Abstract: A method for forming a fiber web and fibrous web useful for compression molding stiff, board-like structural substrates for panels is formed of a thoroughly intermixed blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.

Abstract: An improved, continuous airlaying apparatus for making airlaid articles such as discrete absorbent fibrous cores for catamenial napkins and disposable diapers and the like having high structural integrity, and good edge definition. The articles are airlaid in discrete cavities as they pass through a deposition zone of the apparatus, and are compacted a predetermined amount prior to their being removed from their respective deposition cavities. An exemplary mechanism for effecting the compacting comprises a lugged cylinder having circumferentially spaced lugs which are configured and pitched to mesh in a quasi gear-like manner with the deposition cavities.

Abstract: Superabsorbent articles in the form of soft, nonwoven fibrous webs are produced from aqueous fiber-forming polymer solutions by forming the polymer into water soluble filaments, contacting the filaments with a primary air stream having a velocity effective to attenuate and to partially dry the filaments, contacting the attenuated filaments with a secondary air stream having a velocity effective to fragment the filaments into fibers and to transport the fibers to a web-forming zone while also further attenuating and drying the fibers, collecting the fibers in reticulated web-form in the web-forming zone and curing the web to a water insoluble state. The temperature and air stream velocities are controlled with respect to ambient humidity and water content of the fiber during the fiber and web formation such that the fibers are collected without sticking. Collection is preferably on a wire belt followed by transport through a curing oven to compacting rolls and web take-up.

Abstract: A preform for being embedded in a matrix material for making a composite material is made essentially of many short fibers stuck together by a quantity of dried binder. This preform has a first portion in which the fiber volume proportion is relatively high, a second portion in which the fiber volume proportion is relatively low, and a third portion, joining between the first portion and the second portion, in which the fiber volume proportion changes substantially continuously from its portion adjoining to the first portion to its portion adjoining to the second portion. Thereby, the characteristics of the composite material, such as its strength, heat and wear resistance, and machinability and workability and characteristics with respect to wear on a mating member, alter smoothly from the first portion to the second portion without any severe discontinuity, thus ensuring that no points of weakness are caused.

Abstract: A thin, plate-shaped object, especially a door skin, and a method of manufacturing such object, comprising a resin impregnated outer layer arranged directly onto a layer of a binder impregnated wood fine chips layer acting as a forming support for the fibre sheet material.A layer of coarse wood chips acts as a reinforcing and handling characteristics defining layer for the relatively large (some m.sup.2) and relatively thin (2 to 5 millimeteres) door skin.

Abstract: In a method for producing shaped synthetic members, one begins with superficially plasticized synthetic granulated material in manner known per se. This is sintered to form a preform in a first operation in a preliminary chamber. The preform is then extruded by way of a narrow nozzle into a moulding cavity, the nozzle cross section being so narrow that on the way between the preliminary chamber and the moulding cavity, the individual granular particles must be deformed mechanically. The moulding cavity is then filled by one or more thin strands, which consist of solid, but mechanically deformed and superficially plasticized granulated particles.

Abstract: Method and apparatus for producing high modulus products. A polymer morphology or powdered metal is solid-state deformed under pressure through the rollers of an extrusion rolling die, at a temperature near but below its crystalline melting point, while controlling the extrusion rate and the rate of rotation of the rollers so that the rate of extrusion of the polymer or metal is substantially the same as the rate of rotation of the rolling die surface.

Abstract: In a process for the production of smooth surfaced parts, a paste material, which includes paste or granule pieces which are coated with added pigment and then pressed back together, is applied, in the form of an extrusion or a coating, to a substrate. The extrusion or coating is subjected to a first, incomplete hardening, after which it is no longer flows freely under its own weight. The surface layer, containing added pigment, is then removed from a surface to be used. This surface is subsequently smoothed, and the hardening of the coating to form a hard material is completed. The smoothing and the completion of the hardening can occur in the same processing step as a shaping for the formation of separable shaped parts. The substrate can be inseparable from the hardened coating. The surface layer, containing added pigment, can be removed by mechanical means, solvents or abrasion by a suspension in liquid or air, if appropriate in the presence of ultrasound.

Abstract: A method of and device for imprinting the upper surface of a container that has a closure at its upper surface, especially of a bottle with a head that is wrapped along with its cap all the way around with a blank, especially of foil, by applying the blank around the head while leaving part of the blank to project beyond it, wrapping the sleeve-shaped extension to one side against the upper surface of the cap, and pressing it down with a resilient pad. The disk is embossed at the upper surface, the blank of foil is pressed down with the resilient pad, forcing foil into the embossed areas, and the raised areas of the embossing are then burnished with a hard pressure-application component.

Abstract: To produce doors or other panel elements within the appearance of an infilled panel type, the panelling pattern is achieved through a simple relief pressing of a thin covering plate member which is mounted on a carrier frame work. The covering plate member, coated by a veneer or paper, is produced from wood fiber or a chip mass which is pressed and heated only to the extent that the plate material becomes leather-like, that is, without the incorporated binding agent being hardened. By the relief pressing of the covering plate, heat is supplied in such a manner that the binding agent hardens after the final deformation pressure has been applied, whereby a stable final product is obtained in a simple and inexpensive manner.

Abstract: A molded article, for example, a filter or a preform used in the manufacture of fiber-reinforced composites, is manufactured from an air laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into the desired shape of the molded article in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting article retains the desired shape. If the article is to be used as a fluid filter, it can be used either as it is removed from the mold if a filter of uniform density is desired, of the article can be further processed in a compression mold to densify portions of the article to thereby form, for example, a fluid impervious portion used as a gasket. If the article is to be used as a preform for a structural composite, it is then to be transferred to a resin injection mold.

Abstract: The process serves essentially for the thermal bonding of lightweight nonwovens. For this purpose, the nonwoven is heated up by means of air penetration on a sieve drum of a flow dryer to a high percentage of the bonding temperature, and immediately thereafter is embossed with internally heated rolls in the squeeze roll nip of a calender. The apparatus provided for conducting the process consists of a sieve drum device wherein the embossing calender is arranged.

Abstract: A method for molding articles such as pallets from flake-like wood particles mixed with binder, the pallets housing a deck and integral molding legs. A loosely fitted mat of wood flakes is formed by depositing a first plurality of layers of wood flakes onto a supporting surface with a flake aligners provided for causing alignment of those flakes which will form legs of the pallet. A second plurality of layers are formed with a flake aligner provided for causing alignment of flakes which will form the legs of the pallet and in a direction transverse to the direction of alignment of the flakes of the first layers.

Abstract: A process and apparatus for producing a dry-pressed molding from a particulate or granular molding material such as a ceramic molding composition in which the composition is initially drawn into a loading cavity by applying a vacuum thereto. The loading cavity is formed by a first mold half and a shooting head having a molding surface the shape of which determines the shape of a premolding which is formed upon entry of the composition into the loading cavity and sufficiently compressed to retain its shape after the shooting head has been removed to allow a second mold half to be positioned over the first mold half.

Abstract: A fibrous web comprising fibers which have been differentially cooled to provide a crimped fiber conformation thereto and then thermally relaxed to a sufficient degree to at least partially decrimp the fibers and increase the loft and decrease the density of the web. Also disclosed is a process for forming a web of such type, comprising the steps of forming a web of fibers, bonding the fibers to form a bonded web, differentially cooling the fibers to provide a crimped fiber conformation thereto, and thermally relaxing the fibers to a sufficient degree to at least partially decrimp the fibers and increase the loft and decrease the density of the web, wherein the differential cooling step preferably is carried out prior to bonding of the fibers to form the bonded web and the thermal relaxing step is carried out after bonding of the fibers to form such web.

Abstract: A fluid filter is formed by manufacturing an air laid batt containing randomly disposed structural fibers and a thermoplastic binder fiber. The interstices between the fibers are fixed by applying a latex resin to the batt, thereby fixing the pore sizes of the filtering media before the filtering media is molded. The filtering media is then molded into shape by using a plunger to tuck the media into an open cavity mold. The mold may be heated and pressure may be applied to the batt to mold the batt.

Abstract: The invention relates to a method for the individual marking of precooked anodes used in the production of aluminum by electrolysis in the Hall-Heroult process, and to the anodes produced thereby. These anodes are produced by hot compaction of a carbonaceous paste, and according to the invention, during or immediately after such compaction, a plurality of impressions is formed in the upper part of each anode. The impressions are depressions and/or relief portions, constitute a digital coding for the identification number of each anode, and remain legible until withdrawal of the components of the butt of the worn anode from the electrolysis tank. The marking can be carried out using a binary or ternary code, where the reference plane of the zone of the anode which carries the marking corresponds to a first digit, with other digits corresponding to depressions of a particular depth, depressions of a greater depth, or relief portions.

Abstract: A sculptured structural fiberboard product is formed using a mold that includes porous forming areas which, in one embodiment, are porous forming mandrels movably mounted on the mold, and liquid impervious thimbles which removably cover the porous areas. A fiber network is formed as water is drained off through the porous areas and the thimbles are moved to gradually unveil the porous areas during the mat formation. When mandrels are used, the mandrels are withdrawn in cooperation with a pressing force applied to the mat to consolidate and dry the web. The porous areas can also act as heat and mass transfer means during consolidation and drying. An alternative embodiment permits formation of laminated products and another alternative embodiment permits close control over the product density during consolidation and drying.

Abstract: In a graphite material comprising a mass of expanded graphite particles compressed together so as to form a graphite foil, the graphite foil is provided with a plurality of apertures disposed on at least one surface thereof so as to substantially prevent formation of bubble-like deformations which occur when the graphite foil is heated and/or placed in a vacuum. The method of making the invented foil and devices used to make said foil are also disclosed.

Abstract: The process for making a dimensionally stable, embossed, ornamented surface covering suitable for use as a floor or wall tile, involving, laminating and embossing a resinous thermoplastic top layer having a plurality of openings extending through its thickness to allow the escape of air and extending to a base material or substrate of pre-formed, low-density, reinforced, porous thermoplastic material. The composite structure is subjected to heat and pressure in a flatbed press to emboss the structure without deformation, fuse the resins and render the top layer substantially impermeable. The improvement comprises the use of a rigid vinyl wear layer in a two step embossing operation involving a first embossing step in a heated press and immediately thereafter a second embossing step in a cooled press.

Abstract: A process for producing an improved ceramic fiber molding by submersing the molding into a suspension containing colloidal silica and/or colloidal alumina and chromium oxide powder. The chromium oxide is deposited onto the ceramic fibers thereby increasing the molding's resistance to linear shrinkage and corrosion when subjected to high temperatures.

Abstract: A method of forming a fibrous web useful for compression molding stiff, board-like structural substrates for panels by thoroughly intermixing a blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.

Abstract: The invention generally provides for formation of meltblown material containing wood fiber on to a continuous foraminous belt. During formation a polymer and wood fiber first layer is applied to a moving belt from at least one bank of meltblown forming apparatus. This first layer does not contain superabsorbent. The belt carrying the first layer passes beneath at least one further source of meltblown fiber into which superabsorbent is added along with the wood fibers. This provides at least one additional layer integrally connected to the first-formed layer and having superabsorbent properties. The first layer acts to aid in trapping of any superabsorbent which is not immediately entangled in the meltblown and wood fibers and prevents it passing through the forming belt.

Abstract: The invention relates to a polygranular carbon member of granular or, respectively, pulerulant and/or fibrous carbon particles as filler materials and of a binder, which has been subjected to a thermal treatment for consolidation of the binder, as well as to a method of producing such a carbon member. That kind of a carbon member is to be dimensionally stable, self-supporting and rigid also in the case of extremely low wall thicknesses and relatively large surface area dimensions, and it is to be able to be produced economically.

Abstract: Particulate mats are transported from the downstream end of an upstream conveyor normally moving continuously in a longitudinal transport direction at a predetermined relatively slow speed to a press downstream in the direction from the upstream conveyor that receives the mats and presses them into hard panels by supporting the mats between the upstream conveyor and the press on a downstream conveyor having an upstream end spaced downstream from the downstream end and a downstream end at the press and an intermediate conveyor extending between the upstream end of the downstream conveyor and the downstream end of the upstream conveyor and having a length in the direction at least equal to that of each of the mats in the direction. A carriage supporting the downstream end of the upstream conveyor, the intermediate conveyor, and the upstream end of the downstream conveyor is reciprocated in the direction at a frequency related to mat size and speed.

Abstract: A dry-formed web is transferred at speeds in excess of 300 feet per minute onto a stable, porous, endless belt and both the dry-formed web and the belt are conveyed through the embossing nip. The combination of the dry-formed web and the belt are guided into the embossing nip so that the web and belt partially wraps the embossing roll before entering the embossing nip. As the embossing roll contacts the web, some of the air in the web is forced through the porous belt.

Abstract: A platen assembly is provided having a working surface which can be mechanically converted between planar and corrugated configurations. A mat of wood wafers coated with thermosetting resin binder is deposited between upper and lower, spaced apart platen assemblies of this type. The platen assemblies, in the planar configuration, are then pressed together to a limited extent to pre-compress the mat to fix the wafers. Horizontal force is then applied to the platen assemblies to convert them to the corrugated configuration, with the pre-compressed mat retained therebetween. The mat is therefore forced to adopt a corrugated form. The platen assemblies are then further pressed together and heated, to cure the resin and produce a corrugated wafer board panel.

Abstract: A scarfing method and apparatus are disclosed for making a longitudinally and transversely contoured batt on a moving fibrous web. The apparatus comprises a scarfing roll disposed on one side of a foraminous belt and a contouring roll, having a nonuniform surface, disposed on the opposite side of the belt. As the contouring roll is rotated, it raises the belt and the fibrous web towards the scarfing roll, according to the shape of the nonuniform surface. Hence, a contour is provided in the direction of movement of the web. The transverse contour can be provided by the shape of the scarfing roll itself.

Abstract: A fiber reinforced, composite article is manufactured by forming a nonwoven, air-laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into a preform having the desired shape in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting preform retains the desired shape and is sufficiently stiff to withstand the pressure of the injected resin. The preform is then transferred to a resin injection mold, where the interstices between the fibers are saturated with an appropriate resin matrix. As the fibers of the preform are saturated (or after a saturation but before the resin sets) the resin transfer mold is compressed, thereby forming the preform into its final desired thickness and increasing the concentration of the fibers to give the preform appropriate strength.

Abstract: A process for producing fibrous material moldings surface-coated with a decorative sheeting is described. Cellulose and/or lignocellulose fibers are mixed with binders and are compressed by single-stage or multistage moldings, so that the decorative sheeting covering the finished molded surface is used as a supporting sheet for the non-woven fabric to be shaped. The fibrous material mixture is placed on the side of the decorative sheeting provided with an adhesive, and thus, a mat fleece whose entire surface is joined to the decorative sheeting is produced therefrom. The adhesive between the decorative sheeting and the non-woven fabric can be an adhesive foam.

Abstract: A ribbed, porous tube suitable for use as a vascular graft prosthesis is prepared by scoring a stretched or unstretched tube of PTFE, stretching the tube at 200.degree.-320.degree. C. to develop the desired porosity, and heat setting the scored, stretched tube at 327.degree.-450.degree. C. while restraining the tube from axial shrinkage.

Abstract: In an arrangement for and a method of producing shaped parts of a non-swellable mixture of fibers and heat-hardenable resin, a pressing mass divider is introduced into lower pressing tool during filling of the mixture.

Abstract: A strong, durable nonwoven fabric comprising polyester and/or polyolefin fibers arranged in a pattern of high density, lightly entangled fiber regions. Distributed throughout the fibers is an adhesive binder material to provide the final fabric with improved strength characteristics.Entangled nonwoven fabrics are dry print bonded to produce nonwoven fabrics having an excellent combination of strength, softness and durability.

Abstract: A method of making panels of composite wood material in a wet process includes depositing a layer of wet composite wood material in a mat on a press wire screen mesh and moving the screen mesh to carry the mat into a pressing position between a pair of spaced apart pressure plates having generally matching, contoured facing surfaces for shaping the outer face and a smoothly contoured back face of the panel. The pressure plates are moved toward one another compressing the mat of wet material and biasing the supporting screen mesh to conform generally to the contour of one of the pressure plates. After a suitable time interval for molding, the pressure plates are moved apart and the press wire screen mesh is rewound on a roll to aid in separating the completed panel from the mesh. The finished panel is carried by the screen mesh away from the pressure plates for unloading as the screen is rolled up and the deformations formed in the screen during molding are flattened out as the screen is rewound on the roll.

Abstract: A method for the preformation of a cushion for a seat, characterized by feeding an aggregate of three-dimensional curled short-fiber filaments to conveyor means, causing said conveyor carring thereon said aggregate of filament to be advanced under a rotary member provided on the outer surface thereof with a multiplicity of raised needles and kept in rotation and allowing said needles to come into contact with said aggregate of filaments thereby scraping part of the filaments from said aggregate and giving to said aggregate of filaments a prescribed shape.

Abstract: A ceiling panel resistant to sag when exposed to a fire in a room comprising mineral wool fibers and lithium carbonate, or the fused decomposition product thereof.

Abstract: An improved process is disclosed for forming tiles that are embossed in register with a printed design. A printed design is first applied to a base coat and a wear coat is laminated over the design. Advantageously, the wear coat is applied to the printed web before it is heated for lamination. Before embossing occurs, the laminated product is cooled until partial setting occurs, and the embossing roll is sprayed with water in order to minimize the likelihood that the laminated product will adhere to the embossing roll. To avoid distorting the web during lamination and embossing, proper web tension is maintained by controlling the rotational speeds of the laminating drum and the embossing roll so that a desired ratio is preserved. The web is then cut into oversized tiles that shrink to size during annealing.

Abstract: The present invention relates to wood-like molded products of synthetic resin which are manufactured by mixing a synthetic resin material with a fine aggregate of cellulose base such as wood meal, chaffs, begasse and in which the internal residual stress which may cause deformation (for example, warping and twisting) of the products at the time or after molding is eliminated in advance to prevent chronological deformation. More particularly, it relates to a method of eliminating said residual stress by subjecting the molded products containing cellulose-base aggregate, especially the resinous skin layer thereof, to re-heating, curing and sanding or jetting treatments (sand blasting, shot peening, grit blasting) under predetermined conditions.

Abstract: To produce a panel of variable thickness, a stratified assembly of a layer of fibers containing a non-polymerized binder and at least one cover sheet is placed between the mold and mold-backing of a molding press. The stratified assembly is caused to conform to the interior surface of the mold or mold-backing by forcing the cover sheet against the mold or mold-backing interior. Hot air is blown into the fiber layer from the mold surface opposite the cover sheet, into at least the region that will correspond to the area of greater thickness. The direction of the heated air is reversed after a period of time, the blowing of the air being maintained and adjusted in order to secure polymerization of the binder. At the same time, the portions of the panel corresponding to areas of lesser thickness, generally the edges of an acoustical panel, are cured (the binder polymerized) by contact heating means.

Abstract: A method for producing a fibrous board having a decorative, textured surface comprising the steps of:(a) forming a wet mat of entangled mineral fibers;(b) pressure molding said fibrous mat while it is still wet to create a decorative textured surface thereon; and(c) drying said board.

Abstract: Hydrogen bonding between cellulosic fibriles can be improved in an air-laid process by injecting ammonia or organo-amine catalysts and steam into the cellulosic fibrile mass after such fibers have been reduced to fibrile form and prior to their dispersion in air to form a fibrous mat. Prior to and subsequent to the injection of the catalytic bearing steam, the fibers may be combined with other paper forming material, resins, additives and processed in an air-laid paper making process to form a felted fibrous product with a minimal amount of water content and with acceptable strength and density. Suitable catalysts include gaseous ammonia, ammonium hydroxide, or the organo-amines such as triethanol amine, methyl amine, ethyl amine, cyclohexyl amine, or aniline and the homologous series derivatives thereof.

Abstract: Disclosed is a polyamide film of low crystallinity suitable for use in the manufacture of sheet molding compound (SMC). The sheet is produced from a blend comprising a polyamide selected from the group consisting of polyepsiloncaprolactam, polyhexamethylene adipamide or mixtures thereof, and about 10 to 30 wt. %, based on the total weight of said blend, of a polyolefin compound, or copolymer thereof, such as ethylene-vinyl acetate copolymer. The film has a tear strength of at least about 400 grams in the longitudinal direction as measured by ASTM D-1004-66.

Abstract: Three dimensional molded articles suitable for use as fibrous surfaced panels for automobile trunk compartments and the like are produced by molding a heated non-woven web formed of a blend of relatively high melting fibers and relatively low melting thermoplastic fibers. The low melting fibers form a multiplicity of bonds which impart shape retentive rigidity to the nonplanar three dimensional web. A characteristic feature of the molded article is that the low melting fibers present at one surface of the web have a fibrous form, while the low melting fibers present at the opposite surface of the web have portions which exhibit a nonfibrous fused form and form said bonds.

Abstract: A polyvinyl chloride molding composition, suitable for the manufacture of sheet stock according to the "Luvitherm" method, consists essentially of emulsion polyvinyl chloride and 0.5-3.0% by weight of a processing aid which is a copolymer of 40-90% by weight of vinyl monomers whose corresponding homopolymers have a glass point below 0.degree. C., and of 10-60% by weight of vinyl monomers whose corresponding homopolymers have a glass transition temperature above 20.degree. C.

Abstract: A method of manufacturing a friction article wherein a fiber material (14) having a continuous and substantially uniform three dimensional matrix which is filled with a slurry (24) made up of fillers, friction modifiers, a reinforcing material and a liquid binder. The filled fiber material is conveyed to a dryer (32) where the volatile solution is evaporated leaving the fillers, friction modifiers, reinforcing material and binder. The filled fiber material (14) is thereafter placed in an oven (50) where a compressive force is applied thereto while the binder is cured to define a second matrix which holds the fillers, friction modifiers, and reinforcing material in the three dimensional matrix.

Abstract: Graphite gaskets with an improved release characteristic are pressed (to reduce their void content) and then embossed with a pattern of relatively raised areas surrounded by interconnected depressions.

Abstract: A loudspeaker diaphragm is disclosed which is formed of a slurry of cellulose fibers and polypropylene fibers. In the fabrication of the diaphragm, a felt is made of the slurry, and the felt is subjected to sufficient heat and pressure to fuse the polypropylene fibers together to form a skeleton or matrix which extends through the felt.

Abstract: The present invention relates to a process of forming an extended elongate product from a plurality of strands by subjecting the strands to heat and pressure. The improvement of the present invention comprises a method for compressing the strands in a manner to reduce internal stresses imparted to the product during its subjection to pressure.

Abstract: Disclosed herein is a process for coating a fiber mat with a pigmented coating prior to subjecting the mat to heat and pressure treatment to form a composition board having a smooth, embossed or textured surface. The coating contains a mixture of an acrylic, hydroxyl or carboxyl functional vehicle, a melamine-based coating crosslinking agent for the vehicle, a high-melting wax, and a platelet form of talc. By employing this process, composition board products are obtained which have superior surfaces and surface finishes. In addition, these finishes inhibit composition board extractive migration which causes the formation of discolored spots on the finished composition board's surface.

Abstract: A method and apparatus for processing compressible insulation material of mineral fibers in which a folding shoe guides the insulation material from a strip condition into a cylindrical condition and further including initially compressing the portion of the strip material along the centerline thereof, subsequently compressing the portions of the strip material intermediate the center line and the side edges of the strip material, and, finally, compressing the side edge portions of the strip material.