Abstract: A method for the production of molded bodies comprising foam particles is proposed in which the foam particles are shaped and welded together using microwave energy. The foam particles are accommodated in a foil-like bag and the bag is manually shaped or shaped through the use of a shaped mold with simultaneous change of the shape of the foam particles, and evacuated into a dense package. Microwave energy is subsequently used to melt together at least the surfaces of the foam particles. The method in accordance with the invention is particularly well suited as an economical manufacturing technique for packaging, in particular specialized packaging for models, small production runs, prototypes and the like.

Abstract: A process for production of polyimide molded bodies which comprises a step in which a polyimide resin powder obtained by polymerization and imidation of p-phenylenediamine with 3,3,4,4′-biphenyltetracarboxylic acid, its ester or its dianhydride and 2,3,3′, 4′-biphenyltetracarboxylic acid, its ester or its dianhydride is molded at a pressure of approximately 800-5,000 kgf/cm2, a step in which the pressurized body is subjected to calcination at about 450-550° C. under low pressure, a step in which the calcined molded body is vacuum encapsulated into a metal capsule, and a step in which the encapsulated molded body is isotropically subjected to hot compression at approximately 460-550° C. in an inert gas atmosphere such as argon. The polyimide molded bodies obtained thereby have a density in the range of 1.44-1.38 g/cm3.

Abstract: A composite porous structure capable of absorbing organic pollutants from water is produced by preparing a dispersion of non film-forming PVC particles in a water-soluble organic liquid, impregnating a macroporous matrix such as a cellulosic sponge or paper with the dispersion, and curing the impregnated matrix by heating to achieve sintering of the PVC particles to produce a microporous substrate which is retained within the macroporous matrix.

Abstract: A method for molding composite items, constituted by beads of sintered expanded resin and by inserts, comprising the steps of: using a movable half-mold and first and second half-molds which can perform a translational motion at right angles to the direction of motion of the movable half-mold; performing the molding operation by means of one of the translatable half-molds mated with the movable half-mold, translating the translatable half-mold from a position for accessing the half-mold to a molding position, simultaneously accessing the other one of the translatable half-molds when the other one of the translatable half-molds is located at the region for access to the translatable half-mold.

Abstract: Pre-inked impression members for hand stamps are made from a gel or premix of thermoplastic resin particles and liquid ink with use of a disposable molding device comprising a matrix board that is recessed in its molding area with cavities to form inked indicia of the impression members and has a peripheral surface area to which is adhered fluid-tight, and entirely about the molding area, an upright rigid wall means comprising a structure of fiberboard, wood, hard resin or other suitable material shaped to a height corresponding to the desired thickness of the impression members. As another feature, during the heating for curing of a layer of premix formed over the molding area of a matrix board, the layer of premix is confined in place by a covering means, applied over it and held under pressure, which comprises, together preferably with overlaid pliable ink-absorbent material, e.g.

Abstract: Process for the preparation of end-products based on vinylaromatic polymers with a predominantly syndiotactic structure which comprises: a) compressing the polymer in powder form in a mould at a pressure ranging from 0.1 to 500 Mpa; b) sintering the compressed powder, under pressure, at a temperature ranging from the glass transition temperature of the polymer (Tg) to 150° C.; c) slowly cooling the end-product to room temperature.

Abstract: A method for manufacturing an extrudable product including the steps of (a) providing an apparatus including an extruder having at least one rotor with first grooves, at least one stator with second grooves and a clearance between the rotor and the stator, the first grooves, second grooves and clearance forming a processing cavity having a volume that is equal to the volumes of the first grooves, the second grooves and the clearance, the processing cavity having a cross-sectional area that decreases continuously along at least a part of an axis of the extruder, the extruder further having a supply for feeding a material to be extruded into the processing cavity; b) feeding the material to be extruded in a powder, pellet or granuate form into the processing cavity through the supply and causing rotation of the rotor relative to the stator such that the material is forced to proceed along an x-axis in a shear zone of the extruder where the material is subjected to a shear which causes a fictional heat that melt

Abstract: Foamed beads of polyester resin having rheological and crystallizability characteristics suitable for the preparation of foamed articles by sintering beads in a mold heated with superheated steam or with inert gas or air.

Abstract: A method for manufacturing a floor covering involves leading a glass fiber matt 1 from a supply reel 2 onto a conveyor belt 3. At a first scattering station 4, a saturation material is scattered onto the matt 1 to form a scattered layer. The matt 1 is then led between upper and lower heated belts 10, 11 to gel the scattered layer. The belts are then passed between a pair of smoothing/nipping rollers to form a layer of uniform thickness. The belts are then cooled and the matt 1 with saturation layer applied is wound for further processing. In an alternative arrangement a saturation material is scattered directly onto a substrate belt at the first scattering station 4, a glass fiber matt 26, is applied over the scattered material and, at a second scattering station 28, an amount of the saturation material or a different material is scattered onto the matt 26.

Abstract: Fibrous sorbent media or pads are formed from non-woven mats of thermoplastic fibers, preferably polypropylene fibers, having a mean diameter between about 0.5 microns and about 25 microns. The mats have a weight between about 2 ounces/yd2 and about 25 ounces/yd2; a thickness of at least {fraction (1/20)} of an inch; an oil absorbency ratio of at least 5 to 1 or a water absorbency ratio of at least 5 to 1. The sorbent media have first and second major surfaces with abrasion resistant, liquid permeable, integral skins and fibrous cores. The liquid permeable skins of the media are formed by melting fibers at and immediately adjacent the major surfaces of the mats to form thermoplastic melt layers which are subsequently solidified into the skins on the major surfaces of the mats. For many applications, the thermoplastic fibers of the mats are point bonded together at spaced apart locations to increase the integrity of the mats.

Abstract: A mold assembly and method for molding a substantially hemispherical construct from pre-expanded polystyrene beads. The mold assembly includes a female half mold; a mating male half mold; a first male mold insert mountable on the male half mold and having a continuous, peripheral, beveled edge; and a second male mold insert mountable on the first male mold insert. For forming a construct having an impact-resistant exterior layer and an energy-absorbing interior layer, such as a motorcyclist safety helmet, the beads are initially molded under heat and compression between the female half mold and the first insert to form a first intermediate product of a first volume having a continuous, peripheral, beveled edge; said product is thereafter molded under heat and compression between the female half mold and the second insert to a second, reduced volume to form a compressed, second intermediate product, the beveled edge of the first intermediate product serving to uniformly distribute the force applied thereto.

Abstract: The invention relates to the production of a material compositions where recycled vulcanized rubber constitutes the main component. By using expandable microspheres, an internal pressure is generated when a powder-like mixture of recycled particles of rubber are heated in a sealed mold.

Abstract: A method of curing a polymeric binder onto a powdered metal after such polymer has been coated on the powdered metal but before a part is therefrom molded, thereby forming a polymer matrix-powdered metal composite material. The polymer-coated powdered metal may be cured by retaining the polymer-coated powdered metal in a fluidized bed contained within a fluidized bath (e.g. a fluid bed coater/drier apparatus) even after the coating process has terminated. The temperature of the fluidized bath may then be raised, in turn raising the temperature of the fluidized bed, thereby curing the polymer onto the coated powdered metal in situ. By keeping the polymer-coated power metal in constant motion during the curing process, the polymer-coated powdered metal particles do not agglomerate nor otherwise adhere to other coated powdered metal particles.

Abstract: This invention relates to a process for the production of wood composite materials. This process comprises combining wood particles with a mixture comprising a solid compound comprising urea and/or melamine, and a polymethylene poly(phenyl isocyanate), followed by molding or compressing the coated combination of wood particles.

Abstract: A method and an apparatus for manufacturing thermoset webs of thermoplastic polymer material which is comminuted into particles, such as flakes, granulated material or the like or is ground into powder. The thermoplastic polymer material particles are distributed uniformly on the lower conveyor belt; the distance between the lower and upper conveyor belt is maintained equal to the thickness of the web to be manufactured; the initial layer poured onto the surface area of the lower conveyor belt is applied with such a thickness of the layer that the thermoplastic polymer material particles are subjected during the entire transport between the upper and lower conveyor belts in the heating and cooling sections only to a minimum pressure of at most 0.

Abstract: A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m3; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

Abstract: A method of manufacturing an articulating bearing surface for use in an orthopaedic implant uses a supply of ultra-high molecular weight polyethylene particles which are irradiated with sufficient radiation energy to crosslink at least a portion of the ultra-high molecular weight polyethylene. The irradiated particles are then formed into an orthopaedic bearing surface.

Abstract: Approaches are described for producing porous, polymer electrodes with good characteristics for incorporation into polymer batteries. Two preferred processes are presented. The polymer electrodes can be subjected to additional processing to increase their porosity and electrical conductivity. The polymer electrodes preferably are incorporated into a polymer battery where the components are laminated together.

Abstract: An improved process for producing a consolidated polymeric monolith from an assembly of thermoplastic polymer fibers. The assembly is placed under pressure to fill a majority of the voids thereof by mechanical deformation of the fibers, and heated to a temperature too low to melt the fibers at the deformation pressure but sufficiently high to at least partly melt the fibers at a lower transition pressure. While maintaining the assembly at this temperature, the pressure is reduced to the transition pressure long enough for partial melting of the fibers to fill the rest of the voids, and then is increased to a consolidation pressure at least as high as the deformation pressure. The assembly is cooled slowly to ambient temperature at the consolidation pressure.

Abstract: Coated fuser members such as a fuser roller, pressure roller, or fuser belt, and the method of making the coated fuser members are disclosed. The release coating comprises an outermost layer of fluoropolymer resin uniquely bonded to a fluoroelastomer layer.

Abstract: A polishing pad having a substantially uniform, continuously interconnected porous surface. The pad can be produced by pressure sintering powder compacts of thermoplastic polymer at a temperature above the glass transition temperature but not exceeding the melting point of the polymer. The sintering process is conducted in a mold at a pressure in excess of 100 psi (0.07 MPa). In a preferred version, a mixture of two polymer powders is used, where one polymer has a lower melting point than the other.

Abstract: A process of producing an asphalt-impregnated fiberboard comprises the steps of forming an aqueous slurry of a fibrous material and asphalt, the solids content of the slurry being less than about 8 weight percent, mixing the slurry to uniformly distribute its components, dewatering the slurry to form a wet mat, pressing the wet mat to consolidate it, and drying the consolidated wet mat. Fiberboards made by the process can be employed as durable resilient expansion joints between various types of structural members.

Abstract: Process for the preparation of manufactured products based on vinylaromatic polymers with a predominantly syndiotactic structure which comprises:a) compressing the polymer in powder form in a mould at a pressure ranging from 0.1 to 500 MPa;b) sintering, under pressure, the compact powder at a temperature ranging from the glass transition temperature (Tg) of the polymer to the melting temperature (Tm);c) cooling the manufactured product to room temperature.

Abstract: Disclosed is a process of converting asphalt composition roofing shingles into dimensional construction products. Asphalt composition roofing shingles are de-consolidated, such as by grinding, into a crumble. The asphalt shingle crumble is processed in a manner to increase the fusibility activity of the asphalt without decomposing a substantial fractional amount of the asphalt to an ash-like brittleness. The foregoing can be achieved by heat exchange using infrared heaters as the heat source. One disclosed example trial of the process warmed the crumble to a bulk temperature of between about 130.degree. F. and 150.degree. F. Following that, the asphalt shingle crumble is compacted into the shape of a given dimensional construction product such as blocks, curbs, tiles, beams, posts, and so on. The best quality products are achieved by a two-step compaction process in which there occurs a certain time elapse between the two compaction steps.

Abstract: The invention is used to manufacture an inhomogeneous medium whose porosity and permeability undergo rapid transitions from one point to another of its volume, by juxtaposing different materials without creating a barrier. Such a transition is made by juxtaposing a first material and a second material with a different porosity to the first. One of them can be a rock sample such as sandstone for example, the other can be a composite material obtained by agglomerating pyrex powder for example, the whole being heated according to a specific temperature cycle up to a temperature (TR) lower than the melting point of the two materials but sufficient to achieve partial melting of one of the materials at the interface with the other material, but without formation of a continuous or discontinuous capillary barrier between them, or an interzone with preferred passage for fluids. Thus, different composite materials can be juxtaposed to constitute the inhomogeneous medium.

Abstract: An improvement in the preparation of fiber preforms in which binder and fibers are dispersed to contact on vacuum-supplied screens is disclosed, comprising particularly (a) selecting a particulate binder material which is solid at 25.degree. C; (b) heating the binder material, during initial contact with the fibers, to a viscosity and for a time which is the same as or proportional to 1,000 centipoise for one second; and (c) dispersing the binder material and the fibers such that the preform exhibits a variation in the ratio of fibers and binder which correlates to a coefficient of variation which is less than or equal to about 5 percent. The resulting preform shows superior compaction and uniformity of constitution even when it is prepared in sections or in asymmetric configurations.

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 present invention provides a carbon composite material which is a molded material comprising (a) an expanded graphite powder and (b) a thermoplastic resin or a thermosetting resin or a fired product of the thermosetting resin, and the expanded graphite powder (a) being dispersed in the component (b), wherein the expanded graphite powder has an average particle diameter of 5-12 .mu.m and at least 80% of the total particles of the expanded graphite powder have particle diameters of 0.1-20 .mu.m; and a process for producing a carbon composite material, which comprises mixing and dispersing a thermoplastic or thermosetting resin and the expanded graphite powder as mentioned above, and then pressure-molding the resulting mixture at room temperature to 400.degree. C., or a process for producing a carbon composite material, which comprises mixing and dispersing a thermosetting resin and the expanded graphite powder as mentioned above, pressure-molding the resulting mixture at room temperature to 400.degree. C.

Abstract: Polyolefinic foam beads which can be processed over a wide temperature range to give molded articles where a ratio of the areas of low-temperature peak and high-temperature peak in the DSC curve during the first heating has a value of not more than 3, and where the heat of fusion of the secondary crystals is greater than 10 J/g.

Abstract: A wave absorber comprising first foamed particles comprising foamed particles of a thermoplastic organic polymer and a conductive layer formed on the surface thereof, and second foamed particles comprising foamed particles of a thermoplastic organic polymer, the first foamed particles and the second foamed particles being melt-adhered to each other, and a method for producing same. The wave absorber of the present invention is superior in a long-term shape retention, and shows superior wave absorption performance, thereby rendering itself suitable for use in an anechoic chamber.

Abstract: Pre-inked impression members for hand stamps are made from a gel or premix of thermoplastic resin particles and liquid ink with use of a disposable molding device comprising a matrix board that is recessed in its molding area with cavities to form inked indicia of the impression members and has a peripheral surface area to which is adhered fluid-tight, and entirely about the molding area, an upright rigid wall means comprising a structure of fiberboard, wood, hard resin or other suitable material shaped to a height corresponding to the desired thickness of the impression members. As another feature, during the heating for curing of a layer of premix formed over the molding area of a matrix board, the layer of premix is confined in place by a covering means, applied over it and held under pressure, which comprises, together preferably with overlaid pliable ink-absorbent material, e.g.

Abstract: Rigid-rod and segmented rigid-rod polymers, methods for preparing the polymers and useful articles incorporating the polymers are provided. The polymers incorporate rigid-rod backbones with pendant solubilizing groups attached thereto for rendering the polymers soluble.

Abstract: Disclosed herein is a method for continuously producing an expansion-molded article, comprising feeding foamed particles between a belt continuously traveling along the upper surface within a passageway defined by structural members and having a rectangular form in section and a belt continuously traveling along the lower surface within the passageway, and then causing the foamed particles to successively pass through a super heated steam-feeding region and a cooling region within the passageway. The foamed particles used are foamed particles of a polyolefin resin, in which a recovery factor from compression defined by the equation (1):Recovery factor from compression (%)=V.sub.2 /V.sub.1 .times.100(1)wherein V.sub.1 is the original bulk volume of the foamed particles, and V.sub.

Abstract: A process for producing a porous body of tourmaline includes the step of sintering a mixture of fine powder of tourmaline and fine powder of polyethylene or fine powder of polypropylene.

Abstract: A process for the manufacture of porous structures comprises forming a dry mixture comprising a component providing primary separation capability, a component providing green strength reinforcement capability and, a component providing binding capability and selected from the group consisting of thermoplastic and thermosetting polymers; delivering the mixture to a suitable surface and building a desired thickness thereof; densifying the mixture into tile form desired for the porous structure; removing the densified porous structure from the surface; binding the component providing the primary separation capability by melting the mixture to a temperature of up to about 20.degree. C. higher than the melting point of any thermoplastic component providing binding capability.

Abstract: A method of constructing multi-layer products for absorbing fluids is disclosed. In the methods of the present invention, two or more layers of materials chosen to vary in recovery are compressed such that an absorption gradient forms through the continuous intimately associated layers. A first layer preferably remains densified while a second layer "blooms" to form an open, absorptive layer, which acts as a reservoir, drawing absorbed fluids into the densified layer, where they are retained.

Abstract: Process for the production of sheets or molded bodies from lignocellulosic materials utilising an organic polyisocyanate binder material and a release agent which is an aqueous emulsion of a polyolefin wax.

Abstract: A process for recycling rubber, elastomers, and thermoset materials in which the material to be recycled is pulverized in a manner which maintains the chemical composition of the material, producing a powder. The powder is introduced into a mold which is heated to a temperature of at least about 200.degree. C. and a compression force of at least about 10 tons is applied to the powder for a period of at least one hour, resulting in formation of a single piece of the rubber, elastomeric, or thermoset material, with no change in chemical structure.

Abstract: The invention relates to a molded part made of completely biodegradable starch foamed material to be used for protecting transported articles and to a method for its preparation, wherein the starch foamed material is expanded to form starch foam profiled sections which are self-adhesive when moisture is applied and can be processed individually or so as to form single or multi-layer foam panels. The advantages reside in improved operating properties and minimized expenditure on packaging.

Abstract: A process is described for the manufacture of tannin-bonded particle- and fiberboard wherein the binding of wood chips and fibers is accomplished by obtaining the formaldehyde necessary for the cross-linking of tannin by the hydrolytic decomposition of the binder present in old particle- or fiberboard. The formaldehyde obtained by hydrolytic decomposition is cross-linked with the tannin by high temperature and moisture during pressing.

Abstract: A method of imprinting a workpiece includes lasing the workpiece to create a depression or other opening, depositing a laser-fusible polymer material into the depression, and then lasing the material so as to fuse the material into the depression. Preferably, the laser-fusible polymer material is fusible in the near infrared spectrum. An alternate method for imprinting using colored powder paints includes an additional step of heating the workpiece to ensure thermosetting of the colored powder paint. Laser fusible materials having particular physical characteristics and compositions may be used to facilitate the process.

Abstract: This invention relates to a method of manufacturing molded wooden products composed of a wooden body and a skin material. This method employs materials having long working life and enables simultaneous integral molding of the wooden body and the skin. The obtained molded wooden product has excellent characteristics.

Abstract: Improved compositions useful for the production of foamed rotomolded articles are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a foaming agent and a second thermoplastic resin component which is a powder consisting of a mixture of different particle size and melt index ethylene polymers. An improved process for producing foamed rotomolded articles having uniformly foamed interiors and smooth exterior skins which are substantially free of surface defects is also provided.

Abstract: A method of forming a thermoactive binder composite product is performed by injecting a hot dry gas to activate the thermoactive binder. In the preferred embodiment, the hot dry gas is air. The method is particularly beneficial as applied to forming thermoplastic composite products and particularly thermoplastic/cellulose composites. Also part of the present invention is a two stage pressing process in which hot gas is injected during the first stage and the press charge is precompressed. The press charge is then placed in a second consolidation press where the hot gas is no longer injected and it is consolidated and cooled. Machinery for practicing the method includes a platen with a platen press which includes upper and lower platens with a plurality of hot air injection jets disposed on the surface of each platen. The platens are spaced apart and surrounded on the sides by an air-permeable containment shell structure to form a compression chamber to hold the base material to be pressed.

Abstract: An integrated filter and sleeve assembly has an annular non-porous sleeve having opposing open ends and an outer circumferential wall with an inner surface. The integrated filter and sleeve assembly also has a filtration block disposed within the annular sleeve between the open ends. The filtration block includes a mixture of filtration media and a binder. A seal is formed between the inner surface and the filtration block by applying heat to the annular non-porous sleeve and the filtration block.

Abstract: Improved compositions useful for the production of foamed rotomolded articles are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a foaming agent and a second thermoplastic resin component which is a powder consisting of a mixture of different particle size and melt index ethylene polymers. An improved process for producing foamed rotomolded articles having uniformly foamed interiors and smooth exterior skins which are substantially free of surface defects is also provided.

Abstract: The end face (32) of the optical fiber (24) of a fiber optical terminal (10) is finished by installing the fiber in a terminal ferrule (18), cleaving an end of the fiber close to the end face (54) of the ferrule, and heating the cleaved fiber end face so as to soften its end face and cause it to assume a smooth, rounded configuration. The heating is accomplished, for a glass fiber, by application of the beam of a carbon dioxide laser (60) to the optical fiber end face. The heat softened end face assumes a smooth, rounded configuration that minimizes back reflection. A system including a laser (105), shutter (102), beam expander (108) and parabolic mirror (110) heats the fiber end face that is positioned at the parabola faces by a three axis manipulator (156,158) and holder (152). Orthogonal viewing systems (126, 142) enable visual monitoring of the process.

Abstract: Provided is a process for manufacturing sintered polybenzimidazole (PBI) articles at high yields, said articles having neither voids nor porous, low-strength parts resulting from oxidative deterioration. To produce said sintered PBI articles from a particulate PBI resin, said PBI resin is compacted in a closed mold, the mold is heated up to a predetermined temperature of from 350.degree. to 600.degree. C. without applying any external pressure thereto, then, after having heated up to said predetermined temperature, the mold is pressed to have a predetermined external pressure of from 140 to 1400 kg/cm2 at said predetermined temperature whereby the resin is sintered for from 60 to 350 minutes under that conditions, and finally the sintered PBI article is cooled and taken out of the mold.

Abstract: A composite powder specially adapted for use in selective laser sintering is disclosed. The composite powder includes a polymer powder dry mixed with a reinforcement powder, where the polymer powder has a melting temperature substantially lower than that of the reinforcement powder. In the case where nearfully dense parts are to be formed, the first constituent powder is preferably a semi-crystalline powder, for example nylon 11, of a composition suitable for forming near-fully dense parts when used unblended in selective laser sintering; if porous parts are desired, the polymer powder is an amorphous powder, such as polycarbonate, polystyrene, acrylates, and styrene/acrylate copolymers. The reinforcement powder is preferably microspheres of glass, preferably coated to enhance wetting and adhesion with the polymer powder when selective laser sintering is performed.

Abstract: Rigid-rod and segmented rigid-rod polymers, methods for preparing the polymers and useful articles incorporating the polymers are provided. The polymers incorporate rigid-rod backbones with pendant solubilizing groups attached thereto for rendering the polymers soluble.