Abstract: Process for preparing heat-insulating structural elements, which comprises the steps of:(a) applying to the convex portion of a first half-shell a layer of beads made from a semi-foamed or foamed thermoplastic polymer, in order to produce a layer with an essentially constant thickness;(b) sintering the beads; and(c) applying to the so obtained composite a second half-shell capable of fitting the shape of the sintered layer.

Abstract: Manufacture of granulated self-sintering carbonaceous pulverulent body suitable for precise complicated molding in high speed productivity is conducted in the presence of a wetting agent and a binding agent in the water-pulverulent mixture by using spray drying machine in the atmosphere of the hot air kept at a temperature up to 200.degree. C. optionally in admixture with superheated steam kept at a temperature up to 200.degree. C.

Abstract: A method for forming a dense metal boride composite article having a predetermined shape in which the method comprises blending a metal boride and a nitride to form a mixture of particles, milling the particles to a desired size, coating the particles with a lubricant formed from a polyvinyl acetate, cold forming the particles into an article of desired shape and pressureless sintering the cold formed article.

Abstract: An apparatus for reflow smoothing a molded article made by first heating a face of a mold at a first station, then applying a fusible synthetic resin to the heated face and thereby melting the resin into a continuous coating covering the heated mold face at a second station spaced angularly from the first station, and cooling the coating and mold at the second station until the coating hardens. To reflow smooth the article, the surface of the cooled coating is then smoothed by confining the mold and hardened coating in a substantially closed chamber at the second station and reheating the confined coating until its surface flows. Thereafter the coating is cooled again at a third station angularly spaced from and downstream of the second station until it hardens and the hardened covering is stripped from the mold at a fourth station angularly spaced downstream of the third station and upstream of the first station.

Abstract: A method for manufacturing plastic products from moldable plastic materials, involving the efficient use of a press and a mold is disclosed. The method includes heating the press and the mold to a temperature above the melt temperature of the plastic material, with the mold then being removed from contact with the press and with the press being applied to a replicate mold. The press is utilized so as not to apply pressure to the plastic material and the mold is preferably formed of a light weight material having high heat conductivity.

Abstract: A process for producing a carbon product having coarse and dense structures by carbonizing moldings of a mixture of one or more types of organic polymer substance, asphalt pitches, dry distilled pitches to obtain a dense structure carbon by carbonizing in an inert gas atmosphere or with a mixture of fine particle graphite powder as required, and porous organic polymer produced in point contact between the particles by solubilizing the surface layers of the organic polymer particles to obtain coarse structure carbon by sintering in particle state by carbonizing in an inert gas atmosphere, in an inert gas atmosphere after solidification to integrally mold organic liquid composition remaining high carbon residue in a composite composition, and carbonizing the composite composition in an inert gas atmosphere.

Abstract: A molded article of poly (m-phenylene isophthalamide), which shows a bending strength of higher than 13 kg/mm.sup.2, a density of 1.29 to 1.33 g/cm.sup.3 and a Rockwell hardness of not less than M 120 and has an excellent electric insulation and chemical resistance even at a high temperature and a process for producing the same.

Abstract: Type capable of being used for both printing and embossing consists of a heat-curable resin and is divided into three layers. The uppermost layer constituting a typeface portion employs a finely divided granular heat-curable resin and exhibits a high hardness and surface smoothness. The lowermost layer constituting an impact face portion employs a coarse granular heat-curable resin and exhibits low hardness and elasticity. An intermediate layer formed by mixing these two layers at the interface between them constitutes a joint portion exhibiting intermediate hardness.

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 non glassy state that permits fiber-to-fiber bonding at a characteristic critical temperature. The further compression of the partially compacted mat is stopped when the mat is a small multiple of the desired caliper for the bonded product for a period sufficient to vaporize the moisture content of the mat. During this pause, 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 method of continuously forming a shaped long article of an aromatic polyimide power including supplying a powdery mixture containing an aromatic polyimide powder having a heat loss ratio of not more than 2 wt. % and a mean particle size in the range of 0.1 to 40 .mu.m, and a small amount of a fluororesin powder to a ram-extrusion apparatus having a mold and performing alternately, at a temperature of not lower than 300.degree. C., filling the mold with the above mixture and ram-extruding the same at a pressure in the range of 100-1,500 kg/cm.sup.2. An extruded long article of an aromatic polyimide which has a specific gravity of more than 1.380, a radial crushing strength of not less than 800 kg/cm.sup.2, and a coefficient of linear expansion in the radial direction being less than that in the longitudinal direction.

Abstract: A process is provided with apparatus for molding fiberballs into bonded polyester fiber structures in a continuous line system, whereby novel structures may be economically provided with advantages over bonded batts.

Abstract: A process for providing batches of a mouldable, fibre-reinforced thermoplastic material matched to a moulding to be produced and accompanied by heating, whereby a free-flowing initial product of fibers and thermoplastic material-containing binders is heated as a strand and a matched batch is separated from the strand and supplied to batch further processing.

Abstract: A process for improving the slip properties of a ski sole that includes instantaneously compressing a high density polyethylene powder to soften the material and passing the softened material through a static mixer and a grid. The material is then shaped in an extruder and the extruded tape cooled by passing it between cooling plates prior to its being placed on a storage reel.

Abstract: Porous shaped articles made from a molded composite of ultra high molecular weight polyethylene and polyethylene wax are disclosed. These articles are produced by free-sintering a non intensively mixed blend of UHMW-PE particles and particles of a polyethylene wax. The process involves mixing the UHMW-PE and wax both in powdered form until a heterogeneous mixture is formed, but under conditions which do not lead to any substantial fracturing of the UHMW-PE particles or melting of either component. The heterogeneous mix is then transferred to a press mold to form a shape and pressure is applied sufficient only to maintain the enclosed volume of the shape. The mold is heated to a temperature above the melting point of the UHMW-PE for a period of time to allow the particles to soften, expand, and contact one another at their surfaces. The mixture is then quickly cooled.

Abstract: A process for molding plastic parts includes the steps of providing two or more colors of pigmented powder particles of thermoplastic material; casting the particles against a heated surface to form non-patterned layers of particles with voids therebetween; heating the layers to form color blended fused fringe zones between the particles which fill the voids to form a solid, multi-colored, three-dimensional article while each particle retains its discrete particle core which maintains each particle's central or original color concentration and which cores have discernible light transmissive properties.

Abstract: Porous shaped phenolic resin articles are made by partially curing a phenolic resin to a solid, comminuting the resin, forming into a predetermined shape, and sintering. Porous shaped carbon articles are made by carbonizing the sintered material.

Abstract: By compressing and heat curing a non-resilient, non-flexible recurable material formed by subjecting cured polyimide foam to the action of pressurized steam, a wide variety of useful articles may be produced. These include tough, flame-resistant plastic films, sheets, panels, boards, and shapes in general; composites (both reinforced and unreinforced); and laminates and other articles in which separate shapes or parts are bonded together by a new type of tough, flame-resistant adhesive. Additionally, heretofore worthless waste products such as the kerf cut away from buns of polyimide foam during the foam manufacturing process can be converted and vastly upgraded into any of such an array of new articles of manufacture such as those just mentioned.

Abstract: A process for the production of thick synthetic resin sheets having a multicolor pattern, involves processing heated thermoplastic chips into a coherent sheet by means of a pair of rolls profiled to a depth of about 0.1-0.5 mm which effect partially differing densification.

Abstract: Medical devices for the sutureless repair of lacerated, severed, or grafted nerves comprising longitudinally-openable, porous, rough-surfaced tubes of a body-absorbable polymer are disclosed. The tubular devices of the invention are prepared by sintering or otherwise bonding together granules or fibers, or melt processing suitable polymers in the form of the desired device.

Abstract: Porous shaped articles made from a molded composite of ultra high molecular weight polyethylene and polyethylene wax are disclosed. These articles are produced by free-sintering a non intensively mixed blend of UHMW-PE particles and particles of a polyethylene wax. The process involves mixing the UHMW-PE and wax both in powdered form until a heterogeneous mixture is formed, but under conditions which do not lead to any substantial fracturing of the UHMW-PE particles or melting of either component. The heterogeneous mix is then transferred to a press mold to form a shape and pressure is applied sufficient only to maintain the enclosed volume of the shape. The mold is heated to a temperature above the melting point of the UHMW-PE for a period of time to allow the particles to soften, expand, and contact one another at their surfaces. The mixture is then quickly cooled.

Abstract: A process for producing polyethylene materials is disclosed in which particulate polyethylene is drawn at lower temperatures than its melting point, the polymer having an intrinsic viscosity of 5-50 dl/g at 135.degree. C. in decalin and resulting from the polymerization of ethylene at temperatures below the above melting point and with use of a selected catalyst. The polyethylene materials excel in mechanical strength and elastic modulus.

Abstract: A process for producing a thermoplastic material including the steps of molecularly orienting a thermoplastic material, grinding the oriented material to a particle size between about 0.01 to 10 mm and fusing the ground particulate material to substantially mutually adhere the particles thereby producing a sintered thermoplastic material. The fused product includes discrete fused particles of one or more anisotropically oriented thermoplastic polymers and exhibits isotropic increases in flexural modulus.

Abstract: A method for preparing porous membranes containing a homogeneous microporous structure and narrow pore size distribution which are useful for ultrafiltration, distillation and substrates for composite membranes, including preparing films, pellets or sheets containing alternating microlayers of high density polyethylene and polystyrene, recoextruding these films, pellets or sheets, pulverizing into fine granules or powder, compression molding or sintering into thin films, immersing these films in a solvent bath into which one component is selectively dissolved and separating the resultant porous membrane from the solvent.

Abstract: A method for preparing an asymmetric, semi-permeable membrane containing a uniform microporous structure for gas and liquid separation, including forming a dense separation on one major surface of a microporous support structure. The microporous support structure is initially formed as a solid unitary film, fiber or sheet by the simultaneous extrusion of at least two streams of heat-plastified polymeric materials including at least two differentially soluble polymeric materials. The separation layer can be formed on the support structure prior to or after the soluble polymeric material has been dissolved out of, as by leaching from the solid support structure to form the microporous support for the separation layer. Preparation in this manner greatly reduces the tendency to form undesiralbe pinholes in the membrane.

Abstract: Method for manufacturing a molded article, for use, for example as a fluid filter or as a preform for a structural composite, is prepared from a batt of nonwoven structural fibers and a binder material, such as binder fibers or a thermoresponsive resin. The batt is stabilized by exposing it to a temperature slightly below the melting point of the binder material, so that the binder material becomes tacky and bonds the fiber materials at the surface of the batt. By exposing the batt to the heat for only a few seconds, only the binder material at the surface of the batt bonds the structural fibers; the structural fibers within the batt remain unbonded. Accordingly, the batt is "skinned", so that it is stiff enough to be handled, but is still flexible enough that it can be molded into complex shapes. The molding is effected in a mold in which heated air is drawn through the batt to force it to assume the contours of the mold.

Abstract: Sintered polybenzimidazole articles are obtained by compacting a particulate, dried polybenzimidazole resin under a pressure of 2,000 to 10,000 psi in a mold, heating the formed article to a temperature in the range of 825.degree. to 950.degree. F. for at least four hours, cooling the polybenzimidazole article to below 800.degree. F. while maintaining the article under a pressure of 2,000 to 10,000 psi, and thereafter heating the constrained formed polybenzimidazole article to a temperature in the range of 825.degree. to 950.degree. F. for at least one hour.

Abstract: A moldable fibrous composite having thermal and acoustical insulating characteristics and methods of production thereof are provided. The composite structure comprises a substrate, a middle layer and a non-woven top layer. The substrate may be in the form of a fibrous web or, alternatively, a thermoplastic film. The middle layer comprises mineral fibers of a sufficiently short length to substantially preclude interlocking of any of the mineral fibers with other fibers of the structure and to provide the structure with desired flexibility. The mineral fibers are present in a quantity sufficient to impart desired heat and sound insulating properties to the structure. The top layer may be made of organic fibers or a substantially uniform mixture of organic and inorganic fibers. In making the invention composite structure, the middle layer and the top layer are introduced onto the substrate, respectively. The three layers are thereafter consolidated, such as through needle punching.

Abstract: A process for continuous fabrication of thermoplastic webs from at least one extruded thermoplastic web heated to processing temperature. This thermoplastic web is cooled under the application of area pressure down to a temperature at which smoothing of the surface is terminated. A calibrating and smoothing mechanism in the device for performing the process according to the invention consists of a double-band press which includes an apparatus for conducting heat away from the thermoplastic web in the reaction zone in which the area pressure is applied.

Abstract: A method of producing a composite comprising a self-supporting polycrystalline material obtained by oxidation reaction of a molten parent metal with a vapor-phase oxidant comprising infiltrating a filler exhibiting inter-particle pore volume with a parent metal under conditions which control the respective rates of said metal infiltration and said oxidation reaction.

Abstract: In a method for producing shaped synthetic members, one begins with superficially plasticized synthetic granulated material in manner known per se. This is sintered to form a preform in a first operation in a preliminary chamber. The preform is then extruded by way of a narrow nozzle into a moulding cavity, the nozzle cross section being so narrow that on the way between the preliminary chamber and the moulding cavity, the individual granular particles must be deformed mechanically. The moulding cavity is then filled by one or more thin strands, which consist of solid, but mechanically deformed and superficially plasticized granulated particles.

Abstract: A method for continuously forming a pressboard product from shredded scrap paper having a thermoplastic coated thereon. The shredded paper is deposited between two continuous facing sheets. The sandwiched construction is heated using radiant or convection heat and then compressed to fuse the shredded paper together.

Abstract: A dye-containing porous plastic element, comprising a plastic body having interconnected capillary passageways, and a dry, water-soluble dye located within the passageways. The passageways extend to at least one surface of the body, and the size of the passageways are such that the body, when contacted with water, can absorb the water to wet the dye and make it soluble. The plastic body comprises fused granules of plastic interspersed with dry granules of dye. The plastic granules may have a diameter, prior to fushion, of between about 50 and 800 microns, preferably between about 100 and 300 microns. The dry dye comprises between about 5 percent and 35 percent of the element, by weight, and preferably between about 10 per cent and 20 percent .

Abstract: A method for producing molded articles by supplying to a mold a powdered thermoplastic material; heating the mold to fuse the material and cooling the mold to cause the fused thermoplastic material to solidify. The article is molded from a high density monoolefin thermoplastic polymer which contains a catalyst residue, a crosslinking amount of an acetylinic diperoxy compound and a tetraalkenyl orthosilicate compound. The molded article has at least one of increased crosslinking, lowered bubble formation and increased storage modulus.

Abstract: The invention relates to a method for the production of shaped synthetic members, in which(a) Synthetic granulated particles are mixed and coated with a conducting powder;(b) An electric current is passed through the mixture of granulated particles and conducting powder the surfaces of the granulated particles becoming plasticized;(c) The mixture of granulated particles and conducting powder is sintered to form a preform under the action of pressure;(d) The preform is extruded into a moulding cavity thus forming the shaped synthetic member.

Abstract: An apparatus for the production of a synthetic resin skin uses a mold for forming at least two separate skin sections which are then joined prior or after a final heat treatment. The synthetic resin skin sections are produced in at least two separate mold members, and the skin sections are then caused to contact each other along determined faces or margins which are joined under light pressure. Any so-called selvage is easily removed after the joining which intimately bonds the skin sections to each other due to the curing of the synthetic resin.

Abstract: Particulate styrene polymers containing blowing agents are prepared by a process in which an aliphatic hydrocarbon of 7 to 9 carbon atoms is added in an amount of from 0.01 to 0.5% by weight, based on the styrene polymer, before, during or after the polymerization. The particulate styrene polymers can be processed to foam blocks and moldings having a satisfactory smooth surface.

Abstract: Solid particles are coated with a uniform and continuous polyamide layer by immersion in a reaction medium capable of forming polyamides by anionic polymerization in solution.

Abstract: Prosthetic devices, such as orthopedic, dental and maxillofacial prostheses, are provided which are composed of an inner load bearing, functional component and an outer foamed or sintered porous coating of selected bioengineering thermoplastics. The bioengineering thermoplastic coating is provided in regions where long-term bone fixation is desired by tissue ingrowth. The coatings offer substantial biomechanical advantages over any material system previously reported. Also provided, are anatomically shaped devices comprised totally of bioengineering thermoplastics with select porous areas; these devices include bone gap bridges, bone caps, and alveolar ridge augmentation implants.

Abstract: Apparatus and a process for manufacturing thin walled hollow plastic shells for parts such as automobile door panels, controls and instrument panels from dry thermoplastic powders includes a plurality of powder boxes and an open-ended heated mold. Each charge box is carried by an indexable carousel which has a drive motor controlled by a programmable controller to position the carousel to off-load a given color to a powder casting mold carrier which is associated with means for sequentially and continuously (1) preheating a mold; (2) dumping powder from an off-loaded color box into a heated mold; (3) curing the cast powder in the mold; (4) cooling the mold; and (5) stripping the part from the mold.

Abstract: A method of making a nonwoven fibrous web. A web of primary fibers having uniformly distributed throughout secondary fibers containing 3 to 7 percent polyethylene by weight of the final web is formed on a conveying means. The polyethylene of the secondary fibers has a melting point that is lower than the melting point of the primary fibers. The web is then heated to a temperature below the melting point of the primary fibers but above the melting point of the polyethylene of the secondary fibers thereby causing some of the polyethylene fibers to bond to each other or to the primary fibers. The web is then heated to a temperature above the melting point of the primary fibers to form primary fiber-to-primary fiber thermal bonds which provide substantially all of the useful strength of the web.

Abstract: Fiber mats formed by attenuating molten streams of attenuable mineral material by subjecting the streams to the action of a hot attenuating gas blast. The gas blast induces gas from the surrounding atmosphere, and the combined blast and induced gas forming a fiber-carrying current. The current is directed toward a preforated fiber-collecting conveyor on which the fibers are deposited in the form of a mat and the gas of the current passes through the conveyor. Provision is made for withdrawing a peripheral portion of the fiber-carrying current at a point intermediate the zone of attenuation and the perforated fiber-collecting conveyor.

Abstract: A method for production of a shaped body having high mechanical strength, high modulus of elasticity, and good mold-releasing property, the method comprising steps of charging a metal salt of polyacrylic acid in powder form into a shaping mold; and press-forming the powder material into a shaped body under a pressure in a range of from 100 kg/cm.sup.2 to 1,000,000 kg/cm.sup.2.

Abstract: A multilayered container comprising a wall portion consisting of thermoplastic gas barrier resin (resin B) layers and thermoplastic resin (resin A) layers, with the terminal portion of the mouth opening being of a thermoplastic resin (resin A), said wall portion being a multilayered structure formed by alternately laminating the resin A layers and the resin B layers in such a manner that there are at least two resin B layers, with the proviso that there is one more of the resin A layer than the number of the resin B layers, said structure having been biaxially oriented.

Abstract: The present invention relates to anhydrous crystals of maltitol and the whole crystalline hydrogenated starch hydrolysate mixture solid containing the crystals, and processes for the production and use thereof.

Abstract: Method for making a test phantom and is disclosed which phantom is representative of human tissue containing variable concentrations of iodine to serve as a test device for assessing the performance of X-ray imaging systems such as digital subtraction angiographic apparatus. An iodine/polymer insert is embedded in a polyurethane composition which has X-ray adsorption characteristics similar to human body tissue. The incorporation of additional test details into geometrically fixed positions in the phantom allows accurate and reproduceable measurements of other performance parameters of digital X-ray imaging systems.

Abstract: A powder for use in compressing molding is made by coating a high amount of filler by weight, for example calcium metasilicate with a thermoplastic resin, for example, nylon. The amount of filler to nylon is typically above 60% to 98% by weight of the powder. The resultant powder is employed in a compressive molding process in a metallurgy press to manufacture an article which is structurally stable, and which is later solidified and strength increased by crystallizing the nylon or resin in an oven raised to the crystallization temperature of the resin to result in a compressively molded article having high strength characteristics and requiring a small amount of resin as compared to conventional molding processes.

Abstract: Process for manufacturing of molded objects by hot-pressing lignocellulose-containing materials with polyisocyanates as binders while using an agent to release the molded article from the surface of the metal press used. A mixture of the organosilicon compounds is applied onto the surface of the cauls or molds which faces the material to be pressed, and cured at a temperature from 100.degree. to 200.degree. C., preferably in the presence of known curing catalysts. The mixture of organosilicon compounds comprising(a) 20 to 65 weight percent of a silicone resin of the general formula ##EQU1## in which R.sup.1 is a low molecular weight alkyl radical with 1 to 4 carbon atoms,a has a value of 1 to 1.7,b has a value of 0.3 to 1.0;(b) 30 to 65 weight percent of an .alpha.,.omega.-methylsiloxanediol with an average molecular weight of 1,000 to 20,000;(c) 5 to 15 weight percent of a silicate ester of the general formula ##EQU2## in which R.sup.

Abstract: A fiber reinforced, composite article is manufactured by forming a nonwoven, air-laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into a preform having the desired shape in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting preform retains the desired shape and is sufficiently stiff to withstand the pressure of the injected resin. The preform is then transferred to a resin injection mold, where the interstices between the fibers are saturated with an appropriate resin matrix. As the fibers of the preform are saturated (or after a saturation but before the resin sets) the resin transfer mold is compressed, thereby forming the preform into its final desired thickness and increasing the concentration of the fibers to give the preform appropriate strength.

Abstract: In producing a SiC base sintered material containing a small amount of B as a sintering assistant, a boron-containing organic compound obtained by reaction between a boron compound and an uncross-linked phenolic resin, either a resol or a novolac, is used instead of using an elemental boron powder. The starting boron compound is, e.g., H.sub.3 BO.sub.3, BCl.sub.3 or (C.sub.2 H.sub.5).sub.2 BOH. A mixture comprising 100 parts by weight of SiC powder and 2-10 parts by weight of the boron-containing organic compound is compacted or molded into a desired shape, and the shaped material is heated in a nonoxidizing atmosphere first at a relatively low temperature to accomplish thermal decomposition of the boron-containing compound and then at a sufficiently high temperature such as 1800.degree.-2200.degree. C. to accomplish sintering of SiC. By this method agglomeration of boron in the sintered material is prevented, so that sound sintering is achieved in every region of the shaped material.

Abstract: A process for manufacturing a molded outer covering, comprising the steps of mixing two or more powder resin materials having different colors at a desired mixing ratio to prepare a powder mixture, and then heating the powder mixture in a preheated molded die, so that the powder mixture melts, resulting in a formation of a molded product having a pepper and salt pattern on the outer surface thereof.