Abstract: An improved, essentially scrap-free, solid-phase process for making thermoplastic articles directly from resinous powder. The process can be particularly advantageous to forming large parts from thermoplastic resinous powders. The method essentially comprises taking resinous powder, briquetting the powder, sintering the briquette, repressing the powder in a warm state and then shaping the briquette into a preform or a blank which can then be thermoformed into a resulting container or other product, assuming the blank itself is not the desired end product. Alternatively, sintering can take place after repressing with preheating of the briquette prior to the repressing step.

Abstract: The process includes a first molding step with an upper surface of the glass wool pelt having been sprayed with water and with a lower surface of the glass wool pelt insulated from the lower mold portion by a previously molded glass wool insulating sheet, and a second molding step with the insulating sheet removed.

Abstract: A process for manufacturing embossed, nonwoven fibrous products comprising the steps of subjecting a binder-treated fibrous dry laid web to a low cure treatment to obtain a moldable web with good physical integrity; embossing the low cure treated web; and fully curing the web.

Abstract: A method for making acoustical tile having a pattern of raised portions and portions in relief on the tile surface is provided by contacting deformable, acoustical tile fiber composition pulp with a hollow embossing roll containing the pattern in reverse and interstices communicating from the surface of the roll into the hollow interior of the roll; pressing the roll against the deformable pulp with sufficient force as to dispel the pulp; vent air, between the roll and the pulp surface, through the roll and produce the reversed pattern of the roll upon the pulp surface; and releasing the pulp from the surface of the roll by rotation of the roll.

Abstract: A process is created for incorporating surface structures into wood-cement boards which are pressed during cement hardening in a batch press and then are kept in clamping apparatus in the pressed state for a substantial length of time.In the invention the wood-cement boards freed from their plates and after their storage in the clamping apparatus are fed to a calendering system of which the calendering rolls are provided with a surface structure, the wood-cement boards moving between the calender rolls and being provided by these with surface structures on one or on both sides.

Abstract: A method for forming articles such as crates in which sides of the crate extend generally perpendicular to the base of the crate. The method includes forming a layer of loose binder coated wood particles, precompressing selected portions of the layer which form the sides of the crate, bending the precompressed portions upwardly, inserting the so formed layer in a mould and compressing the layer in the mould to form the desired article. The initial layer can be slightly compressed to hold the particles together and the base of the article can also be slightly precompressed but to a lesser extent than the portions which form the sides.

Abstract: A process for molding a friction material for use as brake lining in automobiles, trucks, buses or similar vehicles. The brake lining contains no more than traces of asbestos and utilizes the mineral vermiculite as a basic constituent. The formulation of the brake lining comprises a non-fibrous natural or synthetic mineral or mineral-like material which on being compressed at ambient temperatures and at pressures of 1700 to 2600 p.s.i. has significant green strength in the order of 2 to 25 p.s.i. and also has appropriate thermal resistance, frictional properties, and shear and flexural strengths, together with a thermosetting resin as the basic components together with other organic and inorganic materials as friction modifiers and fillers. The mineral preferably comprises vermiculite, and together with the resin comprises preferably about 35% to 95% by weight of the brake lining formulation. The ratio by weight of resin to vermiculite is preferably in a range having a upper limit not exceeding about 1.

Abstract: A high loft, low density, nonwoven fibrous web is provided comprising a plurality of irregularly arranged, intersecting, overlapping, mechanically interengaged, loosely assembled fibers including both thermoplastic synthetic wood pulp fibers and other fibers, segments of the thermoplastic synthetic wood pulp fibers being heat fused at a plurality of junctures with segments of other thermoplastic synthetic wood pulp fibers and with segments of fibers of other types, with additional binder distributed throughout the web.The web is prepared by air-laying a blend of thermoplastic synthetic wood pulp fibers and other fibers applying heat without pressure to the air-laid blend to fuse at least some of the thermoplastic synthetic wood pulp fibers to each other and to some of the other fibers to form a self-supporting fibrous web, introducing a latex binder into the web and drying and curing the binder.

Abstract: A method of installing fragile, light-weight, high-temperature fiber insulation, particularly where the insulation is to be used as a seal strip providing a high order of thermal barrier insulation. The process is based on provision of a strip of the mineral batting cut oversize by a predetermined amount, saturated in a fugitive polymer solution, compressed in a mold, dried and cured to form a rigidized batting material which may be machined to required shape. The machine dimensions would normally be at least nominally less than the dimensions of the cavity to be sealed. After insertion in the cavity, which may be a wire-mesh seal enclosure, the apparatus is subjected to baking at a temperature sufficiently high to cause the resin to burn off cleanly, leaving the batting substantially in its original condition and expanded into the cavity or seal enclosure.

Abstract: A laminated decorative tile particularly for flooring purposes, is made by forming a base layer of granulated cellulosic material in a matrix of fusible plastics, and placing on the base layer a thin decorative layer of cellulosic material with natural holes and recesses therein. After a film of fusible plastic has been applied on the decorative layer the laminate is hot pressed and then immediately cooled in a cold press. The tile obtained has a pleasing appearance because the granules of the base layer have been forced up, in the hot pressing operation, into the holes and recesses of the decorative layer, filling out these holes and recesses. In this embodiment the tile has a smooth wear resisting layer surface but this surface can be provided with a relief pattern such that it conforms to the structure of the decorative layer, if the tile after cooling is heated in a free state, i.e. without press plates.

Abstract: In the manufacture of low density air laid webs of predominantly ligno-cellulosic material, the method and apparatus for bonding the dry web with binder and compacting the web with a wet, fabric covered surface so as to increase tensile strength and delamination resistance while reducing binder content and cost is described. Wet compaction of the binder laden web enables controlled penetration of the web with a smaller amount of binder than is possible without wet compaction, and also reduces energy consumption in drying due to the use of less binder.

Abstract: An improved base fabric useful for the manufacture of embroidered lace is disclosed. The base fabric is made from a non-woven, needled fabric composed of water-soluble staple fibers which is processed under special conditions to provide one surface of a film made up of thermoplasticized and fused fiber portions.

Abstract: Method and apparatus for shaping of mats composed of loose fibers with a thermosetting resin interspersed throughout. The apparatus compresses the mat and exposes its laterally extending surfaces to elevated temperatures to obtain partial curing thereof. Slits are made in the surface regions adjacent areas where extra shaping will occur in forming the final product. These slits enable more precise shapes to be impressed upon the mat and eliminate the tendency of the partially cured areas to spring back to a position of lesser compression.

Abstract: A waferboard panel is disclosed and a method of making the panel having a friction surface on at least one side. The friction surface retains the water resistant properties of the panel surface and allows a firm footing when the panel is used in sloped roofs. The waferboard panel has at least one surface being a friction surface comprising a plurality of raised protrusions spaced apart in a predetermined pattern. The process of making the panel comprises the steps of assembling wood wafers coated with an adhesive binder into a mat with a plate, the plate having a surface adjacent the mat with a plurality of indentations or holes therein in a predetermined pattern, and pressing the mat in a press at a high temperature with the plate adjacent the mat to form the wafers into a waferboard panel such that the friction surface of the waferboard panel has a plurality of raised protrusions spaced apart in a predetermined pattern.

Abstract: A method of molding a perforated article involves supplying a formable material to a preforming chamber where the material is compressed so that it substantially assumes the cross-sectional shape of the preforming chamber. The formable material is then transferred under compressive forces to a molding chamber, which has a volume less than the volume of the preforming chamber and a shape which substantially matches the shape of the perforated article to be molded. The formable material is then heated in the molding chamber to cure it and thereby form the perforated article.

Abstract: Nonwoven point-bonded fabrics of improved softness are prepared by simultaneously heating and compressing spaced, discrete areas of a nonwoven, bondable fiber web containing an attenuating bonding liquid in excess of the minimum amount required to provide maximum fabric strength.

Abstract: A pasty mix of granular grits, binder and filler is pressed through a sieve web by rolling action to form cylindrical, worm-like extrusions. After hardening in a heating duct the extrusions are subjected to the same action and thereby granular grit particles are formed each of which contains several grits.The apparatus for carrying out the method includes a sieve web which co-operates with a rotor having several freely rotatable rollers around its periphery.

Abstract: A sheet type forming board for use in heat forming processes without the need for pre-soaking or pre-steaming required of prior hardboard materials. The forming board sheet has at least one layer containing cellulose fibers, a polyolefin, and an inorganic filler. Its moisture content is preferably 4-12%. A multi-layered sheet, wherein plys are joined together, is typically used to achieve the desired thickness and composite sheet composition. The formed products are light weight and have a number of desirable advantages, including rigidity, embossing and graining fidelity, and dielectric processability.

Abstract: An apparatus and method are disclosed for forming a fibrous workpiece comprised of a layer of randomly disposed fibers and adhesive material dispersed throughout the fibers for binding same upon heating and compressing the fibers and adhesive material to define a unitary pad wherein the apparatus comprises a press having a first and a second platen supported for relative movement toward and away from each other, a first and a second mold supported by the first and second platens respectively with the molds having forming surfaces which define the configuration of the pad, and means for heating the workpiece wherein the heating means comprises means for providing hot humid air through the workpiece to provide a rapid penetration and improved heating of the fibers and adhesive material resulting in comparatively high speed forming of the pad with a minimum forming pressure.

Abstract: The present invention relates to a process for producing molded parts from flat tangled fiber fleece mats, preferably formed from binder-containing cellulose or lignocellulose fibers, in which the fiber mat is compressed by press tools and is subsequently optionally provided with a decorative surface layer. The compression takes place in two stages of premolding and final molding in successive strokes in a single press without intermediate cooling and the decorative surface layer is supplied to the press after final molding. Between the press tools which are in the open position for the first process stage is introduced a premolding tool used for premolding the fiber mat, for the decorative process stage following the final molding in the open press tool an auxiliary tool is introduced which, with regards to the compression molding pressure, temperature, shaping and/or surface structure, can be matched to the characteristics of the decorative surface.

Abstract: A radome and the method of manufacture thereof are presented wherein the radome is constructed from a series of rings of fiber reinforced polytetraflouroethylene. The rings are machined from a cold molded PTFE-fiber composite billet and then loaded into a mold cavity. The rings are then subjected to heat and pressure to sinter them together. The resulting structure is machined into its final shape.

Abstract: A method for producing non-oriented film that comprises depositing high molecular weight polyolefin powder on a smooth non-adherent substrate, sintering the deposited powder, contacting the sintered powder with rollers at the sintering temperature at a pressure sufficient to effect densification of the polyolefin normal to the surface but insufficient to effect significant longitudinal flow of the polyolefin to form a void-free film, and stripping said film from said substrate.

Abstract: The disclosure is of a high performance speaker diaphragm which comprises needled and interlocked textile staple fibers of a first, relatively heat-resistant fiber and a second, heat-softenable fiber. The fibers are molded together to soften the second fiber whereby it interlocks with the first fiber.

Abstract: A scrap-free, substantially solid phase, relatively low temperature economical process for rapidly making plastic articles from resinous powders wherein the resultant articles can comprise various polymers including oriented polymers; polymers with a high practical heat distortion temperature; expanded polymers; ultra high molecular weight polymers; blended structures of two or more materials; or multilayered structures. The resinous powders are initially compressed into briquettes, which briquettes are heated to a temperature in the range from about the alpha transition temperature to less than the melting point or melt temperature of the polymer therein to both somewhat soften and sinter the briquettes. The sintered briquettes are forged under conditions which permit substantial plug flow deformation into preforms whereby fusion of the sintered resin powder particles occurs.

Abstract: A method is disclosed for use in the finishing of sleeves (23) made by needle felting thermoplastics fibres. The sleeves (23) are placed over cylindrical supports (13) mounted for rotation about their axes and movable with a base such as a table (11) in a treatment path past heating means (17) where the outer fibres are heated to above their softening temperature to undergo at least partial melting. Simultaneously the sleeves (23) shrink generally onto the supports (13) which are identical, thus ensuring that all sleeves (23) treated have the same final inside diameter. If desired, the sleeves (23) after heating can be moved past and in pressure-loaded contact with a smooth surface (20) to give them a glazed or calendered outer surface.

Abstract: A process for the preparation of shaped bodies includes preparing a plastic mixture of a material selected from the group consisting of aluminum oxides, aluminum hydroxides, silicon oxides, silicon hydroxides and mixtures thereof from a predominantly dry component K1 in powdered form and a paste component K2 comprising water and additional additives, continuously extruding the plastic mixture into cut lengths, shaping the cut lengths into spherical shaped bodies and drying the spherical shaped bodies and optionally tempering such bodies to form catalyst and catalyst supports. The solids content of the powdered component K1 is from 65 to 100% by weight whereas the solids content of the paste component K2 is 10 to 50% by weight. Preferable spherical shaped bodies are based on Al.sub.2 O.sub.3, SiO.sub.2, or Al.sub.2 O.sub.3 /SiO.sub.2.

Abstract: A fibrous sliver having particulate matter substantially homogeneously distributed therethrough is provided. The sliver is formed by first forming a low weight web of fibrous material and depositing unto said low weight web particulate material. The web is then compacted to the desired weight per unit area.

Abstract: A method and apparatus for heat forming hardboard and other types of forming board including the steps of placing a mesh screen in a die between upper and lower platens having mating contours, placing a sheet of heat formable board in the die upon the screen and below the upper platen, pressing the platens together and heating the sheet such that the sheet and screen are formed to the mating contours and gases and vapors released from the sheet follow the contours of the screen to escape from the die, separating the platens, and removing the sheet from the die.

Abstract: A scrap-free, substantially solid phase, relatively low temperature economical process for rapidly making plastic articles from resinous powders wherein the resultant articles can comprise various polymers including oriented polymers; polymers with a high practical heat distortion temperature; expanded polymers; ultra high molecular weight polymers; blended structures of two or more materials; or multilayered structures. The resinous powders are initially compressed into briquettes, which briquettes are heated to a temperature in the range from about the alpha transition temperature to less than the melting point or melt temperature of the polymer therein to both somewhat soften and sinter the briquettes. The sintered briquettes are forged under conditions which permit substantial plug flow deformation into preforms whereby fusion of the sintered resin powder particles occurs.

Abstract: Process for the manufacture of fibrous products by drawing at elevated temperature a sheet comprising sintered particles of a synthetic organic thermoplastic polymer, which sheet also contains 0.1 to 5 phr of a processing aid, being certain fatty acids or compounds thereof.

Abstract: The method of autogenously bonding a nonwoven web formed predominantly of thermoplastic fibers is characterized by the steps of directing heat into the web from only one surface thereof to preheat the web, and then directing the preheated web through a bonding nip formed between opposed rolls, one of said rolls being hotter than the other roll, being capable of heating the web surface it engages to a temperature above the melt point of the thermoplastic fibers and being positioned to engage the surface of the web opposite the one into which heat was directed during the preheating operation; said webs being preheated by means completely independent of the opposed rolls that form the bonding nip, and most preferably by infrared panels. The nonwoven product formed in accordance with this method also forms a part of the instant invention.

Abstract: A method and apparatus for processing compressible insulation material of mineral fibers in which a folding shoe guides the insulation material from a strip condition into a cylindrical condition and further including initially compressing the portion of the strip material along the centerline thereof, subsequently compressing the portions of the strip material intermediate the center line and the side edges of the strip material, and, finally, compressing the side edge portions of the strip material.

Abstract: Nonwoven point-bonded fabrics of improved softness are prepared by simultaneously heating and compressing spaced, discrete areas of a nonwoven thermally bondable fiber web containing an attenuating liquid.

Abstract: Multi-sided decorative moldings and furniture parts are manufactured by drying or hot-pressing a cellulosic fiber-containing mat to consolidate said mat into a unitary blank, cutting the blank to a size larger than interior dimensions of a closed mold in each of its three dimensions and with at least two generally shaped or profiled edge surfaces disposed between a top surface and a bottom surface of the blank. The cut blank is then molded at a temperature of at least 200.degree. F. for a period of time sufficient to permanently transfer the interior shape and design of the mold cavity to every surface of the blank.

Abstract: A cellulosic fiber containing board is molded at a temperature of at least 525.degree. F. to provide a relatively high density skin on at least one surface. A fibrous composition, including cellulosic fibers, is consolidated to form a consolidated blank. The consolidated blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position. Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof. The skin is formed by hot-pressing a consolidated cellulosic fiber-containing board including urea in at least its surface fibers, at a temperature of at least 525.degree. F. The composition of the skin has not been determined but is different than the composition of cellulosic material thereunder.

Abstract: A process is disclosed for forming an outlet passageway in an osmotic dispensing device. The process comprises compressing a drug formulation into a solid mass, forming a recess in the solid mass, and then spray coating the mass with a wall forming material that surrounds the mass. The outlet passageway in the wall is formed at the recess simultaneously and automatically during the coating procedure. The passageway extends through the wall and communicates with the drug and the exterior of the device for dispensing the drug over a prolonged period of time.

Abstract: A low-cost mineral-fiber board having a natural-appearing highly textured surface, and improved uniformity of density is produced by coating the wet-textured surface of a perlite-containing mineral-fiber mat to a depth at least equal to the peak height of the texture with a layer of silicone-coated perlite prior to press-forming the board. The perlite layer fills the voids on the textured surface and provides a buffer layer between the board and press roll, enabling uniform pressure to be applied to the board without disturbing the textured surface. The top perlite layer may be removed by vacuum units before or after drying the board.

Abstract: Permanently embossed, highly porous wallpapers are produced by preparing a sheet from a mixture of up to 90% by weight of cellulose fibers and at least 10% by weight of fibrils of at least one thermoplastic polymer, and subjecting the sheet, in any order, to the following operations:(a) embossing at a temperature lower than the softening temperature of the thermoplastic fiber; and(b) heating at a temperature equal to or higher than the softening temperature of the thermoplastic polymer.The term "fibrils" refers to elongated structures in the form of films or fibers of varying length comprised between about 1.0 mm and about 50 mm and the minor diameter or dimension of which is comprised between about 1.0 and 400 micron.

Abstract: Apparatus for fabricating a prefinished wallboard wherein a layer of settable material is applied to one side of a wall panel and a decorative pattern is formed in relief in the settable material which, when set, is harder than the wall panel. A decorative coating may be applied to the relieved portions of the moldable material, and reinforcing and insulating members may be connected to the opposite side of the panel.

Abstract: A molded unitarily formed pallet is provided, the pallet including wood particles bonded together by a cured binder in compressed relation. Also provided is a method for making such pallets. The pallet includes a deck having an upper supporting surface, a lower surface, a plurality of integral leg sections extending downwardly from the deck, and a densified integral peripheral portion surrounding the deck to provide increased strength at the periphery of the pallet. The pallet may also include narrow elongated wooden strips bonded to the densified peripheral edge to further increase the strength of the pallet.

Abstract: Fibreboard panels and the like, useful as drawer fronts, cabinet doors, table tops, furniture parts, moldings, baseboards and the like are formed of compressed fibre panels or strips with an edge treatment forming a contoured or profiled edge surface. The wood fibres on the edge surface are heat seared and die pressed together to form a heat seared sealed surface of skin which does not require subsequent filling and further mechanical surfacing and which is more easily finished by the application of liquid decorating materials, paints, stains, printing inks and various colorants. The cellulosic fibrous blanks are mechanically preshaped to provide a contoured profile edge which is subjected to heat and pressure from a heated die which sears and seals together the fibres forming a skin over the profiled edge surface. The skin formation results in a reduction of time and labor that is required for any final finishing operations and provides a better appearance for the entire surface of the fibreboard piece.

Abstract: Disclosed is a hardboard with a smooth, highly-consolidated, dense surface and a method for making it. The method of this invention greatly reduces the need for surface sanding after molding because release from the molding caul is improved and results in a product having a surface more free of defects. According to a preferred embodiment, a dry mat of wood particles is sprayed with from 8 to 30 grams per square foot of a surface coating of a consolidating agent comprising from 50 to 95% water, from 4 to 25% ethylene glycol and from 1 to 25% polyvinyl acetate, prior to pressing at elevated temperature. These percentages are based on the weight of the consolidating agent. The preferred products will have at least one highly-consolidated, smooth surface layer which comprises from 0.5 to 4 grams of polyhydric alcohol and from 0.5 to 4 grams of polyvinyl acetate per square foot of surface.

Abstract: A method of embossing wood composition board is disclosed. This method employs a water-borne base-coat composition which facilitates fine line embossing of the filled surface of wood composition board in imitation of fine grain woods, such as, for example, pecan and prima vera.

Abstract: A nonwoven fabric having alternating stripes of high fiber density and low fiber density is made in such a manner that the high fiber density stripes run across the fabric and maximize the cross direction strength to a point that the cross direction/machine direction strength ratio approaches unity. This advantageous and desirable characteristic can be achieved by hydroforming card web; first disposing the carded web on a relatively fine mesh screen and placing a finger-like striping bars over the web with the axis of the bars at 90.degree. to the card web's general fiber orientation. Water was then sprayed over the assembly with sufficient force to rearrange the fibers in the web thereby producing the nonwoven fabric of this invention.

Abstract: Remoldable panels are produced by continuously plastifying and extruding an at least partially aggregated particulate mixture comprising about 40 to about 60% by weight of thermoplastic resin, preferably polypropylene, and about 60 to about 40% by weight of a particulate organic and preferably cellulosic filler such as wood particles, and rolling the web of extruded material prior to its solidification. The extruded and rolled web is cut to panels which can be used, for example, in the production of shaped articles such as dash boards or other components of automotive vehicles, furniture or parts thereof and the like, by pressing at elevated temperature or by other remolding methods conventionally used in the art of processing thermoplastic materials. Alternatively, the panels can be used for purposes where wood panels or ply-wood are normally employed.

Abstract: A method for making a dimensionally stable decorative floor covering product. A sheet is first formed, and this is then provided with a decorative design. A clear wear layer is applied thereon, mechanically embossed-in-register, and then the sheet is cut into a plurality of individual tile units.

Abstract: An article, such as a pallet having a substantially flat deck member and a plurality of hollow legs projecting from the deck member, is molded as a one-piece unit from a papermill sludge. Dried, comminuted papermill sludge is blended with a fibrous reinforcing material, preferably a cellulosic material such as fibrous bark particles, and a resinous particle board binder, the resulting mixture of furnish is formed into a loosely fitted mat, and the mat is placed between dyes of a mold and press and compressed to substantially the desired shape under temperature and pressure conditions sufficient to bond the sludge and bark particles together.

Abstract: A method is provided for shredding and dry-defibrating compressed cellulose pulp, and depositing the resulting fibrous material on a foraminous support to form a batt of relatively uniform density while controlling the feed of cellulose pulp material through the shredding and dry-defibrating operations to the foraminous support according to the output rate of the batt-forming operation, to ensure a relatively uniform density in the batt withdrawn from the foraminous support.

Abstract: Particleboard made from particles in the form of chips or fibers or the like is made by distributing a mass of chip material onto an endless belt conveyer system. The mass of material is subsequently passed to a precompressor, a high frequency preheating device, a further press and a finishing press. The unheated further press serves to reduce the thickness of the material to substantially that of the finished board prior to its consolidation by temperature and pressure in the finishing press. A further endless belt contacts the surface of the material and runs through the precompressor, the high frequency heating device and the further press and serves to counteract any tendency of the chip material to expand after leaving the precompressor. This endless belt additionally yields a number of other significant advantages, in particular a reduction of loss of heat from the material prior to reaching the finishing press.

Abstract: The method of autogenously bonding a nonwoven web formed predominantly of thermoplastic fibers is characterized by the steps of directing heat into the web from only one surface thereof to preheat the web, and then directing the preheated web through a bonding nip formed between opposed rolls, one of said rolls being hotter than the other roll, being capable of heating the web surface it engages to a temperature above the melt point of the thermoplastic fibers and being positioned to engage the surface of the web opposite the one into which heat was directed during the preheating operation; said webs being preheated by means completely independent of the opposed rolls that form the bonding nip, and most preferably by infrared panels. The nonwoven product formed in accordance with this method also forms a part of the instant invention.