US3950460A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for making rigid, electrically conductive, cellular structures
Assignee: EIDP Inc
•
Filing: 1973-10-26
•
Granted: 1976-04-13
•
Expires: 1993-10-26
Abstract
Abstract Disclosed herein is a method for making an electrically conductive rigid cellular structure which comprises (i) coating the exposed surface of a porous, heat or solvent-removable substrate with a mixture of aluminum powder and titanate ester, (ii) decomposing the titanate ester of the mixture to effect cohesive binding of the coating, (iii) removing the substrate, and (iv) heating the remaining structure to develop electrical conductivity.
Inventors
- 👤 Sebastian Vito Rocco Mastrangelo
- 👤 Jerry Allen Nelson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 22:56
CPC Classifications
B; B01; B01J; B01J21/00; B01J21/06; B01J21/063; B01J37/00; B01J37/0009; B01J37/0018; B22; B22F; B22F3/00; B22F3/10; B22F3/11; B22F3/1121; B22F3/1137; H; H05; H05B; H05B3/00; H05B3/10; H05B3/12; B01J35/00; B01J35/50; B01J35/56; Y; Y10; Y10S; Y10S264/00; Y10S264/44
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
190 words
A method for making an electrically conductive rigid, self-supporting, cellular structure which comprises (i) coating the surface of a porous, heat or solvent-removable substrate with a coating mixture of aluminum powder up to about 100-mesh in size and at least one liquid titanate ester that forms cohesive polymeric titanium oxide films by being heated to 200° to 450° C or by being hydrolyzed with water or water vapor, the atom ratio of aluminum to aluminum plus titanium being from 0.81 to 0.96, and removing excess coating mixture, (ii) decomposing the titanate ester of the coating mixture by hydrolysis, pyrolysis or a combination thereof, at a temperature of up to 450° C, to form titanium oxide and to effect cohesive binding of the coating, said temperature being below the decomposition temperature of the substrate, (iii) removing the substrate by heating to a temperature higher than that of step (ii) but below 650° C, or by contacting the substrate with a solvent, and (iv) heating the remaining structure to at least 650° C thereby forming an intimate mixture of aluminum and an intermetallic compound of aluminum and titanium, and developing electrical conductivity.
Claim 2
Independent Claim
190 words
A method for making an electrically conductive rigid, self-supporting, cellular structure which comprises (i) coating the surface of a porous, heat or solvent-removable substrate with a coating mixture of aluminum powder up to about 100-mesh in size and at least one liquid titanate ester that forms cohesive polymeric titanium oxide films by being heated to 200° to 450° C or by being hydrolyzed with water or water vapor, the atom ratio of aluminum to aluminum plus titanium being from 0.81 to 0.96, and removing excess coating mixture, (ii) decomposing the titanate ester of the coating mixture by hydrolysis, pyrolysis or a combination thereof, at a temperature of up to 450° C, to form titanium oxide and to effect cohesive binding of the coating, said temperature being below the decomposition temperature of the substrate, (iii) removing the substrate by heating to a temperature higher than that of step (ii) but below 650° C, or by contacting the substrate with a solvent, and (iv) heating the remaining structure to at least 650° C thereby forming an intimate mixture of aluminum and an intermetallic compound of aluminum and titanium, and developing electrical conductivity.
Claim 3
Dependent Claim
17 words
A method according to claim 1 wherein the coating step comprises additionally drying, after removing excess mixture.
Claim 4
Dependent Claim
37 words
A method according to claim 1 wherein the titanate ester is decomposed by hydrolyzing the ester in situ in an atmosphere having a relative humidity of from about 10 percent to the condensation point of water vapor.
Claim 5
Dependent Claim
26 words
A method according to claim 3 wherein the titanate ester is decomposed by hydrolyzing the ester at a temperature of from about 200° to 450° C.
Claim 6
Dependent Claim
25 words
A method according to claim 1 wherein the substrate is removed by heating the substrate to a temperature above 200° C but below 650° C.
Claim 7
Dependent Claim
15 words
A method according to claim 1 wherein the removable substrate is an open-celled polyurethane foam.
Claim 8
Dependent Claim
12 words
A method according to claim 6 wherein the polyurethane foam is reticulated.
Claim 9
Dependent Claim
183 words
A method according to claim 1 wherein (i) comprises coating the surface of a porous, heat or solvent-removable substrate with a mixture of aluminum powder and a titanate ester selected from the group consisting of: a. an alkyl ortho ester of titanium having the formula Ti(OR) 4 , wherein R is C 1-18 alkyl, b. a partially hydrolyzed alkyl ortho ester of the general formula RO[-Ti(OR) 2 O-] x +1 R, wherein R is C 1-18 alkyl and x is a positive integer, c. A titanium chelate, having the formula ##EQU8## wherein R' is H, C 1-18 alkyl or X-Y, wherein X is an electron donating group and Y is an aliphatic radical having two or three carbon atom chain d. a titanium acylate having the formula Ti(OCOR) 4-n (OR) n wherein R is C 1-18 alkyl and n is an integer of from 0 to 3, e. polymeric forms of (d), and f. mixtures thereof, wherein each of (a) through (f) is capable of forming cohesive titanium oxide films when heated at temperatures in a range from about 200° to 450° C.
Claim 10
Dependent Claim
36 words
A method according to claim 8 wherein R' of the titanium chelate of (c) is X-Y, wherein X is oxygen or nitrogen and Y is an aliphatic radical having a two or three carbon atom chain.
Claim 11
Dependent Claim
59 words
A method according to claim 8 wherein R' of the titanium chelate of (c) is X-Y, wherein X is an electron donating group and Y is an aliphatic radical having a two or three carbon atom chain, said chain being selected from the group consisting of: i. -CH 2 CH 2 -, ii. ##EQU9## iii. ##EQU10## and iv. ##EQU11##
Claim 12
Dependent Claim
28 words
A method according to claim 8 wherein the alkyl ortho ester of (a) is selected from the group consisting of tetrabutyl titanate, tetraisopropyl titanate, tetrakis(2-ethylhexyl)titanate, and tetrastearyl titanate.
Claim 13
Dependent Claim
20 words
A method according to claim 8 wherein the partially hydrolyzed alkyl ortho ester of (b) is partially polymerized butyl titanate.
Claim 14
Dependent Claim
91 words
A method according to claim 8 wherein the titanium chelate of (c) is selected from the group consisting of i. titanium acetylacetonate wherein two acetylacetonate groups and two propoxy groups are bonded to titanium, ii. titanium lactate wherein two lactate groups and two hydroxy groups are bonded to titanium, iii. triethanolamine titanate wherein two C 3 H 7 -O- groups and two (HOCH 2 CH 2 ) 2 NCH 2 CH 2 O- groups are bonded to titanium, and iv. tetraoctylene glycol titanate wherein four ##EQU12## groups are bonded to titanium.
Claim 15
Dependent Claim
28 words
A method according to claim 8 wherein the titanium acylate of (d) is a titanium tetraacylate having the general formula Ti(OCOR) 4 wherein R is C 1-18 alkyl.
Claim 16
Dependent Claim
68 words
A method according to claim 8 wherein the polymeric titanium acylate of (e) is selected from i. polytitanyl diacylates of the general formula ##EQU13## wherein R is C 1-18 alkyl and x is a positive integer, and ii. hydroxy or alkoxy polytitanyl acylates containing repeating units ##EQU14## where OR is hydroxy or C 1-18 alkoxy, x is a positive integer, and OCOR" is a C 1-18 acylate group.
Claim 17
Dependent Claim
25 words
A method according to claim 1 wherein the atom ratio of aluminum to aluminum plus titanium in the coating mixture is from 0.87 to 0.94.
Claim 18
Dependent Claim
25 words
A method according to claim 6 wherein the atom ratio of aluminum to aluminum plus titanium in the coating mixture is from 0.81 to 0.96.
Claim 19
Dependent Claim
25 words
A method according to claim 17 wherein the atom ratio of aluminum to aluminum plus titanium in the coating mixture is from 0.87 to 0.94.
Claim 20
Dependent Claim
25 words
A method according to claim 12 wherein the atom ratio of aluminum to aluminum plus titanium in the coating mixture is from 0.81 to 0.96.
Claim 21
Dependent Claim
25 words
A method according to claim 19 wherein the atom ratio of aluminum to aluminum plus titanium in the coating mixture is from 0.87 to 0.94.
Claim 22
Dependent Claim
19 words
A method according to claim 1 wherein the aluminum powder of (i) is a fine type 325-mesh aluminum powder.
Claim 23
Dependent Claim
19 words
A method according to claim 14 wherein the aluminum powder of (i) is a fine type 325-mesh aluminum powder.
Claim 24
Dependent Claim
23 words
A method according to claim 1 wherein the structure is heated to develop electrical conductivity according to (iv) in a nitrogen enriched atmosphere.
Claim 25
Dependent Claim
18 words
A method according to claim 1 comprising, additionally, recoating the structure after step (iii) and before step (iv).
References Cited (Backward Citations)
US2966505A
Cited
US3093513A
Cited
GB923862A
Cited
US3111396A
Cited
US3547833A
Cited
US3536480A
Cited
GB1313174A
Cited
US3682839A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1979-04-13 | 1979-10-13 | 1980-04-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1983-04-13 | 1983-10-13 | 1984-04-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1987-04-13 | 1987-10-13 | 1988-04-13 | $7700.00 | Window Closed / Lapsed |