Abstract: A method for forming a contactor adapted to transmit oil from a reservoir of oil-impregnated wicking material formed of a fluent mixture of oil and oil retaining particles to a bearing surface, includes the steps of filling a mold cavity of a predetermined size and shape with a charge of fibrous particles, compressing the particles to a density such that the spaces between the particles form a network of interconnected pores sized smaller than the interstices between the particles in the wicking material, and bonding the particles together to form a solid porous mass.

Abstract: A densified bonded layer is formed in a panel of fluffed wood pulp fibers having particulate hydrocolloid material distributed therein by passing the panel between first and second compression means to apply pressure to the panel, at least one of the compression means being heated. By suitably selecting the temperature and pressure applied to the panel, an integral, densified, compacted, porous, absorbent fibrous layer or region having relatively high cohesive strength, relatively good capillarity, relatively good shape and volume stability and relatively high fluid retentivity can be formed therein. Particles of the hydrocolloid material are fixed within the panel by being bonded to the fibers substantially throughout the panel, and by mechanical entrapment between fibers in the densified bonded layer.

Abstract: Hollow filaments, which are suitable for use in separating one or more components from a fluid mixture by selective permeation, are embedded, or potted, in a curable resinous mass, and the resinous mass is severed to expose fluid communication openings of the hollow filaments. In accordance with the invention the curable resinous mass is sufficiently partially-cured to provide a solid mass which can be severed but does not tend to smear when severed so as to obstruct fluid communication openings of the hollow filaments; however, the partial curing is insufficient to render the severings of the resinous mass unduly difficult. The resinous mass is then severed, e.g., by cutting, to provide the fluid communication openings in the hollow filaments embedded in the resinous mass.

Abstract: Solid lignocellulosic material is bonded together by heating and pressing at a natural wood, pH by reacting sugars, starches or both in the presence of a catalyst capable of catalyzing transformation of the sugars and starches into a solid, insoluble in water, and an alkaline buffering agent if needed, for example to make waterproof plywood or composite products from particulate wood without hydrolytic degradation of the wood.

Abstract: An amine-modified lignosulfonate is formed from a water-soluble basic amine and a water-soluble lignosulfonate salt. The amine-modified lignosulfonate is incorporated into a phenol-formaldehyde resole resin to provide a binder particularly suitable for mineral fiber insulation mats.

Abstract: A method of molding a cellulosic fiber containing board at a temperature of at least 525.degree. F. to provide a relatively high density skin on at least one surface. A fibrous composition, including cellulosic fibers, is consolidated to form a blank having a density of less than 35 pounds/cubic foot. The blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position. Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof, the skin defined by a thickness of material on said surface of said product having a density greater than the material on which the skin is formed.

Abstract: A fiberboard is manufactured having relatively high density skins on a relatively low density core by including urea in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins.

Abstract: A glass-fiber filter tube and process of preparing the filter tube, which filter tube comprises a plurality of randomly disposed, fine glass fibers bonded, at the junction of the fibers, with a fused thermoplastic fluorocarbon resin, which filter tube may also include a reinforcing support scrim sheet incorporated integrally therein.

Abstract: The disclosure relates to the production of multi-ply battery separators utilizing mats of melt-blown, randomly laid, self-bonded thermoplastic resin fibers. The process involves the production of at least three separate plies of self-bonded, melt-blown thermoplastic fibers, which are joined in the absence of separate adhesive materials to form a cohesive, multi-ply material. The multi-ply material comprises an internal structure having fiber size, porosity and other characteristics particularly suitable for use in lead-acid battery separator application. The outer plies are formed to have characteristics more suitable for strength and abrasion resistance. In the process of the invention, the several plies are separately formed by melt-blowing techniques, in themselves known, and the several plies are joined in the presence of heat and/or heat and pressure, forming a multi-ply structure entirely free of external adhesive material.

Abstract: A premoistened wiper having high initial wet strength in a wetting liquid, and lower wet strength when immersed in substantially neutral water to allow for flushability. The wiper includes a nonwoven web of fibrous material which is bonded together by a polymeric adhesive binder, with the bonded web being moistened until the time of use by a wetting liquid having an acid pH level which is safe for external use on the human body. The binder is composed of a material which is highly adhesive in an acid pH liquid to bind the fibers of the web together, and which is further resistant to weakening over the relatively long periods of shelf life of the wiper. However, the binder loses its binding strength in substantially neutral or alkaline flush water to allow for flushability. The bonded wiper is maintained with wetting liquid thereon within a moisture sealed container until the time of use, and readily loses strength and disintegrates when disposed of in the substantially neutral water of a sewer system.

Abstract: A method for producing a self-sustaining sheet of essentially cellulosic fibrous material with improved strength wherein a dry-laid web is moistened and then consolidated by passage along a heated consolidating surface wherein the web is held against this surface by one side of a supporting band, against the other side of which at least two spaced apart pressure rolls exert a pressure acting through the supporting band against the web, which pressure is preferably between 150 and 500 pounds per linear inch. The supporting band thereby maintains the web against the heated consolidating roll between said pair of pressure nips.

Abstract: A method of forming an article defining an integral protective surface comprising providing a mould defining at least that face of the article to be formed with the protective surface, inserting a plurality of minute hard chemically inactive spheroidal members into a medium bonding substance of less specific gravity than the spheroidal members and in which the article, at least that part of the article at the relevant surface, is to be moulded, maneuvering the mould and placing the bonding substance therein, before or after the spheroidal members have been inserted, so as to cause the spheroidal members by their density displacing the bonding substance to migrate to form a compact layer at the aforementioned surface and allowing the substance to harden to retain the spheroidal members at that surface.

Abstract: A nonwoven, self-sustaining, absorbent fabric comprising a batt of randomly arranged, intermingled cellulosic fibers has a plurality of high loft, loosely compacted regions separated from each other by highly compressed regions. An adhesive material penetrates through the compressed regions to form bonded fiber networks extending completely through the batt, and said adhesive material only partially penetrates through said high loft regions whereby the fibers in the interiors of said high loft regions are unbonded by said adhesive so that said regions are highly absorbent. A method of manufacturing the above-described nonwoven fabric by moistening opposed surfaces of a loosely compacted, randomly oriented cellulosic fiber batt, embossing said moistened batt for providing a pattern in said surfaces, applying an adhesive to the patterned surfaces of the batt and setting said adhesive.

Abstract: A soft abrasive tool is disclosed as comprising a solid molded mixture of edetermined quantities of an aluminum wool material and a catalyst setting elastomeric polyurethane binder material, the unique combination of which has been mixed, molded under pressure, and cured at room temperature in such manner as to have a disc-like, cup-like, or other predetermined geometrical configuration. A power source -- such as a motor or the like -- may be used to mechanically drive the aforesaid soft abrasive tool, so that it will cut, grind, and remove polyurethane paint, polysulfide sealant, and other soft coatings from aluminum aircraft skin without damaging the substrate aluminum thereof when held thereagainst.

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

Abstract: An elongated board of artificial lumber having a length greater than the width and thickness comprising a mixture of irregularly shaped elongated splinters of wood substantially aligned along the length of the board; a substantial portion of the mixture including splinters from about 2" to 10" long; a sealant coating the surface of the splinters; an adhesive carried on the splinters with the sealant restricting the penetration of the adhesive into the splinters so as to produce hardened layers between the splinters for holding the splinters in an interlocking configuration.

Abstract: A fibre bundle is first formed from loosely entangled fibres. Then, the fibre bundle is encased in a plastic shell and dipped into a solution of a synthetic resin in a solvent to fill the spaces among fibers with the solution. After taken out of said solution it is left to stand for a period of time during which the volatilization of the solvent forms a great number of capillary passages for the transudation of ink. After grinding a marking pen is obtained having a nib and an ink reservoir integral therewith.

Abstract: A liquid binder forming material is added to a preform mold, dispersed chopped glass fiber strand is allowed to free fall into the preform mold to build up a layer of chopped fibers wherein substantially all of the strand is horizontal but otherwise randomly oriented, and the layer of chopped strand is forced down into the resin until completely immersed therein. Preferably, thereafter, the preforms so produced are stacked into tubular magazines with separator sheets between the preforms in each magazine; and the magazines are transported first to a maturation room where the viscosity of the binder forming material is increased to above 20 million centipoise, and then to matched metal dies where the preforms are sequentially fed out of the magazine to between the dies which shape and cure the preforms.

Abstract: When producing insulating units, in particular building units, plaster of Paris was previously poured into the mold, bloated polystyrene pearls being prekneaded into said plaster. Plaster of Paris has also been poured into molds, wherein a lining of an aggregate of fused, bloated polystyrene pearls were prearranged. The bloated polystyrene pearls according to the invention are first densely packed in the mold, whereupon plaster of Paris, cement or another hydraulic binding material is filled into the mold through a net or a perforated plate, said net or perforated plate keeping the pearls densely packed during the casting so as to ensure that they do not reposition as a consequence of their buoyancy in the cast, liquid binding material.

Abstract: Solid lignocellulosic material is bonded together by heating and pressing with a bonding composition comprising at least one carbohydrate and an acid capable of catalysing hydrolysis of the carbohydrate, for example to make plywood or particle board.

Abstract: A method and apparatus for forming a fiber preform for use in molding fiber-reinforced, plastic articles is disclosed. The apparatus includes a perforated form which is rotated about its longitudinal axis while a vacuum is applied internally. Cutters deposit short lengths of fibers on the rotating form by traversing the form from one end to another, and a binder resin is sprayed onto the fibers as they are deposited. The form is cylindrical and at least a major portion of its sidewall is initially covered with a flexible bellows. As the cutters traverse the form, the bellows is collapsed ahead of the cutters to incrementally expose the perforations. An oven is provided to cure the resin while the preform remains on the form.

Abstract: A method for manufacturing a curved fiber reinforced body of plastic material by cutting plastic impregnated fibers with a cutter, directing the cut fibers onto a rotating form and applying a plastic material to the fibers. The fibers are deposited in predetermined radial and circumferential directions to build up a proform of overlapping layers of oriented fibers as the form is rotated. The preform is shaped by compression between mating shaping forms to substantially the final molded shape. The plastic material contains a curative and is partially cured under controlled conditions after the preform is built. The preform is then preheated in an oven and molded under predetermined pressures and temperatures.

Abstract: Foldable boxboard made by dry-laying cellulosic fibers and 1-10% starch. The boxboard has a weight of at least 210 g.s.m., a stiffness in the machine direction of at least 5.8 Kenley units, and a ratio of stiffness in the machine direction and in the cross-machine direction of substantially 1:1.

Abstract: A fibre bundle is first formed of entangled fibres by use of a tapered mold of an extruder. Then, the fibre bundle thus formed is dipped into an urethane prepolymer to fill the spaces among fibres by impregnating it with said prepolymer. After removal from the liquid prepolymer, it is left for a period of time to allow the reactions among the constituents in the prepolymer and the volatilization of solvent generate gases to form gas escape holes or capillary passages along the length of the fibre bundle.

Abstract: A fiber bundle is first formed of entangled fibers by passing fibers through the tapered mole of an extruder, and then the fiber bundle is provided with at least one longitudinal groove which provides an air passage in the final product communication between the ink reservoir and the atmosphere. Subsequently, one end of the fiber bundle with the longitudinal groove is dipped into a liquid urethane prepolymer to form a nib portion by impregnating the dipped portion with the prepolymer. After removal from the liquid prepolymer it is left to stand. During this standing or setting period the reactions among the constituents of the prepolymer and the volatilization of solvent produce a set urethane nib portion having capillary passages therein, and an air passageway where the groove was formed. The fiber bundle thus produced which is called "core portion" of the pen, is machined at its impregnated end to form a nib. Thus, the product consists of a nib material portion and an ink reservoir integral therewith.

Abstract: A process for the manufacture of flat sheets or webs from a natural fiber material such as cellulose fibers in which the fibers to be processed are first placed on a substrate in the form of a dry heap after which an amount of water not exceeding the amount of moisture which can be absorbed by the fiber is added, whereupon the wetted fibers are subjected to pressure and temperature causing them to bond together forming a sheet or web. When sheets or webs of greater thickness are being made according to the present invention a further step of cooling before relieving pressure is carried out to avoid steam pockets formed within the web from breaking through upon release of pressure.

Abstract: An improved method for providing lightweight and strong rigid enclosures and molded items formed by enclosing, wrapping or filling a mold of said items or articles with a dry peroxide catalyst-impregnated fabric or solid substrate filler material and applying thereto or mixing therewith an activated thermosetting vinyl-type resin and allowing said fabric or filler material to harden about the article or within the mold of said article. Said resin system and molding procedure is safe and of low toxicity.

Abstract: A method for preparing a non-woven fabric which is less wettable in its marginal portions than in its central portion. The fabric comprises a highly water-absorbent web of mixed long and short fibers that is through-bonded throughout its dimensions with a binder (adhesive) to retain the fibers in their assembled relationship. Since the binder, in its final set stage, is hydrophobic in character and renders the resulting fabric more or less water repellent, the invention involves treatment of the mid-portion of the bonded fabric with a wetting agent (surfactant) to minimize the water-repellent effect of the binder and to make the mid-portion of the fabric readily wettable. Marginal portions of the bonded fabric are not treated with a wetting agent, so that these portions of the fabric throughout their dimensions are more or less water repellent. By this is meant that the marginal portions of the bonded fabric are difficultly wettable as compared to the mid-portion of the fabric.

Abstract: Fibers in non-woven fibrous products are bonded together by a binder comprising a heat-cured product of a water insoluble copolymer of (i) an N-methylolamide which is N-methylolacrylamide or N-methylolmethacrylamide, and (ii) an acrylic acid ester of acrylic acid or methacrylic acid and a C.sub.1 to C.sub.8 alkanol, modified with (iii) a polyalkylene glycol of the formulaHO--(RO).sub.n --Hwherein R is an alkylene group of 2 to 6 carbon atoms and n is a number having an average value of 4 to 50. Preferred acrylic acid esters are ethyl acrylate and butyl acrylate, and the preferred polyalkylene glycol is a polyethylene glycol characterized by a molecular weight in the range of 300 to 2000. The copolymer may also contain units derived from unsaturated aliphatic carboxylic acids. Preferably the copolymer contains units derived from itaconic acid.

Abstract: A method of manufacturing a dry-formed, adhesively bonded, nonwoven fibrous sheet and the fibrous sheet formed thereby.

Abstract: An improved method of controlling monomer loss during the production of a fiber-thermoplastic matrix by in situ bulk polymerization is described, the improvement allowing polymerization to greater than 25% polymer content by weight of the matrix within less than eight minutes. A fibrous web of less than 0.25-inch thickness, saturated with a liquid phase polymerizable composition containing a vinyl monomer and a thermally activated free radical initiator at 1/2-10% by weight of the composition is polymerized under controlled conditions in which the matrix is: (a) confined between heat transfer surfaces at 0.

Abstract: An improved method of making syntatic modules which includes the following steps. A preform mold and a casting mold are formed of predetermined configuration. A woven roving of predetermined size is formed to provide a skin. Additionally a layer of spacer material is formed which includes a plurality of voids. The roving is attached to the spacer material to form a laminate. The laminate is formed to the insidewalls of the preform mold and then the preform mold is filled with a plurality of hollow balls. A thin layer of resin is poured into the preform mold to connect the balls. The composite is removed from the preform mold and placed into the casting mold after spacer material is attached to the exposed end portions of the composite. A syntatic foam resin is added to the casting mold interior so as to fill all spaces between the balls and all voids in the spacer material. The syntatic foam resin is then cured and the mold parts are removed thereby producing a module.

Abstract: Polymeric sheets having on one or both sides a fabric texture and a network of elongated channels in the interior of the structural framework of the sheet. In one embodiment, the sheets comprise a plurality of interbonded continuous polymeric ribs extending in a direction parallel to the plane of the sheet. The ribs impart a fabric texture to both sides of the sheet and define between them recessed portions on each surface of the sheet. The elongated channels extend throughout the ribs. The open area between the ribs can vary from zero to 60%. In another embodiment, the sheets have an ultra-thin, pinhole-free silicone rubber membrane on one side and a fabric texture on the other side. The sheets are useful as burn coverings where they serve as synthetic temporary replacements for damaged or missing skin.

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

Abstract: A method for producing a reduced-pressure shaped mould comprises the steps of placing a pattern having gas-permeable orifices on a surface plate and adhering a coating film that is soluble in a solvent to the pattern by suction through the orifices. A flask having evacuating means is then placed on the surface plate on top of the film and the space portion defined by the film and the flask is filled with solid particles containing no caking agent which serves as a mould material. The mould material and flask are covered with an air-tight sheet and the evacuating means of the flask is actuated while that of the surface plate is released so that the sheet and coating film adhere to the upper and low surfaces respectively of the mould material by suction. The pattern and surface plate are then separated from the flask and a solution containing caking agent dissolved in the solvent is applied to the coating film which is adhered to the surface of a cavity formed at the lower surface of the mould material.

Abstract: Method for laying flooring on a solid sub-floor comprising the step of coating the sub-floor with a loose intermediate layer, screeding and thereafter covering the intermediate layer with a pressure distributing layer of semi rigid or rigid plates, whereby the intermediate layer consists of sawdust which has been sifted in order to remove particles having a size exceeding 5 mm and which have improved slender values by having been cut and split substantially along the grain, the sawdust being spread on the sub-floor, screeded to a thickness of 5-25 mm, and covered with the plate material which may be coated with an outer or wearing layer.

Abstract: The present invention is concerned with a method of shaping fiber materials. Particularly, it relates to the shaping of cellulose-containing fiber materials such as wood fibers and the like. Synthetic fiber materials such as mineral fibers are also contemplated. The method is of that type which uses water as a binder for the fibers. In order to cause the water glass to exert its binding function a substance capable of splitting off acetic acid is added thereto and the acetic acid is liberated at temperatures between 150.degree. and 200.degree. C. Vinyl acetate is preferably used as an agent for splitting off acetic acid to cause gelation and binding to take place.

Abstract: A method of constructing an assembly comprising an insulating fiber mass by pre-compressing the fiber mass to a controlled extent so that damage to the fibers is avoided, introducing the pre-compressed fiber mass into a cavity and releasing the pre-compression so that the fiber mass is retained under compression by the cavity wall.

Abstract: A nonwoven cellulose acetate laminate is made from a base material mainly composed of a cellulose acetate fiber web, in a short time, by the steps of: impregnating a liquid initial condensate of phenol-formaldehyde into the web or spraying a powdery condensate of phenol-formaldehyde onto the web, and then penetrating superheated steam through the resultant cellulose acetate laminate sheet. The sheet possesses good mechanical properties and excellent sound-absorbing and heat-insulating characteristics.

Abstract: The method of the invention consists of forming a web of substantially planar-aligned fibers, applying a surface disposition of bonding material to one side of the web to penetrate only part way through the web in order to form a first surface region having the surface bonding material and a central core region free from the surface bonding material and bounded on the side opposite the first surface region by a second surface region, applying a penetrating disposition of bonding material to one side of the web in a fine, spaced-apart pattern which occupies less area in the plane of the web than the surface bonding material in the first surface region and penetrates through the central core region to connect the first and second surface regions together, and creping the web to decrease the fiber concentration in the central core region to less than that in the first surface region.

Abstract: A succession of rectangular mats, consisting essentially of asbestos fibers or other filamentary material held together by a wet hydraulic binder such as cement, are conveyed by a series of trays through the gap between a pair of horizontal platens of a press. The upper platen carries a die for trimming the edges of a mat to be compacted, with the tray acting as an anvil. The trays are linked near their leading ends with two parallel, endless conveyor chains and have their trailing ends supported by rollers on rails which parallel the upper and lower runs of the chains and which form ramps for guiding these rollers onto the lower level downstream of the press and onto the upper level upstream of the press whereby each tray runs horizontally through the press between a loading and an unloading station.

Abstract: Method of making a beaded retro-reflective material comprising embedding beads in a generally planar plastic matrix and embossing the material so that axes of exposed portions of the beads lie at varying angles to the general plane of the matrix.

Abstract: Particleboard, i.e., wood chip panels having greater transverse strength in that the core layer is characterized by having a central zone therein with a greater amount of binder on the chips in said central zone, based on the total weight of the wood chips in the respective zones, than on the chips in the intermediate zones adjacent the face zones of said core layer.

Abstract: A sparger useful for producing bubbles of uniform size in liquids is formed from a body comprised of a cured, thermosetting resin matrix enclosing spherical particles of substantially uniform size and containing numerous interconnecting passageways formed by the interstices between said enclosed particles.

Abstract: A method of forming a lightweight, airlaid web of wood fibers suitable for tissue and toweling applications comprises airlaying a wood fiber continuum onto a foraminous carrier, bringing the continuum into contact with a transfer member printed with an adhesive in a preselected pattern, the adhesive being disposed in a low viscosity fluid, and removing the fluid to provide an airlaid, adhesively bonded web.

Abstract: A shaped article of refractory heat insulating material is made by forming a mixture of inorganic refractory fibrous material and a binding agent which may be soluble or dispersible in a suitable liquid medium, forming the mixture to the desired shape, drying the shape in a first drying step, impregnating the so-dried shape in a second drying step, one of the drying steps being an homogeneous drying step and the other being a non-homogeneous drying step.

Abstract: A method of fabricating a reinforced plastic tubular article. A mandrel is positioned within a mold in spaced relation to the inner surface of the mold. Dry reinforcing material, in the form of fibrous or particulate material or a combination of both, is located in the annular space between the mandrel and the mold. The interior of the mold is evacuated to remove gas from the mold as well as from the voids within the reinforcing material. An uncured thermosetting resin system, which was mixed under vacuum conditions to remove gas from the system, is introduced into the mold. Pressure is applied to the resin to thoroughly impregnate the reinforcing material with the resin. The resin is then cured by heating while the pressure is maintained on the resin. The resulting cured product has a smooth outer surface which facilitates the attachment of coupling members and has improved mechanical properties.

Abstract: This invention relates to an improved process and apparatus system for the continuous production of thin fiberboard products wherein a binder-impregnated wood fiber mat is continuously formed and then continuously and successively passed through a conditioning zone where the mat temperature is adjusted to about the glass transition temperature of the ligneous hemicellulosic matrix material of the wood fiber at a moisture content from about 6% to 12% by weight, prepressed to reduce the bulk thereof and substantially eliminate entrained air therefrom, hot pressed at a temperature and for a time sufficient to reduce the mat to the final thickness desired and to initiate but not to complete cure of the binder, and thereafter subjected to a temperature sufficient, but not above about 350.degree.F., and for a time sufficient to complete binder cure and mat consolidation.

Abstract: This invention relates to an improvement in consolidating and curing a binder-impregnated fibrous mat to form a consolidated fibersheet or fiberboard comprising hot pressing the mat at a temperature and for a time sufficient to initiate but not to complete cure of the binder, followed by immediately subjecting the mat to post curing at a temperature up to about 350.degree.F. for a time sufficient to complete binder cure and mat consolidation.

Abstract: A process for the production of glass-fiber reinforced plastics by partially copolymerizing a mixture of (A) 35-95% by weight methyl methacrylate, (B) 65-5% by weight of a vinyl aromatic hydrocarbon, and 0.2-5.0% by weight, based on the sum of (A) and (B) of a polymerizable compound containing two or more ethylenically unsaturated groups, discontinuing the partial copolymerization before gelation of said mixture has occurred, impregnating glass fibers with the resultant partially polymerized mixture and then curing the impregnated mixture.