Abstract: A process for reclaiming residuals produced from the manufacture of decorative high pressure laminates (HPLs), and composite materials obtained by the process. Such residuals which include cellulose impregnated with thermosetting resins which are partially condensed, are ground to a predetermined particle size and mixed with a melted mass of thermoplastic resin under controlled pressure and temperature conditions. The mixing time is sufficiently long for completion of the reaction during which physical and chemical interactions occur between the partially polycondensed thermosetting resin and the thermoplastic resin. The material so produced can be converted into granules for subsequent injection molding. There is provided an effective solution to pollution problems and excessive expense problems associated with the disposal of scraps and residuals from the manufacture of decorative HPLs.

Abstract: Process for manufacturing needled spunbondeds from thermoplastic fibers wherein, prior to the needling, the as-spun web is thermally sealed at the surfaces and provided with a lubricant.

Abstract: A mass of ferromagnetic particles moldable into stable, high strength, magnetic cores useful in thermally and chemically hostile environments comprising an iron core and a continuous layer of polyetherimide, polyethersulfone or polyamideimide spray coated onto the surface of each particle. A method of preheating and molding the particles is disclosed.

Abstract: Polyimide which is obtained by polymerization and consists essentially of recurring structural units of the formula (I): ##STR1## wherein X is a single bond or a hexafluoroisopropylidene group, is processed to a form of pellet, followed by heat-treating to obtain crystallinity of 5% or more, and fed to an extruder to obtain articles.

Abstract: A biologically resolvable blind slat and the manufacturing method therefor, wherein PVC powders serve as a basic material and are added with stabilizer, lubricant, calcium carbonate and surface-treated starch to mix therewith, the mixture being processed by a granulating machine into granules which are further heated and pressed by a press machine into strips, the strips being then cut into blind slats in a certain pattern and at a certain length.

Abstract: According to the present invention, a polyolefin sheet, film or fiber having a high strength and a high modulus can be continuously produced by:feeding an ultra-high-molecular-weight polyolefin powder between a pair of upper and lower endless belts opposed to each other,conveying the polyolefin powder between the endless belts under compression to compression-mold the polyolefin powder at a temperature lower than the melting point of the polyolefin powder, the compression being continuously and smoothly effected, via the endless belts, by a pressing means comprising two sets of rollers which are arranged at the back sides of the endless belts so that each one roller of the two roller sets faces each other and each of which rollers is rotatably supported at the shaft ends by a frame, and thenrolling and stretching the resultant compression-molded polyolefin in this order.

Abstract: A novel process for fabricating a multi-colored foamed speckled thermoplastic sheet is disclosed, wherein differently colored preformed thermoplastic sheets are separately comminuted into particles by grinding the sheets at the temperature about equal to the glass-transition temperatures of the sheets. The ground fine particles of different colors are mixed in an appropriate ratio and are then calendered to form sheets. This process is economical and convenient for mass production.

Abstract: The invention relates to a process for recycling thermosetting polyurethane soft foams in which they are comminuted in a mill, irrespective of their initial shape, density and structure, and are then pressed under the influence of pressure and elevated temperatures to high-strength sheets of various structures.

Abstract: A process for producing high-temperature resistant and flame-retardant shaped articles of polyimide polymers of the general formula ##STR1## wherein A represents a four-valent group and R represents a divalent aromatic group, by heating a manipulatable sheet-like structure to a temperature in the glass transition range of between 280.degree. C. and 360.degree. and pressing it at pressures ranging between 10 bar and 500 bar. The polyimide shaped bodies obtained have densities of at least 1.30 g/cm.sup.3. Preferably, they may be completed as sheets having uniform thicknesses of between 0.1 and 6 mm.

Abstract: The invention relates to a process for producing a fuel absorbent, which comprises the steps of: dissolving an organic polymer having a function of trapping fuel in a solvent to produce a polymer solution; adding a crosslinking agent to said polymer solution to allow said organic polymer to react in the presence of said crosslinking agent; and collecting, after the completion of the crosslinking reaction, the resultant fine polymer gel particles. The invention also relates to a porous fuel absorbent produced by the above process comprised of fine cross-linked organic polymer formed into particles. The above fuel absorbent along with the coatings and a carrier may be used to control fuel evaporation loss in automobile canisters or boiler fuel tanks.

Abstract: A batch process and apparatus are provided for molding fiberballs, comprising load-bearing fibers and binder fibers, into shaped articles, preferably using hot air within a perforated mold to allow circulation of the air through the fiberballs. The techniques are particularly adapted to molding cushions of varying shapes and sizes, without excessive wastage of material, using relatively simple flexible equipment.

Abstract: A solvent based plastics recycling process directly reduces large volumes of post consumer plastic waste materials by up to 500% by volume. Minimal sorting and no cleaning is required, and large percentages of contaminants are tolerated. The process yields a highly adhesive resin which cures to a hard wood or masonry type material. The reduced end product, an epoxy sludge, may be formed to provide a lumber or brick substitute. Large percentages of shredded paper and other waste materials, including metals, may be added to the plastic waste materials, if desired.

Abstract: A process for heat treating polymeric compositions into a shaped article comprising the steps of:a. placing a polymeric composition into a molding means;b. adding a compactible material to the molding means to surround the polymeric composition;c. pressuring the molding means containing the polymeric composition to force its particles into intimate contact with the compactible material, and clamping the molding means so as to maintain the pressurized state;d. heat treating the pressurized molding means containing the polymeric composition to form a densified, shaped article; ande. releasing the pressure on the molding means and removing the heat treated, shaped article.

Abstract: The invention relates to a method of preparing directly compressible granular mannitol, wherein a raw material essentially constituted of powder mannitol is subjected to an extrusion treatment inside an installation comprising a heating zone and an extrusion die, the supply flow rate of the installation with raw material as well as the parameters of the extrusion treatment, namely the temperature existing inside the heating zone, the diameter of the extrusion die and the driving speed of the raw material inside the heating zone being selected so that at the exit of the die and before the exit of the mannitol from the latter, the mannitol is partly fused.

Abstract: The invention relates to a process for the production of contoured vehicle internal panelling supports having surfaces smooth on both sides on the basis of wood fibers by depositing an aqueous suspension of wood fiber (pulp) on a preforming screen, drying the preform, pressing and hardening. A deposited layer of fibers is dewatered to a residual water content of 20 to 25% by mass, related to the original quality of suspension, dried in an electric alternating field, then compression molded in a tool without a screen and hardened.

Abstract: The present invention concerns a method of preparing a porous structural unit comprising a plurality of layers having different specific gravities by pressing and heating a material including resin particles between opposing molds having a temperature difference to thereby cause the fusion or bonding of the resin particles, and a porous structural unit which improves acoustic absorption properties and heat insulation properties and in which the specific gravity is continuously changed.

Abstract: Process for preparing lignocellulosic bodies by bringing lignocellulosic parts into contact with a composition comprising a polyisocyanate, fumed silica and a non-ionic liquid gellant and by pressing this combinations of parts and composition.The adhesion of the parts is excellent and the binder composition can be easily sprayed.

Abstract: A process for producing a printed circuit board includes steps, sequentially conducted of dispersing in water or organic solvent:(A) 95 to 20% by weight of a styrene polymer having a syndiotactic structure, (B) 5 to 80% by weight of a fibrous filler having a fiber length of 1 to 50 mm, and (C) 0.1 to 30 parts by weight of at least one of a binder and a binding fiber in proportion to 100 parts by weight of the total amount of the components (A) and (B), to make a slurry having a concentration of 0.5 to 100 g/l; separating the solids from the slurry and drying and molding them. Thereafter the solids are either subjected to melting with heating and pressure forming into the molded article, or they are impregnated with a thermoplastic resin which is then cured. Finally, a metal layer is provided on the molded article.

Abstract: A process for making polyimide sheet molding compounds which involves the preparation of a polyimide precursor solution of adjusted viscosity that includes a mixture of high and low boiling alcohols, and which also includes monomeric reactants including a diester of an aromatic dianhydride, an aromatic diamine, a monoester of norbornene dianhydride, the reactants being present in a relative molar ratio selected to yield a polyimide having a desired molecular weight. The solution, which further contains particular amounts of staple reinforcing fibers is deposited as a sheet between two carrier film layers and is partially dried to remove the low boiling alcohols.

Abstract: A method for the continuous preparation of a polyethylene having high strength and high modulus of elasticity is here disclosed which comprises the steps of mixing 100 parts by weight of an ultra-high-molecular-weight polyethylene powder having an intrinsic viscosity of 5 to 50 dl/g in decalin at 135.degree. C. with 2 to 50 parts by weight of a liquid organic compound having a boiling point higher than the melting point of the polyethylene, feeding the resulting mixture to between a pair of upper and lower endless belts facing each other, continuously compression-molding the mixture at a temperature less than the melting point of the mixture by pressing means disposed inside the endless belts, and rolling and then drawing the same.

Abstract: A process is provided for the continuous production of a high-strength and high-modulus polyethylene material having excellent properties. According to the process, powder composed of ultra-high-molecular-weight polyethylene powder as a principal component is subjected to compression molding, rolling and stretching. The polyethylene powder has an intrinsic viscosity of 5-50 dl/g as measured at 135.degree. C. in decalin. The compression molding is carried out by feeding the polyethylene powder between endless belts arranged in an opposing up-and-down relation, and conveying the polyethylene powder while holding the same between the endless belts and at the same time, continuously compression molding the polyethylene powder at a temperature lower than its melting point by a compressing means provided inside of the endless belts. In at least one of the compression molding step and rolling step, an olefin polymer having a molecular weight lower than the polyolefin polymer is concurrently processed.

Abstract: Sintered bodies made of aromatic polyesters prepared from diphenols, such as 1,1-bis(4-hydroxyphenyl-1-phenylethane or 9,9-bis(4-hydroxyphenyl)fluorene, and halides of phthalic acid which have one or more glass transition temperatures in the range of 220.degree.-400.degree. C. and tensile strengths higher than 40 N/mm.sup.2, and advantageously higher than 60 N/mm.sup.2 are disclosed. To make the sintered bodies, polyester powder is exposed to high pressure within a closed mold and the temperature of the polyester powder is slowly increased by heating until a temperature higher than the glass transition temperature is reached, whereafter the polyester is slowly cooled. During the sintering process the polyester is crosslinked which results in an increased resistance against solvents. The sintered bodies of the invention are used in general as semi-finished products or preformed parts, which will be transformed to bodies with required shapes through subsequent machining.

Abstract: Absorbent polymeric macrostructures that are porous and comprise an interparticle crosslinked aggregate having a circumscribed dry volume greater than about 10.0 mm.sup.3. The interparticle crosslinked aggregate comprises a multiplicity of precursor particles of substantially water-insoluble, absorbent, hydrogel-forming, polymer material; and an interparticle crosslinking agent reacted with the polymer material of the precursor particles to form crosslink bonds between the precursor particles. Because of the particulate nature of the precursor particles, the macrostructure has pores between adjacent precursor particles. The pores are interconnected by intercommunicating channels such that the macrostructure is liquid permeable.

Abstract: A process for the production of carbon-containing electrodes for electricity (current)-producing and/or electricity-storing cells includes mixing carbon-containing material with vinylpolymer-containing material and then heating the thus created mixture to such a temperature and a chemical change of the vinylpoloymer occurs, so that the resultant composition becomes conductive.

Abstract: A process for the solid phase deformation of orientable, semi-crystalline, thermoplastic, polymeric material, in particular polyethylene, is provided in which an improvement of the mechanical properties of the polyethylene is achieved. The process for producing a product from linear polyethylene includes forming a workpiece which is to be extruded in the solid phase by consolidating a mass of solid particulate linear polyethylene under heat and pressure. The resulting workpiece is subjected to heat treatment under pressure to cause the polyethylene to crystallize in an extended chain morphology and to have a melting point of at least 139.5.degree. C. and a density of at least 0.98 g/cm.sup.3. Thereafter the workpiece of polyethylene is deformed in the solid phase to provide a polyethylene product by, for example, passage through a die, the workpiece being subjected to a deformation extrusion ratio of at least 3 and preferably 3 to 25.

Abstract: A fusion bonded fiber product is made by compressing between heated dies a mat of moisture-containing fibers of the type that change irreversibly to an amorphous nonglassy state that permits fiber-to-fiber bonding at a characteristic critical temperature. The further compression of the partially compacted mat is stopped or slowed when the mat is a small multiple of the desired caliper for the bonded product for a period of time sufficient to vaporize the moisture content of the mat. During this time period, most of the vaporized moisture content of the mat is expelled as saturated steam through the mat surfaces while the temperature of the mat is still well below the critical temperature. Then, the compression of the mat is continued under continuous consolidation to the final density and caliper of the fusion bonded product while the mat is heated to a temperature above the critical temperature.

Abstract: A high-strength and high-modulus polyolefin material can be continuously produced from a polyolefin in a powder form by feeding the polyolefin powder between a combination of endless belts disposed in an up-and-down opposing relation, compression-molding the polyolefin powder at a temperature lower than the melting point of the polyolefin powder by means of a pressing device while holding the polyolefin powder between the endless belts and conveying the same, and then rolling and stretching the resultant compression-molded polyolefin. The pressing device is constructed of pressing platens and corresponding sets of rollers, which are all accommodated within the respective endless belts. The rollers in each set are connected together, and the sets of rollers are arranged movably in an endless fashion between the respective platens and the endless belts associated therewith.

Abstract: A method for manufacturing a filter cartridge by polymerization of a polyethylene hydrocarbon with granular elements are set forth. The method involves the preparation of a mixture comprising the hydrocarbon and the granular elements, then introduction of the mixture into a mold which is formed by a first porous wall and a second porous wall, these walls being connected to a jacket, the introduction of the mold in an oven so as to raise the temperature of the mixture and by a thermal polymerization reaction to transform the hydrocarbon into a material binding the granular elements of the mixture, the assembly of the material and granular elements then forming a cartridge, and injection of a chemically inert gaseous composition into the mold through one of the walls to impart fluid permeability to the cartridge.

Abstract: A method for forming a readily soluble or dispersable granular beverage material from a powdered extract of the beverage comprises sintering the powdered extract in a closed environment. Examples are given of coffee, tea and fruit-drink granulate preparations.

Abstract: An expansion-molded article is produced by filling prefoamed thermoplastic particles in a mold cavity formed in combination of mold sections, through each of which plural heating medium holes are defined, and then feeding a heating medium such as steam through the holes to heat and fusion-bond the particles into the article conforming with the mold cavity. Each of the mold sections is covered by a permeable porous sheet at least over the heating medium on a side of the mold cavity.

Abstract: This invention is a method of filling a tire with a composite-foam to eliminate rapid deflation "blow-outs" and for all practical purposes, eliminate flats. The composite-foam tire filling is comprised of a multiplicity of preconstructed, hollow, pressurized, elastomeric, one-piece, seamless cells bonded together into a configuration whereby substantially all of the exterior cell wall surface of all cells in the composite-foam tire filling, is engaged with portions of exterior cell wall surfaces of surrounding cells. This composite-foam mass is placed inside a tire to provide the tire with a composite-foam filled interior.

Abstract: A method of manufacturing a filter element comprises the steps of mechanically crushing two grades or more of a heat resistive synthetic resin material, the grades having different melt flow indices, respectively, the heat resistive synthetic resin material being selected from the group consisting of polysulfone, polyethersulfone and polyphenylenesulfide or containing said selected heat resistive synthetic resin as a main constituent, mixing them with one grade of them being 20 to 80 wt %, sintering the mixture in a metal mold at a melt temperature thereof plus or minus 10.degree. C. when the mixture is crystalline resin or at a temperature in a range from glass transition temperature thereof up to the glass transition temperature plus 40.degree. C.

Abstract: Polyimide which is obtained by polymerization and consists essentially of recurring structural units of the formula (I): ##STR1## wherein X is a single bond or a hexafluoroisopropylidene group, is processed to a form of pellet, followed by heat-treating to obtain crystallinity of 5% or more, and fed to an extruder to obtain articles.

Abstract: A method of forming and bonding fluff pads for diapers and the like wherein both the steps of forming and bonding are performed on the same vacuum drum.

Abstract: Methods of doubly coating iron particles. The methods comprise treating the iron particles with phosphoric acid to form a layer of hydrated iron phosphate at the surfaces of the iron particles. The particles are heated in an inert atmosphere at a temperature and for a time sufficient to convert the hydrated layer to an iron phosphate layer. The particles are then coated with a termoplastic material to provide a coating of thermoplastic material substantially uniformly circumferentially surrounding the iron phosphate layer. Doubly-coated iron particles provided in accordance with this invention are generally useful for forming magnetic components and cores for use in high frequency switching applications.

Abstract: A method of making a composite foamed and shaped article including in the first step in which a thermoplastic resin powder is filled in a slush molding die to form a first resin layer, a second step in which a mixed powder consisting of a heat decomposable foaming agent and the thermoplastic resin powder is filled in the die in which the first resin layer was already formed, to form a second resin layer on the surface of the first resin layer, and a third step in which the heat decomposable foaming agent is made to foam by heat treatment to form a final product of a composite foamed and shaped article wherein the slush molding die is pre-heated by an infrared heating method.

Abstract: An apparatus and method for the production of composite material parts by aligning reinforcing fibers through application of electric fields. The fibers are in the form of rods preimpregnated with a matrix material or coated with a sizing, and aligned within a dielectric alignment fluid. By providing appropriate electrodes, an electric field is created which mimics the stress lines exhibited by the final composite part when under stress. The reinforcing fibers align to the electric field, thereby aligning to the stress lines.

Abstract: A process and apparatus is provided for explosively forming plastic objects from shredded plastic such as recycled plastic having different compositions. The shredded plastic and an explosive gas mixture is introduced into a mold cavity having the shape of the object to be formed, and the gas mixture is ignited, generating sufficient heat and pressure to force the plastic to conform to the shape of the mold cavity. The temperature and pressure in the mold cavity is controlled during the explosion by releasing combustion gases from the mold cavity.

Abstract: A conductive-metal-filled substrate is formed by intermingling oxide coated, non-conductive copper or nickel particles into a substrate having a softening point of at least 200.degree. C. followed by compression molding at a temperature of at least 200.degree. C. The filled substrates are electrically conductive and are useful for a variety of uses such as EMI shielding.

Abstract: A process for preparing an ultrahigh molecular weight linear polyethylene (UHMWLPE) exhibiting a combination of properties including a creep resistance of less than 1% demonstrated under exposure to a temperature of 23.degree. C. (+ or -1.degree. C.) and a relative humidity of 50 (+ or -2% for 24 hours under a compression of 1000 psi) without sacrificing excellent tensile and flexural properties. The invention includes the use of an inert gas and a prescribed pattern of heating and cooling including a further heat and cooling treatment to create the superior properties of the UHMWLPE. Also included is the product of the process invention.

Abstract: A process for eliminating the static charge from expandable polystyrene beads during a molding cycle. Pre-expanded polystyrene beads are injected into a mold cavity by using an air stream created by a venturi-type fill gun. To prevent the beads from carrying static while being injected into the mold, the air is ionized by exposure to high energy nuclear particles prior to contact with the polystyrene beads.

Abstract: A process for producing a polyethylene material for use in products requiring high mechanical strength and high elastic modulus is disclosed. The process involves the use of a specific class of particulate polyethylenes having an intrinsic viscosity of 5-50 dl/g in decalin at 135.degree. C. and the steps of compression molding, solvent immersing, solid-phase extruding or rolling and finally drawing the material in that order.

Abstract: A blend, a batt, and a process for making the batt from the blend is disclosed. The blend and batt are made from a uniform combination of cotton and copolyester binder fibers wherein the binder fibers have a melting temperature of 230.degree. to 340.degree. F.

Abstract: A molded slow-release air freshener prepared by having a liquid perfume composition absorbed into a porous molded product which has been obtained by partially melt-bonding the particles of an ethylenevinyl acetate copolymer powder with each other to obtain said porous molded product having continuous gas-permeable pores and a bulk density in the range of 0.4 to 0.8 g/cm.sup.3, said molded slow-release air freshener having an increased apparent volume of at least 1.2 times as large as its apparent volume before the absorption of said liquid perfume composition.

Abstract: An orthotic footwear insert is made of a resilient shock-absorbing layer. The layer has an upper surface, intended to receive the heel, the upper surface having a plurality of outwardly projecting nodules arranged in a waffle-like pattern which defines the upper plane. The layer also has a lower surface, beneath the heel-receiving surface. The lower surface has a plurality of rib members extending longitudinally between the back and front edges and generally parallel to the side edges of the layer. The rib members are therefore arranged such that air does not become trapped between them when pressure is applied to the layer. The invention also includes a method of making a shock-absorbing composition, which can be used to construct the footwear insert or other products. According to this method, an elastomeric material is comminuted into particles, and the resulting composition is formed into a desired shape. Preferably, a quantity of water is added to the composition.

Abstract: An ultrastretchable polymer material is prepared starting from polyolefine particles with a low entanglement density and a weight average molecular weight (M.sub.w) higher than 400,000, the particles being densified to a coherent material together with a process auxiliary material at an elevated temperature, but below the melting point of the pure polyolefine.From this ultrastretchable material, objects with a high tensile strength and a high modulus can be produced by stretching it, for instance, at a temperature which is at most 70.degree. C. below the temperature at which the polyolefine melts under the prevailing conditions, if desired after removal of the process auxiliary agent present in it.

Abstract: A process for the production of polyethylene materials oriented at a high level is disclosed in which a selected ethylene polymer as produced is extruded or rolled at a temperature lower than its melting point and subsequently subjected to stretching. The polymer is from 5 to 50 dl/g at 135.degree. C. in decalin in intrinsic viscosity and smaller than 60 .ANG. in crystal size on a plane (110) in the diffraction pattern.

Abstract: A process for producing a workpiece by compacting powder material, includes the steps of applying compression to the material along selected preferably orthogonal axes in compression steps, each compression step causing a volume reduction selected to produce the desired final compaction and orientation of material in the workpiece for that axis.

Abstract: A process for producing polyethylene materials in which ultrahigh molecular polyethylene is molded by compression, extrusion or rolling and stretching in a solid phase and at specified temperatures. The polymer is formed by a selected multi-stage polymerization with the use of a composite catalyst of specified compositions. Fibers or films are obtained with improved strength and modulus qualities.

Abstract: The present invention relates to methods and implementation, including apparatus comprising a two-stage, single-unit, and energy-efficient rotary drum-type granulator-dryer device having a granulator section and a separate dryer section in a new and novel combination designed for continuously granulating and/or ammoniating, and subsequently drying, respectively, a variety of materials together with specific processes for effecting such granulating and/or ammoniating, and subsequent drying.