Abstract: A technique that involves selective removal of material from a surface of a polycrystalline diamond (polyD) film such that a non-planar surface results. Exemplarily the technique is used to form polyD optical elements, e.g., convex or concave lenses, or Fresnel lenses, including arrays of such lenses. The technique involves maintaining on appropriately shaped hot template body in intimate contact with a polyD surface for a time (e.g., in the range 1-1000 hours) sufficient to result in formation of the desired feature in the polyD surface. The template body involves a rare earth metal (La and Ce are preferred), Mn and/or Fe, and the temperature is below the melting temperature of the template body. Removal of "spent" template material by, e.g., chemical etching and finishing of the polyD feature, e.g., by laser ablation and/or polishing, are contemplated.

Abstract: A ceramic mirror having a maximum surface flatness of 1 .mu.m and/or a maximum centerline average height of 1 nm as measured by the laser interference method, and a method of manufacturing a ceramic mirror by compacting a titanium oxide powder having an average particle diameter no greater than 1 .mu.m and a purity of at least 99% and then sintering the compact in an ordinary, inert, vacuum, or reducing atmosphere at a temperature between 1000.degree. and 1300.degree. C. The sintering pressure may be a minimum of 50 kg/cm.sup.2. After sintering, the product may be further treated by hot isostatic pressing (HIP) in an Ar atmosphere at 1000.degree. C. and a pressure of 1800 kg/cm.sup.2. The sintered bodies are then surface ground or lapped to produce ceramic mirrors having the above characteristics for use in laser and X-ray apparatuses, cameras, and other precision optical instruments.

Abstract: Improved wood fiber mat comprised of a mixture of thermo-mechanically processed wood fibers and synthetic fibers.

Abstract: Method and apparatus for quickly, and substantially uniformly, heating and cooling a bed of polymeric fibers having high melting point and low melting point fibers therein for softening the low melting point fibers and bonding them to the high melting point fibers to form a seat cushion. Hot and cool gases are flowed through the bed of fibers to effect the heating/cooling.

Abstract: Methods of manufacturing fiberboard from lignocellulose-containing fibrous material are disclosed including defibering the lignocellulose-containing material, drying the defibered lignocellulose-containing material by contact with a heated drying gas in a first drying step to produce a partially dried lignocellulose-containing material, mixing the partially dried lignocellulose-containing material with a glue, drying the admixture of partially dried lignocellulose-containing material and glue by contact with a heated drying gas in a second drying step, which is conducted at a lower temperature than the first drying step, independently controlling the temperature and moisture content in the second drying step to produce a dried lignocellulose-containing material having a predetermined temperature and moisture content, forming the dried lignocellulose-containing material into a fiber mat, and hot pressing the fiber mat into fiberboard.

Abstract: A water soluble dicarboxylic acid acts as a mold release agent for salt blocks when it is sprayed as a fine powder into the block press mold box just prior to a charge of salt. The acid has from 6 to 10 carbon atoms; adipic acid is a preferred release agent. The salt block having a layer of the acid on it surface may be used in water softening systems wherein the block sits in a brine reservoir and supplies salt for the recharging of an ion exchange resin. There is no build up of an unsightly scum on the surface of the brine and on the sides of the reservoir as there has been with the use of calcium stearate as the release agent.

Abstract: A method for manufacturing a mineral fiber product comprises centrifuging mineral fibers with a spinner, forming a veil of the mineral fibers moving in the direction of the axis of the spinner, directing toward the veil, from a position within the veil, polymeric material to cause intermingling of the polymeric material and the mineral fibers, and, collecting the intermingled polymeric material and mineral fibers to form a mineral fiber product.

Abstract: Disclosed are an improved apparatus for collecting fine fibers, such as glass fibers, having a mean diameter of less than two microns from a gaseous stream, a method of collecting fine fibers using the apparatus and the novel new product produced by this method. The improvement lies mainly in the way in which the collection drum is supported and sealed which allows the collection to take place at relatively high partial vacuums. The fiber is also consolidated in the gaseous stream by passing it through a duct having at least one approximately ninety degree turn therein.

Abstract: A die which can press-mold an accurate glass microoptical element such as a grating repetitively can be manufactured easily by adhering a thin film, having an inverse shape of the master of a micro-optical element, on the top flat plane of a hard base body and by forming a protective layer thereon. The die having an inverse shape of the master can press-mold glass repetitively. By press-molding glass with the die, a large number of reliable glass micro-optical elements of the same shape as the master can be produced at a low cost.

Abstract: A laminated fabric material, a nonwoven textile product used to make that material and methods of making each are disclosed. The nonwoven textile product includes a compressed nonwoven textile batt of textile staple fibers and a cured binder disposed substantially throughout the batt. The textile product is suitable as a substitute for foam backing layers in the production of laminated fabric materials.

Abstract: A process for producing a preform includes the steps of retaining a glass fiber fabric (40) on a foraminous screen (14) by use of a vacuum draw and depositing chopped glass fibers (19) onto the glass fiber fabric with a binder that cures in place. The vacuum draw retains the deposited materials in place until the binder is cured.

Abstract: Reinforcing material which does not have a melting point which is compatible with the processing temperature of an elastomer can be incorporated into the elastomer in the form of melt blown fibers. In the method of the invention, melt blown fibers are made by melting a reinforcing material in an extruder, and extruding the reinforcing material through a die comprising many small holes, while simultaneously blowing air or nitrogen, under high pressure, through the die holes, and collecting the resulting material on rotating rolls. The fibers thus formed are mixed into an elastomer using conventional mixing means. A composite made by the method is also provided.

Abstract: The invention relates to an apparatus for the production of formed parts for use as pads in seats, for instance. The object is to provide a new apparatus with a different operating principle by means of which formed parts in which the density of the padding is uniform can be produced. The apparatus according to the invention comprises devices known per se for opening padding raw material into a desired looseness and for transporting it into a weighing device and for transferring the weighed batch of padding material into a filling chamber by means of a suction created by a vacuum pressure acting on the filling chamber.

Abstract: A method and apparatus of forming a preform (12) of structural fibers (14) includes a hermetically sealed housing (18) for controlling air pressures and flow therein. A perforated screen (28) is located within the housing (18) separating same into a high pressure chamber (34) and a low pressure chamber (36). Pressurized air is supplied to the high pressure chamber (34) to agitate and randomize fibers (14), and a vacuum (26) is provided in the low pressure chamber (36) to draw and compact the fibers against the screen (28). The pressure differential between the chambers (34, 36) provides significant compaction of the fibers against the screen. A binder (16) is applied to the fibers (14) to maintain the shape of the preform.

Abstract: The invention relates to a method for forming a hydraulically bound web. A homogeneous mixture of wood pulp and synthetic fibers is blown on a forming surface. The web has a mixture of at least 70% wood pulp by weight of the mixture. The web is subjected to hydraulic bonding to form a stable fabric. The web is further heated to a temperature to cause partial melting of the synthetic fibers and further bonding of the fabric.

Abstract: The invention relates to a process and apparatus for the controlled release of metered quantities of finely divided solids with one or more regulated venturi nozzles for the purpose of applying lubricant or separating compound to the stressed surfaces of pressing tools in tablet making machines or for applying finely divided solids to solid carrier materials particularly in the fields of pharmaceuticals, foodstuffs or catalysts.

Abstract: Simulated granite articles manufactured by coating a mold with a gel coat and then a spray composition including a gel coat material and crushed natural granite, crushed synthetic granite and mixtures thereof. Backing material fills the remainder of the mold. Gel coat and crushed synthetic granite may be sprayed directly on the mold, with a modified spray gun being used to efficiently and uniformly spray the granite composition.

Abstract: A method of making silver halide fibers involves reducing turbulence and friction during extrusion by moving an extrusion die in a direction opposite from flowing fiber and against a stationary preform arrangement. In another embodiment, the preform is doped with AgI or is a metal compound of the formula MY wherein M is selected from Li, Na, K, Rb, Cs; or MY.sub.2 wherein M is selected from Mg, Ca, Sr, Pb, Ba, Cd or Hg, and Y is selected from Cl, Br, or I. The resulting fiber has a more even core/clad interface with decrease in grain size to fiber surface and texture elongated along the fiber axis. This structure together with strengthening and stabilizing dopants, added to fiber material, gives decreased and stabilized optical losses and a higher elasticity of fibers.

Abstract: A process for producing a motor vehicle bumper includes the steps of depositing chopped glass fibers (19) and a curable binder (24) to a center section (38) of a preform (11) that is retained on a preform screen (14) by a vacuum draw from a suction fan (15). A ratio of shredded structural reinforced injected molded plastic (23) and glass fiber (19) is sprayed to form end sections (41) and flanges (39) of the preform (11) along with binder (24). The preform (11) is then cured on the screen (14).

Abstract: A process for producing a preform (44) includes pretreating roving by submerging it in a tank (18) and cooling the binder (20) on the glass fibers before the glass fibers are chopped. The fibers and solidified binder are then chopped and deposited onto a preform screen (32). Heat is applied to soften the binder that is on the chopped glass fibers and cooled to set the binder and form the preform on the screen.

Abstract: Apparatus and method for the forming of fiber structures or webs utilizing a rotor having a plurality of blade sets helically arranged about its periphery for detangling and declumping air-entrained fibers which are deposited against a sizing screen, said blades act to push individualized fibers, with the assistance of positive air pressure, through the screen into a free-fall zone for deposit on an underlying forming wire.

Abstract: In the method for manufacturing a product in the form of a mat containing mineral fibers and a binding agent, the binding agent is mixed with the fibers before the formation of the product. The material used as the binding agent includes thermoplastic particles, such as fibers, a powder, or particles in a dispersion, which are supplied to the fibers being formed of melted mineral into the stream of air. The fibers and the binding agent are carried by a turbulent air flow, in which the heat contained in the melting mineral and the fibers forming therefrom are used for melting or softening thermoplastic particles into a state, in which they effect the binding of the fibers to each other.

Abstract: A shaped body is molded from fine particles such as powder, whiskers and short fibers, by preparing a slurry consisting of the fine particles and a supercritical fluid containing a small amount of binder dissolved therein, and supplying the slurry into a mold cavity through an inlet port, so that the fine particles suspended in the supercritical fluid are stacked in the cavity to form a layer as the supercritical fluid is exhausted out of the mold cavity through an outlet port.

Abstract: The invention relates to a high molecular absorbent sheet manufacturing process and the related equipment for employing such manufacturing process. The process includes a step of sending a paper pulp and a high molecular absorbent compound to a trough for mixing by wired cylinders and spreading over a conveyer system, a step of drying the mixture carried on the conveyer system, and a step of squeezing the dried mixture into a roll of high molecular absorbent sheet through two matched hot impression cylinders. A sheet of thermoplastic mesh fabric may be respectively covered on the mixture on two opposite sides before the process of drying.

Abstract: A method of manufacturing shaped bodies, in particular boards, out of gypsum, water of hydration and comminuted fibers containing lignocellulose and/or cellulose is described in which all components are combined into a single starting mixture and at least one water saturated, essentially ground-moist, light aggregate is dispersed in this mixture as a fixed pore former. From this starting mixture there is formed a mat which is built up symmetrically in cross-section by means of a single double-sided wind sifting scattering process wherein the light aggregates are located in the central layer. This mat which is built up symmetrically in cross-section is pressed while supplying heat.

Abstract: The invention relates to a process and an apparatus for the dry forming of a material web from a long-fiber material, wherein fibrous material is blown into a forming space to form a porous material web on a wire passing through the forming space. The dry forming of long fibers in lengths of at least 20 mm is problematic. In accordance with the invention, this problem has been solved in such a way thatthe fibrous material is blown into the forming space by at least one air current (A) that is substantially horizontal and transverse to the wire,the fibrous material is guided onto the surface of the wire (1) by an air current (D) that is substantially vertical and passes through the wire downwardly,and the desired material web (F) is formed by the combined effect of said horizontal and vertical air currents.

Abstract: A method is provided of producing fibrous product from cellulosic wood fiber. First, a layer of this fiber material is deposited on a moving wire. A binding agent in an aqueous solution is then added to the fiber material. Next, the fiber material is moved through a superheated oven having a minimal amount of moving air to cause a lively boiling of the aqueous solution. The fiber material is then dried. In one embodiment, a mixture of alkali treated and acid treated fiber material is deposited on the moving wire.

Abstract: An apparatus and a process for the continuous production of mineral wool nonwovens in the nonwoven formation process on the drums of the accumulating conveyors arranged at the lower end of a chute. Several fiberization units (1, 2, 3, 4) communicate with a chute (9) for the formation of a nonwoven (14). The fibres are deposited under the influence of suction pressure onto the curved surface of the accumulating conveyor (10, 11). At least one of the drum-shaped accumulating conveyors (10) is designed to swivel around a pivot (23) essentially arranged perpendicular to the flow direction (22) of the mineral wool such and to the extent that a discharge gap (21) can be adjusted to a width corresponding to the thickness of the nonwoven (14) to be formed.

Abstract: Absorbent flakes or particles are transported from a source to a pad form device by an air flow passing the flakes or particles through a conduit between the source and the pad forming device. In order to supply a homogenous flake flow to the pad forming device, baffle devices or at least one baffle device is arranged in the conduit. The baffle device or baffle devices are equipped with baffling rods arranged in a certain position within the baffling device housing so that the flake air mixture must flow through the spaces between neighboring baffling rods to assure a dissolution of any flake accumulations or clumps. Preferably, a cross-section flow area reducer is arranged upstream of each baffling device to increase the flow speed or velocity of the flow entering the respective baffling device.

Abstract: A method and apparatus for applying fibers to a foraminous mold or surface using strands of binder and glass fibers is disclosed. A strand of binder fiber is chopped and entrained into a chute. The chute has a longitudinal airstream directed therethrough toward the foraminous surface. The binder fiber is separated into filaments by the airstream. The glass fiber strand is chopped and entrained into the chute downstream of the filaments. The chopped glass and the binder filaments mix within the chute and are then directed by the airstream onto the foraminous mold or surface. The mixture may be fanned out from the chute to provide more even coverage of large sized molds or surfaces.

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: A precision cartridge filter having an average filter diameter of 10 .mu.m or less is produced by preparing a web composed of conjugate microfine fibers by a conjugate melt-blowing process, wherein the conjugate microfine fibers have a lower melting point component, a higher melting point component, and a melting point difference between the lower melting point component and higher melting point component of 20.degree. C. or more; followed by heating and molding the web at a temperature greater than or equal to the melting point of said lower melting point component, but less than the melting point of said higher melting point component.

Abstract: A preform (11) is formed from sprayed binder and chopped fibers from respective nozzles (21) and (18) onto a foraminous screen (14). A plurality of nozzles (33) are circumferentially spaced about nozzles (21) and (18) and provide heated air to cure the binder. The nozzles (18),(21), and (33) are affixed to each other and are mounted onto a gantry (32) for relative motion with respect to the screen (14). The heated air cures the preform (11) simultaneously with it formation.

Abstract: A shaped body is formed from fine particles such as powder, whiskers or short fibers of ceramics or metal, by preparing a mold having a mold chamber, an inlet port open to the mold chamber at its first portion and adapted to introduce a mixture of the fine particles and a carrier fluid into the mold chamber, and an outlet port open to the mold chamber at its second portion substantially opposite to the first portion and adapted to exhaust substantially only the carrier fluid in a gaseous state out of the mold chamber; preparing the mixture of the fine particles and the carrier fluid; and supplying the mixture under a pressure elevated substantially above atmospheric pressure into the mold chamber through the inlet port while exhausting the carrier fluid out of the mold chamber through the outlet port.

Abstract: An improved apparatus for dry forming adhesive coated wood fibers in an airstream in a particular mold apparatus. The invention permits the manufacture of a mat of differing cross-sectional shapes but of uniform density. The invention includes the advantageous steps of final curing of the mat off of the main molding apparatus, thus achieving efficiencies in use.

Abstract: A directed fiber, directed energy process provides both a method and an apparatus for making structural preforms. Fibrous reinforcement material is chopped into short lengths of fiber and propelled toward a perforate mold part. During propulsion and/or after deposition on the perforate mold part the fibers are sprayed with an electromagnetic radiation-curable binder. The binder-carrying fibers are held on the perforate mold part by a flow of air in that the perforate mold part is rotatably mounted in a plenum which provides an air flow therethrough. Rotation of the perforate mold part and scanning action of the fiber and binder propelling mechanisms effects even and complete coverage of the perforate mold part. After a mat of the chopped fibers has been applied to the perforate mold part, a conforming second mold part closes the mold and presses the fibers to replicate the shape of the three-dimensional rigid perform.

Abstract: A cement-bonded particle board with finer particles concentrated at the surfaces of the board and coarser particles concentrated within the board is formed by spreading the particulate material onto a moving carrier (50), the particulate material initially being projected in a first generally horizontal direction above the carrier and allowed to fall gravitationally without interacting with any fixed surface, whilst the falling particles are subjected to a through-flow of air [B] immediately above the carrier in a second direction opposite to that in which the particles are initially projected, the coarser particles being projected preferentially in said first direction and the finer particles being carried preferentially in said second direction by the airstream [B] to effect a second stage of separation.

Abstract: A process for the production of a complex component made of metal, ceramic or plastic, in which process powder (7) is blown by means of a transport gas into a gas-permeable negative mold (14), which is under reduced pressure and is located in a container (11), and pre-compacted, after which the negative mold (14) is removed from the container (11) and the green compact is sintered, either in a separate ceramic supporting composition or in the negative mold (14) itself, which consists of ceramic. The process allows production of a hollow body or of a layered body as the component by programming the powder injection.

Abstract: Disclosed is a method for forming composite articles, particularly ceramic articles, from particles or fibers mixed in a thermally activated reactant gas stream. The particles or fibers are codeposited with material produced by chemical vapor deposition (CVD) onto a heated substrate until the desired thickness of composite is obtained. Removal of the substrate yields a near-net shaped codeposited composite article having a chemical vapor deposition produced matrix with particles or fibers embedded therein a generally uniform distribution. The method provides high deposition rates, and the composite articles produced may have enhanced strength, thermal shock resistance, and corrosion resistance at elevated temperatures.

Abstract: A method for producing a melt-blown non-woven mat wherein a fiber-forming thermoplastic polymer resin is extruded in molten form through a row of nozzles into a stream of hot gas which attenuates the molten resin into fibers that form a fiber stream. The fibers are collected on a receiver in the path of the fiber stream to form the non-woven mat. At least two spaced rows of nozzles are provided to produce first and second fiber streams spaced from each other. The spaced fiber streams are collected on the receiver to form a first non-woven mat portion and a second non-woven mat portion and with the first non-woven mat portion overlaying the second non-woven mat portion. At a position intermediate the first and second fiber streams, material different than the fiber-forming resin is injected to have the different material captured between the first and second fiber streams and thereby form a collected structure of the first and second mat portions sandwiching the different material.

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 liquid absorbent structure is made by dry laying a fibrous web having incorporated therein a superabsorbent material, and applying a latex coating to at least one surface of said web, which on curing imparts integrity to the resulting structure without substantially impairing the effectiveness of said superabsorbent material to absorb liquid.

Abstract: In the fabrication of wood material panels, processed wood particles are coated with a binder free of a hardener and then are spread in a fleece on a support surface. The fleece is then compacted and pressed to form the panel. Before the compacting step, microcapsules are introduced into the fleece. The microcapsules have enclosing walls that do not react with the binder and contain a hardener in the gaseous phase or in the binary phase with a gaseous carrier agent. When the fleece is compacted, the capsule walls are destroyed and the hardener is released into the fleece. The microcapsules containing the hardener are produced in a device located adjacent to the inlet end of the press so that there is only a short distance between the device and a mixing station where the microcapsules and the bonded processed wood particles are mixed. The mixing station is located just ahead of or at the spreading station where the mixed wood particles and microcapsules are formed into the fleece.

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 method for forming a zoned distribution of particulate material within a fibrous web includes a conveying step for providing a gas entrained supply of the particulate material and a segregating step centrifugally directing at least a portion of the particulate material into an accumulation region. A transferring step selectively directs particulate material from the accumulation region into a delivery gas stream to provide an intermittent flow volume of a selected quantity of particulate material from the accumulation region through a delivery conduit and into a web forming chamber. A fiberizing step provides a flow of a selected fibrous material into the web forming chamber, and a directing step controls the intermittent flow of particulate material from the delivery conduit into the forming chamber.

Abstract: A method and apparatus for depositing straight elongate fiber-bundle strands, such as sugarcane or sweet sorghum rind strands, in a loose pile on a conveyor with the strands randomly oriented in substantially parallel planes during manufacture of structural panel from such strands. The method includes dropping bit by bit a randomly-oriented collection of strands over a drop edge located above the conveyor and flicking the strands onto the conveyor by quick downward motion of counter-rotating arrays of flicker tines in the drop zone.

Abstract: A process for coating wet rubber pellets including coating the pellets with an inorganic partitioning agent, a thickener and binder, and an anionic water soluble dispersant, air conveying the pellets to a dryer, and compressing the pellets to form a bale. By virtue of the coating, the bales are rendered more friable.

Abstract: A method and apparatus for forming fluff pads and the like wherein fluff providing material webs are introduced into separate hammermills and then delivered through a plurality of ducts through a moving screen under vacuum and wherein the ducts are characterized by reverse bends to densify the particle stream at the outside of the curvature for generally perpendicular deposition on the screen.

Abstract: A method and apparatus are disclosed for the transport of a homogeneous mixture of chopped fibers, wherein the fibers remain in a homogeneously mixed condition during their transport from a chopper gun to a workpiece, by use of two transvector apparatus placed in series with a conduit attached therebetween.

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.