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Kevin A. McCullough Patents
Inventor:
McCullough; Kevin A.
Address:
North Kingstown, RI
No. of patents:
47
Patents:




Patent Number Title Of Patent Date Issued
7413691 In-mold metallized polymer components and method of manufacturing same August 19, 2008
A method is provided for forming a net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The method includes injecting a carefully matched mixture of a molten polymer resin and a molten metallic alloy into a mold cavity under
7311140 Heat sink assembly with overmolded carbon matrix December 25, 2007
A net-shape molded heat sink is provided which includes a thermally conductive main body and a number of thermally conductive fins integrally connected to and emanating from the main body. The heat sink is formed by overmolding a carbon-carbon matrix core plate with a thermally conductiv
7236344 Ionic flow generator for thermal management June 26, 2007
The apparatus for generating ionic flow of media includes a DC voltage supply having a positive terminal and a negative terminal with a collector connected to the negative terminal of the direct current voltage supply. The collector has a substantially tubular configuration with a re
7094822 Thermally conductive elastomeric pad August 22, 2006
The present invention relates to thermally conductive, elastomeric pads. The pads can be made by injection-molding a thermally conductive composition comprising about 30 to 60% by volume of an elastomer polymer matrix and about 25 to 60% by volume of a thermally conductive filler mat
7038009 Thermally conductive elastomeric pad and method of manufacturing same May 2, 2006
The present invention relates to thermally conductive, elastomeric pads and methods for manufacturing such pads. The methods involve injection-molding a thermally conductive composition comprising about 30 to 60% by volume of an elastomer polymer matrix and about 25 to 60% by volume
7013555 Method of applying phase change thermal interface materials March 21, 2006
The present invention discloses a method of providing an integral thermal interface on an interface surface of a heat dissipation device, such as a heat sink. In accordance with the present invention, the phase change material is applied directly onto the interface surface of the heat si
6981805 Molded electronic connector formed from a thermally conductive polymer composition and method of January 3, 2006
An electronic connector having a housing containing a circuit board with a heat-generating component, such as a photodiode or laser, is provided. The housing is molded over the circuit board and heat-generating component. The housing is made from a moldable, thermally conductive poly
6899160 Method of forming a thermally conductive article using metal injection molding material with hig May 31, 2005
The present invention discloses a conductive injection molding composition. The thermally conductive composition includes a metallic base matrix of, by volume, between 30 and 60 percent. A first thermally conductive filler, by volume, between 25 and 60 percent is provided in the composit
6886625 Elastomeric heat sink with a pressure sensitive adhesive backing May 3, 2005
The present invention discloses a net-shape molded elastomeric heat-dissipating device that includes an integrally formed conformable interface surface. A base elastomeric matrix material is loaded with thermally conductive filler and injected into a mold cavity to form the completed
6868602 Method of manufacturing a structural frame March 22, 2005
A structural frame (12) for dissipating heat from an electronic device (10) is provided. The structural frame (12), to which an electronic circuit board (14) containing a heat generating electronic component (16) is mounted, is injection molded from a thermally conductive, net-shape
6863729 Nozzle insert for long fiber compounding March 8, 2005
A new die insert for an extrusion machine and a method of using the invention that includes a continuous strand of fiber reinforcing material to be statically drawn directly to the center of the molten flow of polymer base matrix is provided. The insert is placed in line with the dis
6851869 Highly thermally conductive electronic connector February 8, 2005
The electronic connector (10) includes an improved heat dissipating housing for cooling heat generating devices located within the connector (10). The electronic connector (10) of the present invention enables the cost-effective cooling of electronic devices (22, 24) within the connector
6835347 Method of forming a highly thermally conductive and high strength article December 28, 2004
A highly thermally conductive and high strength net-shape moldable molding composition, with a thermal conductivity above 4 W/m.degree. K and a strength of at least 15 ksi includes a polymer base matrix of, by volume, between 30 and 70 percent. A first highly thermally conductive filler
6828672 Thermally conductive silk-screenable interface material December 7, 2004
A novel visible light curable composition for forming a thermally conductive interface and a method of using the same is provided. The composition is used to promote the transfer of heat from a source of heat such as an electronic device to a heat dissipation device such as a heat si
6827470 Thermally conductive lamp reflector December 7, 2004
A thermally conductive lamp reflector is provided that dissipates heat from a light source within the reflector. The reflector assembly includes a shell having a metallized layer on its surface. The shell is made from a composition including about 30% to about 80% by volume of a base pol
6817096 Method of manufacturing a heat pipe construction November 16, 2004
A method of manufacturing a heat pipe construction includes first providing a tubular pipe with an open end. A thermally conductive material, such as a metallic material or a filled polymer composite material is overmolded over or cast around the tubular pipe. Additional heat dissipating
6803328 Print thermally conductive interface assembly October 12, 2004
A novel visible light curable composition for forming a thermally conductive interface and a method of using the same is provided. The composition is used to promote the transfer of heat from a source of heat such as an electronic device to a heat dissipation device such as a heat si
6783716 Nozzle insert for long fiber compounding August 31, 2004
A new die insert for an extrusion machine and a method of using the invention that includes a continuous strand of fiber reinforcing material to be statically drawn directly to the center of the molten flow of polymer base matrix. The insert is placed in line with the discharge end o
6756005 Method for making a thermally conductive article having an integrated surface and articles produ June 29, 2004
The present invention relates to a method of manufacturing a thermally conductive article having an integrated thermally conductive surface. The method involves molding a first thermally conductive composition to form a body of the article and then molding a second thermally conductive
6710109 Thermally conductive and high strength injection moldable composition March 23, 2004
A highly thermally conductive and high strength net-shape moldable molding composition, with a thermal conductivity above 4 W/m.degree. K and a strength of at least 15 ksi includes a polymer base matrix of, by volume, between 30 and 70 percent. A first highly thermally conductive filler
6681487 Method of manufacturing a composite overmolded heat pipe January 27, 2004
The present invention discloses a method of constructing a heat pipe that includes providing a heat pipe with phase change media therein and injection overmolding the heat pipe with a conductive composition. The thermally conductive composition absorbs or reflects electro magnetic in
6680015 Method of manufacturing a heat sink assembly with overmolded carbon matrix January 20, 2004
A net-shape molded heat sink is provided which includes a thermally conductive main body and a number of thermally conductive fins integrally connected to and emanating from the main body. The heat sink is formed by overmolding a carbon-carbon matrix core plate with a thermally conductiv
6649108 Method of manufacturing a U-shaped heat sink assembly November 18, 2003
A method of manufacturing a net-shape moldable U-shaped heat sink assembly includes injection molding a thermally conductive polymer composite material. The method includes forming a heat sink assembly base member with a number of integrated fins members thereon. A right upstanding wall
6635959 Thermally conductive silk-screenable interface material October 21, 2003
The present invention provides a novel visible light curable composition for forming a thermally conductive interface and a method of using the same. The composition is used to promote the transfer of heat from a source of heat such as an electronic device to a heat dissipation device
6585039 Composite overmolded heat pipe construction July 1, 2003
The present invention discloses a heat pipe construction that includes a heat pipe with phase change media therein with a conductive composition molded about the heat pipe. The thermally conductive composition absorbs or reflects electro magnetic interference waves and prevents their
6557859 Injection moldable elastomeric gasket May 6, 2003
A net-shape molded elastomeric gasket for dissipating heat and providing electro-magnetic interference (EMI) shielding for an electronic device is formed by loading a base elastomeric matrix material with thermally conductive filler and EMI reflective metallic filler and injecting the
6555486 Thermally conductive silk-screenable interface material April 29, 2003
The present invention provides a novel visible light curable composition for forming a thermally conductive interface and a method of using the same. The composition is used to promote the transfer of heat from a source of heat such as an electronic device to a heat dissipation device
6547001 Flexible glove-like heat sink April 15, 2003
A heat sink assembly for removing heat from an object having an outer surface includes a main body with an object receiving seat. A pair of flexible securing tabs are connected to the free edge of the open end of the main body which emanate into the open end of the main body. A heat
6543524 Overplated thermally conductive part with EMI shielding April 8, 2003
A net-shape molded heat transfer component is provided which includes a thermally conductive core and a metallic coating for reflection of electromagnetic interference and radio frequency waves. The heat transfer component is formed by net-shape molding a core body from a thermally c
6540948 Injection molding apparatus with bleed off pocket for overmolding heat pipes April 1, 2003
A method of overmolding a heat pipe includes providing an injection mold apparatus having a cavity, an input gate, a bleed off overflow gate in communication with the cavity and a tubular heat pipe charged with phase change media which is capable of being collapsed by imparting an extern
6503964 Polymer composition with metal coated carbon flakes January 7, 2003
A thermally conductive and electromagnetic interference and radio frequency reflective polymer composition and a method for creating the same is disclosed. Thermally conductive filler material is coated with a thermally conductive and electromagnetic interference and radio frequency refl
6487073 Thermally conductive electronic device case November 26, 2002
A case for dissipating heat from an electronic device is provided. The case includes an electronic circuit board with a heat generating electronic component installed thereon. A shield is positioned over the electronic component to protect it from electromagnetic interference. The shield
6478997 Polymer heat pipe with carbon core November 12, 2002
A polymer heat pipe with a carbon core and a method of forming such a heat pipe is disclosed. The heat pipe includes a substantially pure carbon fiber core and an outer jacket of substantially pure polymer material. The heat pipe is formed by extruding a mixture of a base of polymer mate
6407149 Method of manufacturing an evenly colored thermally conductive composite June 18, 2002
A method of molding an evenly colored, thermally conductive composition. Thermally conductive filler material is colored and mixed with a base polymer matrix. The mixture is molded into the desired shape. The step of for coloring the filler material is tailored to the type of thermally
6397941 Net-shape molded heat exchanger June 4, 2002
A net-shape molded heat exchanger is provided which includes a thermally conductive main body and a number of thermally conductive arms connected to and extending from the main body. A number of thermally conductive fins are connected to the arms. The heat exchanger is formed by net-shap
6385047 U-shaped heat sink assembly May 7, 2002
A net-shape moldable U-shaped heat sink assembly formed by injection molding of a thermally conductive polymer composite material is shown. The heat sink assembly includes a base member with a number of integrated fins members thereon. A right upstanding wall extends from a first side of
6367541 Conforming heat sink assembly April 9, 2002
A conforming heat sink assembly for removing heat from heat generating components, having respective top surfaces defining different heights is provided with a flexible thermally conductive base member with a top surface and a bottom surface. The bottom surface is adapted to be posit
6261495 Process of molding a polymer reinforced with particles July 17, 2001
A plunger machine for molding reinforced polymer is provided. The plunger machine has particular application in molding polymer that is reinforced with particles having an aspect ratio greater than 1:1. The plunger machine includes a barrel housing with a smooth barrel bore that defines
6251978 Conductive composite material June 26, 2001
A conductive net-shape moldable molding composition, with a thermal conductivity above 22 W/m.degree.K and a volume electrical resistivity of 0.1 ohm-cm or lower and a surface electrical resistivity of 1.0 ohm or lower, is provided. The thermally and electrically conductive composition
6237223 Method of forming a phase change heat sink May 29, 2001
A method of forming a phase change passive heat sink, with a base member and heat dissipating members, is provided. The base member is hollow and defines an evaporation chamber therein. A number of heat dissipating members are connected to the base member. Each of the heat dissipating
6214263 Method of molding a reinforced article April 10, 2001
A method of molding a reinforced article for optimizing heat transfer, electrical conductivity and/or structural integrity is provided. A mold assembly is first provided which is capable of forming an article of a desired configuration. The desired positioning of the filler within the
6201697 Heat sink assembly with cam lock March 13, 2001
A heat sink assembly, having a number of mounting holes therethrough, is installed on a heat generating surface of an electronic component for removing heat therefrom. A heat dissipating member having a base portion having a bottom surface and an upper surface with heat dissipating e
6139783 Method of molding a thermally conductive article October 31, 2000
A method of molding a thermally conductive article for transferring heat from a heat generating surface is provided. A mold assembly is first provided which is capable of forming an article of a desired configuration. The initial location of contact on the article with the heat gener
6093961 Heat sink assembly manufactured of thermally conductive polymer material with insert molded meta July 25, 2000
An molded heat sink assembly includes an integrally molded attachment clip for securing the assembly to a semiconductor package to be cooled. The assembly removes heat from a semiconductor device package having opposing side wall edges. The heat sink assembly also includes a heat conduct
6048919 Thermally conductive composite material April 11, 2000
A conductive molding composition, with a thermal conductivity above 22 W/m.degree. K., is provided. The thermally conductive composition includes a polymer base matrix of, by volume, between 30 and 60 percent. A first thermally conductive filler, by volume, between 25 and 60 percent is
6014315 Heat sink assembly with multiple pressure capability January 11, 2000
A heat dissipating device which can provide multiple levels of pressure to a semiconductor package, having an outer peripheral ceramic region and an inner silicon region, is provided. A top cover member is provided with a central female-threaded bore. The top member is secured to the cer
5945736 Heat sink assembly with snap-in cover plate having multiple pressure capability August 31, 1999
A heat dissipating device which can provide multiple levels of pressure to a semiconductor package, having an outer peripheral ceramic region and an inner silicon region, is provided. A top cover member is provided with a central female-threaded bore. The top member is secured, without t


 
 
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