Abstract: The present invention provides an amorphous polymer article produced by hot compaction and a method of producing the same. The article is heated to a temperature and maintained at a pressure sufficient to cause softening of the polymer strands to sufficient a degree to allow bonding to adjacent fibres to take place without actually transforming the polymer into a liquid state.

Abstract: A composite material comprising an inorganic filler material and a oriented fibrous polymeric material characterised in that the fibrous material has areas of adjacent fibres fused together to form a network or continuous matrix while retaining oriented fibrous structure in the composite.

Abstract: Particulate materials are cold molded by preheating a binder and the material to be bound to a temperature of from 160 to 240° C., and then press molding at a temperature less than 80° C. and at a pressure of from 1 to 120 bar to give a molding, wherein the binder contains a polymer powder or aqueous polymer dispersion thereof, the polymer having a glass transition temperature Tg greater than 80° C. and a complex viscosity less than 15,000 Pa·s at 190° C., and derived from one or more comonomer units from the group of vinyl esters of optionally branched C1-18 alkylcarboxylic acids, (meth)acrylic esters of optionally branched C1-15 alcohols, dienes, olefins, vinylaromatics, and vinyl halides. The moldings exhibit excellent properties including resistance to sagging at elevated temperatures, and are recyclable.

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: A method of producing molded wood flake or strand three-dimensionally curved products using draft angles of 10 degrees or larger with little or no blistering or wood flake springback from over densification. A loosely felted mat of wood flakes is placed between top and bottom molds which slidably engage one another at pinch points to pinch and sometimes remove excess flashing/pinch trim.

Abstract: A method of forming a thermally bonded, nonwoven polypropylene fabric is provided and includes passing a web of thermally bondable skin-core polypropylene fibers through a calender nip under heat and pressure to produce a nonwoven fabric having elongation. The patterned calender roll is embossed with a plurality of spaced and staggered lands particularly dimensioned, configured and oriented to provide the desired bonding spot size and spacing between the bonding spots such that when utilized in the calender roll, an improved soft polypropylene fabric or cover sheet having a high elongation results.

Abstract: Ethylene (co)polymers each having specified values of (a) density, (b) molecular weight distribution (Mw/Mn), (c) relationship between die swell (DS) and shear rate (&ggr;) in a region of shear rate ({dot over (&ggr;)}), (d) relationship between stress (&sgr;) and maximum stress (&sgr; max) in a stress-strain curve in uniaxial stretching, (e) the ratio of sample diameter to initial sample diameter and the time for sample breakage during uniaxial stretching under a constant tension, blow molding process in which the thickness of a parison is adjusted by using the said ethylene (co)polymer, and the method of improving fire resistance in moldings, laminates and hollow moldings made by using the same.

Abstract: A method for manufacturing a combustion resistant and water resistant large container is disclosed. A starch or cereal powders are mixed with water at a certain ratio, and the mixture is heated to a certain temperature so as to form a glue. A drying is carried out, a powderizing is carried out, and then it is mixed with powders of a natural resin (rosin). Then this mixture is mixed with water, and then, it is fabricated by using a fabricator.

Abstract: A wood composite board or panel, such as particleboard, fiberboard, oriented strand board or waferboard and a method of producing the same. The composite board or panel comprises a plurality of wood pieces, thermoset resin to bind the wood pieces and a filler having a high thermal conductivity. Examples of such a filler include natural and synthetic graphites, metal, carbon, silicon carbide and other similar compounds and their mixtures.

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 plastic closure that includes a cap having a base with a peripheral skirt defining a cap interior and threads on the skirt for securing the closure to a container. A liner is secured to the interior of the cap, preferably by compression molding in situ. The liner preferably consists essentially of a blend of matrix polymer material, particulate barrier polymer material and compatibilizer material. The heat and pressure of compression forms the particles of barrier polymer material into platelets that are oriented essentially parallel to the plane of the closure base.

Abstract: The invention relates to modified isocyanates for use in producing fiberboards. Particularly, the invention relates to the use of polymeric MDI having a relatively low diisocyanate content for producing fiberboards. The invention also relates to fiberboards produced utilizing such modified polymeric MDI.

Abstract: The present invention provides a method of manufacturing an exfoliated graphite/phenol resin composite foam of a porosity of 50-95%, a density of 0.1-0.8 g/cm3, by forming under contact pressure or reduced pressure at a temperature of 140-200° C. a mixture comprising 100 parts by weight of powdered and/or crushed exfoliated graphite and 40-240 parts by weight of phenol resin; an exfoliated graphite/phenol resin composite foam obtained by the method; and a method of obtaining an exfoliated graphite/glassy carbon composite foam of a porosity of 50-95%, a density 0.1-0.8 g/cm3 with volumetric baking shrinkage of 10% or less by baking the exfoliated graphite/phenol resin composite foam.

Abstract: Two types of synthetic resin are used with fibers (2) made from a wide range of bamboo canes from undried to dried. An appropriate amount of special thread (4) comprising a core thread (5) having a high melting point and a core-thread covering skin (6) having a low melting point are added to the fibers and kneaded together. When molding the kneaded material, it is heated to the temperature at which the skin starts to melt and pressed. Then the skin works as a binder that binds the fibers and the core thread. The core thread supplements the strength and the flexibility of the bamboo fiber board.

Abstract: A method for producing self-supporting activated carbon structures is disclosed. The method comprises the steps of mixing a granular activated carbon, a binder material, a carbonization agent, and a liquid to produce a semi-plastic mixture; compacting the mixture using compacting pressures of or greater than about 100 pounds per square inch to form a three-dimensional structure; and heating the structure to an elevated temperature of or greater than about 300° C. to produce a self-supporting activated carbon structure. The granular activated carbon is of any particle size between approximately 4 and 325 mesh U.S. Sieve Series, and the binder is a ground cereal grain, cereal rain flour or a tuber flour. The resultant structure may then be cooled to near-ambient temperatures under an essentially inert atmosphere. Such structures can exhibit good mechanical strengths, adsorption capacities nearly equivalent to those of the activated carbon used in their preparation, and appreciable electrical conductivity.

Abstract: A method of manufacturing a separator for a polymer electrolyte fuel cell in which the specific resistance is small, and the coefficient of thermal conductivity and the gas shielding property are high and have high strength. The sintering material comprises a phenol resin coated to the surface of a powder of carbon, and the plate is a metallic plate having plating on both surfaces. After the metallic plate is arranged in a mold provided with grooves, the sintering material is filled to both sides of the metallic plate, and then they are heated and sintered. The separator for a fuel cell becomes homogeneous, and, as a result, the gas shielding property rises with high strength, because phenol resin has been uniformly distributed in the sintering material. Moreover, because oxides are not generated on the surfaces of the separator by sintering, the specific resistance will be relatively small.

Abstract: The manufacture of porous molded bodies by sintering of a mixture of powderous thermoplastic polymers and a liquid is described, the boiling point of the latter being at least equal to or higher than the sintering temperature. Sintering takes places in a mould, the process may be performed continuously and is suitable for the manufacture of porous molded bodies such as pipes, panels and the like which can be used as filter, gas distribution, air distribution, coalescing elements, as suction elements for oil, as carriers of active substances etc.

Abstract: According to a molding method for a conductive plate of this invention, a substrate having through holes each corresponding to each protruded portion is employed and the substrate is sandwiched between both dies. Then raw powder is filled into each housing portion provided opposing each through hole in the substrate provided in each of both dies, through the through hole in order to form each protruded portion. Then the protruded portion is formed integrally with the substrate by heating the raw powder under pressure.

Abstract: Shaped bodies, such as boards, are manufactured from particles having a surface with a wax layer, such as straw, hemp stalks, maize stalks, grapevine stalks and the like. The particles are first comminuted, then heated and then further comminuted. Thereafter the particles are admixed with a binder to form a mixture, the mixture is scattered into a mat, and the mat is then pressed into the shaped body of the desired size.

Abstract: A process for making an absorbent composite including absorbent fibers, superabsorbent polymer and, optionally, thermoplastic fibers and other ingredients is provided. The synthesis (i.e., polymerization) of the superabsorbent is completely integrated into the process for forming the absorbent composite. Specifically, the polymerization of superabsorbent is initiated from within a plurality of absorbent and/or thermoplastic fibers, which are then formed into a web. The integrated process eliminates the need for separate manufacture of superabsorbent polymer prior to the fiber forming and web forming processes. Also, the superabsorbent polymer thus formed tends to disperse better and remain adhered to the absorbent and/or thermoplastic fibers, providing a stable and uniform absorbent composite for various end use applications.

Abstract: A forming method for a fiber aggregate in which fibers are heated to be welded with each other includes a heating step of applying upward heated air to a bottom of a block of the fibers to pass the heated air therethrough and to cause the block of fibers to float, wherein at least parts of fibers are melted while the block of fibers float, and a compression step of compressing substantially in a vertical direction the heated block of fibers into a desired height. The compressed block of fibers is cooled to solidify melted portions of the fibers at portions where the fibers intersect with each other.

Abstract: A particulate silicone based material and method for forming a heat resistant composite 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 composite is formed. The solid composite is resistant to melting and thermal decomposition when heated to temperatures of at least 3000° F. The particulate silicone based material may be formed by mixing liquid silicone resin with a catalyst and powdered silicone molding compound.

Abstract: A method of preparing wood and plastic to produce a composite material.

Abstract: According to the invention, a synthetic resin composition having a desirable a low coefficient of friction when submersed in a liquid is provided. In addition, a method of making a low friction bearing for use under liquid is provided as well as a low friction bearing or use underwater.

Abstract: A continuous sheet having a combination of acidic and basic water-absorbing resin particles that are essentially not neutralized and can be continuously manufactured on conventional papermaking apparatus, using a wet, dry, or wet-dry process to manufacture a water-absorbent sheet-like substrate containing 50%-100% by weight of the combination of acidic and basic water-absorbent particles. The acidic and basic essentially unneutralized resins can be contained in the sheet material articles of the present invention as separate acidic and basic resin particles, or as multicomponent particles containing both the acidic and basic resins. The sheet materials can be manufactured having new and unexpected structural integrity, with little or no shakeout or loss of superabsorbent particles during or after manufacture while exhibiting exceptional water absorption and retention properties.

Abstract: The invention is directed to methods involving rewetting of expandable polymers with a wettable liquid to allow for enhanced expansion at or below room temperature without breakage, and in some cases, allows one to achieve a greater expansion ratio than that allowed at elevated temperatures using known methods. The present invention also allows one to achieve material with unique properties and handling characteristics. These properties included decreased material thickness, increased density, an altered node/fibril morphology, and a more consistent web in the case of flat material. This method is not limited to room temperature conditions and can be applied whenever the expandable polymer material is wet with a wettable liquid, and the expansion is performed at a temperature preferably below the vaporization or boiling points of that liquid.

Abstract: Polypropylene resin pre-expanded particles having an expandability of 1.0 to 1.

Abstract: A method of producing an open, porous structure having an outer surface defining a shape having a bulk volume and having interconnecting openings extending throughout said volume and opening through said surface, and products resulting from the method. The method comprises preparing a viscous mixture comprising a sinterable powder dispersed in a sol of a polymer in a primary solvent, replacing the primary solvent with a secondary liquid in which the polymer is insoluble to produce a gel comprising an open polymeric network having the sinterable powder arranged therein, removing the secondary liquid from the gel; removing the polymer network, and sintering the sinterable powder to form the open, porous structure. Also disclosed are shaped, porous products resulting from methods of the invention.

Abstract: An automated process for manufacturing rubber paving blocks uses crumb rubber recovered from used automotive tires. A production line in which the molds are emptied of the formed rubber paving block and then filled with a fresh crumb rubber mixture is balanced with an oven line in which the compressed crumb rubber mixture is heated, cured and cooled before being returned to the production line for further processing. The mold includes a lid having latching mechanisms that are actuated by compressed air. The formed rubber paving block is removed from the cooled mold through a compressed air extraction mechanism so that the formed block is not damaged during the extraction process. The rubber paving block is formed with a textured bottom surface having a central depressed disk and a plurality of grooves forming interconnected passageways for water to pass beneath the blocks when installed.

Abstract: A method of producing a sintered article of polybenzimidazole by using a polybenzimidazole resin is disclosed. This method comprises the steps of: filling a mold with a polybenzimidazole resin; after closing the mold so that the polybenzimidazole resin can be densely packed in the mold, heating the mold to a predetermined temperature ranging from 500° C. to 600° C. without applying pressure to the mold from the outside; after increasing the pressure on the mold from 0 kg/cm2 to 50-750 kg/cm2, sintering the polybenzimidazole resin while maintaining the temperature and the pressure for 15 to 200 minutes; cooling the mold; and removing the sintered article of the polybenzimidazole resin from the mold. By this method, sintered articles of polybenzimidazole resins having no weak parts can be obtained in high yields.

Abstract: A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm3 to about 0.5 g/cm3 is disclosed. The method utilizes a thermally expandable polymer microsphere material wherein some of the microspheres are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130° C., and then cooling the mold to a temperature below 80° C. the molded part achieves a bulk density which varies by less then about ±6% everywhere throughout the part volume.

Abstract: A method of fabricating a motor-pump combination with the motor including a stator including a plurality of teeth extending between opposite stator end faces and a plurality of tooth tips defining a generally axial bore, the method including: forming a magnetic portion of a generally annular sleeve by compression molding a plurality of axially extending ferromagnetic strips using a plastic binder; forming a non magnetic portion of the annular sleeve by injection molding plastic material between adjacent ferromagnetic strips; molding a resin material casing member for the pump with the casing member having a generally annular cylindrical section and including the annular sleeve in part in the annular cylindrical section; and inserting the annular cylindrical section into the bore of the stator and aligning the ferromagnetic strips of the annular sleeve in abutting engagement with the tooth tips on the teeth of the stator.

Abstract: A consolidated cellulosic article of increased thickness and target face density, as well as an apparatus and method of manufacturing same, are disclosed. The apparatus includes first and second dies adapted to move toward on e another with a mat of cellulosic material and a binding agent therebetween. When the dies move together, the mat is compressed under pressure and heat with forms on one of the dies forming identations in the mat. Compression zones of increased density form between the indentations and a first face of the mat. By spacing the forms appropriately, the compression zones overlap, and the face of the resulting consolidated board is provided with substantially uniform density. Since the entire board is not compressed to the same degree, its overall thickness is enchanced while the density of the first face of the mat is increased, and relatively little material is used.

Abstract: An improvement to existing board manufacturing process which utilize lignocellulose particles is described wherein the adhesive to be applied as a binder is at least partly applied before the particles are dried. Using the invention improvement in resin application rates without increase in the water content of the particles fed to a press is achieved. Reduction in edge thickness swelling has been achieved.

Abstract: The present invention relates to a dry-laid composition comprising: hollow synthetic fiber, absorbent and a binder system. The hollow fiber comprises from about 10 to about 50 percent by weight of said composition. The hollow synthetic fiber has a denier of between about 2 to about 18. The hollow synthetic fiber is selected from the class of polyolefins, polyesters, polyamides, acrylics, as well as mixtures and copolymers thereof. The absorbent comprises from about 40% to about 80% of the weight of said composition. The absorbent is a natural absorbent, or a synthetic absorbent, or a mixture of these. The natural absorbent is selected from the class of wood pulp fluff, cotton, cotton linters, and regenerated cellulose fibers, or a mixture of these. The synthetic absorbent is selected from the class of agar, pectin, guar gum, and synthetic hydrogel polymers. The binder fiber comprises from about 3 to about 15 percent by weight of said composition.

Abstract: Material compositions for use in orthopedic implants comprising blends of ultra high molecular weight polyethylene (UHMWPE) and hard ceramic powders prepared by blending powdered UHMWPE and the ceramic powder in a high shear mixer are described. Orthopedic implants are then fabricated by pressure/thermo-forming the ceramic/polymer blend into a net shape prosthesis or a rod suitable for subsequently machining the desired components using diamond tooling. Net shape forming is the preferred method for preparing the orthopedic implants.

Abstract: A method for producing three-dimensional bodies of a large number of mutually connected layers of a particle-shaped material such as a powder, and where the information of the appearance of each layer is achieved from a computer's CAD-unit or similar. An essentially even particle layer (7) of building material is applied on a support base (6) and on a masking device (9) is arranged a masking pattern in accordance with the information from the CAD-unit, which masking device is led over said particle layer and close to it. A radiation producer (8) is arranged or is led over the masking device (9), whereby the particles which are not covered by the masking pattern are exposed for radiation and thereby are attached to each other. The masking pattern is removed from the masking device and new sequences in accordance with the above are carried through until the three-dimensional body (19) is produced.

Abstract: Protective containers are provided for transporting moldable preform charges used in precision molding operations, in which the moldable material includes a conductive filler in a thermosetting resin matrix. The granular moldable material is loaded into the containers and compacted. Next, the loaded containers are transported to a molding station, where each preform of the moldable material is ejected from its container. The containers are sufficiently rigid to hold their shapes under high compaction pressures, thus to determine preform shapes with greater precision. By surrounding the preforms, the containers minimize evaporative loss of monomer, maintaining the preforms in a condition more suitable for molding, and reducing the impact of monomer loss on the surrounding environment. Each such container can take the form of a sleeve, or may have an end wall incorporating a flexure at one end.

Abstract: A process for producing a thermoplastic polyurethane film by means of sintering a particulate thermoplastic polyurethane in a heated mold, is described. The thermoplastic polyurethane has: (i) a melt index of 20 to 100, measured at 190° C. and under an applied force of 21.2 N; (ii) a relative solution viscosity of 1.15 to 1.45, the relative solution viscosity being determined by, measuring the viscosity (a) of a solution of 0.4 grams of the thermoplastic polyurethane in 99.7 grams N-methyl-2-pyrrolidone containing 0.1% dibutylamine at 25° C., measuring the viscosity (b) of N-methyl-2-pyrrolidone containing 0.1% dibutylamine at 25° C., and dividing viscosity (a) by viscosity (b); and (iii) a Shore hardness of 80 to 98.

Abstract: Disclosed is a method for manufacturing composite granules having a homogeneous particle distribution, comprising powders of multimodal particle size distribution and phenol resins, and a method for manufacturing green bodies having homogeneous microstructure without particle separation from the granules.

Abstract: A multicolored, patterned floor covering is disclosed along with a method for its manufacture. The floor covering is made of a sheeting which has a first color, and a granular material dyed differently from the sheeting which is embedded in the sheeting along at least in the area of the top side. The sheeting and the granular material consist of cross-linkable, elastomeric materials, the granular material comprising particles which have at least two subregions dyed differently from each other and from the sheeting. The quantity and color of the fractions of each component as selected so that the mixed color resulting from an homogeneous intermixing of all the components contained in the floor covering agrees with the first color.

Abstract: A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm3 to about 0.5 g/cm3 is disclosed. The method utilizes a thermally expandable polymer microballoon material wherein some of the microballoons are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130° C., and then cooling the mold to a temperature below 80° C. the molded part achieves a bulk density which varies by less then about ±6% everywhere throughout the part volume.

Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.

Abstract: A method of forming a composite panel includes the steps of supplying a material to a forming station, supplying a dry additive to the material at the forming station, producing a mat comprising the material and the additive, and applying heat and pressure to the mat to produce a composite panel. An apparatus for forming a composite panel includes a reservoir of raw material and at least one forming station configured to form a mat of the raw material. A dry material dispensing assembly introduces an additive to the forming station, and press applies heat and pressure to transform the mat into a panel.

Abstract: Porous products of thermoplastic polymers and the like are formed by sintering pellets, especially micropellets and/or pellets made by rapid water quenched pelletizing of the polymers, such as by underwater pelletizing or water ring pelletizing. The pellets are of a uniform size and shape, each having approximately equal dimensions along three mutually perpendicular axes, thereby producing porous products having smooth surfaces, narrow pore size distributions, greater strength and other improved characteristics. The porous products include antiperspirant and deodorant applicator heads, wastewater treatment bubblers and selective filters.

Abstract: The invention provides a glass fiber facing sheet for engineered surfaces such as cement boards which reduces the pitting associated with open mesh glass scrims. The glass fiber facing sheet comprises an open mesh glass scrim having a plurality of intersecting continuous multifilament yarns which are bonded at their crossover points to provide dimensional stability to the scrim. A melt blown polymer web is preferably joined to one face of the glass scrim and covers the mesh openings in the scrim. The opposed face of the scrim defines an exposed grid profile surface which is available for mechanical interaction between the scrim and the cementitious slurry used in cement boards. In cement boards, the glass fiber facing sheet of the present invention is preferably mechanically integrated into a surface portion of the cement core along the exposed grid profile of the scrim.

Abstract: A method of forming a headliner includes providing a lap mat including a first region having a first material composition, and a second region having a second material composition different than the first composition, wherein the second region is configured as at least one of an energy management region and a support region; positioning the mat between two mold sections of a mold; and moving at least one of the mold sections toward the other mold section to shape the mat into a desired shape. A method for forming the mat is also disclosed.

Abstract: The present invention involves a method and system for manufacturing a multiple density substrate for impact energy absorption with a mold having a mold cavity of a predetermined shape. The multiple density substrate is integrally formed by the method comprising providing a first set of unbonded pre-expanded beads having a first density and a second set of unbonded pre-expanded beads having a second density, loading a portion of the mold with the first set of unbonded beads at a predetermined location in the mold sufficiently to leave a void in the mold, and separately injecting the loaded mold portion with a sufficient second set of unbonded beads into the void. The method further includes bonding the first and second sets of beads together with heat to define a molded set of bonded beads having the predetermined shape and cooling the molded set of bonded beads sufficiently to define the multiple density substrate.

Abstract: There is now provided a method for producing a product comprising plastic foam in an automatic molding machine. The method comprises providing a woven fabric on at least one surface of the mold cavity, with the woven fabric comprising a fabric having a fine-mesh woven fabric ply that faces the interior of the mold cavity upon assembly and a coarse-mesh woven fabric ply that is disposed adjacent at least one surface of the mold cavity and beneath the fine-mesh woven ply upon assembly to support the fine-mesh woven ply. The method further provides for introducing beads comprising plastic foam into the mold cavity; contacting the beads with a gaseous heat transfer medium, such as superheated steam; introducing the gaseous heat transfer medium into the mold cavity; flowing the gaseous heat transfer medium along a first surface of the mold cavity; and removing gaseous heat transfer medium along a second surface of the mold cavity; and removing the finished product from the mold.

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.