Abstract: The present invention provides a method of preparing a heat exchange element comprising a molded product of a paper-like material made of ceramic fibers as a matrix, the interstices among the ceramic fibers being uniformly filled with molecular sieve particulates having an average particle diameter of 5.5.mu. or less, the ceramic fibers and the molecular sieve particulates being bound by a silicic acid gel.

Abstract: The ceramic article, after molding and while in a porous condition, is surface hardened not by being placed in a kiln and exposed to high temperatures, but is operatively arranged to have a combustible gas-air mixture pumped under appropriate pressure through the porosity of its molded shape. The exiting gas-air mixture is, according to the present invention, ignited, and this causes the exterior surface of the molded shape to incandesce, with the result that the external surface hardens without causing internal stresses within the article, and also avoids causing differential thermal expansion between the exterior surface and the fiber substance of the article adjacent thereto.

Abstract: There is prepared an aqueous suspension which in addition to water, consists of 2 to 50 weight % of a mixture of bentonite and inorganic fibers, with the portion of inorganic fiber being 1 to 30 weight % and the portion of bentonite being 1 to 30 weight % and wherein the total amount of solids does not exceed 50 weight %. With the suspension there is attained an improvement of the mechanical properties of thermal insulating molded objects which are employed for thermal insulation and which for example, contain pyrogenically produced silica as a filler by delivery of this suspension on the thermal insulating plate. The suspension can also be delivered on thermal insulating molded bodies on which there is pressed a fiber net or a fiber felt. After applying the suspension several thermal insulating molded bodies can be joined together where the coating formed consisting of bentonite and inorganic fibers acts as binder.

Abstract: Sheet composites containing asbestiform crystalline calcium M phosphate fibers wherein M is a metal cation selected from the group consisting of sodium and lithium, and mixtures thereof, are useful as a replacement or substitute for asbestos sheets in applications where fibrous materials are needed.

Abstract: A process is disclosed for producing a sheet for a catalyst carrier for vapor-phase reactions which comprises mixing highly heat resistant ceramic fibers, organic fibers and an organic binder to form a slurry, forming the slurry into a paper sheet, impregnating the paper sheet with a silicon compound, converting the silicon compound to silica gel and heating the impregnated sheet to burn up the organic fibers and organic binder. The process produces an improved catalyst carrier for vapor-phase reactions having high porosity and good strength properties.

Abstract: The present invention provides a heat exchange element comprising a molded product of a paper-like material made of ceramic fibers as a matrix, the interstices among the ceramic fibers being uniformly filled with molecular sieve particulates having an average particle diameter of 5.5.mu. or less, the ceramic fibers and the molecular sieve particulates being bound by a silicic acid gel.

Abstract: The present invention is directed to the production of articles exhibiting high mechanical strengths which are relatively insensitive to changes in relative humidity. The articles consist essentially of organic and/or inorganic fibers and a binder, the binder being composed of the product of reaction between an organic polycation, and/or an aminosilane, and/or an organic chrome complex and crystals of a lithium and/or sodium water-swelling mica selected from the group of fluorhectorite, hydroxyl hectorite, boron fluorphlogopite, hydroxyl boron phlogopite, and solid solutions among those and between those and other structurally-compatible species selected from the group of talc, fluortalc, polylithionite, fluorpolythionite, phlogopite, and fluorphlogopite.

Abstract: An improved inorganic fiber mat containing mineral wool, preferably a composite mat of mineral wool and fiberglass, is prepared by:(a) forming an aqueous slurry of the inorganic fiber raw material containing non-fibrous, particulate contaminants;(b) agitating the slurry to separate heavier contaminant materials;(c) passing the slurry through a unique cleaning apparatus whereby the moving slurry is cascaded and subjected to air induced hydraulic turbulence to separate any remaining contaminant materials; and(d) thereafter transferring the fibrous material, preferably as an admixture of cleaned mineral wool fibers and glass fibers, to a mat forming device.

Abstract: The present invention contemplates a process for producing a reactor cylinder for use in a radiant heater and the reactor cylinder produced by that process. A liquid vehicle is initially prepared including an alumina dispersion, magnesium sulfate, colloidal silica and powdered talc. An antifoam agent may be added. The alumina dispersion includes dispersable alumina in an amount between about 1% and about 5% by weight, an acid in an amount up to about 0.2% by weight and water in an amount between about 10% and about 30% by weight, all calculated as weight percent based on the weight of the liquid vehicle. The alumina dispersion is then further diluted by the addition of water in an amount between about 40% and about 80% by weight. To the diluted alumina dispersion is added magnesium sulfate in an amount up to about 4% by weight, colloidal silica in an amount up to about 10% by weight and powdered talc in an amount between about 0.0001% and about 0.1% by weight.

Abstract: A paper cover sheet material for use in the production of gypsum wallboard, the paper cover sheet material having excellent drainage, porosity and drying properties, and a wallboard product produced therefrom, the paper cover sheet material being produced from fibers comprising a major proportion of cellulose fibers and a minor proportion of mineral fibers, the paper composition additionally comprising a cellulose gel, a latex binder and a flocculating agent, thereby enabling the mineral fibers to be dispersed in an aqueous slurry without materially fracturing the fibers, and retaining the shot present in the mineral fibers without permitting the shot to be released and thereby to contaminate the papermaking equipment. The excellent porosity, drying properties and drainage of the paper permit the gypsum wallboard formed with the paper to be readily set and dried with reduced heat energy requirements.

Abstract: There is provided an improved non-woven fibrous felt material made up of fibers, partially fibrous agglomerates of forsterite, enstatite and silica as filler and an organic binder. The improved felt material possesses increased hot tensile strength over felt material made from non-calcined asbestos tailings or inert inorganic fillers.

Abstract: The fibrous material is for the preparation of a sheet material containing large amounts of inorganic fine powders or inorganic short fibers by a usual paper-making method. A raw material for forming the fibrous material is previously impregnated with a polymer flocculant of the polyacrylamide type or the like in the amount of 0.01 to 5% (dry solids). The fibrous material is adaptable for sheets which can be prepared easily by individuals at home as well as at factories. The fibrous material can be utilized for a wide range of application, for example, for various ceramic products, construction materials, papers for special use, filters and so on and for recovery of solids from waste water or the like.

Abstract: A flexible ceramic fiber board is formed from fibers with a homogeneous latex binder coating. The coating is formed from a slurry of the latex, a cationic acrylamide base copolymer and aluminum sulfate solution. The cationic copolymer aids the aluminum sulfate in homogeneously depositing the latex and forming a uniformly flexible board. The shape that is formed is dried dielectrically. The crystalline, high Al.sub.2 O.sub.3 fibers may be mixed with non-crystalline, Al.sub.2 O.sub.3.SiO.sub.2 fibers.

Abstract: The present invention contemplates a process for producing a reactor cylinder for use in a radiant heater and the reactor cylinder produced by that process. A liquid vehicle is initially prepared including an alumina dispersion, magnesium sulfate, colloidal silica and powdered talc. An antifoam agent may be added. The alumina dispersion includes dispersable alumina in an amount between about 1% and about 5% by weight, an acid in an amount up to about 0.2% by weight and water in an amount between about 10% and about 30% by weight, all calculated as weight precent based on the weight of the liquid vehicle. The alumina dispersion is then further diluted by the addition of water in an amount between about 40% and about 80% by weight. To the diluted alumina dispersion is added magnesium sulfate in an amount up to about 4% by weight, colloidal silica in an amount up to about 10% by weight and powdered talc in an amount between about 0.0001% and about 0.1% by weight.

Abstract: A carboxylated latex is added to an aqueous slurry of fibers to remove metal ions contained in solution. The water is removed to form a felt. The demetallized water removed during felt formation is recycled in a closed process water system. The carboxylated latex is formed by polymerizing an unsaturated carboxylic acid on a substantially surfactant free styrene-diene polymer latex.

Abstract: A strengthened fiber diaphragm and method for making such a diaphragm for use in electrochemical cells, the strengthening being accomplished through solution introduction of a zirconium compound into the fabric of the diaphragm.

Abstract: The invention relates to a method for the manufacture of diaphragms of fibrous potassium titanate and an organic binder for electrochemical cells and has as the object to develop such a method in such a direction that it allows the manufacture of diaphragms which are relatively thin but have, at the same time, a sufficient long-term chemical and mechanical stability at high operating temperatures. According to the invention, provision is made for this purpose to apply potassium titanate, together with polytetrafluoroethylene and a styrene-butadiene copolymer, from a suspension, to a screen with a mesh width between about 0.1 and 0.4 mm. The diaphragms made by the method according to the invention are suitable particularly as cover layers in fuel cells with an alkaline electrolyte.

Abstract: A light-weight thick-walled unitary burner block adapted to embrace a burner installed in the wall of a high temperature furnace. The block is formed of spun refractory fibers accreted by vacuum deposition from an aqueous slurry.

Abstract: A process is disclosed for producing a non-woven, boron nitride-bonded boron nitride fiber mat, suitable for use as an electric cell separator in a lithium-sulfide battery. Molten boron oxide is centrifugally spun into strands and attenuated by an annular gas stream into fibers which are compacted at a controlled relative humidity into a bundle and heated in an anhydrous ammonia atmosphere to convert boron oxide in the fibers to boron nitride (BN). The BN fibers are blended with a lesser amount of boron oxide fibers and a nonaqueous liquid medium to form a slurry. The slurry is processed through a Fourdrinier machine to form a felt; and, the felt is calendered by passing it through the nip of a pair of calender rolls at an appropriate temperature and pressure to soften the boron oxide binder to fuse the BN fibers together. The interstitial boron oxide then is converted to boron nitride.

Abstract: A high temperature resistant compressible sheet material has a thickness of 0.001 to 1 inch and includes a crosslinked elastomer as a binder and high temperature staple fibers. A major amount of a particulate filler which has been chemically modified to coreact with the crosslinked elastomer is incorporated into the sheet material. The binder preferably has incorporated therein an addition polymerized silane coupling agent. The sheet material is fabricated according to papermaking techniques. The sheet material is useful in the fabrication of gasketing and in heat shields.

Abstract: A method of producing an improved mineral board and the resulting product are disclosed. According to the present invention, the board is predominantly composed of perlite and a binder therefor, preferably urea-formaldehyde resin. The perlite is crushed after the composition is in its final shape but before the binder is set whereby its strength is substantially increased. The composition and process of making the board substantially reduce energy costs as compared to known methods for making wet-process mineral boards. The product composition may include up to 95% perlite by weight.

Abstract: A suspension of artificial mineral fibers and cellulosic fibers is dewatered during shaping on a wire. The sheet is thereafter pressed and dried. A latex emulsion binder is added to the mat after the mat has been partially dried to a solids content of 60 to 90%. The mat product has physical properties, including impression resistance, comparable to previously known asbestos-containing products.

Abstract: The invention provides inorganic fibers based on calcium sulfate dihydrate or calcium sulfate aluminate hydrate (or their dehydration products), wherein the ratio of average length to diameter of the fibers is more than 100:1 and the length of the fibers is at least 0.2 mm; preferably the ratio of average length to diameter is 300-800:1, and the length is 0.5-6 mm.

Abstract: A process is provided for the separation of nonfibrous material from mineral wool fibers which comprises dispersing the fibers in an aqueous solution comprising a surfactant having at least one hydrophobic group containing at least eight carbon atoms and at least one cationic hydrophilic group having at least one nitrogen or sulfur atom, such as a quaternary ammonium surfactant. The fibrous material is dispersible in the surfactant solution, while the nonfibrous material is not and consequently can be separated by centrifuging or settling and decantation.

Abstract: The disclosure relates to the production of a mineral fiber product for example to replace asbestos fibers in different products. In the method of production, at most 7% by weight of mineral fibers is dispersed in water which contains a wetting agent, undispersible material being then separated and the dispersion being then mechanically dewatered to a dry content of from 30 to 70% by weight and a fiber density of from 200 to 400 kg/m.sup.3. In a subsequent, separate stage, the fibers are redispersed in water substantially without the addition of wetting agent, are provided with possible additives such as cellulose fibers, are shaped, dewatered and dried.

Abstract: A material of the board type for various thermal shielding applications preferably contains 10 to 50% by weight of a mineral substance based on silica or silicates in fibrous form prepared from the fused substance, 10 to 70% by weight of clay, if necessary 10 to 60% by weight of a mineral having a needle-like crystal structure, and a small proportion of an organic binder for maintaining the mineral constituents in a coherent structure at least during fabrication, conversion and utilization of the end product. The total quantity of organic substances does not exceed 8% by weight of dry substances. The material has high temperature strength by virtue of the combination of an organic binder with a mineral binder and also has good dimensional stability.

Abstract: A board product containing glassy inorganic fibre such as mineral wool, in a matrix of a plastic clay such as ball clay. The amounts of clay and inorganic fibre are in the respective ranges 29 to 80 percent by weight and 15 to 55 percent by weight of the product, and its density is at least 500 kg/m.sup.3.The board can replace asbestos millboard and has the advantage of being asbestos-free. It can be made by the standard paper and board-making techniques, when preferred ingredients are pulp fibres e.g. cellulose pulp, and a complementary binder, particularly hydrolyzable starch, the latter enabling the product to be re-mouldable upon moistening with water.

Abstract: A fibrous sheet having a high strength and water resistance and having no resin specks on the surface can be produced by producing a sheet from a fiber slury by the known paper making process, to said fiber slurry being added a flocculate of chlorinated polymer latices which has a particle size of 100.mu.-500 .mu. and is prepared by heating said chlorinated polymer latices to a temperature of at least their minimum film-forming temperature and then adding a water soluble cationic polymer or a polyvalent metal salt with stirring. Examples of said chlorinated polymer latices are anionic polyvinyl chloride latex, polyvinylidene chloride latex or the combination thereof.

Abstract: A process of producing a uniform fiber dispersion involves the use of an in-line dispersing chamber to provide an average fiber dwell time of only about ten minutes and less. The chamber is provided with a plurality of weedless, nonthrusting impellers that generate regions of reduced pressure and flow disruptive turbulence of high intensity, the turbulence being of sufficient intensity to rapidly open fiber bundles and disperse the individual long fibers during said dwell time within said chamber. The process produces a machine-made light weight glass fiber web material of exceptionally uniform fiber distribution. The web is comprised of micron diameter glass fibers having a fiber length of about 1/4 inch or more and a basis weight of about 5-30 grams/square meter. The web material exhibits an isolated multi-fiber defect count of less than 10 per 100 square feet and a visually perceptible overall uniform fiber distribution essentially devoid of "cloud effect" fiber density variations.

Abstract: A polymeric silicate material having a substantially fibre- or flake-like microstructure is manufactured from a starting material comprising mainly natural or synthetic silicate mineral e.g., Olivine and/or Granate (garnet), having a hardness exceeding the value 6 on the Moh's hardness scale and which are compound(s) having the general formulae:2(R.sup.I O).multidot.SiO.sub.2wherein R.sup.I may be the same or different and is Mg and/or Fe; and3(R.sup.II O).multidot.R.sub.2.sup.III O.sub.3 .multidot.3 SiO.sub.2wherein R.sup.II may be the same or different and is Mg, Fe and/or Ca; and R.sup.III is Al or Fe, by finely dividing said material to a specific surface area of at least 15,000 cm.sup.2 /cm.sup.3, measured according to Blaine, and subsequently hydrothermally treating the resultant powderous starting material at a temperature of approximately 175.degree.-325.degree. C. and a pH of at least 9 in the presence of water or condensed steam.

Abstract: A bonding composition for incombustible fibrous materials comprising (a) a water-soluble polymer containing hydrazide groups or its adduct with a water-soluble alkaline earth metal salt of an inorganic acid and (b) a heavy metal ion capable of forming chelate with the water-soluble polymer or its adduct. The bonding composition is employed as bonding agents to prepare incombustible sheet materials from incombustible fibrous materials by adding the components (a) and (b) to an aqueous dispersion of the fibrous materials and forming sheets or by forming wet or dry sheets containing the component (b) and then making the component (a) contain in the sheets. The bonding composition has excellent bonding effect and the polymer itself becomes incombustible, so incombustible sheet materials having excellent strength can be economically obtained.

Abstract: In a fiberboard composed of fibers bound together with a starch derivative produced by reacting maleic, phthalic, or succinic anhydride, or a combination of these anhydrides, with starch, an improvement in the Fourdrinier process for producing said fiberboard wherein the reaction product of the anhydride and starch is directly mixed, without drying, with fiber and other conventional ingredients, such as clay, and is then passed directly to the Fourdrinier machine.

Abstract: A process is provided for preparing hydrophobic porous fibrous sheet material suitable for use as a filter due to its inertness, strength, resistance to deterioration at elevated temperatures, and porosity, comprising impregnating a porous fibrous substrate with an aqueous dispersion consisting essentially of polytetrafluoroethylene or polytrifluorochloroethylene in an amount within the range from about 2 to about 40% by weight of the emulsion, and a silicone resin prepolymer such as a reactive polydimethylsiloxane in an amount within the range from about 0.1 to about 8% by weight of the emulsion; and drying the substrate at a temperature above about 525.degree. F.

Abstract: Highly heat-resisting ceramic fibers are manufactured either by simply coating the surface of ceramic fibers with at least one phosphorus compound or by further subjecting the resultant coated ceramic fibers to a heat treatment. The ceramic fibers having the surface coated with said phosphorus compound or the ceramic fibers having the phosphorus compound contained therein at a gradually decreasing concentration in the direction of increasing depth from the surface which are manufactured by the aforesaid method are capable of high resistance to heat.

Abstract: A method for the manufacture of a sheet containing mineral fibers and binder. An aqueous suspension containing fibers and binder is formed into a layer. The layer is de-watered to form a wet sheet. Additional binder is applied evenly to the entire surface of the de-watered sheet. The sheet is then dried. The sheet may be compressed to an extent of 20% during drying.

Abstract: An improved method for producing acoustical fiberboard, which method comprises adding agglomerate articles formed from an aqueous composition comprising fiberboard dust, a glactomannan gum or glactomannan gum derivative, and a crosslinking agent to an aqueous fiberboard slurry, is disclosed. The resulting acoustical fiberboard exhibits excellent sound absorption.

Abstract: This invention relates to a method for making an asbestos-free calcium silicate board, which comprises preparing a slurry of a mixture of silicic acid material, lime material, fibrous wollastonite and pulp with a large amount of water, forming the slurry into a raw board by means of the sheet-forming technique, steaming the raw board and drying. This invention also relates to the board produced in accordance with the above method.

Abstract: A porous tubular element of uniform density and porosity is formed by uniformly depositing binder and crushable fibers selected from the group consisting essentially of polycrystalline, alumina, zirconia, aluminum silicate and potassium polytitanate fibers from an aqueous dispersion onto a cylindrical mold. The tubular element is then compressed with sufficient pressure to crush and rearrange the fibers to obtain uniform density and porosity.

Abstract: A surfactant foaming agent added to a wet fibrous sheet just before initiation of vacuum water extraction forms foam within the sheet. The foam expels water from the sheet while increasing the resistance to vacuum. Water removal time is lengthened and the fractional amount of water removed by suction is increased. The reduced residual water provides a proportional decrease in drying time and drying energy.The addition of an anti-foaming agent with the surfactant reduces the water drainage time as compared to the normal case. This increases the drainage rate but does not increase the amount of water drained from the sheet.

Abstract: A method for manufacturing carbon-carbon composite bodies consisting essentially exclusively of carbon, of about 20 to about 96 weight percent from carbon fiber, from 0 to about 72 weight percent from a carbonaceous flour, and from about 4 to about 15 weight percent from a carbonized resin, which consists in forming a mat by allowing a mixture of the solid ingredients to settle to equilibrium height by the force of gravity or by centrifugation in a solution of the resin and an appropriate solvent, then pressing the settled solids at up to about 100 psi and removing the excess liquid therefrom. Heating the formed and pressed mat to cure the resin, and then baking and optionally graphitizing the cured mat completes the process.

Abstract: A method of lining a cavity, such as, for example, the head box for an ingot mold, comprising applying to the surface to be lined a lining of a self-supporting deformable fibre mat refractory composition and then exerting pressure on that lining so as to deform and conform it to the shape of the cavity.

Abstract: A dilute slurry that includes mineral wool fibers, a clay binder, other binders and a flocculent is introduced into a forming tank at several elevations and with sufficient velocity to circulate toroidally therein. A mandrel having the desired configuration of one surface of the shaped article is lowered into the forming tank and rotated at a preselected speed. Vacuum is applied to the rotating mandrel and a substantially uniform layer of solids is deposited on the outer surface of the mandrel while the filtrate is withdrawn through an internal portion of the mandrel and conveyed to a filtrate recovery tank. After a layer of a preselected thickness is deposited on the outer surface of the mandrel, the mandrel is removed from the forming tank and vacuum is maintained on the mandrel to reduce the water content of the accreted fibers to between about 40 to 65% by weight water. Thereafter, while on the mandrel, the accreted fiber-shaped article is trimmed to provide an outer surface of a desired configuration.

Abstract: An aesthetically pleasing texture is imparted to wet-laid fibrous mats by distributing a layer of solid expanded particles of synthetic thermoplastic resinous foamed material on the upper surface of the mat. The particles are then pressed into the wet lap to embed the particles in the fibrous material and the wet lap is subsequently heated to reduce the volume of the particles and leave depressions in the surface which result in a unique random surface texture.

Abstract: A paper product comprising mineral fibers and a nonfibrous, highly refined gel binder, the product having a thickness no greater than about 0.080 inches and an apparent specific gravity of between about 0.25 and about 0.85. The product may be a sheet no thicker than about 0.012 inches, or a paperboard.

Abstract: A mineral wool insulation product containing a major portion of mineral wool fibers, a conventional binder, and predetermined quantities of an admixture of selected colloidal mineral clays to provide an insulation product having extremely low quantities of free silica and excellent physical properties. The colloidal clay admixture comprises selected quantities of kaolinite clays and bentonite clays.

Abstract: An insulative material comprises a random network of ceramic fibers and a binder for holding the fibers together. In addition, it may include a filler material composed of hollow ceramic spheres which locate at the interstices of the fibrous network and increase the strength of the network. The insulative material can withstand extremely high temperatures and thermal shock without degradation, has an extremely low density, has excellent insulating properties, and has reasonably high compressive strength. The material is formed by making a slurry which contains the ceramic fibers, with or without the filler, and the binder; felting the slurry; subjecting the felt so formed to microwave energy for drying; and firing the dried felt at 2300.degree.-3200.degree.F. to increase its strength.

Abstract: Casting mold for metals, wherein paper-like sheet of carbon or graphite fibers is lined onto the inner surface of the mold to prevent seizure phenomenon between the mold and the cast article.