Plural Layers Formed By Uniting Randomly Associated Particles Patents (Class 264/113)
  • Publication number: 20020180092
    Abstract: A textured airlaid web is disclosed. The textured web is formed on a three-dimensional fabric under sufficient force to cause the web to conform to the surface of the fabric. The textured web includes, on a minute scale, peak areas and valley areas. The peak areas and valley areas can improved the liquid handling properties of the web. For instance, webs can be produced having improved absorbency characteristics and/or wicking characteristics.
    Type: Application
    Filed: December 21, 2001
    Publication date: December 5, 2002
    Applicant: Kimberly-Clark Worldwide, Inc.
    Inventors: Rodney L. Abba, Robert J. Makolin, David J. Nickel, Charles W. Colman, Jeffrey Dean Lindsay, Fung-Jou Chen, Julie Marie Bednarz
  • Publication number: 20020168909
    Abstract: Method of forming a fiber web (210) intended for use in absorbent products, such as sanitary towels, by air-laying fibers. Separate air flows containing fibers are fed to a number n of different mat-forming wheels (160, 170, 180), where n is a whole number which is at least 2. Separate web layers (161, 171, 181) are formed on each mat-forming wheel. The fiber web (210) is formed by virtue of said web layers being combined downstream of the mat-forming wheels to form a common fiber web which is imparted very great manufacturing accuracy by virtue of the manufacturing method. The manufacturing speed and thus the web speed can be very high, and the desired manufacturing accuracy at the web speed concerned is achieved by selecting a sufficiently great number n of mat-forming wheels. The invention also relates to a fiber web manufactured according to the method.
    Type: Application
    Filed: April 19, 2002
    Publication date: November 14, 2002
    Inventors: Gunnar Edwardson, Claes Goransson
  • Patent number: 6475576
    Abstract: A reinforced interior trim panel assembly and method of making same for attachment to structure of a vehicle includes a reinforcement and a carrier formed from a plastic material for attachment to the structure of the vehicle and incorporating the reinforcement within the plastic material.
    Type: Grant
    Filed: November 13, 2000
    Date of Patent: November 5, 2002
    Assignee: Delphi Technologies, Inc.
    Inventors: Mansour Ashtiani, David Wayne Whitehead
  • Patent number: 6467571
    Abstract: In order to provide a sound absorbing material superior in acid resistance, alkali resistance and sound absorbing quality and a sound absorbing layer using this sound absorbing material, multiple pieces of basalt yarn obtained by dissolving basalt to be continuous fibers are bundled by a fiber bundling agent to acquire a bundled material, and the bundled material is fibrillated to obtain a bulky sound absorbing material. Moreover, the sound absorbing material is arranged on the outer periphery of a perforated pipe constituting a muffler to form a sound absorbing layer.
    Type: Grant
    Filed: December 11, 2000
    Date of Patent: October 22, 2002
    Assignees: Nakagawa Sangyo Co., Ltd., Toyota Jidosha Kabushiki Kaisha
    Inventor: Yukihiro Nakagawa
  • Patent number: 6464914
    Abstract: The invention relates to a process and an installation for the production of pressed-stock boards in a continuous sequence. The invention includes forming and transporting the mat of pressed stock on the molding and charging belt in a space bounded at the longitudinal sides. Two upright side supporting bands on the molding and charging belt run along and guide the pressed stock or the mat of pressed stock in such a way as to limit its width from the scattering station up to compaction in the prepress. The height of these side supporting bands correspond to the changing height of the press nip. The installation includes two side supporting bands arranged upright on the molding and charging belt, on both longitudinal sides. Supporting rollers bear against the side supporting bands in the region from the scattering station up to the prepress.
    Type: Grant
    Filed: October 18, 1999
    Date of Patent: October 15, 2002
    Assignee: Maschinenfabrik J. Dieffenbacher GmbH & Co.
    Inventor: Matthias Graf
  • Publication number: 20020145213
    Abstract: A solid freeform fabrication method and related apparatus for fabricating a three-dimensional, multi-material or multi-color object from successive layers of a primary body-building powder, at least a modifier powder and a binder powder in accordance with a computer-aided design of the object, the method including: (a) feeding a first layer of the primary body-building powder to a work surface; (b) operating an electrophotographic powder deposition device to create at least a modifier powder image and a binder powder image in accordance with this design; (c) transferring these powder images in a desired sequence to the first layer of a primary body-building powder; (d) applying energy sources to fuse the binder powder, forming a binder fluid that permeates through the first layer of a primary body-building powder for bonding and consolidating the powder particles to form a first cross-section of the object; (e) feeding a second layer of a primary body-building powder onto the first layer and repeating the ope
    Type: Application
    Filed: April 10, 2001
    Publication date: October 10, 2002
    Inventors: Junhai Liu, Bor Z. Jang
  • Patent number: 6458299
    Abstract: Disclosed is a process for producing fiber webs by the airlaid process of laying down the fibers and the pulverulent binder in an air stream, which includes a first step of laying a fiber web or fibers up to a basis weight of 10 to 50 g/m2, a subsequent step of laying down fibers and a thermoplastic polymer powder based on polymers of one or more monomers such as a vinyl ester or a (meth)acrylic ester separately or as a mixture in the air stream in an amount of 10 to 300 g/m2 and, if appropriate, repeating this step until the desired basis weight is obtained, and consolidating the fiber material at temperatures of 80° C. to 260° C. and, if appropriate, at a pressure of up to 100 bar.
    Type: Grant
    Filed: April 17, 2000
    Date of Patent: October 1, 2002
    Assignee: Wacker Chemie GmbH
    Inventors: Konrad Alfons Wierer, Holger Poths, Richard Goetze
  • Publication number: 20020121721
    Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.
    Type: Application
    Filed: March 18, 2002
    Publication date: September 5, 2002
    Applicant: Lear Corporation
    Inventors: George B. Byma, Brian A. Cristea, Richard Muhlbacher
  • Patent number: 6444150
    Abstract: A method for packing a stationary phase into a small diameter fluid passageway or flow channel. Capillary action is employed to distribute a stationary phase uniformly along both the length and diameter of the flow channel. The method disclosed here: 1) eliminates the need for high pressure pumps and fittings and the safety hazards associated therewith; 2) allows the use of readily available commercial microparticles, either coated or uncoated, as the stationary phase; 3) provides for different types of particles, different particle sizes, and different particle size distributions to be packed in sequence, or simultaneously; 4) eliminates the need for plugging the flow channel prior to adding the stationary phase to retain the packing particles; and 5) many capillaries can be filled simultaneously.
    Type: Grant
    Filed: September 25, 1998
    Date of Patent: September 3, 2002
    Assignee: Sandia Corporation
    Inventor: Don W. Arnold
  • Publication number: 20020105114
    Abstract: To provide a three-dimensional molding technique capable of generating a three-dimensional molded article in short time.
    Type: Application
    Filed: February 5, 2002
    Publication date: August 8, 2002
    Applicant: Minolta Co., Ltd.
    Inventors: Naoki Kubo, Toshio Norita, Makoto Miyazaki, Akira Wada
  • Patent number: 6423255
    Abstract: A method for manufacturing a structural part by a multi-layer deposition technique, in particular a part in the form of a casting mold or a casting core, a porous first layer of bulk particulate material consisting of particles of a predetermined particle size being deposited to form a layer of a predetermined layer thickness, a predetermined dose of liquid binder material being applied onto the layer, so that the liquid binder material penetrates the layer and becomes distributed within the layer and wets the particles of the layer and a predetermined residual porosity of the layer remains after distribution, a predetermined dose of liquid curing agent being selectively applied to a predetermined sub-area of the layer containing the binder material, a second layer being deposited on the first layer containing the binder material and the curing agent and being treated with a binder material and selectively with a liquid curing agent, the curing agent being applied to the second layer before the binder materia
    Type: Grant
    Filed: August 14, 2000
    Date of Patent: July 23, 2002
    Inventors: Rainer Hoechsmann, Ingo Ederer
  • Publication number: 20020093115
    Abstract: A method and related apparatus for fabricating a three-dimensional object in accordance with a computer-aided design of the object in a layer-by-layer but not point-by-point fashion.
    Type: Application
    Filed: January 12, 2001
    Publication date: July 18, 2002
    Inventors: B. Z. Jang, Junhai Liu, Liangwei Wu
  • Patent number: 6419865
    Abstract: Bonded fluff structures and a method for producing such bonded fluff structures in which a pulp sheet having a material suitable for producing fluff and a heat activatable fiber material is fiberized to produce a mixture of fluff and heat activatable fibers. The mixture is contacted with a hot air stream, heating the heat activatable fibers to an activation temperature. The resulting heated mixture is then deposited onto a forming structure, forming a bonded fluff/fiber composite matrix structure.
    Type: Grant
    Filed: September 30, 1997
    Date of Patent: July 16, 2002
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Stanley Michael Gryskiewicz, David Martin Jackson, Jason Douglas Hadley, Jerome Joseph Schwalen, Frank Paul Abuto, Kuo-Shu Edward Chang, Susan Carol Paul, Richard John Schmidt
  • Patent number: 6416697
    Abstract: A method and apparatus for forming an article (94) includes a moving of a forming surface (22) through an operative forming chamber (24) along a forming path length (40). A first fibrous stratum (26) of fiber material (96) can be deposited onto the forming surface (22), and the first fibrous stratum (26) can have a first stratum thickness (28). A first quantity of a first superabsorbent material (30) can be directed to form a selected combination with the first fibrous material to provide a first superabsorbent-containing stratum. A second fibrous stratum (32) of fibrous material can be deposited to overlie the first fibrous stratum (26), and the second fibrous stratum (32) can have a second stratum thickness (34). A second superabsorbent material (36) can be directed to form a selected combination with the second fibrous material to provide a second superabsorbent-containing stratum.
    Type: Grant
    Filed: December 3, 1999
    Date of Patent: July 9, 2002
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Michael Barth Venturino, Randy Keith Burr, John Wallace de Vos, Leon Robert Flesburg, David Willis Heyn, Richard Francis Keller, Thomas George Olsen, Lorry Francis Sallee
  • Patent number: 6413455
    Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam, a foaming agent and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.
    Type: Grant
    Filed: May 1, 2000
    Date of Patent: July 2, 2002
    Assignee: Trico Sports, Inc.
    Inventor: Paul M. Yates
  • Patent number: 6401795
    Abstract: In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.
    Type: Grant
    Filed: January 3, 2000
    Date of Patent: June 11, 2002
    Assignee: Sandia Corporation
    Inventors: Joseph Cesarano, III, Paul D. Calvert
  • Patent number: 6403002
    Abstract: Method for producing a shaped body, which method comprises the following steps; (1) applying a layer of pulverulent material to a surface, (2) patternwise applying at least one liquid to the layer of pulverulent material, forming a layer of patternwise bound-together pulverulent material, (3) repeating steps (1) and (2) a predefined number of times, so that a number of successive layers of patternwise bound-together powder, is formed, the successive layers of bound-together pulverulent material together forming the shaped body, and (4) removing the unbound powder, in which the liquid comprises water and the pulverulent material comprises at least one component which forms a binder after contact with water in step (2).
    Type: Grant
    Filed: December 3, 1999
    Date of Patent: June 11, 2002
    Assignee: Buss Muller Technology GmbH
    Inventor: Adrianus Franciscus van der Geest
  • Patent number: 6399001
    Abstract: Procedure for the fabrication of a blank for a structural product, such as a blank for a structural board, from material (1) comprising longer (L) and shorter (S) particles and possibly also particles (F) smaller than these. The particles are mixed with a binding agent and possible additives and then passed into at least one blank former, from where the particles are brought onto a base (10). Longer particles (L) are brought onto the base (10) to form a first surface layer, onto which is brought at least one layer of smaller particles (F, S), and onto this layer is again brought a layer of longer particles (L) to form a second surface layer, the smallest particles (F) being so brought onto the base that they mainly end up in at least one middle layer in the cross-section of the blank while the amount of the smallest particles (F) diminishes towards the surface layers as seen in the cross-section of the blank.
    Type: Grant
    Filed: February 5, 1998
    Date of Patent: June 4, 2002
    Assignee: Sunds Defibrator Loviisa Oy
    Inventors: Aarne Laatikainen, Jarmo Laitinen
  • Patent number: 6391236
    Abstract: The process for forming ceramic tiles comprises depositing a layer of multi-coloured powdery material on a moving transport plane, in order to achieve a predetermined pattern, and subsequently transferring said layer internally of a moulding cavity, due to a movement of the transport plane and a contemporary displacement of the transport plane with respect to the cavity. The forming plant comprises a conveyor belt (2) able on command to perform displacements with respect to the forming cavity. A plurality of silk-screening devices (9) is predisposed to deposit a layer of powdery material bearing a predetermined design on the transport plane. The invention can be especially useful in the production of decorated vitrified stoneware tiles.
    Type: Grant
    Filed: December 9, 1999
    Date of Patent: May 21, 2002
    Inventor: Alberto Franceschini
  • Publication number: 20020058135
    Abstract: A method for making a resilient cushion includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.
    Type: Application
    Filed: September 24, 1999
    Publication date: May 16, 2002
    Inventor: PAUL M. YATES
  • Patent number: 6387307
    Abstract: The present invention relates to a method for feeding a granular or powderlike material to a pressing apparatus for the dry pressing of the material. The device comprises containers for the materials and rollers arranged at openings of the containers. Each roller has a cavity which is suitable to be filled by the material and to be freed of the material following a rotation of the rollers so as to pour the material into a mold. In the method, the rotation of the rollers is produced simultaneously with a movement of the rollers in a direction which lies at right angles to its axis. The invention allows to obtain particular color effects, such as colorings, color shades, basic decorations, complex decorations, natural stone-like effects, et cetera, on the resulting ceramic products, particularly tiles.
    Type: Grant
    Filed: September 8, 1999
    Date of Patent: May 14, 2002
    Assignee: S.I.T.I. S.p.A. Societa Impianti Termoelettrici Industriali
    Inventor: Renato Bossetti
  • Patent number: 6379595
    Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.
    Type: Grant
    Filed: April 28, 2000
    Date of Patent: April 30, 2002
    Assignee: Lear Corporation
    Inventors: George B. Byma, Brian A. Cristea, Richard Mühlbacher
  • Patent number: 6375885
    Abstract: A method for coating a surface with a magnetic composite material exhibiting distinct flux properties due to gradient interfaces within the composite. Surfaces coated with such a composite can be used to improve fuel cells and to effect improved transport and separation of different species of materials. A wide variety of devices can incorporate such composite-coated surfaces, including separators, fuel cells, electrochemical cells, and electrodes for channeling flux of, or for effecting electrolysis of, magnetic species.
    Type: Grant
    Filed: July 27, 1998
    Date of Patent: April 23, 2002
    Assignee: The University of Iowa Research Foundation
    Inventors: Johna Leddy, Sudath Amarasinghe
  • Patent number: 6375874
    Abstract: A printer forms three-dimensional objects from a powder by selectively applying a binder liquid to incremental layers of the powder. The binder binds layers of the powder into solid two-dimensional cross sections of the desired object provided from memory. The printer can use dithering and halftoning techniques to shade the object and can also print in color. A filtration system removes airborne powder and recirculates the clean air. The printer also includes additional features to manage excess and airborne powder.
    Type: Grant
    Filed: October 13, 1999
    Date of Patent: April 23, 2002
    Assignee: Z Corporation
    Inventors: David B. Russell, Timothy Anderson, James F. Bredt, Michael J. Vogel, Walter J. Bornhorst
  • Patent number: 6365077
    Abstract: A process for the preparation of cellulosic composites from divided cellulosic fibrous material, which process comprises a hydrothermolytic treatment of the divided cellulosic fibrous material, carried out at a temperature in the range of 160 to 200° C., using water as softening agent, a drying or a drying and a curing step and a step in which dried or dried and cured particles of treated material are contacted with an adhesive, subsequently curing the adhesive-laden particles at increased temperature and pressure under formation of the desired composite.
    Type: Grant
    Filed: April 24, 1998
    Date of Patent: April 2, 2002
    Assignee: CR&DO B.V.
    Inventors: Gerard Tjarko Pott, Hendrik A. C. Groeneveld, Franciscus Hillebrand Adriaan Zomers
  • Patent number: 6361722
    Abstract: A method of producing a carbon-carbon part having a filamentized composite fiber substrate is provided. A substrate having a plurality of discontinuous filamentized fibers and a binder that binds said filaments together to form a composite substrate is provided, and carbon atoms are deposited onto the filaments at a predetermined temperature so that the binder is removed completely from the filaments and replaced with carbon atoms to from a dense carbon-carbon part.
    Type: Grant
    Filed: February 12, 1999
    Date of Patent: March 26, 2002
    Assignee: Cytec Technology Corp.
    Inventors: William Theys, Donald E. Wantock, Jeffrey J. Rose, Martin T. Choate
  • Publication number: 20020033548
    Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a dental restoration. Three-dimensional printing comprises inkjet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound restoration can be deposited concurrently slice after slice and sintered/cured simultaneously. The amount of green body oversize is equivalent to the amount of shrinkage which occurs during sintering or curing.
    Type: Application
    Filed: October 5, 2001
    Publication date: March 21, 2002
    Inventors: Dmitri Brodkin, Carlino Panzera, Paul Panzera
  • Patent number: 6358460
    Abstract: Methods are disclosed for producing multi-layer peelable sheaths having formed tips, for use as medical introducer devices, e.g., sheaths for inserting a catheter or the like into a patient. The methods include the steps of preparing a first composition blend for forming an inner layer of the multi-layer sheath, preparing a second composition blend for forming an outermost layer of the multi-layer sheath, combining the first and the second composition blends into a multi-layer pre-form, processing the multi-layer pre-form for producing tubing, and forming a tip at one end of the tubing using a thermal process, thereby producing the multi-layer sheath having the inner layer, the outermost layer, and the formed tip. The methods of the present invention include adding a detectable material to the blend used for making the inner layer for facilitating external visualization of the multi-layer sheath, thereby achieving a sheath with a formed tip having no visible discoloration.
    Type: Grant
    Filed: December 23, 1999
    Date of Patent: March 19, 2002
    Assignee: TFX Medical Incorporation
    Inventors: William E. Hunt, Jr., George Purtell, Peter D. Spohn
  • Patent number: 6357855
    Abstract: This invention relates to the formation of three-dimensional objects on substantially layer-by-layer basis with enhanced resolution. The invention utilizes a unique offset printhead containing groups of jets to selectively deposit a hot-melt material.
    Type: Grant
    Filed: February 25, 1999
    Date of Patent: March 19, 2002
    Assignee: 3D Systems, Inc.
    Inventors: Thomas A. Kerekes, Bryan J. L. Bedal, Joe M. Brown
  • Publication number: 20020020945
    Abstract: The technical disclosures of this invention are comprised of (1) a process for manufacturing parts, (2) techniques used for material distribution in this process, and (3) techniques used for consolidation of material in this process. The manufacturing process is an embodiment of layered freeform fabrication of parts of arbitrary geometry based on the use of bulk consolidation operations as opposed to previous methods which selectively consolidate regions of a layer at a time. In order to select which areas are consolidated, variations of material properties are created before consolidation. Two techniques are presented for creating these variations: a technique using an additive to change material properties and a technique using multiple materials distributed in an arbitrary pattern to form a layer. When an additive is used, a single material is deposited to form a layer and additive is selectively applied with an inkjet-style print head.
    Type: Application
    Filed: August 17, 2001
    Publication date: February 21, 2002
    Inventors: Uichung Cho, David Charles Thompson
  • Publication number: 20020011687
    Abstract: Used and manufacturing scrap asphalt shingle material is processed into a fine material comprising smaller sized pieces of shingle material and a relatively high aggregate content. The fine material is finish processed into shaped products adapted to take advantage of the high aggregate content therein. Processing of the fine material includes (i) grinding and heating the aggregate and smaller sized pieces of shingle material into a homogenous mixture, (ii) forming the shaped products via molding with pressure, or extruding and cutting the extruded mixture, and embedding a surface treatment material into the shaped products.
    Type: Application
    Filed: April 18, 2001
    Publication date: January 31, 2002
    Inventor: Donald J. Mischo
  • Publication number: 20020011680
    Abstract: In addition to a loading apparatus (10) for loading material through the upper mouth of the mold cavity (6), the unit comprises a blower device (30) for blowing air, means for moving said device while held a short distance from the upper surface of the material (B′) loaded into the mold cavity, such as to lift in a gauged manner a thin layer of material from the top thereof, and means (51, 55) for collecting the material lifted by the blower device (30), in order to remove it from the mold cavity. In particular, the blower device (30) comprises a relatively narrow, long blowing port (31) arranged to emit an air jet in the form of a thin sheet extending in a horizontal direction, and means (33, 34) for feeding compressed air to said blowing port (31), which is moved while maintained a short distance from the upper surface of the material (B′) loaded into the mold cavity (6) in order to lift a thin gauged layer of material.
    Type: Application
    Filed: July 25, 2001
    Publication date: January 31, 2002
    Applicant: L.B. - Officine Meccaniche - S.P.A.
    Inventor: Giorgio Prodi
  • Publication number: 20020003318
    Abstract: Ceramic sintered bodies having a different thickness along a predetermined axial direction are manufactured in the following manner. At first, a ceramic formed body to be sintered having different thickness along the predetermined axial direction is accommodated in a hot press apparatus. An upper forming mold and a lower forming mold each having a forming surface corresponding to an upper surface and a lower surface of the ceramic formed body to be sintered are set. A pressure along the predetermined axial direction is applied to the ceramic formed body to be sintered via the upper forming mold and the lower forming mold while heating the ceramic formed body to be sintered to perform a hot press sintering thereof. A thickness of a ceramic sintered body in such a manner that a maximum thickness in the predetermined direction is not two times larger or more than a minimum thickness in the predetermined direction.
    Type: Application
    Filed: September 4, 2001
    Publication date: January 10, 2002
    Applicant: NGK Insulators, Ltd
    Inventors: Hiromichi Kobayashi, Satoru Yamada, Tetsuhisa Abe
  • Patent number: 6322728
    Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound restoration can be deposited concurrently slice after slice and sintered/cured simultaneously. The amount of green body oversize is equivalent to the amount of shrinkage which occurs during sintering or curing.
    Type: Grant
    Filed: July 9, 1999
    Date of Patent: November 27, 2001
    Assignee: Jeneric/Pentron, Inc.
    Inventors: Dmitri Brodkin, Carlino Panzera, Paul Panzera
  • Patent number: 6319342
    Abstract: A method of forming a meltblown web having meltblown fibers and particles is provided. The particles are heated to a temperature approximating that of the meltblown fibers as they are being extruded. As a portion of any heated particle impacts the skin of one or more solidifying meltblown fibers, that portion of any heated particle penetrates into one or more solidifying particles. Although a portion of any particle becomes embedded in and retained by one or more meltblown fibers, such surface penetration is generally slight desirably leaving a substantial amount of surface area of any particle available for interaction with any medium to which a web may be exposed.
    Type: Grant
    Filed: October 15, 1999
    Date of Patent: November 20, 2001
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventor: Wilfred Eugene Riddell
  • Patent number: 6319441
    Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.
    Type: Grant
    Filed: February 22, 2000
    Date of Patent: November 20, 2001
    Inventor: Paul M. Yates
  • Patent number: 6306325
    Abstract: Ceramic sintered bodies having a different thickness along a predetermined axial direction are manufactured in the following manner. At first, a ceramic formed body to be sintered having different thickness along the predetermined axial direction is accommodated in a hot press apparatus. An upper forming mold and a lower forming mold each having a forming surface corresponding to an upper surface and a lower surface of the ceramic formed body to be sintered are set. A pressure along the predetermined axial direction is applied to the ceramic formed body to be sintered via the upper forming mold and the lower forming mold while heating the ceramic formed body to be sintered to perform a hot press sintering thereof. A thickness of a ceramic sintered body in such a manner that a maximum thickness in the predetermined direction is not two times larger or more than a minimum thickness in the predetermined direction.
    Type: Grant
    Filed: November 5, 1999
    Date of Patent: October 23, 2001
    Assignee: NGK Insulators, Ltd.
    Inventors: Hiromichi Kobayashi, Satoru Yamada, Tetsuhisa Abe
  • Patent number: 6284176
    Abstract: An industrial precursor suitable for making resilient construction materials for use in interior and exterior applications is produced by homogenizing a glassy material together with a plasticizer and suitable solvent. The homogenized material is extruded, dried, and ground into pellets. The industrial precursor may be stored indefinitely, and is processed into construction materials by packing the industrial precursor into a heat-resistant mold, and thermally treating the industrial precursor to sinter it into a construction material having a substantially defect-free surface and strong tensile strength.
    Type: Grant
    Filed: December 11, 1997
    Date of Patent: September 4, 2001
    Assignee: Futuristic Tile, L.L.C.
    Inventor: Frantiśek Oujiri
  • Patent number: 6273978
    Abstract: The present invention provides a process for producing a carded and air-laid non-woven composite fabric. First, a fiber is subjected to carding treatment through a carding machine to form a carded web. Then, a fiber, powder, or particulate material is subjected to air-laying through an air-laying device to form an air-laid web. The sequence of carding and air-laying steps can be exchanged, and the carding machine and the air-laying device are disposed on the same production line. Finally, the above webs are consolidated into a non-woven composite fabric. In the present invention, since carding and air-laying are conducted on the same production line, the procedure for producing air-laid webs off-line can be omitted. Therefore, the thermoplastic polymer amount added to increase the web strength can be decreased, thus decreasing the production cost.
    Type: Grant
    Filed: January 25, 2001
    Date of Patent: August 14, 2001
    Assignee: Kang Na Hsiung Enterprise Co., LTD
    Inventor: Jung Chi Tai
  • Patent number: 6267575
    Abstract: An apparatus for forming a substantially uniform distribution of particulate material within the cross direction of a fibrous web includes a conveying mechanism for providing a gas entrained supply of the particulate material. A transferring mechanism directs the particulate into a delivery gas stream to provide a flow volume of the particulate material a delivery conduit and a delivery nozzle into a web forming chamber. A fiberizing mechanism provides a flow of a selected fibrous material into the web forming chamber, and a directing mechanism controls the flow of particulate material from the delivery conduit and the delivery nozzle into the web forming chamber. A foraminous forming layer is disposed within the web forming chamber for receiving the fibrous material and the particulate material to produce a fibrous web which includes a substantially uniform distribution in the cross direction of the particulate material therein.
    Type: Grant
    Filed: October 20, 1999
    Date of Patent: July 31, 2001
    Assignee: Kimberly Clark Worldwide, Inc.
    Inventors: John Anthony Rooyakkers, David Arthur Fell, Thomas Joel Halloran, Paul Martin Niemi, Martin Karl Olsen, Kenneth Raymond Schueler, Jr., Darold Dean Tippey
  • Publication number: 20010007716
    Abstract: A mold assembly and method for molding a substantially hemispherical construct from pre-expanded polystyrene beads. The mold assembly includes a female half mold; a mating male half mold; a first male mold insert mountable on the male half mold and having a continuous, peripheral, beveled edge; and a second male mold insert mountable on the first male mold insert. For forming a construct having an impact-resistant exterior layer and an energy-absorbing interior layer, such as a motorcyclist safety helmet, the beads are initially molded under heat and compression between the female half mold and the first insert to form a first intermediate product of a first volume having a continuous, peripheral, beveled edge; said product is thereafter molded under heat and compression between the female half mold and the second insert to a second, reduced volume to form a compressed, second intermediate product, the beveled edge of the first intermediate product serving to uniformly distribute the force applied thereto.
    Type: Application
    Filed: December 29, 2000
    Publication date: July 12, 2001
    Applicant: Future Foam Technology, LLC, a Washington Limited Liability Company
    Inventor: Philip William Cutler
  • Patent number: 6254821
    Abstract: Bulked and liquid-permeable fleeces are used in the hygienic products industry for diapers and bandages. These fleeces have the purpose of rapidly absorbing fluid secreted from the body, storing it, and slowly giving it up to the absorber located beneath, uniformly over the entire surface of the absorber. As a result of the idea according to the invention, a fleece is formed from shrunk and/or crimped fibers together with non-shrinking man-made fibers, and the fleece is then compacted by a hydrodynamic compacting method without using binders, after which the fleece is dried and the shrinking ability present in the shrinking fibers and/or the crimping ability present in the crimping fibers in latent form are triggered immediately and/or subsequently by the action of temperature. This fleece can be manufactured economically and meets all of the requirements imposed upon it.
    Type: Grant
    Filed: August 5, 1998
    Date of Patent: July 3, 2001
    Assignee: Fleissner GmbH Co., Maschinenfabrik
    Inventor: Gerold Fleissner
  • Patent number: 6241926
    Abstract: A mold assembly and method for molding a substantially hemispherical construct from pre-expanded polystyrene beads. The mold assembly includes a female half mold; a mating male half mold; a first male mold insert mountable on the male half mold and having a continuous, peripheral, beveled edge; and a second male mold insert mountable on the first male mold insert. For forming a construct having an impact-resistant exterior layer and an energy-absorbing interior layer, such as a motorcyclist safety helmet, the beads are initially molded under heat and compression between the female half mold and the first insert to form a first intermediate product of a first volume having a continuous, peripheral, beveled edge; said product is thereafter molded under heat and compression between the female half mold and the second insert to a second, reduced volume to form a compressed, second intermediate product, the beveled edge of the first intermediate product serving to uniformly distribute the force applied thereto.
    Type: Grant
    Filed: May 7, 1999
    Date of Patent: June 5, 2001
    Assignee: Future Foam Technology, LLC
    Inventor: Phil Cutler
  • Patent number: 6237208
    Abstract: A process for the manufacture of section material composed of thermoplastic material, such sections being suitable for the production of door and window jambs and frames. A thermoplastic material component and a second component containing additives are mixed and compacted to form a strand-forming mixture. In so doing, the thermoplastic component is thermally plasticised. The strand-forming mixture is formed into section material, which may then be further machined, shaped and coated to form the final product.
    Type: Grant
    Filed: February 17, 1998
    Date of Patent: May 29, 2001
    Inventor: Ernst-Josef Meeth
  • Publication number: 20010001512
    Abstract: The present invention discloses a process for manufacturing tablets using a press provided with at least one compression chamber having an upper and a bottom mold and a lubrication device having at least one two-substance nozzle which sprays the lubricant onto the walls of said compression chamber in a cone shaped pattern, wherein at least one additive is added to the lubricant to thereby apply the additive onto the surface of the tablets during the manufacturing process.
    Type: Application
    Filed: January 16, 2001
    Publication date: May 24, 2001
    Inventor: Gunter Voss
  • Patent number: 6228298
    Abstract: A water soluble dicarboxylic acid or an alkali metal salt thereof acts as a mold release agent for salt pellets when a salt-contacting surface of a roll-type briquetting press is coated with from about 0.02 to about 5 mg/cm2 of a powder of the acid or alkali metal salt just prior to a charge of salt. The coating is achieved by spraying an air stream entraining the powder onto the press rolls or by spraying a solution of the release agent onto the rolls and evaporating the solvent to leave the powder on the rolls. The acid has from 6 to 10 carbon atoms; adipic acid being preferred. Salt pellets having a layer of the powder on their surface may be used in water softening systems wherein the pellets sit in a brine reservoir and supply salt for the recharging of an ion exchange resin. There is no formation of an unsightly scum on the surface of the brine and on the sides of the reservoir.
    Type: Grant
    Filed: March 25, 1999
    Date of Patent: May 8, 2001
    Assignee: Morton International, Inc.
    Inventor: Kurt J. Waatti
  • Patent number: 6221291
    Abstract: A method of forming a preform, for use in manufacturing a part having a predetermined part outline, includes positioning waste plastic material within an unconsolidated blank. The unconsolidated blank has an outline corresponding to a desired outline of the preform and the part outline. The method further includes selectively positioning reinforcing material within the unconsolidated blank for added strength. The unconsolidated blank is then heated and compressed to form the preform.
    Type: Grant
    Filed: February 26, 1999
    Date of Patent: April 24, 2001
    Assignee: Lear Corporation
    Inventors: Jack M. Van Ert, Gregory A. LaPorte, John P. Slaven, Xianping Liu, John F. Witt, Jr.
  • Patent number: 6216896
    Abstract: A fossil molding fabrication method includes the steps of (1) preparing a fossil skeleton material; (2) mixing the fossil skeleton material with water to form a paste-like fossil skeleton material, then filling the paste-like fossil skeleton material in the cavity of a flexible mold; (3) preparing a base rock material, then mixing the base rock material with water to form a paste-like base rock material, and then covering the paste-like base rock material over the fossil skeleton in the flexible mold; and (4) keeping the paste-like base rock material away from the radiation of the sun and letting it be dried in the air, and then removing the molding thus formed from the mold, so as to obtain a fossil molding. A cover rock may be covered on the base rock over the fossil skeleton.
    Type: Grant
    Filed: December 16, 1998
    Date of Patent: April 17, 2001
    Inventors: Mann-Hwang Chern, Li-Sung Chiang, Kuo Yao-Te
  • Patent number: 6207099
    Abstract: A method for forming a substantially uniform distribution of particulate material within a fibrous web includes a conveying step for providing a gas entrained supply of the particulate material. A transferring step directs the particulate material into a delivery gas stream through a delivery conduit and delivery nozzle into a web forming chamber. A fiberizing step provides a flow of a selected fibrous material into the web forming chamber. A foraminous forming layer is disposed within the forming chamber for receiving the fibrous material and the particulate material to produce a fibrous web.
    Type: Grant
    Filed: October 20, 1999
    Date of Patent: March 27, 2001
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: John Anthony Rooyakkers, David Arthur Fell, Thomas Joel Halloran, Paul Martin Niemi, Martin Karl Olsen, Kenneth Raymond Schueler, Jr., Darold Dean Tippey
  • Patent number: RE37875
    Abstract: Solid objects are formed in an imagewise layering process in which components of a dispersion are homogenized to form an alloy. Imagewise exposure of the layers to radiation to form an alloy permits separation of the exposed, homogenized regions from non-exposed, non-homogenized regions. As each layer is formed and imagewise homogenized, contiguous layer regions are bonded together to form a homogenized, three-dimensional object which may be separated from surrounding dispersion.
    Type: Grant
    Filed: November 13, 2000
    Date of Patent: October 15, 2002
    Inventor: John A. Lawton