Abstract: Very small, individual polymeric microspheres with very precise size and a wide variation in monomer type and properties are produced by deploying a precisely formed liquid monomer droplet, suitably an acrylic compound such as hydroxyethyl methacrylate into a containerless environment. The droplet which assumes a spheroid shape is subjected to polymerizing radiation such as ultraviolet or gamma radiation as it travels through the environment. Polymeric microspheres having precise diameters varying no more than plus or minus 5 percent from an average size are recovered. Many types of fillers including magnetic fillers may be dispersed in the liquid droplet.

Abstract: In a fluidized-bed granulating apparatus for continuously producing granular particles from a powdered raw material, while a granulated product is continuously exhausted in a substantially constant amount from the bottom or bottom side wall of a fluidizing chamber and is introduced into a classifying section where the granulated product is classified by classifying means thereby selecting and delivering the granules granulated to particle size greater than the desired size and returning ungranulated material to the fluidizing chamber, the pressure drop of the fluidized bed is detected to adjust the charging rate of the powdered raw material into the fluidized bed and the moisture content of the material to be granulated in the bed is detected to adjust the feed rate of a binding liquid, thereby producing a granulated product of a desired particle size.

Abstract: An apparatus and process for producing liquid droplets having a narrow size distribution. Thin liquid streams are forced under pressure through a plurality of orifices in an orifice plate, the largest of which orifices has a diameter not greater than about three times the diameter of the smallest of those orifices. Also the thin liquid streams are vibrated to cause the breakup of each stream into droplets having a narrow size distribution.

Abstract: Fiber reinforced hollow microspheres made from dispersed particle film forming compositions including fibers, dispersed particles, a binder, a film stabilizing agent, a dispersing agent and a continuous liquid phase. Porous and non-porous fiber reinforced hollow microspheres can be made. The fiber reinforced hollow microspheres have walls with voids which are interconnected to each other and to the inner and outer wall surfaces, and the fiber reinforced hollow microspheres can be used as membrane substrates in selective separation processes and in biotech processes. The fiber reinforced hollow microspheres can be used as supports for catalysts and as enclosures for catalysts, adsorbents and absorbents. The fiber reinforced hollow microspheres can also be used as filler materials and as proppants for increasing gas recovery from gas wells.

Abstract: A method for producing fine particles of a thermoplastic resin by mixing the thermoplastic resin with a medium which does not dissolve the resin, at a temperature not lower than the softening point or melting point of the resin to prepare a hot dispersion, cooling the dispersion to a temperature lower than the softening point or melting point of the resin and separating the solidified particles of thermoplastic resin from the medium. The medium is a silicone oil with a viscosity of 100 cst/25.degree. C. or higher.

Abstract: Monosized ceramic particles produced through synergistic combination of monosized latex particles and organometallic reagents in a solvent system. By swelling a poly(vinyltoluene) or other monosized latex with an appropriate organometallic reagent, decomposing the organometallic to ceramic within the latex vehicle, and then removing the latex polymer through thermolysis, monosized ceramic particles are produced. The swelling of the monosized latex particles with the organometallic reagent requires the judicious selection of a solvent system specific to the latex polymer and organic being employed.

Abstract: The invention involves a method for making uniformly sized particles from water-insoluble drugs or other organic compounds. First, a suitable solid organic compound is dissolved in an organic solvent, and the solution can be diluted with a non-solvent. Then, an aqueous precipitating liquid is infused, precipitating non-aggregated particles with substantially uniform mean diameter. The particles are then separated from the organic solvent. Depending on the organic compound and the desired particle size, the parameters of temperature, ratio of non-solvent to organic solvent, infusion rate, stir rate, and volume can be varied according to the invention.

Abstract: A method and apparatus for producing uniform, monosize ceramic particles forming the microsize particles by vapor condensation or ultrasonic cavitation. Organometallic liquids are directed to an aerosol generator where a droplet stream is projected in free flight within a reaction chamber and a particle sorter. Through the process of sorting the droplets according to their velocity in flight, monosize droplets are collected. The particles may be reacted prior to or after sorting and collection to form the monosize ceramic particle of interest. Sintering aids are introduced into the process to produce ceramic particles capable of improved green body formation.

Abstract: A process and apparatus for preparing a homogeneous dissipation of a viscous, liquid-dissipatable polymer. The process comprises continuously feeding molten polymer into a first inlet of a mixing chamber, feeding a stream of a relatively low viscosity dissipating liquid into a second inlet of said mixing chamber at an angle, at a velocity and at a flow rate relative to the structure of said chamber such that shearing action is created at the advancing end of the polymer to continuously erode the end of the polymer, and further mixing the polymer and dissipating liquid downstream from an outlet of the chamber to form a homogeneous dissipation of polymer in dissipating liquid.

Abstract: A method is provided for producing commercially large quantities of high melting temperature solid or hollow spherical particles of a predetermined chemical composition and having a uniform and controlled size distribution. An end (18, 50, 90) of a solid or hollow rod (20, 48, 88) of the material is rendered molten by a laser beam (14, 44, 82). Because of this, there is no possibility of the molten rod material becoming contaminated with extraneous material. In various aspects of the invention, an electric field is applied to the molten rod end (18, 90), and/or the molten rod end (50, 90) is vibrated. In a further aspect of the invention, a high-frequency component is added to the electric field applied to the molten end of the rod (90).

Abstract: A manufacturing method for ceramic microspheres including the steps of; forming a suspension of ceramic fine powders as a dispersed phase and water as a dispersion medium; dispersing the suspension as droplets in a high boiling point liquid which has substantially the same specific gravity as the suspension and which is immiscible with water and nonreactive with the ceramic fine powder to make spherical particles; and subjecting the resultant product to drying and calcination.

Abstract: A process for producing a mixed ultrafine powder, which comprises reacting at least two metals or ceramics in the molten state with hydrogen, nitrogen, oxygen, a mixture of hydrogen and nitrogen or a mixture of nitrogen and oxygen. Each said gas or gaseous mixture being activated with a hot plasma, in an atmosphere of hydrogen gas, nitrogen gas, oxygen gas, a gaseous mixture of hydrogen and nitrogen, a gaseous mixture of nitrogen and oxygen, or a gaseous mixture of any of said gases with an inert gas under a pressure of 50 torr to 3 atmospheres to form ultrafine particles of said at least two metals or ceramics afloat in the atmospheric gas, and thereafter mixing the floating ultrafine particles of the metals or ceramics by a gas current.

Abstract: A minute metal powder is obtained by a method which comprises melting a metal, imparting ultrasonic vibration to the resulting melt, introducing an inert or reducing gas into the ultrasonically vibrated melt thereby producing minute bubbles therein, allowing cavitation to occur as soon as the bubbles reach the surface of the melt and consequently convert the melt into minute droplets, exposing or not exposing the minute droplets to oxygen, nitrogen, or propane, and solidifying the minute droplets by cooling. An apparatus for working the method described above comprises a metal melting tank, metal feeding means, gas feeding means, an ultrasonic vibration generator, means for detecting and retaining the surface of melt, and means for converting melt into minute droplets and solidifying the minute droplets by cooling.

Abstract: Very finely granular metal powders are produced by atomizing a liquid jet of metal by means of a gas jet which, in addition to a continuous band of sound frequencies, contains at least one discrete sound frequency which is at least 5 decibel above the average intensity of this band, and which is generated in a rotationally symmetrical device by means of a nozzle (4) which has the shape of a hollow cone and by means of an annular resonance space (7) with an annular edge (6) and is projected concentrically against the liquid jet of metal at a total opening angle of an average 35.degree. to 55.degree.. The atomization zone of the gas jet should preferably contain at least three discrete sound frequencies which are each at least 10 decibel above the sound intensity of the continuous band.

Abstract: A process for continuous production of fibrous, bonded material directly from a polymeric solution, primarily characterized by the polymeric solution being fed through a flow duct in which the fibers are formed by subjecting the solution, during its passage through the duct, to turbulence vibrations and simultaneous cooling.

Abstract: A process of making a wound dressing is suggested, in which a technical conventional viscose solution is mixed with a polysaccharide derivative; the mixture is treated at increased temperatures such that it is thermally coagulated; the coagulate is wetted with a polyalkylene glycol and dried, whereby a particulate structure of the wound dressing is produced.

Abstract: Granular solid particles, in particular hard, comminuted material of any given shape, are kept continuously in relative movement in a funnel-shaped container by means of a stream of liquid whereby they are rounded off. The rounded-off particles are suitable as filler material for wear-resistant coatings.

Abstract: Film with piezoelectric and pyroelectric properties is obtained by extruding PVDF, stretching the extrudate and applying a corona discharge, preferably at the place where stretching occurs. The PVDF may be homopolymer, but copolymers of at least 50 mole % of vinylidene fluoride with tetrafluoroethylene and/or trifluoroethylene may be used.

Abstract: A process is provided for reducing the size and number of undesirable gauge bands in wound-up rolls of wide nonwoven sheet that is produced by a plurality of oscillating fiber streams depositing fiber on a moving receiver. The desired effect is accomplished by varying the oscillation frequency of the fiber streams by more than .+-.5% of the average oscillation frequency.

Abstract: Relatively long metal microfilaments are used to make superior high strength structural materials and/or are used as reinforcing materials in plastic and rubber compositions. A blowing gas is applied at a positive pressure to the inner surface of a metal film formed across a coaxial blowing nozzle to blow the film and form an elongated hollow tube having a thinned wall or weakened portion. An entraining fluid is directed at an angle over and around the blowing nozzle and as it passes over and around the blowing nozzle fluid dynamically induces a pulsating or fluctuating pressure field at the opposite side of the blowing nozzle in the wake thereof and produces a laminar flow of entraining fluid in the vicinity of the forming elongated tube.

Abstract: The invention relates to a process comprising the cooling and comminuting of molten calcium carbide, wherein a molten stream of calcium carbide is tapped off from a furnace at 1900.degree. to 2100.degree. C., cooled and comminuted. More particularly, the molten calcium carbide is initially comminuted into droplets and the droplets are cooled to less than 200.degree. C. The process can be carried out with the aid of an apparatus comprised of a heatable or coolable feed duct, a nozzle for comminuting the molten stream, and a series of fluidized bed cooling zones.

Abstract: A process and apparatus for the preparation of aqueous synthetic resin dispersions by using water to precipitate the synthetic resins from their solutions in water-miscible solvents. The solutions may contain pigments, extenders, and additives. The precipitated solids are separated off and dispersed uniformly in an aqueous medium. The precipitation of the synthetic resins is carried out in the presence of inert grinding bodies.

Abstract: Solid products of spheroidal shape and having a maximum diameter of 1 to 5,000 microns are prepared starting from a mixture of at least two immiscible, mutually chemically inert liquids, one of which is in the form of a molten solid, said liquids being prsent in the mixture in a ratio such that one forms the dispersed phase while the other is the continuous phase, at least the liquid forming the dispersed phase being one which solidifies on cooling.

Abstract: Molten magnesium alloy is stirred under a substantially inert atmosphere as it is cooled to freezing, thereby forming discrete solid particles of the alloy. The process may be carried out batch-wise or continuously.

Abstract: Apparatus for the pelletization of heat liquifiable materials, such as metallurgical slags consists of a downwardly-extending feed plate onto which the molten material is fed together with water, if required to promote the expansion of the molten material and for control of the cooling. The material discharges from the feed plate onto a rotating radially vaned drum by rotor by which it is projected into the air for simultaneous cooling and pelletization after it has first passed through a flow control gap formed between the feed plate surface and the periphery of a second rotor mounted above the feed plate. The second rotor is rotated in the direction such that it promotes the flow of the molten material down the plate, forcing the material between the vanes of the projecting rotor, while at the same time spreading the material across the width of the plate against its natural tendency to form a compact stream.

Abstract: A method is provided for producing ultra fine particles of metal by delivering a molten stream of metal onto a rotating primary annular surface, discharging molten fine droplets from the edge of the primary annular surface against an inclined secondary annular surface surrounding the primary surface at an angle such that the molten droplets striking the secondary surface are sub-divided and discharged from the secondary surface to be cooled and collected as ultra fine particles.

Abstract: Metal in the form of granules is solidified from the molten state by forming a jet of molten metal which is caused to pass through a vibrating orifice in order to divide the jet into individual drops and causing solidification of the drops by cooling so as to form the granules. The drops of the jet are caused to fall from the vibrating orifice under the action of gravity through an inert gas atmosphere which is maintained at a temperature below the solidification temperature of the molten metal. In the case of reactive metals, the jet is formed by withdrawal from a mass of molten metal maintained in contact with a bath which is not miscible with the molten mass and selectively dissolves the derivatives produced in the event of oxidation.

Abstract: A vibrating body is so provided as to surround a jet stream composed of a capsule film material and a capsule filler material extruded from the orifice of two coaxial conduits positioned in a cooling liquid medium. The vibrating body can be controlled in reciprocating vibration in the upward and downward directions whereby it is possible to produce waves in the cooling liquid medium which are most suitable for obtaining the required diameter of capsules and the required speed of manufacture. The jet stream is formed into spherical capsule drops at markedly increased speed of manufacture owing to the control of vibration of the vibrating body and interfacial tension.The method for obtaining seamless capsules can ensure the possibility of manufacture of very small capsules, i.e. miniature capsules by mass production which has never been accomplished satisfactorily by the conventional methods and apparatus in the industry.

Abstract: A process for producing an open cell foam. The process comprises mixing a polyvinyl chloride composition, plasticizer, at least one stabilizer, and a foaming agent to form a blend; gelling the blend; forming the gelled blend into a sheet; and heating the sheet to decompose the foaming agent thereby forming the open cell foam. The sheet formed by the process. The process for forming an intermediate used in the process and the intermediate itself.

Abstract: Substantially pure, free flowing, sodium amalgam particles of predetermined composition and controlled particle size are prepared for use as vaporizable fill for high pressure discharge lamp devices, whereby accurately measurable quantities of the sodium amalgam may be introduced into the lamp devices. A process for producing the substantially pure amalgam particles of accurately controlled size includes heating a mixture of sodium and mercury to form a melt, passing the melt through a vibrating discharge nozzle and subjecting the droplets so formed to an inert cooling fluid maintained at a temperature below the solidification point of the amalgam. An apparatus for producing the amalgam particles comprises a vessel to contain an alkali metal amalgam melt, a virbrating discharge nozzle adatped to form the melt into uniformly sized droplets, and a column of inert cooling fluid maintained at a low temperature at which the melt droplets are solidified.

Abstract: Hollow metal microspheres are made by forming a liquid film of molten film forming metal composition across a coaxial blowing nozzle and applying a blowing gas at a positive pressure on the inner surface of the metal film to blow the film and form an elongated cylinder shaped liquid film of molten metal. An inert entraining fluid is directed over and around the blowing nozzle at an angle to the axis of the blowing nozzle so that the entraining fluid dynamically induces a pulsating or fluctuating pressure field at the opposite side of the blowing nozzle in the wake of the coaxial blowing nozzle. The continued movement of the entraining fluid produces asymmetric fluid drag forces on the cylinder and closes and detaches the elongated cylinder from the coaxial blowing nozzle. Surface tension forces acting on the detached cylinder form the latter into a spherical shape which is rapidly cooled and solidified by cooling means to form a hard, smooth hollow metal microsphere.

Abstract: Oxide refractory materials (for example, alumina-zirconia mixtures) can be cast to have an extremely fine crystal structure by casting them onto a non-reactive, non-melting particulate solid cooling media of a material other than that of the oxide refractory material (for example, steel spheres having a size ranging from about 5 to about 60 mm). By using steel spheres as the cooling media, the spheres can be removed from the solidified material with a magnet. The solidified material, when crushed and graded, has exceptional utility as an extremely tough abrasive grain.

Abstract: This disclosure is directed to strengthening carbon-black particulate "Teflon" (PTFE) mixes destined to be formed into active layers in air cathodes, which comprises mixing an aqueous dispersion of particulate polytetrafluoroethylene with an aqueous suspension of particulate carbon-black; washing and drying; mixing with a pore-forming agent; fibrillating said mixtures; washing and drying; adding polytetrafluoroethylene fibers while chopping said dried fibrillated mixture and thereafter forming said chopped mixture into a sheet, which was washed and dried.

Abstract: A process is provided for obtaining particles of thermoplastic resin which comprises agitating said resin in the molten state in an aqueous dispersion system comprising a resin dispersing amount of an alkali metal soap and an oversized particle formation-suppressing amount of an alkaline earth metal soap and cooling the resulting dispersion to obtain said resin as finely divided particles of which no more than about 5 weight percent of the total exceeds an average diameter of about 420 microns.

Abstract: Latex material disposed in a solvent is injected into a sheath fluid into which the solvent is soluble, but the latex is not. The solvent being jetted from a vibrating nozzle forms droplets within the flowing sheath, which is then delivered onto an inclined hydrophobic surface reposing at a low angle to the jet. As the droplet containing stream strikes and flows down the surface, its velocity is taken up as the phase separation process for forming microparticles begins.

Abstract: In the processes for the production of solid particulate sulfur by prilling or granulation, wherein molten sulfur emanates from a spray means, such as a prilling device or spray nozzle, interruptions occur in the flow of sulfur from the spray means. The uneven flow of molten sulfur from a spray means can be substantially eliminated by applying vibration to the spray means, preferably in the diection of flow of molten sulfur through the spray means, at a low frequency in the range of 0.2 to 30 cycles per second. The molten sulfur emanating from the spray means is at a temperature of at least one Celsius degree above the melting temperature of sulfur and under a pressure of at least 250 Pa. The flow rate of sulfur from the spray means is uniform and steady, the particulate sulfur product is hard and closely sized, and the emission of sulfur fines discharging from the process is reduced.

Abstract: A core/sheath vibrating system is utilized to produce core droplets within the sheath, which in turn form into microparticles through phase separation. The flow momentum is first arrested by means of an inclined surface, and the combination is thence deposited, in a continuous, helical channel extending from one end to the other of the inside of a hollow, rotating drum. Rotation of the drum moves the forming microspheres through the channel. At the exit end of the drum, the sheath fluid which carries suspended microspheres, may be filtered, and the microspheres collected and utilized.

Abstract: Latex material disposed in a solvent is injected into a sheath fluid into which the solvent is soluble, but the latex is not. The solvent being jetted from a vibrating nozzle forms droplets within the flowing sheath, which is then delivered onto an inclined hydrophobic surface reposing at a low angle to the jet. As the droplet containing stream strikes and flows down the surface, its velocity is taken up as the phase separation process for forming microparticles begins.

Abstract: A method is disclosed for producing solid materials in form of microspheres or spherules for a number of applications, such as nuclear fuel, catalyst, fluid beds for fluidization and other like applications. An inert gas shield is provided to surround the droplets of liquid from which the microspheres shall be originated so as to prevent a premature reaction of such droplets with the reactive gas. Provision is made for renewing the braking foam placed over the liquid reactive bath and the reactive gas is supplied in the form of a blade-like stream so as to improve the contact time and intensity between the droplets and the reactive gas.

Abstract: A system is described for forming hollow spheres containing pressured gas, which includes a cylinder device (14) containing a molten solid material (20) and having a first nozzle (18) at its end, and a second gas nozzle (24) lying slightly upstream from the tip of the first nozzle and connected to a source (26) that applies pressured filler gas that is to fill the hollow spheres. High pressure is applied to the molten metal, as by moving a piston (22) within the cylinder device, to force the molten material out of the first nozzle and the same time pressured gas fills the center of the extruded hollow liquid pipe that breaks into hollow spheres (12a). The environment (54) outside the nozzles contains gas at a high pressure such as 100 atmospheres, the gas is supplied to the gas nozzle (24) at a slightly higher pressure such as 101 atmospheres, and the pressure applied to the molten material (20) is at a still higher pressure such as 110 atmospheres.

Abstract: Powders of thermoplastic resins such as polyethylene homopolymer and ethylene-vinyl acetate copolymer are obtained by agitating molten resin in admixture with water and in the presence of a dispersing amount of a substantially water insoluble ionomer polymer.

Abstract: A process for the preparation of dispersions of optionally cross-linked ethylene-vinyl ester graft polymers wherein an ethylene-vinyl ester copolymer is used as graft substrate and a vinyl ester of a C.sub.1 -C.sub.18 carboxylic acid and/or a C.sub.1 -C.sub.10 -alkyl ester of acrylic and/or methacrylic acid are used as a graft monomer which is polymerized, optionally together with a cross-linking agent having two or more C--C double bonds, in organic solution until at least 25% by weight of the graft monomer has been reacted, the reaction product is converted into a stable finely divided dispersion by the addition of a precipitating agent under the action of shearing forces and polymerisation is completed before, during or after the formation of the dispersion.

Abstract: Powders of thermoplastic resins such as polyethylene homopolymer and ethylene-vinyl acetate copolymer are obtained by agitating molten resin in admixture with water and in the presence of a dispersing amount of a substantially water soluble salt of an interpolymer of (i) at least one ethylenically unsaturated ester derived from an alpha, beta-ethylenically unsaturated carboxylic acid and a lower alkanol and (ii) at least one alpha, beta-ethylenically unsaturated carboxylic acid as dispersing agent.

Abstract: Powders of self-dispersing ionomer polymer of controlled particle size distribution are obtained by agitating molten resin in admixture with water and in the presence of a particle size distribution regulating amount of acid or base.

Abstract: The disclosure is directed to a method for producing relatively uniform hollow spheres of a substance, the hollow spheres being formed with a gas therein as a result of the production process. The spheres, formed for example of hydrogen isotopes, are particularly useful as a fuel target for laser fusion applications. In accordance with the method of the invention, a jet of the substance of which the spheres are to be formed is provided in liquid form. Relatively uniform gas bubbles are injected into the liquid jet. In this manner, the bubbles break up or separate the liquid jet into relatively uniform hollow spheres of the substance, each with a bubble of the gas inside. The hollow spheres can be visualized as liquid droplets, each having a relatively uniform gas bubble therein.

Abstract: This invention provides a process for producing spherical carrier particles for olefin polymerization catalyst, which comprises(i) forming a suspension of molten droplets of an adduct of a halogen-containing magnesium compound and an active hydrogen-containing organic compound in an organic liquid medium in the presence of at least one oil soluble surface-active agent as an auxiliary component, and(ii) quenching the resulting suspension to solidify the adduct particles.

Abstract: Uniform particles are produced by introducing a laminar stream of a core liquid into a laminar flowing body of an immiscible sheath liquid. The core liquid or the sheath liquid, or both liquids, can contain one or more materials dispersed (dissolved or suspended) in them from which the uniform particles are formed. The two liquids and the dispersed material are expelled from a nozzle to form a liquid jet. The liquid jet is disturbed at a uniform, periodic rate to form liquid droplets which contain a uniform amount of the core liquid, the sheath liquid and the dispersed material. The droplets are collected and held in a catch liquid until the core and the sheath liquid in each droplet have diffused into the catch liquid leaving the uniform particles formed from the dispersed materials. There can be more than one sheath liquid which can also contain one or more materials dispersed in it.

Abstract: Hollow spheres with precisely concentric inner and outer spherical surfaces are formed by applying vibrations to a nonconcentric hollow sphere while it is at an elevated temperature at which it is fluid or plastic, the vibrations producing internal flows which cause the inner and outer surfaces to become precisely concentric. Concentric spheres can be mass produced by extruding a material such as glass or metal while injecting a stream of gas into the center of the extrusion to form a gas-filled tube. Vibrations are applied to the extruded tube to help break it up into individual bodies of a desired uniform size, the bodies tending to form spherical inner and outer surfaces by reason of surface tension, and the continuing application of vibrations causing these surfaces to become concentric.

Abstract: A mixture of powdered metal oxide and thermally decomposable organic binder is formed into particles or beads of a controlled size. The beads are heated to a temperature sufficient to decompose the binder to carbon or to oxidize it completely. If desired, porosity control agents, such as starch, may also be included in the original mixture.

Abstract: Powders of thermoplastic resins such as polyethylene homopolymer and ethylene-vinyl acetate copolymer having controlled average particle sizes are obtained by agitating molten resin in admixture with water in the presence of a dispersing amount of a polyalkylene oxide surface active agent and a particle size-controlling amount of an alkanolamide surface active agent.