Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powders. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Abstract: A process for producing inorganic spheres, which comprises injecting an aqueous liquid containing an inorganic compound into a laminar flow of an organic liquid which runs at a flow rate of from 0.001 to 2 m/s in a flow path compartmentalized by a partition wall through a plurality of inlet holes formed in one partition wall to form a W/O type emulsion containing the organic liquid as a dispersion medium and the aqueous liquid containing the inorganic compound as a dispersed phase, and solidifying the aqueous liquid containing an inorganic compound in the W/O type emulsion, wherein the partition wall having a plurality of inlet holes is made of a metal sheet having a surface subjected to water repellent treatment.

Abstract: A method for obtaining urea prills in a prilling tower (1) comprising the step of making a plurality of melt urea droplets to fall from a urea melt distributing device (4) towards an urea prills collecting bottom (6) of the prilling tower, further comprises the step of cooling the collecting bottom (6).

Abstract: Thermistor elements composed mainly of a metal oxide sintered body are prepared by mixing a metal oxide precursor in a liquid phase to prepare a solution or slurry of the precursor. The precursor solution or slurry is sprayed to form droplet particles which are heat treated to form a thermistor raw material powder which powder is then molded and sintered into a shape to provide a metal oxide sintered body.

Abstract: Environmentally degradable molded or extruded articles comprising a blend of polyhydroxyalkanoate copolymer and an environmentally degradable thermoplastic polymer or copolymer are disclosed. Such compositions provide annealing cycle times to form molded or extruded articles that are less than annealing cycle times to form a molded or extruded article lacking the environmentally degradable thermoplastic polymer or copolymer.

Abstract: A method for producing high-alumina bodies with superior chemical properties at reduced sintering temperatures, including the steps of providing an alumina powder precursor, adding about 4 weight percent magnesia powder precursor, homogenizing the resultant green powder precursor, pressing a green body from the green powder precursor, removing residual moisture and organic material from the green body, and firing the green body to about cone 13, wherein the resulting high-alumina body is substantially non-vitreous, has a substantially uniformly sized grain structure, is very resistant to dissolution in molten aluminum, and has superior resistance to chemical attack over substantially the entire pH range.

Abstract: The present invention can provide particles for electro-rheological fluid for providing a high electro-rheological effect over a wide temperature range at low electric power consumption, and having high strength and excellent durability, not being susceptible to break-up due to the load of stress. Particles for an electro-rheological fluid of the present invention comprise spherical carbonaceous particles, obtained substantially from a solvent and a condensation product of a methylene type bond of aromatic sulfonic acid or a salt thereof.

Abstract: A method and apparatus to process a diverted molten polymer waste stream directs the polymer stream to one of at least two passages, separates it into individual segments while containing and discharging it from a containment exit, cools each segment with a quench fluid to form a solid or semi-solid polymer, and transports the solidified segments away from the exit and into a container using the quench fluid. The apparatus includes a cross-section transition connector, a moveable block with two passages, a block oscillator, a cut-off plate, and open space above an inclined transporting device, a quench fluid jet, and a quench fluid transporting trough.

Abstract: A method for depositing a substance on a substrate that involves forming a supercritical fluid solution of at least one supercritical fluid solvent and at least one solute, discharging the supercritical fluid solution through an orifice under conditions sufficient to form solid particles of the solute that are substantially free of the supercritical fluid solvent, and electrostatically depositing the solid solute particles onto the substrate. The solid solute particles may be charged to a first electric potential and then deposited onto the substrate to form a film. The solute particles may have a mean particle size of less than 1 micron.

Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powers. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Abstract: Fine battery powders and methods for producing fine battery powders. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes batteries formed from the powders.

Abstract: A filter and a method of manufacturing the filter which is formed by spinning a fiber in a semi-molten state onto a mold such that the mold is provided as a filter structural member. The method obviates the need to remove the filter from the mold and thus simplifies the manufacture of the filter.

Abstract: Chemical-mechanical planarization slurries and methods for using the slurries wherein the slurry includes abrasive particles. The abrasive particles have a small particle size, narrow size distribution and a spherical morphology and the particles are substantially unagglomerated.

Abstract: The present invention relates to a method for forming microparticles of a material from microdroplets of a solution, wherein the solution comprises the material dissolved in a solvent. The method includes the steps of directing the microdroplets into a freezing zone, wherein the freezing zone is surrounded by a liquified gas, and wherein the microdroplets freeze. The frozen microdroplets are then mixed with a liquid non-solvent, whereby the solvent is extracted into the non-solvent, thereby forming the microparticles.

Abstract: The present invention relates to a method for improving the abrasion resistance of a spun-bonded nonwoven without substantially adversely affecting its hand or drape characteristics, by incorporating low melt binder fibers into the web during the laydown phase of the spun-bonded nonwoven production process. More specifically, improved abrasion resistance is achieved by intimately blending continuous binder fibers with the primary extruded fibers in a spun-bonded nonwoven web. Also encompassed within this invention is a spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber such that the binder fiber comprises between about 1 and about 50 weight percent on weight of the spun-bonded nonwoven fabric.

Abstract: A method of making a spherical seamless capsule formed by encapsulating a filler material such as a medicine with a capsule shell material shell such as gelatin. A liquid capsule shell material is stored in a tank at a low temperature, and supplied to a concentric multiple nozzle while it temperature is raised to a predetermined temperature upon being gradually heated while being transferred to the concentric multiple nozzle. This prevents deterioration in the capsule shell material and excessive decrease in its viscosity. When the liquid filler material and the capsule shell material flow out of the concentric multiple nozzle, their flows are cut by imparting a vibration thereto, to form a droplet in which the filler material and the capsule shell material are disposed at the center and on the outside, respectively. Such droplets are dropped into a curing liquid while in a dispersed state to cure the surface of the capsule shell material.

Abstract: A device for exchanging a die plate of a molten bisphenol A prilling tower is described. The device comprises: (a) at least two die plates; (b) a guide which is in contact with the die plates; and (c) a drive mechanism, wherein the drive mechanism moves the die plates linearly and serially between an operating position and an exchange position along the guide. Also described is a process of automated operation of the device at the top of a bisphenol A prilling tower.

Abstract: Pigment-containing granules for use in coloring cement. The granules comprise at least one pigment selected from the group consisting of maganese oxide and iron oxide and a binder. The binder is a hydrophilic clay, and is preferably pozzolan.

Abstract: A method for producing bisphenol A in prill form is disclosed. Molten bisphenol is top-fed into a prilling tower via a plate containing a plurality of nozzles. A gas coolant guided through a circuit is led into said tower in a counter flow direction. The prills are cooled to about room temperature, collected at the bottom of the tower and removed. Also disclosed is the device for carrying out the inventive method and the prills thus produced.

Abstract: The invention provides exemplary silicon carbide ceramic bodies and processes for making such ceramic bodies. In one embodiment, a raw batch for producing a ceramic body includes a silicon carbide slurry and agglomerates of particles defining a dry lubricant mixture. The mixture includes a binder and a dry lubricant such as graphite, with a majority of the agglomerates having a shape that is generally spherical.

Abstract: A method of producing a nanoparticle, the method comprising: a reducing step of adding an reverse micelle solution (II) obtained by mixing a water-insoluble organic solvent containing a surfactant with an aqueous metal salt solution to an reverse micelle solution (I) obtained by mixing a water-insoluble organic solvent containing a surfactant with an aqueous reducing agent solution, to carry out a reducing reaction; and a maturing step of raising the temperature of the reduced mixture to mature the reduced mixture is provided. A method of producing a plural type alloy nanoparticle, the method comprising producing a nanoparticle made of a plural type alloy through a reducing step of mixing one or more reverse micelle solutions (I) containing a metal salt with an reverse micelle solution (II) containing a reducing agent to carry out reducing treatment and a maturing step of carrying out maturing treatment is also provided.

Abstract: A method for producing semiconductor or metal particles comprises the steps of: storing a semiconductor or metal melt in a crucible having a nozzle; supplying a gas comprising at least one selected from the group consisting of He, Ne, Ar, Kr and Xe into the crucible such that the pressure of the supplied gas in a space over the melt in the crucible is higher than the pressure of a gaseous phase into which the melt is dropped; dropping the melt from the nozzle into the gaseous phase by the pressure of the gas to form liquid particles; and solidifying the liquid particles in the gaseous phase to obtain semiconductor or metal particles. The crucible comprises at least one selected from the group consisting of hexagonal BN, cubic BN, Si3N4, TiB2, ZrB2, zirconia and stabilized zirconia at least near the nozzle.

Abstract: In a process for producing marl slags and marl slag cements or mixed components for mixed cements from marl having a basicity CaO/SiO2 of <2.0, it is provided that in a first process step argillaceous marl or a mixture of marl and clay having a basicity of <2.0 is dried, preheated and calcined and that, after this, the obtained product in a second process step is melted in a separate melting furnace at higher temperatures than applied in the first process step and is granulated from the melt.

Abstract: The present invention relates to a method for making a hexagonal boron nitride slurry and the resulting slurry. The method involves mixing from about 0.5 wt. % to about 5 wt. % surfactant with about 30 wt. % to about 50 wt. % hexagonal boron nitride powder in a medium under conditions effective to produce a hexagonal boron nitride slurry. The present invention also relates to a method for making a spherical boron nitride powder and a method for making a hexagonal boron nitride paste using a hexagonal boron nitride slurry. Another aspect of the present invention relates to a hexagonal boron nitride paste including from about 60 wt. % to about 80 wt. % solid hexagonal boron nitride. Yet another aspect of the present invention relates to a spherical boron nitride powder, a polymer blend including a polymer and the spherical hexagonal boron nitride powder, and a system including such a polymer blend.

Abstract: A plastic particle is formed of a plastic material having at least one integral protruding ring disposed on its outer surface. The ring may be continuous or intermittent around a perimeter of the plastic particle. Preferably, the particles have an outer diameter in the range of 0.007 inches to 0.040 inches.

Abstract: The present invention relates to a method for improving the abrasion resistance of a spun-bonded nonwoven without substantially adversely affecting its hand or drape characteristics, by incorporating low melt binder fibers into the web during the laydown phase of the spun-bonded nonwoven production process. More specifically, improved abrasion resistance is achieved by intimately blending continuous binder fibers with the primary extruded fibers in a spun-bonded nonwoven web. Also encompassed within this invention is a spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber such that the binder fiber comprises between about 1 and about 50 weight percent on weight of the spun-bonded nonwoven fabric.

Abstract: The invention includes a method of forming a plurality of spheres. A passageway is provided, and the passageway terminates in an orifice. A liquid is flowed through the passageway and expelled through the orifice to form drops. The drops are then passed through a fluid to cool and solidify the drops into a plurality of spheres. At least some of the spheres are collected. A pressure of the liquid is maintained within about ±10% of a value during the formation of the drops that are cooled into the collected spheres. The invention also includes a plurality of at least several hundred spheres having a diameter of less than about 0.05 inches and characterized by at least 95% of the spheres being within ±1.3% of a mean diameter of the spheres.

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: A crucible is formed of a cylindrical body member and a disk-shaped nozzle member fitted to the bottom portion of the body member, and the nozzle member is provided with a nozzle hole for discharging out a semiconductor molten solution dropwise therethrough. The semiconductor molten solution drops discharged out of the crucible through the nozzle hole are cooled and solidified during falling to become semiconductor grains. Silicon grains having high crystal quality can be manufactured at low cost.

Abstract: The present invention relates to a method for forming particles of a substance, comprising the step of introducing into a mixing chamber (8), in which the temperature and pressure are controlled, a fluid gas (4) and at least one vehicle system (1) comprising at least one substance in solution or suspension such that droplet formation and extraction of the vehicle occur substantially simultaneously by the action of the fluid gas (4). Turbulence is induced in at least one of said fluid gas (4) and said vehicle system (1) so as to create a controlled disorder in the flow of the at least one of the fluid gas (4) or the vehicle system (1) in order to control the particle formation in said mixing chamber (8), said controlled disorder being created by at least one flow perturbation means (11).

Abstract: A method including synthesizing polymeric precursors via organic acid modification; fabricating a fibrous material of the polymeric precursors; and fabricating a body of the fibrous material. One body has dimensions suitable as an electrode component of an electrical storage device.

Abstract: A microcapsule composition comprising a core material in a matrix of polymorphic shell material, releases said core material in an aqueous environment in accordance with zero order linear release profile. A preferred composition comprises a core material having a degree of water solubility entrapped in a beta crystalline matrix of water insoluble shell material which matrix may, optionally, be surrounded by a contiguous core material-free layer of water insoluble shell material. Also disclosed is a process for the preparation of microcapsules comprising subjecting a flowable mixture of core material and a first amount of water insoluble shell material to a pressure force to form a pressure-treated mixture, and passing said pressure-treated mixture through a spray nozzle into a chilling zone to form a solidified composition.

Abstract: Disclosed is a method for manufacturing composite granules having a homogeneous particle distribution, comprising powders of multimodal particle size distribution and phenol resins, and a method for manufacturing green bodies having homogeneous microstructure without particle separation from the granules.

Abstract: The present invention discloses an apparatus and method for pelletizing polycarbonate oligomers and polymers. A heated pressurizable cylinder holds aggregate polycarbonate oligomers or polymers which becomes a melt. The bottom of the cylinder is connected to a distributor plenum having nozzles. A funneling device receives the polymer droplets that emerge from the plenum and channels them into a container that has a screen on the top that collects the product pellets. Finally, a blowing agent, such as phenol, can be added to the melt to impart small voids in the product pellets.

Abstract: A method of making cermet inert anodes for the electrolytic production of metals such as aluminum is disclosed. The method includes the step of spray drying a slurry comprising ceramic phase particles and metal phase particles. The resultant spray dried powder, which comprises agglomerates of both the ceramic phase and metal phase particles, may then be consolidated by techniques such as pressing and sintering to produce a cermet inert anode material. The ceramic phase may comprise oxides of Ni, Fe and at least one additional metal selected from Zn, Co, Al, Li, Cu, Ti, V, Cr, Zr, Nb, Ta, W, Mo, Hf and rare earths. The metal phase may comprise Cu, Ag, Pd, Pt, Au, Rh, Ru, Ir and/or Os. The consolidated cermet inert anode material exhibits improved properties such as reduced porosity. The cermet inert anodes may be used in electrolytic reduction cells for the production of commercial purity aluminum as well as other metals.

Abstract: The present invention can provide particles for electro-rheological fluid for providing a high electro-rheological effect over a wide temperature range at low electric power consumption, and having high strength and excellent durability, not being susceptible to break-up due to the load of stress. Particles for an electro-rheological fluid of the present invention comprise spherical carbonaceous particles, obtained substantially from a solvent and a condensation product of a methylene type bond of aromatic sulfonic acid or a salt thereof.

Abstract: In a process for producing a pulverulent product from a liquid substance or mixture of substances, the liquid substance or mixture of substances to be pulverized is first provided in a pressure vessel. A gas is then dissolved under elevated pressure in the liquid substance or mixture of substances. The resulting liquid/gas solution is then conducted out of the pressure vessel and to an expansion element, through which it is passed and rapidly expanded. Upstream of the expansion element, in the expansion element or downstream, in particular just downstream, of the expansion element, a solid pulverulent auxiliary is admixed. In this manner, a stable pulverulent product results from the solution or from the substance or mixture of substances.

Abstract: A system and method for making very small (e.g., 1 millimeter diameter) spherical shaped devices is disclosed. The system includes a supply system for providing predetermined amounts of raw material into a chamber, which is used for melting the raw material. The melted raw material is then provided to a dropper for measuring predetermined amounts of the melted raw material (droplets) and releasing the droplets into a drop tube, where they are cooled and solidified into spherical shaped silicon devices. The system includes a container of silicon powder in which the solidified spherical shaped devices are received from the drop tube, the container including a stirring mechanism for agitating the silicon powder. The system also includes a separating device for separating the powder from the solidified spherical shaped devices after the devices have been received into the container.

Abstract: Spherical particles having a diameter between 0.007″ and 0.040″ are formed from melt extruded thermo-plastic material suitable for casting on a heated mold surface and melting thereon to form a thin layer of material having a nominal thickness of 0.040″ that is cooled and removed from the mold surface as a part having a porosity less than a visually observable threshold. The process includes the steps of providing microspheres formed of blended and melt extruded thermo-plastic, plasticizers and pigment additives that constitute less than 5% by weight of the blend and shaped as a smooth round spherical particle; providing a heated casting surface and distributing a predetermined charge of such microspheres against the heated casting surface; melting the microspheres as a layer of thermoplastic material having a porosity less than 0.003 inches and thereafter cooling and removing the non-porous layer from the casting surface.

Abstract: A drop former includes a rotary screen forming an internal chamber into which a flowable chemical is introduced, the chamber being kept at atmospheric pressure. The screen has a thickness in the range of 0.05 to 0.4 mm. As the screen moves, the flowable chemical is caused to impinge against a pressure member disposed within the chamber to create a hydrodynamic force which forces the chemical through openings of the screen, thereby forming drops which are transferred onto a transfer surface. The drops harden into particles on the transfer surface and are subsequently removed therefrom and collected. The screen may be formed of a photochemically etched, or laser-drilled, metallic sheet.

Abstract: A system and method for making very small (e.g., 1 millimeter diameter) spherical shaped devices is disclosed. The system includes a supply system for providing predetermined amounts of raw material into a chamber, which is used for melting the raw material. The melted raw material is then provided to a dropper for measuring predetermined amounts of the melted raw material (droplets) and releasing the droplets into a drop tube, where they are cooled and solidified into spherical shaped silicon devices. The system includes a container of silicon powder in which the solidified spherical shaped devices are received from the drop tube, the container including a stirring mechanism for agitating the silicon powder.

Abstract: A method for obtaining urea prills in a prilling tower (1) comprising the step of making a plurality of melt urea droplets to fall from a urea melt distributing device (4) towards an urea prills collecting bottom (6) of the prilling tower, further comprises the step of cooling the collecting bottom (6).

Abstract: Lipids are used as aids in the production of solid drug forms by melt extrusion.

Abstract: The invention relates to a process and an apparatus for producing stably fine-particle powders. The invention starts from a process for producing stably fine-particle powders in which one or more substances A and one or more substances B are dissolved in supercritical fluids, and the solutions are decompressed along a holdup section. In the process, substances A and B are each dissolved in separate supercritical compressible fluids, and the holdup sections interpenetrate, with the solubility limit of A in the appropriate fluid being exceeded at an earlier time than is the solubility limit of B in the appropriate fluid.

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: The present invention relates to a method for forming microparticles of a material from microdroplets of a solution, wherein the solution comprises the material dissolved in a solvent. The method includes the steps of directing the microdroplets into a freezing zone, wherein the freezing zone is surrounded by a liquified gas, and wherein the microdroplets freeze. The frozen microdroplets are then mixed with a liquid non-solvent, whereby the solvent is extracted into the non-solvent, thereby forming the microparticles.

Abstract: Provided is an aerosol method, and accompanying apparatus, for preparing powdered products of a variety of materials involving the use of an ultrasonic aerosol generator (106) including a plurality of ultrasonic transducers (120) underlying and ultrasonically energizing a reservoir of liquid feed(102) which forms droplets of the aerosol. Carrier gas (104) is delivered to different portions of the reservoir by a plurality of gas delivery ports (136) delivering gas from a gas delivery system. The aerosol is pyrolyzed to form particles, which are then cooled and collected. The invention also provides powders made by the method and devices made using the powders.

Abstract: A grain aggregate is formed by bonding a plurality of cross-linking polymeric grains via a substance (binder) having a reactive functional group, and alternatively, the grain aggregate is formed by bonding at least two different types of a plurality of grains, thus providing the grain aggregate having the improved heat resistance, solvent resistance, strength and light-diffusing properties. Further, a light-diffusing agent made up of the grain aggregate has the improved light-diffusing properties. Therefore, when applying a light-diffusing mold article including the light-diffusing agent to, for example, a backlight of a liquid crystal display device, high brightness and a wide angle of visibility can be attained. Further, by spray drying of a dispersion liquid containing the grain aggregate, the grain aggregate can be produced with ease.

Abstract: A method of producing mullite fibers by inviscid melt spinning includes providing mullite and excess silicate, melting the mullite at a temperature of 1800-2500° C., and extruding the mullite through an orifice. Apparatus for carrying out the method preferably includes a boron nitride (BN) crucible and an argon atmosphere, with a melt temperature of around 2000° C., and a spinning pressure of around 276 kPa (40 psi).

Abstract: Particle compositions are described comprising certain metal halides in combination with a strengthening agent. The addition of the strengthening agent to a metal halide particle increases the particle's strength thereby reducing breakage on impact and during handling. When used as a vaporizable metal halide fill in discharge lamps, the particle strength is increased without significantly altering the spectral and electrical characteristics of the lamp. Methods of making the particles and arc tube containing the particles are also disclosed.