Abstract: A method of manufacturing an external cover edge of a molded cup lid and a product manufactured by the method includes an intermediate product of the molded cup lid made of plant fiber and manufactured by both “pulp suction shaping” and “thermal compression shaping” processes. A protruding-out outer cover edge is formed around the periphery of the intermediate product.

Abstract: A paper pulp molding device has a reversing demolding mechanism and a vacuum set. The reversing demolding mechanism has a transmission set and at least one suction set. The at least one suction set is rotatable and driven by the transmission set. Each one of the at least one suction set has multiple sucking structures. Each sucking structure has a hollow unit and a vacuum suction disc communicating with the hollow unit. The vacuum set has a vacuum apparatus and multiple hoses. Each hose respectively communicates with the hollow unit of one of the sucking structures and the vacuum apparatus. The vacuum suction disc of each sucking structure enlarges the contact area between the vacuum suction disc and a container to reinforce the suction force produced by the vacuum apparatus.

Abstract: A method for using a washer press for washing and dewatering a wide range of solids concentrations of pulp in liquid suspensions includes multiple distinct displacement wash zones about a drum with multiple nips.

Abstract: Methods for making a molded beverage container insulator from a slurry including water and a polysaccharide by presenting at least one male mold, which may have an elliptical cross section, therein and causing a portion of the slurry to temporarily adhere to the at least one mold. After a suitable period of time, removing the mold from the slurry and then removing the insulator. At such time, and particularly if the mold is not characterized as elliptical in cross section, the insulator is subject to bidirectional compression in order to collapse the same. Opposing hinge elements may be formed in the insulator, either at the time of molding or subsequently, to localize stresses resulting from the collapsing of the insulator. The resulting insulator is fully recyclable/compostable and possesses a constricting bias to mitigate container slip issues.

Abstract: In a process for producing a loudspeaker diaphragm, pulp is deposited on a paper-making mold in the presence of vortex stream of water having pulp dispersed therein in a paper-making bath. Pulp is deposited on the paper-making mold while at least the water having pulp dispersed therein is rotated by the vortex stream in the paper-making bath. Consequently, variation of pulp fiber orientation is suppressed, and a loudspeaker diaphragm with high reproducibility and stable quality is produced with a high productivity.

Abstract: A method of producing a lipped molded article comprising the steps of forming a molded article having an opening portion by papermaking and outwardly curling the peripheral wall portion which constitutes the opening portion to make a lip. The method is characterized in that the inner surface of the molded article is coated with a resin layer to make a multilayer molded article, the part to be curled of the peripheral wall portion of the molded article is impregnated with a liquid, and the part to be curled is subjected to curling processing while or after being heated.

Abstract: A loudspeaker diaphragm manufacturing apparatus of the present invention comprises; a paper tank, a pulp dispersion reservoir tank connected to the paper tank, a stirring means provided in the paper tank, a water inlet unit connected to the paper tank, a drain unit disposed under the paper tank, and a paper mold disposed at the bottom of the paper tank or in the drain unit, wherein a sectional area of the drain unit is larger than the plane area of the paper mold. The drain unit may be further provided with a water flow control plate in a draining direction of the paper mold. According to the manufacturing apparatus and the manufacturing method of the present invention, diaphragms with very uniform internal composition and diaphragms with intentionally varied internal composition in accordance with required sound characteristics can be mass-produced with good reproducibility.

Abstract: A liquefied paper material is used as raw materials. A paper frame member 1 supporting a vibrating plate is paper-skimmed and formed. On paper-skimming and forming, a central hole for use in voice coils, air-release hole 1a releasing air pressure in a rear of the vibrating plate to outside due to vibration of the vibrating plate. A loudspeaker system is manufactured using the paper frame member 1.

Abstract: A method for producing a pulp molded article is disclosed. The method comprises the steps of forming and drying a pulp molded precursor (15). The drying step includes a first step and a second step. In the first step, the precursor (15) is set in a cavity of a heating mold, and is hot-pressed. The cavity has a configuration in conformity to the contour of the pulp molded article to be produced. In the second step, the hot-pressed precursor (15) is taken out from the heating mold and is heat-dried in a drying furnace.

Abstract: A speaker diaphragm is formed from a material combining a fiber-type material and a ceramic-type-coating agent including metal alkoxide, metal hydroxide, and a colloidal or fine-particulate inorganic substance. The combining process for the ceramic-type-coating agent is performed before or after the fiber-type material is formed into a shape of the diaphragm.

Abstract: Apparatus for producing a molded pulp product from a fiber slurry comprising a dip tank containing a fiber slurry therein and having a liquid level. A platen is provided. A porous mold is carried by the platen. The platen and the mold carried thereby are lowered into the fiber slurry in a downward direction with the platen being disposed upwardly of the mold so that the mold is introduced through the liquid level into the fiber slurry. A vacuum is supplied to the platen and to the mold while the mold is disposed in the fiber slurry to cause fibers in the fiber slurry to collect onto the mold and form a wet molded pulp product. The platen and the mold with the wet molded product thereon are moved out of the fiber slurry through the liquid level to permit water to drain from the mold and the wet molded pulp product. The wet molded pulp product is then dried.

Abstract: A process for manufacturing wet-felted and thermally bonded porous structures is provided to produce formed porous media for use in filters with improved filtration performance. The process includes the steps of forming a slurry with a primary media consisting of natural or synthetic fibers, a wet strength agent consisting of fibrillated fibers, and a binding agent; vacuum forming the slurry to produce a formed media; drying the formed media using a gas at a temperature below the melting temperature of the binding agent; bonding the formed media using a gas at a temperature above the melting temperature of the binding agent; and cooling the formed media using a gas at ambient temperature. The process produces a formed porous media with improved bonding which results in improved filtration performance.

Abstract: A method for manufacturing a preform having a desirably uniform distribution of structural forms (for example and without limitation, particles, flakes, and fibers) therethrough. The method according to the present invention includes using an electrical charge reaction between cationic and anionic agents (such as, without limitation, cationic and anionic polymers) to cause the structural forms to floc or clump together in a mass in which the structural forms are desirably uniformly distributed therethrough. The flocculent mass is then dewatered and/or dried to form a preform that is ready for further processing.

Abstract: Pulp deposited bodies (7 and 8) are formed on the surfaces (2a and 3a) of a set of splits (2 and 3) of a papermaking mold, each split having a plurality of interconnecting holes connecting the outside to the inside thereof, and the splits (2 and 3) are mated to join the pulp deposited bodies (7 and 8).

Abstract: A method of producing a pulp molded article comprising the steps of assembling splits (10, 11) each having a suction passageway and a papermaking screen (5) into a papermaking mold (1), filling the cavity of the papermaking mold (1) with a pulp slurry, discharging the liquid component of the pulp slurry through the suction passageway to deposit pulp fiber on the inner side of the papermaking screen (5) into an undried wet molded article, and dewatering the undried molded article deposited on the inner side of the papermaking screen (5), wherein the splits (10, 11) each have a large number of flow passageways (2) for feeding a purging fluid for cleaning the papermaking screen (5), and the purging fluid is ejected from the outer side of the papermaking screen (5) toward the cavity through the flow passageways (2) during the filling with the pulp slurry.

Abstract: A method of producing pulp moldings having a paper-making process comprising the steps of assembling split mold halves (11, 12) having suction passageways (14) to form a paper-making mold (10), feeding pulp slurry of predetermined set feed concentration into the cavity (13) in the paper-making mold (10), and sucking the pulp slurry through the suction passageways (14) to form a pulp layer (15) on the inner surface of the paper-making mold (10), wherein the concentration of the pulp slurry in the cavity (13) in the initial and/or final period of formation of the pulp layer (15) in the paper-making process is lower than the above-mentioned set feed concentration of the pulp slurry.

Abstract: A method for producing a pulp molded article (7) comprising the steps of supplying a pulp slurry into the cavity (1) of a mold (10) composed of a set of splits (3 and 4), the set of splits (3 and 4) being assembled together to form the cavity (1) with a prescribed configuration, to form a pulp deposited body (5), feeding a fluid into the cavity (1) to press the pulp deposited body (5) onto the inner wall of the cavity (1) for dewatering.

Abstract: The invention relates to an apparatus and method for producing articles (5) from moulded pulp material that are laminated with a plastic film (4). Thus an environmental friendly and water-resistant package for food products and for other moulded pulp products such as packages for industrial products is provided. The apparatus comprises a moulding line 1 and a laminating line (3). The moulding line (1) comprises a suction moulding station (20) with a pulp vat (25) and a number of suction moulds (22), a drying oven (28) and conveying means (26,28) for transporting the moulded pulp articles through the moulding line (1). The articles are transported in line by a conveyor 10 from the moulding line (1) to the laminating line (3), the laminating line (3) comprises a plastic film supply unit (47), a heating station (69) a laminating station (80) and conveying means (56) for conveying the articles (5) through the laminating line (3).

Abstract: A method for producing a pulp molded article is disclosed. The method comprises the steps of forming and drying a pulp molded precursor (15). The drying step includes a first step and a second step. In the first step, the precursor (15) is set in a cavity of a heating mold, and is hot-pressed. The cavity has a configuration in conformity to the contour of the pulp molded article to be produced. In the second step, the hot-pressed precursor (15) is taken out from the heating mold and is heat-dried in a drying furnace.

Abstract: A mold with integral screen comprising a body of material having a surface, the body has a grid-like pattern of vacuum holes extending through the body of material and opening through said surface and permitting a vacuum to be supplied to said surface, a screen overlying said surface, said screen and said body being formed of the same material as the body and being integral.

Abstract: A papermaking mold for producing a pulp molded article comprising a core of prescribed shape which has a plurality of holes for fluid passage interconnecting the outside and the inside and is made of an elastically deformable material and a fluid-permeable material which covers the outer surface of the core, the fluid-permeable material being capable of forming passages for a fluid in its thickness direction even when pressed and deformed.

Abstract: A method for producing a pulp molded article (7) comprising the steps of supplying a pulp slurry into the cavity (1) of a mold (10) composed of a set of splits (3 and 4) the set of splits (3 and 4) being assembled together to form the cavity (1) with a prescribed configuration, to form a pulp deposited body (5), feeding a fluid into the cavity (1) to press the pulp deposited body (5) onto the inner wall of the cavity (1) for dewatering.

Abstract: Method of manufacturing articles from an aqueous fibre suspension, by deposition of fibres on a suction mould (2), comprising the steps of: applying suction to the suction mould, supplying a fibre suspension to the mould by immersing the suction mould in a vat (5) containing the fibre suspension, raising the suction mould from the fibre suspension, flowing ambient air by said suction through an article formed by a layer of fibre material deposed on the suction mould, characterised by the steps of: providing a substantially hermetically sealed space over the article or articles on the suction mould, supplying a de-watering fluid to the sealed space, and flowing substantially exclusively the de-watering fluid through the article or articles.

Abstract: Pulp deposited bodies (7 and 8) are formed on the surfaces (2a and 3a) of a set of splits (2 and 3) of a papermaking mold, each split having a plurality of interconnecting holes connecting the outside to the inside thereof, and the splits (2 and 3) are mated to join the pulp deposited bodies (7 and 8).

Abstract: A pulp molded article is produced by depositing pulp fiber on the outer surface of a papermaking core mold having a plurality of interconnecting paths connecting the outside and the inside to form a pulp deposited body, placing the pulp deposited body in a set of split molds, and then pressing the pulp deposited body for dehydration by a prescribed means.

Abstract: The invention relates to a method and an arrangement for producing a flow of stock in a moulding tank (1). In this, stock is pumped into the moulding tank (1) at the bottom (1a) and allowed to flow up over the brim (1b) thereof. During its rise in the moulding tank (1), the flow of stock pumped in is distributed by at least one grating placed essentially horizontally and provided with flow openings. An arrangement for performing the said method comprises a line (2a, 2b), connected to the moulding tank (1) and a machine vat for ready prepared stock, for delivering fresh stock to the moulding tank (1) by means of a pump (5) connecting with the line (2a, 2b). The line (2b) opens out in an area close to the bottom (1a) of the moulding tank (1) in such a way that an upwardly directed flow of stock is obtained. The pump (5) is adapted to deliver excess stock so that excess stock is allowed to flow over the brim (1b) of the moulding tank (1).

Abstract: An efficient, low cost method and apparatus for controlling fiber deposition in a fiber reinforced preform is provided. In the method, a main screen is placed in a tank filled with liquid. The main screen has a major surface, upright side walls and a plurality of openings formed therein. Reinforcing fibers are added to the liquid to create a slurry. The main screen is raised through the slurry to a level beneath the top of the slurry, thereby causing the reinforcing fibers to be deposited on the main screen. A retainer screen is inserted into the slurry so that the reinforcing fibers are sandwiched between the main screen and the retainer screen. Both the main screen and retainer screen are raised out of the tank effectively forming a preform with minimal deformation. An alternative embodiment includes a bubbler zone control device for mixing the slurry. The tank is divided into separate areas or zones whereby the supply of fluid to each bubbler zone is controlled.

Abstract: In a filter manufacturing method, during a time period from the start of the suction of the slurry to a point in time when fibers in the slurry accumulate on the outer peripheral surface of the protector to a prescribed thickness, the protector and its leg portions are held spaced away from each other. The leg portions are moved toward the protector so that the leg portions are disposed at a position spaced by a uniform distance from the outer peripheral surface of the protector and the suction operation is continued. Thus, the slurry containing the fibers therein can be easily caused to flow deeply into recess portions of a fin-like portion with no fiber being caught between the protector and the leg portions, thus reducing non-walled portions.

Abstract: An efficient, low cost method and apparatus for controlling fiber deposition in a fiber reinforced preform is provided. In the method, a main screen is placed in a tank filled with liquid. The main screen has a major surface, upright side walls and a plurality of openings formed therein. Reinforcing fibers are added to the liquid to create a slurry. The main screen is raised through the slurry to a level beneath the top of the slurry, thereby causing the reinforcing fibers to be deposited on the main screen. A retainer screen is inserted into the slurry so that the reinforcing fibers are sandwiched between the main screen and the retainer screen. Both the main screen and retainer screen are raised out of the tank effectively forming a preform with minimal deformation. An alternative embodiment includes a bubbler zone control device for mixing the slurry. The tank is divided into separate areas or zones whereby the supply of fluid to each bubbler zone is controlled.

Abstract: Water-proofed natural pulp or organic synthetic fibers are with polyester-type fibers having a low melting point, and subjected to a paper fabrication process. The fabricated product is dried with hot air at a temperature higher than the melting point of the polyester-type fibers, thereby melt-bonding only intersections of the fibers without completely fusing the polyester-type fibers. The pressure of the hot air contributes to the formation of a predetermined shape. Thus, a water-proof diaphragm for a loudspeaker, having a large thickness, a low density, a high internal loss and a high stiffness, is obtained. By incorporating the thus formed diaphragm, a high-performance loudspeaker having a low distortion and a broad reproducing range is obtained.

Abstract: An acoustic diaphragm employed in a speaker or the like and a method for producing the acoustic diaphragm are disclosed. A diaphragm substrate is a diaphragm exhibiting air permeability, such as a paper diaphragm. The substrate is processed with filling by microfibrillated pulp. For filling, the substrate is immersed in the liquid dispersion of the microfibrillated pulp and the pulp is deposited on the substrate under suction. When the microfibrillated pulp is deposited on the substrate under suction, any voids present in the substrate are closed by the microfibrillated pulp so that air tightness is improved without lowering the sound quality or detracting from desirable properties of the diaphragm, such as low density, high toughness and low losses.

Abstract: Free-flowing dunnage of molded pulp pieces (10), having random non-nestable shapes to insure the free-flowing characteristic, is made by a method and apparatus involving partially drying pulp fibers on a forming-die screen (38) to form intermediate dish-shaped pieces, form-free removal of such pieces from the screen, and thereafter drying them free of form support to obtain random shapes. One preferred embodiment involves blowing intermediate pieces from the screen onto a conveyor (50) for subsequent drying, such blowing and landing altering the intermediate piece shapes to enhance randomness in the shapes of the dunnage pieces, and another involves using heated air for partial drying.

Abstract: A paper decoration is made by immersing a perforated mold having a predetermined shape into a liquid pool containing paper-making ingredients. A layer of the ingredients deposited on the mold is then dried in situ, after which, the dried paper layer is detached and formed into the paper decoration.

Abstract: A light-weight fiber brick is formed from a water-fiber suspension including ceramic fibers. A molding device is introduced into the suspension and has plurality walls including at least three walls each of which extends perpendicular to the other two of the three walls. Water is withdrawn simultaneously from the interior of the molding device through at least the three walls, thus causing the fibers of the suspension to tend to align longitudinally within the interior of the molding device in three spatial coordinate directions (X, Y, Z). Thereby there is formed a brick having fibers thereof aligned with longitudinal directions thereof having directional components in three spatial coordinate directions.

Abstract: A method and apparatus for making fiber reinforced plastic preforms via a wet slurry process. A screen with the desired preform configuration is placed in the bottom of a tank. The tank is then filled with water and chopped fibers to create a slurry. The screen is raised up through the slurry causing fibers to be deposited on the screen in the shape of the preform. The preform is then removed from the screen, placed in a mold and injected with resin to form the desired structure.

Abstract: The process for producing a tridimensional piece from an aqueous suspension containing at least a thermoplastic resin and reinforcing fibers, comprises the following steps:(a) the elements of the suspension are wet-molded into a preform in a mold, said preform having, in the three dimensions, the general outline of the final piece;(b) the preform is then at least partly de-watered;(c) then the preform is pre-heated to a temperature higher than the melting point of the thermoplastic resin;(d) the preform is then molded under pressure into its final shape in a press heated to a temperature below the melting point of the thermoplastic resin.

Abstract: A process of forming a gasket with a minimal production of waste material is disclosed. A suitable fiber is mixed with a binder in water to form a fiber-binder aqueous mixture. The mixture is then deposited on a screen in a predetermined pattern to form a gasket preform with apertures in predetermined locations therein. The gasket preform is subsequently dewatered and cured. The gasket preform can be provided with differential thicknesses and preformed inserts to impart, respectively, selective control of the sealing capability of and reinforcement to the resulting gasket.

Abstract: The present invention is directed to a highly pure, partially stabilized, fibrous zirconia composite for use as thermal insulation in environments where temperatures up to about 2000.degree. C. are utilized. The composite of the present invention is fabricated into any suitable configuration such as a cone, cylinder, dome or the like by vacuum molding an aqueous slurry of partially stabilized zirconia fibers into a desired configuration on a suitably shaped mandrel. The molded fibers are infiltrated with zirconyl nitrate and the resulting structure is then dried to form a rigid structure which may be removed and placed in a furnace. The structure is then heated in air to a temperature of about 600.degree. C. for driving off the nitrate from the structure and for oxidizing the zirconyl ion to zirconia. Thereafter, the structure is heated to about 950.degree. to 1,250.degree. C. to fuse the zirconia fibers at their nexi in a matrix of zirconia.

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: The process relates to the formation of diaphragms, for example those used for alkali chloride electrolysis in an aqueous solution. The formation of a layer-type diaphragm, accreted on a hollow diaphragm support from a slurry having a high solids content of diaphragm material, is made uniform.During the accretion step, the diaphragm support is periodically lifted and lowered in the slurry (frequency 0.1-10 min.sup.-1 ; amplitude 10-100 cm; velocity 2-20 cm/sec); its topside, at the upper reversal point of the oscillating motion, has a certain spacing (10-25 cm) from the constantly measured height of the level of slurry in the accretion tank and its underside cannot reach below a minimum distance (30 cm) from the bottom of the basin. The suction pressure of the slurry through the hollow diaphragm support is maintained at a constant value and is controlled (10-500 mbar below the atmospheric pressure of the surroundings).

Abstract: A new and improved molded egg cell construction and method for its manufacture, wherein the molded egg cell includes a cushion or pillopad on an up-post side wall of the cell which projects inwardly, a thin area formed on the outside of the cell adjacent its bottom which is square, the sides of which are oriented at 45.degree. to the sides and ends of the egg carton incorporating the cell, and in which the bottom is planar on its interior surface but formed with thin areas on the exterior of the bottom, in between which, is a footed formation.

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 method of manufacturing a fibrous, nonwoven, flow filter tube and the filter tube so prepared, which method comprises forming a filter tube from an aqueous slurry containing an admixture of both low-melting-point binder and high-melting-point filter fibers, and, thereafter, heating the filter tube to a temperature greater than the temperature of the low-melting-point fibers and less than the temperature of the high-melting-point fibers, to effect melting of the low-melting-point fibers, the molten material of the low-melting point fibers forming at the crossover points of the high-melting-point fibers to act as a bonding agent, thereby preparing a nonwoven, self-supporting, fibrous filter tube composed of the filter fibers.

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 coffin for a human being molded of papier-mache. The coffin is formed with ribs that provide strength to the structure and at the same time have a decorative effect. The improved method of forming the coffin includes drawing paper pulp onto the molds while the latter are inverted so that there is a heavy flow of pulp by gravity to the open end of the coffin to produce heavier flanges. When the mold is received from the pulp with the coffin molded onto it, an air impervious blanket is placed over the coffin when the vacuum is applied to suction the water from the papier-mache so that greater compression of the pulp is obtained to produce a stronger papier-mache structure and reduce the drying time.

Abstract: Method of eliminating warpage of molded fiber trays during free drying by pressing the back side of the preform where ribs cross with a dimpling projection on a rubber insert in a pressure head on a molding machine.

Abstract: Fibrids from the constituents of the effluent from the manufacture of styrene bead polymers are used to product papery sheet-like structures, boards and shaped articles.

Abstract: An improved method of pulp or pressure molding a multilayer container is disclosed wherein the inner layer consists of fused water dispersible polyolefin fibers whereas the outer layer consists of a mixture of cellulosic fibers bonded together by fused water dispersible polyolefin fibers. The containers are useful because the polyolefin layer is resistant to the passage of liquid such as lubricating oils and semi-solids such as greases while the mixed layer of cellulosic fibers and the polyolefin fiber supplies sufficient strength to permit the stacking of the containers when filled.

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 process of preparing an inside-to-outside flow filter tube, which process comprises dispersing a plurality of glass fibers in water to form a water slurry of the fibers, the glass fibers having a diameter range of from about 0.001 to 10 microns; forming a filter tube comprising a wet mat of the glass fibers from the water slurry on a cylidrical mandrel; during the forming of the wet mat of fibers into a filter tube, incorporating an open-scrim, reinforcing sheet material within the internal wall thickness of the wet mat of fibers forming the filter tube, the sheet material extending generally the length of the filter tube and at least about 11/2 revolutions of the filter tube diameter; drying the filter tube containing the scrim sheet material within the filter tube wall; bonding the dried filter tube with a bonding agent at the junction of the glass fiber crossover points and with and through the scrim sheet material; and recovering an integral filter tube having a high burst strength.