Abstract: A sponge of decrystallized cellulose modified by an acetyl group content, where the average degree of substitution is 0.2 to 1.5. No organic or inorganic sulfur compounds are present in the sponge. The sponge is produced by treating pulp with sodium hydroxide solution, then treating it with acetylating substances, drying and dissolving in an organic solvent with the addition of a pore-forming salt, fibers and optionally pigment dyes, pressing the mixture into a perforated mold whose receiving volume corresponds to the dimensions of the sponge to be produced, then placing the mold with its contents in boiling water, and removing the sponge thus formed in the mold.

Abstract: A method and apparatus in which an extruder with vacuum evacuation and gas injection means is multi-charged with a plurality of materials to extrude these over streamlined fuel-admitting pipes to make a laminated tubular feedstock serving as a moving enclosure for an intense fire with a fusible liner-layer of encapsulating glaze shielding the said feedstock outer lamination as it exits the said nozzle to telescope within a rotating perforated support tube that permits the centrifugal escape of heat-generated fluids and gases within a prior evacuated, pressure-modulated enclosure from which said gases are fractionally expelled to thermal diffusion and centrifugal/parabola/cyclotronic means providing molecular division by mass and weight after which the said divided gases are delivered into an evacuated inert media mass of particles moving in a like extrusion means to a like said rotating perforated tube but with elimination of the said laminated extruded lining replaced by a permanent solid support tube creati

Abstract: The invention relates to a method for producing plate-shaped or contoured components from an aqueous suspension containing 20 to 50% by weight of natural fibers, up to 4% by weight of a fixing agent and as the remainder of the suspension, thermoplastic material comprising a powder or fiber-like materials or a combination thereof. The components are made by a process comprising the steps of depositing the suspension on a screen, drying, heating and shaping the component under pressure.

Abstract: Stressed-skin panels are provided having internal open-cell grids molded from material such as fibers, and methods and apparatus for the production thereof are disclosed. The invention utilizes a porous screen having a plurality of elastomeric pads spaced apart thereon. Fiber dispersed in fluid is introduced into the apparatus and over and around the pads. Pressure exerted thereon expels fluid through the screen and consolidates the fibers to form a panel. The pads are designed and constructed in a manner so as to consolidate the fiber mat located below the pads compressed by the pressure, so that the finished panel includes an integrally-molded flange. The height, shape and/or spacing of the pads in the present invention advantageously provide improved mold release and greater resistance to compression set after repeated use. The pads provide greater consistency and improved quality in the flange formation on the panels.

Abstract: A foamed aqueous dispersion of a mixture of particulate plastics material is formed when the fibers are between 5% and 35% of the volume of the mixture, where no more than about 7% of the volume of the mixture is conductive fibers between about 7 and 20 mm long, and where any other fibers are reinforcing fibers with a high modulus of elasticity and between about 7 and about 50 mm long. A web is formed from the foamed dispersion using a wet laying process. The web is dried and compacted under heat and pressure. The compacted web is cooled to form a consolidated element in which the conductive fibers extend as a conductive lattice. The resulting element can be formed or molded into shielding to provide attenuation of electrical or magnetic fields.

Abstract: A shaped body of amorphous silicon dioxide, which has a chemical purity of at least 99.9% and a cristobalite content of at most 1% and which is impermeable to gas, is known. To provide shaped bodies of amorphous silicon dioxide which have a high precision, which can be small or large in size and of simple to complicated shape, which have a chemical purity of at least 99.9%, are impermeable to gas above wall thicknesses of 1 mm, which have a high cold flexural strength, low thermal conductivity and low radiation of heat, which are thermal shock resistant and can be exposed repeatedly or also long-term to temperatures in the range from 1000.degree. to 1300.degree. C. and which can be welded in a sharply delineated manner without spreading joins and which have a low spectral transmission from the ultraviolet to the middle infrared spectral region, the shaped body is opaque, contains pores, at a wall thickness of 1 mm has a direct spectral transmission which is virtually constant in the wavelength range from .

Abstract: A method is now disclosed for the making of compressed refractory fiber shapes, e.g., compressed ceramic fiber shapes, having a textured surface and an aggregate body. The shapes can be obtained by molding and therefore may be simple or complex. For the process, small discrete fragments of refractory fiber in accumulated form are suspended in a colloidal dispersion, such as the colloidal dispersion provided by colloidal silica. Colloidal mixtures, as of colloidal silica with colloidal alumina are also most serviceable. The fragments and the dispersion are mildly mixed so as not to thoroughly disperse the fiber fragments, but rather to form globules of the fiber in the resulting blend. The resulting material is shaped, e.g., molded under pressure, and usually dried while under pressure, which drying can be at elevated temperature.

Abstract: A reinforced molded body of ceramic, which is to be fired, is produced by adding ceramic fibers to a matrix of ceramic. The ceramic fibers are composed of silicon, nitrogen, oxygen, and carbon, the carbon and the oxygen having a total content of at most 10 weight % and having respective contents at a ratio ranging from 0.08 to 2.

Abstract: A building material and a method for its manufacture is provided wherein cellulosic, polymeric and acid wastes are treated and combined to produce a building panel which demonstrates low weight, high strength and good fire resistance.

Abstract: The object of the present invention is to improve the overall strength and interlaminar strength of a compact (green sheet) before hydrothermal reaction by using alunites, alums and aluminum sulfate having a specified specific surface area which does not require the addition of a setting retarder or a curing accelerator together with a curing agent in order to provide a method of manufacture for a lightweight calcium silicate board which does not give rise to interlaminar peeling or bursting during hydrothermal reaction and to provide such a calcium silicate board. The method of manufacture for a calcium silicate board according to the present invention is characterized by use of one or more species selected from alunites and alums with a Blaine specific surface area of 4000 cm.sup.2 /g or more or aluminum sulfate with a Blaine specific surface area of 2000 cm.sup.2 /g or more.

Abstract: The invention relates to a process for the production of shaped bodies, in particular packaging shaped bodies, from biologically decomposable material using a viscous mass containing biologically decomposable fiber material, water and starch, which is baked with the formation of a composite of fiber material and starch in a baking mould, and a shaped body produced according to this process. The use of native and pre-gelatinated or modified starch in connection with a fiber material feed stock from fibers or fiber bundles of differing lengths is especially advantageous.

Abstract: A method of making randomly oriented carbons fibrils having a cylindrical constant diameter with c-axes perpendicular to their cylindrical axis, which are free of pyrolytically deposited carbon, with a diameter of between 3.5 and 70 nanometers, by dispersing carbon fibrils in a medium and separating them from the medium, by filtration or evaporation to form a porous mat or sheet.

Abstract: A unique method of producing a reinforced moulded sheet having one continuously planar face and having a plurality of ribs or thickened areas which provide a corresponding plurality of prominences directed outwardly of the other face, said prominences having predetermined shapes, locations and dimensions to serve as reinforced areas for said sheet. And a series of new or improved composite hollow moulded panels, each comprised of at least two co-extensive elements, each of said panels being reinforced and improved by the provision of at least one of said reinforced moulded sheets as an external element of said at least two co-extensive elements, the ribs or thickened areas of said reinforced sheet being glued internally of said hollow panel to the adjacent co-extensive element thereof.

Abstract: A friction material and process of forming a friction material embodies a slurry of aramid, acrylic and carbon fibers, together with kaolin clay and aluminum oxide used as fillers in a phenolic resin binder. The matrix formed by the fibers entraps a relatively large quantity of carbon particles. The carbon particles comprise more than forty or fifty percent of the weight of the material. During the process of formation, the slurry is de-watered to reduce moisture content to the order of two percent before the resin binder is cured under heat and pressure.

Abstract: A concrete form liner includes a microporous membrane having pores that transmit water, but prevent the passage of particles with a diameter of 2 microns or greater, and a porous sheet having pores in the range of 0.2 microns to 60 microns on one side of the microporous membrane, the porous sheet having an air permeability at least five times greater than that of the microporous membrane. The form liner is permeable to air and water in a concrete mix, but is substantially impermeable to cement particles in the concrete mix. A drainage scrim may be juxtaposed against the side of the microporous membrane opposite the porous sheet.

Abstract: A method and apparatus for binding the fibers of, and forming a fiber reinforced plastic structure. A fiber reinforced plastic preform is created by depositing a mixture of reinforcing fibers, binding fibers and resin matrix fibers on a screen having a preselected geometry. The fiber reinforced plastic preform is exposed to high temperature fluid causing the binding fibers to melt and, thereafter, to cool air to temporarily bind the preform in a tackified state. The tackified preform is exposed to a higher temperature fluid causing the resin matrix fibers to melt and, thereafter, to cool air to solidify and thus bind and lock the reinforcing fibers of the tackified preform in place to create a homogeneous fiber reinforced plastic structure.

Abstract: A process is described for making a gypsum board having improved water resistance. The resulting gypsum board products are also described. The process comprises adding an aqueous siloxane emulsion to an aqueous slurry of a calcium sulfate material and host particles, where the siloxane emulsion is stable under the condition in which the slurry is maintained. The process further includes passing said siloxane containing slurry onto a flat porous forming surface to form a filter cake; removing a substantial portion of the water from the filter cake through the porous surface; pressing the filter cake to form a board and remove additional water; and drying the board to remove the remaining free water and to cause the core of the board to reach a temperature sufficient to cure the siloxane.

Abstract: A method and apparatus of producing and using composite fibers in a liquid molding process. The composite fibers are formed from a base material and filler particles which are lighter or less expensive than the base material. A preform screen is placed at the bottom of a tank. The tank is filled with liquid, the composite fibers and a mass of reinforcing fibers creating a slurry above the screen. The screen is raised up through the slurry causing the composite fibers and the reinforcing fibers to be deposited on the screen creating a fiber preform. The preform is then removed from the screen and is placed in a mold for use in a liquid molding process.

Abstract: A method for manufacturing a mineral fiber panel which comprises uniformly dispersing in water 60 to 90% by weight of a mineral fiber, 2 to 19% by weight of an organic binder, 1 to 20% by weight of an inorganic microfiber, 0.5 to 3% by weight of a flocculant and 0.5 to 10% by weight of a thermally expansible resin fine particle which has a diameter after expansion of not less than 0.03 mm but less than 3.0 mm, the expansion degree of the above diameter being at least 3 times, and which has an expansion-starting temperature of 50.degree. to 105.degree. C., as the composition components, to prepare a slurry, and thereafter subjecting the slurry to wet forming and then to drying. The above production process enables the enhancement of productivity and the mineral fiber panel obtained by the above production process is light in weight and excellent in sound-absorbing qualities and fireproof properties.

Abstract: The well known slip casting process for the production of ceramic green parts, in which hardening is achieved by water removal with porous molds, is characterized by disadvantages in terms of strength, shrinkage during drying and problems with cracking during drying. The present invention avoids these disadvantages and produces ceramic green parts by changing the surface potential of powder particles in the slip instead of by removing water. Further more the coagulation strength is increased by adding polymers or extremely fine divided colloidal particles.

Abstract: A method for forming thin green ceramic igniter shapes having a thickness characterized by a tolerance of no more than about +/-0.001 inch includes providing an apparatus having a porous mold having a well which defines a pair of opposing porous walls, and a plurality of vertical dividers positioned in the well in substantially parallel, substantially spaced relation where each divider contacting each opposing wall to define a plurality of compartments. A ceramic slip formed from a ceramic powder and a liquid carrier is poured into the compartments of the apparatus, dewatered through the opposing porous walls to form a plurality of green ceramic igniter shapes. The plurality of green ceramic igniter shapes are removed from the plurality of compartments.

Abstract: A method for producing insulating panels based on mineral fibers and paper fibers is disclosed. The panels are formed by preparing a suspension of mineral fibers, binders and conventional additives in water, forming the insulating panel by applying the slurry on a screen, drying and consolidating the insulating panel. Due to the use of surface active siloxanes, which contain betaine or quaternary groups, a more rapid and better dewatering of the filter residues, which are intended for the drying process, is attained.

Abstract: A ceramic porous body is constituted of ceramic particles which have a substantially continuous, monotonic size distribution in the thickness direction of the porous body.

Abstract: A ceramic body comprising at least about 80 w/o silicon nitride and having a mean tensile strength of at least about 800 MPa.

Abstract: A method of producing a self-sustaining body of refractory boride from the group consisting of the borides of titanium, chromium, vanadium, zirconium, hafnium, niobium, tantalum, molybdenum and cerium. This body includes a refractory boride and a dried colloid from the group consisting of colloidal alumina, silica, yttria, ceria, thoria, magnesia, lithia, monoaluminium phosphate and cerium acetate and is obtained from a slurry of the refractory boride in one or more of said colloids by casting the slurry on a porous plaster layer, and drying the cast slurry by draining through the plaster, or by pressing/drying. Subsequently, the dried body is subjected to heat treatment to bond the refractory boride in the dried colloid. The bodies are useful as components of aluminium electrowinning cells.

Abstract: The apparatus according to the invention for the slip casting of ceramic parts has essentially a bell which is arranged on a holding device and is vertically displaceable and a plurality of mold parts. The latter together with a base part form a mold which stands on a rigid plate. During operation of the apparatus, the mold and the bell covering it form an intermediate space in which are arranged a plurality of inflatable inflatable bladders air pockets which can cooperate in order to clamp the mold and prevent it from moving during the entire casting process. For this purpose, the inflatable bladders are connected to a compressed air source. In addition, a slip supply pipe which communicates with the stated compressed air pipe leads into the mold cavity of the mold, so that pressure equilibration between the mold cavity and the inflatable bladders can be brought about by means of the apparatus according to the invention.

Abstract: Improvements relating to composite materials. In a first aspect of the invention a distinctive and a less costly RTM preform is provided, along with a method of making it. In a second aspect of the invention, a distinctive preheating of an RTM preform provide enhanced surfaces on RTM composite articles.

Abstract: A method of molding at article capable of enduring temperatures of at least 1250.degree. F. without deformation or deterioration. High temperature resistant fibers cut to a length of one eighth of an inch are mixed with water to create a pool of slurry. A flexible mold having an article-forming cavity affixed to a suction chamber having means for injecting slurry into the cavity and means for the flow of liquid out of the cavity when the flexible mold and the suction chamber are under vacuum to create within the mold cavity an article of compacted high temperature resistant fibers. The mold is flexed causing the molded article to be released from the cavity within the mold.

Abstract: A method of slip casting for the manufacture of ceramic items, wherein the wall thicknesses are accurately determined by providing confined slip pool samples which visibly solidify on an external portion of the plaster of paris mold being used. The solidification of the sample is indicative of the moist wall thickness of the object being molded, when the mold is decanted at that instant of still liquid slip.

Abstract: This invention relates to making backwindable rod shaped batts or logs from highly oriented flash-spun continuous fibers. The fibers are conducted from the exit of a spinneret through a tunnel and into a two stage diverging nozzle to slow down the fibers for an organized collection in the collection section. The invention further includes an inflatable bladder in a discharge section for initiating the formation of the log and a mesh screen in the collection section for reducing the occurrence of fiber blow out through the gas discharge ports.

Abstract: The invention concerns the field of slip casting for producing green compacts. The disadvantage of state-of-the art slip casting is among others the need for removing the water through porous molds, the resulting shrinkage and the tendency of the green compact to form shrinkage cracks. These disadvantages are eliminated by internally coagulating by compression the double layer of solid slip particles, so that the green compact may be solidified without the need for removing the water.

Abstract: A solid o/w-type cosmetic composition, a process for molding it, and a container used for aqueous-type solid cosmetics. The cosmetic composition comprises (a) a water-soluble solidifying agent selected from agar and gelatin, (b) an oil component and (c) water, and optionally, (d) a powder or (e) a water-soluble adhesive. The composition has superior characteristics inherent in an o/w-type cosmetic, while providing excellent usability and portability. The molding process comprises applying a water-carrying sheet material to the surface of the composition before solidification and releasing it after solidification. The container for an aqueous-type solid cosmetic composition is characterized by having a water-absorbing material secured to a receptacle of the container.

Abstract: A sealing assembly for molds used for casting sanitary fixtures including at least one female die which is capable of defining the molding cavity of the item as well as at least one male die which is designed to be introduced into and withdrawn from said molding cavity, and which is provided with a mating surface capable of interacting with an associated mating surface of at least one female die. The sealing assembly includes a tubular elastic body of annular shape which is placed within a peripheral groove recessed in the mating surface of at least one male die, and which is connected to an assembly capable of alternately deflating and inflating said elastic tubular body so that the latter assumes a first transverse shape which is completely accommodated within the corresponding transverse-shape of the groove, and a second transverse shape which projects beyond the mouth of the groove, where it comes to rest against the facing associated mating surface of at least one female die.

Abstract: A disclosed gradient function material is produced by molding and thereafter firing a slurry which contains a plurality of groups of particles having different specific gravities. The plurality of groups of particles include at least a first group of particles and a second group of particles. The first group of particles comprises a group of nonmetal particles having a specific gravity ranging from about 3 to 7 and a maximum particle diameter equal to or smaller than a deflocculation limit, said nonmetal particles being made of one or more materials selected from the group consisting of an oxide, a carbide, a nitride, and an oxynitride. The second group of particles comprises a group of metal particles having a specific gravity which is about 1.5 times the specific gravity of said first group of particles, and particle diameters distributed across the deflocculation limit.

Abstract: Coated shields useful in a sputtering deposition chamber comprise a binder and particles of the same material as the target. Application of the coating material to interior surfaces and appliances of the sputtering chamber reduces contamination of the sputtered material.

Abstract: An improvement in a thermally insulating component for an engine part, made by sintering from ceramic materials, comprises, the thermally insulating component having a composition, consisting of a mixture of zirconium oxide in the range of about 5% to about 25% by volume and mullite in the range of about 75% to about 95% by volume. Further, the mixture of zirconium oxide and mullite is obtained by chemically mixing the zirconium oxide and mullite in their molecular states, rather than mechanically mixing them. Another feature of this invention includes, forming said thermally insulating component by slip casting and pressureless sintering the mixture of zirconium oxide and mullite at a temperature no greater than 1700.degree. C. This improvement in a thermally insulating component for an engine part, made from a mullite-zirconia ceramic composite, embodying the present invention, is particularly useful in making flame decks for cylinder heads, and insulating coverings for pistons and exhaust ports.

Abstract: A slurry is molded from ceramic fibers and/or microparticles to form a soft felt mat which is impregnated with a sol prior to drying the mat. A catalyst for the sol is caused to diffuse into the mat by exposing the mat to the catalyst and subjecting the mat to a soak time during which the catalyst diffuses into the mat and causes the sol to gel. The sol-gel binder forms bonds so that the mat is dimensionally stabilized. The mat is dried to produce ceramic insulation, ceramic insulation having a consistent microstructure and a fully gelled sol-gel binder through its entire thickness.

Abstract: A green body of a vessel-shaped piece of sanitary ware made by slip casting, such as a washbasin, is demolded by a robot having an arm provided at its free end with a suction pad which is brought into contact with the outer surface of the bottom of the green body to hold it by suction. The green body is, then, rotated or otherwise moved for finishing by a stationary device, while it is held by the robot. The robot enables the automatic demolding and finishing of the green body.

Abstract: A ceramic composite is provided comprising ceramic fibers and microparticles bound together as a porous matrix with a ceramic binder. The ceramic composite is particularly useful for transporting cryogenic fluids.

Abstract: A slip supply system for supplying slip to one or more casting molds includes a slip supply pipe 2 to which the base ends of pouring hoses 3 each having a pouring valve 4 are connected. The ends of the pouring hoses 3 are detachably connected to casting molds 1. A slip discharge pipe 20 having communicating holes 22 is laid in the vicinity of the slip supply pipe 2. The ends of the pouring hoses 3 are removed from the casting molds 1 and connected to the communicating ports 22 before supplying slip to the casting molds 1. Slip is fed in this condition, so that the solid matters attached to the interior of the slip supply pipe 2 and the interiors of the pouring hoses 3 are washed away to the slip discharge pipe 20. Thereafter, the ends of the pouring hoses 3 are connected to the casting molds 1 to feed slip to the casting molds 1.

Abstract: A porous mold for manufacturing ceramics comprises a porous mold body including a mold central portion and a mold outer peripheral portion and having mold surface of a shape corresponding to an outer shape of a suspension insulator and other similar ceramics to be manufactured having a small diameter hollow cylindrical central core portion with a closed head portion and a large diameter shed portion extended from the core portion in a radial direction, wherein water absorption percentage of a mold surface side portion of the mold outer peripheral portion is larger than that of the mold central portion. The water absorption percentage of the mold surface side portion of the mold outer peripheral is 20-30%, and that of a mold head portion of the mold central portion is 10-20%. A difference of the water absorption percentage between the mold surface side portion of the mold outer peripheral portion and the mold head portion is 5-20%.

Abstract: This invention relates to the preparation of a highly densified boron carbide ceramic body by the pyrolysis of a mixture comprising boron carbide powder and a preceramic organosilicon polymer selected from the group consisting of polysiloxanes, polysilazanes, polysilanes, metallopolysiloxanes and metallopolysilanes. Such highly densified ceramic bodies can be prepared by sintering under pressure or by utilizing a pressureless process.

Abstract: A metal shavings and chips compactor for extruding oil from metal chips and shavings and compacting the metal into easily transportable pellets. A compactor cylinder contains a piston and has an opening through which an auger feeds metal chips and shavings. A gate closes an end of the cylinder. A first hydraulic drive drives the piston under low pressure to close the opening and apply a first compacting pressure on the metal to form a loosely compacted pellet in the cylinder. High pressure then operates the piston to form a compact metal pellet substantially void of interstices. A second hydraulic drive opens the gate; the piston is operated at low pressure to discharge the compact metal pellet from the chamber and oil is collected below the cylinder. The compacting pressures are achieved through mechanical advantages provided by the size of the piston to that of the first hydraulic drive.

Abstract: A predominantly .beta.'-sialon-bonded silicon carbide refractory article is produced by reaction-nitriding a green body containing a plurality of silicon carbide powders, none having an average particle size greater than about 200 micrometers, a metal oxide oxygen source, fine grained silicon, and a source of aluminum. The invention also includes a raw batch and a process for producing the refractory article.

Abstract: The invention relates to a process for producing heat-insulating material from silicate-containing material, hydrated lime, water, foam and a reactive aluminates-containing quick-setting cement, from which a pourable raw mixture is produced which is poured into molds, the green moldings formed in the molds being demolded and autoclaved after sufficient setting. To achieve very low bulk densities, it is provided that, as silicate-containing material, a quartz powder with a specific surface area according to BET of at least approx. 3 m.sup.2 /g, in particular approx. 4 to 5 m.sup.2 /g, is used, the raw mixture is produced with a weight ratio of water/solids (excluding foam) of at least approx. 1.25 and an essentially stoichiometric amount, with respect to the virtually complete reaction of the quartz powder and the reactive aluminates, of hydrated lime with a surface area according to BET of at least approx. 15 m.sup.

Abstract: A ceramic article such as a sanitary pottery ware is produced by slip casting using a porous composite mold. A green ceramic body of a part such as a trap of sanitary ware is separately formed in advance by, for example, slip casting. The green ceramic body is placed in the mold cavity of the porous composite mold. Then, a slip as the material of the main part of the sanitary ware is supplied into the mold cavity to form deposit integral with the green ceramic body, whereby an integral sanitary ware is obtained by slip casting.

Abstract: A molded article is prepared by forming a core of glass beads secured together with a binder, inserting the core into a mold, injecting resin into the mold, curing the resin, solubilizing the binder to detach the glass beads from one another, and removing the glass beads from the molded article.

Abstract: This method is to mold a ceramic port liner from a ceramic material by drain casting. The slurry of the ceramic material is subjected to a pressure of 5 kgf/cm.sup.2 or higher in a mold. The method is also to mold under the condition that the mold is transformed by reducing a certain volume within the range of 0.3%-1.0% in the direction of constriction applied. According to this method, a ceramic port liner without deformation and unevenness in thickness can be obtained.

Abstract: Modified slip casting technique is used to manufacture a layered-ceramic structures having alternate layers of ceramics and carbon. The resulting layered structure has a density of over 95% of its theoretical density, fracture toughness of over 19,7 MPa.m.sup.1/2 and fracture strength of over 400 MPa.

Abstract: A machinable plaster prepared from a blend of water, plaster of paris and polyvinyl acetate. Making a pattern where the blend is poured into a form, and after solidification is cut to produce the pattern. The machinable plaster does not dust when cut, and can withstand moderate temperatures without softening.