Abstract: The invention discloses a vehicle tire with reduced rolling noise emission. The tire tread is provided with one or more air-permeable channels or pores (6), which serve to neutralize air pressure differences between different parts of the tread surface in road contact, for example on each side of a tread block in a tread pattern. The invention also discloses how these channels or pores can be created by piecewise vulcanization of rubber or plastic balls or otherwise shaped rubber or plastic bodies of which the tread is built up so that communicating channels or pores remain between such bodies.

Abstract: This invention provides composite material compositions comprising wastepaper, a thermoplastic resin and/or other additive(s), said compositions having higher heat resistance, flame retardancy and mechanical strength and smaller linear shrinkage in molding than the conventional compositions of synthetic resins alone or blended with woodmeal or an inorganic filler. There is also provided a method of producing said compositions comprising a wastepaper crushing step, a step of mixing crushed wastepaper with a thermoplastic resin and/or other additive(s) while drying said wastepaper, a blend melting step, a blend kneading step and a blend granulating step. In an embodiment of this invention, scraps of moldings from the composite material compositions using wastepaper may be mixed with wastepaper, a thermoplastic resin and/or other additive(s) and similarly treated and molded into a new composition.

Abstract: Disclosed is a method and apparatus for making stress free plastic articles from plastic particles such as powder utilizing heat and pressure in which a quantity of plastic particles is supplied to a first member, a flexible diaphragm is disposed in opposed relationship to said first member with said plastic particles therebetween, a microporous air release means is positioned between said plastic particles and said flexible diaphragm, a fluid-like pressure is applied to said diaphragm to cause said diaphragm to apply an even fluid-like pressure through said air release means to said plastic particles, heat is applied to said plastic particles while under said fluid-like pressure and any entrapped gases between the particles is vented by means of the air release means. The pressure and heat are controlled to effect a consolidation of the plastic particles into the article.

Abstract: An electrical component which includes a circuit element such as a solid electrolytic capacitor arranged within a metallic casing or can. One electrical lead of the component is connected to the casing; the other lead is connected to the circuit element and extends through an opening in the casing. This opening is filled with a first plastic material to seal the circuit element within the casing against environmental conditions. A conformable coating of a second plastic material is disposed over the outer surface of the casing and extends over the edges of the casing into the opening so as to join with the first plastic material disposed in the opening.

Abstract: In a process for producing a fused fabric a fluid is passed in contact with the surface of a fabric on the surface opposite that exposed to sufficient infrared radiation to fuse at least a portion of the synthetic thermoplastic fibers which comprise at least a portion of the fabric.

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

Abstract: A panel of a plurality of electrically connected photocells wherein each photocell has a lower face, a side face and a radiation receiving face, is produced by (a) embedding at least the lower faces and side faces of the photocells and their electrical connectors in a thermoplastic resin in particulate form which resin becomes transparent upon fusion; (b) enclosing the photocells embedded in step (a) between two rigid sheets to form a sandwich-type assembly, with at least the rigid sheet enclosing the receiving faces of the photocells being optically transparent; (c) disposing the stacked assembly formed in step (b) within a flexible bag; (d) subjecting the interior of the flexible bag to a vacuum while applying relatively high pressure to the outside of the bag, and raising the temperature within the bag to fuse the thermoplastic resin particles; and (e) cooling the contents of the bag to solidify the resin and form thereby the panel comprising the photocells adhesively embedded in the solidified resin betwe

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

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

Abstract: A method of forming, in two steps, panel, or shaped article, by first providing a bath of fluent cementitious material under a core of cellular, preexpanded and cohered polystyrene cells or pearls, having a density less than that of the cementitious material, allowing the core partially immersed to rise in a controlled way over the cementitious material, maintaining the core under pressure until the bath has partially set to prevent further rise of the core, pouring onto the core and partially set bath, a second quantity of fluent cementitious material to completely enrobe the core and form thereover a top revetment, smoothing the surface of the second quantity of cementitious material and letting it set to complete the panel.

Abstract: A non-water dispersible water-softening bead is disclosed having from 80 to 90% sodium alumino silicate and from 10 to 20% low density polyethylene. The bead has a diameter of between 200 and 1000 microns and a calcium capacity of at least 200 mg calcium carbonate/g. The sodium alumino silicate has a silica to aluminum oxide molar ratio of between 2:1 and 4:1 and a sodium oxide to aluminum oxide molar ratio of between 0.8:1 and 1.2:1.

Abstract: According to the invention, there is provided a highly hydrophilic and porous sintered body having open-cellular pores and including a polypyridine ring structure represented by the following formula of: ##STR1## (wherein n is an integer.) which is obtained by sintering a pulverized copolymer made from acrylonitrile, a conjugated diene monomer and an .alpha.,.beta.-unsaturated olefinic carboxylic ester represented by the following formula of: ##STR2## (wherein R.sub.1 is hydrogen, a lower alkyl group having 1 to 4 carbon atoms or a halogen; and R.sub.2 is an alkyl group having 1 to 6 carbon atoms.

Abstract: A process for the preparation of extrudable polyimide granules comprising heating and compacting a powder containing polyimide particles to form a partially densified porous mass and crushing the mass to form granules which may be ram extruded to give uniform articles of high strength.

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

Abstract: A reconstituted leather and method of manufacture wherein leather is pulverized to form a fine powder which is then treated to polarize the particles and cause them to form groups or aggregates. The aggregates are then intermixed with a resinous binder to form said reconstituted leather which is then buffed to expose the natural leather and produce a structure closely resembling natural leather in feel, odor and appearance.

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

Abstract: A plastic ornament and a method of making the ornament. Plastic pellets are placed in the holes of a mesh according to a predetermined pattern, each hole being sized to accommodate a single pellet. The pellets and mesh are heated until the pellets begin to fuse together. The mesh is then separated from the fused pellets. The fused pellets may be heated further until the plastic ornament achieves the desired smoothness.

Abstract: A method of accelerating the cooling of articles made from polymeric particles, such as thermoplastic particles, in which compacted particles are subjected to a heat effect so that selected regions thereof are preferentially heated and the remaining regions thereof remain substantially unheated to produce a heterogeneous temperature distribution within the particles. When the heating effect is removed the preferentially heated regions cool in a rapid fashion by heat transfer therefrom to the unheated regions thereof.

Abstract: In an apparatus for the ram-extrusion of non-melt fabricable polymeric resin comprising means for forcing the resin through a forming die from an extrusion chamber, the improvement wherein the ram head comprises at least about 10 percent fluoropolymer.

Abstract: Improvements in molded articles from sinterable particulate solids, improvements in method for making such articles, and novel sacrificial binders for use in making such articles are disclosed. The sacrificial binders used in this invention comprise block polymers having the structural formulaAB--AB--.eta. Awherein ".eta." is 0 or a positive integer, "A" is a linear or branched polymer that is glassy or crystalline at room temperature and has its softening point in the range of about 80.degree. C. to about 250.degree. C. and "B" is a polymer different from A that behaves as an elastomer at processing temperatures, a plasticizer which may be oil, wax, or oil and wax, and optionally other components.

Abstract: A corner is formed in corrugated thermoplastic material or board using ultrasonic vibrations by disposing the corrugated material between an anvil and a half wavelength resonator having a portion of its frontal surface shaped for producing a crease. Contact is provided between the shaped portion of the resonator frontal surface and the material so as to crush the material. The resonator is rendered resonant for causing the material in contact with the resonator frontal surface to soften and flow. After a sufficient period of time, usually a fraction of a second, the frontal surface is withdrawn from contact with the material. When the softened and flowing material solidifies a crease is manifest in the material which then is folded to form a corner.

Abstract: A friction disc for a clutch or brake is formed from a plurality of arcuate segments. The segments are stamped from a rectangular sheet of pregrooved friction material, interconnected by integral tab and slot structures to form an annulus, and bonded to an annular metal member.

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

Abstract: Three dimensional shapes, typically of convex-concave form and having sufficient rigidity to maintain that form are molded from nonwoven, needlepunched fabrics containing certain ethylene-vinyl acetate fibers in admixture with fibers of a higher melting point polymer. Molding is accomplished by heating the fabric to a temperature whereat the ethylene-vinyl acetate fibers soften or melt but below the melting point of the other fibers and thereafter pressing the fabric between the mating faces of a mold pair and allowing the ethylene-vinyl acetate fibers to solidify and cool while in the mold.

Abstract: A melt bonded fabric is produced by blending particular ethylene-vinyl acetate fibers with fibers of higher melting materials, forming a fabric thereof as by needle punching, and thereafter subjecting the fabric to temperatures above the melting point of ethylene-vinyl acetate but below that of the other fibers in the fabric.

Abstract: There is disclosed a method for the imprinting and decorating rotomolded products. The method comprises the application to the interior surfaces of the mold of a viscous suspension of pigment in a preselected pattern. The suspension is applied to the mold surface in an oil carrier using a vegetable, animal or mineral oil that is inert under the molding conditions and that has a sufficient viscosity at the molding conditions to maintain the film on the mold surfaces. The pattern of the pigment suspension is applied by spraying, brushing, screen printing and the like and, after its application, the conventional rotomolding can be practiced. In this method, the powdered plastic, typically high density polyethylene, in powder form is charged to the mold, the mold is closed and placed in an oven heated to from 500.degree. F. to about 800.degree. F.

Abstract: Dry mixed and sintered PVC battery separators having predetermined thicknesses less than 0.012 inch, porosities greater than about 50%, and pores sufficiently small to substantially prevent interplate "treeing" (i.e., less than about 10 microns average) are produced by: mixing about 3% to about 15% by volume of leachable, pore-forming particles with the PVC particles; scraping the particle mix into a layer less than about 0.012 inch thick; sintering the PVC into a continuous strip; compressing the strip in the temperature range of about 250.degree. F.-450.degree. F. to a thickness no greater than about 50% of its as-sintered thickness; thereafter immediately allowing the strip to recover much, but not all, of its as-sintered thickness; and cooling the strip to substantially fix the separator thickness at the recovered thickness. The leachable, pore-forming particles are preferably formed in situ by the thermal degradation of a gasifiable filler such as sodium bicarbonate.

Abstract: The invention relates to a process for improving the processing properties of powdery polyolefins. It is endeavored by this process to obtain a polyolefin powder which can be processed on screw extruders to an almost bubble-free product.The polyolefin powder is heated to a temperature of between 40.degree. C. and its melting point and introduced into a gap between two gap-forming elements. In this gap, the powder is compressed with a pressure of from 0.1 to 10 t per cm of gap length, and the powder so compressed is then comminuted.

Abstract: A unique method for recycling rubber scrap to yield a final product of at least about one inch in thickness characterized by the absence of the use of alkalis, acids or organic solvents in the steps of the process. Finely ground dry rubber scrap is intimately mixed with a cure mix comprising about nine parts, by weight, dry sulfur and not more than about one part, by weight, zinc stearate. The resulting dry cure mix and dry rubber scrap mixture is placed into a mold and cured in a steam autoclave for about 1.25-4 hours at a temperature of about 325.degree. F., preferably, while maintaining a steam pressure within the autoclave of about 125 psi, preferably. Actual curing time is determined by the thickness of the final product. The final recycled rubber product is also claimed.

Abstract: A method of forming a shaped article from non-melt fabricatable, high temperature, polymeric (polyimide and polyamide) resins, using an apparatus including a die with compaction, back pressure and relief zone. Such resins are ram-extruded at a temperature of between about 20.degree. C. and 400.degree. C., but below the second order glass transition temperature of the resin to form a shaped article, followed by heating at a temperature above about 250.degree. C. for a time sufficient to coalesce the resin. Such method and apparatus is particularly well-suited to produce close tolerance articles of precise dimensions, such as rods and tubes.

Abstract: Solid particulate waste material is coated with a thermosetting resin which is compressed and cured to form a rigid core. The rigid core is coated with a flexible thermoplastic resin to provide a sealed encapsulated waste agglomerate which can withstand moderate compressive loads.

Abstract: A non-water dispersible water-softening bead is disclosed having from 80 to 90% sodium alumino silicate and from 10 to 20% low density polyethylene. The bead has a diameter of between 200 and 1000 microns and a calcium capacity of at least 200 mg calcium carbonate/g. The sodium alumino silicate has a silica to aluminum oxide molar ratio of between 2:1 and 4:1 and a sodium oxide to aluminum oxide molar ratio of between 0.8:1 and 1.2:1.

Abstract: A process for the production of flexible graphite comprising incorporating particulate expanded graphite having a c direction expansion at least 10 times as great as that of the original c direction dimension with an organo-silicon high molecular weight compound having carbon and silicon as the skeletal components, such as polysilmethylenesiloxane, or with a colloidal silica, drying the resulting mixture, pressure molding the dried mixture and heat treating the molded mixture at 500.degree.-2000.degree. C. thereby to produce the flexible graphite. In one embodiment, this invention relates to flexible graphite obtained by the process.

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 method of curing phenolic resin near exposed polyethyleneterephthalate subject to degradation by vaporous materials, comprises removing free phenol from the phenolic resin and heating the resin to a cured state.

Abstract: A sand molded plant receptacle, specifically a flowerpot, made of a non-wetting resin-bonded sand characterized by smooth inside and outside surfaces, a density of about 100 lbs. per cu. ft., a permeability of about 60 to 160, and by being impervious to water and pervious to air. A method of making a sand molded flowerpot which comprises blowing resin-coated sand under pressure into a closed, heated mold.

Abstract: A method for bonding a layer of porous polymeric material to a rigid implantable portion of a prosthetic device, which includes the steps of (a) forming a substrate by coating the implantable portion with material which is chemically compatible with the porous polymeric material and which has a melt viscosity and/or melting temperature lower than that of the porous polymeric material, (b) covering the substrate with a porous polymeric material in powder form capable of forming said porous polymeric layer for forming a composite coating on the implantable portion, and (c) heating the substrate and porous polymeric material to a temperature high enough to cause the substrate material to flow into the adjacent pores and low enough so that the porous material will maintain its shape so that the porous layer will be bonded to the substrate and the outer pores will be open to accommodate tissue ingrowth, and an apparatus formed by said method.

Abstract: A polyolefin foam article having a smooth, lustrous skin is produced by packing small pieces of polyolefin foam in the cavity formed between a male mold and a female mold of a mold assembly. One of the molds has no perforations for the passage of vapor and the other of the molds has: (1) perforations for the passage of a vapor; and (ii) at least two chambers which divide the perforations for the passage of vapor into perforations which permit the entrance of steam into the cavity and perforations which permit the exit of steam carrying entrained air present in and between the small pieces of polyolefin foam from the cavity.

Abstract: A molding process, resinous formulations for use in the process, and the resulting products are disclosed characterized in that the product comprises mainly a bulk or fill resinous body having a film or skin of a cross-linked polyester resin formed about the body. Even though the body has intricate curving surface contours, the film is smooth and free of surface tears and blemishes. The product is molded by first spraying formulated, dry particles of a partially cured polyester resin against a hot female mold to cause the particles to fuse and flow and form a substantially continuous skin or film on the female mold. Thereafter, the bulk resin is added and the mold is heated to cure the polyester resin as well as the bulk resin and to interreact the bulk and polyester resins together to mold the bulk resin with a film of the polyester resin.

Abstract: Basic material for making a porous material for seals comprising powder produced by pulverizing a plastic foams selected from the group consisting of gelated foams and semi-gelated foam of polyvinyl chloride.

Abstract: Battery separators with degradation resistant rib areas are produced from nonwoven mats of thermoplastic fibers by substantially fusing the fibers in raised regions of the mat. The fusion is progressively lessened toward the base of the rib. The rib is formed by the application of heat and pressure. The mat is also supplied with other important characteristics such as small pore size during treatment to compact its fibers.

Abstract: A process for manufacturing prefinished hardboard includes the use of a pre-press sealer comprising an aqueous mixture of a polyvinyl alcohol polymer in conjunction with emulsified fatty acid and/or fatty esters, an amine or similar emulsifier, and aluminum stearate. The pre-press sealer provides excellent sealing and hardening fiber binding to the porous fiberboard surface as well as improving the release from the press after the fiberboard is formed in a press under heat and pressure.

Abstract: A nonwoven fabric is produced from a batt of staple fibers by passing the unneedled batt of staple fibers to at least two needling zones, each needling zone having a plurality of needles which move in a reciprocating motion having a first needling direction and a second needling direction, the needles in a first needling zone having barbs which catch staple fibers of the batt primarily when the needles move only in the first needling direction and the needles in a second needling zone having barbs which catch staple fibers of the batt when the needles move in both the first needling direction and the second needling direction.

Abstract: A process for molding a coherent, pliable, thermally bonded, non-woven fabric comprising potentially adhesive fibers wherein the fabric is molded and new or stronger thermal bonds are developed within the fabric by the application of heat, whereby the cooled fabric retains its molded 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: This invention relates to a process for the production of a heterogeneous ion exchange membrane having a high ion transport number in the presence of a high ion concentration, which comprises mixing a finely powdered ion exchange material with a crystalline polyolefin resin, forming the resultant mixture into a membrane-shaped article and treating the membrane-shaped article with an aqueous solution of at least one salt selected from alkali metal salts and ammonium salts, having a concentration of from 17% by weight to saturation, at a temperature of at least 80.degree. C. for at least 10 minutes.

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

Abstract: Controlling the release of cast polymeric optical lenses from a resinous optical mold by coating the resinous mold material particles with a release agent before forming the resinous material into a lens mold.

Abstract: Improvements in molded articles from sinterable particulate solids, improvements in method for making such articles, and novel sacrificial binders for use in making such articles are disclosed. The sacrificial binders used in this invention comprise block polymers having the structural formulaX--[B (AB).sub..eta. A].sub..eta.'wherein "X" is a linking group, A or B, ".eta." is 0 or a positive integer, ".eta.'" is a positive integer greater than 2, "A" is a linear or branched polymer that is glassy or crystalline at room temperature and has its softening point in the range of about 80.degree. C. to about 250.degree. C. and "B" is a polymer different from A that behaves as an elastomer at processing temperatures, a plasticizer which may be oil, wax or oil and wax, and optionally other components.

Abstract: Improvements in molded articles from sinterable particulate solids, improvements in method for making such articles, and novel sacrificial binders for use in making such articles are disclosed. The sacrificial binders used in this invention comprise block polymers having the structural formulaAB--AB--.sub..eta. Awherein ".eta." is 0 or a positive integer, "A" is a linear or branched polymer that is glassy or crystalline at room temperature and has its softening point in the range of about 80.degree. C. to about 250.degree. C. and "B" is a polymer different from A that behaves as an elastomer at processing temperatures, a plasticizer which may be oil, wax, or oil and wax, and optionally other components.