Abstract: A process and apparatus for making densified glass fiber pellets substantially encapsulated in a polymeric shell from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube, drying the pellets and encapsulating them in a polymeric composition. The resulting pellets exhibit enhanced degradation resistance during bulk storage and handling.

Abstract: Procedure for the fabrication of a blank for a structural product, such as a blank for a structural board, from material (1) comprising longer (L) and shorter (S) particles and possibly also particles (F) smaller than these. The particles are mixed with a binding agent and possible additives and then passed into at least one blank former, from where the particles are brought onto a base (10). Longer particles (L) are brought onto the base (10) to form a first surface layer, onto which is brought at least one layer of smaller particles (F, S), and onto this layer is again brought a layer of longer particles (L) to form a second surface layer, the smallest particles (F) being so brought onto the base that they mainly end up in at least one middle layer in the cross-section of the blank while the amount of the smallest particles (F) diminishes towards the surface layers as seen in the cross-section of the blank.

Abstract: A method of forming a joint comprises the steps of: (a) at least filling a container with granular particles, the granular particles having a size of 0.25 mm to 1 mm; (b) inserting a component part into the container; and (c) at least partially filling the container containing this component part and the granular particles with a flowable, curable liquid, this liquid having curing time of less than 90 seconds. According to one embodiment of the present invention, the curable liquid has a gap fill of less than 0.25 mm and the curing time is less than about 5 seconds or less.

Abstract: A printer forms three-dimensional objects from a powder by selectively applying a binder liquid to incremental layers of the powder. The binder binds layers of the powder into solid two-dimensional cross sections of the desired object provided from memory. The printer can use dithering and halftoning techniques to shade the object and can also print in color. A filtration system removes airborne powder and recirculates the clean air. The printer also includes additional features to manage excess and airborne powder.

Abstract: A method of producing a non-woven fabric having a high recovery after elongation and a substantially uniform surface including the steps of microcrepeing the fabric between about 20% and 35%, and heat setting the fabric to a temperature between its glass transition temperature and its melting temperature. A non-woven fabric having a recovery of at least 40% after five cycles of 35% elongation is made from a microcreped fabric of basis weight from 1-3.5 osy. The non-woven fabric has a uniform surface that is substantially free of bunching, gathering, and that is otherwise substantially flat to the eye and touch.

Abstract: A process for the preparation of cellulosic composites from divided cellulosic fibrous material, which process comprises a hydrothermolytic treatment of the divided cellulosic fibrous material, carried out at a temperature in the range of 160 to 200° C., using water as softening agent, a drying or a drying and a curing step and a step in which dried or dried and cured particles of treated material are contacted with an adhesive, subsequently curing the adhesive-laden particles at increased temperature and pressure under formation of the desired composite.

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 hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. Patterned hydroentanglement of the web acts to entangle the fibers to provide the fabric with desired performance characteristics. A method of making the nonwoven fabric is disclosed. The nonwoven fabric is particularly suited for use in a mattress pad assembly, as also disclosed herein.

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.

Abstract: This invention relates to a process for the production of composite wood products. This process comprises a) applying a binder composition to wood particles, and b) molding or compressing the wood particles treated with the binder to form a composite wood product. Suitable binder compositions comprise a polymethylene poly(phenyl isocyanate) and a solid novolac resin.

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.

Abstract: A molded magnetic article and fabrication method are provided. Particles of ferromagnetic material embedded in a polymer binder are molded under heat and pressure into a geometric shape. Each particle is an oblate spheroid having a radius-to-thickness aspect ratio approximately in the range of 15-30. Each oblate spheroid has flattened poles that are substantially in perpendicular alignment to a direction of the molding pressure throughout the geometric shape.

Abstract: The invention relates to glass fibers coated with an sizing composition. The said sizing composition, which is obtained in particular from an aqueous solution, comprises as bonding film-forming agents, a combination, of at least one low-molecular-weight polyvinyl acetate A, of at least one thermally self-crosslinking polyvinyl acetate copolymer B, in an A/B weight ratio greater than or equal to 1.

Abstract: A hexagonal mold is formed by a unitary base and a unitary cover. Each of the base and the cover form three of the six surfaces of a hexagonal mold cavity when the cover is placed on top of the base. The hexagonal mold may be used to form field emission display spacers and field emission display microchannels by placing etchable single fibers in the hexagonal mold to form hexagonal multiple fiber preforms. The preforms are then drawn to form multiple fibers that are placed in a rectangular mold to form a rectangular fiber block. The rectangular fiber block is then sliced into sheets which are then placed between a field emission display baseplate and a field emission display faceplate.

Abstract: A process for forming carbon nanofibers by means of pyrolyzation with plasma in a reactor is disclosed. The process includes the steps of: providing, in a reactor, a first catalyst in the form of solid catalytic particles; applying a vacuum to the reactor to create a reduced pressure in the reactor; feeding a first mixture of gases including a carbon-based gas into the reactor; forming, from the carbon-based gas, a plasma containing carbon free-radical species; and forming, in the presence of the catalytic particles, carbon nanofibers.

Abstract: A system for producing three dimensional components by bonding together successive layers of a porous material with droplets of a binder material. A binder printhead has an array of nozzles which controllably supply jets of binder material droplets to the layers of porous material. The printhead is scanned in a raster scan fashion over each layer of porous material along a first scan axis in one direction to provide first fast scanning paths of droplets. The printhead is then moved laterally of such one direction and is then moved along the fast-scan axis in the opposite direction to provide second fast scanning paths of droplets which are interlaced with the first scanning paths. The supply of the droplets to the porous material can be controlled so as to control the overlapping thereof to produce various desired surface and interior characteristics of the components.

Abstract: The invention has for its object to provide a seamless belt comprising a polyimide resin and an electrically conductive powder. The seamless belt of the invention is one containing a polyimide resin and an electrically conductive powder and obtainable by, for example, centrifugal molding or the like. The seamless belt of the invention is minimal in variation of electric resistance value, excellent in mechanical and other physical properties and can be expected to find broad application as, for example, the functional belt of an electron photographic copying machine.

Abstract: Continuous methods for manufacturing finished board are disclosed which include disintegrating lignocellulose material prior to drying, gluing, and forming into mats, and in which the pressing of the mat into a board includes a first step in which the mat is pressed in the presence of steam in a heating medium to produce a partially pressed board having a substantially uniform density, and a second compressing step in which the outer layers of the partially pressed board are increased in density as compared to the center of the board.

Abstract: In a method for producing an optical cable (1), at least one optical fiber (3), is surrounded by an extruded tubular sheath (5) which comprises an inner layer (7) and an outer layer (9) and is produced in a single operational step. Tension elements (11, 11') are embedded in the tubular sheath (5) for increasing the tensile strength of the tubular sheath (5). The optical cable made by the method of the invention is particularly suited for applications as an indoor cable and as a non-self-supporting cable for installation on ground wires or phase wires of high voltage transmission lines.

Abstract: A prepress sealer for use in the process of making wood composition board is provided. The prepress sealer incorporates a crosslinking resin and an aqueous dispersion of acrylic polymer particles. The acrylic polymer particles have a THF gel content of greater than about 70%. Use of the prepress sealer provides improved press release during board manufacture and improved surface toughness and water resistance to the produced board.

Abstract: A marker pen including an improved nib. The nib has an elongated body portion and an integral tip portion. The nib is constructed of a needled nonwoven material preferably impregnated with a thermoset resin, such as melamine. The nib member may have a specific gravity generally falling within a range of 0.34 through 0.80, with a specific gravity of 0.38 being preferred in one construction. The needled nonwoven material preferably contains needle tracks characteristic of inefficient needling. A method of producing the improved nib member is also disclosed.

Abstract: Disclosed is a method of making a graded index polymer optical fiber comprising a multicomponent spinning process employing spinning masses comprising a core spinning mass and a sheath spinning mass, the spinning masses comprising a polymer, a polymerizable monomer, and an initiator. The monomer in the core spinning mass has a higher refractive index than the monomer in the sheath spinning mass, and the spinning masses are extruded and cured. The spinning conditions are chosen such that the monomers are substantially contained within the fiber during extrusion and curing and the total of the spinning masses is intrinsically thread forming. The spinning masses may be extruded in, e.g., water. The core and the sheath polymer may be, e.g., poly(methyl methacrylate); the core monomer may be methyl methacrylate, and the sheath monomer may be 2,2,3,3-tetrafluoropropyl methacrylate; or the core and the sheath polymer may be, e.g.

Abstract: A thermal and acoustical insulation product prepared from a mixture of fiberglass, scrap nylon of less than 0.25" in length and a thermo-setting resin. The insulation product is in a ductliner or molded form. The fiberglass will generally be in a concentration of from 20 to 80 percent by weight of the product; the nylon will be from 1 to 30 percent by weight of the product; and the thermo-setting resin will be from 5 to 35 percent by weight of the product.

Abstract: A method and apparatus for making carbon/carbon composite discs for an aircraft brake employs a continuous feeding of fiber strands into a mold. Water is then combined with the fibers and the fibers are compressed to form a moisturized mat or preform. The fibers are then needled such that the fibers within the mat or preform extend in radial, circumferential, and axial directions. The mat or preform is then subjected to densification. The resulting disc is of total carbon construction. The water introduced into the mat during the processing serves as both a sacrificial binder and a lubricant during the fabrication.

Abstract: The invention comprises a plasticating machine for the working and forcing of plastic material into a mold, the machine including an elongated barrel housing having a first or proximal end and a second or distal end, and an elongated screw shaft with a screw flight therearound, the screw shaft being rotatably supported in the elongated barrel housing, for the working of plastic between the screw shaft and the elongated housing. At least one delivery conduit is generally longitudinally arranged within the wall of the housing. The delivery conduit with the housing wall may be arranged to heat or cool the screw and any plastic being worked therethrough. In a further embodiment, it may permit delivery of a medium within the wall, from an upstream location of the housing, into the primary flow path of any plastic being driven from the machine and into a mold.

Abstract: A simplex optical fiber cable of this invention includes an optical fiber, a buffer preferably of nylon, surrounding and in contact with the optical fiber, a yarn layer with strength fibers, preferably aramid fibers, disposed about the buffer and a sheath preferably formed of polyvinyl chloride (PVC) surrounding and in contact with the yarn layer. In cross-section, the simplex optical fiber cable has a diameter less than 2.0 millimeters (mm), and thus is much smaller in diameter than optical fiber cables presently available. Preferably, if the buffer is relatively tin providing limited protection to the optical fiber, a slick substance such as talc is applied to an outer surface of the buffer before the yam layer is disposed thereon. The slick substance allows the buffer of the optical fiber to slide to a degree in contact with the yarn layer and thus reduces fatigue caused by axial movement of a ferrule of the connector terminating the optical fiber cable.

Abstract: A method and apparatus for determining and controlling the excess length of a communications element disposed in a conduit is disclosed. The method includes the steps of measuring the length of a communications element being disposed within the conduit, placing a mark on the conduit each time a pre-determined length of the communications element is disposed within the conduit, and measuring the distance between the marks on the conduit. The excess length is determined by comparing the distance between the initial mark and the subsequent mark on the conduit to the measured length of the communications element disposed within the conduit. To control the excess length ratio, the conduit may be stretched, or process parameters related to formation of the conduit may be changed.

Abstract: In a method of manufacturing a self-support optical cable, a support wire and an optical cable body arranged in parallel are fed with each other; a sheath into an eight figure shape is extruded by an extruder to collectively coat the outer circumferences of the support wire and the optical cable body with the sheath, and thereafter, the self-support optical cable is cooled before hardening while the cable passes through a plurality of guide wheels so that an excess length is given to the optical cable body.

Abstract: An improvement in the preparation of fiber preforms in which binder and fibers are dispersed to contact on vacuum-supplied screens is disclosed, comprising particularly (a) selecting a particulate binder material which is solid at 25.degree. C; (b) heating the binder material, during initial contact with the fibers, to a viscosity and for a time which is the same as or proportional to 1,000 centipoise for one second; and (c) dispersing the binder material and the fibers such that the preform exhibits a variation in the ratio of fibers and binder which correlates to a coefficient of variation which is less than or equal to about 5 percent. The resulting preform shows superior compaction and uniformity of constitution even when it is prepared in sections or in asymmetric configurations.

Abstract: In an optical fiber ribbon including a plurality of optical fibers arranged in a common plane in generally side-by-side relationship and surrounded by a layer of matrix material, at least one stress concentration is formed in the matrix material surrounding the optical fiber ribbon. The stress concentration extends along at least a portion of the ribbon parallel to a longitudinal axis of the ribbon and concentrates stress applied to the ribbon such that the matrix material easily separates at the stress concentration. Each stress concentration may be formed directly in the matrix material during its application on the optical fibers, or an abrasive surface may be applied to the fiber to form the stress concentration. Stress concentrations may formed on at least one extreme edge of the optical fiber ribbon such that the entire matrix material may be easily removed from a section of optical fiber ribbon at a desired ribbon access location.

Abstract: A method for making a container for an electrowinning cell where the first step 10 provides a mold plug 11 and woven glass rovings 12 are applied in the second step shown at 13. Vinylester resin is applied to the glass rovings at 14 to a thickness of about 4 mm. The liner shown at 14 is 97% vinylester resin. The liner is then allowed partially to harden. The liner 15 is then completely removed from the mold plug and then placed on a slightly smaller support 16 which forms the inner portion of a mold having its walls built up around the support 16 with the liner 15 in place as shown at 17. The mold is supported on springs and a vibrator 18 is employed to vibrate the mold as the outer supporting layer is being poured. Four separate pours 19, 20, 21 and 22 are employed. Each pour has progressively less resin. Pour 19 comprises 12% resin, 0.5% glass, 30% fine and coarse river sand and 57.5% gravel mix. Pour 20 comprises 11% resin. 0.5% glass, 30% fine and coarse river sand and 58.5% gravel mix.

Abstract: A low density compression resistant cellulosic-based nonwoven fabric having good absorbency and et tensile strength is formed from cellulosic-based fibers which are treated for use in an air laid process, with an aqueous dispersion of a self-crosslinkable polymeric binder and a chemical stiffening agent for the cellulose fibers and then dried at temperatures that result in intrafiber crosslinking and interfiber binding. The cellulosic-based nonwoven fabrics, thus formed, are useful in personal care products such as diapers and feminine care products.

Abstract: A method and arrangement for producing a basic element of a multi-element fibre optic cable having a coating tool (6) for forming a tubular sheathing around a single optical fibre (3) or a fibre bundle formed of several optical fibres (3), and a pulling device (8) placed after the coating tool (6) for pulling the sheathing and the fibres forward as a unit. In order to produce a stable product, the tension (t.sub.3) of the fibres (3) passed to the coating tool (6) is kept continuously at a controlled level. The direction of travel of the fibres and the sheathing is kept straight before and at the pulling device (8), and the pulling device (8) is spaced from the coating tool (6) at a distance depending on the production rate of the production line, so that desired sliding of the fibres (30 inside the sheathing is provided at the pulling device (8).

Abstract: An optical cable has tensile elements and supporting elements embedded in an extruded outside cladding. The tensile elements are hauled-off from a supply reel and introduced into an extruder head serving to manufacture the outside cladding. The supporting elements are manufactured in a coextrusion with the outside cladding by appropriate channels formed in the extruder head.

Abstract: Acrylic light pipe as described in Bigley et al., U.S. Pat. Nos. 5,406,641 and 5,485,541, has adequate thermal stability for many purposes. It has been found that improved thermal stability, as reflected in color formation, can be imparted by adjusting the polymerization conditions to produce the uncured core polymer of the core/clad construction with a much reduced terminal vinyl content, preferably below 0.5 vinyl groups/1000 monomer units.

Abstract: A process is provided for producing a plastic optical fiber by drawing while melting an optical fiber preform under heating. The optical fiber preform includes at least a core containing an organic polymer and a cladding layer disposed on the outer circumference of the core and containing an organic polymer. The drawing is conducted under a drawing tension of 10 g or more, and preferably under a drawing tension of 100 g or less, until winding-up of the optical fiber.

Abstract: In a method for producing an optical fiber ribbon, a plurality of coated optical fibers is fed out so that the plurality of coated optical fibers are arranged in a plane in a concentrator. A ribbon matrix composed of ultraviolet-curing resin is applied onto the plurality of coated optical fibers in a coater. Ultraviolet rays is radiated to cure the ribbon matrix. The plurality of coated optical fibers are arranged at intervals in a plane in the concentrator.

Abstract: A method of processing refuse wherein layers of resin-coated pulverized refuse are cross-blended, compressed, heated, recompressed, shaped and cured to form useful structural members.

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.

Abstract: This invention relates to a method of manufacturing molded wooden products composed of a wooden body and a skin material. This method employs materials having long working life and enables simultaneous integral molding of the wooden body and the skin. The obtained molded wooden product has excellent characteristics.

Abstract: Apparatus for use in applying particles to an external layer of uncured resin material of a coating of an optical fibre unit with at least one optical fibre, said apparatus including means (50) defining an axially extending through-passage (52) through which, in use, such an optical fibre unit is passed, said passage defining means having an inlet (62) for admitting fluidized particles into said through-passage, and said through-passage being provided with means (64) for generating turbulence in such fluidized particles in said through-passage.

Abstract: A method for forming a tool such as a mold includes the steps of initially selecting a cooling channel configuration for the mold. The initial selected cooling channel is evaluated utilizing a computer program. The program analyzes whether there would be local hot or cool spots in the mold with the initially selected channel. The channel is then modified based upon this evaluation. The modified channel is again subjected to the evaluation. This iterative process continues until an acceptable cooling channel configuration is achieved. The invention utilizes a generally helical cooling channel.

Abstract: An apparatus and process for obtaining the desired outside diameter for a tension-resistant core element, which includes assembling mixed filaments containing glass fibers and thermoplastic fibers, heating the bundle of mixed filaments to melt the thermoplastic fibers to form a matrix with the glass fibers embedded therein, then extruding an outer covering of the desired outside diameter for the core element onto the bundle. If desired, the melted bundle can be passed through a shaping device, which is preferably heated prior to extruding the coating thereon, and, subsequent to extruding, the extruded coating and bundle are cooled in the cooling device before being wound on a take-up drum or entering a stranding device for having communication elements stranded thereon.

Abstract: A system for producing three dimensional components by bonding together successive layers of a porous material with droplets of a binder material. A binder printhead has an array of nozzles which controllably supply jets of binder material droplets to the layers of porous material. The printhead is scanned in a raster scan fashion over each layer of porous material along a first scan axis in one direction to provide first fast scanning paths of droplets. The printhead is then moved laterally of such one direction and is then moved along the fast-scan axis in the opposite direction to provide second fast scanning paths of droplets which are interlaced with the first scanning paths. The supply of the droplets to the porous material can be controlled so as to control the overlapping thereof to produce various desired surface and interior characteristics of the components.

Abstract: An air cannon (100), formed by associating an inlet cone (116), an air amplifier (104) and an outlet cone (124) with one another, receives chopped fibers and forcefully deposits the chopped fibers on a collection surface (102) or web moving beyond an outlet end (126) of the outlet cone (124). A binder is applied to the resulting mat (172) of chopped fibers, the binder is activated by the application of energy with the resulting treated mat (182) being compacted, cooled and rolled up to form a chopped strand mat package (194). For wide mats, one or more banks (130) of air cannons (100) extend across the moving collection web. The air cannons (100) of each bank (130) are alternately directed up-line and down-line of the web to reduce interference between the air cannons (100) by means of L-shaped support rods (136) which have generally horizontal and generally vertical legs (136H, 136V) which are separated from one another by acute and obtuse angles (140, 142) for up-line and down-line direction, respectively.

Abstract: A method of manufacturing a multi-core optical fiber, the method including assembling together a plurality of substantially identical polished single-core optical fiber preforms (2', 2"), referred to as "single-core preforms", each of which includes a core bar (3) surrounded by a layer of optical cladding (4), so as to form a "multi-core preform" (10), and drawing down the multi-core preform (10) so as to obtain the multi-core optical fiber. The assembly step includes securing the single-core preforms (2', 2") to one another by fusing them over their entire lengths or over portions thereof along their tangential lines of contact (T), without inserting the multi-core preform (10) into a holding tube. A vacuum is maintained in the preform during the drawing step, the vacuum being formed before or during the drawing step.

Abstract: A method of making a bonded and creped type absorbent paper web that has improved bulk to peel strength characteristics includes steps of (a) printing a low density pattern of a bonding material onto a first and a second side of a paper web; and (b) in no particular sequence with respect to step (a), printing a high density pattern of a bonding material onto the first side of the paper web. Steps (a) and (b) are performed so that the high density pattern of bonding material penetrates into the paper web by a distance that is about 166 to about 470 percent of the distance by which the low density pattern of bonding material penetrates into the web. This results in a web that has superior bulk and peel strength characteristics. Another characteristic of the product is that it has a visible depression pattern in one surface, but not the other surface, which creates an attractive aesthetic effect and has functional benefits as well.

Abstract: A method of injecting a filler in controlled manner into a protective tube for protecting optical fibers, the method consisting in regulating the delivery rate of the filler being injected as the closed tube advances. In the method, the delivery rate is regulated by detecting the position of the front of the filler contained in the protective tube relative to at least one detection point on the line for advancing the closed protective tube.

Abstract: A method of forming a composite material including the steps of: providing a surface against which the composite material can be molded; providing a plurality of discrete filler particles; placing a plurality of discrete filler particles against the surface; preventing the particles from shifting freely along the surface; directing a liquified matrix material against the particles on the surface; and solidifying the matrix material to unite the discrete particles and matrix material into a composite structure.

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.