Abstract: A candle assembly including a receptacle candle comprising a wick-clip-less wick. A method for manufacturing a candle assembly is also provided, comprising feeding a portion of a wick (e.g., a roll of wick) into a candle mold, and cold compressing a candle material (non-atomized wax droplets, solidified from raw wax material) into the mold about the portion of the wick to form a receptacle candle.

Abstract: A method for the production of a wood composite board is provided that comprises the steps of: providing a quantity of wood in the form of strands; coating the wood strands with a binder composition to from coated strands; forming a mat from the coated strands; exposing said mat to steam; ventilating steam; and pressing the mat, at a high temperature, to form the wood composite board having a final thickness.

Abstract: A multi-layer absorbent product in a preferred embodiment includes a fibrous nonwoven top sheet, a fibrous nonwoven absorbent core layer, and a fibrous nonwoven substantially water-impervious back sheet. Each component layer or sheet is manufactured at a fiberizing station (i.e., melt spinning) and laminated together at a combining station. The preferred melt spinning apparatus is spunbond for the top sheet, meltblowing for the core layer, and a combination of spunbond and meltblowing for the bottom sheet.

Abstract: A method of making a lid for a casket comprises providing tooling configured to produce a one-piece, unitary casket lid having a crown, a pie, a rim and a header, providing settable material from which to mold the lid, molding the settable material with the tooling, permitting the settable material to set thereby producing a one-piece, unitary casket lid having a crown, a pie, a rim and a header, and adhesively applying a wood veneer sheet to at least a portion of the lid. The veneer sheet can be applied with either a membrane press or a profile wrapping machine.

Abstract: Disclosed is an incombustible composition for a fire door/wall, the fire door/wall using the incombustible composition, and a method of producing the fire door/wall. The incombustible composition includes 1 to 80 wt % of organic or inorganic fiber, 1 to 80 wt % of fly ash or bottom ash, 1 to 80 wt % of fire-proofing agent, 1 to 30 wt % of curing fire-retardant resin, and 1 to 40 wt % of incombustible hollow filler.

Abstract: A method for manufacturing press molded bodies having at least two separate layers of material is disclosed. The method comprises providing a pair of cooperating parallel arranged rollers (1, 2) defining a nip (3) therebetween and having cavities defined on their outer surfaces, each cavity on one of the rollers (1, 2) cooperating with another cavity of the other roller (2, 1) to form die means, the axes (4, 5) of the rollers (1, 2) being arranged substantially horizontally, feeding at least two contiguous separate streams of different particulate materials into die means adjacent to the nip (3), so that each die means will be filled with portions of different material and counter-rotating the rollers (1, 2) so that the materials contained in the die means will be compressed into press molded bodies (briquettes) having at least two separate layers of material. An apparatus for the manufacture of press moulded bodies is also disclosed.

Abstract: Methods for making glasses and glass-ceramics comprising Al2O3 and SiO2. Glasses made according to the present invention can be made, formed as, or converted into glass beads, articles (e.g., plates), fibers, particles, and thin coatings. Some embodiments of glass-ceramic particles made according to the present invention can be are particularly useful as abrasive particles.

Abstract: The present invention relates to a method for forming a fire combustion modified batt. The method comprises the step of forming a blend of nonwoven and oxidized polyacrylonitrile fibers into a web. The oxidized polyacrylonitrile fibers are fire resistant and when blended with nonwoven fibers are relatively easily processed into a batt. A second blend of nonwoven fibers can be formed into a web and layered with the oxidized polyacrylonitrile fiber web to form the batt. The fibers are bonded together with heat, resin or other bonding material and are compressed and cooled. The fire combustion modified batt is useful as fire barriers and fillers in bedding, upholstery and vehicle and aircraft seats, as insulators for apparel, appliances, walls and ducting, as barriers to separate control systems from a heat source, and as components in fire safety gear such as race driver suits and oven and welding mitts.

Abstract: A method of making a one-piece, unitary lid for a casket comprises providing tooling configured to produce a casket lid having a crown, a pie, a rim and a header, providing settable material, preferably a mixture of wood chips and binder, from which to mold the lid, molding the settable material with the tooling and permitting the settable material to set. The tooling transmits a wood grain pattern into the settable material. The wood grain pattern of the lid is continuous when viewed rotated 180° about an axis perpendicular to the plane defined by the lid, located medially of the transverse extent of the lid and coinciding with the header end edge of the lid. Thus two such caps placed end-to-end have a continuous wood grain pattern extending from the head end of the casket to the foot end of the casket. Resin impregnated tissue paper is applied to the settable material prior to molding. The resin impregnated tissue paper conforms to the wood grain and conceals the wood chips.

Abstract: A bi-layered fire resistant (FR) nonwoven fiber batt and an associated method for manufacturing the same. The bi-layered FR nonwoven fiber batt includes a first, gray, FR layer, formed from a blend of black oxidized polyacrylonitrile (oxidized PAN), white dry polyester carrier fibers and white low-melt polyester binder fibers, and a second, white, layer, formed from a blend of white FR rayon, white dry polyester carrier fibers and white low-melt polyester binder fibers, disposed in a conforming relationship with the first, gray, FR layer.

Abstract: A calcium phosphate-synthetic resin-metal composite body produced by pressing a metal member, calcium phosphate particles (or calcium phosphate particles and a calcium phosphate block) and synthetic resin particles I, which are at least partially cross-linked in advance, uncross-linked, synthetic resin particles II while heating, the calcium phosphate particles and/or the calcium phosphate block being exposed on at least part of the surface of the composite body.

Abstract: Disclosed are uni-layer and bi-layer FR nonwoven fiber batts formed of various blends of charring fibers such as FR treated rayon, oxygen-depleting fibers such as modacrylic fibers and nonwoven fibers such as carrier fibers and binder fibers and associated methods for forming the same. Variously, the uni-layer and bi-layer FR nonwoven fiber batts may include layers formed entirely of blends of charring fibers and nonwoven fibers, layers formed entirely of blends of oxygen-depleting fibers and nonwoven fibers and/or layers formed of blends of charring fibers, oxygen-depleting fibers and nonwoven fibers.

Abstract: Disclosed herein is a method of manufacturing expanded graphite products. The method comprises the steps of a) compressing expanded graphite to form a graphite thin film, b) milling the graphite thin film to form graphite flakes, and c) placing the graphite flakes in a mold and compressing the graphite flakes to form a predetermined shape, wherein during at least any one of the steps a), b) and c), a binder is mixed with the expanded graphite. There are provided advantageous effects that as the density of the expanded graphite product increases through respective manufacturing steps, not only are initial equipment costs reduced due to minimized equipment, but also an expanded graphite product having a uniform density and a closely packed structure is provided. Additionally, since the expanded graphite product is finally compressed in the mold, the expanded graphite product does not have directional preference and can be formed into various shapes.

Abstract: Nanocomposite hardcoats having smudge and abrasion resistant properties are disclosed. Latent reactive nanoparticles are contained within a binder phase to form a nanocomposite. When deprotected and treated with a reactive fluorochemical, nanoparticles present at the surface of the nanocomposite become permanently modified and impart smudge resistance. The nanocomposite hardcoats may optionally be supported on a primary substrate.

Abstract: One of the exemplary filter systems described includes a bracket and a filter module that can be suspended from the bracket by a plurality of flexible supports. The bracket can support the filter system beneath the grate of a storm drain without the need for the filter system to be attached to the grate. The grate can be lifted out of the storm drain separately from the filter unit, which allows the filter system to be lifted without the added weight of the grate. When the grate has been lifted out of the way, a suitable fastener structure can be attached to the bracket of the filter system to make the use of mechanical lifting devices more convenient. The bracket can be manufactured to known dimensions, or it can be offered from among a set of brackets that are pre-configured for known storm drain dimensions or as a standard bracket that can be modified to fit the dimensions of a particular storm drain.

Abstract: The invention relates to a method of preparing a mineral fiber comprising one or more shaped cavities and a mineral fiber panel prepared by the method and an apparatus for preparing mineral fiber panels comprising one or more shaped cavities. Furthermore the invention relates to uses of the mineral fiber panel comprising one or more shaped cavities.

Abstract: A method for forming a solidified granular material (15), in which granules (16, 17) are charged into a tubular frame member (11) and then heated together with the frame member, to solidify the granules. The granules include a mixture of first granules (16) and second granules (17), each of which second granules has a thermoplastic resin shell enclosing a solid or liquid which expands by vaporization. The mixture is charged into the frame member and heated together with the frame member. The heating causes the second granules (17) to expand and the surfaces of the second granules to melt for bonding with the first granules (16). The mixture, upon cooling, becomes a solidified granular material (15), filling the frame member with no space therebetween.

Abstract: A process for producing tablets comprising one or more active substances, in which pulverulent to granular starting components are shaped and then solidified, wherein the solidification takes place by reacting a component A and a component B with one another, components A and B being mixed with the starting components, applied to them or added after shaping.

Abstract: Disclosed are both a method and composition for providing a flooring visual by agglomeration of components. The flooring visual is comprised of a jaspe or marble like finish. The agglomerated mix may be formed into welding rods or into decorative sheets. The decorative sheets may be seamed with the welding rods.

Abstract: In a process and apparatus for making a reinforced fibrous absorbent member, fibrous material is collected on a forming surface to at least partially form the absorbent member. Fibrous material is entangled with a reinforcing web which is overlaid on at least a portion of the partially formed absorbent member. Additional fibrous material is collected on the forming surface to further form the absorbent member whereby at least a portion of the fibrous material forming the absorbent member becomes entangled with at least one of the reinforcing web and the fibrous material entangled with the reinforcing web to secure the reinforcing web within the absorbent member.

Abstract: A powder molded magnet manufactured by a method comprising the steps of: (1) forming a granular compound of diameter of not more than 250 ?m with a rare earth-iron rapid-quenched flake, which has not more than 150 ?m in diameter, being coarsely ground if necessary, and a binder, (2) dry-blending the granular compound with fatty acid metallic soap powder, (3) forming compressed powder from the granular compound dry-blended with the fatty acid metallic soap powder, by powder molding, and (4) heat-treating the compressed powder to a temperature higher than a thermally dissociating temperature of stabilized isocyanate.

Abstract: A body (5) of set, initially pasty material, such as concrete, includes an electrically conducting path formed by a concentrated layer (6) of electrically conducting magnetizable elements, such as fibers (F) or granules (G), embedded in the initially pasty material and extending through at least a portion of the body (5). Electrically conducting terminal members (9) may be connected to the electrically conducting layer (6) at spaced-apart positions along the layer (6). A method of providing such a body (5) includes the steps of: (a) forming a body of the pasty material in which electrically conducting magnetizable elements (F) are dispersed, (b) applying a magnetic field to the body of pasty material to form from the magnetizable elements an electrically conducting layer embedded in the body of pasty material and extending at least through a portion the body (5), and (c) causing the body of pasty material containing the layer (6) to set.

Abstract: The present invention relates to a method for fabricating a functional dental element, such as a crown. According to the invention, use is made of a three-dimensional printing technique. The major advantages of the invention are that no mold is needed anymore, which entails a considerable saving of costs, that a great accuracy is achieved, and that the element can be made of different materials.

Abstract: A method for making in a single step a multiple-ply panel comprising the steps of forming and sandwiching a raw mat assembly of resinated furnish between two sheets of green incised wood veneer, applying a layer of thermosetting high-moisture tolerant adhesive at interfaces between the green veneer and core mat, and applying pressure and heat to cure the consolidated panel assembly for a duration sufficient to secure good internal bond within the substrate panel.

Abstract: A backing or an intermediate layer for a surface covering is described which comprises a fused recycled material, wherein the material comprises a thermoplastic material, for instance, a vinyl material from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both. Surface coverings containing the backing or intermediate layer of the present invention are also described as well as methods of making the backing or intermediate layer and methods of making the surface coverings containing the backing or intermediate layer of the present invention.

Abstract: A method of producing boards or panels from cereal straw includes the steps of treating and mechanically refining the straw with steam under elevated pressure which may be in excess of 8 bar (800 kPa). The resulting fiber may then be pressed in to boards or panels without added binder or mixed with a urea formaldehyde or melamine urea formaldehyde binder.

Abstract: Method for loading ceramic moulds presenting a die plate having at least one forming cavity in which a die is slidingly received, comprising the following operative steps for each complete loading cycle: preparing a powder layer at least the upper part of which has properties conforming to the required aesthetic characteristics of the exposed face of the tile; transferring said layer to above said at least one forming cavity; depositing into said at least one cavity a powder layer having a thickness greater than that necessary to obtain the desired tile thickness, and before pressing removing, by suction, the surface layer of the powder contained in the mould cavity, without appreciable mixing of the powder present at the interface between the surface layer and the underlying material.

Abstract: A composite comprising a structural component and a matrix component, the structural component comprising structural fibers and a toughening additive comprising non structural fibers of a first thermoplastic material and the matrix component comprising a second thermoplastic material. The structural component is a fabric formed from the structural fibers and the non structural thermoplastic fibers, the fabric comprising non structural thermoplastic fibers which are in fibre form in the final composite. The first and second thermoplastic materials differ as to their molecular weight or are dissimilar.

Abstract: In a method of producing a composite magnetic body, flat soft magnetic powder subjected to annealing to be free from stress strain is prepared and mixed with a binder and a solvent for dissolving the binder to form a slurry-like mixture. The mixture is formed into a film. Then, the solvent is removed. Thus, a sheet of the composite magnetic body is produced.

Abstract: A process for extruding of products from fluoropolymers preferably shaped as rods or tubes which have unique physical and other properties resulting from the addition of nanoparticles under unique processing conditions while also utilizing accurate control of processing parameters such as time and temperature and others according to novel methods.

Abstract: A method for making high temperature filter media is provided by melt-spinning a plurality of fibers of preceramic thermoplastic polymer to form a nonwoven textile web of the fibers, curing and cross-linking the thermoplastic polymer to a thermoset polymer, and thermally decomposing the thermoset polymer to ceramic. Between the melt-spinning step and the curing step, the web is formed to a filter pre-form in a green state while still pliable and malleable. The filter pre-form is cured without re-melting the thermoplastic polymer and without destroying morphology.

Abstract: A method of making a lid for a casket comprises providing tooling configured to produce a one-piece, unitary casket lid having a crown, a pie, a rim and a header, providing settable material from which to mold the lid, molding the settable material with the tooling, permitting the settable material to set thereby producing a one-piece, unitary casket lid having a crown, a pie, a rim and a header, and adhesively applying a wood veneer sheet to at least a portion of the lid. The veneer sheet can be applied with either a membrane press or a profile wrapping machine.

Abstract: An apparatus and a method for preparing an absorbent article is disclosed. The apparatus has at least two forming surfaces which differ in terms of air permeability to allow the selective placement of fibrous material. The forming surface comprises a perforated forming screen. The forming screen has multiple zones with different amounts of open area through which air may pass. Particles carried in the air which flows through the open area are deposited on different zones of the forming screen resulting in different basis weights corresponding to the different air permeabilities. The apparatus and method thus provide an article having optimal zoned absorbency in a cost-effective manner.

Abstract: A to be molded wood flake (12) or strand part is shown, having sharp definition in a bend in the part. The method of making such part includes using fines (13) to sharply define the bends of the part.

Abstract: A method for forming a laminated sheet material from a slurry having a liquid component. The method comprising the steps of: applying the slurry to a substrate in successive layers to form a wet sheet of predetermined thickness; applying at least one of the layers by spattering; removing the wet sheet from the substrate; and drying or curing the wet sheet so as to remove at least a substantial proportion of the liquid component and thereby forming the sheet material.

Abstract: A process for manufacturing a door trim panel with an integral soft armrest pad is provided which includes providing male and female steam chest mold halves, loading and restraining a cover material onto the female mold half, closing the male mold half to a fill position to form a cavity, inserting a divider into the cavity to separate the cavity into a low density volume and a high density volume, filling the high density volume with first polymeric material, filling the low density volume of the mold cavity with second polymeric material, withdrawing the divider from the mold cavity, and heating the first and second polymeric materials such that the first and second polymeric materials are melt bonded together, including at positions where particles from the first polymeric material contact particles from the second polymeric material. The low density volume creates the soft armrest pad.

Abstract: A process for producing a three-dimensional model is provided. The process includes a step (layer formation step) of forming a layer of a powder material, the layer having a predetermined thickness, a step (cross-sectional shape formation step) of imagewise bonding the powder material layer by a binder according to sliced cross-sectional data of a modeled object so as to give a cross-sectional shape, and sequentially repeating the above steps. The surface gloss of the three-dimensional model obtained when measured at 20° is 20% or more. Furthermore, production equipment used in the above process is provided. Moreover, a three-dimensional model is provided that contains a powder material and a binder and is formed by imagewise curing the binder, the three-dimensional model having a surface gloss when measured at 20° of 20% or more.

Abstract: A flexible or semi-rigid support fixture is sized and shaped to supportably engage a surface of a polymeric matrix object such as an organic bonded abrasive grinding wheel. The support fixture is utilized to support the object to help prevent slumping and/or expansion during thermal curing operations. The fixture is fabricated from a material, such as silicone rubber, that is capable of withstanding heat commonly associated with thermal curing operations and which provides sufficient resilience to permit use with objects manufactured within a relatively wide range of dimensional tolerances. Suitable materials include silicone rubber or other polymers or copolymers such as PTFE, FEP, Polyimide or blends with or without fillers or substrates.

Abstract: A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer rendering of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216).

Abstract: A composite crucible for pulling up monocrystalline silicon, which is superior in shape stability and suitable for a large-sized one is provided. The composite crucible is characterized in that a carbonaceous material as an outer layer and a quartz glass as an inner layer are integrally formed. Methods for preparing and regenerating a composite crucible are also disclosed.

Abstract: The present invention provides a functional film for transfer, by means of the application method, having a functional layer capable of exhibiting various functions, for example, a transparent conductive layer being low in electric resistance value, an article provided with the functional layer, and a method for producing the article provided with the functional layer. A functional film at least having a functional layer (4) on a support (1), said functional layer being releasable from the support (1), wherein the functional layer (4) is a compressed layer of functional fine particles. The compressed layer of the functional fine particles is obtained by applying a liquid in which the functional fine particles are dispersed onto the support (1) followed by drying to form a layer containing the functional fine particles, and compressing the layer containing the functional fine particles.

Abstract: A method for producing an anisotropic magnet with high energy product through extrusion and, more specifically, by placing a particle charge of a composition from the which magnet is to be produced in a noncircular container, heating the container and particle charge and extruding the container and particle charge through a noncircular extrusion die in such a manner that one of the cross-sectional axes or dimension of the container and particle charge is held substantially constant during the extrusion to compact the particle charge to substantially full density by mechanical deformation produced during the extrusion to achieve a magnet with anisotropic magnetic properties along the axes or dimension thereof and, more specifically, a high energy product along the transverse of the smallest cross-sectional dimension of the extruded magnet.

Abstract: A freeform fabrication method for fabricating a 3-D multi-material or multi-color object from successive layers of a primary body-building powder, at least a modifier material and a binder powder in accordance with a computer-aided design of the object.

Abstract: A particle board having wooden materials coated with an adhesive of a thermosetting resin and pressurized with being heated includes a core layer and face layers provided on both, front and back, sides of the core layer. The wooden materials of the face layer are smaller in the average particle diameter than the wooden material of the core layer and voids between the adjacent wooden materials in the face layer and the core layer are filled with resin particles of a thermoplastic resin by being pressurized with being heated.

Abstract: A process for manufacturing a decorative mainly isometric thermosetting laminate (1) comprising an isometric core (2), a primary surface layer (10) and optionally a secondary surface layer (20). 85 parts by weight of preferably organic particles are mixed with 15-85 parts by weight of a thermosetting resin such as phenol-formaldehyde resin, melamine-formaldehyde resin, urea-formaldehyde resin or mixtures thereof under powerful kneading in an extruder sot hat friction heat forms. The thermosetting resin is hereby bonded to or impregnating the particles. The particles possibly bonded to one another are parted whereby an agglomerate of resin and particles is formed. The particle/resin mixture is then dried to a water content of below 10%. The dried particle/resin mixture is then evenly distributed and continuously or discontinuously compressed in one or more steps under heat and pressure so that the resin finally cures, whereby an isometric core (2) is formed.

Abstract: A method of making panel-shaped products by hot-pressing a multi-layered formed body of chips of lignocellulose-containing annual plants impregnated with an isocyanate binder, is to avoid the problem of the adhesion of the isocyanate binder. For this purpose, the cover layer material is divided into a cover layer material fine fraction (5a) and a cover layer material coarse fraction (5b), whereby the cover layer material fine fraction (5a) is pre-mixed with adhesion promoters and/or wetting agents and/or acids and/or bases, and next glued with amino and/or phenolic plastics, and the cover layer material coarse fraction (5b) is glued with isocyanate or mixtures of isocyanate and amino and/or phenolic plastics. Next, a five-layered formed body is spread, whereby the outermost cover layers of the formed body consist of the cover layer material fine fraction glued with amino and/or phenolic plastics.

Abstract: A process for the manufacturing of a board, used as a core, forming a carrying structure for decorative laminates. Particles are achieved by grinding cured, and possibly foamed, rigid, polyurethane, polyisocyanurate and/or phenolic resin so that it passes through a 2 mm screen, preferably a 1 mm screen.

Abstract: A filter and a method of manufacturing the filter which is formed by spinning a fiber in a semi-molten state onto a mold such that the mold is provided as a filter structural member. The method obviates the need to remove the filter from the mold and thus simplifies the manufacture of the filter.

Abstract: Chemically or biochemically active agents or other species are patterned on a substrate surface by providing a micromold having a contoured surface and forming, on a substrate surface, a chemically or biochemically active agent or fluid precursor of a structure. A chemically or biochemically active agent or fluid precursor also can be transferred from indentations in an applicator to a substrate surface. The substrate surface can be planar or non-planar. Fluid precursors of polymeric structures, inorganic ceramics and salts, and the like can be used to form patterned polymeric articles, inorganic salts and ceramics, reactive ion etch masks, etc. at the surface. The articles can be formed in a pattern including a portion having a lateral dimension of less than about 1 millimeter or smaller. The indentation pattern of the applicator can be used to transfer separate, distinct chemically or biochemically active agents or fluid precursors to separate, isolated regions of a substrate surface.

Abstract: A microcrystalline cellulose-based excipient having improved compressibility, whether utilized in direct compression, dry granulation or wet granulation formulations, is disclosed. The excipient is an agglomerate of microcrystalline cellulose particles and from about 0.1% to about 20% silicon dioxide particles, by weight of microcrystalline cellulose, wherein the microcrystalline cellulose and silicon dioxide are in intimate association with each other. The silicon dioxide utilized in the novel excipient has a particle size from 1 nanometer to about 100 microns. Most preferably, the silicon dioxide is a grade of colloidal silicon dioxide. An extra low moisture excipient is provided which exhibits improved compressibility as compared to conventional microcrystalline cellulose, while providing a moisture content of of from about 0.5 to 2.5% LOD, preferably between about 0.5 and about 1.8%, more preferably between 0.8 and 1.5%, and most preferably between about 0.8 and about 1.2%.