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: Provided by the present invention is a process for making a wet-layed metal fiber nonwoven sheet. The process comprises first dispersing metal fibers into an aqueous dispensing fluid which contains a non-carboxy containing water soluble polymer in an amount such that the viscosity of the dispensing fluid with dispersed metal fibers is suitable for wet-laying techniques. Generally, the amount of the water soluble polymer comprises from about 1 to about 5 weight percent of the aqueous dispensing fluid. In a preferred embodiment, starch is used as the water soluble polymer.

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.

Abstract: A non-bonding pulp is obtained by contacting a cellulosic pulp with a non-oxidizing gaseous medium at a temperature of at least 400.degree. F. for a period of time greater than 3 seconds or more. When a cellulose pulp comprising at least about 10% hemicellulose, i.e., wood pulp, is treated thermally with a non-oxidizing gaseous medium, a novel non-alpha pulp is obtained. When formed into a substrate such as a 60-70 pound per 3000 square feet paper, the thermally treated pulp forms a non-bonding cellulosic substrate possessing (i) a void fraction of at least 0.85, (ii) a porosity of at least 30 cubic feet per minute per square foot, and (iii) sufficient tensile strength to withstand the tension of wind-up, e.g., at least 6 lbs/inch.

Abstract: The disclosure related in part to a novel and highly superior high bulk pulp formed of lignin-containing fibers, and to process conditions for manufacture of the pulp. The process involves selection of a lignin-containing fiber source, having a lignin content of at least about 10%, and thermomechanically pulping the fiber source under temperature/pressure conditions of 300.degree. F.-350.degree. F./50 psig-120 psig and a refiner energy utilization of about 8-35 HPT/ADT, using a double disc, counter rotating disc refiner. The thermomechanically produced fibers are characterized by a high degree of stiffness, and an extremely smooth surface, free of fine fibril formation and thus substantially non-self-bonding. The new pulp has a wide variety of specialty uses which are attractive in terms of both economics and technical performance, because of the exceptionally high bulk and other distinctive characteristics of the fiber.

Abstract: The disclosure relates to a novel and highly superior filter media formed of random-laid, lignin-containing fibers, and to a process for manufacture of the filter media. The process involves selection of lignin-containing fiber source, having a lignin content of at least about 10% and thermomechanically pulping the fiber source under temperature/pressure conditions of 300.degree. F.-350.degree. F./50 psig-120 psig and a refiner energy utilization of about 8-35 HPD/ADT. The thermomechanically produced fibers are characterized by a high degree of stiffness, and an extremely smooth surface free of fine fibril formation and thus substantially non-self-bonding. An improved filter media is formed by a random lay-up of the lignin-containing fibers, typically with selected other pulp fibers having technical characteristics suitable for filter media utilization.

Abstract: Non-aqueous solvents are removed from a substrate, e.g., paper, by contacting the substrate with a condensable, vaporous heat transfer medium that is in a superheated state, e.g., superheated steam, and maintaining said substrate in contact with said superheated heat transfer medium, while also maintaining said heat transfer medium in superheated state, for a period of time sufficient to effect removal of said non-aqueous liquid from said substrate without concomitant condensation of said superheated heat transfer medium thereon. The superheated heat transfer medium, as well as being the source of energy for evaporating the solvent, acts as a solvent vapor transport medium. Upon evaporation of the solvent, the solvent vapor-heat transfer medium mixture can be sent to a recovery zone to easily recover said solvent via condensation of the mixture and thereby avoid the discharge of said solvent vapors into the atmosphere.