A method for manufacturing a current collector head for a current collector consisting of an electrically conductive contact shoe and an electrically insulating contact shoe holder includes the following steps: inserting a section of the contact shoe into an outwardly open cavity in the contact shoe holder dimensioned to match this section; clamping the contact shoe in the cavity of the contact shoe holder by acting on the contact shoe holder with at least an external force directed onto the inserted section of the contact shoe; heating the contact shoe to a temperature sufficient to form a bonded connection with the contact shoe holder; and cooling the current collector head formed from the contact shoe and the contact shoe holder.

A method for fabricating an electrochemical sensor material includes positioning sheets of molded graphene nanoplatelets on each side of a proton exchange membrane and integrating graphene nanoplatelets into regions of the proton exchange membrane adjacent its surfaces by applying heat to increase the temperature of the proton exchange membrane to its glass transition temperature and applying compressive pressure to press a portion of each sheet of molded graphene nanoplatelets into the softened polymeric material of the proton exchange membrane. Following application of heat and pressure, the proton exchange membrane is cooled and excess graphene material is exfoliated. Electrochemical sensor components are cut from the material and electrochemical devices and systems are constructed therefrom.

A high-performance optical absorber, having a texturized base layer, the base layer comprising one or more of a polymer film and a polymer coating; and a surface layer located above and immediately adjacent to the base layer. The surface layer is joined to the base layer and the surface layer has a plasma-functionalized, non-woven carbon nanotube (CNT) sheet, wherein the base layer texturization comprises one or more of substantially rectangular ridges, substantially triangular ridges, substantially pyramidal ridges, and truncated, substantially pyramidal ridges.

A material system may include: an aluminum layer; a glass composite layer adjacent to the first aluminum layer; and a carbon composite layer adjacent to the first glass composite layer, and opposite to the first aluminum layer. A method of manufacturing a material system may include: stacking an aluminum layer, glass composite layer that may include thermoplastic prepreg plies, and carbon composite layer so that the aluminum layer is adjacent to the glass composite layer, and the glass composite layer is adjacent to the carbon composite layer; and consolidating the thermoplastic prepreg plies to soften the aluminum layer. A method of manufacturing a material system may include: stacking an aluminum layer, glass composite layer that comprises thermoplastic resin, and carbon composite layer so that the glass composite layer is between the aluminum and carbon composite layers; and adjusting temperature and pressure to consolidate the stack.

The processing apparatus includes: a first roller 10 around which a gas-diffusion layer sheet (carbon paper CP) is wound, the gas-diffusion layer sheet being an electrically conductive porous member; a second roller 20 configured to take up the carbon paper CP wound around the first roller 10; and a processing oven configured to heat process a portion of the carbon paper CP, the portion having been fed from the first roller 10 but not yet taken up by the second roller 20. A heat-resistant lead LE is provided, the heat-resistant lead LE having a length at least extending from the first roller 10 to the second roller 20 through the processing oven, being configured to be taken up by the second roller 20, and being bonded to the carbon paper CP impregnated with a thermosetting resin AD.

A material system may include: an aluminum layer; a glass composite layer adjacent to the first aluminum layer; and a carbon composite layer adjacent to the first glass composite layer, and opposite to the first aluminum layer. A method of manufacturing a material system may include: stacking an aluminum layer, glass composite layer that may include thermoplastic prepreg plies, and carbon composite layer so that the aluminum layer is adjacent to the glass composite layer, and the glass composite layer is adjacent to the carbon composite layer; and consolidating the thermoplastic prepreg plies to soften the aluminum layer. A method of manufacturing a material system may include: stacking an aluminum layer, glass composite layer that comprises thermoplastic resin, and carbon composite layer so that the glass composite layer is between the aluminum and carbon composite layers; and adjusting temperature and pressure to consolidate the stack.

A method for fabricating an electrochemical sensor material includes positioning sheets of molded graphene nanoplatelets on each side of a proton exchange membrane and integrating graphene nanoplatelets into regions of the proton exchange membrane adjacent its surfaces by applying heat to increase the temperature of the proton exchange membrane to its glass transition temperature and applying compressive pressure to press a portion of each sheet of molded graphene nanoplatelets into the softened polymeric material of the proton exchange membrane. Following application of heat and pressure, the proton exchange membrane is cooled and excess graphene material is exfoliated. Electrochemical sensor components are cut from the material and electrochemical devices and systems are constructed therefrom.

Methods for microwave melting of fiber mixtures to form composite materials include placing the fiber mixture in a receptacle located in a microwave oven. The methods further include microwave heating the mixture, causing a heat activated compression mechanism to automatically increase compressive force on the mixture, thereby eliminating air and void volumes. The heat activated compression mechanism can include a shape memory alloy wire connecting first and second compression brackets, or one or more ceramic blocks configured to increase in volume and thereby increase compression on the mixture.

The processing apparatus includes: a first roller 10 around which a gas-diffusion layer sheet (carbon paper CP) is wound, the gas-diffusion layer sheet being an electrically conductive porous member; a second roller 20 configured to take up the carbon paper CP wound around the first roller 10; and a processing oven configured to heat process a portion of the carbon paper CP, the portion having been fed from the first roller 10 but not yet taken up by the second roller 20. A heat-resistant lead LE is provided, the heat-resistant lead LE having a length at least extending from the first roller 10 to the second roller 20 through the processing oven, being configured to be taken up by the second roller 20, and being bonded to the carbon paper CP impregnated with a thermosetting resin AD.

A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.