Abstract: A method for decontaminating of concrete and more specifically to methods used for in-situ thermal desorption of contaminants from concrete, such as PCBs is disclosed. The methods employed heat the concrete at reduced pressure and at a temperature sufficient to volatilize and draw off the contaminant vapors so that the concrete is decontaminated to greater depth than previously obtained, that no concrete waste is created which requires disposal, that the methods produce no secondary liquid waste, that no chemical agents are required, that the decontaminated concrete material can be reused, that the methods are safer for workers because there is no contaminated dust formed during the process and specifically that the process produce a low energy cost per unit area decontamination for the concrete.

Abstract: The process for removal of contaminants from coolants involves using an inorganic hydrophilic membrane, such as a ceramic membrane with varying pore sizes, to remove lead particulates, including soluble lead that is converted to insoluble lead precipitates, and oil from machining coolant solutions. The treated coolant with the lead substantially removed is then recycled back to the coolant tank that is used for machining lead alloy parts.

Abstract: This invention provides a method or process for separating an organic chlorinated contaminant such as polychlorobiphenyl from an inert porous material which comprises admixing the material with an effective amount of a volatilizable organic liquid in which the contaminant is soluble, heating the admixture under vacuum to a temperature above the boiling point of the organic liquid but below the decomposition temperature of the organic liquid and the contaminant, while maintaining a flow of an inert sweep gas through the porous material, and collecting the vapors for further treatment which includes recovery of the organic liquid for reuse in the decontamination of soil and other porous materials. Recovery of the organic liquid is achieved by passing the vapors from the separation step through a bed of activated carbon at a temperature above the vaporization temperature of the organic liquid.

Abstract: An insulated mold insert is provided for injection molding compact disks and optical disks. The mold insert is removably located in the mold cavity behind the stamper. The mold insert has an insulation layer retaining heat at the molding surface, thereby increasing surface smoothness of the molded part. The insert may have a metal surface for contacting the back side of the stamper.

Abstract: Fluoride is recovered from an aqueous ammonium fluoride and ammonium hydroxide solution by electrolyzing the solution in an electrochemical cell having an ion-exchange membrane between a catholyte chamber and an anolyte chamber whereby hydrofluoric acid is formed and the concentration of ammonium hydroxide is enriched. Part of the hydrofluoric acid can be combined with the ammonium fluoride remaining after the ammonium hydroxide had been stripped from the treated solution to produce ammonium acid fluoride.

Abstract: An expanded fiber composite structure and process for making an expanded fiber composite structure are provided. The expanded fiber composite structure is made up of a fiber mat held in partial compression by a monolithic plastic coating on the fibers, the structure having a plurality of interstitial voids which may optionally be filled with a polymeric interstitial material. The process includes impregnating a fiber mat with a plastic material, compressing the mat to impregnate the mat with the plastic, fully wetting each fiber and creating a substantially void-free fiber/plastic matrix, and reducing the compressive forces on the mat, allowing the fibers to rebound and expand the mat to a predetermined desired thickness, in the process creating the interstitial voids. The structure is then cooled such that the plastic material stiffens and itself retains the structure at the desired thickness.

Abstract: Apparatus and method for regenerating saturated adsorbents using microwave energy. A saturated adsorbent, such as activated carbon, is fed onto a continuously moving conveyor belt. The conveyor belt transports the carbon to a microwave cavity where the carbon is exposed to microwave energy. The cavity is defined by a containment enclosure which is sealed to prevent radiation leakage. The carbon is heated to a sufficient temperature to cause the contaminants to desorb. The system also includes vents for removing the desorbed contaminants and a holder for receiving the treated carbon discharged from the belt. The microwave cavity may be divided into a number of heating compartments so that the carbon on the belt is heated to different temperatures in each compartment. Each compartment is separately vented, thereby allowing selective recovery of the different contaminants in the carbon.

Abstract: An expanded fiber composite structure and process for making an expanded fiber composite structure are provided. The expanded fiber composite structure is made up of a fiber mat held in partial compression by a monolithic plastic coating on the fibers, the structure having a plurality of interstitial voids which may optionally be filled with a polymeric interstitial material. The process includes impregnating a fiber mat with a plastic material, compressing the mat to impregnate the mat with the plastic, fully wetting each fiber and creating a substantially void-free fiber/plastic matrix, and reducing the compressive forces on the mat, allowing the fibers to rebound and expand the mat to a predetermined desired thickness, in the process creating the interstitial voids. The structure is then cooled such that the plastic material stiffens and itself retains the structure at the desired thickness.

Abstract: A process for impregnating a glass fiber mat with a resin, and for producing composite structures having impregnated glass fibers, is provided which substantially reduces the number of voids in the resulting structure, provides fast and efficient heating of the materials, and requires low capital cost equipment to perform the process. The process includes heating a glass fiber mat and an RF-sensitive resin in a radio frequency electromagntic field to quickly heat the mat and resin, the resin flowing into voids in the glass fiber mat, thereby impregnating the mat; forming the resulting composite structure into a desired end shape; and cooling the structure. Reduction in the number of voids is advantageously accomplished by impregnating the resin into the mat under vacuum, which removes air and decomposition products which result from the RF heating of the resin.

Abstract: A multilayered insulated mold structure is provided. An insulation layer provided on each of the mold cores retains heat at the molding surface, thereby increasing surface quality of the finished part. The insulating layer has a varying density across its thickness so as to have a low density center region and high density surface regions. By having a relatively low denisty, the center region of the insulating layer has a low thermal conductivity. Thus, the insulating layer may be made from the same material as the core and still have an acceptable insulating value. The use of the same material for adjacent layers reduces the potential of delamination of the layers. The multilayered mold is compatible with passive or active heating of the molding surface.

Abstract: A process for forming an expanded fiber composite structure. The process includes impregnating a fiber mat with a plastic material, compressing the mat to impregnate the mat with the plastic, fully wetting each fiber and creating a substantially void-free fiber/plastic matrix, and reducing the compressive forces on the mat, allowing the fibers to rebound and expand the mat to a predetermined desired thickness, in the process creating interstitial voids. The structure is then cooled such that the plastic material stiffens and itself retains the structure at the desired thickness. The process optionally employs the addition of a molten polymeric material to the expanded or lofted mat, the material filling the interstitial voids in the structure. A composite structure may optionally be produced from a fully compressed plastic-impregnated fiber mat by heating to a temperature sufficient to loft the material and controlling the amount of lofting after the heat is applied.

Abstract: A thermoplastic sheet is placed between a pair of mold members each having a thermal insulator and a mating metal mold insert. RF energy is applied to the inserts to dielectrically heat and melt the thermoplastic sheet. The heated sheet is then deformed in a low pressure press with the insulators. The insulators are then replaced with cool thermally conductive structures to shorten the cooling cycle time. The thermally conductive structures cool the sheet by pressing the sheet in a high pressure press.

Abstract: A process for forming a thermoplastic resin coating on glass fibers comprises heating a thermoplastic resin powder until molten and applying it to the glass fibers. The coated fibers can then be heated and drawn into a desired shape which also removes resin. Then the coated fibers are cooled to make a preform. The coated fiber preform can then be molded. Several resin layers with glass fibers of varying lengths can be deposited to make a graded preform. Apparatus for forming a thermoplastic resin on glass fibers sprays hot thermoplastic powder on the glass fibers. The coated fibers can then be heated such as by IR lamps and then drawn through a die which has a spigot to remove excess plastic. Alternately, a plurality of plastic and glass fiber layers can be deposited on a veil.

Abstract: Expandable thermoplastic resin beads coated with a novel very high frequency energy absorbing material are expanded with microwave energy.

Abstract: A metal mold core which is partially insulated includes a metal continuous hard skin layer over the core and over the insulation to avoid discontinuity caused delamination in the presence of flowing injected plastic. The skin layer includes abrasion resistant nickel deposited over electroytically and electrolessly deposited copper applied over an interface metal layer on the core. The insulation layer includes multiple layers of a polyimide resin one of which layers includes glass micro spheres for decreasing the thermal conductivity to increase its insulation property and for decreasing the coefficient of thermal expansion (CTE) of the insulation to more closely match the core CTE to further preclude delamination in the presence of temperature excursions.

Abstract: A dielectric mold member has different thicknesses producing different radio frequency (RF) voltage drops thereacross. An RF electrode is spaced differently from a thermoplastic sheet to be dielectrically heated by the RF energy such that in one implementation the sheet receives uniform potentials and is heated uniformly. In other implementations, the sheet can receive selectively controlled heating over different regions. In an alternative embodiment, multiple pairs of electrodes apply different RF field levels to different portions of the thermoplastic sheet to compensate for the different voltage drops due to different mold thicknesses or to applied different controlled heating levels to different regions.

Abstract: A mold structure including layers with different physical properties is used to provide hot surface during molding. The use of a thin layer of low thermal conductivity covered by a smooth skin layer prevents quick cooling of the surface of the pre-heated plastic to be molded. The plastic surface remains molten and flows to fill the mold during press closing, resulting in smooth surfaces even when fiber reinforced plastics are used.

Abstract: A molding system utilizes a cold mold with a large thermal mass and contoured thin mold inserts with a low thermal mass. A composite sheet blank of glass fibers in a thermoplastic matrix resin is placed between the inserts, heated and then transported to the cold mold. The composite sheet is pressed in the cold mold between the mold inserts to flow form and then cool the part. The mold inserts keep the surfaces of the composite sheet hot during the forming process, thereby enabling the matrix resin to flow and form smooth surfaces.

Abstract: A multilayer mold for use in blow molding parts within short cycle times is provided. The multilayer mold has a hard skin layer, an insulating layer and a base containing cooling means. The transient temperature increase of the skin layer of the mold as a hot parison contacts the mold is used to produce smooth surfaces on parts since the skin layer remains hot during parison inflation.

Abstract: A process for forming a thermoplastic resin coating on glass fibers comprises heating a thermoplastic resin powder until molten and applying it to the glass fibers. The coated fibers can then be heated and drawn into a desired shape which also removes resin. Then the coated fibers are cooled to make a preform. The coated fiber preform can then be molded. Several resin layers with glass fibers of varying lengths can be deposited to make a graded preform. Apparatus for forming a thermoplastic resin on glass fibers sprays hot thermoplastic powder on the glass fibers. The coated fibers can then be heated such as by IR lamps and then drawn through a die which has a spigot to remove excess plastic. Alternately, a plurality of plastic and glass fiber layers can be deposited on a veil.