Abstract: A method of producing dense, free-flowing alkali metal silicate-based particles which, when sufficiently heated, will form lightweight particles of a spumiform nature which may be employed as thermal or acoustical insulation or as a lightweight filler for gypsum or cement or for numerous other purposes. The method comprises premixing a liquid alkali metal silicate with selected fillers and/or insolubilizers, adjusting the temperature and solids content of the mixture until it passes into a dilatant gel state which will fracture when extended at a rate of between about 3 and 95 cm/minute, and subsequently extruding or pelletizing the gel at this temperature to form particles which are conditioned in an air stream for at least one second and then dried to a moisture level of between about 5 and 30%. These particles or pellets serve as a stable intermediate which can be expanded to form lightweight spumiform particles by further heating at a later time or at a remote location.

Abstract: The present invention relates to a multicomponent fibrous nonwoven structure and the process and apparatus for producing the same. More specifically, the present invention relates to a process for forming nonwoven materials using a forming chamber in conjunction with multiple fiber sources and a forming surface to create multicomponent nonwoven materials with varying features. The materials so produced are suitable for use in a wide variety of applications including personal care products such as diapers, feminine pads and adult incontinence products.

Abstract: An abrasion resistant synthetic aggregate made from an intimately intermixed combination of lime, fly ash and sulfate/sulfite sludge (e.g. FGD sludge), mixed to the point where the mixture is nearly optimum density and compressible or non-compressible and plastic. This mixture is placed in a landfill. After a relatively brief cure period, the landfill is ripped and the material is crushed and graded. The aggregate, which in some instances may qualify as a light weight aggregate, has a Los Angeles Abrasion Resistance of less than 60%, and may in some cases be less than 50% (medium particles passing) according to that test.

Abstract: Described herein is a method of producing nodules from paper pulp. The method includes partially dewatering the paper pulp and tumbling the partially dewatered pulp in an externally heated enclosure until the nodules are formed. Additives may be added to the pulp prior to tumbling.

Abstract: Polyimide which is obtained by polymerization and consists essentially of recurring structural units of the formula (I): ##STR1## wherein X is a single bond or a hexafluoroisopropylidene group, is processed to a form of pellet, followed by heat-treating to obtain crystallinity of 5% or more, and fed to an extruder to obtain articles.

Abstract: A biologically resolvable blind slat and the manufacturing method therefor, wherein PVC powders serve as a basic material and are added with stabilizer, lubricant, calcium carbonate and surface-treated starch to mix therewith, the mixture being processed by a granulating machine into granules which are further heated and pressed by a press machine into strips, the strips being then cut into blind slats in a certain pattern and at a certain length.

Abstract: A process for using shredded scrap or virgin fiber glass in combination with starch, water and other components to make ceiling tiles. The tiles are made by initially preparing a mixture of water, starch, boric acid and fire clay. That initial mixture is then heated to form a gel. Fiber glass is then added to the gel to form a pulp. The pulp is fed into trays to form slabs. The slabs are dried and finished into tiles.

Abstract: Disclosed is a process for the preparation of a carbonaceous molded body, which comprises mixing elastic graphite particles with a binder and molding the mixture. A carbonaceous molded article having a light weight and an excellent elasticity, which is characterized by a bulk density lower than 1.0 g/cm.sup.3 and a recovery ratio of 50% or more at a compressibility of 5 to 50%, is obtained according to this process.

Abstract: A lightweight, biodegradable packaging material and method for manufacturing the same. The product is made from an initial or starting material which is principally corn grit that is mixed with a binding agent and water extruded under heat and pressure and allowed to expand to form the packaging material.

Abstract: A granular material containing zinc oxide and precipitated silica which is readily dispersible in rubber mixtures.

Abstract: Metal and ceramic particles of various morphologies are clad with a coating from the transistion metal group consisting of silver, gold, copper, nickel, iron, cobalt, aluminum etc., or combinations thereof, to provide improved coated particles for microelectronics or metal matrix composites or other uses. Refractory metal precursor core particles, such as tungsten, molybdenum, niobium and zirconium, as examples, are provided from a composite of tungsten and copper, for example, made by pressurizing and infiltrating or liquid phase sintering of molten copper into a porous tungsten skeleton. Precursor chip particles derived from a tungsten impregnated billet are used as starter particles which may be further enhanced by cogrinding in an attritor ball mill with smaller copper particles to thereby produce an enhanced copper clad-coating of tungsten particles with predetermined percent by weight of copper and tungsten content.

Abstract: The process of preparing granules of sodium perborate monohydrate having an increased density by dry-compacting a mixture of sodium perborate monohydrate and from about 0.2 to about 30% by weight of a compacting aid, based on the weight of the mixture. The compacting aid is selected from the group consisting of an alkali metal salt, alkaline earth metal salt, carbohydrate, anionic surfactant, and nonionic surfactant. After forming a compactate of the mixture, the compactate is size-reduced to obtain granules having the desired particle size.

Abstract: The invention relates to a process for producing a fuel absorbent, which comprises the steps of: dissolving an organic polymer having a function of trapping fuel in a solvent to produce a polymer solution; adding a crosslinking agent to said polymer solution to allow said organic polymer to react in the presence of said crosslinking agent; and collecting, after the completion of the crosslinking reaction, the resultant fine polymer gel particles. The invention also relates to a porous fuel absorbent produced by the above process comprised of fine cross-linked organic polymer formed into particles. The above fuel absorbent along with the coatings and a carrier may be used to control fuel evaporation loss in automobile canisters or boiler fuel tanks.

Abstract: A process for forming a poured slab, preferably of concrete, which has different colored portions. The process includes (a) pouring a wet concrete mixture of cement particles, sand particles and gravel particles into a horizontal mold cavity having a stepped mold bottom surface, (b) curing the mixture to produce a slab with a roughly horizontal rear surface and a stepped front surface corresponding to the mould bottom surface, and (c) mechanically removing the cured mixture between a cut plane generally parallel the rear surface through the slab and the front surface. The resultant slab has different portions with different coloration and appearance due to the cut plane passing through portions of the concrete having different proportions of cement, sand and gravel particles.

Abstract: The present invention relates to a method and apparatus for producing a formed structural element of fiber material bonded with synthetic resin such that a fine-grained or flowable synthetic resin bonding agent is sprinkled on or sprayed on a nonwoven fabric made entirely or predominantly of natural fibers. The nonwoven fabric which is permeated with synthetic bonding agent is fragmented, whereupon the parts are stored in a tower on a perforated female mold which belongs to a molding press and are precompressed on the female mold by means of an air stream that is suctioned through the perforations. To produce formed structural elements with a stable shape, the synthetic resin bonding agent, after a similarly perforated male mold has been placed on top and pressed on, is hardened by means of a hot air stream that is conducted through the perforations in the male mold and the female mold.

Abstract: A process for preparing a polytetrafluoroethylene granular powder which comprises agitating primary particles of a finely divided polytetrafluoroethylene powder having an average particle size of not more than 100 .mu.m in an aqueous medium containing no organic liquid to form agglomerates while crushing an agglomerated powder in an apparatus having an agitating mechanism of the aqueous medium and a crushing mechanism of the agglomerates within a temperature range between not less than 20.degree. C. and less than 60.degree. C. According to the present invention, the dense polytetrafluoroethylene granular powder having the excellent electric properties and the high bulk density can be obtained without using the organic liquid which is expensive and whose use is restricted.

Abstract: A molding process for preparing long and thick, large porous PTFE articles comprising preparation steps of a powder for molding which includes a step of gelation of PTFE powder; a pre-forming step by a ram-extrusion; a baking step of the pre-formed article under a non-constrained circumstance; and if necessary, a cooling step; said powder for molding being containing a binder which has a melting point of lower than that of PTFE and does not decompose at a baking temperature of PTFE.

Abstract: A molded product is made having uniform strength throughout the product. The molded product is made by mixing together fibrous materials such as cellulosic fibers and a heat-fusible binding agent such as a phenolic resin to form an admixture. The admixture is then sprayed with a binding agent such as starch as it is dispersed to form a fibrous molding preform. Heat and pressure are applied to the molding preform to form a molded product.

Abstract: An applicator trap guide is used to guide and coat newly synthesized synthetic filaments with a protective coating. The trap guide secures the filament against slippage while allowing rapid insertion of a filament into the trap guide and providing visual monitoring of the coating process.

Abstract: A process and a plant for manufacturing decorative panels or slabs of granular or particulate mineral material bound by a binder are provided in which at least one bottom or base layer comprising an intimate mixture of said material and said binder is continuously formed and at least one upper decorative layer constituted by the same materials but in which the binder is colored is continuously applied to the base layer followed by pre-compression, diversion into slabs, pressing and baking.

Abstract: A wooden hanger having a shoulder-shaped frame, a hook and a cross bar fixed between both ends of the frame, which is cut from a shoulder-shaped plywood plate formed into such a shape by compressing it in a mold with heat in a press.

Abstract: A biologically degradable film is prepared consisting of a synthetic polymer and a biologically degradable polymer. The biologically degradable polymer is divided into small particles in an aqueous suspension by means of enzymes that split and release small molecules from the surface of the biopolymer particles. After achieving desired particle size, an emulsion is formed with vegetable oil and the particles coated with enzyme protein become coated with vegetable oil, which at the same time interrupts the degradation of the biopolymer particles by the enzyme. The coated particles with the oil are separated from the suspension to remove small molecules after which the particles are re-dried and then pulverized. The final film is prepared in a film extruder in which the biopolymer is mixed with the synthetic polymer and possibly other additives that are generally used informing polymer films.

Abstract: A method of preparing a composite material in the form of ultra fine particles which is mainly composed of organic polymers and has improved physical properties that cannot be obtained for organic polymers of one kind. This method includes a step of providing a dispersion in which organic polymer particles of at least two kinds, having different physical properties are dispersed in a dispersion medium, and an impingement and crushing step of causing the organic polymers dispersed in said dispersion to impinge with each other at high speed is repeated at least twice in order to crush each organic polymer and to combine, or fuse, the organic polymers simultaneously.

Abstract: A method for producing sanitizing compositions in compressed form which includes:a) admixing an alkali metal carbonate with a solid water soluble aliphatic carboxylic acid to form an acidic mixture,b) compressing the acidic mixture to produce a compressed form of the acidic mixture,c) crushing the compressed form to produce granules of the acidic mixture, and,d) admixing granules of the acidic mixture with an alkali metal chloroisocyanurate, and an alkali metal bicarbonate to produce a sanitizing composition.

Abstract: A method for manufacturing a substantially rigid water-dispersible article includes the step of mixing together an ionic water-soluble film-forming polymer, a non-ionic water-soluble film-forming polymer, a chemically purified finely divided highly bleached cellulose, and glass fiber wool. Water is added to the dry mixture to form a dough which is subsequently molded into the desired form and dried while being maintained in the molded form. A filler or extender such as talc or paper pulp may be added prior to the molding step. In addition, a wetting agent may be added to accelerate rewetting and dispersal of the article upon disposal thereof, while a hydrophobic composition may be added to the dough to form a water repellant surface layer or film during drying of the molded article.

Abstract: The method includes the steps of mixing the sand and the decomposable binder to form a dough-like consistency, forming the dough-like mixture into a sheet. Cutting the sheet into silhouette shapes and then drying the shapes to form a rigid article suitable for a variety of purposes. The preferred article is coated with a decomposable waterproof sealant. Method of forming planar frangible targets as well as formed three-dimensionsl tableware and food containers are disclosed.

Abstract: In connection with a device for casting lead grids for electric battery plates, a highly porous ceramic mold lining, preferably of zirconium oxide, is prepared by flame-spraying. Such a lining can include a thin surface coating on a profiled, basic metallic mold or a separately prepared insert plate which is retained to a metallic mold molder. The ceramic surface coating may be accurately formed in place, or may be formed as an over-spray which is then reduced in thickess. Formation of the surface coating may be accomplished by placing masks on the basic metallic mold during the flame spraying, for those areas of the grid which tend to accumulate material, or by adjusting an initially coarse profile of the ceramic layer to the exact profile of the casting by a material-removing treatment.

Abstract: A process for the production of concrete roofing products of reduced weight loading having a thickness in section of not greater than 15 mm. The process involves forming an asbestos-free cementitious composition comprising (i) lightweight aggregate, (ii) hydraulic cement, (iii) water and (iv) reinforcing fibers in an amount of not more than 4% by weight of the total weight of the composition but the fibers being present in an amount sufficient to provide a reinforcing effect and impact strength in the roofing product, the cementitious composition being capable of being shaped by a roller and slipper method, and thereafter shaping the cementitious composition by the method to provide a shaped extrudate, dividing the extrudate to form sections and curing the sections to provide roofing products, wherein the reinforcing fibers have lengths of 0.5 mm to 20 mm. The impact resistant roofing products are useful as roofing tiles, or a replacement for shingles, shakes and slates.

Abstract: The production of concrete building products having thickness in section of not greater than 15 mm includes forming a cementitious composition containing aggregate, hydraulic cement and water. The composition is shaped by a roller and slipper method to produce a shaped extrudate which is then divided into form sections. The sections are then cured to provide the aesthetically pleasing product. The cementitious composition also contains reinforcing fibres. The building products are used for roofing tiles or replacement of shingles, shakes and slates.

Abstract: A method of making an absorbent granulate of paper, with or without additives, includes mechanically comminuting paper into irregular and/or strip-shaped fragments, crumpling and interlacing the fragments with attendant development of internal spaces (cavities) in the interlaced and crumpled fragments, rough pressing the interlaced and crumpled fragments into prepressed formations (e.g., into tubes having a diameter of up to or even in excess of 10 mm), and converting the prepresssed formations into particles, particularly into granules or pellets. The crumpling and interlacing step can include agitating the fragments in one or more streams of a gaseous fluid and/or kneading the fragments.

Abstract: An insulation panel comprises a mineral fiber board having a density between 8 and 28 pounds per square foot, the fibers having no organic binder thereon, and between 5 and 40 percent by weight of particulate material packed in the interstices of the board, and a gas-tight envelope encapsulating the board, the envelope being evacuated to a vacuum between 10.sup.-4 Torr and 10 Torr.

Abstract: A method attaches small plastic parts securely in a defined position on compression molded parts consisting substantially of bonded or synthetic resin bound natural fibers or chips. The parts are compression molded into the desired shape in a compression mold from a preformed, loose layer of a mixture of at least one of natural fibers and chips and of binder introduced into the compression mold, while undergoing a setting reaction of the binder and a volume reduction of the layer. During the compression molding operation, at least one clearance or thin portion, smaller than the small plastic part, is formed in the wall of the compression molded part at the fastening point of the small plastic part on the compression molded part. Thereafter, a direct form-fitting injection molding of the small plastic part or parts onto the wall of the compression molded part at the fastening point is carried out.

Abstract: A system for making synthetic wood products from waste wood fiber and recycled plastic material by mixing waste wood fiber having a moisture content of less than about 15% with dry waste plastic material, including low density and/or high density polyethylene; heating and kneading the mixture to form a homogeneous mass; sizing the mass into discrete chunks suitable for use as an extruder feed material; extruding the material to form products having predetermined cross sections; and rolling and cooling the product to prevent deformation of the product shape.

Abstract: Process and installation for making a composite product, obtained by removing the fibre from wood chippings or other cellulose raw material, especially for above-ground cultivation purposes. The chippings (3) are place in a two-screw (2) fibre-removing machine (1), the overall characteristics being adjusted in such a way as to obtain, at the outlet of the machine (1), a mixture (31) based on isolated fibres and agglomerated bunches of fibres, of varying lengths and grain dimensions. An adhesive binder is inserted at a set feed-rate in the sleeve (11) during fibre removal so that it spreads through the fibre mixture in a discontinuous manner. By controlling the temperature the hardening of the binder can be delayed until the product emerges from the machine (1). Also covered is the product obtained in the form of a rigid block inserted in a sealed jacket.

Abstract: A method for making a composite material including a discontinuous phase of cellulosic fiber encapsulated in and bonded to a continuous phase of a polymeric component containing a major portion of polyethylene by mixing the cellulosic fiber and polymeric component while raising the temperature of the mixture to the encapsulation point, maintaining the encapsulated material within the encapsulation range while reducing the particle size, and thereafter extruding the material while controlling its temperature within the encapsulation range and substantially aligning the fibers in the flow direction until the material contacts a heated die.

Abstract: A process for consistently making ceiling tiles having uniform density and surface texture includes using a conveyor along which trays are moved in a generally horizontal direction. A feeder box is used to deposit pulp in the trays, the pulp being comprised of a mixture of water, starch, fibrous material, and other ingredients. The feeder box through which pulp is deposited in the trays is of a special design, and includes a sloping front edge which creates a negative rake angle with respect to layers produced by the system. The lower front edge of the feeder box includes a surface having a compound curvature. Ceiling tiles are produced by the process having improved uniformity of density and surface texture.

Abstract: A method of making insecticidal pellet compositions of N-hydrocarboyl phosphoroamidothioates and phosphoroamidodithioates, combined with a herbicide, fungicide, fertilizer or other insecticide is provided.

Abstract: The present invention includes apparatus for and a method of producing compacted particulate articles, as well as the compacted particulate articles made by that method. A particulate material mixed with a binder is introduced to and directed through a briquetting press wherein said particulate material is first sandwiched between polymer film, the sandwich formed in resilient polymer dies, then the polymer film is peeled off of the formed articles and collected while the formed articles are collected, accumulated and further processed.

Abstract: The invention discloses fuel nuggets with high heat value which is virtually dust-free, and a method of making the same. The nuggets are preferably made of scrap particleboard made of wood particles bonded together by a urea/formaldehyde adhesive. The scrap is hogged and shaped into roughly spherical nuggets of a preselected size suited for automated furnaces. The nuggets are then coated with an aqueous urea solution and then oven-dried to achieve a preselected moisture content.

Abstract: Polyimide which is obtained by polymerization and consists essentially of recurring structural units of the formula (I): ##STR1## wherein X is a single bond or a hexafluoroisopropylidene group, is processed to a form of pellet, followed by heat-treating to obtain crystallinity of 5% or more, and fed to an extruder to obtain articles.

Abstract: A process for treating calcium phosphate fine particles which includes the step of compacting the particles under pressure to form a sheet.

Abstract: A process for recycling and reblending dry, difficult to hydrate polymer fines into a water-swellable fluid absorbent polymer gel is disclosed. The process requires feeding the dry polymer fines into a first mixing zone where they are subjected to spraying with water that at least partially hydrates the fines and mixing, substantially simultaneously with the water contact, at high shear such at the fines are substantial completely hydrated without agglomeration. The hydrated fines are then transported from the first zone into a second mixing zone where blending of the hydrated fines with fresh polymer gel occurs at medium shear such that a substantially uniformly blended product results. The resulting process successfully re-introduces fines into the main product stream wherein the resulting product has high aqueous fluid absorbent capacity and good particulate mechanical integrity.

Abstract: An iron ore or mill scale is crushed to form a powder having an average particle diameter not exceeding 12 microns. The powder is heated at a temperature of 600.degree. C. to 900.degree. C. in the presence of oxygen to form an iron oxide containing at least 98.0% of Fe.sub.2 O.sub.3. The iron oxide is mixed with strontium oxide or carbonate. The mixture is calcined to form strontium ferrite. The calcined product is pulverized, the crushed material is molded in a magnetic field, and the molded product is sintered to yield a magnet of strontium ferrite having a high level of performance.

Abstract: A finishing process for water-slurried elastomers wherein a partially dewatered elastomer is presented to an enclosed, low shear, self-cleaning, long residence time dryer for drying at low temperatures in order to remove the remaining water and residual volatiles. The dried product is then cooled in a pneumatic conveyor to temperatures required for baling.

Abstract: A sealing element for use with a radial lip oil seal includes a mounting section formed of a first polymer and a sealing section formed of a second polymer. The sealing element sections are bonded together during a common sintering operation so that each polymer is sintered only once. This reduces molecular degradation of the polymers typically caused by multiple sintering operations.

Abstract: A process for preparing pigmented PVdF-based powder coating products is disclosed, which comprises the steps of (i) mixing PVdF resin with a compatible thermoplastic resin, preferably PMMA in a weight ratio of about 80:20 to 40:60, with pigments, and with a small amount of flow promoter, (ii) pelletizing the mixture of (i), and (iii) cryogenically grinding the pellets and sieving the large particles. Also disclosed is a process for coating a substrate, comprising the steps of (a) applying the above prepared powder coating product on a substrate, and (b) subjecting to a heat treatment.

Abstract: Metallic salt powder pellets are formed by blending metallic salt powder of aliphatic monocarboxylic acid, with a binder material capable of binding the metallic salt powder under normal bulk handling and transport conditions without altering end use properties of the metallic salt powder, and passing the blended composition through a pellet mill. The metallic salt powder pellets can be handled and transported with greatly reduced risk of generating hazardous dust, and readily disintegrate in conventional blending and mixing apparatus to disperse in a manner similar to unpelletized metallic salt powder.

Abstract: A corrugated metal-clad sandwich panel with a wafer composite core is provided. The single stage process for the panel manufacture involves utilizing a press platen system which is mechanically convertible between a planar and a corrugated configuration. The metal sheet is first placed on the lower platen which is in the planar configuration. The wafers and an isocyanate resin in admixture are uniformly distributed over the metal sheet. Optionally, a second metal sheet is placed over the wafer/resin mat. The platens are converted from the planar to the corrugated configuration, thus forming the corrugated metal-clad sandwich panel having a waferboard core in a single stage.

Abstract: In a process for producing fibrous mats as a starting material for compression moulded articles, fiberized waste materials are mixed with thermoplastic and/or thermoset or thermosetting binders, the mixture is spread onto an air-permeable conveyor belt to give a first fleece layer, on said fleece layer is loosely placed a polyester fabric or lattice with at least partly multifilament threads, a mesh size between 4 and 7 mm and a thermoset or thermosetting finish, then a second fleece layer is spread onto the fabric or lattice and then the layers are compressed at elevated temperature and under pressure to give a transportable mat, from which individual moulded articles are produced by compression moulding at temperatures between 180.degree. and 220.degree. C., the polyester fabric undergoing thermal conditioning prior to its use at temperatures roughly corresponding to the mould temperature.

Abstract: The present invention relates to methods and implementation, including apparatus comprising a two-stage, single-unit, and energy-efficient rotary drum-type granulator-dryer device having a granulator section and a separate dryer section in a new and novel combination designed for continuously granulating and/or ammoniating, and subsequently drying, respectively, a variety of materials together with specific processes for effecting such granulating and/or ammoniating, and subsequent drying.