Abstract: A process for producing meltblown polyolefin fibres having an effective diameter of less than 5 microns, comprising providing a polyolefin having a melt flow index of at least 1000, mixing a fluorochemical with the polyolefin in order to increase the melt flow index of the polyolefin to at least 2000, and meltblowing the polyolefin with the fluorochemical in order to produce the meltblown polyolefin fibres, and the polyolefin being such that during the meltblowing the fluorochemical is able to migrate to the surface of the formed polyolefin fibres without the need for a separate annealing step.

Abstract: A method for chemical vapor deposition using a very fine atomization or vaporization of a reagent containing liquid or liquid-like fluid near its supercritical temperature, where the resulting atomized or vaporized solution is entered into a flame or a plasma torch, and a powder is formed or a coating is deposited onto a substrate. The combustion flame can be stable from 10 torr to multiple atmospheres, and provides the energetic environment in which the reagent contained within the fluid can be reacted to form the desired powder or coating material on a substrate. The plasma torch likewise produces the required energy environment, but, unlike the flame, no oxidizer is needed so materials stable in only very low oxygen partial pressures can be formed.

Abstract: A method of integrating organic fibers with mineral fibers includes centrifuging organic fibers from molten organic material, using a rotating organic fiber spinner, directing the organic fibers into a downwardly moving veil of organic fibers and gases, with the veil having an inwardly converging shape as it moves downward, centrifuging mineral fibers from molten mineral material using a rotary mineral fiber spinner positioned concentrically within the downwardly moving veil of organic fibers, directing the mineral fibers into a downwardly moving veil of mineral fibers and gases within the veil of organic fibers, wherein the veil of mineral fibers intersects with the veil of organic fibers to integrate the mineral fibers with the organic fibers, and collecting the integrated mineral fibers and organic fibers as a fibrous pack. An apparatus for performing the method is also disclosed.

Abstract: Systems, apparatus combinations and methods for producing a powder coating are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.

Abstract: A process for making an indium-tin-oxide shaped body, comprising: (a) filling an indium-tin-oxide powder into a first flexible mold, the indium-tin-oxide powder having a specific BET surface of at most 3 m.sup.2 /g with a mean primary particle size of 0.03 .mu.m to 1.0 .mu.m and/or having a density of at least 40% of theoretical density after cold pressing at a pressure of 100 MPa and/or the indium-tin-oxide powder being made by reacting at least two reaction partners comprising a molten indium-tin-metal alloy as a first reaction partner and oxygen as a second reaction partner in a plasma arc in a plasma chamber provided with an inlet opening for the reaction partners and an outlet with a gas-supply device to obtain a material, and quenching the material at the outlet opening of the plasma chamber with a gas stream which cools the material at a cooling rate of 10.sup.5 K/s to 10.sup.8 K/s to +50.degree. C. to +400.degree. C.

Abstract: Methods for preparing dry powders having hydrophobic and hydrophilic components comprise combining solutions of the components and spray drying them simultaneously in a spray dryer. The hydrophilic and hydrophobic component are separately dissolved in separate solvents and directed simultaneously through a nozzle, usually a coaxial nozzle, into the spray dryer. The method provides dry powders having relatively uniform characteristics.

Abstract: Systems, apparatus combinations and methods for producing a coating powder are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.

Abstract: Non agglomerating hollow sub-micron size, 0.5 to 2.0 um, indium oxide microspheres are produced using an aerosol pyrolysis method using an indium compound, preferably, an indium acetate precursor, which is dissolved in water, without the use of chlorine or other dangerous chemicals, to generate an indium constituent such as, acetate dihydroxy indium (III), formed in droplets which, when heated by furnace temperatures of 650-700.degree. C., form the indium oxide microspheres particles suitable for polymer loading as a polyimide matrix particularly useful as antistatic coatings.

Abstract: There is a process for producing spherical metal-oxide powder particles. They are used as finely ground raw and filler materials in mineral, ceramic and refractory construction, technical and auxiliary materials, as well as for polishing and grinding agents.

Abstract: A plastic lens includes an optically functioning section, a flange section disposed at an outer periphery thereof, a reference surface formed at an outer peripheral portion of the flange section and adapted to become a reference for attachment, and a tapered surface formed on at least a part of the outer peripheral portion of the flange section which is located closer to the optically functioning section side than is the reference surface so as to taper down its diameter along the optical axis of the optically functioning section. The tapered surface forms a surface at which a gate for resin injection is located upon manufacture.

Abstract: The invention concerns a process for preparing coating powder compositions in which one or a plurality of base resins and one or a plurality of hardeners, each of which is in solid form, is dissolved with a low-molecular compound above its critical pressure and critical temperature. This low-molecular compound is inert with respect to the base resins and hardeners and is in gaseous form under normal operating conditions with respect to pressure and temperature. The pressure of the resultant solution is then reduced, for example, by spraying. The resultant coating powder composition can be sprayed directly onto a substrate to be coated. Coating powders can also be recycled according to the process of the invention.

Abstract: An improved process for manufacture of expandable polymer particles is provided. The continuous process disclosed produces expandable polymer pellets in a single step while eliminating many of the dangers inherent in processes of prior art employed for the same. The polymers produced herein are of uniform size, and may be molded into various articles of manufacture using existing equipment and techniques known to those skilled in the art.

Abstract: Fine fibers are formed and carried in a high energy, high temperature gaseous stream to a primary fine fiber collection surface where fine fibers are collected from the gaseous stream. Gases of the gaseous stream along with fine fibers not removed from the gaseous stream by the primary collection surface are drawn through the primary collection surface and formed into an exhaust gas stream which is passed through a secondary fine fiber collection surface to remove additional fibers from the exhaust gas stream before it is discharged to the atmosphere. To reduce the operating temperatures at and surrounding the primary and secondary collection surfaces, the gas streams are cooled by evaporative cooling. Water is sprayed into the gas streams by nozzles, shielded from the gas streams by scoops, so that fibers do not collect on the nozzles and form fiber wads.

Abstract: Novel hollow silicone resin particles, having an average particle size of 0.1 to 100 .mu.m are disclosed. The silicone resin particles comprise a skin formed from thermoplastic silicone resin configured in the shape of a hollow capsule. The hollow thermoplastic silicone resin particles are prepared by spraying a dispersion of water and thermoplastic silicone resin dissolved in solvent into hot gas. The hot gas evaporates the solvent and water and at the same time causes solidification of the thermoplastic silicone resin while it is in the spray state, so as to form a plurality of hollow particles therefrom.

Abstract: A continuous hydrothermal synthesis method which comprises pressurizing and heating a material slurry below a saturated vapor temperature or pressurizing a material slurry at normal temperature, pressurizing and heating an aqueous liquid above the saturated vapor temperature, atomizing and mixing the slurry and the aqueous liquid, effecting hydrothermal synthesis in a reaction section above the saturated vapor temperature, cooling the reaction product and taking out the product while retaining the pressurized state in the system by alternately opening and closing shut-off valves provided above and below a product discharging section or through a thin pipe provided in the product discharging section. The method is performed using an apparatus comprising heating-pressurizing sections respectively connected to a material slurry feeding section and an aqueous liquid feeding section, an atomizing-mixing section and a reaction section provided after these feeding sections, and a product discharging section.

Abstract: A method for preparing spherical phosphor particles is disclosed, wherein a precursor solution of phosphors is decomposed to solid particles by aerosol pyrolysis and rapid cooling and subsequently the solid particles are heat-treated at a temperature of 1000.degree. C. to 1600.degree. C. for a period of 1 hour to 9 hours.

Abstract: A method and an apparatus useful for the production of microparticles and nanoparticles are disclosed in which a compressed fluid and a solution including a solvent and a solute are introduced into a nozzle to produce a mixture. The mixture is then passed out of the nozzle to produce a spray of atomized droplets. The atomized droplets are contacted with a supercritical antisolvent to cause depletion of the solvent in the droplets so that particles are produced from the solute. Preferably, these particles have an average diameter of 0.6 .mu.m or less. The invention can be used in the pharmaceutical, food, chemical, electronics, catalyst, polymer, pesticide, explosives, and coating industries, all of which have a need for small-diameter particles.

Abstract: The present invention provides an apparatus for producing a single layer batt of fibers prepared by multiple die tips. The present invention also provides a novel multiple tip blow spinning die.

Abstract: A system and method for producing fine powders. The system includes a rotary atomization device for forming a moving flow of a molten source material; a source of atomizing material; a nozzle for directing a jet of the atomizing material at the moving flow of molten source material for atomizing and for producing fine droplets of the source material; and a chamber for collecting the fine droplets.

Abstract: A Pulse Detonation Synthesis (PDS) process for the manufacture and deposition of ceramic powders and coatings is disclosed. PDS may use multiple detonation pulses that are initiated in a reaction chamber to synthesize ceramic materials from reactants introduced into the chamber. The reactants may be provided in the form of divided solids, gases, liquids, gels, and/or mixtures of the foregoing. The synthesized ceramic materials may take the form of micron and/or nano-scale powders or coatings. Non-coating powders may be collected for later use. The coatings produced by the present invention include, but are not limited to, gradient coatings, uniform coatings, thermal barrier coatings, and other commercially useful coatings.

Abstract: A method for the dewatering of a material layer of paper fibers in a double-screen former, where the sheet weight (oven-dried sheet weight (otro)) is more than 100 g/m.sup.2 and/or the screen circulates with a speed of at least 100 m/min. Two screens are guided at two guide surfaces that, for example, belong to open forming cylinders. In this arrangement forming cylinders of this kind are so dimensioned and positioned that no dewatering elements that contact one of the screens are present between the run-out line of the screens from the first guide surface and the run-in line at the second guide surface.

Abstract: Improved methods and apparatus for particle precipitation and coating using near- or supercritical fluid conditions are described. A fluid dispersion having a continuous phase dispersant and at least one precipitatable substance therein is contacted with a supercritical fluid (SCF) antisolvent so as to generate focused high frequency antisolvent sonic waves, breaking up the dispersion into extremely small droplets; the enhanced mass transfer rates between the droplets and the antisolvent causes precipitation of very small particles on the order of 0.1-10 .mu.m. In coating processes, a turbulent fluidized flow of core particles is created using an SCF antisolvent in an enclosed zone. The core particles are contacted therein at near- or supercritical conditions by a fluid dispersion containing a dispersant together with a precipitatable substance. The antisolvent depletes the dispersant and the substance is precipitated onto the fluidized core particles.

Abstract: A thermal reactor system that produces nanoscale powders by ultra-rapid thermal quench processing of high-temperature vapors through a boundary-layer converging-diverging nozzle. A gas suspension of precursor material is continuously fed to a thermal reaction chamber and vaporized under conditions that minimize superheating and favor nucleation of the resulting vapor. According to one aspect of the invention, the high temperature vapor is quenched using the principle of Joule-Thompson adiabatic expansion. Immediately after the initial nucleation stages, the vapor stream is passed through the nozzle and rapidly quenched through expansion at rates of at least 1,000.degree. C. per second, preferably greater than 1,000,000.degree. C. per second, to block the continued growth of the nucleated particles and produce a nanosize powder suspension of narrow particle-size distribution.

Abstract: Complex protein walled microcapsules (40) incorporate lipid-walled microcapsules (48) that include constituents to be retained in the presence of hydration such as water soluble vitamins and minerals. The protein walled microcapsules (40) are cross-linked, and include constituents (46) that are excluded from the lipid-walled microcapsules (48) and which are leachable from the protein walled microcapsules upon hydration. Other constituents (42 and 44), such as high molecular weight compounds and particulates may also be included in the protein walled microcapsules (40). Preferably, these other constituents (42 and 44) are chosen to be retained within the protein-walled microcapsules (40) upon hydration.

Abstract: Systems, apparatus combinations and methods for producing a powder coating are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.

Abstract: A die for melt-blowing apparatus, which has a die body, a nozzle piece, and a lip plate. The nozzle piece is divided into plural temperature-controlling regions in a direction crosswise to a spinning direction. A temperature sensor is used to measure the temperature at a portion surrounding a nozzle orifice in the nozzle piece in each of the divided temperature-controlling regions. A heated gas is applied directly to the nozzle piece for controlling the temperature of the portion surrounding the nozzle orifice to a predetermined temperature. Using this die body, a melt-blown non-woven fabric with a uniform distribution of the weight per unit area can be easily obtained.

Abstract: A method of making a shaped part of sintered silicon nitride is disclosed which includes preparing a mixture of Si.sub.3 N.sub.4 having a BET specific surface area in the range of from 2 to 15 m.sup.2 /g, having an O.sub.2 content of <1.5% by weight, a .beta.-form content of <2% by volume with finely divided Y.sub.2 O.sub.3, Al.sub.2 O.sub.3 or HfO.sub.2 and/or ZrO.sub.2, the total additive content being in the range of from 6 to 13% by weight, based on the total weight of the mixture, then mixing and milling mixture in a liquid dispersion medium, drying and agglomerating the suspension so produced, subsequently pressing, injection molding or redispersing and casting the agglomerated material obtained to make shaped parts, and finally sintering the shaped parts at temperatures between 1725.degree. and 1850.degree. C. under nitrogen for a period of up to 2 hours. The shaped parts produced according to the method have high mechanical strength and include at least 87% by weight Si.sub.3 N.sub.

Abstract: An apparatus for forming artificial fibers and a non-woven web therefrom includes a device for generating a substantially continuous fluid stream along a primary axis, at least one extrusion die located adjacent to the continuous fluid stream for extruding a liquefied resin into fibers, a member for entraining the fibers in the primary fluid stream, and a perturbation mechanism for selectively perturbing the flow of fluid in the fluid stream by varying the fluid pressure on either side of the primary axis to produce crimped fibers for forming the non-woven web. The inventive manufacturing method finely tunes non-woven web material characteristics such as tensile strength, porosity, barrier properties, absorbance, and softness by varying the fluid stream perturbation frequency and amplitude. Finally, the inventive apparatus may be implemented in combination with melt-blown, spunbond and coform techniques for producing non-woven webs.

Abstract: A metal or an alloy thereof, or a ceramic that has a liquid phase is introduced in the form of a rod or a wire or as a liquid stream into the apex formed by a plurality of converging plasma jets. Atomization takes place and upon controlled cooling good quality spheroidal powders are obtained whose size varies generally between about 10 and 300 .mu.m.

Abstract: There is provided a fabric produced by a spunbond or a meltblown apparatus, wherein the apparatus has a pneumatic chamber having at least one wall containing a plurality of spaced protrusions. Preferably, both opposing walls contain protrusions aligned in staggered angled rows and the rows on one wall are angled opposite the rows on the opposing wall, thereby causing controlled lateral flow near the chamber walls. This lateral flow exhibits drag on the fibers, imparting rotational energy to the fibers. The fibers are imparted with rotational energy derived from the lateral component of the two turbulent airflow fields that oppose one another, and have a tendency to twist and crimp. Fabrics so produced have improved loft, drape, and feel and may be useable as a loop material for hook-and-loop type fasteners.

Abstract: Hydrogen peroxide complexes in powder form are prepared by spray drying aqueous or alcoholic solutions.

Abstract: Meltblown thermoplastic fibers are cooled by microsized water droplets produced by airless ruby nozzles. The droplets have an average diameter of less than 20 microns.

Abstract: A process for making gel bead having a mean diameter of less than 50 microns by adiabatically atomizing a hydrocolloid sol to droplet of less than 50 microns under conditions that lower the temperature of the hydrocolloid below its gel temperature.

Abstract: A process for producing a carbon-filled ceramic composite material comprising a ceramic matrix and a carbon domain dispersed therein with a carbon domain diameter of from 0.01 to 30 .mu.m and a carbon domain area ratio of from 5 to 70%; comprising the steps of mixing ceramic powder, sintering aids and a carbon source, calcining the mixture at 300.degree.-600.degree. C., granulating the mixture, molding and sintering.

Abstract: A process is provided that permits the rapid quenching of molten ceramics by passing a flow of the molten ceramic into a turbulent fluid flow such that the flow is broken up into particles which then solidify as they pass into and through a cyclone and are finally separated from the fluid flow and collected as dry particulate ceramic materials.

Abstract: Ceramic oxide powders and methods for their preparation are revealed. Ceramic oxide powders are obtained using a flame process whereby one or more precursors of ceramic oxides are introduced into a counterflow diffusion flame burner wherein the precursors are converted into ceramic oxide powders. The nature of the ceramic oxide powder produced is determined by process conditions. The morphology, particle size, and crystalline form of the ceramic oxide powders may be varied by the temperature of the flame, the precursor concentration ratio, the gas stream and the gas velocity.

Abstract: An anhydride-containing thermoplastic resin such as a styrene maleic anhydride copolymer is processed in a vented extruder in the present of a nitrogenous chemical blowing agent to both imidize at least a portion of the anhydride groups and remove volatile residues such as unreacted styrene monomer from the resin.

Abstract: A metblowing die designed to efficiently receive a preassembled die tip assembly is described. The die assembly includes a die body (19) mounted on a meltblowing machine and a replaceable die tip assembly (20). The die tip assembly (20) includes a mounting block (25), to which are mounted a die tip (26) and air knives (27, 28) on opposite sides or the die tip (26). The positions of the air knives (27, 28) are adjustable to set air gap and set back parameters important in proper operation. The die tip assembly (20) is moved into and out of the die body (19) after air knife adjustment permitting adjustment to be made with the die tip assembly (20) off the machine, allowing rapid replacement. The replacement die tip assembly (20) is preheated, permitting replacement while the die body (19) is still hot.

Abstract: Portland cement particles having the characteristics of slow hardening is oduced by a process of heat treating portland cement particles in the temperature range from 1500.degree. to 3000.degree. C. for from 0.5 to 10 seconds and cooling to obtain particles containing an amorphous, glassy shell as an outside layer.

Abstract: Modular die constructions includes a plurality of side-by-side self-contained, interchangeable meltblowing modules on a manifold so that the length of the die can be varied by adding modules or removing modules from the manifold.

Abstract: A cuprous oxide powder is produced by the steps of discharging a molten copper, which is kept at a temperature at or higher than the melting point and at or lower than 1450.degree. C. and contained in a container having a nozzle at a bottom, from the nozzle into a reactor vessel disposed below the container to form a downward flow of the molten copper, atomizing the downward flow by a jet stream of an oxygen-contained gas and, thereby simultaneously, oxidizing the molten copper to form cuprous oxide, cooling liquid droplets or solid particles of the thus formed cuprous oxide and then collecting the droplets or particles from the reactor vessel. A cuprous oxide powder can be produced, without requiring a large-scale production facility, in simple steps, and efficiently and continuously.

Abstract: A meltblowing die for producing nonwoven polymer webs includes an inner tube having a plurality of orifices arranged in a row thereon, and an outer tube encasing the inner tube and having a slot formed therein in registry with the row orifices. The inner tube and outer tubes are constructed to define converging air passages on either side of the row of orifices, whereby hot air delivered to the outer tube converges on polymer fibers extruded through the orifices and imparts drag forces thereon to attenuate and draw down the fibers to microsize.

Abstract: An apparatus provides high temperature and short residence time conditions for the production of nanoscale ceramic powders. The apparatus includes a confinement structure having a multiple inclined surfaces for confining flame located between the surfaces so as to define a flame zone. A burner system employs one or more burners to provide flame to the flame zone. Each burner is located in the flame zone in close proximity to at least one of the inclined surfaces. A delivery system disposed adjacent the flame zone delivers an aerosol, comprising an organic or carbonaceous carrier material and a ceramic precursor, to the flame zone to expose the aerosol to a temperature sufficient to induce combustion of the carrier material and vaporization and nucleation, or diffusion and oxidation, of the ceramic precursor to form pure, crystalline, narrow size distribution, nanophase ceramic particles.

Abstract: Close-coupled atomization systems and methods employing non-axisymmetric gas flow have demonstrated superior efficiency in the production of fine superalloy powder, compared to conventional close-coupled atomization utilizing an axisymmetric annular gas orifice and an axisymmetric melt nozzle. A means has been devised for convening otherwise axisymmetric plenums into non-axisymmetric plenums that produce non-axisymmetric gas flow.

Abstract: A meltblowing die designed to efficiently receive a preassembled die tip assembly is described. The die assembly includes a die body mounted on a meltblowing machine and a replaceable die tip assembly. The die tip assembly includes a mounting block, to which are mounted a die tip and air knives on opposite sides of the die tip. The positions of the air knives are adjustable to set air gap and set back parameters important in proper operation. The die tip assembly is moved into and out of the die body after air knife adjustment, permitting the adjustment to be made with the die tip assembly off the machine, and allowing rapid replacement. The replacement die tip assembly is preheated, permitting replacement while the die body is still hot.

Abstract: A method of manufacturing a three-dimensional fabric of the type which may be used in absorbent garments, dressings or the like involves the use of an apertured collector element which has a predetermined three-dimensional shape. The method involves positioning material adjacent to one side of the apertured collector element and developing a pressure differential between the one side of the apertured collector element and a second, opposite side to force the fabric material against the apertured collector element. The material, which has conformed to the shape of the collector element, is then solidified into its intended three-dimensional shape.

Abstract: A metal spray apparatus is provided with a supersonic nozzle. Molten metal is injected into a gas stream flowing through the nozzle under pressure. By varying the pressure of the injected metal, the droplet can be made in various selected sizes with each selected size having a high degree of size uniformity. A unique one piece graphite heater provides easily controlled uniformity of temperature in the nozzle and an attached tundish which holds the pressurized molten metal. A unique U-shaped gas heater provides extremely hot inlet gas temperatures to the nozzle. A particularly useful application of the spray apparatus is coating of threads of a fastener with a shape memory alloy. This permits a fastener to be easily inserted and removed but provides for a secure locking of the fastener in high temperature environments.

Abstract: A method of attenuating a molten thermoplastic polymer stream into polymer fibers for forming a non-woven fiber mat, and the non-woven fiber mat formed thereby. The method applying a gas stream to a molten polymer stream, and inducing a cyclic pulsation in the gas stream. The cyclic pulsation further comprises a discontinuous flow of the gas stream. The application of the gas stream to the molten polymer stream causes the attenuation of the molten polymer stream into a plurality of fibers which are collected onto a receiving surface thereby forming a non-woven fiber mat. The method may be used to impart a particularly unique or otherwise desirable configuration to the fibers or to the fiber mat produced from them. The gas stream may be comprised of a primary gas flow having a first stream and a second stream. The gas stream may be further comprised of a secondary gas flow having a first stream and a second stream.

Abstract: An apparatus and method for atomizing liquid metal are disclosed. A liquid metal supply is coupled to a nozzle for atomizing a stream of liquid metal in an atomizing zone extending from the nozzle. A viewing instrument provides a field of view extending to the atomization zone. A sensor coupled with the viewing instrument generates an image of the atomizing zone, and a control adjusts a flow rate of the stream responsive to the image.

Abstract: A process for the preparation of toner additive wax particles which comprises the micronization of said particles from a supercritical solution.