Abstract: A method of manufacturing flexible sheets of expanded graphite material from recycled materials, comprising providing source materials in the form of flexible sheets of expanded graphite; comminuting the source materials into particles; re-expanding the particles; and preparing a mat from the re-expanded particles. Also described herein is a process of manufacturing a graphite material comprising grinding a cured resin impregnated graphite material into particles; removing at least part of the resin from the particles; and expanding the resin removed particles.

Abstract: The present invention relates to a flexible graphite sheet having increased isotropic properties. More particularly, the present invention relates to a flexible graphite sheet formed from particles of expanded natural graphite formed from graphite flake sized no more than about 30% by weight +80 mesh prior to expansion. The resulting sheet of flexible graphite exhibits improved conductive and fluid sealing properties.

Abstract: An apparatus and method for producing a sheet of brake lining material utilizes a mold which has a mold base and a mold frame. The mold frame is slidingly received on the mold base. The sliding relationship between the mold frame and the mold base results in a mold cavity which has a variable volume. The variable volume of the mold cavity allows the cavity to adjust to the size of material initially placed in the mold cavity thereby eliminating any mold flash and/or scrap material.

Abstract: Powder of a polymer active material 1 exhibiting an electro-chemical oxidation-reduction reaction is mixed with powder of a conductivity assisting agent 2 to obtain a mixture. The mixture is molded by a thermal press into a unitary block. Thus, a cell electrode having a large film thickness is produced without causing cracks or breakage. The electrode having a large film thickness improves the energy density of the polymer secondary cell.

Abstract: In a manufacturing method for hollow panels wherein highly rigid, lighter and various shapes of hollow panels constructed by layering board material made from fibers, wood elements, or wood strands can be obtained economically, wood strands on which a binder is added are layered with a plurality of cores, a thermal compression molding is performed on this layered material uniformly, cores are extracted after the thermal compression molding, and thus ribs and holes are formed in the panel. Also in the core is a bar which may be of irregular shape, and the core can be a combination of bars having the same or different cross sections. The cores are joined by joining boards in a direction of the short dimension of the core.

Abstract: Method of production of molded wood strand products having relatively narrow projections, such as channels, by inserting binder coated implants into projection forming voids in the mold cavity used to form the product.

Abstract: A method of manufacturing sheets, films, and articles of manufacture from a corn zein resin. A wet corn zein resin is formed including corn zein and a fatty acid, and the wet zein resin is cold rolled into sheets. The sheets are dried, and the dried zein resin is processed to form sheets, films, and/or articles of manufacture.

Abstract: FIGS. 25 and 26 show in sequence a 270° bending of a tile predisposed on a bottom surface thereof in which surface a straight groove has been made at a position where a bend is to be performed. FIG. 5 is a detailed illustration showing the groove after having been filled following bending. In the illustrated example, the bend of the tile is obtained, after making the groove in the opposite surface to the upper surface, by subjecting the tile to overall or localized heating as it is resting on a support made of refractory material which support has two surfaces which are reciprocally perpendicular and inclined with respect to a vertical, at a suitable angle for the tile to be stable thanks to a part thereof resting on the surface, and a projecting part of the tile to be able, when softened, to fall by gravity until it reaches and rests perfectly on the other surface 10″ of the support.

Abstract: The invention is directed to methods involving rewetting of expandable polymers with a wettable liquid to allow for enhanced expansion at or below room temperature without breakage, and in some cases, allows one to achieve a greater expansion ratio than that allowed at elevated temperatures using known methods. The present invention also allows one to achieve material with unique properties and handling characteristics. These properties included decreased material thickness, increased density, an altered node/fibril morphology, and a more consistent web in the case of flat material. This method is not limited to room temperature conditions and can be applied whenever the expandable polymer material is wet with a wettable liquid, and the expansion is performed at a temperature preferably below the vaporization or boiling points of that liquid.

Abstract: The invention is embodied in an electrical device which includes at least a layer of a ferroelectric polyvinylidine flouride polymer that has been processed to exhibit an electrostrictive strain of 4% or more when an electric field gradient of 50 megavolts per meter or greater is applied thereacross. The processing of the polymer preferably involves subjecting it to either electron beam radiation or gamma radiation. The polyvinylidine flouride polymer is selected from the group of: polyvinylidine fluoride, polyvinylidine fluoride-trifluoroethylene P(VDF-TrFE), polyvinylidine fluoride tetrafluoroethylene P(VDF-TFE), polyvinylidine fluoride trifluoroethylene-hexafluoropropylene P(VDF-TFE-HFE) and polyvinylidine fluoride-hexafluoropropylene P(VDF-HFE).

Abstract: Method of production of molded wood strand three-dimensionally curved articles of manufacture using at least one hole punch comprised of a base and a funnel shaped hole-defining portion having a funnel angle of 20 degrees or greater to vertical for producing molded holes at angles of 20 degrees or greater to vertical, to facilitate insertion of items such as a T nut within the molded hole in an assembly-line like fashion.

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: A container manufacturing method and device. The container manufacturing method includes steps of mixing, board-making, molding, guiding/crimping and demolding. Lower protruding guide bodies are arranged along the circumference of the mold cavity of the lower mold seat of the container manufacturing device at intervals. Upper protruding guide bodies are arranged on the press board and aimed at the intervals between the adjacent lower guide bodies. In the step of guiding/crimping, when the press board is pressed down by an oil pressure cylinder, the interlaced upper and lower guide bodies clamp and press the circumference of the board body to form regular crimps thereon. Therefore, when the upper mold block presses the board body into the mold cavity, the material can be evenly distributed and flowed so that the wall of the molded container can have uniform thickness.

Abstract: The present invention provides a cardable fiber blend which forms a moldable fiber batt, the blend comprising fibers having a modulus of 550 g/denier or more with fibers of a thermoplastic polymer wherein the high modulus polymer fibers are all uncrimped fibers or a mixture of crimped and uncrimped fibers. The moldable batt is useful in making speaker cones.

Abstract: A vehicle headliner having a panel formed of a compressed and molded thermoplastic polymer fiber batt, wherein the fibers are thermally fused together at a multiplicity of locations to impart to the panel a self-supporting rigidity to allow the headliner to retain its shape while also rendering the panel highly deformable and resilient to allow the panel to be bent during installation and thereafter resiliently recover its original shape, is prepared by a process in which improved loft retention of the batt is achieved by appropriate selection of heating parameters and/or selection of polymeric fibers. Also, a process for achieving reduced plastic deformation and improved mechanical properties by modifying the crystallinity of the binder fibers of the batt is disclosed.

Abstract: From about 50 to about 90% by weight of fibers, in particular wood fibers, and/or pellets made from cellulose or from wood, are mixed with from about 10 to about 50% by weight of a hot-curing resin, each of the percentages by weight being based on the total weight of the mixture. Instead of a single resin it is also possible to use a mixture made from two or more hot-curing resins. The mixture made from fibers and/or pellets and resin is kneaded and homogenized and then passed on to an extruder which has various heating zones in which the mixture is heated. Care has to be taken here that the maximum temperature, arising at the extruder exit, does not exceed about 120° C., since above this temperature the resin(s) begin(s) to cure.

Abstract: A granulator comprising a perforate screen located within a housing, a roller having a curved convex outer surface wherein the roller is pivotable relative to the screen so that in operation plastic material is able to be forced through the perforate screen by the roller surface so the roller pivots. The granulator is useful for wet and dry granulation.

Abstract: A process and apparatus for manufacturing fuel cell plates are disclosed, the apparatus including a continuous press, a sifter, a leveler and rollers for removing air from resin impregnated graphite. An electrostatically charging device and a vibratory dispensing device may also be used. The sifted material is deposited on a heated lower press belt which is the belt having an embossing pattern. The material is leveled to a predetermined height and squeezed to remove air. An upper belt, also having an embossing pattern, contacts the material and heat and pressure are applied in a reaction zone for a predetermined time period. The process may also include the making of a tool integral with one or both belts for embossing the fuel cell plates. The finished product is a relatively low cost fuel cell plate.

Abstract: An improvement to existing board manufacturing process which utilize lignocellulose particles is described wherein the adhesive to be applied as a binder is at least partly applied before the particles are dried. Using the invention improvement in resin application rates without increase in the water content of the particles fed to a press is achieved. Reduction in edge thickness swelling has been achieved.

Abstract: An interface F between upper mandrels and lower mandrels are moved to a predetermined position in a cavity with the upper mandrels and the lower mandrels slidingly moving toward the lower punch while the upper mandrels and the lower mandrels remain in contact with each other, in a manner such that pressure is not applied to powdered dielectric material disposed in the cavity. The powdered dielectric material in the cavity is compressed by an upper punch and the lower punch while the upper mandrels and the lower mandrels remain in contact with each other, thereby forming a dielectric block.

Abstract: The present invention relates to a system for managing the heat from a heat source like an electronic component. More particularly, the present invention relates to a system effective for dissipating the heat generated by an electronic component using a heat sink formed from a compressed, comminuted particles of resin-impregnated flexible graphite mat or sheet.

Abstract: A process for manufacturing ligneous material board with improved surface slip-resistance. The process includes an additional spreading station which spreads fine particles onto the upper and lower covering layers to obtain slip-resistant textured surfaces.

Abstract: Method for forming large-dimension ceramic tiles comprising at least one first pressing stage for the purpose of obtaining a not completely compacted consistent blank (5), and at least one second pressing stage for the purpose of completing the compacting of said blank following its possible surface decoration, said at least one second pressing stage being effected without any lateral retention action on the blank.

Abstract: A textured airlaid web is disclosed. The textured web is formed on a three-dimensional fabric under sufficient force to cause the web to conform to the surface of the fabric. The textured web includes, on a minute scale, peak areas and valley areas. The peak areas and valley areas can improved the liquid handling properties of the web. For instance, webs can be produced having improved absorbency characteristics and/or wicking characteristics.

Abstract: A method for molding an agglomeration of fused microspheres to create a fragrance delivery system by use of room temperature setting binders. The molded pre-glass agglomeration has an extended fragrance release time exceeding a year and a half, and uses microcapillary action to quickly uptake oils and alcohols. The molded pre-glass agglomeration provides a slow release of fragrance without the escape of any residual liquid. The molded pre-glass agglomeration may be replenished, an unlimited number of times, with fragrance containing oils and alcohols after the odor fades. The molded pre-glass agglomerations may also be colored or dyed.

Abstract: An embossed, decorative, man-made embossed article having an embossed surface portion containing at least about 80% by weight cellulosic fibers and sufficient binder to adhere the cellulosic fibers together into a structurally sound article having a specific gravity in the range of 0.96 to 1.08, a surface of said article having a pattern of embossed ticks stained to visually distinguish the embossed ticks from surrounding surface portions of said article, said embossed ticks formed in elongated bundles to replicate a wood grain pattern, said embossed ticks and said bundles of ticks satisfying the following criteria: (a) at least 90% of said embossed ticks, in bundles of three or more adjacent ticks, are spaced at least 0.016 inch; (b) at least 90% of said embossed ticks are embossed a depth in the range of 0.003 inch to 0.

Abstract: A method of preparing fiber preforms disperses fibers and binder on a forming support surface such that the materials are conditioned and then applied to the surface where the composite material solidifies. Reinforcing material, such as fiber, is mixed with binder, such as thermoplastic or thermoset materials, so that the materials adhere. Then, the adhesive mixture is dispersed in a controlled pre-determined weight ratio on the support surface where the mixture sticks to the support surface, cools and solidifies. The deposited mixture can also be shaped further into a final desired shape before complete solidification. This method eliminates the need for solvents and their associated problems. The process does not require a vacuum or plenum system to hold the reinforcing material in place. The preform can be made in any shape, including sections or asymmetric configurations.

Abstract: A continuously operating press for the continuous manufacture of wood material boards having a textured surface on at least one side includes: an upper frame part and a lower frame part; two endless steel belts configured to draw a mat of material through the continuously operating press and to transfer press pressure, each steel belt associated with one of the upper frame part and the lower frame part; an endless metal mesh belt associated with a corresponding one of the steel belts; an insulating tunnel associated with the metal mesh belt and the corresponding steel belt; and a heating tunnel associated with the metal mesh belt and separated from the corresponding steel belt. The metal mesh belt includes a material having a thermal conductivity substantially higher than that of the corresponding steel belt and having a thermal expansion coefficient approximately equal to that of the corresponding steel belt.

Abstract: The invention relates to a method for the manufacturing of a plate (2) of metal or of a ceramic material, the plate comprising one or more fields (3) which occupy the major part of the surface of the plate and which on at least one side of the plate is high relief patterned, more specifically patterned such that the plate on said at least one side within the area of said field or fields has reliefs with high projections and deep valleys (9) or recesses (8) alternatingly, and between the sides a thin web (10), said high relief patterned field or fields being at least partly bordered by broad edge portions (4) which have a thickness larger than the mean thickness of the plate within the region of said high relief patterned field or fields. In a preparatory step an intermediate product (1) is manufactured, comprising at least a first portion (11) which shall form said high relief patterned field(s), which however is/are not yet high relief patterned but contain(s) an adequate quantity of material.

Abstract: A process for manufacturing fuel cell plates including a continuous press, a sifter, a leveler and rollers for removing air from resin impregnated graphite. The sifted material is deposited on a heated lower press belt having an embossing pattern. The material is leveled to a predetermined height and squeezed to remove air. An upper belt, also having an embossing pattern, contacts the material and heat and pressure are applied in a reaction zone for a predetermined time period. The finished product is a relatively low cost fuel cell plate.

Abstract: The invention relates to a solid dosage form which is rapidly disintegrating in aqueous medium. Especially, the invention relates to pharmaceutical, orally ingested solid dosage forms, which are designed to disintegrate rapidly within the mouth, and to analogous veterinary dosage forms. Moreover, the invention relates to a unique process for the manufacture of said solid dosage forms.

Abstract: A rotary foam buffing pad is provided with a concave working face which allows the operator to provide true graduated surface contact in applying polish, buffing or glazing compounds, while containing the polishing compound against centrifugal force which would otherwise result in splattering of the compound. The manner in which the concave working face is formed and in which the edge face is formed and dressed results in dynamic balancing of the pad and reducing vibration and operator fatigue. The working surface forming and pad finishing operations further provide a velvetized texture to the pad working surfaces which further enhances the polishing or finishing process.

Abstract: An apparatus is described for smoothing out the surface weight distribution of one or multilayer mats containing lignocellulose and/or cellulose with a binding agent dispersed therein for manufacturing of shaped articles, in particular in the form of wood chipboard, wood fiberboard or the like, wherein at least one vertically adjustable reverse brushing unit which extends over the width of the web is associated with a mat carrier which is fed via at least one scattering head. This apparatus is characterized, above all, by the reverse brushing unit comprising at least one vertically adjustable brushing roller having flexible bristles of a plastic material such as polypropylene, Teflon or the like which cooperates with a cleaning brush or a cleaning strip.

Abstract: Apparatus for forming building blocks includes an upright compression chamber with an upper end which serves both as an inlet and an outlet. A sliding gate closes the inlet/output. A soil/cement mixture is loaded into the upper end of the compressing chamber, the gate is slide shut, and a ram then compresses the mixture against the gate. The gate is opened while the ram is still under pressure, smoothing the upper end of the block, and allowing it to be ejected through the common inlet/outlet.

Abstract: A topsheet for body fluids absorbent article is made of thermoplastic synthetic fibers mechanically entangled so as to extend substantially in a desired one direction and formed with liquid-permeable openings. The openings comprise a first group of openings each having a substantially oval shape defined by its major axis extending substantially in parallel to the direction in which the fibers extend and its minor axis extending orthogonally to the major axis and a second group of openings each having a substantially oval shape defined by its minor axis extending substantially in parallel to the direction in which the fibers 11 extend and its major axis extending orthogonally to the minor axis.

Abstract: An improved method of making a molded composite article by combining a fibrous material with a binder to form a mixture, drying the mixture to a moisture content of about 6 wt. % to about 14 wt. % based on the weight of the fibrous material to form a mat, coating at least one surface of the mat with an aqueous solution comprising one or more additives selected from the group consisting of: a wetting agent, a mold release agent, a set retarder, and a binder. Thereafter, the mat is consolidated under heat and pressure to form the molded composite article. Articles formed by this improved method exhibit superior surface characteristics (i.e., smooth, hard surfaces), and do not require the need for any further treatment, such as use of tempering oils, application of post-consolidation sealers, or post-consolidation surface sanding procedures, prior to subsequent finishing operations, such as coating, gluing, painting, or other finishing to complete a desired article for commercial use.

Abstract: Methods are disclosed for producing multi-layer peelable sheaths having formed tips, for use as medical introducer devices, e.g., sheaths for inserting a catheter or the like into a patient. The methods include the steps of preparing a first composition blend for forming an inner layer of the multi-layer sheath, preparing a second composition blend for forming an outermost layer of the multi-layer sheath, combining the first and the second composition blends into a multi-layer pre-form, processing the multi-layer pre-form for producing tubing, and forming a tip at one end of the tubing using a thermal process, thereby producing the multi-layer sheath having the inner layer, the outermost layer, and the formed tip. The methods of the present invention include adding a detectable material to the blend used for making the inner layer for facilitating external visualization of the multi-layer sheath, thereby achieving a sheath with a formed tip having no visible discoloration.

Abstract: The invention relates to a process for producing a positive electrode, containing an organic polymer as binder, for primary elements with alkaline electrolytes. The process according to the invention is carried out in the following way: manganese dioxide particles are mixed with a graphite dispersion, which contains an organic polymer, and are compressed to form an electrode body.

Abstract: A process and plant for producing boards of wood-based materials having either a structured upper surface or a smooth upper surface. The plant has a continuously operating production press and a continuously operating embossing press. A discharge section and a transfer section are located between the continuously operating production press and embossing press. The continuously operating production press compresses and cures a mat of pressing stock to create a board that retains heat, while the continuously operating embossing press imparts the permanent embossed pattern on an upper surface of a board. The transfer section has a water spray device and a covered steam hood for cooling the board and producing steam.

Abstract: Used and manufacturing scrap asphalt shingle material is processed into a fine material comprising smaller sized pieces of shingle material and a relatively high aggregate content. The fine material is finish processed into shaped products adapted to take advantage of the high aggregate content therein. Processing of the fine material includes (i) grinding and heating the aggregate and smaller sized pieces of shingle material into a homogenous mixture, (ii) forming the shaped products via molding with pressure, or extruding and cutting the extruded mixture, and embedding a surface treatment material into the shaped products.

Abstract: Used and manufacturing scrap asphalt shingle material is processed into a relatively course material comprising pieces or flakes of a maximum predetermined size, preferably with a relatively low aggregate content. The flakes are finish processed into a composite board product, with advantage taken of the larger size and low aggregate content. The board fabrication process includes (i) mixing the flakes with a relatively high percentage content of solvent suffuced fiber, (ii) grinding and heating the flakes and fiber to form a homogenous semi-liquid mixture, (iii) extruding and conveying the homogenous mixture to a board forming station, and (iv) compressing the mixture into the composite board product. The flakes may be produced by an initial process that includes (i) shredding the used and scrap shingle material into pieces of a predetermined maximum size, and (ii) separating the shredded material into (a) fine material and (b) course material.

Abstract: Mold apparatus and method of production of molded wood strand three-dimensionally carved articles of manufacture using at least one hole punch comprised of a base and a funnel shaped hole-defining portion having a funnel angle of 20 degrees or greater to vertical for producing molded holes at angles of 20 degrees or greater to vertical, to facilitate insertion of items such as a T nut within the molded hole in an assembly-line like fashion.

Abstract: Provided is a method for the production of a reinforced polymer, which method comprises: (a) introducing carbon nanotubes into a polymer to provide a mixture of the polymer and the nanotubes; (b) stretching the mixture at or above the melting temperature (Tm) of the polymer to orient the carbon nanotubes; and (c) stretching the mixture in the solid state to further orient the carbon nanotubes.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: The process relates to the production of boards of wood-based material, in particular, oriented strand board, chipboard or fiberboard comprising lignocellulose- and/or cellulose-containing particles. The particles, in the form of chips, fibers, chippings or the like, are mixed with a binder and scattered in a scattering station onto a moving molding belt to form a mat of pressed stock. The mat of pressed stock is pressed and cured by the application of pressure and heat in a platen press or a continuously operating press. To accomplish surface structuring during the production cycle, the finished board of wood-based material just released from the pressing operation is subjected to a structuring operation on one or both sides.

Abstract: From about 50 to about 90% by weight of fibers, in particular wood fibers, and/or pellets made from cellulose or from wood, are mixed with from about 10 to about 50% by weight of a hot-curing resin, each of the percentages by weight being based on the total weight of the mixture. Instead of a single resin it is also possible to use a mixture made from two or more hot-curing resins. The mixture made from fibers and/or pellets and resin is kneaded and homogenized and then passed on to an extruder which has various heating zones in which the mixture is heated. Care has to be taken here that the maximum temperature, arising at the extruder exit, does not exceed about 120° C., since above this temperature the resin(s) begin(s) to cure.

Abstract: A new and improved composition includes a mixture of: a quantity of a nontoxic premixed mixture of ground cellulose-containing material, plaster of paris, and starch preservative; a quantity of a nontoxic water-based adhesive resin; and a quantity of talcum powder. The water-based adhesive resin is preferably a water-based polyvinyl alcohol resin. The composition of the invention may also include a quantity of a colored acrylic paint.

Abstract: A method of making a one-piece, unitary lid for a casket comprises providing tooling configured to produce a casket lid having a crown, a pie, a rim and a header, providing settable material, preferably a mixture of wood chips and binder, from which to mold the lid, molding the settable material with the tooling and permitting the settable material to set. The tooling transmits a wood grain pattern into the settable material. The wood grain pattern of the lid is continuous when viewed rotated 180° about an axis perpendicular to the plane defined by the lid, located medially of the transverse extent of the lid and coinciding with the header end edge of the lid. Thus two such caps placed end-to-end have a continuous wood grain pattern extending from the head end of the casket to the foot end of the casket. Resin impregnated tissue paper is applied to the settable material prior to molding. The resin impregnated tissue paper conforms to the wood grain and conceals the wood chips.

Abstract: A process for producing a shaped article from a bonded, non-woven, fibrous batt of fibers comprising a number of steps. There is first provided (A) a dry, solid, heat-responsive fiber-binder; and (B) a moisture-responsive fiber-binder which is a dry, solid, particulate, raw, ungelled starch which swells and becomes sticky upon contact with moisture. The heat-responsive fiber-binder is contacted with the fibers to form a raw batt with the heat-responsive fiber-binder loosely adhering to the fibers of the batt. The moisture-responsive fiber-binder is contacted with the fibers to form a raw batt with the moisture-responsive fiber-binder loosely adhering to the fibers of the batt.

Abstract: This invention concerns a method of manufacturing a highly conductive polytetrafluoroethylene sheet; a method of manufacturing a highly conductive unsintered polytetrafluoroethylene sheet: and a method of manufacturing a highly conductive sintered sheet. In the first method, a paste of polytetrafluoroethylene powder admixed with conductive substance and extrusion lubricant is extruded to preform an unsintered tube-like material, and at least one place on the circumference of this extruded material, the material is cut open longitudinally and the resulting sheet is calendered if necessary. The second method includes a sintering process for the sheet. This invention also concerns a highly conductive polytetrafluoroethylene sheet having a wide-width and long-length, which is obtained by the above-mentioned method. This sheet is not less than 170 mm in width and has variance of volume resistivity (conductivity) in the longitudinal direction, 10% or less, preferably 7% or less in the cross direction.