Abstract: Production of a bonded magnet from a composition of a cross-linkable organic material and a particulate magnetic material by(1) placing in a mold a shaped composition in which the particles of magnetic material are optionally aligned and demagnetized,(2) rotating the mold about an axis thereof,(3) cross-linking the organic material in the shaped composition while rotating the mold,(4) recovering from the mold a shaped article, and(5) optionally remagnetizing the particles.

Abstract: A process consisting in preparing a homogeneous system comprising particles of a first electrically conductive material arranged in substantially uniform manner inside a mass of a second liquid material which, when solidified, is both flexible and electrically insulating; and in solidifying the aforementioned mass of the aforementioned second liquid material, so as to form a matrix for supporting the aforementioned particles; throughout solidification of the aforementioned second material, a given pressure being applied on the system for the purpose of producing triaxial precompression of the aforementioned second material when solidified.

Abstract: A method wherein there is provided a source of fiber forming material, with said fiber forming material being pumped into a die having a plurality of spinnerets about its periphery. The die is rotated at a predetermined adjustable speed, whereby the liquid is expelled from the die so as to form fibers. It is preferred that the fiber forming material be cooled as it is leaving the holes in the spinnerets during drawdown. The fibers may be used to produce fabrics, fibrous tow and yarn through appropriate take-up systems. The pumping system provides a pumping action whereby a volumetric quantity of liquid is forced into the rotational system independent of viscosity or the back pressure generated by the spinnerets and the manifold system of the spinning head, thus creating positive displacement feeding. Positive displacement feeding may be accomplished by the extruder alone or with an additional pump of the type generally employed for this purpose.

Abstract: An apparatus and method is disclosed for fabricating mats of ceramic material comprising preparing a slurry of ceramic particles in a binder/solvent, charging the slurry into a vessel, forcing the slurry from the vessel into spinneret nozzles, discharging the slurry from the nozzles into the path of airjets to enhance the sinuous character of the slurry exudate and to dry it, collecting the filaments on a moving belt so that the filaments overlap each other thereby forming a mat, curing the binder therein, compressing and sintering the mat to form a sintered mat, and crushing the sintered mat to produce filament shaped fragments.

Abstract: A system is provided for molding a slurry containing particles in a solution of solvent and binder, which enables the close control of the production of a tape with particles of a high density. A rotor forms a chamber with a cylindrical molding surface, and a conduit carries the slurry from the outside to the surface while the molding surface rotates to use centrifugal force to force particles against the molding surface. The chamber is substantially closed to avoid the uncontrolled loss of solvent, and a means is provided for venting the chamber to remove solvent therefrom after the slurry has been molded into a tape. A container lies within the chamber and holds solvent prior to casting the slurry, to create a solvent-containing environment within the chamber.

Abstract: A molded composite material comprising a plural number of constituents is provided in which at least two of the constituents are distributed with a relative existing ratio varying at least in one direction in the composite material. A process for producing the composite material is also provided.

Abstract: Fiber mats formed by attenuating molten streams of attenuable mineral material by subjecting the streams to the action of a hot attenuating gas blast. The gas blast induces gas from the surrounding atmosphere, and the combined blast and induced gas forming a fiber-carrying current. The current is directed toward a preforated fiber-collecting conveyor on which the fibers are deposited in the form of a mat and the gas of the current passes through the conveyor. Provision is made for withdrawing a peripheral portion of the fiber-carrying current at a point intermediate the zone of attenuation and the perforated fiber-collecting conveyor.

Abstract: To produce a pipe in a centrifugal molding process in a rotating mold, axially parallel oriented fibers are fed in parallel to the axis of the mold, decelerated in the mold, and accelerated, without a change in their orientation, transversely to their feeding direction. A device for performing this process comprises a chamber (3) which can be introduced into a rotating mold (14) and has an outlet opening (10) for cut fibers. In the chamber (3), a rotatable vane (5) is provided which is connected a disk (9) oriented transversely to the axis of rotation (8) of the vane, this disk lying in opposition to the feed conduit (1) for fiber material (2) terminating in the chamber (3). The surfaces of the vane are parallel to its axis of rotation, and so the orientation of the fibers parallel to that axis is maintained.

Abstract: A method for the manufacture of a fiber reinforced thermosetting resin molding material, which comprises feeding a liquid thermosetting resin composition to the surface of at least one transfer roller in rotation, causing the resin composition adhering to the surface to be spread in the form of particles by a spreading roller opposed across a gap to the transfer roller and rotated in the same direction as the transfer roller, allowing the spread said resin composition to be piled up in a state mixed with reinforcing fibers separately spread, and subsequently removing the entrapped air from the resultant pile thereby enabling the resin composition to wet out the reinforcing fibers in said pile.

Abstract: A powdery substance, such as for example pyrogenically prepared silicon dioxide, is subjected to predensification through the utilization of centrifugal force in a centrifuge. Subsequently, the centrifuge receptacles are closed with a free flying piston. Through utilization of the centrifugal force, there is achieved through the use of the free flying piston an additional pressure which is exerted on the predetermined powdery substance.

Abstract: An apparatus for the manufacture of fibrous webs comprises a forming wire and a distributor for depositing dry fibers on the wire. The distributor comprises at least one cylindrical chamber having its axis extending transversely of and in a plane parallel to the wire. The lower semicylindrical wall of the chamber is perforate for distributing fibers on the wire and the upper semicylindrical wall includes a fiber inlet. A helically bladed rotor in the chamber has its axis substantially coincident with the chambers axis of curvature, and upon rotation operates to drive fibers through the screen while evenly distributing them across the wire. Disposition of a pair of chambers in tandem with a common central fiber inlet operates further to create a racetrack fiber distribution across the wire.

Abstract: Methods for pre-forming and feeding a lightly compacted batt of individualized fibers having a controlled cross-directional profile directly to a rotary fiber orienting and screening mechanism across the full width thereof so as to maintain a controlled cross-directional profile in an air-laid web of dry fibers formed in a high speed dry web forming system.

Abstract: Layered glass batch pellets are produced in a continuous process which comprises the steps of:(a) maintaining in the pelletizing zone of a rotary apparatus a moving bed of recycle pellets,(b) feeding sand and particles of a calcium carbonate source into the pelletizing zone,(c) feeding a Na.sub.2 O source comprised of a solution of sodium hydroxide into the pelletizing zone, the recycle pellets being coated with a layer comprised of the solution of sodium hydroxide, the sand and the calcium carbonate source and forming layered pellets,(d) passing the layered pellets into a heated drying zone to form dried layered pellets, the dried layered pellets having a residual moisture content of from about 4 to about 12 percent by weight,(e) passing the dried layered pellets from the drying zone to a recycle zone,(f) recycling a portion of the dried layered pellets to the pelletizing zone as the recycle pellets, and(g) recovering a portion of the dried layered pellets from the recycle zone.

Abstract: In a rotary apparatus and a process for the production of layered glass batch pellets there is provided a drying process and a dryer for final drying of the pellets prior to their being fed to a melting furnace. Relatively cool moist pellets are fed into a static bed-type dryer to form a uniformly distributed pellet bed while a heating and drying gas is directed into the dryer in such a manner that the gas flows countercurrent to the direction of travel of the pellets through the dryer to maintain a temperature differential between the gas and the surface of the solid pellets in the bed throughout the bed's entire height in the range of approximately 5.degree. F. to 120.degree. F. and, ideally, within approximately 50.degree. F.

Abstract: Process and apparatus for centrifugally spinning a fibre-forming material, e.g. a urea-formaldehyde resin, in which the fibre-forming material is supplied in liquid form to the interior of a spinning cup wherein it is divided into separate streams which are led to the outlets of passages through the wall of the spinning cup.

Abstract: Layered glass batch pellets are produced in a continuous process which comprises the steps of:(a) maintaining in the pelletizing zone of a rotary apparatus a moving bed of recycle pellets,(b) feeding sand and particles of a calcium oxide source into the pelletizing zone,(c) feeding a solution of sodium hydroxide into the pelletizing zone, the recycle pellets being coated with a layer comprised of the solution of sodium hydroxide, the sand and the calcium oxide source and forming layered pellets,(d) passing the layered pellets into a heated drying zone exposed to an atmosphere containing carbon dioxide gas,(e) lifting the layered pellets to the upper part of the drying zone and releasing the layered pellets to separately fall through the drying zone,(f) simultaneously absorbing carbon dioxide onto the layered pellets while evaporating and removing water from the falling layered pellets to form dried layered pellets, the dried layered pellets having a residual moisture content of less than 15 percent by weight,

Abstract: A method of making shaped articles from powders comprises forming a cup mold of a destructible organic polymeric material such as nylon, cellulose acetate, poly(methyl methacrylate), polypropylene or polyethylene. The inner surface of the mold corresponds in configuration with the outer surface configuration desired in the shaped article. This mold is placed in a support member and filled with a measured quantity of powder. A plunger composed of a metal having a high specific gravity is placed on top of the powder, and the mold, mold support, powder and plunger combination is positioned in the swing bucket of a centrifugal apparatus where it is subjected to centrifugal force sufficient to achieve the desired degree of compaction of the powder. The mold is then removed and subjected to treatment at a temperature which is sufficient in the first instance to destroy the polymeric mold material, and then sufficient to sinter the powder.

Abstract: A method for forming a uniformly mixed fibrous mat which comprises feeding a continuous high tensile modulus reinforcing fibrous material and a pre-cut thermoplastic fibrous material with a lower melting point or softening point than the temperature at which the reinforcing fibrous material melts or is damaged to a rotating rotor which is provided with projections to thereby cut the continuous fibrous material and pluck the pre-cut fibrous material, dispersing the thus treated fibrous materials into an air flow to mix the same and thereafter collecting the resulting mixed materials on a net to yield the mat. The product can thereafter optionally be compressed under heat to melt only the thermoplastic fibrous material to thereby consolidate the mat.

Abstract: A method of making shaped articles from powders comprises forming a cup mold of an organic polymeric material such as nylon, cellulose acetate, polymethylmethacrylate, polypropylene or polyethylene. The inner surface of the mold corresponds in configuration with the outer surface configuration desired in the shaped article. This mold is placed in a support member and filled with a measured quantity of powder. A plunger composed of a metal having a high specific gravity is placed on top of the powder, and the mold, mold support, powder and plunger combination is positioned in the swing bucket of a centrifugal apparatus where it is subjected to centrifugal force sufficient to achieve the desired degree of compaction of the powder. The mold is then removed and subjected to treatment at a temperature which is sufficient in the first instance to eliminate the polymeric mold material, as by melting or burning, and then sufficient to sinter the powder.

Abstract: A method of agglomerating fine ore powders. The invention is used to agglomerate extremely fine flue dust particles in a collection bin and process them before sending the resultant agglomeration to storage or a further processing location. From its collection bin, the dust particles are discharged by gravity upon a lower rapidly rotating smooth horizontal disc. The bin discharge is offset slightly from the disc's center so that the particles are subjected to centrifugal force to move them to the disc's outer periphery. At the point where the particles are discharged on the disc, a liquid binder, like water, is sprayed on the particles to cause them to begin to agglomerate. After being sprayed, the wetted particles are agglomerated under the influence of centrifugal and tangential forces. A scraper may be used to aid in pushing the particles towards the disc's raised outer edge.

Abstract: In a process for the production of fibre filters, the fibre material is sprayed electrostatically from the liquid state and deposited as a fibre fleece on a conductive support. The starting materials used are solutions of high polymers in readily volatile solvents. The filters obtained have substantially improved properties.

Abstract: This invention relates to a unique method of fabricating a dry-formed, adhesively bonded nonwoven sheet and to the sheet formed thereby. The method of this invention includes the steps of forming a low integrity, dry-formed fibrous web having a basis weight in the range of from about 30 grams per square meter to about 170 grams per square meter; embossing the web to provide spaced-apart densified regions and high loft regions with the densified regions covering from about 15% to about 40% of the planar area of the web and having a density greater than about 0.150 grams per cubic centimeter, and with the high loft regions having a density of less than about 0.

Abstract: A carbon article manufacturing method is disclosed in which a raw material for a carbon article is revolved and heated at the same time, whereby the raw material is pressurized by centrifugal force and baked simultaneously. Further, carbon article manufacturing apparatus is disclosed which is provided with means for housing a raw material and pressurizing it by centrifugal force, means for revolving the housing and pressurizing means, and means for heating the housing and pressurizing means.

Abstract: A method is disclosed of separating a suspension of fine tailings particles from a material of value in a liquid medium which comprises, adding a small but effective amount of fluocculant to said liquid medium while mixing said liquid medium and continuing said mixing to effect flocculation of said fine tailings particles, passing said liquid medium containing said flocculated particles to a rotating pelletizing drum and subjecting said medium to the rotational action of said drum to pelletize said flocculated tailings particles, thickening said pelletized tailings particles to provide an underflow of said pelletized tailings particles, and disposing said pelletized tailings particles.

Abstract: A method for manufacturing carbon-carbon composite bodies consisting essentially exclusively of carbon, of about 20 to about 96 weight percent from carbon fiber, from 0 to about 72 weight percent from a carbonaceous flour, and from about 4 to about 15 weight percent from a carbonized resin, which consists in forming a mat by allowing a mixture of the solid ingredients to settle to equilibrium height by the force of gravity or by centrifugation in a solution of the resin and an appropriate solvent, then pressing the settled solids at up to about 100 psi and removing the excess liquid therefrom. Heating the formed and pressed mat to cure the resin, and then baking and optionally graphitizing the cured mat completes the process.

Abstract: A method for producing a tubular multi-layered porous barrier comprising the step of depositing fine powder onto at least one of the inner and outer surfaces of a sintered tubular porous support member in a layer of uniform thickness to form a fine powder layer and pressurizing said powder layer against said support member to form a porous barrier layer on the support member.

Abstract: A non-woven fibrous web is continuously air-laid by directing a fluid stream of fibers from a rotating spinner against the inner surface of a moving foraminous belt which travels in an arc substantially around the circumference of the spinner, with suction being applied to the outer surface of the foraminous belt to facilitate uniform fiber lay-down and to remove the fluid.

Abstract: Method of making a molded article comprising a hollow body of a crosslinked polymer rotationally molded around a section of at least one piece of non-crosslinked conduit, which conduits protrude from said hollow body, made by attaching said conduits of non-crosslinked material at the desired location to the mold with said section being located inside a heated section of the mold so that the crosslinkable polymer during a rotational molding process is fused and crosslinked inside of the mold and around and in tight welding-type connection with said section, whereas the remainder of the piece or pieces of uncrosslinked polymer are heat-insulated, thus avoiding deformation or collapsing of these pieces.

Abstract: A hollow multilayered article is rotationally molded by introducing into the mold particles of a hompolymer or copolymer of ethylene containing a crosslinking agent and heating the mold during rotation thereof to melt this first polymeric layer. Solid particles of a different polymer are then introduced into the mold at a time after at least substantially all of the particles of the first polymer have melted and prior to the time when the inner surface of the first layer would become smooth and glossy. The mold is then rotated and heated to melt the second polymer. The mold is then cooled and the multilayered article removed.

Abstract: A method of moulding a drum or similar from a thermoplastic resin in powdered form, in which an appropriately shaped mould, after introduction of the thermoplastic material, is subjected to the actions of alternate direction rotation, tilting, heating and cooling in a predetermined sequence with the heating of the drum body and ends being effected and controlled independently.

Abstract: A non-woven fibrous web is continuously air-laid by directing a fluid stream of fibers from a rotating spinner against the inner surface of a moving foraminous belt which travels in an arc substantially around the circumference of the spinner, with suction being applied to the outer surface of the foraminous belt to facilitate uniform fiber lay-down and to remove the fluid.

Abstract: Hollow, multi-layered plastic structures are provided comprising a layer of thermoplastic polyester material and a layer of polyethylene, the polyethylene and polyester layers being cross-linked together at their interface. A process for producing such structures which comprises charging a mold with thermoplastic polyester material, rotating and heating the mold so as to fuse and form a layer of the polyester material on the inner surface of the mold, cooling the mold to a point below the melting point of the polyester but above the melting point of a subsequently added cross-linkable polyethylene material, stopping the rotation and charging the mold with the cross-linkable polyethylene material, resuming the rotation of the mold and heating it to a temperature sufficient to fuse and cross-link the polyethylene with the polyester layer, cooling the mold to a point below the melting point of the polyethylene and removing the finished structure from the mold.