Abstract: Provided is a process for preparing a smooth and glossy surfaced paper web. The process comprises subjecting the paper web to shear by using calender rolls driven at different speeds or calender rolls with different diameters. The resulting paper has a totally different structure than the original paper, as it has a much smaller void structure and a much higher degree of bonding between the elements of the sheet. The process is particularly applicable to improving the electrical insulation properties of an aramid paper web.

Abstract: The present invention relates to a method for forming a non-woven fibrous web comprised of aramid fibers and aramid fibrid which comprises forming a foam furnish by agitating the fibers and fibrid in a foamed medium, and passing the foam furnish onto a screen and defoaming the furnish. In effectively agitating the aramid fibers in the foamed medium, the agitating means is mounted for displacement within the foamed medium and includes a convex leading surface facing in the direction of displacement. The leading surface includes upper and lower portions converging in the direction of displacement to form a generally convex leading surface and driving means for displacing the agitating means in the direction of displacement for dispersing and mutually separating the aramid fibers within the foamed medium.

Abstract: The present invention relates to a nonwoven web comprised of metal or refractory fibers with nylon as a binder. The nonwoven web is prepared by forming a foam furnish by agitating the fibers in a foamed medium, and passing the foam furnish onto a screen and defoaming the furnish. It is preferred that the nylon binder is added to the foam furnish in the form of fibers. Once the furnish is defoamed to form a nonwoven web, the sheet is dried at a temperature sufficient to melt the nylon binder.

Abstract: The present invention relates to an apparatus for effectively agitating non-cellulosic fibers in a foamed medium, comprising agitating means mounted for displacement within the foamed medium and including a leading surface facing in the direction of displacement. The leading surface includes upper and lower portions converging in the direction of displacement to form a generally convex leading surface and driving means for displacing the agitating means in the direction of displacement for dispersing and mutually separating the metal fibers within the foamed medium. The present invention further relates to a method for forming a non-woven fibrous web comprised of non-cellulosic fibers which comprises forming a foam furnish by agitating the fibers in a foamed medium with the aforedescribed apparatus, and passing the foam furnish onto a screen and defoaming the furnish.

Abstract: The present invention relates to a method for forming a non-woven fibrous web comprised of refractory fibers which comprises forming a foam furnish by agitating the fibers in a foamed medium, and passing the foam furnish onto a screen and defoaming the furnish. The present invention employs a unique apparatus for effectively agitating the refractory fibers in the foamed medium, the agitating means being mounted for displacement within the foamed medium and including a convex leading surface facing in the direction of displacement. The leading surface includes upper and lower portions converging in the direction of displacement to form a generally convex leading surface and driving means for displacing the agitating means in the direction of displacement for dispersing and mutually separating the metal fibers within the foamed medium.

Abstract: Provided by the present invention is a process for making wet-layed metal fiber nonwoven sheet. The process comprises dispersing a mixture of metal fibers, wood pulp and a fibrillated material into an aqueous dispensing fluid. The amount of metal fibers dispersed generally ranges from 60 to 80 weight percent, based on the weight of solids, with the amount of wood pulp ranging from 15 to 30 weight percent and the amount of fibrillated material ranging from about 5 to 10 weight percent. The dispersed mixture in the aqueous dispensing fluid is then applied to a screen, with the aqueous dispensing fluid being removed to thereby form a metal fiber sheet.

Abstract: Provided by the present invention is a wet-layed, nonwoven sheet which is comprised of metal fiber and metal powder. Generally, the amount of metal fiber comprises from 20 to 95% by weight and the amount of metal comprises from 5 to 80% by weight of the sheet. Such a wet-layed nonwoven sheet is economically preferable to a sheet comprised totally of metal fiber, since the metal powder is much less expensive. Among other factors, the present invention is based upon the recognition that by using various process techniques, the combination of metal fiber and metal powder can be wet-layed to obtain a structure of sufficient strength for subsequent handling and sintering.

Abstract: Provided by the present invention is a wet-layed, nonwoven sheet which is comprised of metal fiber and metal powder. Generally, the amount of metal fiber comprises from 20 to 95% by weight and the amount of metal comprises from 5 to 80% by weight of the sheet. Such a wet-layed nonwoven sheet is economically preferable to a sheet comprised totally of metal fiber, since the metal powder is much less expensive. Among other factors, the present invention is based upon the recognition that by using various process techniques, the combination of metal fiber and metal powder can be wet-layed to obtain a structure of sufficient strength for subsequent handling and sintering.

Abstract: Provided by the present invention is a process for making wet-layed metal fiber nonwoven sheet. The process comprises dispersing a mixture of metal fibers, wood pulp and a fibrillated material into an aqueous dispensing fluid. The amount of metal fibers dispersed generally ranges from 60 to 80 weight percent, based on the weight of solids, with the amount of wood pulp ranging from 15 to 30 weight percent and the amount of fibrillated material ranging from about 5 to 10 weight percent. The dispersed mixture in the aqueous dispensing fluid is then applied to a screen, with the aqueous dispensing fluid being removed to thereby form a metal fiber sheet.

Abstract: The present invention provides a process for making a paper based product which comprises a paper sheet, an aqueous latex binder and a release agent comprised of an emulsion of lecithin and a fatty acid or derivative thereof. In one embodiment, the process comprises first preparing a slurry of a cellulosic pulp and a polymeric latex binder, and then breaking the stability of the latex so that the polymer particles of the latex are able to be deposited on the fibers of the cellulosic pulp. An emulsion comprised of lecithin and a fatty acid or derivative thereof is added during the process. The addition can be to the slurry, or to the web which is formed when the slurry is drained of liquid. The web is then dried to provide the paper based product. In a preferred embodiment, a slurry of cellulosic pulp is first drained of liquid to form a web, with the polymeric latex binder and emulsion being applied to the web prior to drying.

Abstract: Provided is a process for making a paper based product which comprises first preparing a slurry of a cellulosic pulp, a particulate binder, and an emulsion comprised of lecithin and a fatty acid or derivative thereof. This slurry is then drained of liquid to form a web, with the web being dried to provide the paper based product. The preferred polymeric binder is a hydrolyzed polyvinyl alcohol powder, which binder can be present in the final dried product in amounts of up to about 20 weight percent or more. The use of the emulsion comprised of lecithin and a fatty acid or derivative thereof permits a web containing such a high amount of sticky polymeric binder to be dried at high temperatures, without the web sticking to the drying cans generally used in commercial processes. The process of the present invention thereby permits one to efficiently prepare such a paper based product using conventional, commercial papermaking machinery.

Abstract: Provided is a process for making a paper based product which comprises first preparing a slurry of a cellulosic pulp, a particulate binder, and an emulsion comprised of lecithin and a fatty acid or derivative thereof. This slurry is then drained of liquid to form a web, with the web being dried to provide the paper based product. The preferred polymeric binder is a hydrolyzed polyvinyl alcohol powder, which binder can be present in the final dried product in amounts of up to about 20 weight percent or more. The use of the emulsion comprised of lecithin and a fatty acid or derivative thereof permits a web containing such a high amount of sticky polymeric binder to be dried at high temperatures, without the web sticking to the drying cans generally used in commercial processes. The process of the present invention thereby permits one to efficiently prepare such a paper based product using conventional, commercial papermaking machinery.

Abstract: The present invention provides a process for making a paper based product which comprises a paper sheet, an aqueous latex binder and a release agent comprised of an emulsion of lecithin and a fatty acid or derivative thereof. In one embodiment, the process comprises first preparing a slurry of a cellulosic pulp and a polymeric latex binder, and then breaking the stability of the latex so that the polymer particles of the latex are able to be deposited on the fibers of the cellulosic pulp. An emulsion comprised of lecithin and a fatty acid or derivative thereof is added during the process. The addition can be to the slurry, or to the web which is formed when the slurry is drained of liquid. The web is then dried to provide the paper based product. In a preferred embodiment, a slurry of cellulosic pulp is first drained of liquid to form a web, with the polymeric latex binder and emulsion being applied to the web prior to drying.

Abstract: Provided is a process for making a paper based product which comprises first preparing a slurry of a cellulosic pulp, a particulate binder substantially insoluble in water, and an emulsion comprised of lecithin and a fatty acid or derivative thereof. This slurry is then drained of liquid to form a web, with the web being dried to provide the paper based product. The preferred polymeric binder is a hydrolyzed polyvinyl alcohol powder, which binder can be present in the final dried product in amounts of up to about 20 weight percent or more. The use of the emulsion comprised of lecithin and a fatty acid or derivative thereof permits a web containing such a high amount of sticky polymeric binder to be dried at high temperatures, without the web sticking to the drying cans generally used in commercial processes. The process of the present invention thereby permits one to efficiently prepare such a paper based product using conventional, commercial papermaking machinery.

Abstract: A process for producing high grade polyethylene paper on conventional continuous wet-lay papermaking equipment. In particular, the process comprises preparing a furnish of 75-99 wt. % oriented polyethylene pulp, 0.5-15 wt. % fibrous stabilizing agent and 0.5-10 wt. % strengthening agent and depositing the furnish on the forming screen of a conventional wet-lay papermaking machine. The resulting waterleaf sheet is dried on heated drying cans and then thermally bonded to provide a high grade polyethylene paper having high dry strength and toughness, exceptional dimensional stability and superior uniformity (i.e., no holes). The high grade polyethylene paper made by the inventive process is particularly useful in microfiltration end-uses such as vacuum cleaner bags.

Abstract: Provided is a high tear strength, high tensile strength paper product. The product comprises a wood pulp fiber, a non-cellulosic synthetic fiber having a tear strength enhancing denier and length, and a binder material. The resulting paper product exhibits a combination of tear strength and tensile strength which can equal that of cotton cloth of the same basis weight, and can therefore be used as a less expensive substitute for cotton cloth in many applications.

Abstract: A high performance filter element is provided, which filter element comprises a wound sheet of apertured material formed by hydroentangling webs of disparate fibrous materials. In a most preferred embodiment, the fibrous material disposed upstream of fluid flow should have a fiber diameter smaller than that disposed downstream.

Abstract: Provided by the present invention is a novel magnetic barrier paper comprised of low hysteresis iron powder. Preferably, the iron powder employed has a hysteresis value of not more than about 5 parts per thousand. The magnetic barrier paper of the present invention is particularly applicable to the protection of floppy disks, as well as electronic components, from stray magnetic fields.

Abstract: A method and apparatus for the formation of polymer fibrids. These fibrids are produced by the mixing of superheated water and melted polymer and by passing this mixture through a bank of capillary tubes. The mixture becomes elongated in the capillary tubes and exits those tubes through a nozzle into an expansion chamber where they form fibrids. The fibrids are cooled by the evaporation of liquid water after expansion.

Abstract: Provided is a strong, flexible filter element comprising a wet laid non-woven element of glass fibers, synthetic short fibers, and polymer fibrids having a softening point below the softening point of the short fibers. In the filter element, the glass fibers are bound to the synthetic short fibers, e.g., aromatic polyamide short fibers such as poly(m-phenylene isophthalamide) short fibers, by the polymer fibrids, e.g., cellulose acetate fibrids, which act as a binder. The filter element exhibits excellent chemical resistance and a usefulness in removing particulates from gases at temperatures below 400.degree. F.