Abstract: In one example, a device for printing a three-dimensional object is described. The device may include at least one material application unit to deposit at least one material for a voxel of the three-dimensional object, a vertical cavity surface emitting laser array comprising a plurality of vertical cavity surface emitting lasers, the plurality of vertical cavity surface emitting lasers including a first vertical cavity surface emitting laser to operate at a first wavelength and a second vertical cavity surface emitting laser to operate at a second wavelength, and a processor to control a deposition of the at least one material for the voxel via the at least one material application unit and to control an application of electromagnetic energy via at least one of the plurality of vertical cavity surface emitting lasers to the voxel to alter at least one property of the at least one material.

Abstract: Apparatus for producing a three-dimensional object layer by layer using a powdery material which can be solidified by irradiating it with an energy beam, said apparatus comprising: a working area onto which layers of powdery material are to be placed; a powder storage unit, where said base surface is supporting a supply of powder in said powder storage unit; a powder distribution member, a pivoted powder pushing device for bringing a portion of powder from said base surface to a position between said distribution member and said working area, said distribution member further being arranged to be moveable towards and across the working area so as to distribute the portion of powder onto the working area, wherein a first portion of said pivoted powder pushing device is movable under said distribution member. An associated method and computer program product are also provided.

Abstract: In an example, a processor comprises an ancillary print agent distribution module to determine instructions for a print control module. The print control module may be to control the distribution of print agent onto a first region of a layer of build material in an object fabrication chamber in an additive manufacturing process in which at least one object is generated by selective solidification of each of a plurality of layers of build material and the selective solidification of build material is determined by the distribution of at least one print agent. The instructions determined by the ancillary print agent distribution module may be to cause the print control module to control the distribution of print agent in a second region of a layer of build material in an object fabrication chamber as part of a process which is ancillary to object generation. The first and second regions may be spatially distinct.

Abstract: A reusable countertop mold in accordance with the present invention includes at least one mold sheet, but generally a plurality of mold sheets are required to extend about a predetermined portion of a periphery of a floor mounted cabinet. The mold sheet is dimensioned and configured to ultimately form a countertop having a predetermined configuration with predetermined dimensions. The mold sheet includes a relatively thin base portion and a wall portion perpendicular to the base portion. The reusable countertop mold further includes a plurality of fastener recesses in an inner side portion of the base portion, the recesses ultimately allowing fasteners to pass through a countertop substrate and into the floor mounted cabinet, after the base portion has been inserted between the countertop substrate and the cabinet.

Abstract: The present invention relates to an apparatus for producing plastic parts interspersed with reinforcing fibers, with a mixing chamber (20) for producing a mixture of chemically reactive polymer components, with an outlet chamber (38), which is arranged downstream of the mixing chamber and in which a cleaning ram (28) in which a fiber conveying channel (32) is formed is guided in a reciprocatingly movable manner.

Abstract: In one aspect, the present invention features a process for making a tablet including a pharmaceutically active agent wherein the tablet has both an immediate release region and a modified release region. The method includes the steps of: (a) forming a tablet shape including a powder blend containing a pharmaceutically active agent and a thermally-sensitive material; and (b) applying energy in different amounts to different regions of the tablet shape to form the tablet in a manner such that: (i) a first region of the tablet shape is exposed to said energy for a sufficient period of time to melt the thermally-sensitive material within the first region to form said modified release region of said tablet; and (ii) a second region of said tablet shape is not so exposed to the energy such that said second region forms the immediate release region of said tablet.

Abstract: The present invention relates to a building material consisting of a moulded product of a base material, which moulded product is provided with at least one cavity, which cavity is filled with a filler in the form of loose particles, which loose particles have been bonded together by means of a binding agent, wherein the binding agent is present on the loose filler particles in the form of droplets. The present invention furthermore relates to a method for manufacturing such a building material In addition to that the present invention relates to a use of the present building material.

Abstract: In one aspect, the present invention features a process for making a tablet including a pharmaceutically active agent wherein the tablet has both an immediate release region and a modified release region. The method includes the steps of: (a) forming a tablet shape including a powder blend containing a pharmaceutically active agent and a thermally-sensitive material; and (b) applying energy in different amounts to different regions of the tablet shape to form the tablet in a manner such that: (i) a first region of the tablet shape is exposed to said energy for a sufficient period of time to melt the thermally-sensitive material within the first region to form said modified release region of said tablet; and (ii) a second region of said tablet shape is not so exposed to the energy such that said second region forms the immediate release region of said tablet.

Abstract: In a method for synthesizing polymeric microstructures, a monomer stream is flowed, at a selected flow rate, through a fluidic channel. At least one shaped pulse of illumination is projected to the monomer stream, defining in the monomer stream a shape of at least one microstructure corresponding to the illumination pulse shape while polymerizing that microstructure shape in the monomer stream by the illumination pulse.

Abstract: Certain embodiments provide a bipolar plate for a fuel cell having a novel configuration in which the draining function is improved, the operation is simplified, the resin contained therein is prevented from being decomposed and eluted, and methods for producing the same.

Abstract: The invention concerns a powder application system (1) for feeding and distributing a powder over a working area (3) in an apparatus for producing three-dimensional objects, said system (1) comprising a powder storage unit (11) adapted to contain a supply of powder (2) and further comprising a distribution member (6) that is arranged to be moveable across the working area (3) as to distribute a portion of powder onto the working area (3).

Abstract: A method of preparing an ion-conducting material, for example membrane, having reduced sensitivity to water includes a step of treating an ion-conducting polymeric material (especially a sulphonated polyaryletherketone and/or sulphone) which has at least some crystallinity or which is crystallizable with a means to increase its crystallinity. The ion-conducting material prepared may be used in a Membrane Electrode Assembly of a fuel cell.

Abstract: A process for recycling of powder coating waste comprising the steps of (1) compressing powder coating waste to powder coating compacts having a volume of 0.5 mm3 to 15 cm3 by applying pressing forces; (2) placing the formed powder coating compacts into a vessel, rotating the vessel about a rotational axis inclined at an angle of 20 to 70 degrees relative to the horizontal and (3) heating the powder coating compacts while being moved in the rotating vessel until through-glassed powder coating bodies are formed.

Abstract: Apparatus, systems and methods for use in three-dimensional printing are shown and described. Various embodiments of the invention allow for more precise and controlled delivery of heat to achieve interlayer drying; isolation of the working region from the outside for reasons of cleanliness and in connection with the vapors of organic solvents; better control of the temperature of the working region; better accuracy in the flowrates of binder fluid dispensed; matching of delivered flowrates for multiple dispensers; verification of delivered flowrate or drops; provision for easier changeover of the machine from one powder to another; cleanability; and other needs.

Abstract: Methods for making ceramic aggregate particles comprising forming a plurality of ceramic aggregate precursor particles from a composition by forcing the composition through at least one orifice in a substrate, at least partially curing the ceramic aggregate precursor particles, and heating the ceramic aggregate precursor particles to provide ceramic aggregate particles wherein solid particulates are bonded together by ceramic binder.

Abstract: A method for making abrasive agglomerate particles from a composition comprising at least a radiation curable binder and solid particulates. The method comprises the steps of forcing the composition through a perforated substrate to form agglomerate precursor particles which then separate from the perforated substrate. Then, the particles are irradiated to form soldified, handleable agglomerate particles before being collected.

Abstract: Method and device for manufacturing plastic-based materials in web form, such as floor and wall covering materials, and also such a material manufactured by the method. During the production, spherical particles (12) in substantially one size are used. The particles are deposited as a layer (18) on a substrate (1) by doctoring by means of allowing the particle mass to flow down into a gap between a depositing member (16) and the passing substrate (1). Thereafter, the particles are sintered together by heating, whereafter the solidified layer (25) is caused to fuse into a homogenous form by means of heating during simultaneous compression in order to shape the web material (26).

Abstract: A method of manufacturing an articulating bearing surface for use in an orthopaedic implant uses a supply of ultra-high molecular weight polyethylene particles which are irradiated with sufficient radiation energy to crosslink at least a portion of the ultra-high molecular weight polyethylene. The irradiated particles are then formed into an orthopaedic bearing surface.

Abstract: A method of producing an extruded plastics foam of enhanced physical strength includes intimately mixing a blowing agent incorporation CO.sub.2, the major portion of which is a natural gas, in a plastics resin melt to form a homogenous resin mix, and extruding the resin mix through an exit die into a region of lower pressure. At the point of extrusion out of the exit die, the temperature of the resin mix is adjusted so that it is below the critical temperature.

Abstract: An insulation board (10) insulation board comprising a foam core (11) selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof; the board being devoid of facers. A method of covering roofs comprises applying insulation boards to a roof deck, the insulation boards comprising a foam core selected from the group consisting of polyisocyanurate and polyurethane materials and mixtures thereof, the boards being devoid of facers; and, applying a weather protective layer over the insulation boards.

Abstract: Disclosed is a process of converting asphalt composition roofing shingles into dimensional construction products. Asphalt composition roofing shingles are de-consolidated, such as by grinding, into a crumble. The asphalt shingle crumble is processed in a manner to increase the fusibility activity of the asphalt without decomposing a substantial fractional amount of the asphalt to an ash-like brittleness. The foregoing can be achieved by heat exchange using infrared heaters as the heat source. One disclosed example trial of the process warmed the crumble to a bulk temperature of between about 130.degree. F. and 150.degree. F. Following that, the asphalt shingle crumble is compacted into the shape of a given dimensional construction product such as blocks, curbs, tiles, beams, posts, and so on. The best quality products are achieved by a two-step compaction process in which there occurs a certain time elapse between the two compaction steps.

Abstract: A method for continuously manufacturing a plastic foam reinforced by at least one fibrous material comprising continuously conveying a carrier along a production line, supplying on top of the carrier a foam-forming mixture and at least one continuously moving fibrous material, the fibrous material being non-expansible and having holes penetrable by the mixture, the mixture being supplied above both the fibrous material and the carrier or below the fibrous material and between the fibrous material and the carrier, passing the carrier, mixture and fibrous material between two spaced opposed constricting members which lie one above the other and form therebetween a metering gap for distributing the mixture over the carrier and fibrous material, and allowing the mixture after passing through the gap to freely expand and penetrate the holes of the fibrous material to form a reinforced plastic foam which has an exceptionally flat surface.

Abstract: Fibrous structures containing immobilized particulate matter and processes for making them are disclosed. These structures may be used for filters and for fabrics including chemical defense garments and others. The fibrous structures have webs containing composite fibers having a lower melting component and a higher melting component. The particles are distributed into the interior of the web and fused to the low melting component of the individual fibers without substantially reducing the available surface area of the particle. A fibrous structure of a composite staple having a nylon sheath and a polyester core, with activated carbon particles bonded to the sheath is specifically disclosed. The processes for producing such a fibrous structure include carding a web of staple fibers and distributing particulate matter therein, air laying a web of staple fibers and particulate from a suspension thereof between two wet formed layers of staple fibers.

Abstract: This invention is directed ro flexible plastic sheets of a thermoplastic material with a wear resistant surface, these sheets or panels have a monochromatic or multicolored or colored patterned design, especially in the area of manufacturing wear resistant floor coverings.

Abstract: Disclosed is a compressed, evacuated, open-cell polymer foam, the foam having an open cell content of about 70 percent or more prior to compression, the foam having a thickness of about 40 to about 90 percent of the initial thickness of the foam prior to compression, the foam having an absolute cell gas pressure of about 10 torr or less in its open cells, the foam having a density of about 16 to about 250 kilograms per cubic meter. Further disclosed is an evacuated insulation panel employing the foam.

Abstract: The invention relates to a process for the manufacture of new shaped parts, preferably made from chipboards, wherein a mass formed from at least a binder and a small-particled material brought into contact with this binder is subjected to extrusion at elevated temperature and pressure. In the process according to the invention, a mass possessing a total moisture content of 6 to 25 wt. % or adjusted to the stated moisture content and made up of at least one biopolymeric preferably starch-containing binder, which converts into a melt and/or gel at extrusion temperatures and pressures, and further made up of the small-particled material, is subjected to extrusion and immediately thereafter undergoes decompression and spontaneous expansion.

Abstract: The invention provides a polyglycolic acid sheet obtainable by melt-extruding a thermoplastic resin material into a sheet in a temperature range of from the melting point, Tm of the polymer to 255.degree. C., wherein the thermoplastic resin material comprises polyglycolic acid having a repeating unit represented by the following formula (1): ##STR1## and the following physical properties: (a) the melt viscosity, .eta.* ?as measured at a temperature of (the melting point, Tm of the polymer+20.degree. C.) and a shear rate of 100/sec! being 500-100,000 Pa.s;(b) the melting point, Tm being at least 150.degree. C.;(c) the melt enthalpy, .DELTA.Hm being at least 20 J/g; and(d) the density being at least 1.50 g/cm.sup.3 as measured in an unoriented, crystallized form, and the sheet has tensile strength of at least 60 MPa, and a production process thereof.

Abstract: A novel polyurethane foam is shown which uses ground vehicle tires as a filler material. A method of manufacturing a carpet pad using the novel polyurethane composition is also shown. A frame is provided to which is mounted a conveyor belt. The conveyor belt feeds a first liner having an exposed surface of the polyurethane foam along a conveyor path from a forward end to a rearward end. A foam spray assembly is connected to a conventional uncured polymeric foam supply having a spray nozzle mounted adjacent to the forward end of the conveyor path. The spray nozzle dispenses uncured, resilient polymeric foam as a generally uniform layer on a surface of the first liner of previously cured polyurethane. A second conveyor belt, parallel to the first conveyor belt, feeds a second liner sheet along the conveyor path so that the second liner sheet is positioned over the layers of foam laminate.

Abstract: A process and a device are described for the production of polyurethane foam by application of a froth onto the conveyor belt of a block-foam installation, whereby the froth is applied onto the lower conveyor belt in a free, substantially vertical fall and flowing of the froth contrary to the direction of movement of the conveyor belt is prevented by a stationary, substantially vertical barrier arranged transversely on the conveyor belt.

Abstract: A continuous process for making a structural foam panel with a stiffener is described, and a continuous assembly line for the process is described. The continuous assembly line includes decoilers for decoiling top and bottom skins, uncoilers for releasing top and bottom stiffeners, straighteners for threading and attaching the stiffeners to the skins, respectively, roll formers for shaping both skins and stiffeners into a structural shape, a foam injector for injecting foam between the skins to form an integrated continuous panel, a foam conveyor for pressing the integrated continuous panel, an oven for curing the integrated continuous panel, a clamp and cut-off saw for cutting the continuous panel, and a computer to control the saw to cut the continuous panel into selected kits of discrete panels to assemble selected buildings.

Abstract: A plastic foam-forming mixture, e.g. a polyurethane or polyisocyanurate foam mix, deposited on a carrier, is metered through two spaced opposed members forming therebetween a metering gap. At least one of the members is malleable through changes in temperature so that the profile of the metering gap can be variously defined. Foam boards having a highly uniform thickness are thereby continuously and expeditiously producible.

Abstract: A laminated carpet pad is manufactured by utilizing liner sheets which are fed along a conveyor path. Uncured, polymeric foam material is sandwiched between the liner sheets and is compressed between opposite facing parallel conveyor belts which are spaced apart so that the sandwiched layer of polymeric foam is compressed to a uniform thickness while curing. Additionally, an inner layer of padding material may be sandwiched between the liner sheets with the polymeric foam material bonding the padding material to the liner sheets as it cures.

Abstract: A method of producing an extruded plastics foam of enhanced physical strength includes intimately mixing a blowing agent incorporation CO.sub.2, the major portion of which is a natural gas, in a plastics resin melt to form a homogenous resin mix, and extruding the resin mix through an exit die into a region of lower pressure. At the point of extrusion out of the exit die, the temperature of the resin mix is adjusted so that it is below the critical temperature.

Abstract: A continuous process is disclosed for producing a strip of decorated ski coating material from ultra-high molecular weight polyethylene. A 0.5 to 1.5 mm thick strip of ski coating material produced in a screw-type or piston-type extruding machine or by sintering followed by peeling and printed with thermodiffusion dyes continuously runs through a heating zone in which it is uniformly heated up to a temperature above 140.degree. C., so that the crystalline structure of the ultra-high molecular weight polyethylene is partially decomposed and the thermodiffusion dye diffuses into the molten ski coating material without the need for an intermediate carrier.

Abstract: The invention relates to a method and an apparatus for the continuous production of foam blocks or sheets having an essentially rectangular cross-section from a foamable, liquid reaction mixture, possibly in the form of a liquid froth, in which the reaction mixture is applied from a stationary mixing head onto a moving lower facing sheet inclined in the longitudinal direction. An upper covering sheet is supplied from above and is brought into contact with the reaction mixture by means of a deflecting element. The deflecting element is flat in the longitudinal direction, so that a channel with an essentially constant cross-section is formed between the lower facing sheet and the upper covering sheet guided by the deflecting element, the length of which channel in a longitudinal direction is several times greater than its central height H.sub.M. The deflecting element can be oscillated about an axis at the entry end where it rests on the reaction mixture by the application of pressure.

Abstract: The present invention relates to a device for the continuous manufacture of slabstock polyurethane foam including a conveyor means (1), a mixing head (51) and means (6) for discharging the reaction mixture from the mixing head (51) onto the conveyor means (1). The device further includes a start board (7), a stop board, means for moving the start board (7) along the conveyor means at the beginning of a production run in such a manner that it obstructs the moving reaction mixture to thereby increase the height of the first portion of the produced foam, and means for moving the stop board at the end of a production run in such a manner that it pushes the foaming reaction mixture ahead to thereby increase the height of the end portion. In this way, no operator has to enter the foaming machine and the start and end profiles of the foam blocks are optimised.

Abstract: A method of manufacturing a carpet pad and the apparatus for the same are shown. A frame is provided to which is mounted a conveyor belt. The conveyor belt feeds a first liner sheet along a conveyor path from a forward end to a rearward end. A foam spray assembly is connected to an uncured polymeric foam supply having a spray nozzle mounted adjacent to the forward end of the conveyor path. The spray nozzle dispenses uncured, resilient polymeric foam as a generally uniform layer on a surface of the first liner sheet. A second conveyor belt mounted to the frame is located along the conveyor path and spaced apart from the second conveyor belt a selected distance. The second conveyor belt is parallel to the first conveyor belt and feeds the second liner sheet along the conveyor path so that the second liner sheet is positioned over the layer of foam.

Abstract: A water-based embossing composition for use in chemically embossing a foamable polymeric material having a blowing agent incorporated therein comprising: (A) a film-forming resin dissolved or dispersed in said aqueous composition; (B) a modifier which is effective in modifying the activity of the blowing agent comprising particulate solids which are substantially insoluble and uniformly dispersible in the liquid medium of the embossing composition and which have an average particle size of no greater than about 100 microns, said modifier being present in the composition in an amount of at least about 3 wt. %; and (C) optionally, a colorant or a softening agent for the modifier solids or a mixture thereof.

Abstract: A formed piece continuous manufacturing apparatus formed by four endless belts for carrying out a method utilizing such apparatus. At least three of the endless belts are movably supported by a movable device, and the sectional shape of the forming passage is freely controlled by arbitrarily moving at least three endless belts. A method of forming a fiber reinforced foam resin article using the apparatus is described.

Abstract: An apparatus for forming venting channels in a continuously-formed foam product includes a plurality of channel-forming plates which are removably attachable to the upper endless-type conveyor of a rigid foam laminating apparatus. The channel-forming plates provide a molding surface to form transverse channels in the foam product during the foaming operation. The channel-forming plates are easily removed for repair and/or replacement and include a centering bar which accurately positions each plate on the endless conveyor. The channel-forming plates are configured to form generally U-shaped channels in the upper surface of the continuously formed foam product to provide venting channels when the foam product is cut and used in roof insulation. The product and venting channels therein are sized to provide a continuous channel when a plurality of the foam panels are used as well as to facilitate attachment to standard trusses or joists.

Abstract: In the production of slabstock polymeric foam, foam reactants are delivered to a vessel (1), the reacting foam mixture passes over an overflow outlet (2) from the vessel and along a downwardly inclined fall plate (3) to a conveyor (4), two separate covering layers, namely a lower flaccid plastics film (26) and an upper relatively stiff paper foil (28), are applied over the reacting foam mixture near the overflow outlet (36), a blanket (40) weighted by free floating plates (46) is positioned over the cover layers in the foam expansion zone to press down lightly on the foam. The separate plastics film and paper foil are provided by delaminating a composite sheet (21), and are delivered to the foam surface in substantially tension-free condition by a take-off mechanism (22) which draws the composite sheet from a supply roll. Improved economy is achieved as a result of improved characteristics at the top of the foam block produced.

Abstract: In order to guarantee substantially trouble-free operation when manufacturing sandwich elements on a double conveyor belt installation having a downstream cross cutter and cleaning device, the cleaning device disposed on a transport carriage i) is returned to the carriage of the cross cutter to pick up the next sandwich element, is braked and is then re-accelerated to a speed higher than the production speed, ii) is, after reaching a desired distance.

Abstract: In the continuous production of polyurethane block foam, in particular from fast-reacting reaction mixtures which expand with rise time of less than 1.5 minutes, to achieve a good foam quality and a rectangular cross-section a centrally disposed mixer (44) is used, disposed downstream of which is a rubber-elastic plate (22), which is located in the feeding table (21) and in turn has a centrally disposed prop (33), associated with which, at right angles to the production direction and mounted laterally and symmetrically relative to said prop, are at least two adjustable props (32).

Abstract: A formed piece continuous manufacturing apparatus formed by four endless belts. At least three of the endless belts are movably supported by a movable device, and the sectional shape of the forming passage is freely controlled by arbitrarily moving at least three endless belts.

Abstract: In order to guarantee substantially trouble-free operation when manufacturing sandwich elements on a double conveyor belt installation having a downstream cross cutter and cleaning device, the cleaning device disposed on a transport carriage i) is returned to the carriage of the cross cutter to pick up the next sandwich element, is braked and is then re-accelerated to a speed higher than the production speed, ii) is, after reaching a desired distance.

Abstract: A continuous process for the preparation of a polymer-based foam sheet at ambient temperatures wherein the foam is produced from a reaction product capable of curing at ambient temperatures formed by the reaction of a reactant composition comprising a prepolymer, such as an isocyanate-capped polyether, and water, comprising:(a) providing a continuous substrate;(b) depositing said reaction product onto said substrate;(c) compressing said reaction subjecting said product to at least one compression of a predetermined degree after said reaction product has creamed but prior to the time said reaction product has finally cured; and(d) finally curing said reaction product.

Abstract: Flexible tubular film is helically cut into a flat strip by feeding the tubular film in flattened form from a supply source to a film feeding means advancing the flat film tube at a predetermined velocity to a tube expansion zone in which the flat tube is expanded into a generally cylindrical tube and passed axially over a hollow mandrel slightly less in external diameter than the diameter of the expanded tube to be cut helically while on the mandrel into a flat strop that is removed at an angle to the mandrel axis. The tube is expanded in the zone by inflation with air fed through the mandrel in a direction countercurrent to the direction of tube movement and under a pressure sufficient to render the expanded tube stiff as it slides over the mandrel and resistant to deformation while being helically cut.

Abstract: Processes for manufacturing in an environmentally friendly way, continuous, supported ion exchange membranes from (I) liquids containing vinyl and related monomeric electrolytes and high boiling solvents, the solvents also being swelling agents for the membranes; and (II) an indefinitely long, foraminous substrate.

Abstract: A high strength reinforced composite has an outer polymeric skin and an inner polymeric foam core chemically and mechanically bonded together at a high modulus, three dimensional interface comprising longitudinally continuous strands, randomly arrayed transverse strands, and randomly inclined short strands having end portions embedded in both the skin and the core.

Abstract: A method for continuously producing an insulation board comprising a rigid plastic foam core having two major surfaces and a facing material on one or both of the major surfaces, the method including conveying a facing material along a production line, depositing a partially expanded froth foam of a plastic mixture, which contains at least one frothing agent, on the facing material, and further expanding and curing the froth foam in contact wiht the facing material to form the insulation board. The board is particularly useful as roof insulation.