Abstract: A method of producing large objects from rapidly quenched non-equilibrium powders in which the powder is first slowly precompacted to a predetermined density without causing any substantial temperature rise. The powder is then rapidly compacted by a shock wave having a short rise time. In this way thin surface regions on the particles are rapidly brought to melting to cause interwelding of the particles. These thin surface regions are then rapidly quenched by conduction of heat to the interior of the particles. Because of the very rapid heating and quenching, in the order of a few microseconds, degradation of the material is avoided.

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 fiberboard is manufactured having relatively high density skins on a relatively low density core by including a skin forming chemical in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins. In accordance with another embodiment of the present invention, a skin forming chemical is used to form a skin on higher density mats having a density of 35 pounds/ft..sup.3 or greater. The skin formed on the higher density mats has strength and density properties which are not as significantly different from the core material as is the skin formed over the low density core material of the first embodiment, but the skin on the higher density mats also improves the board strength, stiffness paint holdout and design fidelity properties.

Abstract: A method of producing an improved mineral board and the resulting product are disclosed. According to the present invention, the board is predominantly composed of perlite and a binder therefor, preferably urea-formaldehyde resin. The perlite is crushed after the composition is in its final shape but before the binder is set whereby its strength is substantially increased. The composition and process of making the board substantially reduce energy costs as compared to known methods for making wet-process mineral boards. The product composition may include up to 95% perlite by weight.

Abstract: Manufacturing plastics products from a raw material containing at least 50% by weight reclaimed synthetic thermoplastics material by conveying a mat of the raw material through an oven to heat the material to the softening point thereof, and compressing the softened mat downstream of the oven between three rollers arranged generally one above the other to define a first nip between the upper and middle lower rollers and a second nip or passage between the middle and lower rollers, wherein the middle and lower rollers are of substantially greater diameter than the upper roller.

Abstract: A process for the production of chipboards, fiberboards, and the like boards, from particles containing lignocellulose and/or cellulose and/or other particles which are electrically non-conductive and have a poor thermal conductivity, combined with at least one binder and water. The process includes the steps of combining the particles, binder and water, forming a layer on a moving support, preheating the layer by high frequency and thereafter pressing the layer into boards with the use of contact heat that produces a steam blast that is effective from the outside of the layer toward its inside and is characterized in that the layer is initially provided with the same amount of moisture throughout, which is sufficient to produce, by means of the high frequency preheating step, a steam blast which proceeds from the inside of the layer into the surface zone thereof.

Abstract: Cellulosic fibrous material which can be pressed into moulded parts is manufactured from cellulose-containing material which is separated into a fibrous material, the separated fibrous material then being mixed with a binding agent (particularly a combination of thermoplastic and thermosetting substances) and formed into a fleece which is compressed under heat action. The cellulose-containing starting material is derived from waste cellulosic fibrous material and such waste material is cut up and ground in a dry state and the bonding agent is added in particulate form also in the dry state.An apparatus is described which has a pre-pulverizing apparatus, a mixing chamber, a grinder, an endless fleece conveyor, a forming head, a heating apparatus and a pressing apparatus.The resulting cellulosic fibrous material can be pressed into moulded parts between pressing tolls in the dry state and with a single pressing stroke.

Abstract: A neutron absorbing article, preferably in long, thin, flat form, suitable for but not necessarily limited to use in storage racks for spent nuclear fuel at locations between volumes of such stored fuel to absorb neutrons from said spent fuel and prevent uncontrolled nuclear reaction of the spent fuel material, is composed of finely divided boron carbide particles and a solid, irreversibly cured phenolic polymer forming a continuous matrix about the boron carbide particles, in such proportions that at least 6% of B.sup.10 from the boron carbide content is present therein.

Abstract: Process for the preparation of shaped articles of poly(metaphenylene isophthalamide) by simultaneously heating poly(metaphenylene isophthalamide) and applying moderately elevated pressures.

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 mass of particulate material is sintered or densified by applying a first pressure to the mass in a first direction, applying a second pressure to the mass in a second direction which is transverse to the first direction, and applying a third pressure to the mass in a third direction which is transverse to the first and second directions. The first, second and third pressures may be successively modified while the mass is heated to a sintering temperature.

Abstract: A method of heating a fleece comprises supporting the fleece on a perforate fleece carrier and passing a heated gas through the fleece and fleece carrier, preferably in that sequence to assist compaction of the fleece. Apparatus for performing this method comprises two chambers between which the fleece is passed on the carrier, the chambers being maintained at different pressures by a fan to create the flow through the fleece and through a radiator for heating the gas. The gas may be recirculated and may be filtered and/or augmented by a further supply. A roller at the exit end of the chambers compresses the heated fleece, preferably from above. The fleece carrier may be preheated upstream of the heating station, for example by induction heating in the case of a metal fleece carrier. A freely running roller having adjustable height rests on the fleece and seals the entry to the heating station.

Abstract: In a method for producing large structural components such as boats or swimming pools of fiber reinforced synthetic materials layers of pre-impregnated fiber material are continuously applied to a mold. An air impermeable foil or membrane is sealed over the layers of pre-impregnated fiber material. The air is evacuated between the foil or membrane and the fiber material to press the latter by atmospheric pressure against the mold to cause the material to conform to the shear surfaces of the mold. The layers of pre-impregnated fiber materials are then heat cured by heated mats, for example, similar to electric blankets. The sheer surfaces of the molding apparatus are made of sheet material such as sheet metal or sheets of synthetic material. The pressure application and heat curing takes place sequentially in area after area whereby the final size of the finished structure is not limited by the size of an autoclave nor is it limited by the size of available heating blankets.

Abstract: In fabricating sheet material with closely spaced parallel ribs on one side, a mold with ribbed shaped grooves is uniformly filled with a loose, dry molding material using a coater with a plurality of adjacent blades extending therefrom with the blade tips parallel to and preferably in contact with the mold top surface. The coater is swept across the mold top surface and the blades distribute and compress the molding material into the mold grooves. The invention is particularly useful for molding materials with high fiber content which are difficult to pack uniformly and with sufficient density into the mold.

Abstract: A process for producing a consolidated sheet of substantially dry fibrous material, for example wood pulp, comprising supplying fibrous material, having a moisture content of not more than 30 percent by weight on the total weight of the fibrous material, to a hopper and onto a gas-pervious conveyor while drawing gas through the conveyor (and through the fibrous material thereon), carrying the dry fibrous material on the conveyor surface from the hopper beneath means for reducing upward protrusions therefrom to form a layer of the fibrous material and applying pressure to said layer to consolidate the fibrous material to form a coherent sheet.

Abstract: According to the method of the invention an article of thermoplastic material is partially expanded and preformed in a heated mold. The preformed article is withdrawn from the heated mold to further expand at atmospheric pressure and is transferred still malleable into a cooled mold having the final size and configuration of the article.

Abstract: The invention pertains to the manufacture of articles of thermosetting plastics and other materials. In a first stage, a solid article is formed from a particulate material by introducing such material into a first chamber defined partially by the backing surface of a backing member and partially by the opposed pressing surface of a pressing member. The backing member is frangible and is removably mounted on a support. The first chamber is then closed and the pressing member advanced toward the backing surface to contract the first chamber and compress the particulate material between the pressing and backing surfaces to form the solid article. The pressing member is then retracted, the first chamber is opened, and the backing member and solid article are removed from the support as a unit. Finally, the backing member is fractured and the fragments are removed from the solid article. In a second stage, the convoluted article, or any other similar body is supported in a chamber structure.

Abstract: Strong, low basis weight, spontaneously dispersible sheets of modified cellulosic fibers. The sheets are prepared from modified cellulosic fibers such as cross-linked carboxymethyl cellulose or essentially acidic sodium carboxymethyl cellulose. Mixtures of modified fibers with unmodified fibers are also disclosed. The process of preparing the sheets comprises the steps of airlaying the fibers to form an airfelt, increasing the moisture content of the airfelt, and compacting the moisturized airfelt.

Abstract: The instant invention is directed to a novel process for the production of bonded foam, and particularly polyurethane foam scrap. The process allows for the production of a high quality rebonded product. Significant improvements are seen in the quality of the product, reduction in density, reduction in scrap loss, elimination of density variations in the molded product and overall product consistency.

Abstract: This invention is a method for making a plain bearing in the form of a strong backing strip carrying a bearing lining. The lining is formed from powder material drawn from the bottom of a container by the strip moving past it, and a downstream wall of the container is vibrated towards and away from the strip to compact the powder layer.

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 materials to be sintered are placed in a deformable container which is in turn placed within a non-deformable treatment module equipped with heating means. The temperature of the container is increased under constant pressure until commencement of sintering. The temperature and pressure of the materials are increased simultaneously until sintering conditions are achieved, then maintained at a level stage for a predetermined period of time. The pressure is then reduced to the normal value while maintaining the temperature. The temperature is finally reduced to the room-temperature value.

Abstract: A chipboard beam made of glue coated chips has top and bottom layers extending for the full length of the beam consisting of elongated chips, that may be for example as much as 5 cm in length oriented with their fibers in the longitudinal direction of the beam. The middle layer is made of flat chips having random fiber orientations in a vertical plane parallel to the long dimension of the beam. The chips are glued together under heat and pressure in a press, with the result that there is great coherence both between and within the layers. The pressing is done with the wider cross-sectional dimension of the beam horizontal, so that at this stage the layers of chips are side-by-side longitudinal stringers.

Abstract: A composition of material suitable for in vivo implantation to provide a wear surface which composition includes carbon fibers, perfluorocarbon fibers, fluorinated carbon fibers, fluorinated carbon particles, fluorinated hydrocarbon fibers, fluorinated hydrocarbon particles, polytetrafluoroethylene fibers or combinations thereof and polytetrafluoroethylene resin alone or with a high molecular weight polyethylene all of which composition is processed to align a substantial portion of the fibers with the wear surface. The preferred method of preparing such composition of material includes the steps of mixing, filtering, compressing, rolling, sintering and drying.

Abstract: Coal-containing shaped bodies are made by intimately mixing particulate coal with 10 to 30 percent by weight of a polymer. The mixture is shaped by subjecting it to a pressure between about 295 and 3430 newtons per square centimeter. Shaping takes place within a temperature range of 100.degree. to 250.degree. C. The shaped bodies have high compressive and bending strengths and can be precisely dimensioned.

Abstract: A process for producing an organic friction article from a composition of materials in a dust free environment. Water is mixed with the composition of organic materials to produce a slurry. A fixed volume of the slurry is communicated into a first mold. The slurry in the first mold is compressed to remove up to 95% by weight of the water to form a briquette. The briquette is conveyed to a force air oven or dielectric heater where the water is further reduced to about 1% of the weight of the briquette. This dry briquette is then placed in a second mold and pressed into the shape of a friction pad. The pressed friction pad is placed in an oven and heated to cure the resin in the composition of materials to complete the manufacture of the organic friction pad.

Abstract: An incombustible building element with good thermal insulation properties produced by spraying granules of vermiculite with an organic binder, prepressing the coated granules into a biscuit and heating and pressing the biscuit in a press to transform it into a building material element.

Abstract: A method for monitoring and controlling the operation of a dual platen press used in the manufacture of nuclear fuel pellets is disclosed. The method comprises the steps of indicating the displacements of both platens and imposing the displacements of the platens on orthogonal axes such that the displacements jointly control the motion of a point which traces a lissajous figure representative of the displacement and relative velocity of the press platens. A second lissajous figure representing the desired platen movements and relative velocity may be superimposed on the first lissajous figure, differences between the first and second lissajous figures indicating deviations from the desired operation of the press. Alternately, a press operator may simply use the first lissajous figure constructed from the actual platen displacements to analyze the operation of the press. The completion of preselected portions of the first lissajous figure may be detected and used to trigger subsequent press operations.

Abstract: A method of molding a cellulosic fiber containing board 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 blank having a density of less than 35 pounds/cubic foot. The 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 defined by a thickness of material on said surface of said product having a density greater than the material on which the skin is formed.

Abstract: Six-sided furniture parts are manufactured by 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 every dimension and with two to four generally shaped or profiled edges disposed between a top surface and a bottom surface of the blank. The cut blank is then molded at a temperature of at least 500.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 process for manufacture of porous metal objects particularly for making porous metal molds for use in the casting of ceramic objects. A mixture of aluminum powder and vegetable or animal ash is subjected to cold molding, followed by heating it in an oven to the softening temperature of the aluminum powder and subsequently hot molding of said mixture.

Abstract: A method for molding a cover on a metal core by preforming cover segments and molding the latter to size with the core interposed therebetween. When molded, the preformed segments are gradually deformed and uniformly compacted to a high density particularly in regions in direct contact with the wall surfaces of the mold, with no inclusion of cracks, pinholes or other structural defects therein. The product molded in this manner exhibits a very high corrosion-resisting characteristic with no machining operation conventionally required thereon, particularly when molded of tetrafluoroethylene resin powder.

Abstract: Method for molding articles from agglomerated particles utilizes a press and a plurality of molds mounted to circulate in a closed path. After the pressing step a mold is aligned at one end of a row of molds, the row is placed under pressure and the articles therewithin caused to set. Simultaneously a mold is withdrawn from the other end of the row. The latter mold is then emptied, and the emptied mold returned to the press. The aligned molds are fastened together during the setting step. The invention includes apparatus for carrying out this process.

Abstract: An improvement in the process of forming plastic articles wherein such articles are forged from a compression formed briquette of resinous powder, such improvement comprising (1) compressing a resinous powder having lamellar crystalline nonspherulitic morphology into a substantially unoriented briquette having green strength, (2) removing the briquette from the compressing device and placing the briquette in a forging press wherein lubrication is provided between the contacting surfaces of the briquette and the forging press to permit plug flow, and (3) forging the briquette into a shaped article while maintaining the briquette at a temperature between the alpha-transition temperature and the melt temperature of the resinous powder.

Abstract: A method for producing a self-sustaining sheet of essentially cellulosic fibrous material with improved strength wherein a dry-laid web is moistened and then consolidated by passage along a heated consolidating surface wherein the web is held against this surface by one side of a supporting band, against the other side of which at least two spaced apart pressure rolls exert a pressure acting through the supporting band against the web, which pressure is preferably between 150 and 500 pounds per linear inch. The supporting band thereby maintains the web against the heated consolidating roll between said pair of pressure nips.

Abstract: A polytetrafluoroethylene composite sheet having a tensile strength of at least one megapascal and comprising particulate material distributed in a matrix of interentangled polytetrafluoroethylene fibrils. The composite sheet is prepared by blending the particulate material with polytetrafluoroethylene aqueous dispersion in the presence of sufficient lubricant water to exceed the absorptive capacity of the solids yet maintain a putty-like consistency, subjecting the putty-like mass to intensive mixing at a temperature between 50.degree. C. and 100.degree. C. to cause initial fibrillation of the polytetrafluoroethylene particles, biaxially calendering the putty-like mass to cause additional fibrillation of the polytetrafluoroethylene particles while maintaining the same water content and drying the resultant sheet.

Abstract: A granular sorbic acid having improved properties is prepared in a very simple manner without need of any particular preparation as in conventional methods, i.e. by granulating by extrusion, powder having particle sizes of ASTM No. 70 sieve pass in the presence of water or water containing a surfactant. The resulting granule has a suitable hardness and hence scarcely collapses at the time of drying after granulation and subsequent handling, but has a rapid dispersibility into foods at the time of its use.

Abstract: A liquid binder forming material is added to a preform mold, dispersed chopped glass fiber strand is allowed to free fall into the preform mold to build up a layer of chopped fibers wherein substantially all of the strand is horizontal but otherwise randomly oriented, and the layer of chopped strand is forced down into the resin until completely immersed therein. Preferably, thereafter, the preforms so produced are stacked into tubular magazines with separator sheets between the preforms in each magazine; and the magazines are transported first to a maturation room where the viscosity of the binder forming material is increased to above 20 million centipoise, and then to matched metal dies where the preforms are sequentially fed out of the magazine to between the dies which shape and cure the preforms.

Abstract: A mixture of a fibrous material and a hot-setting binder is formed and subjected to the action of a high-frequency electromagnetic field. The mixture is subsequently cold molded and may then be hot molded. The alternating field slightly heats the binder thereby lowering its viscosity and, in addition, causes the moisture and the binder which are entrapped in the fibers of the fibrous material to be displaced towards the surfaces of the fibers. These effects lead to an improvement in the cold-adhesiveness of the mixture.

Abstract: The present invention relates to the manufacture of new tablets for administration of medicaments, which tablets contain in their mass, controlled-release microcapsules, that is to say elemental particles coated with a protective covering which contains an encapsulated product which is gradually released in a controlled, regular and time-dependent way.These new tablets are characterized in that they are constituted by the association of a plurality of superposed layers of which the medial layer is essentially constituted by microcapsules containing an active substance, while the exterior layers constitute means of protecting the microcapsules of the medial layer, particularly against the shock of compression when compressing them to tablets. The invention thus relates to a process for manufacturing said tablets.

Abstract: Coal-containing shaped bodies are made by intimately mixing particulate coal with 10 to 30 percent by weight of a polymer. The mixture is shaped by subjecting it to a pressure between about 295 and 3430 newtons per square centimeter. Shaping takes place within a temperature range of 100.degree. to 250.degree. C. The shaped bodies have high compressive and bending strengths and can be precisely dimensioned.

Abstract: Cellulose-containing materials such as wood fiber or vegetable fibers are permanently fused in a fast-acting process by subjecting the fibers to conditions producing a new state of fusion and chemical combining under intensive heating while excluding oxygen, and requiring little or no primary binder additives. This fused cellulose is reached by introducing cellulose materials having equilibrium moisture content from 2% to 50% (preferably 3% to 12%) into an oxygen-excluding reaction station having temperature in the range from 450.degree. F to 800.degree. F and wherein dielectric energy is applied in conjunction with high ambient temperature. The temperature is well beyond the normal cellulose carbonizing temperature and cellulose combustibility at temperatures of about 400.degree. F. Specific exposure of the materials to elevated temperature is accurately controlled to minimize possible carbonizing.

Abstract: A process for the manufacture of a molded article from a powder form of a polyolefin of molecular weight of at least one million which comprises introducing a homopolymer of ethylene or a copolymer of ethylene with an .alpha.-olefin of 3 to 10 carbon atoms having a molecular weight of at least one million into a mold loosely closed with a plug, heating the same in said mold in an inert atmosphere at a temperature of 150.degree. to 250.degree. C, whereby said polyolefin is transformed into a rubbery elastic state, thereafter compressing said polyolefin in said mold for at least two minutes at a pressure of 2.5 to 25 N/mm.sup.2 and thereafter compressing said polyolefin for at least one minute at a pressure of 40 to 100 N/mm.sup.2.

Abstract: A method and an apparatus for producing coherent shaped bodies from granular material. The granular material is confined in a mold and the mold is subjected to vibratory motions requisite for compacting the granular material. In accordance with the invention, the granular material is vibrated at its resonant frequency under a light load, then a substantial compressive force is applied to the granular material and the granular material is vibrated at the resonant frequency of the whole vibrating system under compression.

Abstract: Method of molding granular polytetrafluoroethylene powder which comprises compressing the powder in a mold at a pressure of between about 10 and 50 bars to form a preform and subjecting the preform to isostatic molding at a pressure of between about 100 and 1000 bars.

Abstract: Foldable boxboard made by dry-laying cellulosic fibers and 1-10% starch. The boxboard has a weight of at least 210 g.s.m., a stiffness in the machine direction of at least 5.8 Kenley units, and a ratio of stiffness in the machine direction and in the cross-machine direction of substantially 1:1.

Abstract: Press racking, or lateral movement of the movable portions of a press, occurs in certain particleboard processes during heating and pressing of the panels. It is attributed to shingling of wood particles during the formation of a mat. To eliminate or reduce the movement of the press, the mat is subjected to rolling engagement by a relatively small diameter roll located between the forming apparatus and the press. The roll subjects the mat to a downward rolling pressure. The peripheral roll surface is in contact with the newly formed upper surface of the mat and has a linear speed and direction of movement identical to the speed and direction of movement of the mat support. A resulting wave action within the mat is caused by shear and displacement forces applied to the wood particles, such that the shingled nature of the mat is modified to reduce or eliminate resulting lateral movement of the press components.

Abstract: A process for producing a composite graphite material in a molded form having high density and tensile strength as well as impermeability, comprising the steps of mixing expanded graphite material with oxidized graphite material as the binder and compression molding the resulting mixture. In one embodiment, this invention relates to the composite graphite material produced by said process.

Abstract: A process for the production of a building material element comprising spraying granules of vermiculite with an organic binder, prepressing the coated granules into a biscuit and heating and pressing the biscuit in a press to transform it into a building material element.