Abstract: An ultrasonic fuel injector for injecting a pressurized liquid fuel into the combustion chamber of an internal combustion engine that uses an overhead cam for actuating the injector, includes an injector body and an injector needle. The injector needle is disposed within the body and includes a magnetostrictive portion disposed in the region of the body defined by a ceramic wall, which is transparent to magnetic fields changing at ultrasonic frequencies. A wire coil is wound around the outside surface of the ceramic wall and connected to a source of electric power that is controlled to oscillate at ultrasonic frequencies during predetermined intervals of operation of the injector. A sensor is configured to signal when the overhead cam is actuating the injector to inject fuel into the combustion chamber of the engine.

Abstract: An ultrasonic fuel injector for injecting a pressurized liquid fuel into the combustion chamber of an internal combustion engine that uses an overhead cam for actuating the injector includes a valve body having an injector needle disposed therein forming a needle valve to meter the flow of fuel through the injector. The valve body is formed of ceramic material that is transparent to magnetic fields changing at ultrasonic frequencies. The injector needle includes a magnetostrictive portion disposed in the region of the valve body that is surrounded by a wire coil wound around the outside surface of the ceramic valve body. The wire coil is connected to a source of electric power that oscillates at ultrasonic frequencies. A sensor is configured to signal when the overhead cam is actuating the injector to inject fuel into the combustion chamber of the engine.

Abstract: An apparatus and a method for the melt extrusion of a molten thermoplastic polymer, e.g., as fibers and nonwoven webs, which apparatus and method utilize ultrasonic energy to assist in the melt-extrusion process. The apparatus includes a die housing which defines a chamber adapted to receive the molten thermoplastic polymer and a means for applying ultrasonic energy to a portion of the molten thermoplastic polymer. The die housing includes a chamber adapted to receive the molten thermoplastic polymer, an inlet orifice adapted to supply the chamber with the molten thermoplastic polymer, and an extrusion orifice adapted to receive the molten thermoplastic polymer from the chamber and extrude the polymer. The means for applying ultrasonic energy is located within the chamber. The method involves supplying a molten thermoplastic polymer and extruding the molten thermoplastic polymer through an extrusion orifice in the foregoing apparatus to form a threadline.

Abstract: A method employing a ultrasonicator apparatus to emulsify a pressurized multi-component liquid. The apparatus includes a die housing comprising a chamber adapted to receive a pressurized multi-component liquid, an inlet adapted to supply the chamber with the pressurized multi-component liquid, an exit orifice defined by the walls of a die tip, and a means for applying ultrasonic energy to a portion of the pressurized liquid. The method for emulsifying a pressurized multi-component liquid comprising supplying a pressurized multi-component liquid to the apparatus, applying ultrasonic energy to the pressurized liquid but not the die tip while the exit orifice receives pressurized liquid from the chamber, and passing the pressurized liquid out of the exit orifice in the die tip so that the multi-component liquid is emulsified, wherein the means for applying ultrasonic energy is excited, it applies ultrasonic energy to the pressurized liquid without applying ultrasonic energy to the die tip.

Abstract: A method for stretching nonwoven sheet material in the cross-machine direction includes coursing a nonwoven sheet material through a deformable nip, the nip being formed between two rotating stretch surfaces having intermeshing peaks and troughs, the surfaces of the peaks and troughs being covered with a deformable material, and contemporaneously pressing the stretch surfaces together while rotating them, such that as the nonwoven material travels through the nip, the nip deforms from an initial flat formation into a convoluted formation.

Abstract: An apparatus and a method for ultrasonically producing a spray of liquid. The apparatus includes a die housing which defines a chamber adapted to receive a pressurized liquid and a means for applying ultrasonic energy to a portion of the pressurized liquid. The die housing further includes an inlet adapted to supply the chamber with the pressurized liquid, and an exit orifice defined by the walls of a die tip. The exit orifice is adapted to receive the pressurized liquid from the chamber and pass the liquid out of the die housing to produce a spray of liquid. When the means for applying ultrasonic energy is excited, it applies ultrasonic energy to the pressurized liquid without applying ultrasonic energy to the die tip.

Abstract: A method of attaching a substantially uniform distribution of particulates to individual exposed surfaces of a matrix of fibrous material. The method includes the following steps: 1) electrically charging a matrix of fibrous material having individual exposed surfaces to create a substantially uniform distribution of charged sites at the exposed surfaces; 2) applying particulates to the charged matrix of fibrous material so that at least some particulates adhere at the charged sites; and 3) attaching particulates adhering to the fibrous material at charged sites by substantially non-transient bonding.

Abstract: An apparatus and a method for ultrasonically producing a spray of liquid. The apparatus includes a die housing which defines a chamber adapted to receive a pressurized liquid and a means for applying ultrasonic energy to a portion of the pressurized liquid. The die housing further includes an inlet adapted to supply the chamber with the pressurized liquid, and an exit orifice defined by the walls of a die tip. The exit orifice is adapted to receive the pressurized liquid from the chamber and pass the liquid out of the die housing to produce a spray of liquid. When the means for applying ultrasonic energy is excited, it applies ultrasonic energy to the pressurized liquid without applying ultrasonic energy to the die tip.

Abstract: An apparatus and a method for the melt extrusion of a molten thermoplastic polymer, e.g., as fibers and nonwoven webs, which apparatus and method utilize ultrasonic energy to assist in the melt-extrusion process. The apparatus includes a die housing which defines a chamber adapted to receive the molten thermoplastic polymer and a means for applying ultrasonic energy to a portion of the molten thermoplastic polymer. The die housing includes a chamber adapted to receive the molten thermoplastic polymer, an inlet orifice adapted to supply the chamber with the molten thermoplastic polymer, and an extrusion orifice adapted to receive the molten thermoplastic polymer from the chamber and extrude the polymer. The means for applying ultrasonic energy is located within the chamber. The method involves supplying a molten thermoplastic polymer and extruding the molten thermoplastic polymer through an extrusion orifice in the foregoing apparatus to form a threadline.

Abstract: A melt-extrudable polymeric strand with enhanced tensile strength formed by extruding a melt-extrudable polymer while subjecting the a portion of the polymer to ultrasonic energy. The melt-extrudable polymeric strand has a tenacity which is from about 1.5 to about 3 times the tenacity of an otherwise identical strand not made by applying ultrasonic energy to a portion of the melt-extrudable polymer while the melt-extrudable polymer is extruded. Desirably, the strand has a tenacity within a range from about 0.3 to about 0.9 g/denier. In a method for making such a strand, a molten melt-extrudable polymer is extruded through a die assembly, ultrasonic energy is applied to a portion of the melt-extrudable polymer within the chamber and without applying ultrasonic energy to the die tip, while an extrusion exit orifice receives melt-extrudable polymer from an extrusion chamber, and the extruded polymer is attenuated to form a strand.

Abstract: An apparatus and a method for increasing the flow rate of a pressurized liquid through an orifice by applying ultrasonic energy to a portion of the pressurized liquid. The apparatus includes a die housing which defines a chamber adapted to receive a pressurized liquid and a means for applying ultrasonic energy to a portion of the pressurized liquid. The die housing further includes an inlet adapted to supply the chamber with the pressurized liquid, and an exit orifice defined by the walls of a die tip. The exit orifice is adapted to receive the pressurized liquid from the chamber and pass the liquid out of the die housing. When the means for applying ultrasonic energy is excited, it applies ultrasonic energy to the pressurized liquid without applying ultrasonic energy to the die tip.

Abstract: An adsorbent filter for removing caffeine from liquids. The filter is composed of a liquid permeable, electret-treated matrix of fibrous material having individual exposed surfaces; and a relatively uniform distribution of adsorbent zeolite particulate material attached to individual exposed surfaces of the electret-treated fibrous material by substantially non-transient bonding, so that passage of a liquid having a caffeine concentration ranging from about 20 to about 100 mg per 100 mL of liquid through the matrix for a contact time of less than about 2 minutes results in at least a 40 percent reduction in the caffeine concentration of the liquid. The matrix of fibrous material may be selected from woven fabrics, knit fabrics and nonwoven fabrics. Generally speaking, the filter can be adapted to provide at least a 40 percent reduction in the caffeine concentration for about 1 cup to about 40 cups of a liquid.

Abstract: An apparatus and method for controlling an ultrasonic transducer preferably including a signal generator circuit, a signal sensing circuit, a modulator circuit, and a bias circuit. The signal generator circuit provides a pulsed drive signal to the ultrasonic transducer. The signal sensing circuit senses the voltage and current of the drive signal. The modulator circuit provides a frequency control signal and an energy control signal to the signal generator circuit corresponding to a detected phase difference between the sensed voltage and the sensed current of the drive signal. The frequency control signal and energy control signal operate to adjust the frequency and energy level, respectively, of the drive signal.Within the transducer, a movable element in contact with a liquid is preferably positioned corresponding to the level of a dc bias signal provided by the bias circuit. By adjusting the level of the dc bias signal, the flow rate of the liquid is adjusted.

Abstract: An apparatus and method for controlling an ultrasonic transducer preferably including a signal generator circuit, a signal sensing circuit, a modulator circuit, and a bias circuit. The signal generator circuit provides a pulsed drive signal to the ultrasonic transducer. The signal sensing circuit senses the voltage and current of the drive signal. The modulator circuit provides a frequency control signal and an energy control signal to the signal generator circuit corresponding to a detected phase difference between the sensed voltage and the sensed current of the drive signal. The frequency control signal and energy control signal operate to adjust the frequency and energy level, respectively, of the drive signal.Within the transducer, a movable element in contact with a liquid is preferably positioned corresponding to the level of a dc bias signal provided by the bias circuit. By adjusting the level of the dc bias signal, the flow rate of the liquid is adjusted.

Abstract: Disclosed is a method for injection molding certain hydrodisintegratable materials which, when injection molded to form a desired object, acquire and maintain the desired shape. The method includes the steps of maintaining extrusion temperatures of the hydrodisintegratable material at or below about 250 degrees F. and maintaining the temperature of the mold at or below about 55 degrees F. In the presence of water, the molded object has the ability to rapidly disintegrate and disperse when subjected to standardized agitation testing.

Abstract: An ultrasonic apparatus and method for regulating the flow of a pressurized liquid through an orifice by applying ultrasonic energy to a portion of the pressurized liquid. The apparatus includes a die housing which defines a chamber adapted to receive a pressurized liquid and a means for applying ultrasonic energy to a portion of the pressurized liquid. The die housing further includes an inlet adapted to supply the chamber with the pressurized liquid, and an exit orifice defined by the walls of a die tip. The exit orifice is adapted to receive the pressurized liquid from the chamber and pass the liquid out of the die housing. When the means for applying ultrasonic energy is excited, it applies ultrasonic energy to the pressurized liquid without applying ultrasonic energy to the die tip and modifies the flow rate of the pressurized liquid the exit orifice.

Abstract: An ultrasonic apparatus and method for increasing the flow rate of a pressurized liquid through an orifice by applying ultrasonic energy to a portion of the pressurized liquid. The apparatus includes a die housing which defines a chamber adapted to receive a pressurized liquid and a means for applying ultrasonic energy to a portion of the pressurized liquid. The die housing further includes an inlet adapted to supply the chamber with the pressurized liquid, and an exit orifice defined by the walls of a die tip. The exit orifice is adapted to receive the pressurized liquid from the chamber and pass the liquid out of the die housing. When the means for applying ultrasonic energy is excited, it applies ultrasonic energy to the pressurized liquid without applying ultrasonic energy to the die tip.

Abstract: A melt-extrudable polymeric strand with altered physical properties formed by extruding an emulsion comprising a melt-extrudable polymer and an immiscible component while subjecting the emulsion to ultrasonic energy. In one embodiment, a melt-extrudable polymeric strand has a plurality of fissures in the surface of the strand such that the strand has a B.E.T. surface area to six times the B.E.T. surface area of an otherwise identical strand lacking the plurality of fissures. Desirably, the strand of this embodiment has a B.E.T. surface area of within a range from about 0.10 to about 0.18 m.sup.2 /g. In a method for making such a strand, the immiscible component of the extrudable emulsion comprises a substance that is an expandable gas upon extrusion. The expandable gas forms the fissures in the strand. According to another aspect, a polymeric strand has a continuous phase which is a melt-extrudable polymer and a disperse phase which is immiscible with the continuous phase.

Abstract: Disclosed are a number of processes for forming a liquid-impermeable sheet having a fibrous cloth-like surface. In one embodiment the process includes the steps of: (1) forming a sheet having first and second fibrous surfaces; and subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid impermeable skin without significantly altering the fibers of the second surface.

Abstract: Disclosed is a method of attaching a substantially uniform distribution of particulates to individual exposed surfaces of a matrix of fibrous material. The method includes the following steps: 1) electrically charging a matrix of fibrous material having individual exposed surfaces to create a substantially uniform distribution of charged sites at the exposed surfaces; 2) applying particulates to the charged matrix of fibrous material so that at least some particulates adhere at the charged sites; and 3) attaching particulates adhering to the fibrous material at charged sites by substantially non-transient bonding. Also disclosed is a fibrous composite structure composed of a matrix of fibrous material having individual exposed surfaces; and a relatively uniform distribution of particulate material attached to individual exposed surfaces of the fibrous material by substantially non-transient bonding.