcing fiber of the present invention is provided with a coating layer of a thickness of 10 Å to 40 &mgr;m. The coating layer is formed by dry plating and contains at least one metal and/or metal compound selected from the group consisting of cobalt, zinc, copper, titanium, silver, nickel and compounds of the aforesaid metals. With such a coating layer, the rubber-reinforcing fiber of the present invention forms a firm adhesion to a rubber component and drastically improves the fatigue resistance and durability of a rubber article, particularly, a pneumatic tire.

Abstract: Polyolefin compositions in powder form suited for metal coating, including (percentage by weight): 1) from 1% to 40% of hollow microspheres; 2) from 60% to 99% of a composition comprising: a) from 25% to 95% of polypropylene, polyethylene or crystalline propylene copolymers or mixtures thereof; b) from 0% to 70% of an elastomeric copolymer; c) from 0.5% to 10% of propylene or polyethylene modified with polar groups; d) from 0% to 10% of titanium dioxide.

Abstract: Elastomeric seals, including O-rings, may have chemically resistant thin films applied by the technique of plasma polymerization to the surface of the elastomer, enhancing wear resistance and environmental resistance without changing the physical properties of the elastomer. The films may be a silane polymer applied by plasma deposition in a radio frequency/microwave dual power source reactor.

Abstract: A powder of a barrier material (B) is, after having been melted, applied to a substrate of a polyolefin (A) according to flame spray coating process to give a shaped article, in which the barrier material (B) firmly adheres to the polyolefin (A) even when the surface of the substrate is not subjected to primer treatment. The shaped article is favorable to components to fuel containers, fuel tanks for automobiles, fuel pipes, etc.

Abstract: A device, and its production method, the device has a substrate and a coating composition, the coating composition being formed by the gas phase or plasma polymerization of a gas comprising at least one organic compound or monomer. The polymerization is carried out using a pulsed discharge having a duty cycle of less than about ⅕, in which the pulse-on time is less than about 100 msec and the pulse-off time is less than about 2000 msec. The duty cycle can also be varied, thus the coating composition can be gradient layered accordingly. The device has a coating composition which is uniform in thickness, pin-hole free, optically transparent in the visible region of the magnetic spectrum, permeable to oxygen, abrasive resistant, wettable and biologically non-fouling.

Abstract: Polyolefin compositions in powder form suited for metal coating, comprising (percentage by weight):

Abstract: A thermally-sprayed non-skid coating that is comprised of an aggregate material embedded within a layer which is comprised of at least one coalesced, thermoplastic polymer. The aggregate has a melting temperature greater than the melting temperature of the at least one coalesced, thermoplastic polymer, and the coating contains no volatile, organic compounds.

Abstract: A method treats an article and more specifically an aircraft surface in order to prevent icing and to provide a coating that emits very low volatile organic compounds (VOC) during application and setting. Icing on critical aircraft surfaces creates dangerous conditions that impair the stability of the aircraft. The specific areas are referred to as “cold-soak” conditions and some areas on the “leading edges” of the wings. The invention eliminates icing on these surfaces. Ice will not form on the surface of certain polymer coatings with low surface energy such as Teflon. This is a consequence of the high contact angle between the water droplet and the surface that establishes a non-wetting surface. The invention implements such coatings and a deposition process. The coating may be used for other objects such as automobiles, consumer products, such as refrigerators, stoves, etc.

Abstract: The present invention provides a method for the formation of an organic coating on a substrate. The method includes: providing a substrate in a vacuum; providing at least one vaporized organic material comprising at least one component from at least one source, wherein the vaporized organic material is capable of condensing in a vacuum of less than about 130 Pa; providing a plasma from at least one source other than the source of the vaporized organic material; directing the vaporized organic material and the plasma toward the substrate; and causing the vaporized organic material to condense and polymerize on the substrate in the presence of the plasma to form an organic coating.

Abstract: Components for use in plasma processing chambers having plasma exposed surfaces with surface roughness characteristics that promote polymer adhesion. The roughened surfaces are formed by plasma spraying a coating material such as a ceramic or high temperature polymer onto the surface of the component. The plasma sprayed components of the present invention can be used for plasma reactor components having surfaces exposed to the plasma during processing. Suitable components include chamber walls, chamber liners, baffle rings, gas distribution plates, plasma confinement rings, and liner supports. By improving polymer adhesion, the plasma sprayed component surfaces can reduce the levels of particle contamination in the process chamber thereby improving yields and reducing down-time required for cleaning and/or replacing chamber components.

Abstract: Disclosed is a process for making a flexible magnet with an induced anisotropy, and in particular to a process for making a flexible anisotropic magnet by thermal spraying in the presence of an applied magnetic field. The method may be used to fabricate a substrate having a flexible anisotropic magnetic coating or a free standing anisotropic flexible magnet.

Abstract: This invention discloses methods for the deposition of SiO2 and other oxide dielectric materials using a near room temperature thermal chemical vapor deposition process. The films have chemical, physical, optical, and electrical properties similar to or better than those of oxide films deposited using conventional, high temperature thermal CVD methods. The films of the invention are useful in the manufacture of semiconductor devices of sub-micron feature size and for food packaging.

Abstract: A thermally sprayed article and method of making same includes the steps of providing an article to be thermally sprayed and thermally spraying a metal material against the article to form an inner layer having a first predetermined thickness. The method also includes the steps of co-depositing a polymer and the metal material against the inner layer to form an outer layer having a second predetermined thickness.

Abstract: A thermally sprayed article and method of making same includes the steps of providing an article to be thermally sprayed and thermally spraying a metal material against the article to form an inner layer having a first predetermined thickness. The method also includes the steps of co-depositing a polymer and the metal material against the inner layer to form an outer layer having a second predetermined thickness.

Abstract: The present invention provides methods for fabricating a sensor on a substrate having a pair of electrodes. The methods are especially amenable to broad variations amongst individual sensor on a single substrate. The intra-sensor variation within the array can be achieved in various fashions. The method provide intra-sensor variation using quantitative and qualitative differences in each sensor.

Abstract: A curable composition is placed on a candle, and then the composition is exposed to curing conditions such as ultraviolet light, to thereby cure the coating composition and provide a candle having a cured coating. The curable composition may be the reaction product of TMPTA (trimethylolpropanetriacrylate), itself the reaction product of trimethylolpropane and acrylic acid) and oleyl amine (an unsaturated primary amine having eighteen carbons). The candle may be made of wax or a gelled solvent, i.e., a mixture of gellant and solvent, particularly a hydrocarbon or other low polarity solvent. The undiluted coating may be applied by spraying on the oily surface of the candle. Ultraviolet cure of the coating occurs in 1-2 seconds.

Abstract: Multi-layer corrosion resistant polymer composite coatings are described wherein a first coating layer is applied by high velocity high temperature spray, thermal spray, plasma spray, fluidized bed, hot melt or electrostatic spray onto an unprepared, particle embedded or alternatively prepared substrate, and the outer surface of the still warm first layer is roughened by embedding particles therein or the outer surface is roughened mechanically, and a second coating layer is applied thereover. Filler powder may be added to one or both of the layers to substantially match the thermal expansion coefficients of the two layers.

Abstract: An air seal for use in a gas turbine engine provides improved durability, particularly at higher temperatures. The seal includes a seal substrate, and an abradable layer is provided on the substrate by a thermal spray process, with the abradable including a thermoset polymer and a thermoplastic polymer. The abradable may also include a filler to add porosity, or provide lubrication, to enhance abradability.

Abstract: There is provided a method for applying a lower viscosity coating liquid onto a semiconductor wafer substrate so as to prevent adhesion loss and to maintain low defect level characteristics. This is achieved by priming the substrate with a bonding agent at a temperature in the range of 18° C. to 50° C. for a short amount of time. This is performed prior to the application of a liquid solvent. As a result, there is overcome the problems of poor adhesion to the substrates and high defect levels in the coated UTR films.

Abstract: A method for making an aluminum substrate that is subjected to repeated impaction more wear resistant. The method comprises applying at least about 0.005 inch thick coating of an amorphous composition directly to only portions of this substrate, preferably after it is shaped into a product for transporting consumable materials. The coating composition to which steel, aluminum, PTFE and/or polyethylene may be added, can be thermally sprayed to the substrate surface.

Abstract: An abrasion-proof and static-erasing coating is formed on the contact surface of a contact image sensor. The coating comprises a first film having a high hardness and a low conductivity, a second film formed on the first film and having a low hardness and a high conductivity, and a third film having a high hardness and a high resistivity providing an abrasion-proof insulating external surface.

Abstract: This invention relates to methods whereby nanoparticle precursor solutions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. The method allows combining nanoparticle synthesis, melting, and quenching into a single operation.

Abstract: A method of manufacturing a metal and polymeric composite article by the following steps. Droplets of spray deposited metal and spray deposited polymeric material are combined to form an article having the polymeric material interspersed within the metal. A carrier or form that shaped to receive the metal and polymeric layers is provided. The carrier may be made either stationary or movable. Layers of spray deposited metal and spray deposited polymeric material are applied atop the carrier. The spray deposited metal is between 90 and 95 percent by volume of the article. The polymeric layers do not completely cover the metal layers. Succeeding spray deposited metal layers contact bond to previous metal layers. The polymeric material between imbedded between the interconnected metal layers.

Abstract: A method of preparing a planographic printing member is disclosed. In one embodiment, the method comprises forming a hydrophilic layer by thermally spraying a hydrophilic particulate material onto an ablatable layer. Typical hydrophilic materials are SiO2, Al2O3, Cr2O3, TiO2 and ZrO2. Spraying a plasma containing the hydrophilic material in an inert gas atmosphere is preferred method for forming the hydrophilic layer.

Abstract: A two-component aqueous composition for thick horizontal markings on roads or other traffic areas is disclosed. One component includes a drying-accelerated binder, pigments, pulverulent fillers and additives, while the other component includes coarse fillers. The composition is very high solids and fast drying without the cracking, smearing, and dirt adhesion typical of thick film traffic markings.

Abstract: Precursor solutions are provided to produce thin film resistive materials by combustion chemical vapor deposition (CCVD) or controlled atmosphere combustion chemical vapor deposition (CACCVD). The resistive material may be a mixture of a zero valence metal and a dielectric material, or the resistive materials may be a conductive oxide.

Abstract: A process for application of a protective coating to a steel, concrete, or wooden structure so as to provide protection against corrosion, weathering, or other environmental damage in which the surface to be protected is heated to a temperature in a range of about 75.degree. F. to about 150.degree. F. after which a liquid thermoset primer is applied to the heated material in two stages. The first portion is solidified by heating and then coated with a second portion, forming an uncured liquid thermoset outer primer layer. A melted polymer powder layer is then applied by flamespraying over the uncured liquid thermoset primer layer, forming an intermediate polymer powder layer embedded in the uncured liquid thermoset primer layer.

Abstract: Template-imprinted structures 10 are provided having at least one template-imprinted surface 12 defining indentations 14 that are capable of specifically binding cells and/or molecules, such as macromolecules including proteins, peptides and nucleic acids. Presently preferred embodiments of the template-imprinted structures include medical prostheses, such as artificial joints and heart valves, having surface indentations that specifically bind proteins and/or cells that enhance the biocompatibility of the prosthesis, thereby making it less likely that the prosthesis will be rejected by the body. Methods are also provided for making the template-imprinted structures of the present invention.

Abstract: Plasma spraying of particulate thermotropic liquid crystalline polymers onto the surfaces of composite and metallic structures. The present plasma spray process employs a conventional direct current electric arc plasma spray gun in which an inert plasma gas is introduced, caused to swirl, and discharges as a rotating plasma flame having an exceptionally high temperature, above about 14000.degree. K, into which the particulate liquid crystal polymer is discharged for melting and propulsion onto the target surface. The target surface preferably is preheated, and the molten particles deposit and cool to form a build up of the desired thickness. Cooling is regulated by post-heating the deposit to a temperature between about 200.degree. F. and 500.degree. F.

Abstract: Corrosion resistant non-polar polymer coatings and method for applying the coatings to substrates is described, wherein a source of non-polar polymer powder is deposited as a coating onto the surface of a substrate by high temperature thermal spray, wherein the non-polar character of the powder and any additives thereto is substantially preserved during the high temperature thermal spray by using a mixture of a non-oxidizing shielding gas or reducing gas, or combination of the two, at one or more locations along the thermal spray to displace or react with ambient oxygen.