Abstract:
A conductive polymer is disclosed which is suitable for use in applications which require corrosion resistance including resistance to corrosion when subjected to acidic flow at temperature ranging from −40 to 140 degrees Fahrenheit and which can be molded into highly intricate and thin specimens which exhibit consistent conductivity, sufficient strength and flexibility, and appropriate surface characteristics. In particular the invention involves molding unsaturated prepolymer resin composition which have high loadings of conductive fillers. Further to enable the necessary characteristics, the compositions include rheological modifiers such as Group II oxides and hydroxides; carbodiamides; aziridines; polyisocyanates; polytetrafluoroethylene (PTFE); perfluoropolyether (PFPE), and polyethylene. Ostensibly, these modifiers act to alter the apparent molecular weight and three dimensional prepolymer network structures correcting rheological deficiencies which otherwise lead to excessive resin particulate separation during the molding process and large variances in bulk conductivity across the plate surface. The composition is disclosed for use in electrochemical cells, such as fuel cells.

Description:
This patent application is based upon U.S. provisional application Ser. No. 60/125,138, filed Mar. 19, 1999. 
    
    
     FIELD OF INVENTION 
     The field of invention is highly conductive compositions that are particularly useful for molding processes such as those using thermosetting bulk molding compositions. These molding compositions can be formed into high definition complex configurations. For example, they can be molded into thin plate-like specimens (e.g. 60 to 200 thousandths of an inch) having an intricately patterned network of very narrow, relatively smooth, flow passages. These specimens are used as electrochemical cell bipolar plates. These plates desirably have a bulk conductivity of at least 40, 50, 60, 70, 80, 90 or even 96 S/cm. They also have desirable surface characteristics; heat, temperature, chemical and shrink resistance; strength; and cost. 
     BACKGROUND OF THE INVENTION 
     Conductive polymers have applications in providing alternatives to traditional conductive materials, which often involve greater labor expenses to manufacture into complex parts. In particular, in instances where the demand justifies significant volumes of a product, polymer molding expenses may prove far more cost effective than comparable machining expenses for other materials. However in the past, it has proved difficult to achieve both a high level of conductivity and desirable molding characteristics. Generally, high level weight percentages of an appropriate filler in a polymeric matrix are necessary to achieve satisfactory levels of conductivity. However, these high load levels lead to problems with the strength, durability, and moldability of the resulting composition. 
     One area in particular where it would be beneficial to solve the previously mentioned strength, durability, and molding issues is for application in fuel cells. Electrochemical fuel cells have great appeal as a potentially limitless energy source that is clean and environmentally friendly. These fuel cells can, in addition, be constructed at an appropriate scale for small scale energy consumption, such as household use, or for industrial scale use, and even for commercial power generation. They have portable applications to power small appliances (such as computers or camping equipment), or automobiles and other forms of transportation. Although these different applications involve differences in size, the fundamental construction remains the same for generation of power varying from less than one to a few thousand kilowatts. 
     Basically, a fuel cell is a galvanic cell in which the chemical energy of a fuel is converted directly into electrical energy by means of an electrochemical process. The fundamental components of the fuel cell are an electrode comprising an anode and a cathode, eletrocatalysts, and an electrolyte. Work has been done in perfecting both liquid and solid electrolyte fuel cells and the present invention may find use in both types of fuel cells. 
     Solid electrolytes include polymeric membranes which act as proton exchange membranes typically fueled by hydrogen. These membranes usually comprise a perfluorinated sulphonic acid polymer membrane sandwiched between two catalyzed electrodes that may utilize platinum supported on carbon as an electrocatalyst. Hydrogen fuel cells form a reaction chamber, which consumes hydrogen at the anode. At the cathode, oxygen reacts with protons and electrons at the electrocatalytic sites yielding water as the reaction product. A three-phase interface is formed in the region of the electrode and a delicate balance must be maintained between the electrode, the electrolyte, and the gaseous phases. 
     Systems involving the use of other electrolytes have been also been studied. These would include alkaline fuel cells, phosphoric acid fuel cell, molten carbonate fuel cells, and solid oxide fuel cells. However, the principles are similar, as are some of the issues in perfecting these products. 
     A fuel cell reactor may comprise a single-cell or a multi-cell stack. In any case, the cell includes at least two highly conductive flow field plates that serve multiple functions. These plates may function as current collectors that provide electrical continuity between the fuel cell voltage terminals and electrodes. They also provide mechanical support (for example for the membrane/electrode assembly). In addition, these plates act to transport reactants to the electrodes and are essential to establishing the previously mentioned delicate phase balance. 
     Typically, the fuel cell plates are thin relatively flat plate members that include a highly complex network of interconnecting channels that form the flow field area of the plate. The configuration of these channels is highly developed in order to maintain the proper flow of reactants and to avoid channeling or the formation of stagnant areas, which results in poor fuel cell performance. It is critical that the flow of the reactants is properly managed, and that the electrocatalysts are continuously supplied with precisely the appropriate balance of reactants. Thus, it is essential for the plates to define and maintain clear passages within the highly engineered flow labyrinth. Moreover, in order to assure a satisfactory life, the plates must be able to resist surface corrosion under a variety of conditions. For example, fuel cells may be placed outside and subject to ambient weather. Thus, the cells must be resistant to stress cracking and corrosion at temperature ranging from −40 to 200 degrees Fahrenheit. Further, since the conditions within the cell are corrosive, the cells must also be resistant to chemical attack at these temperatures from various corrosive substances. For example, the plates may be subjected to de-ionized water, methanol, formic acid. formaldehyde, heavy naptha, hydrofluoric acid, tertafluoroethylene, and hexafluoropropylene depending on the fuel cell type. Moreover, the conditions within the fuel cell may lead to elevated temperatures, i.e. from 150 to 200 degrees Fahrenheit, as well as elevated pressures, i.e. from ambient to 30 p.s.i. Corrosive decomposition needs to be avoided since it almost certainly would cause a system failure by changing the flow patterns within the fuel cell. 
     Past attempts at solving the various requirements for fuel cell plates have included the use of metal and machined graphite plates. The use of metal plates result in higher weight per cell, higher machining costs and possibly corrosion problems. Machined graphite plates solve the weight and corrosion problems but involve high machining cost and result in fragile products, especially when prepared as very thin plates. Some use of graphite/poly(vinylidene fluoride) plates has been made but these have been characterized as being expensive and brittle and having long cycle times. 
     U.S. Pat. No. 4,197,178 is incorporated herein for its teaching of the working and compositions of electrochemical cells. U.S. Pat. No. 4,301,222 is incorporated herein for its teachings on graphite based separators for electrochemical cells. 
     SUMMARY OF THE INVENTION 
     In the past, known conventional bulk molding compounds have been modified to be conductive by the addition of large amounts of conductive filler, such as graphite. During molding it was observed that the liquid resin phase separated from the filler and was exuded from the molding. Further, it was observed that this occurrence tended to cause cracking in molded specimens that were thin. Moreover, bulk conductivity measurements at different locations within the specimen were inconsistent. In accordance with the present invention, it was discovered that compositions could be formulated which solved the foregoing issues. In particular, the formulations involve the use of a resin matrix with high loadings of a conductive filler; various additional additives, such as initiators, mold-release agents, and carbon black; and one or more rheological agents selected from the group comprising group II oxides, alkaline earth oxides, carbodiamides, polyisocynates, polyethylene and therefore polytetrafluorethylene flouroethylene. One possible explanation for the mechanism by which the molding agents work, is that they act to build the apparent molecular weight of the prepolymer (e.g. vinyl ester resin or unsaturated polyester resin). Alternatively, these agents may promote flow such as by reducing shear during molding. The use of these rheological agents eliminates phase separation, as well as cracking and inconsistent conductivity measurements. It is anticipated that these problems are a result of the complex configuration of the specimens being molded along with the very high concentrations of conductive filler. 
     In addition to solving molding and cracking problems it is anticipated that other properties such as the coefficient of thermal expansion, electrical and thermal conductivity, shrink resistance and mechanical properties may be more uniform and/or otherwise improved as a result of the use of the present invention. In addition to the foregoing improvements it was found that a resin composition of the invention demonstrated a higher glass transition temperature and resulted in an improvement in the hot strength of the molded part. Further improvements are also possible by optimizing both gel time and cure time for the prepolymer by controlling initiator type and amount and inhibitor type and amount. 
     The foregoing improvements in specimens molded from these compositions enable the low cost mass production of bipolar plates as an additional embodiment of the invention. These could be used for portable fuel cells, as well as stationary power units. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an illustration of a fuel cell assembly utilizing a bipolar cell plate; and 
     FIG. 2 is an illustration of a bipolar fuel cell plate that can be made in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention relates to improvements in conductive molding compositions. In particular, the compositions can be used in compression molding processes and in injection molding processes. Further these compositions enable the production of thin and intricate specimens that have high concentrations of conductive filler. 
     Sheet molding and bulk molding compositions are described in U.S. Pat. Nos. 5,998,510; 5,342,554; 5,854,317; 5,744,816; and 5,268,400; all of which are hereby incorporated by reference for their teachings on the various modifications to molding compositions that are known to the art. 
     One component of a molding resin composition is a crosslinkable prepolymer such as an unsaturated polyester resin or vinyl ester resin. Desirably the prepolymer has a relatively low molecular weight such as from about 200 to about 5000 (weight average). They are described in detail with examples in the above patents incorporated by reference. The polyester resins are the condensation product derived from the condensation of unsaturated polybasic acids and/or anhydrides with polyols such as dihydroxy or trihydroxy compounds. Desirably, these polyester resins are the esterification reaction product of diacids, or anhydrides of diacids, generally having from about 3 to about 12, or more preferably from about 4 to about 8 carbon atoms, with a polyol or a cyclic ether having from about 2 to about 12, or more preferably from about 2 to about 6 carbon atoms. 
     In general, the vinyl ester resins that can be used are the reaction products of epoxy resins and a monofunctional ethlenically unsaturated carboxylic acid. More specifically, these vinyl ester resins are the reaction product of an epoxy terminated oligomer, for example, an epoxy functionalized bisphenol A with an acrylic acid, or methacrylic acid forming acrylic terminal groups on the oligomer. The vinyl esters have predominantly terminal unsaturation while the unsaturated polyesters have predominantly internal unsaturation. 
     Another component of the molding composition is one or more unsaturated monomers that are copolymerizable with the resin. Desirably, this component is cabable of dissolving the resin component at room temperature. Thus, in one embodiment the resin is dissolved in the monomeric component prior to being combined with the remaining components. Examples of suitable monomers are styrene, alpha-methyl styrene, chloro-styrene, vinyl toluene, divinyl benzene, diallylphthalate, methyl methacrylate, and mixture of these, with preferred monomers being styrene and methyl methacrylate. The ratio of monomer(s) to resin is desirably from about 40:60 to about 75:25 and preferably from about 40:60 to about 65:35 by weight. 
     Another component to the molding composition is fillers. In accordance with the invention the predominant filler is a conductive filler in order to impart electrical conductivity of the final molded product. A preferred filler is graphite particles, in particular, a synthetic crystalline graphite particle, such as currently supplied by Asbury Graphite in Asbury, N.J. under the designation Asbury 4012. This graphite is characterized as having less than 10% particles greater than 150 microns and less than 10% smaller than 44 microns in diameter. Other graphite fillers include: Ashbury A99, Ashbury 3243, Ashbury modified 4012, Ashbury 3285, Ashbury 230U; TimrexR KS 75 and 150, and TimrexR KC 44, all sold by TIMCAL of Westlake, Ohio; and Calgraph Sold by SGL Technic Inc of Valencia, Calif. This filler is used at a loading of at least 50% by weight. Other conductive fillers such as other forms of graphite (including graphite pitch-based fibers), metal particles, or metal coat particles may be used in conjunction with the graphite filler, or even alone. Desirably conductive fillers are at least about 50, about 60, or about 65 weight percent of the molding composition. More desirably the filler is more than about 70 or 71 percent to about 78 weight percent of the molding composition. Alternatively this amount can be expressed as at least about 250 phr, more preferably at least about 275, or even 300 phr. Alternatively stated the conductive fillers are present in an effective amount to result in a bulk conductivity of at least about 40, about 50, about 60, about 70, about 80, about 85, about 90 or about 96 S/cm when measured in accordance with ASTM Test Standard No. F1529-97 for a molded article having a thickness from about 0.060 to about 0.200 inches. Current technology in fuel cell plates uses a bulk conductivity of at least about 55, and preferably at least about 70. 
     An initiator is another component of the molding composition. The initiator initiates the copolymerization of the resin and the monomer(s). Initiators include any free radical initiator capable of forming radicals in the correct concentration under the molding conditions. They may include peroxides, hydroperoxides, redox systems, diazo compounds, persulfates, perbenzoates etc. The initiators are typically used in amounts of about 0.05 to about 5 weight percent, and more preferably about 0.1 to about 2 weight percent. Alternatively, these amounts can be expressed in parts per hundred parts by weight of resin, i.e. from about 0.5 to about 4.0 phr, preferably from about 0.7 to about 3.0 phr, and most preferably from about 0.8 to about 2.25 phr. Alternatively high temperature initiators such as Di-cup, e.g. dicumyl peroxide can be used for molding applications where higher iniation temperatures are desirable. 
     An essential component to the improved molding composition is a rheological modifier, which may act to increase the molecular weight such as by chain extension of the resin prepolymer. Suitable modifiers include Group II oxides and hydroxides, such as calcium or magnesium oxide; carbodiamides; aziridines; and polyisocyanates. It is believed that the foregoing modifiers act chemically by co-reacting into the polymer backbone at carboxy or hydroxy sites. Other suitable modifiers include therefore polytetrafluoroethylene (PTFE); perfluoropolyether (PFPE), and polyethylene. These modifiers may act to reduce shear and thus promote flow in the composition during molding. Fumed silica is an example of a substance which may act mechanically to increase molding viscosity and therefore be a suitable rheological modifier for this invention. Combinations of two or more rheological modifiers may be desirable for optimum properties. In this application they are used to modify the resin structure to prevent phase separation of the resin from the conductive filler (in particular in view of the high loadings of the conductive filler, i.e. over 50% or even 65% by weight or more of graphite) The modifiers are further used in general to enable the achievement of a high definition conductive polymeric fuel cell plate. 
     Desirably the rheological modifiers are used in an effective amount to prevent phase separation during molding. For the purpose of this application molding will desirably be at pressures from about 400 to about 5000 psi, and preferably from about 2000 to about 3500 psi, and most preferably from about 2500 to about 3000 psi. Desirable amounts of group II oxides (including group II hydroxides and mixtures of these compounds) is from about 0.1 to about 1 or about 2 weight percent, more desirably from about 0.2 or about 0.3 to about 0.7 or about 0.8 weight percent. This can also be expressed as from about 0.5 to about 4.0 phr, preferably from about 1.0 to about 3.0 phr, and most preferably from about 1.5 to about 2.5 phr. Specific preferred compounds include magnesium oxide, or magnesium hydroxide or calcium oxide. Examples of a suitable magnesium oxide additive is 99% pure magnesium oxide sold under the tradename “Elastomag” from Morton Thiokol, Inc. in Danvers, Mass. Other examples include a magnesium oxide dispersion sold under the tradename “pg-9033” by Plasticolors, and a magnesium hydroxide dispersion also sold by Plasticolors under the tradename “pg-91146”. Another suitable magnesium hydroxide is Barcroft which is a powdered version. Examples of aziridine compounds include polyfunctional aziridines supplied by EIT,lnc. under the trade designation XAMA, including XAMA-2, which is identified as trimethylol propane-tris (beta-(N-aziridinyl) proprionate), and, in particular, XAMA-7, which is identified as pentaerythritol-tris-(beta-(aziridinyl) proprionate); a product of Sybron Chemicals, under the tradeneme lonac including PFAZ-322, identified as a trifunctional aziridine; and including CX-100, a product of Zeneca Resins, identified as a polyfunctional aziridine. Desirable amounts of aziridine and/or polyisocyanate modifiers is from about 1 to about 10 or about 15 weight percent, and more desirably from about 2 or about 3 to about 8 or about 9 weight percent. This can also be expressed as from about 0.5 to about 20 phr, preferably from about 1 to about 17 phr, and most preferably from about 2 to about 15 phr. Polyisocyanates in general are described in more detail in U.S. Pat. No. 5,268,400 column 6, line 59 through column 7, line 17. A specific diisocyanate which can be used is diphenylmethane diisocyanate such as that sold by ICI Americas of West Deptford, N.J., under the tradename “Rubinate” R MF-1780. Additionally, a suitable diisocynate is Lupranate MP102, solvent free urethane-modified diphenylmethane diisocyanate from BASF. Desirable amounts of polytetraflooroethylene (PTFE) (and/or perfluoropolyether (PFPE)) is from about 0.5 to about 1 or about 2 weight percent, more desirably from about 0.6 or about 0.7 to about 1.8 or about 1.3 weight percent. This can also be expressed as from about 0.5 to about 20 phr, preferably from about 3 to about 15 phr, and most preferably from about 5 to about 12 phr. A suitable fine particle PTFE powder (having an average particle size by Coulter Counter of less than-microns) is sold under the tradename “Marzon #5 by Marshall Products Company of West Chester Pa. It is preferable to use a linear low density polyethylene such as sold by Equistar of Houston Tex. under the tradename FN 510 It is preferable to use it in amounts of from about 3 to about 20 phr, more preferably from about 4 to about 17, and most preferably from about 5 to about 15 phr. Fumed silica could be used at from about 0.5 to about 20 phr, preferably from about 1 to 10 phr. 
     Other optional components to a molding composition include urethane based or urethane containing oligomers or polymers, low shrinkage additives like polyvinyl acetate or polyethylene; fibrous reinforcing agents such as cotton glass microfibers or graphite microfibers; flexibilizing agents; mold release agents; polymerization inhibitors to inhibit premature polymerization during storage or the initial stages of molding; viscosity modifiers like fumed silica; and mold lubricant like stearates of calcium, zinc or magnesium. Carbon black may be added to influence the surface conductivity and to change the appearance of the molded product. Suitable carbon blacks include an electrically conductive low residue carbon black having a nitrogen surface area m2/g of 270, a STSA surface Area m2/g of 145 a sieve residue at 35 mesh of 0 ppm and at 325 mesh of 20 ppm as sold under the tradename Conductex 975 by Columbia Chemicals of Jamesburg, N.J. Also, suitable conductive carbon black is supplied by Akzo Nobel Chemicals of Chicago, Ill. under the tradename Ketjenblack EC-300 J and EC-600JD. Cabot Corporation of Boston Mass. also supplies a conductive carbon black. It is noted that polyethylene and fumed silica can function as the rheological modifier in addition to the foregoing functions. 
     The molding compositions may be formulated and mixed using a variety of mixing conditions including either continuous or batch and using a variety of known mixing equipment. Specific examples are set forth in the example section. The compositions may be advantageously stored for reasonable times before molding. The compositions can be molded by a variety of methods including compression molding and injection molding. The compositions can be molded under typical conditions for these types of molding including at pressures from about 400 to about 5000 psi, and preferably from about 2000 to about 3500 psi, and most preferably from about 2500 to about 3000 psi and temperatures at from about 225 to about 400 degrees Fahrenheit. Dwell times are from about 70 seconds to about four minutes. The compositions are useful for molding complex configurations including thin or intricate conductive articles such as those having a thickness from about 0.050 to about 0.200 inches, and more preferably from about 0.060 to about 0.150 inches. The compositions are useful for articles having bulk conductivity of at least 40, 50, 60, 70, 80, 85, 90 or even 96 S/cm at a thickness given above. The articles from the composition desirably have tensile strength from about 1500 to about 5000 psi as measured in accordance with ASTM test No.D638 and flexural modulus from about 2500 to about 10,000 psi when tested in accordance with ASTM test No.D790. 
     Molded products made from the compositions of the present invention are useful for a variety of applications demanding complex configurations, conductivity, as well as strength, and corrosion resistance. One particularly advantageous product which can be made by compression molding is a bipolar plate for use in fuel cells. An example of such a plate is shown in FIG.  1 . The drawing of this plate is intended to illustrate the molding capabilities of the conductive compound of the present invention. It is not necessarily intended to provide optimal, or even operative, field flow design. It should not limit the invention in any way. The plate 10 includes a fluid flow face with one or more generally parallel and or serpentine flow channels 12. The flow channels receive and transmit fluids through ports 14 and 16 which are in fluid communication with corresponding entry and exit fluid manifolds 18 and 19. The plate has a dimension which will vary from 1 to 20 inches in length and width, and having a thickness of 0.02 to 0.3 inch, with a cross-sectional depth of the flow channel in the range of about 0.005 to 0.080 inch. The cross-sectional width of a land separating adjacent flow channel sections is in the range of 0.01 to 0.1 inch. The plate may include a number of peripheral through holes 20 that act as a manifold for fuel transportation. 
     FIG. 2 illustrates the unassembled components of a fuel cell. This fuel cell has a base unit 12 which includes debossed means to accept a reformer 14 and a fuel cell stack 16 which is comprised of a plurality of bipolar plates 20 which are sandwiched between a stack cap 22 and a stack base 24. The fuel cell further includes a heat exchanger 26. An enclosure 30 provides a leak-proof housing for the unit. 
     EXAMPLES 
     The following examples use the components set forth below. 
     Resin A is Hetron 922 available from Ashland Chemical Co in Columbus Ohio. It is a low viscosity epoxy vinyl ester resin. It is about 55 wt. % solids and about 45 wt. % reactive monomer. 
     Resin B is Atlac 382ES from Reichhold Chemicals, Inc. in Research Triangle Park, N.C. It is characterized as a bisphenol fumarate resin. It was diluted to about 55 wt. % solids with styrene. 
     Resin C is Dion 6694 diluted to 55 wt. % solids in styrene. It is available from Reichhold Chemicals, Inc. It is characterized as a modified bisphenol fumarate polyester. 
     Resin D is 42-2641 from Cook Composites and Polymers in Kansas City, Mo. It was diluted to 55 wt. % solids with styrene. It is characterized as an unsaturated polyester resin. 
     Resin E is ATLAC 3581-61 from Reichhold Chemicals, Inc. It is characterized as a vinyl ester resin at 19 wt %, polyester at 27 wt % and urethane polymer at 4 wt % combined with 50 wt % styrene. Thus, it was diluted to 50 wt % solids with styrene. 
     Resin F is 580-05 from Reichhold Chemicals, Inc. It is characterized as a urethane-modified vinyl ester resin. It was diluted to 54 wt % solids with styrene. 
     Resin G is 9100 from Reichhold Chemicals, Inc. It is characterized as a bisphenol-epoxy vinyl ester. It was diluted to 54-58 wt % solids with styrene. 
     Resin H is Dow Derakane R8084 from Dow Chemicals, Inc. It is characterized as an elastomer-modified vinyl ester resin. It was diluted to 50-60 wt % solids with styrene. 
     Resin I is 9480-00 from Reichhold Chemicals, Inc. It is characterized as an epoxy novolac vinyl ester. It was diluted to 53.5 wt % solids with styrene. 
     Resin J is Atlac 31-632 from Reichhold Chemicals, Inc. It is an unsaturated isocyanurate vinyl ester resin. 
     Rheological Modifier A is Elastomag from Morton Thiokol. Inc. in Danvers, Mass. It is characterized as 99% pure magnesium oxide. 
     Rheological Modifier B is a polyisocyanate. The material used in these experiments is 40-7263 from Cook Composites and Polymers. It is characterized by a NCO content of 17.7 to 20.9, a viscosity of 110-170, a flash point of 87° F., and a crystallization point of 40° F. 
     Rheological Modifier C is RCI RD THL55 (also known as RD-1070) from Reichhold, Inc. It is specifically a polyurethane resin. 
     Rheological Modifier D is Rubinate 1780 available from ICI. It is characterized as a polymeric methylene diphenyl diisocyanate. 
     Rheological Modifier E is Marzon #5 from Marshall Products Company of West Chester, Pa. It is characterized as a finely divided powder polytetrafluorethylene. 
     Rheological Modifier F is FN-510, a linear low density polyethylene 
     Initiator A is Vazo (2,2-azo bisisobutyronitrile) available from Dupont, I &amp; B Industrial and Biochemical Dept, Wilmington Del. 
     Initiator B is tert-butyl peroxy isopropyl carbonate (Triginox BPIC) available from Durr Marketing in Pittsburgh, Pa. 
     Initiator C is t-butylperbenzoate (TBPB) available from Durr Marketing. 
     Initiator D is 1,3 di-t-butyl peroxy-3,5,5 trimethylcyclohexane catalyst (Trig 29B75) available from Durr Marketing. 
     The mold release agent is calcium stearate. 
     Graphite A is a synthetic, crystalline graphite available from Asbury Graphite in Asbury, N.J. It is characterized by having less than 10% greater than 150 microns and less than 10% smaller than 44 microns in diameter. It is available under the designation 4012. 
     Graphite B is a very fine conductive particulate graphite available from SGL Technic of Valencia, Calif. under the trade designation SGL 02. 
     Graphite C is a conductive particulate graphite available from SGL Technic of Valencia Calif. under the trade designation SGLVFINE. 
     Graphite D is available from Asbury Graphite in Asbury, N.J. It is a modified version of the 4012 product. 
     Graphite E is a conductive flake graphite available from Asbury Graphite in Asbury, N.J. under the trade designation 3243. It is characterized by having less than 18% greater than 75 microns and less than 65% smaller than 44 microns in diameter. 
     Graphite F is a conductive flake graphite available from Asbury Graphite in Asbury, N.J. under the trade designation 230U. It is characterized by having 100% smaller than 44 microns in diameter. 
     Graphite G is a synthetic graphite available from Asbury Graphite in Asbury, N.J. under the trade designation A99. It is characterized by having less than 3% greater than 44 microns and less than 99% smaller than 44 microns in diameter. 
     Graphite H is a synthetic graphite available under the designation KS 75, from Timrex America, Inc. It is characterized by having less than 95% greater than 96 microns and less than 95% smaller than 75 microns in diameter. 
     Graphite I is a synthetic graphite available under the designation KS 150, from Timrex America, Inc. It is characterized by having at least 95% less than 180 microns in diameter 
     Graphite J is a synthetic graphite available under the designation KC44, from Timrex America, Inc. It is characterized by having at least 90% less than 48 microns in diameter. 
     Carbon Black B is characterized as an electrically conductive low residue carbon black having a nitrogen surface area m2/g of 270, a STSA surface Area m2/g of 145 a sieve residue at 35 mesh of 0 ppm and at 325 mesh of 20 ppm as sold under the tradename Conductex 975 by Columbia Chemicals of Jamesburg, N.J. 
     Carbon Black C is conductive carbon black supplied by Cabot Corporation of Boston, Mass. under the tradename, Black Pearls, while Graphite D supplied by this company under the designation XC-72. 
     Carbon Black E is conductive carbon black is supplied by Akzo Nobel Chemicals of Chicago, Ill. under the tradename Ketjenblack EC-300 J and EC-600JD. EC-300 J has an iodine absorption of 740-840 mg/g; a pore volume of 310-345 cm3/100 g and an apparent bulk density of 125-145 kg/m3. EC-600 JD has an iodine absorption of 1000-1150 mg/g; a pore volume of 480-510 cm3/100 g and an apparent bulk density of 100-120 kg/m3. 
     The Glass fibers were from Owens-Corning Fiberglass and are characterized as continuous glass filaments hammermilled into a specific length used as a reinforcing and filler medium. 
     The inhibitor was 2,6-di-tertbutyl-p-cresol (25% in vinyl toluene). 
     The molding compositions are generally prepared by adding the resin, monomer initiator, inhibitor, mold release agent, and rheological modifier (if present) to a high shear cowels disperser and blending for 2 minutes. The conductive filler is added to the mix in a Baker Perkin Mixer and mixed 15 minutes. When mixing is complete the composition is put in a suitable barrier bag and allowed to mature for approximately one day before molding. 
     The molding parameters for the molding compositions are as follows: Molding temperature for plaques was 295° F. with a molding time of 3 minutes and a charge weight of 173 g. The molding temperature for prototype bipolar plates was 290° F. with a molding time of 3 minutes and a charge weight of 300 g. It was observed that the use of specific thermosetting resins with a conductive filler in combination with various rheological additives (thickeners) improved the bipolar plate composition in regards to having a product which can be used in mass production of electrochemical, e.g. fuel, cell bipolar plates. 
     The results of the formulation changes include non-cracking molding compound, better hot strength out of the mold, lower production costs, shorter cycle times, better overall electrical conductivity, increased mechanical properties, and better rheological characteristics. 
     In Table IA the Control L-23012 suffered from cracking during molding of a plate and had non-uniform conductivity and resistivity along the surface of the plate due to phase separation of the conductive filler and resin during molding. Samples L-23185, L-23120, L-23119 and L-23126 had desirable properties. 
     In Table IB Samples L-23125, L-23186, L-23039 had desirable properties. Samples L-23184 and L-23022 had lower than optimal bulk conductivity and higher than optimal resistivity. 
     In Table IC Samples L-23023, L-23063, L-23024, L-323027, and L-23026 had lower than optimal bulk conductivity and higher than optimal resistivity. 
     In Table ID Samples L-23209 and L-23215 had good properties. Samples L-23028, L-23210, and L-23211 had lower than optimal bulk conductivity and higher than optimal resistively. 
     
       
         
               
               
               
               
               
               
             
           
               
                 TABLE IA 
               
               
                   
               
               
                   
                 Control 
                   
                   
                   
                   
               
               
                 Component 
                 L-23012 
                 L-23185 
                 L-23120 
                 L-23119 
                 L-23126 
               
               
                   
               
             
             
               
                 Resin A 
                 30.1 g 
                   
                   
                   
                   
               
               
                 Resin B 
               
               
                 Resin C 
                   
                   
                   
                 19.95 g 
               
               
                 Resin D 
                   
                 17.13 
                 15.63 
                   
                 23.33 
               
               
                 Initiator 
                 0.6 g (A) 
                 0.4 (B) 
                 0.4 (B) 
                 0.4 (B) 
                 0.4 (B) 
               
               
                 Inhibitor 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
               
               
                 Mold 
                 1.2 
                 1.2 
                 1.2 
                 1.2 
                 1.2 
               
               
                 Release 
               
               
                 Graphite A 
                 68 g 
                 75 
                 78 
                 78 
               
               
                 Graphite B 
                   
                   
                   
                   
                 68 
               
               
                 Graphite C 
               
               
                 Modifier A 
                 — 
                   
                   
                 0.35 g 
               
               
                 Modifier B 
                 — 
                 6.17 
                 4.67 
                   
                 6.97 
               
               
                 Glass fibers 
               
               
                 Bulk 
                 85 
                 85 
                 90 
                 90 
                 70 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 300 
                 260 
                 260 
                 260 
                 220 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 3500 
                 3700 
                 3600 
                 3100 
                 3500 
               
               
                 Flexural psi 
                 4100 
                 5500 
                 4300 
                 3500 
                 4200 
               
               
                 Resistivity 
                   
                 70.9 
                 87.51 
                 71.2 
                 37.7 
               
               
                 OHMS/M 2   
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
           
               
                 TABLE IB 
               
               
                   
               
               
                 Component 
                 L-23125 
                 L-23186 
                 L-23039 
                 L-23184 
                 L-23022 
               
               
                   
               
             
             
               
                 Resin A 
                   
                   
                   
                   
                   
               
               
                 Resin B 
                   
                   
                 19.95 
                   
                 29.95 
               
               
                 Resin C 
                   
                 22.65 
                   
                 27.65 
               
               
                 Resin D 
                 23.33 g 
               
               
                 Initiator 
                 04 (B) 
                 0.4 (C) 
                 0.4 (B) 
                 0.4 (C) 
                 0.4 (B) 
               
               
                 Inhibitor 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
               
               
                 Mold 
                 1.2 
                 1.3 
                 1.2 
                 1.3 
                 1.2 
               
               
                 Release 
               
               
                 Graphite A 
                 34 
                 70 
                 68 
                 70 
                 68 
               
               
                 Graphite B 
                 34 
               
               
                 Graphite C 
               
               
                 Modifier A 
                   
                 0.55 
                 0.35 
                 0.55 
                 0.35 
               
               
                 Modifier B 
                 6.97 
               
               
                 Glass fibers 
                   
                 5 
                 10 
               
               
                 Bulk 
                 70 
                 70 
                 65 
                 45 
                 40 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 210 
                 210 
                 200 
                 140 
                 140 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 3400 
                 3000 
                 2800 
                 3000 
                 4100 
               
               
                 Flexural psi 
                 4200 
                 3700 
                 3800 
                 4000 
                 5000 
               
               
                 Resistivity 
                 58.13 
                 123.8 
                 117.6 
                 155.6 
                 222.1 
               
               
                 OHMS/M 2   
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
           
               
                 TABLE IC 
               
               
                   
               
               
                 Component 
                 L-23023 
                 L-23063 
                 L-23024 
                 L-23027 
                 L-23026 
               
               
                   
               
             
             
               
                 Resin A 
                   
                   
                   
                   
                   
               
               
                 Resin B 
                 29.95 
                 29.95 
                 29.95 
               
               
                 Resin C 
                   
                   
                   
                 29.95 
                 29.950 
               
               
                 Resin D 
               
               
                 Initiator 
                 0.4 (C) 
                 0.4 (B) 
                 0.4 (D) 
                 0.4 (C) 
                 0.4 (B) 
               
               
                 Inhibitor 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
               
               
                 Mold 
                 1.2 
                 1.2 
                 1.2 
                 1.2 
                 1.2 
               
               
                 Release 
               
               
                 Graphite A 
                 68 
                 68 
                 68 
                 68 
                 68 
               
               
                 Graphite B 
               
               
                 Graphite C 
               
               
                 Modifier A 
                 0.35 
                 0.35 
                 0.35 
                 0.35 
                 0.35 
               
               
                 Modifier B 
               
               
                 Glass fibers 
               
               
                 Bulk 
                 40 
                 40 
                 35 
                 30 
                 30 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 140 
                 120 
                 130 
                 90 
                 90 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 4200 
                 3500 
                 3100 
                 4700 
                 4300 
               
               
                 Flexural psi 
                 4900 
                 4200 
                 3400 
                 6000 
                 5300 
               
               
                 Resistivity 
                 205.9 
                 — 
                 181.7 
                 320.9 
                 246.8 
               
               
                 OHMS/M 2   
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
           
               
                 TABLE 1D 
               
               
                   
               
               
                 Component 
                 L-23028 
                 L-23209 
                 L-23210 
                 L-23211 
                 L-23215 
               
               
                   
               
             
             
               
                 Resin A 
                   
                   
                   
                   
                   
               
               
                 Resin B 
               
               
                 Resin C 
                 29.95 
                   
                   
                 28.65 
                 22.65 
               
               
                 Resin D 
                   
                 21.49 
                 21.49 
               
               
                 Initiator 
                 0.4 (D) 
                 0.4 (B) 
                 0.4 (B0 
                 0.4 (B) 
                 0.4 (B) 
               
               
                 Inhibitor 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
                 0.1 
               
               
                 Mold 
                 1.2 
                 1.2 
                 1.2 
                 1.3 
                 1.3 
               
               
                 Release 
               
               
                 Graphite A 
                 68 
                 42 
                 42 
                 43 
                 70 
               
               
                 Graphite B 
                   
                 26 
               
               
                 Graphite C 
                 0.35 
                   
                 26 
                 26 
               
               
                 Modifier A 
                 0.35 
                   
                   
                 0.55 
                 0.55 
               
               
                 Modifier B 
                   
                 8.81 
                 8.81 
               
               
                 Glass fibers 
               
               
                 Bulk 
                 30 
                 77 
                 25 
                 45 
                 79 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 100 
                 227 
                 74 
                 132 
                 233 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 3800 
                 2700 
                 3900 
                 3000 
                 2600 
               
               
                 Flexural psi 
                 5100 
                 3900 
                 5500 
                 4500 
                 4300 
               
               
                 Resistivity 
                 220.9 
                 62.02 
                 377.8 
                 186.46 
                 102.74 
               
               
                 OHMS/M 2   
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 2A 
               
               
                   
               
               
                 Component 
                 23012 
                 23039 
                 23022 
                 23023 
                 23063 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin A 
                 100 
                   
                   
                   
                   
               
               
                 Resin B 
                   
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator A 
                 1.99 
               
               
                 Initiator B 
                   
                 2.01 
                 1.34 
                   
                 1.34 
               
               
                 Initiator C 
                   
                   
                   
                 1.34 
               
               
                 Inhibitor 
                 0.33 
                 0.50 
                 0.33 
                 0.33 
                 0.33 
               
               
                 Release 
                 3.99 
                 6.02 
                 4.01 
                 4.01 
                 4.01 
               
               
                 Agent 
               
               
                 Graphite A 
                 225.91 
                 340.85 
                 227.05 
                 227.05 
                 227.05 
               
               
                 Modifier A 
                   
                   
                 1.17 
                 1.17 
                 1.17 
               
               
                 Fiber A 
                   
                 50.13 
               
               
                 Bulk 
                 85 
                 65 
                 40 
                 40 
                 40 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 300 
                 200 
                 140 
                 140 
                 120 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 3500 
                 2800 
                 4100 
                 4200 
                 3500 
               
               
                 Flexural psi 
                 4100 
                 3800 
                 5000 
                 4900 
                 4200 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 2B 
               
               
                   
               
               
                 Component 
                 23024 
                 23119 
                 23186 
                 23184 
                 23027 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin B 
                 100 
                   
                   
                   
                   
               
               
                 Resin C 
                   
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                   
                 2.01 
               
               
                 Initiator C 
                   
                   
                 1.77 
                 1.45 
                 1.34 
               
               
                 Initiator D 
                 1.34 
               
               
                 Inhibitor 
                 0.33 
                 0.50 
                 0.44 
                 0.36 
                 0.33 
               
               
                 Release 
                 4.01 
                 6.02 
                 5.74 
                 4.70 
                 4.01 
               
               
                 Agent 
               
               
                 Graphite A 
                 227.05 
                 390.98 
                 309.05 
                 253.16 
                 227.05 
               
               
                 Modifier A 
                 1.17 
                 1.75 
                 2.43 
                 1.99 
                 1.17 
               
               
                 Fibers A 
                   
                   
                 22.08 
               
               
                 Bulk 
                 35 
                 90 
                 70 
                 45 
                 30 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 130 
                 260 
                 210 
                 140 
                 90 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 135 
                 260 
                 210 
                 140 
                 90 
               
               
                 Flexural psi 
                 3100 
                 3100 
                 3000 
                 3000 
                 4700 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 2C 
               
               
                   
               
               
                 Component 
                 23026 
                 23028 
                 23211 
                 23215 
                 23185 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin C 
                 100 
                 100 
                 100 
                 100 
                   
               
               
                 Resin D 
                   
                   
                   
                   
                 100 
               
               
                 Initiator B 
                 1.34 
                   
                 1.40 
                 1.77 
                 234 
               
               
                 Initiator D 
                   
                 1.34 
               
               
                 Inhibitor 
                 0.33 
                 0.33 
                 0.35 
                 0.44 
                 0.58 
               
               
                 Release 
                 4.01 
                 4.01 
                 4.54 
                 5.74 
                 7.01 
               
               
                 Agent 
               
               
                 Graphite A 
                 227.05 
                 227.05 
                 150.09 
                 309.05 
                 437.83 
               
               
                 Graphite C 
                   
                   
                 90.75 
               
               
                 Modifier A 
                 1.17 
                 1.17 
                 1.92 
                 2.43 
               
               
                 Modifier B 
                   
                   
                   
                   
                 36.02 
               
               
                 Fiber B 
                   
                   
                   
                 22.08 
               
               
                 Bulk 
                 30 
                 30 
                 45 
                 79 
                 85 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 90 
                 100 
                 132 
                 233 
                 260 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 4300 
                 3800 
                 3000 
                 2600 
                 3700 
               
               
                 Flexural psi 
                 5300 
                 5100 
                 4500 
                 4300 
                 5500 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 2D 
               
               
                   
               
               
                 Component 
                 23120 
                 23126 
                 23125 
                 23209 
                 23210 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.56 
                 1.71 
                 1.71 
                 1.86 
                 1.86 
               
               
                 Inhibitor 
                 0.64 
                 0.43 
                 0.43 
                 0.43 
                 0.47 
               
               
                 Release 
                 7.68 
                 5.14 
                 5.14 
                 5.58 
                 5.58 
               
               
                 Agent 
               
               
                 Graphite A 
                 499.04 
                   
                 145.74 
                 195.44 
                 195.44 
               
               
                 Graphite B 
                   
                 291.47 
                 145.74 
                 120.99 
               
               
                 Graphite C 
                   
                   
                   
                   
                 120.99 
               
               
                 Modifier B 
                 29.88 
                 29.88 
                 29.88 
                 41.00 
                 41.00 
               
               
                 Bulk 
                 90 
                 70 
                 70 
                 77 
                 25 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Areal 
                 260 
                 220 
                 210 
                 227 
                 74 
               
               
                 Conductivity 
               
               
                 S/cm 2   
               
               
                 Tensile psi 
                 3600 
                 3500 
                 3400 
                 2700 
                 3900 
               
               
                 Flexural psi 
                 4300 
                 4200 
                 4200 
                 3900 
                 5500 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 3A 
               
               
                   
               
               
                 Component 
                 23227 
                 23236 
                 23237 
                 23274 
                 23275 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.56 
                 1.44 
                 1.51 
                 2.34 
                 2.34 
               
               
                 Inhibitor 
                 0.52 
                 0.48 
                 0.50 
                 0.58 
                 0.58 
               
               
                 Release 
                 6.24 
                 5.77 
                 6.06 
                 7.01 
                 7.01 
               
               
                 Agent 
               
               
                 Graphite A 
                 390.02 
                 350.96 
                 368.50 
                 420.32 
                 420.32 
               
               
                 Carbon A 
                   
                   
                   
                 17.51 
               
               
                 Modifier B 
                 21.68 
                 22.12 
                 28.22 
                 36.02 
                 36.02 
               
               
                 Fiber C 
                   
                   
                   
                   
                 11.68 
               
               
                 Bulk 
                 90 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2672 
               
               
                 Flexural psi 
                 6543 
               
               
                 Density 
                   
                 1.67 
                 1.75 
                 1.77 
               
               
                 g/cm3 
               
               
                 Shrink 
                   
                 −1.5 
                 −1.83 
                 −2.25 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 3B 
               
               
                   
               
               
                 Component 
                 23292 
                 23293 
                 23343 
                 23344 
                 23345 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.48 
                 1.56 
                 1.44 
                 1.29 
                 1.20 
               
               
                 Inhibitor 
                 0.49 
                 0.52 
                 0.48 
                 0.43 
                 0.40 
               
               
                 Release 
                 5.93 
                 6.24 
                 5.75 
                 5.14 
                 4.80 
               
               
                 Agent 
               
               
                 Graphite A 
                 370.74 
                 395.22 
                 349.78 
                 299.91 
                 272.22 
               
               
                 Modifier B 
                 15.67 
                 16.48 
                 21.71 
                 21.68 
                 21.70 
               
               
                 Bulk 
                   
                   
                   
                 72.5 
                 58 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                   
                 2170 
                 2547 
                 2448 
                 2679 
               
               
                 Flexural psi 
                   
                 4616 
                 6503 
                 5423 
                 5897 
               
               
                 Density 
                 1.67 
                 1.73 
                 1.71 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −2.17 
                 −2.08 
                 −2 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 3C 
               
               
                   
               
               
                 Component 
                 23346 
                 23347 
                 23348 
                 23349 
                 23350 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.09 
                 1.03 
                 0.95 
                 0.90 
                 0.84 
               
               
                 Inhibitor 
                 0.36 
                 0.34 
                 0.32 
                 0.30 
                 0.28 
               
               
                 Release 
                 4.37 
                 4.13 
                 3.80 
                 3.61 
                 3.36 
               
               
                 Agent 
               
               
                 Graphite A 
                 236.79 
                 216.57 
                 190.11 
                 174.70 
                 154.19 
               
               
                 Modifier B 
                 21.68 
                 21.69 
                 21.67 
                 21.69 
                 21.67 
               
               
                 Tensile psi 
                 3083 
                 3053 
                 2923 
                 3107 
                 3470 
               
               
                 Flexural psi 
                 5715 
                 5766 
                 5666 
                 5398 
                 5378 
               
               
                 Density 
                 1.75 
                 l.71 
                 1.73 
                 1.7 
                 1.64 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −3 
                 −3.5 
                 −3.33 
                 −4 
                 −5 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 3D 
               
               
                   
               
               
                 Component 
                 23351 
                 23352 
                 23360 
                 23361 
                 23362 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 0.80 
                 0.75 
                 2.27 
                 2.21 
                 2.14 
               
               
                 Inhibitor 
                 0.27 
                 0.25 
                 0.57 
                 0.55 
                 0.54 
               
               
                 Release 
                 3.22 
                 3.02 
                 6.81 
                 6.62 
                 6.43 
               
               
                 Agent 
               
               
                 Graphite A 
                 142.05 
                 125.75 
                 425.41 
                 413.45 
                 402.14 
               
               
                 Modifier B 
                 21.68 
                 21.73 
                 32.16 
                 28.45 
                 24.93 
               
               
                 Bulk 
                   
                   
                   
                   
                 85.5 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2787 
                 2629 
                   
                   
                 2155 
               
               
                 Flexural psi 
                 6167 
                 5998 
                   
                   
                 6017 
               
               
                 Density 
                 1.72 
                 1.71 
                 1.65 
                 1.73 
                 1.68 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.67 
                 −1.83 
                 −1.42 
                 −1.42 
                 −0.67 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 4A 
               
               
                   
               
               
                 Component 
                 23364 
                 23365 
                 23366 
                 23367 
                 23368 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Monomer A 
                 9.72 
                 8.18 
                 7.05 
                 6.20 
                 5.53 
               
               
                 Initiator B 
                 1.46 
                 1.23 
                 1.06 
                 0.93 
                 0.83 
               
               
                 Inhibitor 
                 0.49 
                 0.41 
                 0.35 
                 0.31 
                 0.28 
               
               
                 Release 
                 5.83 
                 4.91 
                 4.23 
                 3.72 
                 3.32 
               
               
                 Agent 
               
               
                 Graphite A 
                 340.30 
                 265.85 
                 211.57 
                 170.54 
                 138.31 
               
               
                 Modifier B 
                 28.43 
                 28.34 
                 28.35 
                 28.37 
                 28.35 
               
               
                 Bulk 
                 55.99 
                 36.57 
                 32.86 
                 18.37 
                 13.59 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2647 
                 2697 
                 2701 
                 2880 
                 2992 
               
               
                 Flexural psi 
                 6044 
                 6131 
                 6149 
                 7002 
                 7338 
               
               
                 Density 
                 1.75 
                 1.74 
                 1.71 
                 1.72 
                 1.71 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −2.5 
                 −2.83 
                 −3.17 
                 −3.33 
                 −3.83 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 4B 
               
               
                   
               
               
                 Component 
                 23369 
                 23370 
                 23371 
                 23372 
                 23373 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.36 
                 1.15 
                 1.00 
                 0.89 
                 0.79 
               
               
                 Inhibitor 
                 0.45 
                 0.38 
                 0.33 
                 0.30 
                 0.26 
               
               
                 Release 
                 5.42 
                 4.61 
                 4.01 
                 3.55 
                 3.18 
               
               
                 Agent 
               
               
                 Graphite A 
                 316.17 
                 249.52 
                 200.33 
                 162.48 
                 132.45 
               
               
                 Modifier B 
                 28.27 
                 28.21 
                 28.21 
                 28.21 
                 28.21 
               
               
                 Bulk 
                 49.49 
                 27.74 
                 25.05 
                 14.01 
                 8.12 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2974 
                 3358 
                 3014 
                 2952 
                 3154 
               
               
                 Flexural psi 
                 6394 
                 6099 
                 6520 
                 6312 
                 6071 
               
               
                 Density 
                 1.72 
                 1.76 
                 1.69 
                 1.73 
                 1.72 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −3.5 
                 −2.5 
                 −2.83 
                 −3.17 
                 −3.53 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 4C 
               
               
                   
               
               
                 Component 
                 23443 
                 23444 
                 23445 
                 23466 
                 23467 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.84 
                 1.72 
                 1.56 
                 1.81 
                 1.54 
               
               
                 Inhibitor 
                 0.46 
                 0.43 
                 0.39 
                 0.45 
                 0.39 
               
               
                 Release 
                 5.52 
                 5.15 
                 4.69 
                 5.44 
                 4.62 
               
               
                 Agent 
               
               
                 Graphite A 
                 322.14 
                 291.85 
                 253.91 
                 317.17 
                 250.29 
               
               
                 Modifier B 
                 30.23 
                 30.04 
                 30.08 
                 28.23 
                 28.23 
               
               
                 Bulk 
                 36 
                 21.2 
                 15 
                 39 
                 21 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                   
                   
                   
                 2312 
                 2765 
               
               
                 Fiexural psi 
                   
                   
                   
                 6154 
                 5994 
               
               
                 Density 
                 1.76 
                 1.76 
                 1.75 
                 1.75 
                 1.73 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −2 
                 −2 
                 −2.33 
                 −1.67 
                 −1.83 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 4D 
               
               
                   
               
               
                 Component 
                 23468 
                 23469 
                 23470 
                 23471 
                 23505 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.69 
                 1.75 
                 1.95 
                 2.11 
                 1.48 
               
               
                 Inhibitor 
                 0.42 
                 0.44 
                 0.49 
                 0.53 
                 0.37 
               
               
                 Release 
                 5.08 
                 5.25 
                 5.85 
                 6.33 
                 4.45 
               
               
                 Agent 
               
               
                 Graphite A 
                 287.77 
                 284.46 
                 331.55 
                 369.39 
                 241.01 
               
               
                 Modifier B 
                 28.23 
                 28.23 
                 28.23 
                 28.23 
                 23.47 
               
               
                 Fiber D 
                   
                 17.51 
                 19.50 
                 21.11 
               
               
                 Bulk 
                 34 
                   
                 45 
                 60 
                 61 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2466 
                 2804 
                 1797 
                 2010 
                 2821 
               
               
                 Flexural psi 
                 5272 
                 7390 
                 6682 
                 4726 
                 4898 
               
               
                 Density 
                 1.71 
                 1.6 
                 1.62 
                 1.58 
                 1.7 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −2.33 
                 −2 
                 −1.42 
                 −1.67 
                 −2.5 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 5A 
               
               
                   
               
               
                 Component 
                 23506 
                 23507 
                 23508 
                 23509 
                 23510 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.63 
                 1.75 
                 1.45 
                 1.59 
                 1.70 
               
               
                 Inhibitor 
                 0.41 
                 0.44 
                 0.36 
                 0.40 
                 0.43 
               
               
                 Release 
                 4.89 
                 5.24 
                 4.34 
                 4.77 
                 5.11 
               
               
                 Agent 
               
               
                 Graphite A 
                 277.10 
                 305.41 
                 235.17 
                 270.38 
                 298.00 
               
               
                 Modifier B 
                 23.47 
                 23.47 
                 20.48 
                 20.48 
                 20.48 
               
               
                 Bulk 
                 55 
                 45 
                 52 
                 60 
                 65 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2680 
                 2645 
                   
                   
                 2483 
               
               
                 Flexural psi 
                 4556.7 
                 5264.4 
                   
                   
                 4773.67 
               
               
                 Density 
                 1.74 
                 1.74 
                 1.79 
                 1.78 
                 1.76 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −2.5 
                 −2.33 
                 −2.33 
                 −2.42 
                 −1.75 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 5B 
               
               
                   
               
               
                 Component 
                 23566 
                 23567 
                 23568 
                 23581 
                 23582 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.85 
                 1.79 
                 1.75 
                 1.77 
                 1.83 
               
               
                 Inhibitor 
                 0.46 
                 0.45 
                 0.44 
                 0.44 
                 0.46 
               
               
                 Release 
                 5.54 
                 5.38 
                 5.26 
                 5.30 
                 5.50 
               
               
                 Agent 
               
               
                 Graphite A 
                 346.42 
                 336.32 
                 328.95 
                 313.33 
                 329.82 
               
               
                 Modifier B 
                   
                   
                   
                 20.48 
                 20.48 
               
               
                 Modifier D 
                 7.62 
                 4.48 
                 2.19 
               
               
                 Bulk 
                   
                 92 
                 94 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.77 
                 1.78 
                 1.75 
                 1.79 
                 1.76 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.67 
                 −1.25 
                 −1.25 
                 −1.67 
                 −1.58 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 5C 
               
               
                   
               
               
                 Component 
                 23583 
                 23584 
                 23585 
                 23592 
                 23593 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.90 
                 1.98 
                 2.07 
                 1.88 
                 1.97 
               
               
                 Inhibitor 
                 0.48 
                 0.50 
                 0.52 
                 0.47 
                 0.49 
               
               
                 Release 
                 5.71 
                 5.95 
                 6.20 
                 5.63 
                 5.91 
               
               
                 Agent 
               
               
                 Graphite A 
                 347.62 
                 366.88 
                 387.80 
                 352.11 
                 369.46 
               
               
                 Modifier B 
                 20.48 
                 20.48 
                 20.48 
               
               
                 Modifier D 
                   
                   
                   
                 9.39 
                 14.78 
               
               
                 Bulk 
                   
                   
                   
                 88 
                 59 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.78 
                 1.75 
                 1.71 
                 1.71 
                 1.71 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.5 
                 −1.25 
                 −1.25 
                 −1.67 
                 −1.67 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 5D 
               
               
                   
               
               
                 Component 
                 23594 
                 23721 
                 23722 
                 23723 
                 23724 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.07 
                 2.19 
                 2.24 
                 1.94 
                 2.00 
               
               
                 Inhibitor 
                 0.52 
                 0.55 
                 0.56 
                 0.48 
                 0.50 
               
               
                 Release 
                 6.22 
                 6.57 
                 6.71 
                 5.82 
                 6.00 
               
               
                 Agent 
               
               
                 Graphite A 
                 388.6 
                 410.51 
                 419.23 
                 354.03 
                 365.18 
               
               
                 Modifier B 
                   
                 27.53 
                 30.24 
                 22.70 
                 26.56 
               
               
                 Modifier D 
                 20.73 
               
               
                 Bulk 
                   
                 86 
                 93 
                 68 
                 65 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.71 
                 1.74 
                 1.77 
                 1.77 
                 1.78 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.25 
                 −1.42 
                 −1.08 
                 −1.5 
                 −1.25 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 6A 
               
               
                   
               
               
                 Component 
                 23725 
                 23726 
                 23727 
                 23728 
                 23729 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.14 
                 1.90 
                 2.14 
                 1.90 
                 2.14 
               
               
                 Inhibitor 
                 0.54 
                 0.48 
                 0.54 
                 0.48 
                 0.54 
               
               
                 Release 
                 6.43 
                 5.71 
                 6.43 
                 5.71 
                 6.43 
               
               
                 Agent 
               
               
                 Graphite D 
                 402.14 
                 347.62 
               
               
                 Graphite E 
                   
                   
                 402.14 
                 347.62 
               
               
                 Graphite F 
                   
                   
                   
                   
                 402.14 
               
               
                 Modifier B 
                 24.93 
                 20.48 
                 24.93 
                 20.48 
                 24.93 
               
               
                 Bulk 
                 96 
                 75 
                 81 
                 62 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.77 
                 1.78 
                 1.81 
                 1.8 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.67 
                 −2.33 
                 −0.83 
                 −1 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 6B 
               
               
                   
               
               
                 Component 
                 23730 
                 23731 
                 23732 
                 23733 
                 23734 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.90 
                 2.14 
                 1.90 
                 2.14 
                 2.14 
               
               
                 Inhibitor 
                 0.48 
                 0.54 
                 0.48 
                 0.54 
                 0.54 
               
               
                 Release 
                 5.71 
                 6.43 
                 5.71 
                 6.43 
                 6.43 
               
               
                 Agent 
               
               
                 Graphite A 
                   
                   
                   
                 249.33 
                 249.33 
               
               
                 Graphite E 
                   
                   
                   
                 152.82 
               
               
                 Graphite F 
                 347.62 
                   
                   
                   
                 152.82 
               
               
                 Graphite G 
                   
                 402.14 
                 347.62 
               
               
                 Modifier B 
                 20.48 
                 24.93 
                 20.48 
                 24.93 
                 24.93 
               
               
                 Bulk 
                   
                 32 
                 30 
                 48 
                 25 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                   
                   
                   
                 1.81 
                 1.81 
               
               
                 g/cm3 
               
               
                 Shrink 
                   
                   
                   
                 −1.33 
                 −1.83 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 6C 
               
               
                   
               
               
                 Component 
                 23735 
                 23736 
                 23737 
                 23738 
                 23739 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.14 
                 2.14 
                 1.90 
                 1.90 
                 1.90 
               
               
                 Inhibitor 
                 0.54 
                 0.54 
                 0.48 
                 0.48 
                 0.48 
               
               
                 Release 
                 6.43 
                 6.43 
                 5.71 
                 5.71 
                 5.71 
               
               
                 Agent 
               
               
                 Graphite A 
                 249.33 
                 249.33 
                 215.52 
                 215.52 
                 215.52 
               
               
                 Graphite D 
                   
                 152.82 
               
               
                 Graphite E 
                   
                   
                 132.10 
               
               
                 Graphite F 
                 152.82 
                   
                   
                 132.10 
               
               
                 Graphite G 
                 152.82 
                   
                   
                   
                 132.10 
               
               
                 Modifier B 
                 24.93 
                 24.93 
                 20.48 
                 20.48 
                 20.48 
               
               
                 Bulk 
                 38 
                 90 
                 50 
                 26 
                 31 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.79 
                 1.67 
                 1.79 
                 1.8 
                 1.8 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −2.08 
                 −1.58 
                 −1.83 
                 −2.33 
                 −2.67 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 6D 
               
               
                   
               
               
                 Component 
                 23740 
                 23755 
                 23756 
                 23757 
                 23758 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.90 
                 2.17 
                 2.20 
                 1.93 
                 1.95 
               
               
                 Inhibitor 
                 0.48 
                 0.54 
                 0.55 
                 0.48 
                 0.49 
               
               
                 Release 
                 5.71 
                 6.52 
                 6.61 
                 5.78 
                 5.85 
               
               
                 Agent 
               
               
                 Graphite A 
                 215.52 
                 407.61 
                 413.22 
                 341.81 
                 356.10 
               
               
                 Graphite D 
                 132.10 
               
               
                 Modifier B 
                 20.48 
                 23.91 
                 22.87 
                 19.52 
                 18.54 
               
               
                 Modifier D 
                   
                 2.72 
                 5.51 
                 2.41 
                 4.88 
               
               
                 Bulk 
                 68 
                 70 
                 97 
                 92 
                 89 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.75 
                 1.77 
                 1.67 
                 1.79 
                 1.79 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.83 
                 −1.83 
                 −1.83 
                 −2 
                 −2.17 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 7A 
               
               
                   
               
               
                 Component 
                 23803 
                 23804 
                 23805 
                 23806 
                 23830 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.06 
                 2.09 
                 2.16 
                 2.19 
                 2.16 
               
               
                 Inhibitor 
                 0.52 
                 0.52 
                 0.54 
                 0.55 
                 0.54 
               
               
                 Release 
                 6.19 
                 6.27 
                 6.49 
                 6.58 
                 6.49 
               
               
                 Agent 
               
               
                 Graphite A 
                 376.29 
                 381.20 
                 394.59 
                 405.48 
                 394.59 
               
               
                 Modifier B 
                 25.26 
                 25.59 
                 25.59 
                 26.30 
                 30.00 
               
               
                 Modifier E 
                 5.15 
                 6.53 
                 10.81 
                 6.85 
                 6.76 
               
               
                 Bulk 
                 62 
                 83 
                 83 
                 90 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.77 
                 1.77 
                 1.76 
                 1.77 
                 1.79 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.83 
                 −1.50 
                 −1.33 
                 −1.67 
                 −1.58 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 7B 
               
               
                   
               
               
                 Component 
                 23831 
                 23832 
                 23833 
                 23834 
                 23835 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.11 
                 2.18 
                 2.23 
                 2.09 
                 2.09 
               
               
                 Inhibitor 
                 0.53 
                 0.54 
                 0.56 
                 0.52 
                 0.52 
               
               
                 Release 
                 6.33 
                 6.54 
                 6.69 
                 6.27 
                 6.27 
               
               
                 Agent 
               
               
                 Graphite A 
                 385.22 
                 397.82 
                 406.69 
               
               
                 Graphite H 
                   
                   
                   
                 381.20 
               
               
                 Graphite I 
                   
                   
                   
                   
                 381.20 
               
               
                 Modifler B 
                 25.59 
                 25.61 
                 25.63 
                 25.59 
                 25.59 
               
               
                 Modifier E 
                   
                 6.81 
                 6.96 
                 6.53 
                 6.53 
               
               
                 Density 
                 1.74 
                 1.76 
                 1.72 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −1.42 
                 −1.33 
                 −1.25 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 7C 
               
               
                   
               
               
                 Component 
                 23836 
                 23837 
                 23838 
                 23839 
                 23840 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.09 
                 2.24 
                 2.24 
                 2.24 
                 2.24 
               
               
                 Inhibitor 
                 0.52 
                 0.56 
                 0.56 
                 0.56 
                 0.56 
               
               
                 Release 
                 6.27 
                 6.71 
                 6.71 
                 6.71 
                 6.71 
               
               
                 Agent 
               
               
                 Graphite A 
                   
                 408.28 
                 408.28 
                 408.28 
                 408.28 
               
               
                 Graphite J 
                 381.20 
               
               
                 Carbon B 
                   
                 0.56 
               
               
                 Carbon C 
                   
                   
                 0.56 
               
               
                 Carbon D 
                   
                   
                   
                 0.56 
               
               
                 Carbon E 
                   
                   
                   
                   
                 0.56 
               
               
                 Modifier B 
                 25.59 
                 25.56 
                 25.56 
                 25.56 
                 25.56 
               
               
                 Modifier E 
                 6.53 
                 6.99 
                 6.99 
                 6.99 
                 6.99 
               
               
                 Modifier F 
                   
                 8.39 
                 8.39 
                 8.39 
                 8.39 
               
               
                 Density 
                   
                 1.77 
                 1.80 
                 1.76 
                 1.74 
               
               
                 g/cm3 
               
               
                 Shrink 
                   
                 −1.08 
                 −0.92 
                 −1.17 
                 −1.08 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 7D 
               
               
                   
               
               
                 Component 
                 23878 
                 23879 
                 23880 
                 23881 
                 23896 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 2.26 
                 2.37 
                 2.28 
                 2.39 
                 1.48 
               
               
                 Inhibitor 
                 0.57 
                 0.59 
                 0.57 
                 0.60 
                 0.49 
               
               
                 Release 
                 6.79 
                 7.11 
                 6.83 
                 7.16 
                 5.93 
               
               
                 Agent 
               
               
                 Graphite A 
                 418.55 
                 444.31 
                 421.41 
                 447.49 
                 370.74 
               
               
                 Modifier B 
                 25.57 
                 25.59 
                 25.57 
                 25.60 
                 5.68 
               
               
                 Modifier C 
                   
                   
                   
                   
                 9.99 
               
               
                 Modifier E 
                   
                   
                 7.12 
                 7.46 
               
               
                 Modifier F 
                 11.88 
                 12.44 
                 5.69 
                 5.97 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 8A 
               
               
                   
               
               
                 Component 
                 23297 
                 23301 
                 23302 
                 23363 
                 23422 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin E 
                 100 
                 100 
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.56 
                 1.38 
                 1.33 
                 1.06 
                 1.75 
               
               
                 Inhibitor 
                 0.52 
                 0.46 
                 0.44 
                 0.35 
                 0.58 
               
               
                 Release 
                 6.24 
                 5.50 
                 5.31 
                 4.24 
                 7.00 
               
               
                 Agent 
               
               
                 Graphite A 
                 395.22 
                 343.88 
                 331.86 
                 240.03 
                 466.74 
               
               
                 Modifier B 
                 5.98 
                 2.66 
                 1.28 
                 2.65 
                 2.68 
               
               
                 Modifier C 
                 10.50 
                 4.63 
                 2.26 
                 4.66 
                 4.67 
               
               
                 Bulk 
                   
                 72.5 
                   
                 35 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                   
                 1.62 
                   
                 1.53 
                 1.6 
               
               
                 g/cm3 
               
               
                 Shrink 
                   
                 −2.33 
                   
                 −1.33 
                 −0.92 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 8B 
               
               
                   
               
               
                 Component 
                 23423 
                 23452 
                 23453 
                 23454 
                 23455 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                   
                 50.03 
                 60.00 
                 70.03 
                 80.00 
               
               
                 Resin E 
                 100 
               
               
                 Resin F 
                   
                 49.97 
                 40.00 
                 29.97 
                 20.00 
               
               
                 Initiator B 
                 2.40 
                 2.14 
                 2.14 
                 2.14 
                 2.14 
               
               
                 Inhibitor 
                 0.80 
                 0.54 
                 0.54 
                 0.54 
                 0.54 
               
               
                 Release 
                 9.61 
                 6.43 
                 6.43 
                 6.43 
                 6.43 
               
               
                 Agent 
               
               
                 Graphite A 
                 680.54 
                 402.14 
                 402.14 
                 402.14 
                 402.14 
               
               
                 Modifier B 
                 2.64 
                 24.93 
                 24.93 
                 24.93 
                 24.93 
               
               
                 Modifier C 
                 4.64 
               
               
                 Bulk 
                   
                 63 
                 70.5 
                 70 
                 83.5 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                   
                 2441 
                 2497 
                 2404 
                 2561 
               
               
                 Flexural psi 
                   
                 5030 
                 5126 
                 4284 
                 5391 
               
               
                 Density 
                 1.47 
                 1.71 
                 1.74 
                 1.75 
                 1.66 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −0.25 
                 −1.17 
                 −1.58 
                 −1.67 
                 −1.42 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 8C 
               
               
                   
               
               
                 Component 
                 23530 
                 23531 
                 23646 
                 23647 
                 23648 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin F 
                 100 
                 100 
                   
                   
                   
               
               
                 Resin G 
                   
                   
                 100 
                 100 
                 100 
               
               
                 Initiator B 
                 1.85 
                 1.79 
                 1.81 
                 1.91 
                 2.02 
               
               
                 Inhibitor 
                 0.46 
                 0.45 
                 0.45 
                 0.48 
                 0.50 
               
               
                 Release 
                 5.54 
                 5.38 
                 5.42 
                 5.72 
                 6.06 
               
               
                 Agent 
               
               
                 Graphite A 
                 346.42 
                 336.32 
                 338.75 
                 357.65 
                 378.60 
               
               
                 Modifier B 
                   
                   
                 5.24 
                 11.11 
                 17.62 
               
               
                 Modifier D 
                 7.62 
                 4.48 
               
               
                 Bulk 
                   
                   
                 86 
                 58 
                 46 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Tensile psi 
                 2305.56 
                 2155.56 
               
               
                 Flexural psi 
                 4548.8 
                 4421.3 
               
               
                 Density 
                 1.69 
                 1.75 
                 1.71 
                 1.72 
                 1.65 
               
               
                 g/cm3 
               
               
                 Shrink 
                 −0.42 
                 −1.67 
                 −1.58 
                 −1.42 
                 −1.33 
               
               
                 mils/in 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 8D 
               
               
                   
               
               
                 Component 
                 23649 
                 23650 
                 23651 
                 23688 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Resin D 
                   
                   
                   
                 53.96 
               
               
                 Resin I 
                 100 
                 100 
                 100 
               
               
                 Resin J 
                   
                   
                   
                 46.04 
               
               
                 Initiator B 
                 1.75 
                 1.77 
                 1.79 
               
               
                 Initiator D 
                   
                   
                   
                 2.08 
               
               
                 Inhibitor 
                 0.44 
                 0.44 
                 0.45 
                 0.52 
               
               
                 Release 
                 5.26 
                 5.31 
                 5.38 
                 6.25 
               
               
                 Agent 
               
               
                 Graphite A 
                 328.95 
                 331.86 
                 336.32 
                 385.42 
               
               
                 Modifier B 
                   
                   
                   
                 15.63 
               
               
                 Modifier D 
                 2.19 
                 3.10 
                 4.48 
               
               
                 Modifier F 
                   
                   
                   
                 10.94 
               
               
                 Bulk 
                 93 
                 79 
                 64 
               
               
                 Conductivity 
               
               
                 S/cm 
               
               
                 Density 
                 1.77 
                 1.74 
                 1.73 
               
               
                 g/cm3 
               
               
                 Shrink mils/in 
                 −1.5 
                 −1.08 
                 −1.5 
               
               
                   
               
             
          
         
       
     
     While in accordance with the Patent Statutes, the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.