Abstract: A method and apparatus for making structural panel from the rinds of sugarcane and similar woody grasses. The method includes providing a collection of straight and rather long rind fiber-bundle strands, coating them with binder, depositing coated strands in a loose pile with the strands randomly oriented in substantially parallel planes, pressing the pile to a final thickness, and curing to interconnect each strand with others. The curing step preferably includes moving air through the pile, which had been deposited on a perforated belt and pressed between a pair of such belts.

Abstract: A method is provided of producing fibrous product from cellulosic wood fiber. First, a layer of this fiber material is deposited on a moving wire. A binding agent in an aqueous solution is then added to the fiber material. Next, the fiber material is moved through a superheated oven having a minimal amount of moving air to cause a lively boiling of the aqueous solution. The fiber material is then dried. In one embodiment, a mixture of alkali treated and acid treated fiber material is deposited on the moving wire.

Abstract: A method of manufacturing a water barrier fabric, in flexible or rigid form, and article manufactured thereby, formed by dispersing a water-absorbent material, in powdered or granular form, among a mass of fibers during the formation of a loose mat of said fibers, to homogeneously disperse the powdered or granular water-absorbent material above, below and on each side of the fibers forming the mat, and thereafter densifying and structurally consolidating the mat, to secure the fibers in position surrounding and entrapping the water-absorbent material, such as by sewing, quilting, needle punching or otherwise bonding the fibers into a consolidated, structurally secure fabric at least partially filled with the powdered or granular water-absorbent material.

Abstract: This invention is a process by which fan blades or any shape needing a lightweight reinforcement are strengthened using hollow spheres, bonded together with an adhesive material used as a matrix. This combination of hollow spheres and adhesive matrix forms a lightweight construction that exhibits extremely high compressive strength. Thermoplastic or thermosetting resins may be used for a matrix material. A plurality of hollow spheres, all being the same size, are inserted into the area to be reinforced. The spheres being round in shape and light in weight, flow easily with fluidic properties, although slight agitation will ensure complete distribution, settling, and contact of each hollow sphere to the next in an organized, virtually symmetrical fashion. The matrix material is then inserted into the interstices surrounding the hollow spheres, forming a bond between each hollow sphere, and mechanically joining them; thus forming a bonded, lightweight reinforced fan blade.

Abstract: A method is provided for forming machinable ceramic compacts, which are in the unfired, preconsolidated condition. The method of this invention adds the binder to the ceramic powder mixture after the compact is formed by compaction, as opposed to conventional practice wherein the binder is added to the mixture prior to compaction. The unfired ceramic compacts which are formed by the method of this invention are characterized by high strength, excellent durability and enhanced machinability.

Abstract: A process for making a component by depositing a first layer of a fluent porous material, such as a powder, in a confined region and then depositing a binder material to selected regions of the layer of powder material to produce a layer of bonded powder material at the selected regions. Such steps are repeated a selected number of times to produce successive layers of selected regions of bonded powder material so as to form the desired component. The unbonded powder material is then removed. In some cases the component may be further processed as, for example, by heating it to further strengthen the bonding thereof.

Abstract: A directed fiber, directed energy process provides both a method and an apparatus for making structural preforms. Fibrous reinforcement material is chopped into short lengths of fiber and propelled toward a perforate mold part. During propulsion and/or after deposition on the perforate mold part the fibers are sprayed with an electromagnetic radiation-curable binder. The binder-carrying fibers are held on the perforate mold part by a flow of air in that the perforate mold part is rotatably mounted in a plenum which provides an air flow therethrough. Rotation of the perforate mold part and scanning action of the fiber and binder propelling mechanisms effects even and complete coverage of the perforate mold part. After a mat of the chopped fibers has been applied to the perforate mold part, a conforming second mold part closes the mold and presses the fibers to replicate the shape of the three-dimensional rigid perform.

Abstract: A mat of reinforcement material, such as glass fiber reinforcement material, is manufactured by forming a layer of continuous strand or chopped fibers on a conveyor belt and conveying the layer along a defined path. At a location downstream of the application of the layer, the layer of fibers is coated with a binder in the range of 2.0-10.0 weight percent, either a microwave-sensitive binder or an ultraviolet-sensitive, binder and the binder-coated layer is fed into a radiation tunnel which includes a compression stage and a curing stage. In this radiation tunnel, the binder-coated layer is compressed to a desired density-thickness ratio and cured, the compression and curing occurring in stages, and the resulting mat is taken from the conveyor belt and wound up for storage.

Abstract: A method is disclosed for preparing a heterogeneous silicone rubber molding wherein a portion of the molding is formed from a semicured silicone rubber particulate and a portion from a thermosetting silicone rubber composition. The mold is filled with the particulate and the thermosetting silicone rubber composition, then closed and pressurized and heated, forming the portions into a single body or element by curing the thermosetting silicone rubber composition at the same time that curing of the semicured silicone rubber particulate is brought to completion.

Abstract: A process for the manufacture of a decorative product particularly for use in the ornamental field, in which selected organic chemical compounds are employed, which are prepared and applied in a way to confer to the same product favorable safety characteristics during use.

Abstract: Process for producing a composite material in which a cellulosic substrate is treated with a solution of a polyfunctional isocyanate in an aprotic swelling solvent and the substrate is then compressed to form the composite material. The substrate may take the form of wood chips, wood particles, wood flakes, wood fibers, wood flour, ground wood, wood veneers and wood laminates, paper, card, straw, refined cellulose such as cotton or viscose and plant fibers such as bamboo or palm fiber.

Abstract: The present invention employs poly(ethyloxazoline) as a temporary binder and lubricant during the preparation of greenware articles. According to the present invention, molten poly(ethyloxazoline) promotes the compressibility of the powder used to form the greenware article, thus improving the density and strength of both the greenware and the abrasive article. The molten poly(ethyloxazoline) acts as a lubricant to permit a more efficient grain rearrangement under applied pressure and thereby increases the average density of the greenware article by 6 to 8 percent as compared to standard cold pressing.

Abstract: A process for the production of a synthetic resin pressure molded body in which a bonding agent containing a condensation resin or condensation resin mixture produced mainly on the basis of phenolic compounds and aldehydes in liquid or brushable form is heated to an elevated temperature to lower its viscosity and is applied to dried wood fibers in an amount of 25 to 50% of the amount of the wood fibers and optionally together with other materials such as surface and/or intermediate layers is hot pressed while the resin is hardening, whereby the moisture content of the dried wood fibers is at most 10%, the condensation resin or condensation resin mixture having a solid resin content of at least 80% by weight and a water content of at most 7% by weight and the bonding agent contains optional additives.

Abstract: A liquid absorbent structure is made by dry laying a fibrous web having incorporated therein a superabsorbent material, and applying a latex coating to at least one surface of said web, which on curing imparts integrity to the resulting structure without substantially impairing the effectiveness of said superabsorbent material to absorb liquid.

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: This invention relates to a fiber reinforced plastic sheet having a gradient layer structure wherein the number of reinforcing fibers continuously varies and a process for producing the same by spreading a mixture of the fibers different in the number of filaments over the traveling zone of a conveyor and then pressing it while it contains a resin. The fiber reinforced plastic sheet of the invention is excellent in smooth appearance, fluidity during molding to an article, fiber filling ability into a complex form portion of an article and mechanical strength and can be produced inexpensively.

Abstract: A barrier is manufactured by inserting a cage frame into the mold. The cage frame forms a clearance gap between the frame side walls and the mold side walls. The cage frame is first substantially filled with vehicle tire material and secondly filled with non-recyclable plastic material. An adhesive-type liquid is poured into the clearance gap to fill the sides of the mold. The top of the mold is coupled into place and the adhesive liquid is poured through the top to fill up the mold. The mold is then cured to produce the barrier.

Abstract: A process for producing a low density fibrous mat from which a molded article may be formed by molding at elevated temperature, and which comprises a first layer of fibers, as well as thermosetting and thermoplastic binders, and at least one open covering layer of tangled fibers connected thereto is disclosed. The process including the steps of producing the first layer spreading a mixture of the fibers and the binders on to a rotating carrier web to form a continuous fleece and compressing the continuous fleece in a continuous process an elevated temperature and accompanied by the activation of part of the binders to give a transportable-resistant fibrous mat. On this fibrous mat are placed the tangled fibers forming the covering layer in the form of a continuous, open tangled fiber fleece and the latter is connected to the fibers and/or the binders of the first layer by binders having an affinity therewith. The covering layer has a higher density than the first layer.

Abstract: A process for coating wet rubber pellets including coating the pellets with an inorganic partitioning agent, a thickener and binder, and an anionic water soluble dispersant, air conveying the pellets to a dryer, and compressing the pellets to form a bale. By virtue of the coating, the bales are rendered more friable.

Abstract: In the manufacture of lightweight structural profile including a resin-bonded core of closely compacted particulate filler, loose filler is packed into a shaping die by means of applied vacuum. The filler is packing within a sheath of glass rovings which is used to draw the packed filler through the die. As the sheath and packed filler are progressed through the die, a liquid bonding resin is introduced to permeate and bond together the packed filler and the sheath. The filler includes layer mineral foam in a coarse particulate form and a free-flowing relatively fine material (such as hollow silicate microspheres) as an additional filler, the additional filler being vacuumed in to occupy the interstices of previously packed foam filler.

Abstract: A method and apparatus for making fiber reinforced plastic preforms via a wet slurry process. A screen with the desired preform configuration is placed in the bottom of a tank. The tank is then filled with water and chopped fibers to create a slurry. The screen is raised up through the slurry causing fibers to be deposited on the screen in the shape of the preform. The preform is then removed from the screen, placed in a mold and injected with resin to form the desired structure.

Abstract: An imitation leather product and a process for the preparation of the imitation leather product from natural hemp which comprises the steps of (a) firstly digesting natural hemp fiber with weak alkali solution, (b) secondly digesting with ammonia gas, (c) presoak treating either with methylol urea and ammonium phosphate, or sodium chromate and sulfuric acid, and immediately adding ammonia thereto, respectively, (d) beating with SBR resin and cyclohexylcarboxyl diphenylamino thiazolyl sulfonamide, (e) jetting through a multiple stage fiber jetting device, and soaking in a soaking bath container containing methylphenol and SBR resin.

Abstract: Low density fibrous mats formed from fibres and thermosetting and thermoplastic binders, transformed by moulding at elevated temperatures are used for the production of mouldings. Such fibrous mats are produced in that a mixture of fibres and binders is spread out to form a fleece and the latter is compressed or compacted to a mat at high temperature. For the planned influencing of the characteristics of the moulding, while simultaneously reducing the binder requirement and the density, it is proposed that the fibrous mat or blanks thereof is passed through a pair of rollers with polished surfaces and by means of at least one roller binder is applied from the aqueous phase to the side of the fibrous mat facing the same under pressure action and that the fibrous mat is passed through the roller pair at a speed lower than the circumferential speed thereof and following onto the roller pair is passed through a drying zone.

Abstract: An air permeable sheet-like structure comprising 5% to 50% by weight of reinforcing fibres, and between about 5 and about 50 millimeters long, and from 50% to 95% by weight of wholly or substantially unconsolidated particulate non-cross-linked elastomeric material, and in which the fibrous and elastomeric components are bonded into an air permeable structure.

Abstract: A process for the manufacture of a stiff permeable sheet-like fibrous structure which includes forming a web with 20% to 60% single fibres having a high modulus of elasticity (as herein defined) and between 7 and 50 millimeters long, and 40% to 60% by weight of a wholly or substantially unconsolidated particulate plastics material, and then treating the web by heating to melt the plastics material and passing it between a pair of nip rollers so that the plastics material can flow and wet out the fibres, the nip between the rollers being set to a dimension less than the thickness of the unconsolidated web and greater than that of the web if it were to be fully consolidated, and allowing the web to expand and remain substantially permeable after passing through the rollers.

Abstract: A resistor including a matrix formed from flexible, insulating material, and metal particles distributed uniformly inside the matrix; which resistor is characterized by the fact that the particles are obtained from mechanical machining chips produced using tools including agglomerates of abrasive granules, and which are passed over the surface of the workpiece; and which particles are magnetized by passage of the aforementioned tool over the surface of the workpiece.

Abstract: In the process for making gypsum fiberboard the boards are formed or molded rom a mash containing calcium sulfate dihydrate and fiberous material. By heating and subsequently cooling the boards the dihydrate is first converted into the hemihydrate and subsequently recrystallized again to the dihydrate. Known processes require day line setting times which are economically disadvantageous. According to the present invention these times are shortened by pulling or drawing water, an aqueous solution or a water containing mixture through the boards after the cooling step. Advantageously a setting accelerating agent can be dissolved in the water. By these features the setting time can be shortened to less than two hours. By addition of a binding agent, e.g. starch, to the fluid drawn through the boards the strength of the boards is increased.

Abstract: In a mold having a pattern forming portion composed of a magnetic material, a pattern is formed by magnetically depositing a magnetic material on the wall of a cavity of the mold, and a resinous material is then injected into the cavity for molding and simultaneously transferring the pattern onto the surface of thus molded article.

Abstract: Microfiber microwebs are provided. The microfiber microwebs have relatively dense nuclei with individual fibers and/or fiber bundles protruding therefrom. The microfiber microwebs can be incorporated into nonwoven webs of blown microfibers, air-laid staple fibers, or wood pulp fibers as well as into shaped articles having porous covering materials. The microfiber microwebs are useful in sorbent, filtration, and thermal insulation materials. The microfiber microwebs are prepared by divellicating a microfiber web to form discrete particles of microfiber microwebs.

Abstract: A process for preparing reinforced thermoset articles of manufacture from a lofted composite sheet employed as a skeleton or preform which is impregnated with a thermoset resin composition and cured. A reinforced thermoset article of manufacture prepared from a lofted composite impregnated with a thermoset resin composition and cured is also provided.

Abstract: A process for producing a moldable non-woven fabric is disclosed, which comprises coating or impregnating a mat made of non-woven fabrics with an aqueous emulsion of a thermoplastic resin having a moldable temperature range of from 80.degree. to 180.degree. C. in such an amount that the resin solids content of the emulsion is 15 to 300 wt % based on the weight of the mat, removing the moisture from the mat by heating, and pressing the mat to adjust the apparent density of the mat to 0.15 to 0.5 g/cm.sup.3. This fabric is useful as an interior material for use in an automobile, for example.

Abstract: A process consisting in preparing a homogeneous system comprising particles of a first electrically conductive material arranged in substantially uniform manner inside a mass of a second liquid material which, when solidified, is both flexible and electrically insulating; and in solidifying the aforementioned mass of the aforementioned second liquid material, so as to form a matrix for supporting the aforementioned particles; throughout solidification of the aforementioned second material, a given pressure being applied on the system for the purpose of producing triaxial precompression of the aforementioned second material when solidified.

Abstract: A device for preparing a very homogeneous and finely divided fine-ceramics mass from ceramic raw materials, liquids, aggregates, and similar materials, whereby the starting materials are finely ground, and liquid is added and later partly removed. The starting materials are ground dry or moist and all or some of the starting materials are first allowed to fall free in and through an upright container while being contacted with all or some of the liquid, which is injected in subject to turbulence, and then agglomerated into a granulate.

Abstract: A particulate mass that can be dusty but is generally sticky, due to the presence of water, is coverted to an apparently dry, non-dusty granular material by polymerizing a polymerizable material within the mass and breaking the mass down to the desired granular form after the polymerization has gone sufficiently far that the mass is substantially non-sticky but before the polymerization is completed.

Abstract: A method of manufacturing a lightweight building element comprises providing a lightweight aggregate of particles having diameters in the range of 2 mm to 20 mm, mixing the particles together to produce graduated particle size distribution of the mixture, adding a quicksetting binder to the mixture in a predetermined amount sufficiently small so that free spaces are produced between the particles after setting and drying, allowing the binder to set and dry to form a porous body of particles bound together by the binder and having free spaces between the particles, introducing expanding plastic into the free spaces, and expanding the plastic in situ to form a cellular plastic structure completely filling the free spaces.

Abstract: A method of manufacturing a liquified fiber-phenol-formaldehyde resin includes heating a mixture of phenol, formaldehyde, liquified cellulosic fiber and alkali at a temperature of 60.degree. C. to 100.degree. C. and a pH of 8-13. The liquified cellulosic fiber comprises about 5 to about 80 percent of the total weight of phenol, formaldehyde and liquified fiber. Also disclosed are fibrous articles manufactured using this resin as a binder, such as fiberboards, particle board, plywood, oriented strand board, and waferboard.

Abstract: A method for the manufacture of cored construction products from dry particulate materials including feeding the materials into a vibrating mould so as to bring the same into pre-compacted condition, and subjecting the materials when in such condition to a transverse pressure so as to effect final compaction thereof. After compaction, a free standing surface of the material is impregnated with a setting liquid. The vibration is of such frequency and amplitude as to bring the individual particles into substantially uniform closely spaced disposition, the subsequent application of pressure bringing the material into a compacted state without any substantial re-arrangement or crushing of the particles.

Abstract: A molded article, for example, a filter or a preform used in the manufacture of fiber-reinforced composites, is manufactured from an 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 the desired shape of the molded article in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting article retains the desired shape. If the article is to be used as a fluid filter, it can be used either as it is removed from the mold if a filter of uniform density is desired, of the article can be further processed in a compression mold to densify portions of the article to thereby form, for example, a fluid impervious portion used as a gasket. If the article is to be used as a preform for a structural composite, it is then to be transferred to a resin injection mold.

Abstract: An insulation suitable for application to building spaces by pneumatic devices comprising a multitude of small pieces of low density fibrous material, the fibrous pieces being uniformly sized and having a hexahedral configuration.

Abstract: The invention provides a process for producing a piezo-electric or pyro-electric composite sheet in which particles of a piezo-electric or pyro-electric sintered body (ceramics) are dispersed in the form of a single layer in an insulating high polymeric substance, and the particles are in direct contact with electrodes made on both sides of the sheet. The composite sheet is produced by forming a sheet of an insulating high polymeric substance having dispersed therein particles of a piezo-electric or pyro-electric sintered body (ceramics) in the form of a single layer, then removing the surface skin from both sides of the sheet to expose the particles from both sides of the sheet; and making electrodes on both sides of the sheet and implying a voltage difference thereto to effect poling of the sheet.

Abstract: Porous, fibrous structures comprising polytetrafluoroethylene fibers in a fluorocarbon binder are prepared by laying down a stabilized dispersion of the fibers, stabilizing agent, and liquid carrier on a support, removing at least a portion of a liquid carrier, preferably drying the laydown, applying an emulsion of a fluorocarbon binder to the laydown and curing the fluorocarbon binder. The resulting structures have void volumes of from about 40 to about 99 percent, strengths of from about 200 to about 6,000 grams per inch of width, and air pressure drops of from about 0.0025 to about 0.1 inch of water at a flow rate of 28 standard cubic feet per minute per square foot of the fibrous structure.

Abstract: A process of manufacturing a composite ski, particularly a laminated ski. The constituent parts of the ski are placed into an evacuable mold, which during or after its evacuation is supplied with a binder, which is preferably liquid and fills the pores of the constituent parts and the cavities between the constituent parts.

Abstract: Wood surfaces are bonded together by heating and pressing with a bonding composition containing, on a bonding agent solids basis, from 10-70% of one or more sugars and from 90-30% of an aminoplast, and the bonding composition being used in an amount equal to the amount of straight condensation resin which would normally be used, i.e. the sugar replaces a quantity of condensation resin normally used thereby reducing the total quantity of condensation resin, thereby reducing cost and formaldehyde emissions and without any disadvantages.

Abstract: A composite wood product, such as waferboard, is treated during manufacture with preservative chemicals to improve resistance to decay and insect organisms. The process avoids having to treat a finished product and is not limited to only surface protection. Molten slack wax is first applied to wood particles having a moisture content not greater than about 10%, the wax coated wood particles are then sprayed with an ammoniacal copper arsenate solution having a concentration of at least about 11% followed by blending with adhesive resin and forming a composite wood product.

Abstract: A process of manufacturing a ski, particularly a laminated ski, which is composed of a plurality of components, and a ski manufactured by that process. In the process, the components of the ski are placed into a mold, which is adapted to be evacuated, and the mold is subsequently evacuated. A liquid binder, such as a liquid resin, is supplied to the mold during or after its evacuation. Air is sucked from the mold at one end of the longitudinal extent of the ski. The liquid binder is supplied to the mold at the other end of the longitudinal extent of the ski. In the finished ski a strip of solidified binder extends in at least one vertical or horizontal longitudinal plane of the ski, preferably in a central longitudinal plane of the ski, over at least part of the length and preferably over at least one half of the length of the ski.

Abstract: The subject invention relates to a method of making a porous rigid structure for use as a mold and the porous rigid structure formed thereby. Finely divided metallic particles are coated with a composition comprising a fluid thermosetting resin dissolved in a volatile solvent. Similarly, carbide particles are coated with the same composition of fluid thermosetting resin dissolved in a volatile solvent. The coated metallic particles and the coated carbide particles are mixed together and compacted into a predetermined shape of particles. Metallic needles are coated with the same composition of fluid thermosetting resin dissolved in a volatile solvent and mixed with fibers thereby forming a substrate structure. The substrate and the predetermined shape of particles are then compacted into a integrally bonded bi-layer to form a rigid structure.

Abstract: A strong, durable nonwoven fabric comprising polyester and/or polyolefin fibers arranged in a pattern of high density, lightly entangled fiber regions. Distributed throughout the fibers is an adhesive binder material to provide the final fabric with improved strength characteristics.Entangled nonwoven fabrics are dry print bonded to produce nonwoven fabrics having an excellent combination of strength, softness and durability.

Abstract: In a fuel cell comprising an electrolyte-retaining matrix interposed between a pair of gas-diffusion electrodes, the matrix comprises particles or fibers of a substance unreactive with phosphoric acid and having electron-insulating properties and an inorganic binder.

Abstract: Graphite gaskets with an improved release characteristic are embossed to form a relief pattern of relatively raised areas surrounded by predominantly interconnected depressions, followed by coating with a silicone rubber.

Abstract: An improved wet granulation process for preparing compressed tablets, particularly those containing a poorly compressible medicament, e.g., paracetamol and derivatives thereof, the improvement which comprises homogenizing part only of particulate solid material including active matter and tabletting aids with at least 90% by weight of a predetermined quantity of granulating fluid, so as to form a substantially homogenous slurry wherein the percentage of weight of solids, both dissolved and undissolved, in the slurry is at least about 25% w/w; and then moistening the remaining part of the particulate solid material in the manner of wet granulation but with the slurry resultant from above (and thereafter with the balance of the granulating fluid, if any) so as thus to form a desired substantially uniform, moist, coherent, non-pasty mass ready for granulation. Said mass is then granulated and dried, and the dried granules compressed and compacted into tablets.