Delphi Technologies, Inc.

Gm Global Technolgoy Operations, Inc.

National Center for Manufacturing Sciences

Daniel William Gorkiewicz

Thomas Hubert Van Steenkiste

Bryan A Gillispie

George Albert Drew

John Robert Smith

Alaa AbdelAzim Elmoursi

Gary G Tibbetts

Donald T Morelli

Brian K Fuller

Robert L Alig

Richard Earl Teets

Jerome Joseph Moleski

Andrew Paul Nowak

Richard H Blunk

Martin Stier

Dean C Hammond, Jr

Robert R Quiel

Nilesh B Patel

An electrode plate is disclosed. The electrode plate includes a plate having an active area, a feed region in fluid communication with the active region, and a tunnel region in fluid communication with the feed region and a manifold region, an ultralyophobic coating on one or more of at least a portion of the tunnel region, at least a portion of the feed region, and an interface between the tunnel region and the manifold region. Fuel cells using the electrode plate and methods of making electrode plates are also described.

Stable ultralyophobic coating for PEMFC bipolar plate water management

Disclosed is a process for applying a kinetic spray coating of powder particles onto a substrate covered in a plastic-type material without first removing the plastic-type material. In one use of the process a mask is used to enable a single kinetic spray pass to both remove the plastic covering and bind particles having average nominal diameters of from 60 to 250 microns to the underlying substrate. In another use of the process the particles have an average nominal diameter of from 250 to 1400 microns and the use of a mask is optional because the particles can penetrate the plastic material and bind directly to the substrate. The process finds special use in forming electrical connections or solderable pads anywhere along the length of a flexible circuit.

Kinetic spray application of coatings onto covered materials

Disclosed is a method for forming a heat sink laminate and a heat sink laminate formed by the method. In the method a particle mixture is formed from a metal, an alloy or mixtures thereof with a ceramic or mixture of ceramics. The mixture is kinetically sprayed onto a first side of a dielectric material to form a metal matrix composite layer. The second side of the dielectric material is thermally coupled to a heat sink baseplate, thereby forming the heat sink laminate.

Kinetically sprayed aluminum metal matrix composites for thermal management

The present invention is directed to electrical contacts that comprise spaced electrically conductive particles embedded and bonded into the surface of conductors in which the particles have been kinetically sprayed onto the conductors with sufficient energy to form direct mechanical bonds between the particles and the conductors in a pre-selected location and particle number density that promotes high surface-to-surface contact and reduced contact resistance between the conductors.

Kinetic sprayed electrical contacts on conductive substrates

A method of maintaining a non-obstructed interior opening in a kinetic spray nozzle is disclosed. The method includes the steps of providing a mixture of particles including first particle population and a second particle population; entraining the mixture of particles into a flow of a gas at a temperature below the melt temperature of the particle populations; and directing the mixture of particles entrained in the flow of gas through a supersonic nozzle to accelerate the first particle population to a velocity sufficient to result in adherence of the first particle population on a substrate positioned opposite the nozzle. The operating conditions of the kinetic spray system are selected such that the second particle population is not accelerated to a velocity sufficient to result in adherence when it impacts the substrate. The inclusion of the second particle population maintains the supersonic nozzle in a non-obstructed condition and also enables one to raise the main gas operating temperature to a much higher level, thereby increasing the deposition efficiency of the first particle population.

Method of maintaining a non-obstructed interior opening in kinetic spray nozzles

A new kinetic spray process is disclosed that enables the coating to withstand severe bending and stress without delamination. The method includes use of a low pressure kinetic spray supersonic nozzle having a throat located between a converging region and a diverging region. A main gas temperature is raised to from 1000 to 1300 degrees Fahrenheit and the coating particles are directly injected into the diverging region of the nozzle at a point after the throat. The particles are entrained in the flow of the gas and accelerated to a velocity sufficient to result in partial melting of the particles upon impact on a substrate positioned opposite the nozzle and adherence of the particles to the substrate. The coating also has a desirable shinny surface. The method finds special application in coating substrates for use in formation of electrical connections.

Method for producing electrical contacts using selective melting and a low pressure kinetic spray process

An apparatus is disclosed for kinetic spray coating of substrate surfaces by impingement of air or gas entrained powders of small particles in a range up to at least 106 microns accelerated to supersonic velocity in a spray nozzle. Preferably powders of metals, alloys, polymers and mixtures thereof or with semiconductors or ceramics are entrained in unheated air and passed through an injection tube into a larger flow of heated air for mixing and acceleration through a supersonic nozzle for coating of an article by impingement of the yieldable particles. A preferred apparatus includes a high pressure air supply carrying entrained particles exceeding 50 microns through an injection tube into heated air in a mixing chamber for mixing and acceleration in the nozzle. The mixing chamber is supplied with high pressure heated air through a main air passage having an area ratio relative to the injection tube of at least 80/1.

Kinetic spray coating apparatus

A method and apparatus is disclosed for kinetic spray coating of substrate surfaces by impingement of air or gas entrained powders of small particles in a range up to at least 106 microns accelerated to supersonic velocity in a spray nozzle. Preferably powders of metals, alloys, polymers and mixtures thereof or with semiconductors or ceramics are entrained in unheated air and passed through an injection tube into a larger flow of heated air for mixing and acceleration through a supersonic nozzle for coating of an article by impingement of the yieldable particles. A preferred apparatus includes a high pressure air supply carrying entrained particles exceeding 50 microns through an injection tube into heated air in a mixing chamber for mixing and acceleration in the nozzle. The mixing chamber is supplied with high pressure heated air through a main air passage having an area ratio relative to the injection tube of at least 80/1.

Kinetic spray coating method and apparatus

In a preferred embodiment, an apparatus and method for forming carbon fibers in a gas phase reaction is disclosed wherein a reactor defines a reaction chamber with a closed end and an outlet and a reactant feed tube which extends generally axially therewithin. Gaseous reactants are injected into the reactor through an opening of the feed tube. The feed tube and chamber are constructed and arranged to define a passageway which is a gas flow path. The reactor includes purge means for intermittently and forcibly moving any fibers clogging the passageway out of the reactor, and means for intermittently oxidizing carbonaceous material in the passageway of the reactor. In use, a period of fiber formation is followed by a forced purge. Periodically, an oxidation purge is used to essentially cleanse the reactor.

Method for forming carbon filters

In a preferred embodiment, an apparatus and method for forming carbon fibers in a gas phase reaction is disclosed wherein a reactor defines a reaction chamber with a closed end and an outlet, and a reactant feed tube which extends generally axially therewithin. Gaseous reactants are injected into the reactor through an opening of the feed tube. Preferred reactants include methane, natural gas, hydrogen sulfide, ammonia, and an iron-containing compound dispersed in a carrier gas. The apparatus includes purge means for intermittently and forcibly moving any fibers clogging the reactor out of the reactor; and means for intermittently oxidizing carbonaceous material in the reactor. In use, a period of fiber formation is followed by one or more purge steps to essentially cleanse the reactor.

Method for forming carbon fibers

In a preferred embodiment, an apparatus for forming carbon fibers in a continuous gas phase reaction is disclosed wherein a reactor defines a vertical reaction chamber with a close upper end and a lower outlet, with a vertical reactant feed tube which extends generally axially therewithin. Gaseous reactants are injected into the reactor through an opening of the feed tube. The feed tube and chamber are constructed and arranged to define a gas flow path which extends generally axially upward through the feed tube into the chamber and thereafter generally axially downward through the chamber. Preferably, the tube and reactor chamber are radially spaced and concentric. The feed tube may encompasss a capillary tube which supplies a vaporizable liquid reactant. The reactor and feed tube are each elongate and of a material which is relatively resistent to heat and corrosion and are preferably of a mullite material. The feed tube extends more than one-half of the axial length of the reactor. Desirably, the feed tube extends at least three-fourths of the axial length of the reactor, and preferably extends at least five-sixths of the length thereof and is concentric with the reactor chamber defined by the tubular reactor.

Growing community of inventors

Washington, MI, United States of America

Daniel William Gorkiewicz