Abstract: The present invention relates to shape deformable materials, which are capable of (1) being deformed, (2) storing an amount of shape deformation, and (3) recovering at least a portion of the shape deformation when exposed to electromagnetic radiation (EMR) energy. The shape deformable materials can advantageously be in the form of films, fibers, filaments, strands, nonwovens, and pre-molded elements. The shape deformable materials of the present invention may be used to form products, which are both disposable and reusable. More specifically, the shape deformable materials of the present invention may be used to produce products such as disposable diapers, training pants, incontinence products, and feminine care products.

Abstract: An apparatus and method for custom blending and fabricating lipstick to the specific demands of individual customers. The present invention provides a kit which enables a user to blend various pigments to arrive at a very specific shade, and then blend the desired shade with a specific base to result in a desired consistency of lipstick, and which also allows the blended bases and pigments to be heated to a liquefied form and poured into a mold for hardening. Upon cooling and hardening, a conventional lipstick case can be attached to the lipstick for removal from the mold and use by the customer. The present invention therefore not only allows a user to quickly attain the specific shade and consistency of lipstick desired, but also eliminates the time consuming and unsatisfactory process of visiting multiple stores having expansive inventories of variously shaded and textured lipsticks.

Abstract: A method of modifying at least part of the surface of a vulcanised rubber object including: (I) treating at least part of a surface of the vulcanised rubber object with at least one halogenating agent to provide a halogenated rubber surface; and (ii) treating the halogenated rubber surface with at least one multi-functional amine-containing organic compound to chemically bind said compound to the halogenated rubber surface; wherein the multifunctional amine containing organic compound consist of the elements carbon, hydrogen and nitrogen and optionally one of more of the elements oxygen, sulphur, halogen and phosphorous.

Abstract: I have developed an agglomeration process by which granules are formed by the steps of:

Abstract: An alkali metal-containing niobate-based piezoelectric material composition comprises a solid solution represented by a composition formula (ANbO3) (A: alkali metal), and at least one additive selected from Cu, Li and Ta.

Abstract: All of the current processes for making molded particleboard products require very long furnish dwell times within a heated press, due to the low heat transfer rates from the heated molds to the furnish being compressed. Furnish dwell times vary between approximately one minute to more than 10 minutes, depending upon the part thickness. Since profitability of a particleboard molding operation is closely related to product throughput, these long furnish dwell times within the heated press limit production rates and continue to be a major economic concern to the industry. The essence of the invention is a heretofore unsuggested use of radiowave energy to speed production of molded particleboard parts by preheating the furnish prior to the application of heat and pressure within the forming mold. Because radiowaves propagate readily throughout the volume of the furnish, rapid heating is obtainable even for a loose, uncompacted particulate furnish that has very poor thermal conductivity.

Abstract: I have developed an agglomeration process by which granules are formed by the steps of: (a) injecting polymer having sufficient viscoelasticity, and (b) impacting particles on the polymer at the injection point. The present invention is advantageous because it overcomes the problems of previous granulation process and subsequent art processes by having a very low recycle rate and allowing for control of granule size. It is particularly useful for fertilizer granule formation using a ureaform polymer and particles comprised of ammonium sulfate.

Abstract: A method for the production of molded bodies comprising foam particles is proposed in which the foam particles are shaped and welded together using microwave energy. The foam particles are accommodated in a foil-like bag and the bag is manually shaped or shaped through the use of a shaped mold with simultaneous change of the shape of the foam particles, and evacuated into a dense package. Microwave energy is subsequently used to melt together at least the surfaces of the foam particles. The method in accordance with the invention is particularly well suited as an economical manufacturing technique for packaging, in particular specialized packaging for models, small production runs, prototypes and the like.

Abstract: The present invention is a short time curing method of epoxy resin compositions composed of epoxy resins with more than 1.8 epoxy groups and curing agents which can react with epoxy groups and cure the epoxy resins at ambient temperatures or under the temperature raising conditions radiating microwave in the range of 300 MHz to 30 GHz frequency.

Abstract: A susceptor-impregnated thermoplastic foam is molded by heating the susceptor-impregnated thermoplastic foam, preferably by induction; imprinting an object against the foam; and allowing the foam to cool into a hardened form conformed to the object.

Abstract: A method and apparatus for producing tubular molded products from molding material includes a mold casing and a mold core having a common longitudinal central axis which is vertically disposed. The mold casing and mold core are spaced from one another to define a molding space therebetween. A supply device supplies molding material from above the molding space into the molding space. Treatment apparatus is disposed at treatment zones on the mold core for treating the molding material in the molding space, the treatment including treating the molding material by shaking the molding material or treating the molding material by heating the molding material, or both.

Abstract: The present invention relates to an improved method of manufacture of molded polymeric devices using variable frequency microwaves. Molded polymeric devices include, for example, contact lenses, corneal rings, intraocular lenses and drug delivery devices such as anterior or posterior chamber inserts. Contact lenses include soft and rigid gas permeable contact lenses as well as, lens blanks lathed into finished contact lenses. Molded polymeric devices further include medical devices such as prosthetics including hip joints. According to the present invention, a mold having a cavity the shape of the desired molded polymeric device, the cavity containing a composition comprising one or several monomers having double polymerizable bonds, is placed in a microwave chamber. The mold can be plastic, glass, ceramic or metal. Plastic is preferred. The mold is then swept with at least one range of microwave frequencies to polymerize the composition, thus forming the molded polymeric device.

Abstract: A method of consolidating metal powder to form an object, includes: a) pressing the powder into a preform, and preheating the preform to elevated temperature, b) providing flowable pressure transmitting particles and transmitting microwaves into the particles to heat same, and providing a bed of the flowable and heated pressure transmitting particles, c) positioning the preform in such relation to the bed that the particles substantially encompass the preform, d) and pressurizing the bed to compress said particles and cause pressure transmission to the preform, thereby to consolidate the preform into a desired object shape.

Abstract: A method for stretching plastic nets and grids having the peculiarity that it consists in subjecting the product to be stretched to irradiation with electromagnetic waves with a wavelength above the infrared range, so as to heat the product by dielectric loss, and in subjecting the product to traction in order to produce stretching in at least one direction. The method allows to substantially improve the ability of the polymer to absorb the energy in order to profitably perform the stretching process.

Abstract: For manufacturing a composite foam, having acoustic properties, foam flakes (8) of differing sizes, differing origins, and/or differing material compositions are wetted with a small quantity of a polyurethane dispersion binding agent. The mixture is subsequently combined to a molded part (1) or to continuous web and under the effect of hot (water) steam or microwave energy is cured and subsequently dried. The composite foam can be used for sound insulation purposes in vehicles and in general machinery construction, and also in building construction.

Abstract: A solid freeform fabrication process and apparatus for making a three-dimensional reinforcement shape. The process comprises the steps of (1) operating a multiple-channel material deposition device for dispensing a liquid adhesive composition and selected reinforcement materials at predetermined proportions onto a work surface; (2) during the material deposition process, moving the deposition device and the work surface relative to each other in an X-Y plane defined by first and second directions and in a Z direction orthogonal to the X-Y plane so that the materials are deposited to form a first layer of the shape; (3) repeating these steps to deposit multiple layers for forming a three-dimensional preform shape; and (4) periodically hardening the adhesive to rigidize individual layers of the preform.

Abstract: With a device for heating parts 8 made of a microwave absorbing plastic and having a microwave generator 1 that generates microwaves of a certain wavelength, an antenna 4 to which the microwaves are conducted, having at least one free end 5 and a device 6 which surrounds the antenna 4, it is proposed that the device for shielding 6 be designed with a tubular shape, so that the device 6 has an inside diameter smaller than half the wavelength, projects beyond the free end 5 of the antenna and has an opening 7 in its end face. With this device it is possible to achieve a spatially limited and nevertheless homogeneous heating of parts 8. Furthermore a method of heating or welding, shaping or crosslinking parts made of a microwave absorbing plastic using this device is also proposed.

Abstract: The present invention is an improved method involving microwaves for making polymer optical fiber cable and graded index optical fibers. The polymer can be any shape including, but not limited to, sheets, films or cable. The present invention also includes improved polymer optical fibers that incorporate quinine and quinone based compositions that shift the wavelength of radiation from ultraviolet radiation to visible radiation.

Abstract: A calendering apparatus and method for heatsetting a traveling multi-filament tow basically utilizes plural heated rolls about which the tow travels in a sinuous path to be conductively heated by the rolls and, at each roll, a plurality of infrared lamps in an arcuate arrangement facing the portion of the respective roll in contact with the tow simultaneously applies infrared radiation to the opposite side of the tow. In one embodiment, this arrangement of infrared lamps is retrofitted to a conventional calendering apparatus. An alternative embodiment provides for reducing or eliminating the number of calender rolls followed by a series of infrared heating tunnels collectively effective to accomplish heatsetting of the tow. The speed and/or throughput rate of each calendering apparatus and method is effectively twice that of conventional equipment of similar size.

Abstract: In order to manufacture compound composite bodies having at least two lay with a support material made completely or substantially from a polymer and with a porous layer firmly connected thereto, a substantially microwave-permeable polymer is utilized for the support material and a polymer having microwave absorbing properties is utilized for the porous layer. The polymer for the porous layer, treated with foaming agent, is heated with microwave energy up to the decomposition temperature of the foaming agent. The resulting polymer foam is sufficiently heated using microwave energy that the support material, at its bordering layer adjacent the foamed polymer, is sufficiently melted substantially due to heat conduction out of the foamed layer that, subsequent to cooling, a firm composite between the support material and the foamed polymer is effected.

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 microwaveable confection mold for use in a conventional microwave oven. The mold permits solid confection capable of melting when exposed to microwave energy to be introduced into the mold. The mold comprises a clear microwave transparent plastic material to facilitate observation of the confection melting process with subsequent settling in the mold sections. A pigment in the mold changes the colour to indicate to the user when the liquified confection has hardened and the mold cooled.

Abstract: The invention relates to a method and an arrangement for manufacturing a fiber product. The method and the process are characterized in that a first male mold (6) is immersed in stock in a molding tank (2a). By means of a vacuum, fibers are induced to form a fiber layer of predetermined thickness on the male mold (6). The male mold (6) is thereafter removed from the molding tank (2a) and a female mold (8) is brought under force against the male mold (6) in order to express the stock water, following which the fiber product (P) is transferred to the female mold (8). A second male mold (10) is brought under force against the female mold (8) so that the fiber is subjected to pressing in order to increase the dry solids content of the fiber product and give this a predetermined external structure, following which the fiber product (P) is released and subjected to final drying under the effect of microwave or IR radiation.

Abstract: The invention relates to a process for the chemical modification of solids containing alkyl groups. It is provided that the solids containing alkyl groups are heated to temperatures above their melting point and subjected to a plasma treatment in a frequency range from 10 kHz to 10 GHz.

Abstract: Disclosed is a method of manufacturing a cellulose ester film, the method comprising the steps of dissolving a cellulose ester and a plasticizer in a solvent containing a cyclic diether solvent to obtain a cellulose ester solution, casting the solution on a support to form a cellulose ester film, separating the cellulose ester film from the support, and drying the separated film, wherein the water content of the solution is 0.06 to 15 weight %, and the residual solvent content in the film at the separation step is 50 to 450 weight %.

Abstract: A continuous automated process is provided for manufacturing a phosphor product having controlled particle size characteristics and enhanced luminescent performance characteristics for use in a luminescent display. A precursor host lattice solution, a precursor dopant solution and reagent solution are initially selected as the starting materials for the phosphor product and are mixed together to produce a liquid starting material mixture. The mixture is conveyed to a microwave reactor and heated therein in a first heating stage by subjecting the mixture to microwaves at a predetermined frequency for a time sufficient to convert the starting material mixture to a precursor complex. The precursor complex is conveyed to a fluidized bed reactor and heated therein in a second heating stage by a hot fluidizing gas for a time and at a temperature sufficient to convert the precursor complex to the phosphor product in particulate form.

Abstract: The invention relates to a process for the chemical modification of solids containing alkyl groups. It is provided that the solids containing alkyl groups are heated to temperatures above their melting point and subjected to a plasma treatment in a frequency range from 10 kHz to 10 GHz.

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: A bed of particulate solids including some hydrated materials can be converted by controlled irradiation with subinfrared electromagnetic radiation into a unitary porous solid that is mechanically strong enough for easy handling. When the particulate solids include typical acid to alkaline cleaner materials, a block or tablet especially suitable for automatic cleaning machinery, with a very fast dissolution rate in water, can readily be obtained.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria. The inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength. The articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.

Abstract: A method for improving consolidation of powder resin is provided. The method broadly includes the steps of: (1) sorting particles of the powder resin according to their diameter; (2) combining the sorted particles having a first diameter D1 with the sorted particles having a second diameter D2 so as to form a particle mixture; (3) applying a vibration to the particle mixture; (4) heating the particle mixture; and (5) delivering the particle mixture through a nozzle or into a mold. The particle diameters D1 and D2 are chosen so that once combined there is optimal close packing of the three-dimensional spaces between the powder resin particles.

Abstract: A method for heating a glass sheet includes the steps of heating a glass sheet to a first predetermined temperature and applying microwave energy to the glass sheet to heat the glass sheet to at least a second predetermined temperature to allow the glass sheet to be formed.

Abstract: A method and apparatus for liquid thermoset resin or polymer molding using electromagnetic waves (particularly radiofrequency waves or microwaves), is described. The method and apparatus uses a metal mold (10, 212) with a cavity (401) for the molding as well as for confinement of the electromagnetic waves. Multiple low loss ports (A, B, C, D, E, p1, p2, p3) are provided for introducing the microwaves into the cavity.

Abstract: A method for the manufacture of pneumatic vehicle tires with a carcass extending between two bead rings and a breaker disposed between carcass and tread is described in which a tire blank is built up making exclusive use of non-metallic components and at least a part of the thermal energy required in the course of the vulcanization and shaping, which take place under the action of heat and pressure, is introduced into the tire in the form of microwave energy.

Abstract: Methods and apparatus for rapidly drying and compacting wet fiber mats are disclosed. Rapid drying is produced by heating the wet fiber mats with a combination of radiowave energy and conductive heating. As the fiber mats are heated, three-dimensional compacting forces are applied by pressing the fiber mats between a flat surface press and a porous support on which is mounted a resilient mold insert. At high radio frequencies in the microwave range, power is transmitted from a multimode cavity through the porous support and resilient mold insert to the fiber mat. At low radio frequencies, differential radio-frequency voltages are applied directly to metal press plates which contain and compact the fiber mat. Methods and apparatus can be adapted to conveyorized or multi-opening press operations. Objects suitable for use with the invention are most commonly characterized by having a flat face surface on one side and webs or other features which may extend normal or generally normal to the flat surface.

Abstract: A method of manufacturing pneumatic vehicle tires, the tires having a carcass which extends between two bead rings and a breaker arranged between the carcass and a tread, wherein the respective tire blank is built up using exclusively non-metallic components, and wherein, in the course of vulcanization and shaping which takes place under the action of heat and pressure, at least a part of the thermal energy that is required is introduced into the tire in the form of microwave energy. In order to improve the tire quality and in particular to avoid defects as a result of incorrect thermal treatment, the temperature which prevails in the tire is controlled in different tire regions in dependence on the temperature development and differently for different tire regions.

Abstract: A cellulose mixture including a protein based adhesive binder and colorant. The mixture can be compression molded or extruded and upon curing in the presence of microwave or radio frequency energy or in thermally controlled appliance, produces board or shape formed stock. The produced stock exhibits colorations and a grain pattern comparable to natural stone. Unlike stone, the material exhibits a light weight, low density, structural rigidity and ready machinability. A preferred method includes admixing separate, colorized batches of feedstock, each feedstock includes shredded waste newsprint, soybean flour, water and a colorant; reducing the moisture content of each feedstock or a proportioned admixture of several feedstocks, such as by air drying or compressing or performing the admixture in the presence of heat; compacting the admixture to final shape; and curing the shaped material. Final forming and finishing apparatus complete the process.

Abstract: A device for microwave treatment of materials includes a mold (1) used to hold the material (3) to be treated and a microwave generator which is used to apply to the mold (1) the microwave energy necessary for treatment of the material. The mold includes at least two dielectric materials (4,5,6,7) surrounding the material (3) to be treated. The dielectric materials have dielectric permittivities which differ so that the attenuation of one elementary segment of length l located between the points of side z(n-1) and zn of the longitudinal dimension of the material (3) to be treated which includes at least one section broken up into segments of length l, is controlled by the relationship: ##EQU1## in which: .alpha. is the attenuation in the elementary segment in question,.alpha.o is the initial attenuation in the body of the section which includes the elementary segment in question,Po is the microwave power applied to the section, P(n-1) is the microwave power transmitted in the plane of side z(n-1).

Abstract: Compositions and methods for manufacturing sheets having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more inorganic aggregate materials, fibers, and optional admixtures in the correct proportions in order to form a sheet which has the desired performance criteria. The inorganically filled mixtures are formed into sheets by first extruding the mixtures and the passing the extruded materials between a set of rollers. The rolled sheets are dried in an accelerated manner to form a substantially hardened sheet, such as by heated rollers and/or a drying chamber. The inorganically filled sheets may have properties substantially similar to sheets presently made from traditional materials like paper, cardboard, polystyrene, plastic, or metal. Such sheets can be rolled, pressed, scored, perforated, folded, and glued.

Abstract: Process and apparatus, in which a stream of liquid reactants is heated in a resonant microwave cavity operating in a TM.sub.0n0 mode and then provided with sufficient time in an annular plug flow reactor to complete the reaction results in improved time-temperature uniformity for all volume elements of the stream and are particularly suited for production of polyurethane prepolymer. A special cleaning method is provided for removing polymeric residues from the equipment with a solution of a monofunctional secondary amine in an organic solvent.

Abstract: Compositions suitable for application in powder coating processes are produced by melt atomisation of thermosettable mixtures. The product is characterised by improved particle size distribution and by a generally rounded particle shape.

Abstract: Superior microwave transparent thermal insulations for high temperature microwave sintering operations were prepared. One embodiment of the thermal insulation comprises granules of boron nitride coated with a very thin layer of glassy carbon made by preparing a glassy carbon precursor and blending it with boron nitride powder to form a mixture. The blended mixture is granulated to form a grit which is dried and heated to form the granules of boron nitride coated with a glassy carbon. Alternatively, grains of glassy carbon are coated with boron nitride by blending a mixture of a slurry comprising boron nitride, boric acid binder, and methyl alcohol with glassy carbon grains to form a blended mixture. The blended mixture is dried to form grains of glassy carbon coated with boron nitride. In addition, a physical mixture of boron nitride powder and glassy carbon grains has also been shown to be an excellent thermal insulation material for microwave processing and sintering.

Abstract: A method of removing a core from a molded product in which the core is formed of a particulate inert material, such as .[.sand-bound.]. .Iadd.sand, bound .Iaddend.together by a cured binder of a water soluble carbohydrate alone or mixed with a silicate is disclosed. The silicate is preferably an alkali earth metal silicate, preferably sodium silicate, and the carbohydrate is preferably a saccharide or starch. The binder is cured by heat. The core and molded product are exposed to water, preferably heated water in a bath or steam, to rapidly disintegrate the core and remove it from the molded product.