Abstract: Polycrystalline grits and methods of making grits which allow for a high degree of shape and size distribution control, as well as improved abrasive performance are described and disclosed. In one aspect, an abrasive slurry can be formed into a plurality of abrasive precursors arranged on a substrate using screen-printing or other techniques. The abrasive slurry can include a binder and a plurality of abrasive particles. The abrasive precursors on the substrate can then be covered with a pressure medium and then subjected to pressure and temperature conditions sufficient to cause sintering of the abrasive particles to form polycrystalline grits. The polycrystalline grits produced by such methods can have a substantially uniform shape and size distribution.

Abstract: A process of manufacturing a non-woven web from virtually endless composite filaments. The filaments used in the process are arranged in a sheath-core arrangement in which the sheath component comprise a thermoplastic polymer and the core component is selected from the group of an elastomer, a water-soluble polymer or a biodegradable polymer. The sheath component constitutes at least 20 percent by weight of the filament and that the core component constitutes at least 10 percent by weight of the filament. The process according to the invention provides a simple and inexpensive process for manufacturing water soluble or elastic non-woven webs of any width, using virtually endless filaments.

Abstract: This invention relates to a process of a lightweight, heat insulating, high compressive strength, water insoluble material by heat treatment at temperatures between 650-950° C., possessing a low bulk density (from 300 to 800 kg/m3) and improved heat insulating capacity (?=0.07 to 0.25 W/m·deg.) when it has been used to form an article having a compressive strength of from 0.49 to 5.59 Mpa. The starting chemical composition comprising more than 90% by weight of either perlite, pumice or pumice related group of materials or mixture of them and an additive in quantities less than 10% by weight containing Na2O and B2O3.

Abstract: A method for manufacturing a ceramic heater includes mixing a conductive ceramic powder, an insulating ceramic powder, a sintering aid powder, and a solvent so as to obtain a slurry, drying the slurry so as to obtain a heating-element material powder, forming a green resistance-heating element from the heating-element material powder, embedding the green resistance-heating element in a ceramic substrate, and firing a resultant assembly. Water is used as the solvent. Drying of the slurry is performed by use of a fluidized-bed drying apparatus, a rotary drying apparatus, or a vibratory drying apparatus and, the apparatus being employed in combination with a medium for pulverization.

Abstract: A process for transforming pre-used asphaltic roofing shingles into products such as paving bricks, by removing foreign matter, using a comminutor that pulls shingles downwardly through a plurality of pairs of high-speed, counter-rotating, inter-meshing blades stacked within a housing; classifying the particles, applying a release agent to the inside of the mold, charging the mold with a predetermined weight and size distribution of particles, compressing the material in the mold at high pressure, and ejecting the formed material from the mold for delivery to customers. The brick and other products are included in the scope of the application.

Abstract: Disclosed are methods and systems for selective inhibition of sintering in 3D fabrication. The disclosure provides methods and systems that use selective heating arrangements to selectively sinter areas during fabrication thereby reducing waste improving efficiency.

Abstract: Foam sheets are continuously produced by metering foam particles, which are free of any added binder or adhesive, from a storage location onto a moving conveyor at a controlled volumetric rate so as to continuously form a layer of the particles on the conveyor, heating the layer of particles to a temperature sufficient to render the particles tacky such that the particles adhere to one another so as to form a substantially integral sheet, compressing the sheet with a compression device that applies pressure on the advancing sheet so as to compress the sheet to a smaller thickness and enhance the integrity of the sheet; and cooling the compressed sheet.

Abstract: Process for layer-wise production of a three dimensional body (generative rapid prototyping), in particular by 3D binder printer, including a multiple succession of the steps of depositing a powder particle layer, activating in defined areas an adhesive present on the powder particles and/or in the powder particle coating, as well as adhering the powder particles to each other and to the layer thereunder, wherein the powder particle layer is electrically discharged by ionized particles and brushed flat by means of an electrically insulated blade prior to activation of the adhesive material, and the invention further concerns a device adapted for application of thin powder particle layers, including at least one ionizing device.

Abstract: An auxetic material, which has a negative Poisson ratio so that it has the property of expanding or contracting transversely to a direction in which it is extended or compressed, is made in filamentary or fibrous form. A suitable process involves cohering and extruding heated polymer powder so that the cohesion and extrusion is effected with spinning to produce auxetic filaments. Typically the powder is heated to a temperature sufficient to allow some degree of surface melting yet not high enough to enable bulk melting.

Abstract: A platen press for pressing loose wood-based material into structural panels at high temperature while exhausting steam generated in the process through vents distributed across the face of a platen to thereby produce an improved product. The vents are periodically cleaned to remove elements of the panel material that have been deposited into the vents with steam flow or mechanical pressure by pins carried within the platen. The pins are positively extended into respective vents by actuating elements housed within the thickness of the body of the platen.

Abstract: A negative impression of an anatomical portion of a person is captured by forcing the anatomical portion into impression foam to collapse the impression foam into the negative impression. The impression foam has a crush characteristic of approximately constant resistance force over a relatively wide predetermined range of collapse distances. The negative impression is obtained by collapsing the impression foam within the range of constant-force collapse distances, thereby creating the negative impression under conditions which reflect an equally-loaded anatomical portion. A cushion support contour created from the equally-loaded negative impression is beneficial in more appropriately supporting the anatomical portion. The present invention is particularly useful in fabricating wheelchair seat cushions.

Abstract: An improved cutting tool insert and a method for the preparation of such cutting tool insert, having a sintered alumina and silicon carbide whisker composite material body, comprising the steps of milling and mixing the powdered starting materials of said composite material and forming said material into a preformed workpiece, heating up said workpiece at a heating rate of from about 20 to about 60° C. per minute to a sintering temperature of between from about 1600 to about 2300° C., and holding at said sintering temperature for a holding time of from about 5 to about 60 minutes at a pressure of between from about 20 to about 100 MPa.

Abstract: A process for making engineered lignocellulosic-based panels with superior strength and dimensional stability. The process comprising adding to green lignocellulosic particles a low-nitrogen content, high molecular weight, phenol-formaldehyde resin before the green particles are dried. The resin is added in an amount from about 1 to 25 weight percent based on the dry weight of the green lignocellulosic particles. The resin has a nitrogen content of from about 0 to 3%, a viscosity of from about 20 to 2000 cps at 20° C., and a molar ratio of formaldehyde/phenol of from about 1.2 to 3.0. The green lignocellulosic particles treated with the resin are dried until the particles have a moisture content of from 1 to 8%. A second resin is added to the dried particles and then the dried particles are consolidated under heat and pressure to form the engineered panel.

Abstract: The present invention relates to golf ball components and golf balls comprising high levels of pre-vulcanized or pre-crosslinked materials, as well as methods of making same. The pre-vulcanized or pre-crosslinked materials are typically thermoset materials that are fragmented or ground into a powder, exposed to high pressure, high temperature sintering (“HPHTS”) and molded into the desired shape.

Abstract: A mixture of particulate silicone based material and small hollow elements, such as spheres and/or fibers, is provided. The particulate silicone based material is heated to a temperature between about 200° F. and about 400° F. The particulate silicone based material is cooled until a solid body is formed. The solid body is resistant to melting and thermal decomposition when heated to temperatures of at least 3000° F. The solid body may contain cavities formed by the small hollow elements. The solid body may contain reinforcing fibers. The solid body may contain both small hollow elements and fibers.

Abstract: The present invention relates to a device and a method for monitoring each of the propagated light beams that are propagated in each waveguide of an arrayed waveguide device and a method of fabricating the device. In the prior art, problems were encountered in deriving monitor light and photodetecting the derived monitor light within the waveguide substrate. In the present invention, waveguide directional couplers are formed in the spaces between the arrayed waveguides to derive a portion of the propagated light as monitor light. Cavities are provided at the ends of auxiliary waveguides connected to the directional couplers, and monitor light is guideded into these cavities. The monitor light, after being reflected upward or downward of the substrate by optical path conversion elements installed inside the cavities, is photodetected by photodiodes. The optical path conversion elements can be fabricated by inserting metal bumps into the cavities and then forming the bumps with a mold.

Abstract: Used and manufacturing scrap asphalt shingle material processed into a fine material comprising smaller sized pieces of shingle material with a relatively high aggregate content is finish processed into shaped products by grinding and heating the aggregate and smaller sized pieces of asphalt shingle material into a homogenous mixture, extruding the homogenous mixture, and forming the shaped products via molding or cutting the extruded mixture. A surface treatment material may be embedded into a softened surface of the shaped products.

Abstract: Densified composites of silicon nitride and silicon carbide that exhibit high creep resistance are obtained by mechanically activating a mixture of amorphous powders of silicon nitride and silicon carbide and sintering the mechanically activated mixture in the presence of an electric field under high pressure. The grain size in the resulting composite is less than 100 nanometers for all components of the composite, and the composite exhibits high creep resistance.

Abstract: Novel release agents comprising a carboxylic acid comprising at least six carbon atoms and at least one free carboxylic acid group and a polysiloxane comprising at least one organically bound active hydrogen group, which release agents are particularly suited for use in forming lignocellulosic composites prepared using an isocyanate adhesive. Processes for the use of such release agents in the synthesis of lignocellulosic composites prepared using isocyanate adhesives.

Abstract: The present invention relates to an effective and rapid method and apparatus for sintering carbon filter blocks having a polymeric binder. The method employs direct contact heat transfer by gas molecule to powder particle, as opposed to conduction heat transfer from an external heating source, using commercially available sintered porous metal sheets and cylinders to form the mold and confine the powder, while allowing heated gas to pass uniformly through the mixture.

Abstract: Process for producing hollow bodies comprising fiber-reinforced ceramic materials, where mold cores whose shape corresponds to that of the hollow spaces are produced in a first step, at least one mold core together with a press moulding composition or formable fiber composition are introduced into a mold, where the press moulding composition comprises carbon fibers and/or carbon filaments and thermally curable carbonizable binders, in such a way that the position of the cores corresponds to the desired position of the hollow spaces to be formed in a second step, the composition is cured in a third step by heating to a temperature of from 120° C. to 280° C., to give a green body, the strengthened green body is carbonized and or graphitized in a fourth step by heating in a nonoxidizing atmosphere to a temperature of from about 750° C. to about 2400° C.

Abstract: Process for producing shaped bodies comprising fiber-reinforced ceramic materials, where a green body is produced in a first step by introducing a press moulding composition into a mold, where the press moulding composition comprises carbon fibers and/or carbon filaments and pitch and/or resins which, when treated thermally and with the exclusion of oxidizing agents, form carbon-containing residues, the green body is cured in a second step by heating to a temperature of from 120° C. to 280° C. under pressure, the cured green body, also referred to as intermediate body, is carbonized in a third step by heating in a nonoxidizing atmosphere to a temperature of from about 750° C. to about 1100° C.

Abstract: A method for adhering a friction material for a lockup clutch, with which a friction material is adhered to a flat surface of a core plate, comprises a disposing step of disposing the friction material between a heated member and the flat surface of the core plate, a pressing/heating step of bringing the heated member into contact with the core plate and applying load to the core plate by a plurality of pins from a back side opposite to the flat surface of the core plate, and a step of maintaining a state under the above-mentioned pressing/heating step for a predetermined time.

Abstract: The invention relates to a method for the manufacture of chipboard comprising a centre layer (18) of coarse chips and outer layers (20) of chips whose fibers are oriented in the plane of the board. In order to be able to reduce the density of the finished board while retaining the intrinsic characteristic profile of the board, it is proposed in accordance with the invention that the chips used to compose the centre layer (18) will comprise end-grain cut, flake-like chips (22) whose fibers are oriented in the thickness direction (24) of the chips, the chip fibers in the centre layer being oriented substantially transversely to the plane of the chipboard. The invention also relates to chipboard manufactured in accordance with the method.

Abstract: Channeled articles having very small diameter channels spaced very closely can be made by packing elongated cores in a fixture, clamping them, and then introducing matrix material around the cores. The matrix material is formed into a unitary body and solidified. The cores are pulled out, leaving open channels where they had been. Some core and matrix combinations will permit the cores to be pulled out. Others require a core release coating to be applied to the cores. The cores can be metal or ceramic or polymer, and the matrix can be metal or ceramic or polymer. The cores can be solid, or hollow. Rather than pulling the cores out, if they are polymer, they can be burned out. The matrix can be formed by liquid state, solid state, or hybrid liquid/solid state techniques. A related technique uses hollow cores, which are not pulled out, but which remain in the body after unification. For such tube-walled articles, the matrix can be formed similarly. Rather than insuring core release, core retention is required.

Abstract: A backing or an intermediate layer for a surface covering is described which comprises a fused recycled material, wherein the material comprises a thermoplastic material, for instance, a vinyl material from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both. Surface coverings containing the backing or intermediate layer of the present invention are also described as well as methods of making the backing or intermediate layer and methods of making the surface coverings containing the backing or intermediate layer of the present invention.

Abstract: A method for making a dry plating built-up film comprises providing silicon carbide as a starting source and subjecting to dry plating while changing a concentration of a reactive gas continuously or intermittently to deposit and form, on a substrate, a thin film having different refractive indices along its thickness. A method for making a sputter built-up film is also described, which comprising providing silicon carbide as a target and subjecting to sputtering while changing making electric power against the target continuously or intermittently to deposit and form a thin film having different refractive indices along its thickness.

Abstract: An auxetic polymeric material is manufactured in a filamentary or fibrous form. The auxetic polymeric material has a negative Poisson ratio so that it has the property of expanding or contracting transversely to a direction in which it is extended or compressed. The process for forming the material involves cohering and extruding heated polymer powder so that the cohesion and extrusion is effected with spinning to produce auxetic filaments. Typically, the power is heated to a temperature sufficient to allow some degree of surface melting yet not high enough to enable bulk melting.

Abstract: A process for producing a honeycomb structure, which comprises adding water to a mixed raw material of a raw material powder and a binder, kneading the mixture to obtain a plastic mixture, molding the plastic mixture into a honeycomb shape to obtain a green honeycomb structure, drying the structure by a step including hot-air drying, and firing the resulting dried honeycomb structure, wherein the binder contains hydroxypropyl methyl cellulose as a major component. The process can produce a crack-free high-quality honeycomb structure rapidly at a low cost.

Abstract: An improved sintered porous thermoplastic filter incorporating a second thermoplastic treated with a non-leaching antimicrobial agent for the purification of liquids. The method of making the filter is also disclosed.

Abstract: A plant (10) for the production of highly flexible and relatively thin sheets or panels (38) of agglomerate material comprising: a mixer crusher (12), a hopper (15) designed to accept the crushed and rolled material (24) and to transfer it to a distributor or spreader (16) positioned below the hopper, said spreader (16) comprising a substantially cylindrical container (30) with a loading opening (31), adjacent, in use, to said hopper (15) and comprising a discharge slot (32) on the opposite side to said opening (31), and a mixing device of the agglomerate material (24) inside said container (30). The mixing device comprises a pair of blades (35) fixed to a shaft (34) rotating around an axis not corresponding to that of said container (30) and in particular offset towards said slot (32), so that during their rotation the blades almost skim said slot.

Abstract: A method for making an article by cold compaction molding. The method comprises compacting a resin composition comprising high molecular weight and ultra high molecular weight polyethylene (HMW-PE and UHMW-PE, respectively) homopolymer, copolymer, and/or blend and an inorganic acid scavenger at a temperature below the softening temperature of the composition. An article prepared in accordance with the claimed method shows lower corrosion test data compared to articles prepared from virgin HMW-PE and UHMW-PE, and an improved cold compaction strength compared to articles prepared using resins containing metal soaps.

Abstract: The present invention relates to an oxide sintered body having a perovskite structure represented with a chemical formula of MRuO3 (M: one or more types among Ca, Sr, Ba), characterized in that the total content of alkali metals such as Na, K, and Fe, Ni, Co, Cr, Cu, Al is 100 ppm or less, the content of respective elements U, Th is 10 ppb or less, and the relative density is 90% or more, and provides an oxide sintered body and the manufacturing method thereof having a pervoskite structure represented with the chemical formula MRuO3 (M: one or more types among Ca, Sr, Ba) by using a MRuO3 sintered body raw material refined to a high density of 4N or more, which enables sintering at low temperatures, and which is capable of obtaining a high-density sintered body.

Abstract: The aim of the invention is to provide filtering candles (1) comprising a sintered filtering tube (2) and a collar (3) which is connected thereto, and having an increased shelf life and improved resistance values. To this end, the collar (3) comprises an annular collar wall (4) which oriented towards the filtering tube (2) from the neck. Said wall comprises at least one recess (8) which is arranged in a perpendicular manner and at an angle in relation to a plane which is perpendicular to the axis of the filtering tube.

Abstract: A description is given of a filling level measuring device operating with microwaves, having a housing and an insert composed of a dielectric, and of a process for producing the dielectric, in which the dielectric constant of the insert is adjustable and in which the insert has a high chemical resistance and a mechanical strength adequate for industrial applications. The dielectric is a composite material composed of a fluoroplastic, in particular polytetrafluoroethylene, and ceramic and is produced by mixing powdered ceramic and powdered fluoroplastic, drying the mixture, pressing the mixture and sintering the pressed mixture.

Abstract: The present invention relates to a process for the production of a braking band for a brake disk with venting passages and to a braking band which can be produced by the process. The process comprises the following steps: molding a core (200) of the braking band in a suitable mold (1), molding two covers (8) onto the core in a further suitable mold (101) so as to form a semi-finished product having a “sandwich” structure, firing the semi-finished product so as to produce a predetermined porosity of the covers, firing the semi-finished product further, in the presence of silicon, at a temperature such as substantially to bring about fusion of the silicon and its infiltration into the covers.

Abstract: A method of making a low friction bearing for use when immersed in a liquid particularly water is provided comprising a synthetic resin composition which includes powders of a rice bran ceramic, carbon rice bran ceramic or both which are uniformly dispersed in a synthetic resin. The weight ratio between the RBC or CRBC powders and the synthetic resin is 30:90 to 70:10.

Abstract: A method of producing a fuel cell separator in which dry granules of a composition for a fuel cell separator mainly containing a conductive material, a binder, and an additive are produced by mixing raw materials including at least the conductive material, the binder, and the additive, granulating the resultant mixture to obtain granules, and drying the granules. The dry granules may be further sized. Then the granules are packed in a mold and hot-press molded. The granules have a residual volatile matter content in a range of 4 weight-% or less, and an average particle size in a range of 200 to 700 &mgr;m (60 to 160 &mgr;m for the sized granules) and a specific particle size distribution.

Abstract: A metal injection-molding feedstock is heated and plasticized. Supercritical carbon dioxide is injected into the feedstock to form micropores when the pressure is reduced and a parts mold is filled. The micropores are retained when the green parts are debindered and sintered.

Abstract: The invention relates to a method for producing a monolithic, porous, ceramic shaped body and to the shaped bodies produced according to this method. Said shaped body is used predominantly as a support material for porous, inorganic and/or organic membranes for the flow filtration of liquids and gases. The aim of the invention is to provide a method for producing a shaped body consisting substantially of TiO2 with an open porosity >10%, an average pore size of between 1 and 50 &mgr;m and a mechanical stability >20 N/mm2. To achieve this, a first TiO2-powder fraction is pre-sintered at temperatures >1200° C.

Abstract: In a method of manufacturing a friction member used for a vibration wave driving apparatus including a vibration member, a contact member which is brought into frictional contact with the vibration member and relatively moved by vibrations produced in the vibration member, and the friction member formed on one of friction portions of the vibration member and contact member, a molded member is formed by compression molding of a plastic powder and an additive, a sintered member is formed by sintering the molded member, a sheet is formed by cutting the sintered member in the form of a sheet, and a modified layer formed by cutting is removed from the friction surface of the sheet.

Abstract: A solid compacted pellet of organic material for use in a vapor deposition source, and a method of making same is disclosed. The solid compacted pellet includes: a support member for permitting rotation of the pellet, or transmitting cooling fluid, or both; and a compacted solid core of organic material molded onto and about the support member.

Abstract: There is provided composite media and a method of producing them. The composite media contain a coalesced composite mixture of particles of an active ingredient, binder particles, and stabilizing particles. The stabilizing particles fuse the composite structure to both front and back substrates while the binder particles fuse the particles of active ingredient to each other and to one of the front and back substrates.

Abstract: A laminate composite material comprises a layer of an open weave supporting fabric having a layer of breathable resin adhered thereto by an extruded layer of a thermoplastic resin blended with a high temperature volatile particulate. The resultant composite material is substantially impervious to air and water and permeable to water vapor and having a water vapor transmission rate exceeding one (1) perm of water vapor.

Abstract: A mixture of carbon-containing fibers, such as mesophase or isotropic pitch fibers, and a suitable matrix material, such as a milled pitch, is compressed while resistively heating the mixture to form a carbonized composite material having a density of about 1.5 g/cm3, or higher. The composite material is formed in under ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. Consequently, carbon/carbon composite materials having final densities of about 1.6-1.8 g/cm3, or higher are readily achieved with one or two infiltration cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking.

Abstract: A method to produce an electrically conductive floor covering made of first particles of a polymer material which are surrounded with electrically conductive second particles and compressed in the intermediate space between the top and bottom sides of the floor covering, with the floor covering having at least one cut surface and the electrically conductive second particles forming conductive paths which connect the upper side and the lower side of the floor covering in an electrically conductive way, in which the first particles comprise at least one granulated elastomer material and form a matrix, in which the second particles form electric conductive paths along the particle boundaries of the first particles.

Abstract: A device for manufacturing a three-dimensional product, which device comprises a work table on which said three-dimensional product is to be built, a powder dispenser which is arranged to lay down a thin layer of powder on the work table for the formation of a powder bed, a ray gun for giving off energy to the powder whereby fusion of the powder takes place, members for controlling of the beam released by the ray gun across said powder bed for the formation of a cross section of said three-dimensional product through fusion of parts of said powder bed, and a controlling computer in which information about successive cross sections of the three-dimensional product is stored, which cross sections build the three-dimensional product, the controlling computer intended to control said members for guiding the ray gun across the powder bed according to a running schedule forming a cross section of said three-dimensional body, whereby said three-dimensional product is formed by successive fusion of successively forme

Abstract: A bed of particulate solids including some hydrated materials can be converted by controlled irradiation with subinfrared electromagnetic radiation into a unitary porous solid that is mechanically strong enough for easy handling. When the particulate solids include typical mildly acid to alkaline cleaner materials, a block or tablet especially suitable for automatic cleaning machinery, with a very fast dissolution rate in water, can readily be obtained.

Abstract: A method of making heat engine components, such as rocket nozzle throats, includes forming a body having at least one surface, wherein the body is made of a refractory metal, and compressing a ceramic powder between a die and the at least one surface of the body, with sufficient heat and pressure to densify and thus form a solid ceramic coating on the at least one surface of the body. Nozzle throats made according to the invention have bodies made of refractory metals, such as tantalum, and ceramic coatings on the inner surfaces of the annular bodies, wherein the ceramic coatings are made of ceramic materials such as tantalum carbide.

Abstract: A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 ?m, provided further that the number average ratio of particles smaller than 53 ?m is greater than 80%, the remaining larger particles being in the size range from 53 ?m to 180 ?m. A powder with slow recrystallization rates, as evidenced by non-overlapping or slightly overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10° C. to 20° C.