W. R. Grace Co.

W. R. Grace Co.-Conn.

Christian B Lundsager

Joseph T Lundquist, Jr

Joseph T Lundquist

Stewart C Feinberg

Robert A Balouskus

Wu-Cheng Cheng

James L Guthrie

John W Lau

Robert M Spotnitz

Dennis D O'Rell

Jack H Enloe

Nigel I Palmer

Howard J Troffkin

Nguyen V Hien

Helen F Roberts

Roy W Rice

Robert M Murch

Marc E Parham

Louis Hegedus

Anthony J Laccetti

RIchard C Hartwig

Victor S Chang

Richard T Giovannoni

Edwin M Glocker

A battery separator composed of a microporous sheet product having first and second major surfaces and a thickness of less than about 50 mils, formed from a uniform mixture of a halogenated polyolefin polymer and a filler or a halogenated polyolefin polymer and surfactant/filler agent, said sheet product having a fibrous sheet embedded within said mixture and between the first and second major surfaces. The porosity of the sheet product is at least about 50 volume percent composed of pores such that the average pore diameter increases from each major surface towards the interior of the sheet product's thickness.

Battery separator

Boron nitride green sheets are made of boron nitride powder in an organic binder which leaves no undesirable residue upon pyrolysis in the absence of oxygen. These boron nitride green sheets can be placed on each side of the ceramic green sheet to form a composite for hot pressing ceramic green sheets containing ceramic powder to produce dense ceramic sheets suitable for electronic substrates.

Boron nitride sheets

Dense ceramic sheets suitable for electronic substrates are prepared by hot pressing ceramic green sheets containing ceramic powder and organic binders which leave no undesirable residue upon pyrolysis in the absence of oxygen. Boron nitride sheets made of boron nitride powder in a similar binder are placed on each side of the ceramic green sheet to form a composite. After hot pressing the composite so as to remove the binder and densify the ceramic, the BN layers are removed.

Hot pressing dense ceramic sheets for electronic substrates and for

Porous ceramic greenware comprising finely divided ceramic filler, finely divided metal, and polyolefin controls shrinkage in fired shape. In a preferred embodiment the metal and ceramic filler are bound together with the clean burning polyolefin and a plasticizer. After molding the mixture into the final shape, the plasticizer is removed to introduce porosity into the shaped article. Next the article is heated to decompose the polyolefin which can exit as a gas through the pore openings. Finally, the article is fired to a high temperature to oxidize the metal to metal oxide which becomes sintered with the ceramic filler particles to form a sintered porous article where the oxidized metal bonds the filler particles together in the desired shape.

Ceramic product and process

Catalysts made by the Raney process (e.g., Raney process nickel) pelletized in matrix of polymer and plasticizer are activated by either (a) removal of plasticizer (e.g., by solvent extraction) followed by leaching out Al with caustic solution, leaving an active catalyst made by the Raney process in a polymer matrix; or (b) removal of plasticizer, then calcining to remove polymer, followed by leaching with caustic. The activated catalyst pellets have sufficient strength and attrition resistance for efficient use in fixed beds and packed columns for superior hydrogenation of toluene, heptene, butyraldehyde, and other conventional feedstockers used with catalysts made by the Raney process.

Shaped catalysts and processes

Shaped catalyst and process for making it

A multiply sheet product useful as a battery separator having at least two plies each in the form of a microporous sheet of predetermined length and breadth and a thickness of less than 10 mils wherein (a) at least one of said ply being a sheet capable of transforming to a substantially non-porous membrane at a temperature between about 80.degree. C. and 150.degree. C. while essentially maintaining its length and breadth dimensions and (b) at least one ply being a sheet capable of maintaining its dimensions and porosity at temperatures from ambient to at least about 10.degree. C. greater than the transformation temperature of sheet (a).

Forming thin-wall honeycomb structures using novel extrusion die; method of making the die. The die has feed holes feeding to slots of a primary extrusion grid. A secondary grid is milled between slots of the primary grid, and successive subsequent grids can be provided between previously milled slots (secondary grid, tertiary grid, quaternary grid), and so on. Extrudable material is fed to the die under pressure; the material flows through the feed holes longitudinally to the primary grid, when the material flows to subsequent grid or grids. The material emerges from the die face as a thin-walled honeycomb structure. It is then rigidified to prevent deformation.

Die and processes for manufacturing honeycomb structures

A hollow fiber suitable for ultrafiltration formed from a microporous polyolefinic composition comprising from 8 to 93 volume percent polyolefin, from 7 to 92 volume percent of filler and from 0 to 10 volume percent of a plasticizer for the polyolefin to provide hollow fiber walls having pores at least 70 percent of which have a diameter of 0.3 micron or less.

Hollow fiber

A weldable sealant composition is made by adding ferrous metal particles to a sealant having a viscosity of at least 6 million centipoises. The sealant composition is placed between two metal plates and permits resistance welding, i.e. spot welding, to take place.

Welding sealants for metals and method of use

A multiply sheet product useful as a battery separator having at least two plies each in the form of a microporous sheet of predetermined length and breadth and a thickness of less than 10 mils wherein (a) at least one of said ply being a sheet capable of transforming to a substantially non-porous membrane at a temperature between about 80.degree. and 150.degree. C. while essentially maintaining its length and breadth dimensions and (b) at least one ply being a sheet capable of maintaining its dimensions and porosity at temperatures from ambient to at least about 10.degree. C. greater than the transformation temperature of sheet (a).

Weldable sealants for metal and method of use

Disclosed herein are ribbed catalyst-coated solid-state electrolyte sheets as well as a method for producing such sheets. Also disclosed is a fuel cell reactor comprising a plurality of said sheets stacked one upon another and cemented together to form a monolithic structure. Novel reactions utilizing the reactor to produce useful chemical oxidation products and/or electricity are set forth. Also disclosed is a novel wiring system to collect electrical power generated by the reactor.

Solid electrolyte sheet

A battery separator useful in alkaline battery systems, and a process of forming the same, is formed from a composition having 30-70% by weight synthetic pulp, 15-65% by weight alkali resistant inorganic filler, and 1-35% by weight of long fibers having lengths of between 1/4 and 1 inch. The long fibers may be polyester, polyacrylic, polyamide, polyolefin, or other staple fiber material. The process for forming the subject battery separator requires first forming a substantially uniform aqueous mixture of the subject composition, sequentially treating said composition with a combination of a cationic and an anionic agent, applying the treated composition to a standard paper-making apparatus at a grammage rate to cause the resultant dried sheet to have a thickness of less than about 10 mils, and forming a sheet product.

A battery separator, and a method of forming the same, which exhibits good electrical conductivity and a high degree of inhibition to dendrite formation, is in the form of a thin sheet formed from a substantially uniform mixture of a thermoplastic rubber, a filler, a rubber modifier, and a processing aid.

Growing community of inventors

Ashton, MD, United States of America

Christian B Lundsager