Abstract: A structural member is press-molded from a mass of elongated cellulosic particles and a binder. The mass is randomly filled, that is with the particles not extending parallel to one another, into a horizontally elongated compartment defined between a pair of horizontally confronting side walls having central portions, a top wall, and a bottom wall confronting the top wall and extending generally parallel to the top and side walls. The top and bottom walls are then displaced vertically toward each other into predetermined intermediate positions without substantial movement of the side walls so as to vertically pre-compress the mass in the compartment. Thus the particles engaging the top and bottom walls are generally parallelized therewith.

Abstract: An elongated composite structural member such as a pallet cleat is made from elongated cellulosic particles and a binder by first providing a stiff and relatively incompressible board on a first wall confronting a second wall and defining therewith and with adjacent walls a compartment. A mass of the particles and binder are filled into the compartment between the walls and the first wall is displaced with the board toward the second wall and into the compartment into a predetermined intermediate position without substantial movement of the adjacent walls so as to subject the mass in the compartment between the first and second walls to a relatively low compression in a predetermined direction. At least one of the adjacent walls is then displaced transversely into the compartment without substantial movement of the first wall and the board from their intermediate position so as to subject the compressed mass in the compartment to a relatively low compression transverse to the direction.

Abstract: A substantially non-overlapping tightly packed layer of plastic chips is formed and attached to the surface of a substrate by a method in which the chips are dispersed onto the surface of a liquid, flowing from a first location to a second location. The rate of flow of the surface of the liquid is reduced at the second location to cause the chips to pack together in a single-chip-thickness layer. The layer of chips is then removed from the liquid by passing a porous web upward at an angle from below the liquid surface through the chip layer-liquid interface. The chip layer is then transferred to a heat-sensitive transparent adhesive coating on a suitable prepared substrate and secured thereon by means of heat and pressure. A resinous wear layer which is transparent after fusion is then applied.

Abstract: A method of manufacturing a friction article wherein a fiber material (14) having a continuous and substantially uniform three dimensional matrix which is filled with a slurry (24) made up of fillers, friction modifiers, a reinforcing material and a liquid binder. The filled fiber material is conveyed to a dryer (32) where the volatile solution is evaporated leaving the fillers, friction modifiers, reinforcing material and binder. The filled fiber material (14) is thereafter placed in an oven (50) where a compressive force is applied thereto while the binder is cured to define a second matrix which holds the fillers, friction modifiers, and reinforcing material in the three dimensional matrix.

Abstract: A melamine-urea-formaldehyde resin characterized by a low rate of formaldehyde emission when cured. Made by a process where the initial reaction mixture has an F/U molar ratio of from about 3:1 to about 1:1, and undergoes a methylolation reaction at an alkaline pH. Preferably at least some of the melamine is present in the initial reaction mixture. The subsequent condensation is at a substantially neutral pH. Has a final F/U molar ratio of 1.3:1 to 0.9:1, a final F/Ueq molar ratio of 1.3:1 to 0.7:1, and a melamine content of from 0.15% to 40% by weight, dry solids basis. Useful for adhesive purposes, particularly as a particleboard binder characterized by low emission rate.

Abstract: A method for producing board materials of cellulose containing components using formaldehyde-based curable glues. By treatment of at least one part of the components at a low moisture content with a formaldehyde absorbing agent the board materials obtained after pressing get a low content of free formaldehyde and very good strength properties. The moisture content of the components at the treatment is lower than 12 percent by weight. the formaldehyde absorbing agent is preferably urea.

Abstract: In a process for producing fiber-reinforced hydraulically setting extruding materials, the process which comprises, not adding the reinforcing fiber in the form of single fibers to the starting materials, but employing it as collected yarns by collecting the single fibers with a collecting agent, uniformly dispersing them in the starting materials, then releasing the collected condition of said dispersed collected yarns and splitting into single fibers by swelling and dissolution of the collecting agent and by the shear force by a screw etc., thereby the dispersion is improved.The single fibers having a great aspect ratio which have been released from the collected condtion are uniformly dispersed in the extruding material, and a remarkable reinforcing effect is obtained.

Abstract: A paper-polymer product as a fibrous, open web structure with polymer within the fiber structure of the cellulose fibers. The polymer is formed in-situ from a liquid, non-polar vinyl monomer such as p-chlorostyrene or p-methylstyrene. The open spaces of the fibrous web structure are substantially free from polymer.

Abstract: A process of moulding a product (and a product thus formed) wherein particulate ligno-cellulose such as shredded paper, flour, Portland cement, a small amount of caustic soda, and water are mixed together, placed in a mould, and subjected to both pressure and heat until set, and the moulded product is then removed from the mould.

Abstract: A board of cellulose containing components using formaldehyde-based curable glues. By treatment of at least one part of the components at a low moisture content with a formaldehyde absorbing agent the board obtained after pressing get a low content of free formaldehyde and very good strength properties. The moisture content of the components at the treatment is lower than 12 percent by weight. The formaldehyde absorbing agent is preferably urea.

Abstract: A process for manufacturing embossed, nonwoven fibrous products comprising the steps of subjecting a binder-treated fibrous dry laid web to a low cure treatment to obtain a moldable web with good physical integrity; embossing the low cure treated web; and fully curing the web.

Abstract: In the fabrication of composite articles, a binder containing hydroxymethylfurfural is employed.

Abstract: A process and apparatus for the internal gating of molds used to make a shaped article of aggregate filler infiltrated with a curable binder, including preparing a mold having a cavity and having gating tubes extending through the mold cavity and spaced from its surfaces, and the gating tubes having walls with multiple openings therethrough which are located inside the mold cavity, the cavity being dry-packed outside of the tubes with aggregate filler and the interstitial spaces therebetween being pumped full of liquid binder to form a matrix, the binder entering through the tubes and their openings and progressively expanding through the interstices while expelling air from breather holes, the binder then being cured in the mold either with the tubes still in place or with the tubes removed and the spaces filled with similar aggregate and binder before curing is completed.

Abstract: Reinforced polymer composites having a uniform mix of fiber, polymer and binder and having good physical properties are prepared by forming dilute aqueous slurries of a solid heat fusible organic polymer, a reinforcing material and a bound charge latex binder.

Abstract: A high loft, low density, nonwoven fibrous web is provided comprising a plurality of irregularly arranged, intersecting, overlapping, mechanically interengaged, loosely assembled fibers including both thermoplastic synthetic wood pulp fibers and other fibers, segments of the thermoplastic synthetic wood pulp fibers being heat fused at a plurality of junctures with segments of other thermoplastic synthetic wood pulp fibers and with segments of fibers of other types, with additional binder distributed throughout the web.The web is prepared by air-laying a blend of thermoplastic synthetic wood pulp fibers and other fibers applying heat without pressure to the air-laid blend to fuse at least some of the thermoplastic synthetic wood pulp fibers to each other and to some of the other fibers to form a self-supporting fibrous web, introducing a latex binder into the web and drying and curing the binder.

Abstract: An improved floppy disk having a liner material into the fibers of which has been compounded identically the same lubricant as that compounded into the surface of the magnetic recording disk.

Abstract: In the manufacture of low density air laid webs of predominantly ligno-cellulosic material, the method and apparatus for bonding the dry web with binder and compacting the web with a wet, fabric covered surface so as to increase tensile strength and delamination resistance while reducing binder content and cost is described. Wet compaction of the binder laden web enables controlled penetration of the web with a smaller amount of binder than is possible without wet compaction, and also reduces energy consumption in drying due to the use of less binder.

Abstract: A method for producing a synthetic board from cellulosic and/or lignocellulosic materials wherein a polyisocyanate binder is applied to the hot and wet fibrous material in the blow line out of the refiner of the board forming process. Polyphenylpolyisocyanates, such as a mixture of diphenylmethane-4,4'-diisocyanate and polymethylene polyphenyl polyisocyanates, are a particularly suitable binder.

Abstract: A method and apparatus for producing a synthetic board from cellulosic and/or lignocellulosic materials wherein a thermosettable binder, preferably a polyisocyanate binder, is applied through a cooled nozzle to the hot and wet fibrous material in the blow line out of the refiner of a board forming process. Polyphenylpolyisocyanates, such as a mixture of diphenylmethane-4,4'-diisocyanate and polymethylene polyphenyl polyisocyanates, are a particularly suitable binder.

Abstract: A method of producing reconstituted wood boards in a conventional press by introducing saturated steam through apertured press platens into a partially-compressed mat, composed of lignocellulosic material and a thermosetting resin binder, under specified conditions of mat density. Use of saturated steam in this manner allows production of a reconstituted wood board with shorter total press time than usual and with a more efficient use of energy. In addition total press time can be further reduced by injecting a gaseous catalyst into the mat to speed the cure of the thermosetting resin binder.

Abstract: A piano action mechanism wherein a shaft pin for rotatably supporting a rotatable member on a flange is carried in bearings formed of bushing cloth glued to the surface of bushing holes in the rotatable member. With a pin inserted through the cylinders of bushing cloth, the assembly is dipped in water, dried, dipped in a solution of resin bonded fluorocarbon solids, again dried and the pin removed, to provide a durable and stable bearing having a low coefficient of friction and which is essentially noise-free and insensitive to changes in temperature and humidity.

Abstract: A method for the manufacture of a cushioning material comprising the steps of compressing three-dimensionally crimped short synthetic filaments to form a shaped mass of filaments, applying an adhesive agent to the resultant shaped mass of filaments, then heating the shaped mass thereby drying the adhesive agent adhering to said short filaments and uniting adjacent filaments at the points of their mutual contact, and pressing the resultant crude cushioning material in the presence of steam thereby compressing the crude cushioning material.

Abstract: A method of forming structural board panels from short strands of bagasse or other cellulistic material. The material resinated, compressed and cured to give an open structural block. A mortar screed of portland cement and sand is then applied to penetrate interstices between the strands and is built up with rendering and facing layers of mortar. A reinforcement, such as an open mesh net of resinated nylon strands may be incorporated in the facing layer.

Abstract: A method of forming an air-laid web or sheet of wood pulp fibers suitable for tissue and toweling applications comprising airlaying a web of wood pulp fibers, applying water containing a chemical softening agent to the web, pressure bonding the water-treated web to provide dry stength, preferably drying the pressure-bonded web, applying an adhesive containing solution to the dried web to provide increased wet strength, and drying the web to form the finished product. By adding a chemical softening agent to the water applied to the air-laid web ahead of the pressure bonding rolls, the strength and softness of the finished web can be controlled. Alternatively, the chemical softening agent can be added to the printing adhesive solution.

Abstract: Apparatus for the deposition of a uniform web of dry wood pulp fibers on a forming wire in combination with melt blowing die means operable to deposit melt blown fibers on the web of dry fibers to strengthen the web. Means for depositing the webs comprise serially disposed sets of fiber distributors, and the die means is disposed between the sets of fiber distributors so that the melt blown fibers are deposited as separate layers on the finished web.

Abstract: The invention relates to apparatus for manufacturing elements made of a hardenable binding agent, wherein this element is obtained by successive deposits of the dry binding agent in powder form, each deposit being followed by a wetting. The invention is applicable to the production of construction elements, such as plates, tiles, etc.

Abstract: A method of dispersing glass fibers in a rubber solution comprises forming a rubber-bonded glass sheet and dissolving the rubberbond of the glass sheet in a rubber solution comprising rubber and a solvent compatible with that used to form the rubber-bonded glass sheet.

Abstract: Particle board contains, as a fibrous material with good structural properties, at least a proportion of chicory root particles. Preferably the chicory is mixed with bagasse fibres to provide strength to the board, and a filler in the form of coffee grounds is included. The coffee and chicory constituents are conveniently obtained as wastes from the manufacture of instant coffee.

Abstract: Aqueous latex base binder of a synthetic polymer for manufacturing nonwoven fabrics, and specifically webs for sanitary use having improved breaking strength. The content in the latex of hydrosoluble compounds dissolved in the aqueous phase is less than 0.5% by weight in relation to the polymer.

Abstract: A process for producing glass fiber-reinforced, transparent cast sheets comprising impregnating glass fibers with a resin syrup comprising 10 to 50 parts by weight of a copolymer (A) consisting essentially of 20 to 95% by weight of an aromatic vinyl compound and 5 to 80% by weight of other polymerizable monomer, 1 to 40 parts by weight of an aromatic vinyl compound (B), 50 to 90 parts by weight of other polymerizable monomer (C) and optionally 0.5 to 10 parts by weight of maleic anhydride, and casting the resulting mixture.

Abstract: This invention relates to a bonded non-woven fabric capable of absorbing water vapor, containing fibers of cellulose hydrate modified by at least one organic polymeric compound, either solely or blended with synthetic, natural or regenerated fibers.

Abstract: A process for producing an easily handleable sheet molding compound which comprises impregnating glass fibers with a resin composition comprising (A) an unsaturated polyester having a hydroxyl value of 20 to 55 and an acid value of 5 to 20 with a hydroxyl value/acid value ratio of from 1.7 to 10, (B) a polymerizable monomer and (C) a polyisocyanate compound having not more than 20 carbon atoms excepting the carbon atoms of the isocyanate groups and selected from the group consisting of diisocyanates and polymethylenepolyphenyl isocyanates, the proportions of the unsaturated polyester (A) and the polyisocyanate compound (C) being such that the mole ratio of the hydroxyl groups of the unsaturated polyester (A) to the isocyanate groups of the polyisocyanate compound (C) is from 0.7 to 1.

Abstract: A method for the preparation of pharmaceuticals which comprises using a piezoelectric dosing system to dot liquid, dissolved or suspended active substance onto a pharmaceutical carrier.

Abstract: A method for the manufacture of a locked material of filaments, which comprises compression molding in a prescribed shape short fibers of three-dimensionally crimped synthetic filaments, applying an adhesive liquid to the shaped article of filaments thus obtained, then lifting the shaped article in a substantially vertical direction and, at the same time, subjecting it to dielectric heating and thereby drying the adhesive adhering to the shaped article.

Abstract: Fibrous glass blowing insulation is made by slitting and crosscutting a blanket of fibrous glass wool into small columns and conveying the columns to a bagging machine, the columns normally breaking up at random during conveying and packaging into approximate cubes and smaller flakes or prisms of various thicknesses.

Abstract: Methods by which a dry-formed loose fibrous web is bonded by applying to one of its surfaces a low add-on level of a relatively high binder solids concentration bonding material to form a once-bonded web, and to the other side of the web, a greater add-on level of a relatively lower solids concentration bonding material, the first-applied emulsion preferably adding from about 20% to about 40% binder solids by weight, and the second-applied adding the rest of the total binder solids to be included in the fibrous web product. The bonding material can be a solution or emulsion. Preferably, the first and second-applied bonding materials are water-based latex emulsions, the solids concentration of the first-applied emulsion is from about 15% to about 25% by weight, that of the second-applied emulsion is from about 10% to about 20% by weight based on the total binder solids to be included in the fibrous web product, and a vacuum draws the second-applied bonding material into the web.

Abstract: A nib-type writing pen is formed by compressing a plurality of fibers into a bundle, extruding a plastic sheath around the fiber bundle, cutting the sheathed fiber bundle to a suitable length and injecting a urethane prepolymer into one or both ends of the cut and sheathed fiber bundle.

Abstract: A reconstituted leather and method of manufacture wherein leather is pulverized to form a fine powder which is then treated to polarize the particles and cause them to form groups or aggregates. The aggregates are then intermixed with a resinous binder to form said reconstituted leather which is then buffed to expose the natural leather and produce a structure closely resembling natural leather in feel, odor and appearance.

Abstract: A polyurethane elastomer which comprises a reaction product of (A) a polymeric diol having a molecular weight of about 800-5000, (B) a mixture of organic diisocyanates wherein about 2-70 mol % is composed of aliphatic diisocyanate (said aliphatic diisocyanate having no direct bond between an aromatic ring and an isocyanate group) and wherein the balance 98-30 mol % is composed of aromatic diisocyanate which includes a direct bond between an aromatic ring and an isocyanate group, and (C) a chain extender comprising hydrazine and/or a derivative having the formula NH.sub.2 NHR and another chain extender having two functional groups constituting amino and/or hydroxyl groups,and wherein about 30-80% of the carbon atoms which are bonded to nitrogen atoms constituting the ureylene and/or urethane bonds of said polyurethane elastomer constitute benzene and/or naphthalene ring skeletons.

Abstract: A fiberboard is manufactured having relatively high density skins on a relatively low density core by including urea in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins. In accordance with another embodiment of the present invention, urea is used to form a skin on higher density mats having a density of 35 pounds/ft..sup.3 or greater. The skin formed on the higher density mats has strength and density properties which are not as significantly different from the core material as is the skin formed over the low density core material of the first embodiment, but the skin on the higher density mats also improves the board strength, stiffness, paint holdout and design fidelity properties.

Abstract: A process is disclosed for forming an outlet passageway in an osmotic dispensing device. The process comprises compressing a drug formulation into a solid mass, forming a recess in the solid mass, and then spray coating the mass with a wall forming material that surrounds the mass. The outlet passageway in the wall is formed at the recess simultaneously and automatically during the coating procedure. The passageway extends through the wall and communicates with the drug and the exterior of the device for dispensing the drug over a prolonged period of time.

Abstract: A glass fiber mat having excellent tensile strength and flexibility is provided herein. The mat includes a plurality of glass fibers and a binder therefor which is characterized by comprising about 25% to 90% by weight of a urea-formaldehyde resin and about 10% to 75% by weight of a styrene-butadiene latex copolymer containing about 0.1% to 5% by weight of an acrylamide type monomer.

Abstract: Disclosed is a hardboard with a smooth, highly-consolidated, dense surface and a method for making it. The method of this invention greatly reduces the need for surface sanding after molding because release from the molding caul is improved and results in a product having a surface more free of defects. According to a preferred embodiment, a dry mat of wood particles is sprayed with from 8 to 30 grams per square foot of a surface coating of a consolidating agent comprising from 50 to 95% water, from 4 to 25% ethylene glycol and from 1 to 25% polyvinyl acetate, prior to pressing at elevated temperature. These percentages are based on the weight of the consolidating agent. The preferred products will have at least one highly-consolidated, smooth surface layer which comprises from 0.5 to 4 grams of polyhydric alcohol and from 0.5 to 4 grams of polyvinyl acetate per square foot of surface.

Abstract: A nonwoven fabric having alternating stripes of high fiber density and low fiber density is made in such a manner that the high fiber density stripes run across the fabric and maximize the cross direction strength to a point that the cross direction/machine direction strength ratio approaches unity. This advantageous and desirable characteristic can be achieved by hydroforming card web; first disposing the carded web on a relatively fine mesh screen and placing a finger-like striping bars over the web with the axis of the bars at 90.degree. to the card web's general fiber orientation. Water was then sprayed over the assembly with sufficient force to rearrange the fibers in the web thereby producing the nonwoven fabric of this invention.

Abstract: A process for producing a glass fiber-reinforced molded sheet by impregnating glass fibers with a resin syrup and thereafter hardening the resin syrup with which the glass fibers are impregnated, wherein the resin syrup is 20 to 35% by weight vinyl aromatic hydrocarbon and comprises 25 to 50 parts by weight acrylonitrile-vinyl aromatic hydrocarbon copolymer and 75 to 50 parts by weight acrylic acid, methacrylic acid, methacrylic acid ester, acrylic acid ester or mixtures thereof, the copolymer comprising 10 to 50 parts by weight acrylonitrile and 90 to 50 parts by weight vinyl aromatic hydrocarbon and having a viscosity average molecular weight of 30,000 to 100,000. A process for producing a glass fiber-reinforced resin molded sheet is also disclosed which is more effective than the aforesaid process wherein the acrylonitrile-vinylaromatic copolymer is modified with 0.05 to 0.2 part by weight of a polyfunctional monomer based on a total of 100 parts by weight of acrylonitrile and vinyl aromatic hydrocarbon.

Abstract: A method of forming particle board characterized by the use of an adhesive comprising a polyisocyanate and a phenolic adhesive. Enhanced adhesive characteristics and other advantages are associated with the method in which the polyisocyanate is added to the wood particles, etc. prior to application of the phenolic adhesive.

Abstract: The invention comprises the process for making an inorganic refractory insulation article by forming a fiber mat from a fiber slurry, impregnating the mat with a conditioned colloidal silica composition comprising colloidal silica, acid, aluminum chlorhydrate and water and drying the mat to form the article. The invention further comprises an inorganic refractory insulation article comprising randomly oriented refractory fibers retained by dried colloidal silica uniformly distributed throughout the article and from about 0.001 to about 1.5 weight percent of aluminum chlorhydrate which article is manufactured in accordance with the process.

Abstract: A process for coloring nonwoven webs of fibrous material, particularly air-layed webs, in which solid, water insoluble particulate pigments are introduced and intermixed with the fibers of the web to provide the coloring thereof. An initial formed web of fibrous material has a suspension of insoluble pigment in a liquid applied thereto, is fiberized, and is reformed into a web and bonded with a binding liquid. Alternatively, the pigment may be mixed with the separated fibers after the fibrous material is fiberized and before reforming.

Abstract: Migration-resistant binder compositions for bonding nonwoven fibers are disclosed. These compositions comprise (A) an anionically-stabilized polymer latex; (B) a water-soluble polymer of 20-100% by weight of mer units containing an amine group and having a viscosity average molecular weight between 5,000 and 300,000; (C) a volatile base and (D) 0 to 80% of pigment based on the total polymer weight of (A) and (B). Usually, the compositions have a solids content between 10% and 60% by weight, a viscosity below 3,000 centipoise, a pH above 5, and a component (B) content between 0.1% and 20% by weight of the solids. In alternative compositions, component (B) is replaced by component (B'), a water-insoluble polymer with the same amine group content and a viscosity average molecular weight between 5,000 and 100,000. (A), (B) and (B') are polymers of a .alpha.-.beta. ethylenically unsaturated monomers.

Abstract: A method of producing an electrically conductive plastic material, the conductive pigment in said material being selected from lamp black, graphite and a mixture of lamp black and graphite wherein the conductive pigment is dispersed in a hydrocarbon solvent, the pigment-hydrocarbon dispersion then being subjected to a vibrational force to cause swelling of the conductive pigment in the solvent and adding a bonding agent having an interface surface tension substantially equal to that of the solvent.