Abstract: A method of manufacturing sheets, films, and articles of manufacture from a corn zein resin. A wet corn zein resin is formed including corn zein and a fatty acid, and the wet zein resin is cold rolled into sheets. The sheets are dried, and the dried zein resin is processed to form sheets, films, and/or articles of manufacture.

Abstract: A method of preparing wood and plastic to produce a composite material.

Abstract: A method of making expanded graphite. The method comprises grinding flexible graphite foil, preferably recycled material, to a small particle size, wetting the graphite foil with a water solution, thermally shocking the particles to expand them, mixing the expanded graphite with a thermoset phenolic resin, heating the mixture under pressure to form a solid sheet and then heat treating the solid sheet.

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 fibre may then be pressed in to boards or panels without added binder or mixed with a urea formaldehyde or melamine urea formaldehyde binder.

Abstract: Methods for making high wet performance webs. A polymeric anionic reactive compound is applied heterogenously to a cellulosic fibrous web followed by curing of the compound to crosslink the cellulose fibers. The resulting tissue has high wet resiliency, high wet strength, and a high wet:dry tensile strength ratio.

Abstract: The invention provides a method of producing styrenic resin granulates including dry-compression-molding a powder of styrenic resin having a syndiotactic configuration at a compression pressure of 1-20 t/cm and at a molding temperature falling within the range of the glass transition temperature of the powder of styrenic resin to the melting point thereof, inclusive; and crushing the resultant molded product. High-quality styrenic polymer granulates can be produced in an industrially advantageous manner by means of a large-scale apparatus for producing styrenic polymer having a syndiotactic configuration.

Abstract: A wooden material is made by bonding together with a binder resin, ozonized wood elements obtained by acetylating wood elements and then ozonizing the acetylated wood elements.

Abstract: A recycling method of producing magnetic material powder from bonded magnets which are produced by mixing magnetic material powder, as raw material powder, with a binder and subjecting a mixture to molding forming, has at least the steps of: (a) separating and collecting the magnetic material powder from the bonded magnets by removing all or a prescribed percentage of the binder contained in the magnets; (b) removing all or a prescribed percentage of the particles of diameter smaller than a prescribed particle diameter from the separated and collected magnetic material powder; and (c) mixing the magnetic material powder, from which the particles of diameter smaller than the prescribed one are removed, with a virgin magnetic material powder in a prescribed mixing ratio, so as to produce a new raw material powder.

Abstract: An arrangement for producing a fibrous mat from a heated die source wherein the produced mat includes a first layered, preselected fiber portion of substantially straight fibers produced by directing such fibers directly to a collector source and a second layered preselected fiber portion of substantially curled fibers produced by diverting and exerting an external vortically creative curling force thereon before reaching the collector source.

Abstract: The present invention describes a process of using agricultural biomass to make particle or fiberboards. The preferred biomass is selected with high cellulose and hemicellulose concentration and low silica content. The process utilizes short refining time and low steam pressure.

Abstract: A process for preparing a target for use in production of a thin metal oxide film that comprises molding an amorphous powder of organic metal chelate complexes to obtain the target. The process also includes mixing metallic materials with an organic chelating agent so as to give a predetermined metal composition to prepare a transparent aqueous solution of organic metal chelate complexes. The process also includes spray-drying the aqueous solution to obtain an amorphous powder of the organic metal chelate complexes.

Abstract: The invention involves recycling scrap material having a thermoplastic. The invention includes a method of forming a thermoplastic pre-preg sheet for use in a subsequent molding operation. The method includes shredding a first scrap material having a thermoplastic to form fluff. The fluff has at least about 20 percent weight of thermoplastic. The method further includes sufficiently compacting the fluff into a thermoplastic state sufficient for forming the thermoplastic pre-preg sheet.

Abstract: An improvement to existing board manufacturing process which utilize lignocellulose particles is described wherein the adhesive to be applied as a binder is at least partly applied before the particles are dried. Using the invention improvement in resin application rates without increase in the water content of the particles fed to a press is achieved. Reduction in edge thickness swelling has been achieved.

Abstract: A hog fuel board is made by placing a hog fuel mat including an ammonium chloride catalyst with flexible non-sticking layers on outside surfaces between screens in a preheated platen press and pressing the mat to preset stops and for a predetermined time and pressure to cause adhesives naturally present in the hog fuel to disperse throughout the board. The presence of ammonium chloride as a catalyst uniformly distributed through the hog fuel mat significantly lowers the temperature required at the heating press platens to form a board which also has improved properties. There is also described a hog fuel veneer board with a hog fuel mat sandwiched between veneer sheets and a lumber product with a hog fuel coating thereon. These additional products are both formed using the ammonium chloride catalyst to reduce press temperatures and create a product with improved properties, particularly, internal bond strength.

Abstract: The invention provides a compounded polymer feedstock formed by cold-pressing of the ingredients into tablets or pellets. This avoids the need for heating associated with conventional pellet-forming processes, and is particularly suitable for compounding of heat-sensitive materials such as PVA. The invention also provides a novel tablet-forming apparatus, suitable for forming large volumes of pressed compounded polymer feedstock, together with tablets of the feedstock, and methods of manufacturing plastics products using the tablets.

Abstract: A method for manufacturing plastic-substitute goods by using natural materials is disclosed. Agricultural byproducts and wood byproducts such as rice husks, rice plant stems, corn plant stems, bean plant stems, wheat plant stems, saw dust and the like are crushed into a particular size, then the crushed particles are mixed with natural adhesives (such as corn starch, potato starch and the like), and are coated with rosin or natural resins, and then a molding is carried out by applying a pressure in a molding machine, thereby manufacturing the plastic-substitute goods. The raw materials of the present invention are readily available from the rural areas, and the molding is carried out at a temperature of 100-300 degrees C.

Abstract: A process is disclosed in which coarse silica, calcium oxides and magnesium oxides are treated in a ball mill together with grinding aids and cold-strength binders. This material is then agglomerated with water to produce a product that reacts at elevated temperatures, e.g. in a fluidized bed reactor, to produce synthetic silicates.

Abstract: An apparatus for fiberizing bales of pulp into substantially dry fibers and fiber aggregates. One embodiment includes: a bale support member for supporting a bale of pulp, the bale support member defining two openings; two rotatable fiberizing assemblies having disrupting elements protruding through the openings an adjustable distance above the bale support member to contact a surface layer of the bale of pulp, the surface layer having a dimension parallel to the longitudinal axis of the fiberizing assembly, a transportation assembly for moving the bale of pulp back and forth along the bale support member and over the openings so that the disrupting elements contact a surface layer in the bale, an adjustable reciprocating assembly permitting adjustment of the frequency by which the transportation assembly moves back and forth over the opening.

Abstract: A method and apparatus for converting paper fiber articles into molded parts. The method and apparatus are particularly advantageous in converting paper fiber cores, utilized for winding and unwinding large quantities of paper products, into plugs which are inserted into the ends of the paper fiber cores. The method and apparatus are advantageous in that the material of the paper fiber cores is converted into a molded product without requiring repulping or slurrying of the paper fiber material as in conventional paper recycling methods. The method and apparatus also do not require the introduction of adhesives, and the paper fiber material is preferably maintained substantially dry throughout the process and apparatus.

Abstract: A method of producing a rubber-based covering comprising at least one layer formed from fragmented cohesible material comprises the steps of forming a substantially continuous bed of the fragmented cohesible material and subjecting the material of the bed to a compacting step so as to form a sheet material as a result of the cohesion of the material. The compaction step is performed with a substantial absence of stretching stresses on the fragmented material.

Abstract: The present invention relates to aqueous powder coating dispersions which comprise from 5 to 60% by weight of powder coating, from 0.2 to 10% by weight of effect pigment and, if desired, further surface-coating auxiliaries. The invention also relates to the preparation of the aqueous powder coating dispersions and to their use.

Abstract: A method of producing a rubber-based covering comprising at least one layer formed from fragmented cohesible material comprises the steps of forming a substantially continuous bed of the fragmented cohesible material and subjecting the material of the bed to a compacting step so as to form a sheet material as a result of the cohesion of the material. The compaction step is performed with a substantial absence of stretching stresses on the fragmented material.

Abstract: Fibers obtained by opening waste plastics of different kinds and fibers obtained by opening wastepaper are mutually woven, and molded under heat and pressure. As a result, different kinds of waste plastics can be recycled without requiring separation or classification.

Abstract: A method and apparatus for converting paper fiber articles into molded parts. The method and apparatus are particularly advantageous in converting paper fiber cores, utilized for winding and unwinding large quantities of paper products, into plugs which are inserted into the ends of the paper fiber cores. The method and apparatus are advantageous in that the material of the paper fiber cores is converted into a molded product without requiring repulping or slurrying of the paper fiber material as in conventional paper recycling methods. The method and apparatus also do not require the introduction of adhesives, and the paper fiber material is preferably maintained substantially dry throughout the process and apparatus.

Abstract: A method of manufacturing flexible sheets of expanded graphite material from recycled materials, comprising providing source materials in the form of flexible sheets of expanded graphite; comminuting the source materials into particles; re-expanding the particles; and preparing a mat from the re-expanded particles. Also described herein is a process of manufacturing a graphite material comprising grinding a cured resin impregnated graphite material into particles; removing at least part of the resin from the particles; and expanding the resin removed particles.

Abstract: Phenothiazine and its derivatives products are provided with a minimal level of fines or dust as a result of forming such products in prill form. The prills are generally spherical. Also provided is a method for reducing the level of powder in phenothiazine product which includes forming the phenothiazine product in prill form such that the prills have a generally spherical shape. The prill product achieves improved handling, flowability and dissolution times, while minimizing the generation of phenothiazine fines and dust, and the problems associated with worker exposure, irritation and sensitization to such fines and dust.

Abstract: A process is described for the production of mouldings based on biological material, wherein potato skins, optionally in the presence of a plasticiser such as glycerol or urea and lecithin and of a water-resistant biodegradable polymer such as polylactic acid, is subjected to a thermomechanical treatrment such as extrusion and then shaped. The mouldings have good mechanical properties and a good biodegradability.

Abstract: A method for manufacturing plastic-substitute goods by using natural materials is disclosed. Agricultural byproducts and wood byproducts such as rice husks, rice plant stems, corn plant stems, bean plant stems, wheat plant stems, saw dust and the like are crushed into a particular size, then the crushed particles are mixed with natural adhesives (such as corn starch, potato starch and the like), and are coated with rosin or natural resins, and then a molding is carried out by applying a pressure in a molding machine, thereby manufacturing the plastic-substitute goods. The raw materials of the present invention are readily available from the rural areas, and the molding is carried out at a temperature of 100-300 degrees C.

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 about 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 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 %.

Abstract: A system and a method for reducing the level of moisture of fluent materials or wet solid materials, characterized in that the material to be treated is provided in a particle form and then exposed to a relatively high volumetric flow of gas treating medium which is drawn through the material so as to force the moisture in the center of each individual piece to migrate towards the periphery thereof where it can be easily evaporated. Air at ambient temperature may be used as gas treating medium so as to minimize the level of energy required to provide an efficient drying operation.

Abstract: A method and apparatus (20) for scarfing a fibrous web (22) can include a scarfing housing (24) which has been provided with a web entrance portion (26), a web exit portion (28), a discharge conduit (30), and an air flow inlet (32, 54). A rotatable scarfing roll (34) can be located in the scarfing housing (24), and in a particular feature, the discharge conduit (30) can be configured with a distinctive conduit angle (36).

Abstract: Compositions having improved gas/vapor barrier qualities are described. The compositions are composed of a substantially non-polar resin and a lamellar filler, the lamellar filler delaminating under high shear, to increase its aspect ratio. Also described are compositions composed of a non-polar thermoplastic resin filled with platelets of talc having an aspect ratio of at least 5; the platelets have an average aspect ratio of between 16-30 and a CIE whiteness index of at least 40.

Abstract: The bioavailability of fenofibrate is improved by making a solid dispersion of a disentegrant in the fenofibrate. Method of making said solid dispersion comprising melting the fenofibrate, blending the disintegrant into the melt, and resolidifying the mixture.

Abstract: A waste PVA foam recycling process to crashes the waste PVA foam into evenly distributed grains, then grains are placed into a molding die while a PVA mixing agent is added into grains. Both of the agent and grains are polymerized, heat dehydrated and hardened into an integral compound to create friction resistance between soft and hard components for removing pollutants. The PVA foam grains can be further admixed with color grains to create merchandisable patterns. Therefore, the present invention, by reclaiming the waste PVA foam and to producing zero pollutant recycled PVA foam with economic value.

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.

Abstract: Porous products of thermoplastic polymers and the like are formed by sintering pellets, especially micropellets and/or pellets made by rapid water quenched pelletizing of the polymers, such as by underwater pelletizing or water ring pelletizing. The pellets are of a uniform size and shape, each having approximately equal dimensions along three mutually perpendicular axes, thereby producing porous products having smooth surfaces, narrow pore size distributions, greater strength and other improved characteristics. The porous products include antiperspirant and deodorant applicator heads, wastewater treatment bubblers and selective filters.

Abstract: The invention provides a glass fiber facing sheet for engineered surfaces such as cement boards which reduces the pitting associated with open mesh glass scrims. The glass fiber facing sheet comprises an open mesh glass scrim having a plurality of intersecting continuous multifilament yarns which are bonded at their crossover points to provide dimensional stability to the scrim. A melt blown polymer web is preferably joined to one face of the glass scrim and covers the mesh openings in the scrim. The opposed face of the scrim defines an exposed grid profile surface which is available for mechanical interaction between the scrim and the cementitious slurry used in cement boards. In cement boards, the glass fiber facing sheet of the present invention is preferably mechanically integrated into a surface portion of the cement core along the exposed grid profile of the scrim.

Abstract: A method for manufacturing plastic-substitute goods by using natural materials is disclosed. Agricultural byproducts and wood byproducts such as rice husks, rice plant stems, corn plant stems, bean plant stems, wheat plant stems, saw dust and the like are crushed into a particular size, then the crushed particles are mixed with natural adhesives (such as corn starch, potato starch and the like), and are coated with rosin or natural resins, and then a molding is carried out by applying a pressure in a molding machine, thereby manufacturing the plastic-substitute goods. The raw materials of the present invention are readily available from the rural areas, and the molding is carried out at a temperature of 100-300 degrees C.

Abstract: A process for producing a work piece includes providing raw material which is cellulose-containing and fibrous, which is not any part of a tree, and which is selected from the group consisting of, crude plant fibers, pure cellulose, waste paper, and waste cardboard; adding water to the raw material; finely chopping the raw material in a machine by continuously grinding the raw material with a total energy expenditure of at least 0.

Abstract: Structural members for doors and the like can be manufactured from plastic foamed composites containing wood flour by the steps of (1) dry mixing a blend of powders including PVC powder, wood flour, powdered thermal stabilizers, powdered foaming agent and a powdered gelatinization agent, (2) adding the mixed powder to a thermal stirring mixer to obtain a homogeneous dispersion of the several powders (3) transferring the homogeneous dispersion of powders to a cold stirring mixer and stirring at speeds sufficient to avoid agglomeration of the homogeneous dispersion of the several powders and (4) placing the non-agglomerated homogeneous dispersion of the several powders in a feeding hopper of an extrusion machine and extruding shapes for the desired components. The vacuum venting of the extrusion machine can be controlled to achieve components with more desirable surface features. Lubricants can be added to the homogeneous dispersions of the several powders to aid in the extrusion process.

Abstract: An improved method for preparing microparticles that exhibit controlled release of an effective amount of an active agent over an extended period of time. More particularly, a method is provided for preparing microparticles having a selected release profile for release of active agent contained in the microparticles. By adjusting the degree of drying that is performed during the preparation of the microparticles, the release profile can be controlled. By performing no intermediate drying, an initial burst and a substantially linear release profile is achieved. By performing substantially complete intermediate drying, an initial lag phase and a substantially sigmoidal release profile is achieved.

Abstract: A method and apparatus for charging fibers that contain a nonconductive polymer. A polar liquid 32, 34 is sprayed onto free-fibers 24, and the free-fibers 24 are then collected to form an entangled nonwoven fibrous web 25 that may contain a portion of the polar liquid. The nonwoven web 25 is then dried 38. By applying an effective amount of polar liquid 32, 34 onto the nonconductive free-fibers 24 before forming the nonwoven web 25, followed by drying 38, the individual fibers 24 become charged. The method and apparatus enable the fibers 24 to be charged during web manufacture without subsequent processing.

Abstract: A nonwoven material including at least a meltblown web is stretched by about 1-35% in at least one direction using a short-distance drawing process, to provide a fabric having improved softness and liquid barrier compared to otherwise similar fabrics prepared using longer drawing distances. The drawing process may include one or multiple stages. When multiple stages are employed, the fabric has adequate liquid barrier at a lower basis weight.

Abstract: An improved method of making a molded composite article by combining a fibrous material with a binder to form a mixture, drying the mixture to a moisture content of about 6 wt. % to about 14 wt. % based on the weight of the fibrous material to form a mat, coating at least one surface of the mat with an aqueous solution comprising one or more additives selected from the group consisting of: a wetting agent, a mold release agent, a set retarder, and a binder. Thereafter, the mat is consolidated under heat and pressure to form the molded composite article. Articles formed by this improved method exhibit superior surface characteristics (i.e., smooth, hard surfaces), and do not require the need for any further treatment, such as use of tempering oils, application of post-consolidation sealers, or post-consolidation surface sanding procedures, prior to subsequent finishing operations, such as coating, gluing, painting, or other finishing to complete a desired article for commercial use.

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.

Abstract: The present invention describes a process of using agricultural biomass to make particle or fiberboards. The preferred biomass is selected with high cellulose and hemicellulose concentration and low silica content. The process utilizes short refining time and low steam pressure.

Abstract: Apparatus and method reclaim make-up of the type ordinarily supplied in block form by processing broken, unusable random-sized pieces of such make-up into a block of usable make-up of prescribed consistency, size and configuration, by advancing the random-sized pieces through a mesh member of selected mesh size to form intermediate particles of a size appropriate for agglomeration into the block of usable make-up. A measured charge of intermediate particles is established in a compression chamber where the measured charge is compressed by a ram into a mold member to form the block. The mold member preferably includes a tray which selectively is removed to a cosmetic case for ease of carrying and using the reclaimed make-up.

Abstract: A method of manufacture of a nonwoven cellulose fabric is disclosed. The fabric is made from fibers formed by extrusion of a solution of cellulose through a spinning jet. The extruded fiber is attenuated with a high velocity gas flow, and the attenuated fiber is collected on a surface (such as the curved surface of a rotating drum) on which the fiber web is subsequently coagulated. Apparatus for carrying out the method is also disclosed. The method and apparatus permit the manufacture of a nonwoven lyocell fabric web in which fibers are bonded together without the use of a binder.

Abstract: A memorial product generated from the cremation remains of a deceased human or animal whereby a predetermined amount of bone ash is combined with a predetermined amount of a glass forming additive. In addition, a glass modifier may be added to enchance the durability of the final solid product. A flux may also be added to reduce the melting temperature of the mixture. These additives are combined with bone ash and milled to a desired particulate size to form a powder mixture. The mixture is heated to a melting temperature for a resident time to form a glass melt which is then poured into a mold. The cast or molded form is annealed for a resident time at a predetermined temperature to avoid stress fracture or crystalization from cooling too quickly or slowly.

Abstract: Used and manufacturing scrap asphalt shingle material is processed into a relatively course material comprising pieces or flakes of a maximum predetermined size, preferably with a relatively low aggregate content. The flakes are finish processed into a composite board product, with advantage taken of the larger size and low aggregate content. The board fabrication process includes (i) mixing the flakes with a relatively high percentage content of solvent suffuced fiber, (ii) grinding and heating the flakes and fiber to form a homogenous semi-liquid mixture, (iii) extruding and conveying the homogenous mixture to a board forming station, and (iv) compressing the mixture into the composite board product. The flakes may be produced by an initial process that includes (i) shredding the used and scrap shingle material into pieces of a predetermined maximum size, and (ii) separating the shredded material into (a) fine material and (b) course material.