Abstract: A low cost method of binding lignocellulosic materials utilizing a novel ammonium based spent sulphite liquor, with phenol and formaldehyde or phenol-formaldehyde thermosetting resin as the binder is disclosed. Phenol-formaldehyde which normally reacts with ammonium lignosulfonate under acidic conditions and is unstable under these conditions, can be dispersed or otherwise held in suspension and can be mixed direct with the material by spraying. The constituants of the novel binder can also be mechanically dispersed when in dry powder form. The binder has improved adhesion characteristics and a shorter cure time over existing binders using a spent sulphite liquor base when in combination with phenol-formaldehyde.

Abstract: A nonwoven stretch fabric is provided. The fabric is produced from a web of bicomponent fibers bonded together by fusion of fibers at points of contact and thermally crimped in situ in the web. The fabric has good uniformity, good thermal insulating properties, and is produced by subjecting a fibrous web of thermally bondable, thermally crimpable bicomponent fibers to heated gas supplied continuously to the top of the web and intermittently to the bottom of the web.

Abstract: Molded filtration products, such as disposable face masks, are prepared by assembling at least one fibrous shaping layer and one fibrous filtration layer in face-to-face contact and subjecting the assembly to heat and molding pressure. Preferably the assembly comprises two shaping layers, one on each side of the filtration layer. The shaping layers in total weight no more than about 150 pounds per ream and contribute no more than about 20 percent of the total pressure drop through the filtration product. At least one of the shaping layers comprises fibers that can be bound together at points of fiber intersections by coalescence of binder material on the fibers.

Abstract: In a method of making molded articles, such as particleboard from mixtures of wood chips or like particles, bonding agents and reaction accelerators, initially the particles are divided into two portions A and B. Portion A is wetted with bonding agents and portion B is wetted with reaction accelerators. The two portions A and B are maintained separate until they are mixed loosely layered together and introduced randomly into a mold forming a mat. Within the mold, the mat formed by the particles of portions A and B are pressed together and the pressing action triggers the reaction hardening. Prior to the pressing step, the mutual contact of the particles in the mat of portions A and B causes only limited hardening bridges.

Abstract: A method of manufacturing construction products which involves feeding dry or substantially dry constituents including a liquid-setting powder and a reinforcement therefor into a molding zone. At least a part of the mold is vibrated to effect compacting of the constituents in the molding zone to such a degree that the constituents will stand and be self-sustaining upon removal of an upstanding portion of the mold. At least a portion of the mold is removed from contact from the compacted constituents, thereby exposing at least one upstanding surface of of the compacted constituents. A quantity of setting liquid is applied to substantially the full extent of the surface. The quantity of setting liquid is sufficient to wet all of the compacted constituents in the molding zone so as to initiate a chemical setting reaction but not sufficient to completely saturate the compacted constituents and to cause the associated effect of structural collapse of the compacted constituents in the region of the exposed surface.

Abstract: Construction products are moulded by mixing the dry constituents, including a proportion of fine particulate material, feeding (1, 2) the mixture into a mould (5), compacting the mixture, removing part (6) of the mould (5), lightly spraying (9) an exposed upstanding surface of the product with setting liquid, removing the product from the mould (5) and allowing it to set. Sufficient fine particulate material to surround the coarse particles and compaction, using vibration (7) of the mould (5) and compression of the mixture, to cause the fine particles to fill the interstices between the coarse particles, provide sufficient support of the exposed surface to prevent collapse or erosion thereof during wetting even though no fibre reinforcement is included in the mixture. Sufficient liquid to wet the product but not to saturate it is applied by the spray (8, 9).

Abstract: Aqueous plastic molding compositions based on ceramic raw materials characterized by containing a dual binder system consisting of water-soluble and/or water-dispersed air-drying high molecular weight film-forming agents, as well as of water-insoluble thermoplasts of fine particle form sinterable at temperatures below 250.degree. C. and a method of producing molded articles using the said compositions are disclosed.

Abstract: A mixture of crumb rubber, binder, such as polyethylene, and slip contact agent, such as talc, and lubricant, such as a metal stearate, is formed in a blender (10), is shaped into pellets (32) by extruding a strand of the mixture (26) into water (28) and breaking the strand into pellets. The pellets (32) are adjusted to a preselected water content in drier (46) before storage in closed bags (50), stored and reinforced in a container (54).The controlled water content pellets (32) are formed into porous pipe (88) by extrusion in pipe extruder (62) having the feeding, transition and metering zones separately heated to temperatures from 320.degree. F. to 400.degree. F. (T.sub.1, T.sub.2, T.sub.3). The die has a separate jacket (90) receiving heat exchange fluid for heating the die (68) to a temperature from 290.degree. F. to 380.degree. F. to form a porous pipe (88) having more uniform porosity. Porosity is controlled by selecting water content of the pellets and controlling die temperature.

Abstract: The present invention relates to a method of forming an extended elongate pressed composite assembly from a plurality of strands by subjecting the strands to heat and pressure. The improvement of the present invention comprises methods for compressing a particularly arranged composite mat of strands so as to compensate for internal stresses imparted to the pressed composite assembly during its subjection to pressure because of a converging compressing zone and card decking.

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 nonswelling mass of fibers and a thermosetting synthetic resin are cold pressed into a preform body having a predetermined primary volume. This preform body is then hot pressed into an intermediate body having a secondary volume smaller than the primary volume. The press is then opened and a thermosetting synthetic-resin skin is applied to at least a portion of the surface of the intermediate body. Thereafter the skin and body are together pressed into a final integrated body having a volume smaller than the secondary volume. The skin is applied to the intermediate body as a foil.

Abstract: A support device, suitable for the physically handicapped, and also for packaging delicate objects, consists of an airtight flexible bag filled with a granular material coated with an adhesive. A non-return valve is provided to allow a partial vacuum to be established within the bag. In use, the bag when non-evacuated of air, is pushed against a body to be supported so that the granular material flows and assumes a shape closely conforming to the body. Air is then evacuated from the bag and as a result the granular material is compressed into a rigid mass in the conformed shape. The mass is then made permanently rigid by activating the adhesive coating, for example with microwave radiation.

Abstract: A process for the preparation of solid unit dosage forms is disclosed wherein a fine spray of a dilute solution of a pharmaceutically active material is gradually finely sprayed over an extended time period onto fine excipient particles undergoing agitation. Extremely small amounts of the pharmaceutically active material are deposited on the excipient particles, allowing the resulting powder to be formed into solid unit dosage forms, such as tablets, containing 100 mcg or less of the active ingredient per unit, with high content uniformity among the solid unit dosage forms.

Abstract: An auger-type icemaker for producing hard chip ice of high quality comprises a refrigerated cylinder for forming ice grown on an inner wall surface thereof, a scraper auger rotatably mounted in the refrigerated cylinder for scraping off the ice on the inner wall surface of the refrigerated cylinder, and upper and lower bearing by which said scraper auger is rotatably supported in the refrigerated cylinder. The upper bearing has standard peripheral surfaces and a plurality of axial ribs projecting radially outwardly from the standard peripheral surfaces into abutment against the inner wall surface of the refrigerated cylinder. The standard surfaces include slant surfaces extending upwardly and radially outwardly progressively toward the inner wall surface of the refrigerated cylinder, and parallel surfaces extending upwardly contiguously from the slant surface and substantially parallel to the inner wall surface of the refrigerated cylinder.

Abstract: An apparatus for making a foam pad for carpets has features to improve the quality of the pad. The apparatus has a hopper section for receiving foam particles coated with heat activated bonding agent. An extruder section compresses the particles as they are moved continuously along a conveyor belt. A heat section heats the particles after being compressed. A raking device in the hopper section rakes the top of the body of particles prior to entering the extruder section. The raking device rakes in a direction opposite to the movement of the body of particles. The raking device can be raised and lowered to change the level of the particles, and thus the density. The raking device also forms the top of the body of particles with upwardly tapered corners. A plate located below the hopper and extruder sections supports the lower conveyor belt. The heat section uses steam chambers with a perforated top, which also serves to support the conveyor belt.

Abstract: A flowable thermoplastic polymer powder is fed to the nip of a pair of cooperatively rotating compression rolls whereupon the polymer feed is passed between the rolls which compact and cause the particles to coalesce into a shaped article which thereupon emerges from between the rolls in the form of a sheet or film. During the operation, the circumferential speed of the rolls is maintained essentially equal to the linear speed of the sheet or film exiting therefrom. The sheet or film is withdrawn from between the rolls under tension at a force which is adjusted so as not to exceed the elastic limit of the resulting sheet or film product. Flowable thermosetting polymer powder is also compacted into fully dense products by feeding the powder to the nip of a pair of cooperatively rotating compression rolls, whereupon the polymer feed is passed between rolls which compact and cause the particles to cold weld.

Abstract: A method of making light weight flame resistant structures from bonded polyimide macroballoons and products thereof. An aromatic tetracarboxylic acid dianhydride is reacted with an oxoimine to produce an N-substituted imide, which is then esterfied with a suitable alcohol. The resulting liquid is dried and the dry residue is reduced to a uniform powder having particles with diameters generally in the 0.5 to 10 mm. range. The powder is preferably further dried, either before or after final size reduction, in a moderate vacuum at moderate temperature to remove any excess residual alcohol. The powder spontaneously expands to form a closed cell foam when heated to a temperature in the range of about 90.degree. to 150.degree. C. for a suitable period. When the powder is expanded in a closed mold, a well consolidated, uniform, closed cell foam product results. The closed cell foam produced has excellent flexibility and resistance to heat and flame, and does not shrink appreciably when exposed to flame.

Abstract: An improved floppy disk having a liner material into the fibers of which has been compounded identically the same lubricant as that compounded into the surface of the magnetic recording disk.

Abstract: A process and apparatus are provided for pressing fibrous, particulate or laminar materials to provide laminated products of low to medium density. The system is characterized by the use of lightweight pressing plates which have horizontal and vertical permeability, by the sealing of the press to provide a closed environment, and by heating substantially entirely by the use of a fluid heat carrier which heats the materials by convection.

Abstract: A material suitable for thermosetting includes a collection of hollow particles adhesively mixed with a thermosetting resin in such proportions that the mixture exists in a granular form and may be converted by thermosetting into a fused solid mass having a density not greater than 0.5 grams per cubic centimeter.The particles may be glass microbubbles or phenolic microballoons and the resin may be a hardenable Friedel-Crafts resin. The material according to the invention is more suitable for packing into shaped cavities than known resins including those containing filler particles.

Abstract: Sheets or moulded bodies, for example particle board, are manufactured by hot pressing a lignocellulosic material in contact with an organic polyisocyanate and a wax release agent which is a vegetable wax, a modified vegetable oil, a microcrystalline wax or a mineral wax, said wax release agent having a melting point of at least 70.degree. C. Preferably the wax release agent is applied to the lignocellulosic material in the form of a dispersion in an aqueous emulsion of the polyisocyanate. The process facilitates the release of the sheets or moulded bodies from the caul plates or platens of the press.

Abstract: A solid composition of coated water-soluble polymer is made from 80 to 250 parts b.w. of solid particles of at least one water-soluble polymer coated with 100 parts b.w. of at least one paraffinic product solid at room temperature and whose melting point is preferably from 40.degree. to 90.degree. C. The solid composition is made by dispersing particles of the water-soluble polymer in the molten paraffinic product and then cooling down to room temperature.

Abstract: The method of the present invention is a method for producing disposable targets, for example so-called skeets, to be used in shooting sports and other similar purposes. The invention introduces a method for producing skeets made of a material which is firm and cheap and which doesn't cause health complication for men or animals or doesn't cause other damage when it spreads in nature during shooting competitions. These purposes are achieved by a process wherein a compound formed of gypsum containing crystal water (CaSO.sub.4.2H.sub.2 O) with water and possibly other ingredients as impurities in smaller amounts, is mixed with another compound containing some highly water-binding substance, for example calk (CaO), as well as possibly other substances as impurities in smaller amounts, whereafter the resulting mixture is put under high pressure, for example 10kN/cm.sup.2, owing to which pressure the said mixture is instantaneously congealed.

Abstract: Composite products are formed, such as of lignocellulosic particles, by bonding through the transformation of added sugars and/or starches together with lignin and/or other phenolic containing materials, with the optional presence of added catalyst, the transformation causing the composition to convert into a furan-lignin type binder in situ by heat and pressure. The bonding composition is suitably activated by contact with live steam.

Abstract: An unpatterned (grooveless) porous tire tread and a pneumatic tire incorporating the porous tread, together with methods of manufacturing the tire tread as a separate item and as an integral part of the tire are described. The tire tread has numerous randomly orientated and randomly distributed interconnected passages extending from the surface substantially throughout the tread. These passages provide water drainage paths preventing build-up of water between the tire tread and a wet road.The tire tread is preferably manufactured by bonding particulated elastomeric material with a binder mixture that forms a polymer upon curing. Whether formed separately or integrally with a tire, the tread mould is unpatterned.

Abstract: A method of manufacturing shaped rigid articles comprises preparing a mixture of thermally stable particulate material and a liquid resin having a viscosity of less than about 10 Stokes to form a thin coating of resin on the particles, at least a major portion of the particulate material comprising fly ash spheres, and forming the resulting mixture into a preselected shape with the resin bonding the particles together to form a rigid article having the preselected shape and containing less about 15% by weight resin. A rigid article also preferably has a cold tensile strength of at least about 125 psi.

Abstract: A method and apparatus for laminating a plurality of plastic layers together is disclosed in which the lamination is carried out under heat and pressure with at least all but one of the layers being gas permeable in order that any gases within or between layers may be vented to the atmosphere during lamination under said heat and pressure. If desired, all of the layers may be gas permeable. One or more of the gas permeable layers may be plastic powder which meets and consolidates into a continuous, integrated ply during lamination.

Abstract: Novel form of metal sulphate produced by alternate dehydration and rehydration, e.g., by cycling prismatic metal sulphate between 0.degree. C. and 70.degree. C., 20 minutes at each temperature, for 200 or more cycles, until a low-density powder is formed having a coral-like morphology at 8000 magnification.

Abstract: A technique is disclosed for heat treatment of fibrous mats, especially mats formed of mineral fibers such as glass and carrying a heat hardenable binder material, such as a thermosetting resin. The method disclosed provides for continuous feed of the mat through a curing or treating oven having a plurality of heat treatment zones. In one form of the method, the heat treatment in at least one zone is effected by circulation of a heated gas, such as air, through the mat in said zone, and the mat is also subjected to heat treatment in a localized area lying within said zone by passage of a second heated gas through the mat, the second heated gas having a pressure higher than that in the surrounding portions of said zone.

Abstract: Perlite board made from expanded perlite and a binder having the property of permanent tackiness in the dry state. The board may be made by expanding the perlite, adding a tacky resin emulsion to the perlite, drying the mixture and forming it into a board-like product.

Abstract: An unpatterned (grooveless) porous tire tread and a pneumatic tire incorporating the porous tread, together with methods of manufacturing the tire tread as a separate item and as an integral part of the tire are described. The tire tread has numerous randomly orientated and randomly distributed interconnected passages extending from the surface substantially throughout the tread. These passages provide water drainage paths preventing build-up of water between the tire tread and a wet road.The tire tread is preferably manufactured by bonding particulated elastomeric material with a binder mixture that forms a polymer upon curing. Whether formed separately or integrally with a tire, the tread mould is unpatterned.

Abstract: A thermally-insulating, non-flammable, air-permeable insulation for installation in the field, for example, in closed cavities between the walls of a house. A multitude of individually preformed, foamed plastic particles are initially entrained in a carrier stream, and thereupon drenched with a settable film-forming, non-flammable, liquid substance, such as a sodium silicate solution. The liquid substance sets to form a film which covers and adheres the particles to one another to form a thermally-insulating dense structural aggregate mass having structural integrity, resistance to fire, and venting capability. A method of making and installing the insulation, and a preferred apparatus therefor, are disclosed.

Abstract: Disclosed is a method of producing composite piezoelectric materials exhibiting a high flexibility and a high piezoelectric effect, comprising the steps of treating an inorganic dielectric material powder with a latex-containing dispersion so as to coat the surfaces of the powder particles with the rubber particles in a manner to provide encapsulated powder particles, kneading the encapsulated powder particles, shaping the kneaded mass, and polarizing the shaped mass.

Abstract: A method of encapsulating electrical apparatus in a particulate filler material which is cohesively bonded together by a binder material which forms beads around the points of contact between contiguous particles. The filler material includes uncoated and dry, resin-coated particles, with the dry resin being redistributed after the particles of filler are in position about the electrical apparatus by the step of liquifying the resin coating with a liquid solvent, to form beads around the points of contact between contiguous particles.

Abstract: The present invention relates to a method for manufacturing an insulating element, floor element, etc., consisting of bark pieces joined together by a glue material. The bark pieces, which have a piece size of preferably 8-30 mm.sup.3, are coated with a thin layer of the glue material and, after moulding and during pressing to desired element dimension, are heated and fixed by high-frequency energy fed into the element.

Abstract: An exact replica of a tool for deep drawing, moulding, extruding and the like is manufactured by a method according to the present invention by thermally spraying the wearing surface of the tool to be produced onto a negative replica of the tool to be produced, said last replica being constituted of an easily fusible metal with a lower melting point than the plastic material used for backing up (1) the easily fusible negative replica and (2) the thermally sprayed wearing surface of the tool. According to the method of the invention the wearing surface of the tool can be constituted of steel, carbide or oxide.

Abstract: A method of reclaiming thermoplastic material from municipal waste wherein the thermoplastic material is separated from the municipal waste and is decimated into fragments which are of a size to pass through a screen of a predetermined mesh, for example a mesh with one-half inch openings. Similarly, fallen leaves are kept segregated from other municipal waste and are shredded or similarly decimated so that they may pass through a screen having a predetermined mesh, for example of a mesh comparable to that through which the plastic must pass. The fragments of thermoplastic material and the leaf fragments are blended so as to be thoroughly intermixed, subjected to sufficient heat and pressure so that the thermoplastic material may coat and bond to the surfaces of the leaf fragments and form a unitary mass of leaf fragments and plastic material. The consolidated mass of leaves bonded by the thermoplastic material is then permitted to set and cure so as to be formed into any desired shape.

Abstract: A process of manufacturing molded parts using a mold with relatively movable parts enclosing a mold cavity which is fed with plasticizable material, comprises directing grains of the plasticizable material into a vertically elongated vestibule having a lower end connected to the feed of the mold cavity and directing hot gases into the lower end of the vestibule and upwardly through the plasticizable material therein to make the material weldable and, thereafter, directing the weldable material into the cavity under pressure. The device for carrying out the process includes a feed conduit which is connected into the cavity which is disposed below a vertically elongated vestibule which has a closed top and a bottom opening into the conduit.

Abstract: A novel battery separator for a flat-pack or planar battery is disclosed wherein a nonwoven fabric is disposed on and across a plastic frame or grid, the outer edges of the fabric being disposed on said plastic frame are of extremely low fiber density and being oriented predominantly in a direction normal to each side of the frames so as to facilitate the more complete thermal pressurized bonding of a stack of separators and similarly electrodes by a sealing of the outer edges of the respective plastic frames. A more complete seal is thus formed insuring against the leaking or escaping of the liquid electrolyte contained therein.

Abstract: The present invention relates to a method of producing a mouldable material having a high content of a crystallizable glass made in a rotary kiln in a highly bubble-containing form, and grinding the glass in a ball mill.

Abstract: The process for making a surface covering having an embossed wear surface, including embossed design portions which differ in elevation and shading, by depositing a liquid resinous base coating onto a backing, depositing a layer of resinous dryblend onto the liquid resinous coating while it is still wet, heating to sinter the dryblend and at least partially set the base coating, producing a design on the sintered layer by appling settable resinous ink to at least a portion thereof in sufficient amounts and viscosity to permit penetration of the ink into the dryblend layer to a depth of about 10 mils (0.254 mm) at the points of application, at least a portion of the design being formed by applying the ink in minute separate but closely spaced deposits, and heating the composite structure for final fusion to form a non-porous sheet wherein the design areas containing the closely spaced ink deposits may differ in shading and elevation in their ink-containing and non-ink-containing portions.

Abstract: In a process for the production of fibre filters, the fibre material is sprayed electrostatically from the liquid state and deposited as a fibre fleece on a conductive support. The starting materials used are solutions of high polymers in readily volatile solvents. The filters obtained have substantially improved properties.

Abstract: An improved process for preparing compacts of finely divided fluorspar for metallurgical use is provided in which water, hydrated lime and molasses are added in specified ratios to fluorspar in a heated mixing vessel. The water facilitates the formation of a lime-molasses coating on the fluorspar particles and impedes reaction of the lime and molasses. The water also provides evaporative cooling of the mixture, subsequent to the mixing operation, causing the molasses to become much more viscous and, resultingly, the mixture to be much less tacky so that it can be efficiently compacted immediately. Following compaction in a compacting machine the compacts are heated in an oven to force the lime and molasses reaction to completion providing a water insoluble binder for the fluorspar particles.

Abstract: Novel polymer compositions which can be extruded to prepare films of good quality are obtained when 20 to 150 parts by weight of a petroleum wax are blended with 100 parts by weight of an ethylene polymer having an annealed density of at least 0.95 and an intrinsic viscosity of at least about 3.0.

Abstract: Rigid shaped articles are formed by providing a novel thermosetting phenol-formaldehyde resin having a characteristic structure and infra-red spectrum as a coating over the surfaces of a plurality of individual elements, forming the coated elements into a shape and thermosetting the resin of the coating.

Abstract: An electrolyte compact for fuel cells includes a particulate support material of lithium aluminate that contains a mixture of alkali metal compounds, such as carbonates or hydroxides, as the active electrolyte material. The porous lithium aluminate support structure is formed by mixing alumina particles with a solution of lithium hydroxide and another alkali metal hydroxide, evaporating the solvent from the solution and heating to a temperature sufficient to react the lithium hydroxide with alumina to form lithium aluminate. Carbonates are formed by reacting the alkali metal hydroxides with carbon dioxide gas in an exothermic reaction which may proceed simultaneously with the formation with the lithium aluminate. The mixture of lithium aluminate and alkali metal in an electrolyte active material is pressed or otherwise processed to form the electrolyte structure for assembly into a fuel cell.

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: The disclosure is of a method of making air filter fabrics from non-woven, thermoplastic, synthetic polymeric resin, staple textile fibers and of the fabrics so made. The method comprises providing a non-woven web of the fibers, coating the fibers with a fiber stabilizing agent, pressing the fibers together so as to rupture the film at cross-over points and fusing the fibers together at the sites of the ruptured film. The product filter fabrics are characterized by controlled high permeability, strength, wear resistance, dimensional stability, lint free surfaces and advantageous particle release properties.

Abstract: A thermally segmentally bonded non-woven fabric having an attractive pattern of irregular bonds and a process for preparing it using heated patterned calender rolls having thereon surface patterns of lands with depressions between, one consisting of continuous lands and the other of isolated projections arranged in a particular way so that lands which oppose each other in the nip overlap to different extents.

Abstract: A process is disclosed for the preparation of liquid, storage-stable, polyisocyanate compositions containing a release agent formed in situ which compositions are useful, for example, as binder resins in the formation of particle boards which latter, because of the presence of the release agent, show no tendency to adhere to the face of metal platens used in their formation. The process comprises heating an organic polyisocyanate (polymethylene polyphenyl polyisocyanate preferred) with an acid phosphate (e.g. a mixture of mono- and di-alkyl acid phosphates) under conditions controlled as to time and temperature so as to yield a product which is storage stable and shows no tendency to deposit solid or to separate into two liquid phases.