With Reshaping Or Surface Embossing Of Formed Article Patents (Class 264/119)
  • Patent number: 6258224
    Abstract: A process of producing multi-layer cathode structures. In one aspect, the process comprises providing a carbonaceous cathode substrate, and forming at least one layer of a metal boride-containing composite refractory material over the substrate, wherein the surface of the carbonaceous substrate to be coated is roughened prior to the formation of the layer overlying the said surface. The roughening of the surfaces reduces the tendency of the layers to separate in high temperature operating conditions. In another aspect, the process comprises providing a carbonaceous cathode substrate, and forming at least two coating layers of a metal boride-containing composite refractory material successively over the substrate, wherein the content of metal boride in the coating layers increases progressively as the distance of the layer from the substrate increases.
    Type: Grant
    Filed: November 16, 1999
    Date of Patent: July 10, 2001
    Assignee: Alcan International Limited
    Inventor: Amir A. Mirtchi
  • Patent number: 6254814
    Abstract: There is disclosed a molding compound for making an article including a cellulose fiber, which is prepared by mixing a cellulose fiber added with at least starch, water and a long chain fatty acid salt of a non-alkali metal. There is also described a method for molding an article including a cellulose fiber by employing the above compound and, further, a mold for molding an article including a cellulose fiber with a cavity formed by a stationary side and a movable side which is used therefore.
    Type: Grant
    Filed: February 11, 1999
    Date of Patent: July 3, 2001
    Assignee: Daiho Industrial Co., Ltd.
    Inventors: Seiichi Ueda, Seio Higaki, Manabu Sudo, Kousuke Yagi, Masahiko Funaki
  • Patent number: 6245180
    Abstract: Methods for forming a lined brake shoe having a curved brake lining attached to a table of the lined brake shoe. The curved brake lining is manufactured by molding a flat sheet of brake lining material in a partially polymerized state. This flat sheet is allowed to cool prior to be positioned within a press having warmed dies. The warm dies of the press form the curved brake lining while holding the curved brake lining in its desired shape. The warm dies restart the polymerization process. When further polymerization has been completed the curved lining is removed from the press. One embodiment places the table of the lined brake shoe in the press. Then, by adding a bonding material, the completed lined brake shoe can be manufactured while the polymerization process continues in the press.
    Type: Grant
    Filed: April 2, 1999
    Date of Patent: June 12, 2001
    Assignee: Midwest Brake Bond Company
    Inventor: Keith F. Barnhardt
  • Patent number: 6243931
    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.
    Type: Grant
    Filed: September 15, 1998
    Date of Patent: June 12, 2001
    Assignee: Batesville Services, Inc.
    Inventors: John E. Linville, Donald R. Maier, Patrick M. Saaf
  • Patent number: 6228299
    Abstract: A gelcasting composition has improved drying behavior, machinability and shelf life in the dried and unfired state. The composition includes an inorganic powder, solvent, monomer system soluble in the solvent, an initiator system for polymerizing the monomer system, and a plasticizer soluble in the solvent. Dispersants and other processing aides to control slurry properties can be added. The plasticizer imparts an ability to dry thick section parts, to store samples in the dried state without cracking under conditions of varying relative humidity, and to machine dry gelcast parts without cracking or chipping. A method of making gelcast parts is also disclosed.
    Type: Grant
    Filed: August 17, 1999
    Date of Patent: May 8, 2001
    Assignee: UT-Battelle, LLC
    Inventors: Mark A. Janney, Claudia A. H. Walls
  • Patent number: 6197235
    Abstract: An improved method for texturing gypsum fiber panels and producing surface textured panels, edge tapers, and deeper patterned wainscot-type panels, involving the use of a flexible die with a textured surface. The die is pressed onto the panel in its slurry state just after the onset of an exothermic rehydration reaction. Partial hydration and setting occur during pressing by the die to form a textured mat. The mat is removed from contact with the die at a point along the rehydration temperature curve about at or less than one-half of the rise to the greatest rehydration temperature.
    Type: Grant
    Filed: February 9, 1999
    Date of Patent: March 6, 2001
    Assignee: United States Gypsum Company
    Inventors: David Paul Miller, Matthew Huss
  • Patent number: 6193771
    Abstract: Relatively thin type 27 depressed center abrasive wheels are made from initially flat “green” wheels made in a hydraulic press that has flat upper and lower surfaces in each press cavity. These thin flat wheels are clamped in a fixture that forms the center portions as the wheels are clamped to provide “green” wheels that are not only thin, but that have depressed center portions of undistorted internal geometry. The “green” wheels are then cured in this clamped condition in a furnace at appropriate temperatures that achieve the necessary hardening of the resinous mixture to yield thin depressed center abrasive cutting wheels.
    Type: Grant
    Filed: July 16, 1996
    Date of Patent: February 27, 2001
    Assignee: United Abrasives
    Inventor: Joseph Patrello
  • Patent number: 6171688
    Abstract: Composite products incorporating a polymer matrix, polymer microspheres, glass microspheres and natural fibers, particularly kenaf and wood fibers, are described. The polymer microspheres are 15 to 50 microns in diameter and are smaller than the glass microspheres which are 50 to 200 microns in diameter. The polymer microspheres reduce voids and prevent cracking of the glass microspheres upon compression. The composites have low cost and high strength.
    Type: Grant
    Filed: February 8, 1999
    Date of Patent: January 9, 2001
    Assignee: Board of Trustees operating Michigan State University
    Inventors: James Zheng, Roger J. Morgan, Robert Jurek
  • Patent number: 6136240
    Abstract: A self-lubricating plastic center plate assembly bearing liner for placement between a body bolster center plate and a truck bolster center plate of a center plate assembly in a railroad car, wherein the liner is configured to substantially mate with the center plates and includes a body having an integrally formed electrically conductive ring of plastic material which provides electrical continuity between the plates in the center plate assembly.
    Type: Grant
    Filed: December 22, 1998
    Date of Patent: October 24, 2000
    Assignee: Zeftek, Inc.
    Inventors: Michael K. Burke, Richard F. Murphy
  • Patent number: 6133171
    Abstract: To avoid breakage and weak points at the points of deflection in case of a large deflection angle and deep deformations a non-woven is formed of several fiber components, which forms a flexible, dimensionally stable molded article under pressure and temperature. An additional CoPES-fiber component facilitates lamination with other fibers without having to use additional auxiliaries.
    Type: Grant
    Filed: November 13, 1997
    Date of Patent: October 17, 2000
    Assignee: Lohmann GmbH & Co., KG
    Inventors: Bernd Potzler, Wolfgang Riediger
  • Patent number: 6123884
    Abstract: Methods for the continuous manufacture of board from lignocellulose-containing material are disclosed including disintegrating the lignocellulose material into particles or fibers, drying, coating with glue, forming the glued board into a mat, heating the mat with steam, compressing the heated mat to a predetermined thickness approximately equal to the final desired thickness of the board, and pressing the compressed mat into the board.
    Type: Grant
    Filed: October 7, 1997
    Date of Patent: September 26, 2000
    Assignee: Valmet Fibertech Aktiebolag
    Inventors: Goran Lundgren, Kurt Schedin, Lars-Otto Sisleg.ang.rd, Sven-Ingvar Thorbjornsson
  • Patent number: 6110580
    Abstract: The invention relates to a method for the recycling of trim components of vehicles. The method comprises the steps of shredding manufacturing scrap and post-consumer scrap from vehicle headliners into small particles to produce fluff. This fluff is then combined with water and a binder reagent composed of either polyisocyanates, or polyisocyanates combined with various polyols. The solution of fluff, binder reagent and water are mixed, and then placed in a mold where the mixture is formed into a pre-preg sheet. Subsequently, the pre-preg sheet is subjected to compression molding at elevated temperatures to produce a finished composite trim panel. As part of the final compression molding step, a decorative coverstock can be included to produce a finished trim panel having a decorative cover.
    Type: Grant
    Filed: August 6, 1998
    Date of Patent: August 29, 2000
    Assignees: Lear Corporation, University of Detroit Mercy
    Inventors: Girma Gebreselassie, Harold G. Wolf, Jr., Kurt C. Frisch, Daniel Klempner, Vahid Sendijarevic
  • Patent number: 6103180
    Abstract: A method for the production of a porous, sound- and heat-insulating shaped element, in particular for lining of sound- and/or heat-emitting vehicle components, by shaping and solidifying a bonded fiber fabric made of natural fibers mixed with a thermoplastic binder in a press mold. The binder is crosslinked uniformly in all regions of the porous shaped element to produce a shaped element featuring a formaldehyde emission of less than 2 ppm due to the replacement of conventional resins with the thermoplastic binder.
    Type: Grant
    Filed: January 16, 1997
    Date of Patent: August 15, 2000
    Assignee: Matec Holding AG
    Inventors: Willy Haeseker, Harald Freyer
  • Patent number: 6083339
    Abstract: Processes for producing durable three-dimensional bowls such as water basins comprising acrylic plastics heavily filled with alumina trihydrate, some embodiments including colorants and visible particles such as those used for simulating stone such as granite. A preferred process for manufacturing the bowls of such material includes defining a flat rigid blank in the approximate top outline shape of bowl to be formed, e.g., the blank being a flat oval for an oval bowl and circular for a circular bowl. The flat blank is provided a smooth side or sides which will be the concave finished side in use. The blank is heated to a point of softening and of uniform temperature throughout, and located within a molding die such as a matched molding die having a female cavity of the desired bowl shape. The heated blank is indexed to the die, but left generally unrestrained so that the heated blank and edges thereof are un-clamped, thereby allowing the edges to be moved inward to help minimize tension loads during forming.
    Type: Grant
    Filed: December 5, 1997
    Date of Patent: July 4, 2000
    Assignee: Transfer Flow International, Inc.
    Inventors: Chris R. Peters, James E. Young
  • Patent number: 6066279
    Abstract: A method of gelcasting includes the steps of providing a solution of at least hydroxymethylacrylamide (HMAM) and water. At least one inorganic powder is added to the mixture. At least one initiator system is provided to polymerize the HMAM. The initiator polymerizes the HMAM and water, to form a firm hydrogel that contains the inorganic powder. One or more comonomers can be polymerized with the HMAM monomer, to alter the final properties of the gelcast material. Additionally, one or more additives can be included in the polymerization mixture, to alter the properties of the gelcast material.
    Type: Grant
    Filed: August 17, 1998
    Date of Patent: May 23, 2000
    Assignee: Lockheed Martin Energy Research Corp.
    Inventors: Claudia A. Walls, Glen H. Kirby, Mark A. Janney, Ogbemi O. Omatete, Stephen D. Nunn, April D. McMillan
  • Patent number: 6066367
    Abstract: The present invention provides a method for forming a pattern on a synthetic wood board to form, on a surface of the synthetic wood board, a pattern such as wooden grain and the like which is close to natural wood, to enhance the reality of woody like appearance. The synthetic wood board is formed by mixing 35-80 wt % of thermoplastic resin material and 20-65 wt %. By a first grinding process, the synthetic wood board is formed at its entire surface of at least one side thereof with a large number of wound stripes in one direction. By a colorant coating process, a colorant is coated on the surface on which said wound stripes are formed, the colorant impregnates in wood meal on the surface to generate blur. And some colorant remain in recess portion of the wound stripes to form recess pigment layer.
    Type: Grant
    Filed: September 25, 1998
    Date of Patent: May 23, 2000
    Assignee: Ein Engineering Co., Ltd.
    Inventor: Sadao Nishibori
  • Patent number: 6030562
    Abstract: A method of forming a consolidated wood product is disclosed wherein zinc borate and resin are mixed with cellulosic material to form treated cellulosic material, followed by applying heat and pressure to form a consolidated cellulosic product. A consolidated product comprises zinc borate, resin, and cellulosic material, wherein the zinc borate is distributed throughout the lignocellulosic material. A steam injection process is also disclosed.
    Type: Grant
    Filed: December 4, 1997
    Date of Patent: February 29, 2000
    Assignee: Masonite Corporation
    Inventors: Thomas A. Lehtinen, Thomas M. Ruffin, John Peter Walsh, Allen R. Hill
  • Patent number: 6010747
    Abstract: Optical diffusing structures can be fabricated from photopolymerizable material by directing light through a transparent or translucent substrate and then through the photopolymerizable material for a period of time sufficient to photopolymerize only a portion of the material. The resultant structure can be utilized as a diffuser, a viewing screen, and in other applications, and can be combined with other light-directing structures such as arrays of tapered optical waveguides.
    Type: Grant
    Filed: December 2, 1996
    Date of Patent: January 4, 2000
    Assignee: AlliedSignal Inc.
    Inventors: Karl Beeson, Scott Zimmerman, Jose Diaz, Mac Maxfield
  • Patent number: 5951730
    Abstract: Fused silica boules (19) having improved off-axis homogeneity are produced by controlling the air flow around the boule (19) during its formation. The boule is formed in a containment vessel (13) which collects soot from a plurality of burners (14). The containment vessel (13) rotates and oscillates relative to the burners (14) as the boule (19) is formed. Surrounding the containment vessel (13) is an air flow wall (130) which oscillates with the containment vessel (13). The air flow wall (130) is spaced from the containment vessel (13) by a gap (175) through which air flows during boule formation. The dimensions of this gap (175) remain constant as the boule is formed. Surrounding the air flow wall (130) is a stationary wall (160). The stationary wall (160) is spaced from the air flow wall (130) by a gap (165) whose dimensions change as the boule is formed. A motion accommodating seal (155) blocks air flow in this gap (165).
    Type: Grant
    Filed: May 1, 1998
    Date of Patent: September 14, 1999
    Assignee: Corning Incorporated
    Inventor: Paul M. Schermerhorn
  • Patent number: 5948507
    Abstract: Absorbent articles containing absorbent cores of fluff pulp frequently contain wrinkles in the absorbent core that run from side to side of the article, typically normal to the machine direction in the manufacturing process. Side-to-side wrinkles are deleterious in that they provide large flow channels for urine or other body fluids to escape to the edge of the article. Frequently, such wrinkles are present after manufacturing, before the article has been folded or worn. The cause of the wrinkles is believed to be due to natural instabilities during compression of the fluff pad shortly after it is formed. Means for reducing cross-directional wrinkles include the use of grooved, drilled, or patterned compression rolls to densify the fluff pulp while providing opportunities for reduced in-plane displacement during compression or, if in-plane displacement does occur, providing paths for cross-directional displacement as well as machine-direction displacement so that continuous CD wrinkles cannot form.
    Type: Grant
    Filed: July 13, 1998
    Date of Patent: September 7, 1999
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Fung-jou Chen, Jeffrey Dean Lindsay
  • Patent number: 5945050
    Abstract: A method for fabricating a sintered oilless bearing using a correcting rod having a projection correcting portion and a groove forming portion having outer diameters respectively identical to inner diameters of projections and grooves to be formed into the oilless bearing. An upper punch is inserted into the upper portion of the correcting rod for pressing the sintered oilless bearing to allow the inner periphery of the sintered oilless bearing to closely contact the groove forming portion and, simultaneously, fit into the projection forming portion.
    Type: Grant
    Filed: November 24, 1997
    Date of Patent: August 31, 1999
    Assignee: Samsung Electro-Mechanics Co., Ltd.
    Inventor: Dae Hyun Jeong
  • Patent number: 5916507
    Abstract: A method of constructing multi-layer products for absorbing fluids is disclosed. In the methods of the present invention, two or more layers of materials chosen to vary in recovery are compressed such that an absorption gradient forms through the continuous intimately associated layers. A first layer preferably remains densified while a second layer "blooms" to form an open, absorptive layer, which acts as a reservoir, drawing absorbed fluids into the densified layer, where they are retained.
    Type: Grant
    Filed: November 7, 1994
    Date of Patent: June 29, 1999
    Assignee: McNeil-PPc, Inc.
    Inventors: Shmuel Dabi, Kays Chinai
  • Patent number: 5911926
    Abstract: A porous material of a polytetrafluoroethylene (PTFE), which can retain at least 90% of 0.109 .mu.m latex spheres and has a flow rate (IPA flow rate) of at least 0.6 ml/cm.sup.2 /min as measured with isopropyl alcohol under a differential pressure of 1 kg/cm.sup.2. A process for the production of a porous material of PTFE, which comprises, after forming a molded article from fine powder of PTFE by paste extrusion, (1) sintering the molded article, (2) rolling up the molded article thus sintered and heat-treating it at a temperature lower than the melting point of the polytetrafluoroethylene in a state as rolled up, and then (3) stretching the molded article thus heat-treated in at least an uniaxial direction. The porous material of PTFE according to the present invention has micropores and good permeability and particularly is excellent in performance of retaining fine particles.
    Type: Grant
    Filed: January 3, 1995
    Date of Patent: June 15, 1999
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Akira Harada, Atsushi Uno, Shousuke Yamanouchi, Akira Nishimura
  • Patent number: 5897738
    Abstract: A process for preparing a sign that includes the steps of providing a sheet of material; defining on a surface of the sheet a series of image-bearig areas and non-image-bearing areas; treating the surface of the sheet with an essentially solvent-free composition comprising a colorant and a polymeric binder to selectively deposit the composition on the non-image-bearing areas of the surface of the sheet; and fusing the composition to create a continuous polymer film on the non-image-bearing areas.
    Type: Grant
    Filed: May 20, 1997
    Date of Patent: April 27, 1999
    Assignee: Minnesota Mining and Manufacturing Company
    Inventors: Sundar J. Rajan, Joseph M. McGrath
  • Patent number: 5887402
    Abstract: A core component is shaped to compensate for varying widths and depths of the shell or framing of a building or structural member. The component includes two major surfaces defining respective front and rear sides of the component, and the rear side of the component is preferably the mirror image of the front side. The core component is preferably pre-formed and provided in a space or void on the interior of building or structural members, e.g., two prefabricated molded doorskins. The core component is preferably made from a composite soft board material. Processes for the production of a core component and a building member such as a composite door product are also disclosed.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: March 30, 1999
    Assignee: Masonite Corporation
    Inventors: Mark A. Ruggie, Steven K. Lynch, Keith S. Fischer, James J. Pelletier, John B. Stukenborg
  • Patent number: 5866060
    Abstract: The method and apparatus for making a preform which is a rigid shaped item formed of glass fibers rigidly joined to each other where adjacent fibers touch. The interstices between the fibers are unfilled for the use of matrix resin to subsequently form a molded article. The preform is formed by shaping fibers into the preform shape, applying a binder to the fibers so that they are coated at the locations where they touch. The binder is sensitive or responds to the application of electromagnetic energy. In completing the preform after the application of the binder, the preform is subjected to electromagnetic energy so that the binder hardens to form a rigid preform. In one species form, the electromagnetic energy is applied in the form of microwave energy. The application of electromagnetic energy causes a reaction in the binder without requiring heating of the glass fibers so that the preforms can be rigidified rapidly and efficiently.
    Type: Grant
    Filed: March 10, 1995
    Date of Patent: February 2, 1999
    Assignee: C. A. Lawton Company
    Inventor: Daniel T. Buckley
  • Patent number: 5855832
    Abstract: A high density fiber product is made from natural lignin containing plant fibers. Plant fibers ranging in size below about 3000 microns in diameter are used. Binding agents and other additives may be mixed with the fibers to enhance product or process performance. The plant fibers or mixture of fibers and additives are heated to between about 50 degrees C. to about 140 degrees C. The heated fibers are compressed in a mold to an average density of about 50 pounds per cubic foot to about 100 pounds per cubic foot. Compression pressures of about 500 psi to about 2500 psi are used to achieve product densities within this range. The compressed fibers are cured under these temperature and pressure conditions. After the curing time has elapsed, the compressed fiber product is released from the mold and the mold may be reused. A high density product made from small plant fibers is provided.
    Type: Grant
    Filed: June 27, 1996
    Date of Patent: January 5, 1999
    Inventor: Robert N. Clausi
  • Patent number: 5817400
    Abstract: Absorbent articles containing absorbent cores of fluff pulp frequently contain wrinkles in the absorbent core that run from side to side of the article, typically normal to the machine direction in the manufacturing process. Side-to-side wrinkles are deleterious in that they provide large flow channels for urine or other body fluids to escape to the edge of the article. Frequently, such wrinkles are present after manufacturing, before the article has been folded or worn. The cause of the wrinkles is believed to be due to natural instabilities during compression of the fluff pad shortly after it is formed. Means for reducing cross-directional wrinkles include the use of grooved, drilled, or patterned compression rolls to densify the fluff pulp while providing opportunities for reduced in-plane displacement during compression or, if in-plane displacement does occur, providing paths for cross-directional displacement as well as machine-direction displacement so that continuous CD wrinkles cannot form.
    Type: Grant
    Filed: November 27, 1996
    Date of Patent: October 6, 1998
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Fung-jou Chen, Jeffrey Dean Lindsay
  • Patent number: 5811176
    Abstract: A method of making a substantially lattice-like composite material having a large percentage of open spaces comprises the steps of disposing generally elongate and flexible strips in a randomly-oriented chaotic mass; atomizing a liquid bonding substance into the mass; carrying out a mass-forming process involving volume reduction to make a lattice-like structure of a large percentage of open spaces, in a desired shape; hardening the bonding substance. Thus a substantially lattice-like material having a high percentage of open spaces is achieved, which is formed of a plurality of generally elongate and flexible strips disposed in a randonly-oriented chaotic mass, the strips being bonded to each other at discrete points in the mass. This material can be manufactured to advantage starting from waste materials, such as paper and wood chips, and it can be formed into sheets and panels of flat shape or of different conformations to make packages and the like.
    Type: Grant
    Filed: June 12, 1996
    Date of Patent: September 22, 1998
    Inventor: Giuseppe Locati
  • Patent number: 5811175
    Abstract: A method of manufacturing an injection molded object having an outer shell with a front face and a light transmitting assembly molded into the outer shell which assembly is visible from the front face. The method includes the following steps. Supporting a light transmitting assembly on a mold projecting tool which is closable with a mold cavity tool having an interior wall which defines the front wall of the outer shell. Forming narrow passages through the light transmitting assembly to connect its front and rear faces. Closing the mold to position the front face of the light transmitting assembly adjacent the interior wall of the mold cavity tool while leaving a narrow peripheral recess therearound in communication with the narrow passages.
    Type: Grant
    Filed: June 19, 1997
    Date of Patent: September 22, 1998
    Assignee: The Grigoleit Company
    Inventor: Robert K. Howie, Jr.
  • Patent number: 5807513
    Abstract: The invention relates to a method for the recycling of trim components of vehicles. The method comprises the steps of shredding manufacturing scrap and post-consumer scrap from vehicle headliners into small particles to produce fluff. This fluff is then combined with water and a binder reagent composed of either polyisocyanates, or polyisocyanates combined with various polyols. The solution of fluff, binder reagent and water are mixed, and then placed in a mold where the mixture is formed into a pre-preg sheet. Subsequently, the pre-preg sheet is subjected to compression molding at elevated temperatures to produce a finished composite trim panel. As part of the final compression molding step, a decorative coverstock can be included to produce a finished trim panel having a decorative cover.
    Type: Grant
    Filed: July 8, 1997
    Date of Patent: September 15, 1998
    Assignee: UT Automotive Dearborn, Inc.
    Inventors: Girma Gebreselassie, Harold G. Wolf, Jr., Kurt C. Frisch, Daniel Klempner, Vahid Sendijarevic
  • Patent number: 5766395
    Abstract: A molded, self-supporting, composite part or panel for automotive and similar applications comprises a vapor impervious wood fiber filled polymeric (preferably polypropylene) sheet adhered to one major face of a corrugated paperboard medium and a layer of fibrous insulation (preferably glass fiber) or a second wood fiber filled polymeric sheet adhered to a second major face of the corrugated paperboard medium. The sheet and corrugated medium provide the structural strength for the composite and the fibrous insulation, when used, provides the composite with good sound absorption properties. The wood fiber filled polymeric sheet is formed during the molding process from a wood and polymeric fiber sheet. The heat and pressure of the molding process cause the polymeric fibers to melt and flow about the wood fibers to form the wood fiber filled sheet and bond the sheet securely to the corrugated medium.
    Type: Grant
    Filed: August 28, 1995
    Date of Patent: June 16, 1998
    Assignee: Johns Manville International, Inc.
    Inventors: David William Bainbridge, Mario Peter Tocci, Larry Maxwell Bauman
  • Patent number: 5756024
    Abstract: A method for manufacturing a container from husk includes the steps of comminuting the husk into powder form, mixing the powder with an edible adhesive, with the introduction of steam, to form a paste, forming a blank from the paste, shaping the blank into a primary semi-product, re-shaping the primary semi-product to force the paste to flow and fill into cracks formed on the primary semi-product during the shaping step to form a secondary semi-product, drying the secondary semi-product and applying a surface coating to the dried product and then drying the surface coating.
    Type: Grant
    Filed: August 14, 1996
    Date of Patent: May 26, 1998
    Inventor: Fu Ming Huang
  • Patent number: 5753308
    Abstract: Containers use in the storing, dispensing, packaging, and/or portioning of food and beverage products. The disposable and nondisposable food and beverage containers are manufactured from aggregates held together by organic binders in order to be lightweight, insulative, inexpensive, and more environmentally compatible than those currently used for storing, dispensing, packaging, or portioning such products. The food and beverage containers of the present invention are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrices of the food and beverage containers include a hydrated organic binder paste (formed by mixing the binder with water) in combination with appropriate aggregate materials, such as fibers to add flexibility and strength, glass spheres to make the product more lightweight and insulative, or clay to make the product extremely inexpensive yet strong.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: May 19, 1998
    Assignee: E. Khashoggi Industries, LLC
    Inventors: Per Just Andersen, Simon K. Hodson
  • Patent number: 5735982
    Abstract: An environmentally sound vegetation growth-enhancing erosion control blanket is formed from an elongated rectangular excelsior/wood wool mat. The mat is held together with adhesive and a surface pattern is embossed therein. When the finished blanket is placed atop the ground, the blanket serves to shield the earth area from wind and water erosion forces, without the presence of the plastic netting often used in the prior art. As the ground vegetation grows, it ultimately replaces the blanket which decomposes and furnishes the ground vegetation with a nutritive mulch.
    Type: Grant
    Filed: March 10, 1995
    Date of Patent: April 7, 1998
    Assignee: American Excelsior Company
    Inventors: Timothy Prunty, Wendell E. Johnson, deceased, by John W. Johnson, legal representative
  • Patent number: 5730918
    Abstract: Filter material in the form of activated charcoal compacts useful for selectively separating an organic phase from an inorganic phase, is prepared by a process comprising the following steps.A. Homogeneously blending activated charcoal particles having a particle size distribution of 1-100 .mu.m with psuedoboehmite-configured aluminum oxide in a weight ratio of 1:1 to 5:1;B. Adding distilled water to the homogeneous mixture while thoroughly mixing the same;C. Adding dilute acetic acid to the aqueous mixture while thoroughly mixing the same;D. Adding more distilled water to the mixture;E. Compacting the resulting mixture into tablets or similar objects in a mold under pressure, andF. Successively heating the resulting molded objects first at 80-100.degree. C. for 6 to 10 hours, then at 140.degree.-160.degree. C. for 8 to 10 hours, and finally at 180.degree.-200.degree. C. for 6 to 10 hours.
    Type: Grant
    Filed: August 5, 1996
    Date of Patent: March 24, 1998
    Assignee: MST Micro-Sensor-Technologie GmbH
    Inventors: Elena J. Nikolskaja, Natalia W. Maltzeva, Elena W. Loseva, Evgenia B. Koroljeva
  • Patent number: 5702657
    Abstract: Disclosed is a method for the continuous production of a polyethylene material having high strength and high modulus of elasticity by rolling an ultra-high-molecular-weight polyethylene film or film like material and then drawing the rolled material, wherein a thermoplastic resin film having incorporated therein at least one additive selected from the group consisting of a coloring agent, a weathering stabilizer, an antistatic agent, a hydrophilicity-imparting agent, an adhesion promoter and a dyeability-imparting agent is laminated to the film material in the rolling step and the resulting polyethylene material is further slit or split as required. This method makes it easy to color the polyethylene material having high strength and high modulus of elasticity and to impart weather resistance and other desirable properties thereto.
    Type: Grant
    Filed: December 26, 1995
    Date of Patent: December 30, 1997
    Assignees: Nippon Oil Co., Ltd., Polymer Processing Research Institute Ltd.
    Inventors: Sumio Yoshida, Takashi Komazawa, Kazuhiko Kurihara, Hiroshi Yazawa
  • Patent number: 5670228
    Abstract: A tile having a desired pattern is provided. The pattern goes through the tile in the thickness direction. For manufacturing such a tile, e.g. a partition plate 84 is disposed in a pressure forming die 91 so as to divide its inside space into an outer forming space 95 and an inner forming space 96. Light black granules and light red granules are filled respectively in the outer and inner forming spaces 95, 96. Then, the partition wall 84 is taken out from the die 91, and lining granules are filled over the colored granules. Thereafter, they are pressed into one body and burned.
    Type: Grant
    Filed: November 3, 1995
    Date of Patent: September 23, 1997
    Assignee: Mino Ganryo Kagaku Corporation
    Inventors: Yoshinori Kakamu, Shinichi Kakamu, Shukichi Kakamu
  • Patent number: 5660908
    Abstract: A recyclable automotive headliner consists 100% of polyethylene terephthalate (PET) material and includes reverse ribs of varying density of PET fibers filled with reinforcements of full density PET material. A method of manufacturing such headliners includes forming the reverse ribs in the PET fibers and either preforming the full density reinforcements and bonding them between the ribs or forming the ribs and then injecting molten full density PET material therebetween.
    Type: Grant
    Filed: March 22, 1996
    Date of Patent: August 26, 1997
    Assignee: Davidson Textron Inc.
    Inventors: Josh Kelman, Richard D. Rhodes
  • Patent number: 5656561
    Abstract: A composite and pressureless sintering process for making whisker-reinforced alumina composites using about 1 to about 7.5 wt. % of a nitride modifier consisting essentially of silicon nitride, aluminum nitride, or mixtures thereof that produces a sintered body having a density of greater than 95% theoretical.
    Type: Grant
    Filed: November 24, 1994
    Date of Patent: August 12, 1997
    Assignee: Advanced Composite Materials Corporation
    Inventors: William M. Rogers, James F. Rhodes
  • Patent number: 5624518
    Abstract: A housing lining for a piston engine, drive motor, or machine composed of a sound-absorbent layer of fibers. The fibers are compressed and glued to form an essentially pore-free supporting frame at least in the vicinity of the edge of the layer.
    Type: Grant
    Filed: June 1, 1995
    Date of Patent: April 29, 1997
    Assignee: Firma Carl Freudenberg
    Inventors: Reinhard Stief, Roger Schork, Gerhard Muller-Broll, Thomas Jost, Manfred Mattutat, Klaus-Dieter Schmitt
  • Patent number: 5601770
    Abstract: A method for producing SMC where a multilayered, multistructured, multipolymer release/barrier film is used as a polymeric film. The multilayered, multistructured, multipolymer release/barrier film is preferably produced by multilayered cast extrusion process. The tensile strength of the multilayered, multistructured, multipolymer release/barrier film should not be less than 8000 psi when tested to ASTM D882. Preferably, the film should inhibit styrene transmission at a rate no less than 2.0.times.10.sup.-11 g. cm/cm.sup.2 -hr. as tested per ASTM F739-81 and a surface tension level not to exceed 30 dynes/cm when tested in accordance with ASTM D2578.
    Type: Grant
    Filed: September 29, 1995
    Date of Patent: February 11, 1997
    Assignee: Airtech International, Inc.
    Inventor: John D. Maligie
  • Patent number: 5578258
    Abstract: An insulation assembly and method of making is disclosed. A fiber pack is engaged along its side edges to tuck the fibers inwardly and also establish a desired width. The insulation assembly has the longitudinally extending tucks along each of its side edges and each of the side edges has a generally concave cross section.
    Type: Grant
    Filed: June 5, 1995
    Date of Patent: November 26, 1996
    Assignee: Owens Corning Fiberglas Technology, Inc.
    Inventors: Larry J. Grant, Raymond V. Monnin, James W. Scott
  • Patent number: 5569419
    Abstract: This invention relates to a continuous flow process of mold making or die making using a reusable bondable mixture substance to make selected finished products.
    Type: Grant
    Filed: August 12, 1994
    Date of Patent: October 29, 1996
    Assignees: Stephen E. Brenot, Arnold G. Althoff, Randy M. Schneider
    Inventors: Stephen E. Brenot, Arnold G. Althoff
  • Patent number: 5540875
    Abstract: A system and a method for manufacturing plastic structures using ultra-violet curable plastic materials is provided. Specifically, the present invention applies a resin layer to a conveyor belt. The resin layer is then warmed and various types of reinforcing elements are added. The conveyor belt with the resin layer is then passed through a forming apparatus where a predetermined shape is imparted to the layer. The predetermined shape become permanent as the resin layer is exposed to ultra-violet radiation which cures and hardens the resin layer. The completed structure is then extracted from the process.
    Type: Grant
    Filed: February 16, 1995
    Date of Patent: July 30, 1996
    Inventor: Rafael R. Rubio
  • Patent number: 5532050
    Abstract: A densified batt comprising a mixture of low melting and high melting synthetic fibers or high melting synthetic fibers coated with a low melting material formed by building up the fibers into a batt of unbonded fibers of substantial height, compressing the unbonded fibers to the extent that the batt has a height of at most one-third the height when not compressed, heating the compressed batt to bond the fibers together, and cooling the heated compressed batt while still compressed to provide the densified batt. The batting being in a single layer and uniform throughout can be readily fabricated into cushioning or the like having controlled characteristics.
    Type: Grant
    Filed: June 30, 1986
    Date of Patent: July 2, 1996
    Assignee: Wm. T. Burnett & Co., Inc.
    Inventor: Troy L. Brooks
  • Patent number: 5503920
    Abstract: Fiberglass insulation having improved parting strength is prepared by forming a fiberglass mat, applying an aqueous acid aluminum phosphate binder, curing the binder, and autoclaving the resultant insulation batt.
    Type: Grant
    Filed: December 27, 1993
    Date of Patent: April 2, 1996
    Assignee: Owens-Corning Fiberglass Technology, Inc.
    Inventors: Roberta L. Alkire, Michael E. Evans, William S. Miller
  • Patent number: 5494627
    Abstract: A process to form a body of thermoplastic polymeric fibers and improve the body's resistance to permanent deformation. The vehicle seat component of this invention is compressed twice at progressively greater pressures during the molding process in order to break and reform the bonds between the polymeric fibers.
    Type: Grant
    Filed: October 17, 1994
    Date of Patent: February 27, 1996
    Inventors: James A. Kargol, Neil J. Bush, Steven M. Winoker, Gregary A. Haupt, Ming Y. Kao
  • Patent number: 5492662
    Abstract: An improved method of making a more comfortable and easily recyclable body for a vehicle seat component using thermoplastic polymeric fibers is described. This method produces a body of thermoplastic polymeric fibers consisting of zones of different densities.
    Type: Grant
    Filed: October 17, 1994
    Date of Patent: February 20, 1996
    Inventors: James A. Kargol, Gregary A. Haupt
  • Patent number: 5468437
    Abstract: A process is provided for producing a fiber reinforced thermoplastic sheet. The process involves the steps of forming a dilute aqueous slurry of organic polymer particulates and reinforcing fibers, collecting the particulates and fibers in the form of a continuous mat by dewatering the slurry over a porous substrate, applying a stabilizer composition to a surface of the solid mat, stamping of the mat at an elevated pressure and temperature to consolidate the organic polymer particulates and yield a solid sheet-like structure. The process provides for efficient application of the stabilizer composition by applying it to the mat separately from the formation of the slurry, and in the case of ultraviolet light stabilizers and absorbers, the process applies the stabilizers to the surface of the mat where they are most needed.
    Type: Grant
    Filed: January 18, 1994
    Date of Patent: November 21, 1995
    Assignee: General Electric Company
    Inventor: Walter L. Hall