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: Disclosed are a composition and process for the production of suppositories wherein a mixture comprising at least one ester out of the group of glycols preferably 1,2-propyleneglycol esterified with one saturated higher fatty acid such as myristic, palmitic and stearic acid and at least one pharmacologically active ingredient is formed, this mixture then is granulated with a solution of at least one film-forming polymer and the resulting granulate is pressed into suppositories on a tableting machine.

Abstract: A nonwoven fabric is produced by forming a batt comprising staple fibers oriented primarily in the fill direction, drafting the batt in the warp direction in a first warp-drafting zone, needling the drafted batt, drafting the needled batt in the warp direction in a second warp-drafting zone, and drafting the warp-drafted, needled batt in the fill direction in a fill-drafting zone. A fabric, apparatus for producing the fabric, and a method for fusing a nonwoven batt are provided.

Abstract: A process for manufacturing a continuously extruded running length of construction paneling from continuous flow sources of thermoplastic material bits and a mixture thereof with cellulose fiber bits, by successively fusing and pressure rolling even-distribution layers of thermoplastic bits, a mixture of thermoplastic and cellulose fiber bits, and, again thermoplastic bits, in respective ones of three cascaded oven chambers through which a material carrying conveyor is selectively advanced. Raw material distribution operates in concert with intermittent conveyor advance motions to provide even layer material distribution from the continuous flow sources, with each distributed layer being exposed to an oven environment to facilitate thermoplastic fusion during the time between intermittent conveyor advances and prior to subsequent pressure rolling.

Abstract: In a method of manufacturing garments, a mold is provided in the shape and size of the desired garment. The mold includes a matrix of conductors by which variable predetermined electrostatic fields can be established over the mold. A plurality of fiber layers are electrostatically deposited onto the mold to form a garment wherein at least some of the fibers comprising preselected layers are oriented according to the elasticity requirements of particular areas of the garment. Preferably, the garment is then at least partially precured, after which a plurality of colorants can be applied in sequence electrostatically to the garment to produce predetermined patterns, if desired. The garment is then cured to set the fiber layers and colorants, after which the garment is removed from the mold for subsequent finishing.

Abstract: An Electrolytic cell having a separator positioned between a positive electrode and a negative electrode is disclosed in which the separator is a moulding of polymer material derived from a particulate polymer material having a polar graft-copolymerized surface. The separator may be deposited as a coherent film of the surface of an electrode by sintering the particulate material into a coating around the electrode using heat and/or pressure. Alternatively a shaped article such as a case, envelope, sheet film or the like may be prepared and used to wrap around or encase an electrode.

Abstract: A process for the patterned deposition of powdered thermoplastic adhesive materials on the outer surface of a textile or other porous-flexible surface form, wherein there is first insertion raked in a pattern of depressions formed in an engraved component an adhesive powder material and then on this powder a further adhesive powder material is insertion raked in the depressions, so that both the powder layers superposed one on the other are taken up by the surface form which is positioned on the engraved component.

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: Tissue absorbable synthetic polymeric fibers, such as polyglycolic acid, are felted to form a thin mat with at least one, and preferably both, surfaces compacted by contact with a heated embossing surface such as a hot roller. Porosity is reduced but the compacted felt retains its flexibility, and conforms readily to the surface of a bleeding wound to give effective rapid hemostasis. The hemostatic felt is conveniently but not necessarily allowed to remain in place during the healing process and is absorbed by living tissue.

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

Abstract: Large void-free castings of polyethylene can be made by blending high density polyethylene pellets with low density polyethylene powder, followed by heating to above the melting point of the low density polyethylene and below, or only slightly above, the melting point of the high density polyethylene. Flame proofing additives, crosslinking agents and other materials can be readily incorporated into the blend before fusing. The mixture of high density and low density polyethylene significantly reduces the amount of shrinkage which takes place during the cooling from the melting temperature to ambient temperature. The low density polyethylene should have a sufficiently low melt viscosity so that it will flow under small pressures above the melting temperature.

Abstract: A method of adhering resin coated spherical particles of substantially uniform size together in the presence of an inert lubricant and under pressure at their points of contact to produce a porous matrix having numerous interconnecting passageways useful in making a body for a sparger for producing bubbles of uniform size in liquids.

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

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

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

Abstract: The apparatus comprises a double walled mould interior divided into two halves, a heat exchange exterior hollow envelope and a pressure-exchange compartment within the envelope surrounding the adjacent abutting surfaces of the rims of the two mould halves, heat-exchanges and pressure-exchanges producing means to rotate the apparatus on two axes, means to introduce a protective gas into the mould to avoid combustion of vapors and optional means cooperating between the heat-exchange and pressure-exchange means in the heating and cooling phases.The method includes controls of pressure and heat-exchange steps during the heating and cooling stages to avoid formation of bubbles, deformities and combustions, particularly when transparent plastic materials difficult to mould are used.

Abstract: A porous polymeric bearing is formed of a sintered composite of polyphenylene sulfide and a cured condensation thermosetting resin such as a phenolic compound wherein the presence of the thermoset material affords structural support during the sintering of the polyphenylene sulfide and further induces highly interconnected porosity in the fabricated composite adaptable for impregnation with a liquid lubricant. The fabrication includes a curing and degassing of the compressed greenware bearing followed by sintering and a subsequent post cure.

Abstract: An improved method is described for thermally bonding contacting pieces of a thermoplastic material provided in a variable volume confined space surrounded by a combustible gas. The combustible gas is ignited and explosion diffused externally of the pieces of thermoplastic material and thus heats the pieces without damage sufficiently to produce interbonding when the heated pieces are compacted in the confined space. The heated pieces are compacted isostatically or non-isostatically using various apparatus which reduce the volume of the confined space. Preferably a moveable piston is provided in a cylinder to form the confined space for the pieces. The driving means for the piston can be a combustible gas which is ignited or non-combustible gas under pressure or a resilient means or other mechanical means. The products of the method are in the form of a porous mass composed of the interbonded pieces which are undamaged by the explosion.

Abstract: A method for preparing a fiber-reinforced, thermoplastic composite, wherein the fiber is randomly oriented and the fiber length and integrity is maintained, which leads to better mechanical properties and fiber dispersion in manufactured articles prepared from said composite.

Abstract: A nonwoven fabric is produced by forming a batt comprising staple fibers oriented primarily in the fill direction, drafting the batt in the warp direction in a first warp-drafting zone, needling the drafted batt, drafting the needled batt in the warp direction in a second warp-drafting zone, and drafting the warp-drafted, needled batt in the fill direction in a fill-drafting zone. A fabric, apparatus for producing the fabric, and a method for fusing a nonwoven batt are provided.

Abstract: Method of making structural members from pliant, porous, solvent-free prepreg sheet comprising fusible resin microfibers and heat-resistant reinforcing fibers, which microfibers provide a lofty, clinging surface quality and fuse under heat and pressure to provide an essentially void-free matrix for the reinforcing fibers. Pieces of the novel prepreg sheet are conveniently molded under heat and pressure to provide laminated structural members.

Abstract: In manufacturing pressed boards, a flowable mixture of thermosetting resinous material and filler is blown through one or more nozzles into a converging throat formed by a pair of relatively inclined perforated conveyor bands in which the mixture is compacted into a continuous, coherent but preferably still pliable web by the application of heat to preset the resinous material thereof. The web may be immediately converted into a rigid board by being led, without intermediate cooling, into a continuously working press for final condensation of the resin; on the way to that press it may be subjected to a finishing operation, as by adhesion of preheated strips of paper or other coverings to its still tacky surfaces.

Abstract: Air-laid fibrous webs are formed from randomly-oriented mixed fibers containing a minor proportion of short, flock-length, thermoplastic and thermoretractile fibers. The air-laid web is then heated, without pressure, to cause melting of the thermoplastic fibers to the point of substantially complete loss of fiber identity. The relative orientation of the web thus formed is stabilized so that the fibers therein maintain their general positional relationships through subsequent stresses incurred during the operations of printing, saturating, drying, winding into roll form and the like.

Abstract: A method for making candles from solid wax including the steps of: sizing, compressing, drilling, and inserting of a wick. Further steps which may be included are coloring and/or adding other candle specializing ingredients such as deodorizing, scenting, insect repellants, and the like.

Abstract: A method and apparatus for producing synthetic resin sheets having geometric decorative patterns extending through the thickness of the sheet as a substantially identical pattern image corresponding to the image portions of the exposed surfaces thereof, wherein differently colored resin particles are selectively introduced into individual pattern spaces which are confined by enclosing members on a support to provide a regular pattern of differently colored resin particle masses over the surface of the support in a regular pattern, the differently colored resin particle masses are then converted into a pre-formed sheet on the support, the regular color pattern still being retained, and the resulting assembly then being heated at a temperature sufficient to cause fusion or sintering together of the masses of differently colored resin particles comprising the sheet, wherein the original differently colored resin particle masses exist as a repeating pattern of differently colored areas which extend through the th

Abstract: A method of making a multi-circuit electrical interconnector comprises the molding of an elastomeric, non-conductive frame member having a number of openings extending therethrough corresponding to the number of circuits that are to be interconnected. Each of the openings is overfilled with a module of uncured, heat curable elastomeric resin containing a plurality of electrically conductive particles. All of the modules are subjected to compression and the modules are cured while maintaining them under compression. All of the cured modules are exercised and stabilized physically and electrically by subjecting them to successive applications of compressive force.

Abstract: A method for coating powders with nylon by mixing the powder with the nylon and a solvent for the nylon, precipitating the nylon out of solution and coating the powder particles, and separating the coated powder substantially in the form of agglomerates of individually coated particles. The coated powder can then be readily compressed to form a shaped structure, such as, a molded article. A nylon coated powder especially suitable for conversion into shaped structures by melt processes, such as, injection molding or melt extrusion, is obtained by incorporating an organic polymer modifier into the nylon coated powder.

Abstract: Apparatus for molding products from polymeric material comprising cooperating mold elements forming a mold cavity for receiving polymeric material to be molded, means for introducing steam into thermoconductive relationship with the respective mold elements and separate valved conduits through which the steam in thermoconductive relationship with the respective mold elements is discharged. Also a method of molding products from polymeric material comprising introducing polymeric material into a mold cavity formed by cooperating mold elements, causing steam to flow in thermoconductive relationship with the respective mold elements and separately controlling the duration of such steam flow in thermoconductive relationship with the respective mold elements.

Abstract: Apparatus for molding products from polymeric material comprising cooperating mold elements forming a mold cavity for receiving polymeric material to be molded and means for optionally introducing steam into thermoconductive relationship with the respective mold elements in parallel and in series. Also a method of molding products from polymeric material comprising introducing polymeric material into a mold cavity formed by cooperating mold elements, causing steam to flow in thermoconductive relationship with the respective mold elements in parallel during a portion of the molding cycle and causing steam to flow in thermoconductive relationship with the respective mold elements in series during another portion of the molding cycle.

Abstract: Shaped articles composed of compacted polymeric particles wherein said polymer comprises substantially linear, aromatic polymer selected from the group consisting of aromatic hydrocarbon polymers, aromatic halocarbon polymers and aromatic halohydrocarbon polymers, consists essentially of substantially heteroatom-free aromatic linkages along the polymer backbone, is thermally stable at about 400.degree. C as evidenced by decomposition temperatures above about 400.degree. C, is infusible at the decomposition temperature, and is insoluble in conventional solvents are toughened by sintering said shaped article under a time-temperature cycle such that, when .sup.T /T.sub.10 is plotted against t in the graph of the drawing, the point falls between the line representing the equationlog t + 34.5 .sup.T /T.sub.10 = 34.5and the line representing the equationlog t + 69 .sup. T/T.sub.10 = 60wherein t is the sintering time in seconds, T is the sintering temperature in degrees Kelvin, and T.sub.

Abstract: A medical body implant element that is intended to experience rolling or sliding pressure during its function in the human body comprises microparticles of ultra-high molecular weight polyethylene which are fused together into a matrix. A quantity of graphitic carbon fibers of short, random lengths is disposed in intersticies of the matrix. The resultant composite is wear-resistant and substantially isotropic.

Abstract: Improved process for applying locking patches of resilient resin to internally threaded articles such as nuts having openings at both ends of the threaded portions in which process there is used apparatus including, a support and treating member, preferably a rotatable, circular table with edge notches complementary to a portion of the exterior of a threaded article to be treated, which receives a succession of threaded articles heated to a temperature above the melting point of the resin to be applied and moves the articles along a path for treatment with the axes of the threaded articles in an up and down position and with the openings at the upper and lower ends of the threaded portions substantially uncovered, conduits on the support and treating member are associated with each threaded article to direct particles of heat fusible resin upwardly through the opening at the lower end of the article against a portion of the threaded surface of the article to form a first deposit of resin on an area of the thr

Abstract: A porous film of polytetrafluoroethylene having an accurately controlled pore diameter and a superior pore diameter distribution, and a process for preparing the film.

Abstract: A nonwoven fabric is produced by forming a batt comprising staple fibers oriented primarily in the fill direction, drafting the batt in the warp direction in a first warp-drafting zone, needling the drafted batt, drafting the needled batt in the warp direction in a second warp-drafting zone, and drafting the warp-drafted, needled batt in the fill direction in a fill-drafting zone. A fabric, apparatus for producing the fabric, and a method for fusing a nonwoven batt are provided.

Abstract: Self-bonded webs of non-woven carbon fibers in the form of blankets, felt, paper, fiberboard, and the like, are produced by spinning a carbonaceous pitch having a mesophase content of from about 40 percent by weight to about 90 percent by weight to form carbonaceous pitch fiber; disposing staple lengths of the spun fiber in intimately contacting relationship with each other in a non-woven fibrous web; heating the web produced in this manner in an oxidizing atmosphere to thermoset the surfaces of the fibers to an extent which will allow the fibers to maintain their shape upon heating to more elevated temperatures but insufficient to thermoset the interior portions of the fibers; heating the web containing the externally thermoset fibers under compressive pressure in an oxygen-free atmosphere to a temperature sufficiently elevated to cause the mesophase pitch in the unoxidized interior portions of the fibers to undergo liquid flow and exude through surface pores or flaws in the fibers and contact the surfaces o

Abstract: Shaped articles are produced by heating and compressing particles of foamed olefin polymer containing crosslinked portions in molds, the pressure being reduced during compression in the mold.

Abstract: Plastic articles without foam spots are produced by an improved powder forming process wherein a powder of normally solid, thermoplastic polymer is compacted by means of vibratory energy into briquettes which are subsequently forged and formed into articles of fused polymer.

Abstract: Shaped articles composed of compacted polymeric particles wherein said polymer comprises substantially linear, aromatic polymer selected from the group consisting of aromatic hydrocarbon polymers, aromatic halocarbon polymers and aromatic halohydrocarbon polymers, consists essentially of substantially heteroatom-free aromatic linkages along the polymer backbone, is thermally stable at about 400.degree. C as evidenced by decomposition temperatures above about 400.degree. C, is infusible at the decomposition temperature, and is insoluble in conventional solvents are toughened by sintering said shaped article under a time-temperature cycle such that, when T/T.sub.10 is plotted against t in the graph of the drawing, the point falls between the line representing the equationlog t + 34.5 T/T.sub.10 = 34.5and the line representing the equationlog t + 69 T/T.sub.10 = 60wherein t is the sintering time in seconds, T is the sintering temperature in degrees Kelvin, and T.sub.

Abstract: A method for high speed sinter molding having endless chains mounted side by side. Mold halves are attached at spaced intervals down the chains. The paired mold halves come next to each other to form a female mold into which is deposited a polymeric material. A treating core extends inside the mold and as the mold traverses its path, it surrounds the core and the core deposits polymeric powder, heats the polymeric powder, and then cools it. At the end of the mold path, the finished article is ejected and is ready for the next operation.Another embodiment of the same essential process is to place the paired mold halves in juxtaposition as they moved down over the core. This will result in the fabrication of a continuous conduit. A container may be fabricated by using hollow mold halves with heating and deposition accomplished before the hollow mold halves are pressed together to form a hollow container.

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: Polymeric bodies having selected morphological properties are prepared by effecting an apparent increase in the glass transition temperature of the polymer to cause it to become glassy and manipulating the polymer while it is in the glassy state. In the preferred practice of the invention, the apparent increase in the glass transition temperature is a reversible function so that after the morphological properties of the polymer have been developed, the normal glass transition temperature of the polymer may be restored.The process of this invention finds utility in the preparation and formulation of polymers in powdered form; it provides a practical method for the formation of powders in unusual size ranges, which, in turn, makes possible the formation of shaped articles by novel processes; and it provides a simple method for making products, such as open-cell foams and surfaces in relief, that have unique physical characteristics.

Abstract: A cation exchanger in paper-like or felt-like form is obtained by making a fibrous sheet from a blend of polyethylene fibers into which sulfonic groups have been introduced with 0.1 to 50% by weight of thermoplastic resin fibers and heating the sheet at the softening temperature of said thermoplastic resin or higher temperatures. This cation exchanger is useful in softening or desalination of raw water, separation and recovery of various metals, and adsorption of basic dyestuffs and cationic dyestuffs.

Abstract: Heat shrinkable fibers are laid down on a backing element, needle-punched and thereafter heated on one surface of the needle-punched fabric in a relaxed condition to a temperature to fuse at least a portion of the fibers adjacent the heated surface and shrink said fibers and first material surface relative to the opposed surface for providing a nonwoven material having a randomly uneven surface. In another embodiment, the backing element is eliminated.

Abstract: Foam moldings of olefin polymers are prepared by heating, and pressing together, foamed particles of an olefin polymer, containing crosslinked constituents, in molds, a temperature gradient of from 0.5.degree. to 25.degree. C per cm of loose mass of particles being established in the mold, which has a gas-permeable wall on the lower-temperature side.

Abstract: Method of making a molded article comprising a hollow body of a crosslinked polymer rotationally molded around a section of at least one piece of non-crosslinked conduit, which conduits protrude from said hollow body, made by attaching said conduits of non-crosslinked material at the desired location to the mold with said section being located inside a heated section of the mold so that the crosslinkable polymer during a rotational molding process is fused and crosslinked inside of the mold and around and in tight welding-type connection with said section, whereas the remainder of the piece or pieces of uncrosslinked polymer are heat-insulated, thus avoiding deformation or collapsing of these pieces.

Abstract: Process for continuous bonding of a fibrous non-woven web of polyethylene terephthalate matrix and copolyester binder filaments which comprises depositing the matrix and binder filaments as a nonwoven web on a moving belt, steam treating the nonwoven web under restraint thereby consolidating the web, removing the restraint, transferring the consolidated web from the moving belt to a bonder, and finally bonding the web with a flow of hot air through the web.

Abstract: A powder metallurgy compact and a sintered product is provided from high performance alloys difficult to compact and/or sinter. The green compact comprises a mixture of the alloy powder, which, as a result of blending and extruding is coated with a film of a solid organic binder, and consolidated to discrete bodies of an intermediate density. The green compacts are sintered to produce a final solid product.

Abstract: A method of making an inking platen suitable for use with impact printers and comprising a unitary microporous nylon body having a thin microporous flexible tough outer skin portion, and a ribbon affixed to the skin; the ribbon being woven of nylon fibers, the body being compression molded from a predetermined particulate nylon blend of a minority of high mesh nylon and the remainder of low mesh nylon.

Abstract: Manufacture of rapidly hardening phenol formaldehyde resin molding compositions having improved thermal stability and good flow characteristics by incorporating into the molding compositions hexamethylenetetramine in the form of a metaboric acid addition product. The resulting molding composition is then rolled and ground to produce the molding composition of improved properties.