Revolutionary Plastics, LLC

Technical Research Associates, Inc.

Jared Lee Sommer

Jack Raymond Prince

Joseph K Weeks, Jr

Strengthened thermoplastic materials use fly ash or cinders as extenders. The extended materials use fly ash or cinders that preferably contain no more than about 2% by weight of moisture. The thermoplastic materials are preferably foamed and extruded to form extruded closed cell foam articles, for example a window blind slat, shutter louver, shutter stile, or shutter frame. Thermoplastic materials formed with the fly ash or cinders can also be formed into non-foamed products or into pellets for use in later extruding to form products.

Thermoplastic composition with fly ash material

The particle size distribution of a first fly ash is compared to an ideal particle size distribution that was empirically developed to provide a resin melt with a lower viscosity as more fly ash is added. A second fly ash material is similarly compared to the ideal curve and then is blended or optimized to provide an optimum filler for use with a suitable resin or similar material. The blended optimum filler is combined with a resin, an acid scavenger and an anti-oxidant to form a master batch which is available for mixing with other resins to form a material that is processed into a final product. Additional additives may be added for, among other things, foaming and coloration.

Master batch method with optimized filler

The particle size distribution of a first fly ash is compared to an ideal particle size distribution that was empirically developed to provide a resin melt with a lower viscosity as more fly ash is added. A second fly ash material is similarly compared to the ideal curve and then is blended or optimized to provide an optimum filler for use with a suitable resin or similar material. Additional fly ash materials may be similarly compared and blended. Additional additives may be added for, among other things, foaming and coloration.

System for forming a composition with an optimized filler

Fly ash and cinder strengthened thermoplastic

A carbonaceous material coated with a molybdenum carbide coating, the molybdenum carbide coating protecting the carbonaceous material against attack by molten metal while simultaneously providing a wetting action for the molten metal to infiltrate the carbonaceous material. The carbonaceous material is any suitable carbonaceous material such as diamond; graphite fibers, both continuous and discontinuous; carbon and graphite particulate; lampblack; and carbon-rich surfaces. The molybdenum carbide coating is produced by reacting a gaseous molybdenum compound with the surface of the carbonaceous material under a reducing atmosphere. The molybdenum carbide coated carbonaceous material is formed into a metal/carbonaceous material composite by being heated with the metal under an inert atmosphere until the molten metal infiltrates the molybdenum carbide coated carbonaceous material. The metals include copper, aluminum, magnesium, iron, nickel, cobalt, titanium, silver, gold, platinum, rhodium, tin, zinc, and alloys of these metals.

Method for coating a carbonaceous material with a molybdenum carbide

A composite of a metal infiltrated into a carbonaceous material. The carbonaceous material is coated with a molybdenum carbide coating, the molybdenum carbide coating protecting the carbonaceous material against attack by molten metal while simultaneously providing a wetting action for the molten metal to infiltrate the carbonaceous material. The carbonaceous material is any suitable carbonaceous material such as diamond; graphite fibers, both continuous and discontinuous; carbon and graphite particulate; lampblack; and carbon-rich surfaces. The molybdenum carbide coating is produced by reacting a gaseous molybdenum compound with the surface of the carbonaceous material under a reducing atmosphere. The molybdenum carbide coated carbonaceous material is formed into a metal/carbonaceous material composite by being heated with the metal under an inert atmosphere until the molten metal infiltrates the molybdenum carbide coated carbonaceous material. The metals include copper, aluminum, magnesium, iron, nickel, cobalt, titanium, silver, gold, platinum, rhodium, tin, zinc, and alloys of these metals. The composite exhibits a high degree of thermal and electrical conductivity and a low coefficient of thermal expansion.

Metal and carbonaceous materials composites

A novel heat transfer apparatus and method including a body of carbon/carbon material with cooling tubes brazed therein. The carbon/carbon material includes carbon, graphite, carbon fibers, graphite fibers and combinations of the same and silicon carbide and boron carbide. The cooling tubes are prepared from stainless steel, nickel and its alloys, cobalt and its alloys, copper, molybdenum, molybdenum rhenium alloy, and carbon. A wetting agent is applied to the carbon surfaces to protect the carbon surfaces from attack by the molten brazing material and is selected from molybdenum niobium, tantalum, tungsten, and carbides of these refractory metals. The brazing material is selected from copper, copper alloys, silver, and gold. Advantageously, the wetting agent not only protects the carbon surfaces from attack by the brazing metals but its surface tension therewith holds the brazing metal into intimate thermal contact between the carbon surface and the cooling tubes even while the novel heat transfer apparatus of this invention is operating at temperatures above the melting temperature of the brazing metal.

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North Salt Lake City, UT, United States of America

Jared Lee Sommer