Abstract: A process for the continuous production of a high modulus article comprising a composite of an oriented plastic material and an oriented particulate material, said process including the steps of:a. continuously forcing an orientable plastics material, while it is close to or at its softening temperature and in admixture with an orientable particulate material, through a converging passage of which the cross-sectional area diminishes in the forward direction of plastic flow, thereby to produce an extrudate;b. deforming the extrudate, while it is maintained at or close to its melt temperature, to produce an oriented, deformed extrudate; andc. cooling the deformed extrudate to preserve the orientation and provide said composite. The foamed and unfoamed composite articles have strength, modulus and density values comparable to typical hardwoods or softwoods.

Abstract: A sun visor having a sun-visor body with a stiffening at or close to the edge of the sun-visor body. The sun visor body and stiffening being comprised of polypropylene particle foam, the stiffening being substantially harder and stiffer than the remaining regions of the sun-visor body. A method and an apparatus for the manufacture thereof are also disclosed.

Abstract: In a method and apparatus for making highly densified compression sheets from thermoplastic polymeric compounds preferably together with reinforcement fiber mats in a continuous fashion in a double-band press in which the compound material is heated and compressed between two compression bands which extend between reversing inlet and outlet drums and define between adjacent sections a wedge-shaped precompression zone adjacent the inlet drums wherein the compound material is increasingly compressed and also heated and a final compression zone adjacent the precompression zone, wherein the compound is heated under pressure such that the thermoplastic melts and fully wets any fibers in the sheet and an end compression zone in which the sheet is cooled which the pressure is maintained and the compound material is retained in the space between the compression bands by seal bands extending along the side edges of the compression bands and maintained in sealing engagement therewith.

Abstract: A method of producing a form-stable sintered porous shaped phenolic resin article with continuous open pore structure and high macroporosity, in which a phenolic resin mixture is partially cured to a solid which is then comminuted to give a comminuted resin. The comminuted resin is admixed with water, hexamethylene tetramine and a cellulose ether, and the resulting comminuted resin mixture is formed into a shaped article which is allowed to come to equilibrium with air having a relative humidity of less than 100% at a temperature below 100.degree. C. The shaped article is then sintered to produce a form-stable sintered porous product.

Abstract: A method of manufacturing a cushion material including steps of: a mixed fiber manufacturing process in which main fibers and a plurality of types of heat-fusible fibers, which are formed of main fibers and sheath portions and whose sheath portions have different melting points, are mixed so as to make mixed fibers; a supplying process in which the mixed fibers are spread at a substantially uniform density at an entire one forming mold of a plurality of forming molds; and a heating process in which the mixed fibers spread at the entire one forming mold are heated such that a heating temperature of portions of a cushion material which are to be formed hard differs from a heating temperature of portions of the cushion material which are to be formed soft so that a number of types of the heat-fusible fibers which melt at the portions of the cushion material which are to be formed hard is greater than a number of types of the heat-fusible fibers which melt at the portions of the cushion material which are to be f

Abstract: Moldings of ultra high molecular weight polyethylene powder are produced by heating the polymer powder at 160.degree. to 280.degree. C. in a mold without applying pressure or at a pressure of up to 0.5 MPa, and then cooling it to room temperature at a pressure of from 4 to 20 MPa.

Abstract: A process for creating a three-dimensional shaped object by providing a container having a fluidized bed of fusable particles therein and a base plate disposed within the particle bed below an upper level of the particles. A heat beam is directed in a desired pattern onto the upper level of particles above the base plate to fuse certain of the particles together to form a formed shape with the base plate then being lowered. A new upper level of fusable particles from the particle bed covers the formed shape, selected of which particles are then heated by the heat beam in a desired pattern to fuse the thus-heated particles to one another and to fuse the particles to the previously fused formed shape of particles with the process continuing until the desired three-dimensional shaped product is formed and removed from the particle bed.

Abstract: A method for producing articles comprised of reinforced composite materials including primarily wood or cellulosic fiber and plastic is disclosed.. The wood fibers are comminuted to substantially a specific thickness and classified according to length. Plastic is comminuted and mixed with wood fibers to form a reinforced composite mixture in predetermined ratios. The composite materials form the main structural or bonding components of the finished article. Other chemicals, such as a coupler can be added, as can other structural components, such as fiberglass. The mixture is deposited onto a mold when forming articles having deep drawn portions, and subjected to sufficient temperature and pressure to cause the composite mixture substantially to assume the mold form. The process variables disclosed can be selectively modified to produce predetermined physical characteristics in the finished article, such as strength, thickness or prestressed qualities.

Abstract: A method is disclosed for forming a reinforced plastic skin for an automobile interior trim structure. The method includes the steps of supplying a plastic material onto a mold surface, heating the plastic material to fuse it into a unitary layer, embedding a reinforcing material into the layer, and cooling the plastic and reinforcing materials. The method can be used to reinforce an air bag door cover by incorporating a tear seam into the plastic layer and embedding the reinforcing material into the layer such that it surrounds the tear seam. The reinforcing material aids in rupturing of the cover along the designated tear seam during deployment of the air bag. Also disclosed is an air bag door cover formed in accordance with the disclosed method.

Abstract: Quaternary ammonium polyarylamides are provided that are useful in articles of manufacture that require minimal ionic impurities. The polyarylamides are produced by reacting certain polyamides together with quaternary ammonium bases of the formula R.sup.4.sub.4 N.sup.+ X.sup.-, wherein each R.sup.4 is independently selected from hydrocarbyl or substituted hydrocarbyl, provided that at least one of the R.sup.4 groups contains at least one beta hydrogen atom. There is also provided the process for producing the polyarylamides, the process for making articles of manufacture from the polyarylamides, and a process for modifying the surfaces of such polyamides.

Abstract: A process for manufacturing latex-, PVC- and plasticizer-free textile or plastic floor or wall coverings, which contain a foamed layer, in which a powder mixture containing:(1) 100 parts by weight of a thermoplastic polymer;(2) 0-100 parts by weight of fillers;(3) 0.5-7 parts by weight of blowing agents; and(4) 0-30 parts by weight of additives;is scattered onto a backing layer, melted at a temperature within the range of from about 70.degree. to about 110.degree. C. smoothed between smoothing rolls and foamed at a temperature within the range of from about 120.degree. to about 200.degree. C.

Abstract: Disclosed are a foamable resin composition which comprises a copolymer with a weight-average molecular weight of 150,000-350,000 produced by copolymerization of a monomer mixture of 55-85% by weight of styrene and 45-15% by weight of a methacrylic acid ester represented by general formula (I)CH.sub.2 .dbd.C(CH.sub.3)COOR (I)(wherein R represents a C.sub.

Abstract: Bearing compositions having a polymeric core and cast outer metal exhibit excellent structural integrity in use.

Abstract: A sintered product based on mesocarbon microbeads is prepared by pressure-molding mesocarbon microbeads (MCMB) having an MSP (maximum solubility percent) value of 30 to 38% by volume whereby a body is formed, and sintering the body, wherein MSP represents the percentage volume reduction (volume %) determined by heating a given amount of an MCMB to 350.degree. C. under a pressure load of 10 kgf/cm.sup.2. The quality of a molded MCMB sintered product can be controlled by determining the percentage volume reduction (MSP) of an MCMB by heating it under a given pressure load in a predetermined space using the MSP value so found as an indicator.

Abstract: A non-woven solidified by means of a melt binder is described, which is based on supporting aramid fibers and on binding fibers made of thermoplastic aramids whose melting point is below the melting or decomposition point of said supporting aramid fibers. In the non-woven, the binding fibers are virtually completely melted. The non-wovens are distinguished by high strength.

Abstract: Particles of a fine powder of a thermoplastic synthetic resin (host powder) having a suitable broad range between its initial glass transition temperature (initial T.sub.g) and its final T.sub.g, are partially coated with an anti-caking coating powder (coating powder) by blending at an elevated temperature to form "mottled" particles. The elevated temperature is defined in relation to the initial and final T.sub.g s as: (initial T.sub.g -20).degree. C. but below the final T.sub.g. Mottled particles, without being encapsulated, have the unique ability to maintain their individual particulate characteristics at a temperature at least 10.degree. C. above the initial T.sub.g of the uncoated host powder, and flow freely under applied pressure. Such pressure is applied by a rolling drum which spreads the mottled particles onto a target bed where they are selectively sintered With a controlled high energy beam, usually a laser beam.

Abstract: Flexible, porous, absorbent polymeric macrostructures having flexibility even after extended periods at elevated temperatures and/or low humidities are disclosed. The macrostructure comprises an interparticle crosslinked aggregate and an effective amount of a suitable plasticizer. The macrostructures are suitable for use, for example, in disposable absorbent articles such as diapers.

Abstract: Ecologically safe constructional materials, and particularly large-sized constructional structures such as wall plates can be economically produced. Wood or another vegetable material ground to the particle size of not more than 2.times.10.sup.-3 m, dried to 9-11% moisture content, heated by heating the press-mold to the 200.degree. to 220.degree. C. temperature and adding ground material heated at least 120.degree. C., and loaded it into the press-mold for 1 to 1.5 min. per 1.times.10.sup.-3 m of produced pressed material. After that, pressing is done in a hermeticly sealed press-mold at this temperature at a pressure of not less than 30.0 MPa with exposure to this pressure for 1 to 1.5 min. per each 1.times.10.sup.-3 m of produced pressed material followed by cooling of press-mold without depressurization at full pressure.

Abstract: A method of manufacturing a cushion material for seat pads comprises a step for filling a mold part that will form the cushion material with a mixed fiber containing a thermofusible fiber, a step for engaging this mold part with another mold part, and a step for applying heat to a specific region of the mixed fiber that will form a bottom surface so that the thermofusible fiber in the specific region melts before the thermofusible fiber in the other region of the mixed fiber that will form a sitting surface of the cushion material.

Abstract: A sintered film containing a copolymer and optionally other common additives is described. The film contains about 30 to 70 parts by weight of a propylene copolymer with a melt index MFI 230/2.16 of at least approximately 3 g./10 min. and about 70 to 30 parts by weight of an ethylene-ethyl acrylate copolymer with a melt index MFI 230/2.16 of at least approximately 3 g./10 min. and with a Vicat softening point of at least about 40. The ethylene-ethyl acrylate copolymer contains approximately 7 to 35 wt % of ethyl acrylate. This film exhibits advantageous properties, particularly a good Shore A hardness.

Abstract: Method for forming polyvinyl alcohol (PVA) into surgical elements include forming a mixture of PVA and water into a film by vacuum pressing with a first force, heating, applying a second force two to two hundred times the firs force, drying the film to remove water to a content of less than about 10% by weight based on the weight of the film, and molding the film into a desired shape.

Abstract: The present invention generally relates to manufacturing apparatus, method of manufacture, and products manufactured thereby and more particularly to an integral three-dimensional object (6, 15) formed from individually contoured laminations (4, 62) of the same or gradually varying shape, successive laminae of that object being produced out of thin sheet or powder based materials (1, 60) through the cutting, fusing or physiochemical property changing action generated by a computer directed beam (7) of concentrated energy or matter, successive substantially planar laminations (4, 62) of that object (6, 15) being automatically stacked together for step-wise laminar buildup of the desired object (6, 15).

Abstract: A novel, heterogeneous ion exchange membrane, methods for making such a membrane, and devices containing such a membrane are disclosed. Such membranes comprise linear low or linear medium density polyethylene or high molecular weight high density polyethylene as a binder and can incorporate a wide variety of ion exchange resin materials. The membranes can be fabricated using extrusion or other melt processing procedures to produce a product, which upon conditioning in water, exhibits properties adapted for use in numerous applications.

Abstract: An isocyanate bonded wood composite, such as a doorskin, comprising about 95% to about 99% by weight wood fiber, about 1% to about 4% by weight of an organic isocyanate and 0% to about 2% by weight of a wax, and its method of manufacture, are disclosed. The isocyanate bonded wood composite is manufactured by admixing the ingredients, then pressing the admixed ingredients at a temperature of about 200.degree. F. to about 320.degree. F., for a sufficient time and at a sufficient pressure, to provide an isocyanate bonded wood composite having a density of about 0.9 g/cc to about 1.1 g/cc, and that demonstrates improved porosity and adhesive properties.

Abstract: A process for thermoplastic processing and sintering an unplastifiable polymer comprises dispersing the unplastifiable polymer in powder form in a melt of a polyacetal or a mixture of polyacetals, cooling the resulting mixture, granulating it, forwarding the granules to a thermoplastic processing stage, injection or extrusion molding, exposing the molding to an atmosphere which contains an acidic gas, thereby de-polymerizing the polyacetal, enveloping the remaining porous molding on all sides in a gas/liquid-impermeable film, heating in an autoclave, and isostatically sintering the molding with pressure from all sides to form the finished article.

Abstract: Binding compositions for the manufacture of lignocellulosic composites comprising an aqueous emulsion of polyisocyanates and a release agent obtained by reacting a polyisocyanate with an oxyalkylic hemiester of a C.sub.9 -C.sub.18, saturated or unsaturated, monocarboxylic fatty acid.

Abstract: Bonding non-woven fibrous structures, especially using polyester fibers as the load-bearing elements, with electromagnetic radiation after applying an electromagnetic radiation susceptor to a polyester fiber with a high amorphous content so it acts as a binder fiber between load-bearing elements.

Abstract: A fiber blending system includes an apparatus and method of forming a mat of cellulosic fibers and synthetic fibers, as well as a mat thereby formed. The method includes the steps of fiberizing cellulosic material into cellulosic fibers in a fiberizer, volumetrically metering a metered amount of synthetic fibers, and injecting the metered amount of synthetic fibers into the cellulosic fibers. The cellulosic fibers are blended with the metered amount of synthetic fibers in a blending chamber to form a fiber blend. The fiber blend is dispersed through a fiber disperser having apertures of a preselected size and shape to provide a dispersed fiber blend. A third type of fiber may also be mixed with the dispersed fiber blend. The dispersed fiber blend is collected as a mat on a fiber collector to provide a mat of blended cellulosic and synthetic fibers. The mat may be thermobonded by a thermobonder and sandwiched between a facing sheet and a backing sheet.

Abstract: A process for producing shaped or molded articles made of polymer particles containing aromatic imide linkages includes the steps of introducing the polymer particles into a chamber for heating the particles, the chamber having a blade which rotates in the chamber and heats the particles by impacting them; heating the polymer particles to a forming temperature; discharging the polymer particles into a shaping device, such as a mold; and, pressurizing the polymer in the shaping device until the polymer particles consolidate into the shape desired. The process has proven to be effective with polymers that are difficult to process, such as thermoplastic polyimide polymers, polyetherimide polymers, bismaleimide polymers, polyarylate polymers, amideimide polymers, and other polymers containing fully reacted aromatic imide linkages.

Abstract: A method for making a particulate filled polymeric matrix composite film includes mixing a polymeric matrix material with a dispersion of particulate filler in a carrier liquid to form a casting composition and adjusting the viscosity of the casting composition to retard separation of the particulate filler from the composition. A layer of the viscosity-adjusted casting composition is cast on a substrate and the layer is consolidated to form the particulate filled polymer matrix composite film. Films made by the method include very thin, e.g. less than 1.0 mil, fluoropolymeric matrix films highly filled with very small diameter, preferably spherical, particles for use as, e.g. dielectric substrate materials in laminar electrical circuits.

Abstract: An iron powder composition comprising an iron powder coated with a substantially uniform coating of a thermoplastic material and admixed with a boron nitride powder and a method of utilizing the mixture to produce a magnetic core component is provided. The iron powder mixture is formulated with up to about 1% by weight of boron nitride which reduces the stripping and sliding die ejection pressures during high temperature molding and also improves the permeability of the magnetic part over an extended frequency range.

Abstract: Disclosed is a process for preparing a multilayered cylindrical article which comprises introducing into a cylindrical mold a composition comprising a liquid, uncured resin material and a magnetically attractable filler material, spinning the mold about its axis, applying a magnetic field to the composition within the mold, thereby attracting the magnetically attractable filler material in the direction dictated by the magnetic field and causing the magnetically attractable filler material and the liquid uncured resin material to separate into layers, and subsequently curing the uncured resin to form a cylindrical article having at least two layers. Subsequent to formation, the multilayered cylindrical article can be coated with additional layers. Further, additional layers can be added to either the inside or outside surface of the cylinder by introducing the additional layer material into the mold and spin casting to form a layer.

Abstract: In order to prepare thermoplastic molding materials from pulverulent polyphenylene ethers and aromatic vinyl polymers by melt extrusion, the pulverulent polyphenylene ether is first of all compacted and/or sintered under pressure and if necessary with the addition of heat, preferably under a pressure corresponding to a nip pressure of from 1 to 100 kN/cm, to form a porous compact. The compact is then fed in the form of agglomerates having a particle size of from about 0.5 mm to about 20 mm into an extruder or the like, mixed with the aromatic vinyl polymer and if desired further components, and melted. In this way the proportion of the fines in the polyphenylene ether is considerably reduced, with the result that there is virtually no further danger of dust explosions. Further advantages include improved ease of metering and reduced electrostatic charge of the agglomerates. The extruded molding materials have good mechanical properties and also high thermal stability.

Abstract: In a batch process for repetitive molding of fiberballs into cushions that are required in the same specific shape in large numbers, the molds are filled continuously by means such as a chute.

Abstract: A composite element which comprises an elastic, cellular top layer (A) and a rigid base layer (B) of thermoplastic polyurethanes, the polyurethane elastomer (B) of the base layer being prepared by reactingBa) 1 mol of at least one essentially linear, relatively high-molecular-weight polyesterol or polyetherol,Bb) from 6 to 15 mol of an organic diisocyanate, preferably 4,4'-diphenylmethane diisocyanate, andBc) from 5 to 14 mol of at least one alkanediol or dialkylene glycol,in the presence ofBd) from 0.05 to 0.3% by weight, based on the total weight of (Ba) to (Bc), of water, and, if desired,Be) a catalyst, andBf) assistants and/or additives, is used as a cushioned fitting for vehicles.

Abstract: Process for creating a shaped product from a plurality of particles by having a heat beam directed thereon in a desired pattern, fusing the particles into a structure in the desired pattern where the heat beam was directed, such shaped product being removed from the remainder of the unfused particles, such process in some embodiments being a continuous process.

Abstract: Disclosed is a cold molding process for the production of a unitary article from a plurality of plastic particles. The process may be conducted without the addition of heat. A plurality of homogeneous or heterogeneous plastic particles are introduced into a mold, softened by exposure to a softening agent, and thereafter compressed to form the unitary article. Preferred softening agents comprise an organic component and an aqueous component. One preferred softening agent-plastic combination comprises aqueous methylethylketone and polystyrene.

Abstract: A method for making improved surface profile composite structures containing crystalline thermoplastic materials involves employing individual glass filaments and molding with a hot mold insert. The method provides composites having smooth surfaces suitable for automotive applications.

Abstract: A method for forming a hidden tear seam in the cover for a safety air bag assembly comprises the steps of filling a heated open mold with liquid plastisol or dry powder comprised of polyvinyl materials; forming a gel layer of polyvinyl chloride material on the open heated thin metal mold; dumping excess polyvinyl liquid plastisol chloride material from the gel layer; fusing the gel layer; stamping a tear seam in a fused layer while it is still plastic by providing an anvil having a surface thereon of a first predetermined area and including an embossment thereon extending outwardly of said first predetermined area and stamping the tear seam by directing the embossment into the fused layer until the surface engages the fused layer and wherein the first predetermined area is sized to produce a reaction force on the anvil to determine the depth of penetration of the embossment and thereafter finally curing and cooling the fused layer and removing same from said thin metal mold.

Abstract: Method for obtaining an organic polycrystalline material having in particular electro-optical properties, said material obtained and an electro-optical modulator comprising said material. This method includes a stage (1) for preparing a powder having a size grading of 500 to 800 nm of an organic compound having a delocalized system of .pi. electrons and presenting a non-centrosymmetrical crystalline structure, as well as intramolecular load transfer groupings, a stage (2) for drying the powder under vacuum, a stage (3) for pre-pressing the powder under vacuum, and a hot stage (5) for the uniaxial compression of the dried powder under vacuum. This method enables polycrystalline materials to be obtained, said materials comprising elongated monocrystalline grains orientated according to a given direction.

Abstract: Moldings made from polyolefin particle foams having a mean density of from 0.015 to 0.100 g/cm.sup.3 and having at least two different regions whose densities differ by from 0.005 to 0.030 g/cm.sup.3 have a transition zone between the different density regions having a thickness of not more than 25 mm. A method of forming the moldings, using removable mold dividing walls, is described.

Abstract: A method is disclosed for the densification of crosslinked fibers having a crosslinking agent loading level of from about 2.5 molar to about 5 molar %. The crosslinked fibers are compressed from an initial density of from about 0.02 g/cc to about 0.04 g/cc to a second density of from about 0.20 g/cc to about 1.00 g/cc by either the simultaneous or sequential application of heat and pressure. The surface temperature of the press is typically between about 60.degree. C. to about 180.degree. C. The compression force for the air laid or wet laid webs is in the range of about 800 psi to about 115,000 psi. Densifying the crosslinked fiber in this manner produces a compressed web having enhanced absorbent capacities of from about 21 g/g to about 15 g/g.

Abstract: A process for consolidating/molding a material made of (a) block copolymers of rigid or semi-rigid PBZ with thermoplastic polymers, (b) block copolymers of rigid PBZ with semi-rigid PBZ, (c) molecular composites of rigid or semi-rigid PBZ with thermoplastic polymers, (d) molecular composites of rigid or semi-rigid PBZ with non-rigid PBZ polymers or (e) semi-rigid PBZ polymers, whereby the material, in its substantially acid-free, wet coagulated state, and in the form of a plurality of films or film layers, filaments or fibers, powders or granules, film layers, filaments or particulate, is subjected to a first pressure P1 which is sufficient to provide a substantially void-free consolidated material upon molding. Heat and a second pressure P2 is then applied to the wet coagulated material in amounts sufficient to fuse the films or film layers, filaments or fibers, powders, or granules into a single entity.

Abstract: A process for the production of an integral composite molded item including(i) a surface portion having a synthetic resin phase containing a fibrous reinforcing material,(ii) a core portion having the synthetic resin phase containing bubble-containing particles, and(iii) a separation layer positioned between the surface portion and the core portion, the process including the steps of:providing in a substantially sealed mold (1) a separation layer which does not substantially pass therethrough bubble-containing particles but which is capable of passing a synthetic resin or its precursor that is liquidized at the time of molding; (2) a synthetic resin or its precursor on either or both sides of the separation layer; (3) a fibrous reinforcing material between the separation layer and the mold, and (4) an aggregate of bubble-containing particles on the side of the separation layer opposite to the mold;causing volume expansion of the aggregate;causing the resin to flow through the separation layer to thoroughly di

Abstract: A method of producing a molded foam article having an integral skin and a backing layer of foam comprising mixing particles of two polyvinyl compounds one of the compounds having a molecular weight less than that of the other compound and a higher solvating plasticizer than that of the other compound and casting the mixture against a heated mold surface and melting the one compound to flood the interstices of the particles of the other compound and float to the surface of the heated mold to form a skin and wherein the other compound includes foaming constituents to simultaneously form a layer of foam material behind the skin.

Abstract: The present invention relates to a process and a device for processing plastic waste, such as packaging foil of polyvinylchloride, polyethylene, polypropylene etc. into blocks by compressing it in a container. The processing of the plastic waste is achieved by compressing with a punch at a temperature of 120.degree.-180.degree. C. and a pressure of 250-400 g/cm.sup.2 and preferably at a temperature of 140.degree.-160.degree. C. and a pressure of 260-290 g/cm.sup.2, followed by cooling with air. The cooling is carried out by the introduction of air in the container by a fan, which cooling takes place in 5-15 minutes, and preferably 8-10 minutes. The device of the invention is provided with a punch, whereas the inner surfaces of said container and/or said punch are provided with a coating in order to prevent said softened and compressed plastic waste from adhering to the walls. The coating is preferably teflon, whereas the heating elements advantageously are electrical heating elements.

Abstract: According to the invention a moulding is produced by compression and extrusion at a temperature between 120.degree. and 160.degree. of a mixture of heat-setting resin and at the most 30% related to the total weight of mixture of a filler with a grain size between 50 micrometers and 4 mm. The filler is a mineral filler and/or natural fibres.

Abstract: A method of manufacturing an electromagnetic device having regions of ferromagnetic material and permanent magnet material is disclosed. The electromagnetic assemblies of this invention utilize thermoplastic encapsulated iron powders and epoxy resin encapsulated permanent magnet powder. A motor frame and permanent magnet assembly is formed in a first example, while a permanent rotor assembly is formed in a second. The motor frame and permanent magnet assembly has a ferromagnetic frame defined by a region of encapsulated iron powder and an annular array of permanent magnets defined by a region of encapsulated permanent magnet material. The permanent magnet rotor assembly has a ferromagnetic core defined by a region of encapsulated iron powder and a permanent magnet shell defined by a region of encapsulated permanent magnet material.

Abstract: A method for making stock shapes from a composition which includes a liquid crystal polymer having a high crystallization temperature, the method including: (a) densifying the composition into a compact; and (b) processing the compact at one or more temperatures below the crystallization temperature using a moderate to high strain rate. For the liquid crystal polymer consisting essentially of p, p' biphenol, p-hydroxybenzoic acid and terephthalic acid monomers and sold under the trademark "XYDAR.RTM.", a preferred embodiment includes heating the compact to one or more temperatures between about 400.degree.-650.degree. F.; and extruding the heated compact in the solid state through a uniform flow-type die at a strain rate of at least about 2 sec.sup.-1.

Abstract: A method for recycling expanded polystyrene foam materials. Unexpanded virgin polystyrene beads having pentane gas contained therein are thermally expanded to produce a supply of expanded beads. Next, a supply of used expanded polystyrene foam is obtained and ground into small portions, preferably of the same size as the expanded beads. The used polystyrene foam pieces are then placed in contact with pentane gas. The expanded beads and the pentane-treated foam pieces are thereafter combined to form a mixture which preferably contains not less than about 50% by weight foam pieces. The mixture is then placed in a mold, followed by the application of heat and pressure thereto in order to produce a final product with a high degree of structural integrity. The pentane gas treatment of the foam pieces enables the fusion thereof to the expanded beads, resulting in a highly durable product.