Abstract: A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: A thermal insulating material with a cellular structure is disclosed which comprises a bound SiO.sub.2 -containing material converted to at least 90% into a tobermorite phase. The SiO.sub.2 -containing material is diatomaceous earth, the density of the thermal insulating material is less than 150 kg/m.sup.3 and the thermal conductivity (declared value)is less than 0.05 (W/m.sup..multidot. K).

Abstract: The process obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

Abstract: A method of making mesoporous carbon involves combining a carbon precursor and a pore former. At least a portion of the pore former dissolves molecularly in the carbon precursor. The pore former has a decomposition or volatilization temperature above the curing temperature and below the carbonization temperature of the carbon precursor. The carbon precursor is cured, carbonized, and optionally activated, and at the same time the pore former is removed.

Abstract: A process is disclosed for producing a positive-material with a skeleton made of shell-like structures and an interconnecting pore system designed between the skeleton structures. Also disclosed is a process for producing a negative-material made of shaped bodies interconnected by bridges a process for producing a positive/negative-material, materials produced by this process and their use as bone replacement materials, implants, filters and drug delivery systems. According to this process deformable shaped bodies in bulk are poured into a mold that forms a negative model of the material.

Abstract: A wiring body, used for manufacturing a substrate, includes a columnar body, having an axis, made of fired porous inorganic insulator impregnated with an organic insulator; and a large number of metallic fine wires embedded in the columnar body in parallel with the axis while the metallic fine wires are arranged at intervals, wherein a ratio of the inorganic insulator in the columnar body is 50 to 80 volume %, preferably 50 to 60 volume %. A method for manufacturing a wiring body includes the steps of charging a dispersed solution, in which inorganic insulating powder is dispersed, into a container in which a number of metallic fine wires are arranged in parallel with the axis, drying the dispersed solution, and firing inorganic insulating powder so that the porosity of the fired body can be in a range from 20 to 50 volume % so as to form a columnar body; and the steps of impregnating the obtained porous columnar body with uncured organic insulating material, and curing the organic insulating material.

Abstract: Porous zirconia or zirconium-containing particles, methods of making such particles and methods of using such particles including modifications to the surface of the particles are described. The method comprises heating zirconia particles to provide a substantially homogeneously liquid melt, quenching the particles of melt to effect spinodal decomposition to provide quench particles of a silica rich phase and a zirconia rich phase, annealing the quenched particles to provide non porous solid particles of zirconia and silica and, leaching the silica from these particles to produce porous solid zirconia particles comprising a three dimensionally substantially continuous inter penetrating network of interconnected pores.

Abstract: A method of making an article from a lightweight cementitious composition includes molding a castable cementitious mixture including an aqueous slurry of at least perlite and concrete into an article, such as a hollow, decorative article. The castable cementitious mixture can include a fibrous material, for reinforcing the cement and perlite, and an air entraining agent, for facilitating mixability and reducing a density of the cementitious mixture and facilitating casting. The mold can include an external mold form that contains the cementitious mixture and an internal mold form that displaces the cementitious mixture within the external mold form to cast the hollow article in various shapes and with various surface textures. The external and internal mold forms include liners made of a lightweight flexible material that can be removed, unfolded, and prepared and/or cleaned.

Abstract: There is provided a light-weight ceramic acoustic absorber including an alumina based ceramic containing SiC whiskers, as a perforated body with a void ratio in the range of 80 to 92%, where there are voids with a mean diameter in the range of 50 to 450 .mu.m near the front surface of the body, and the void diameters are larger towards the rear surface of the body, and a mean diameter of the voids is in the range of 500 to 3,400 .mu.m near the rear surface of the body, and there is an increasing trend in void diameters from the front to the rear surfaces. The light-weight ceramic acoustic absorber provides various advantages such as light weight, high resistance to thermal stresses, high acoustic absorptivity, and high resistance to the gas jet from a jet engine.

Abstract: A coating fluid holding member including a porous molded body which is formed of heat-resistant fibers (or a mixture of heat-resistant fibers and a filler) bound to each other with a binder, has intercommunicating pores having an average pore size of 1 to 500 .mu.m, and has a porosity of 20 to 90%, and a coating fluid holding member including a porous molded body which is formed of heat-resistant fibers bound to each other with a binder, contains fine intercommunicating interstices between fibers and uniformly distributed pores having a diameter of 0.05 to 2 mm, and has a porosity of 30 to 90%. The holding member has a high fluid holding capacity for its volume and releases the coating fluid, such as a parting agent, an oil or a coating compound, in a stable manner for an extended period of time.

Abstract: In order to manufacture a light, open-pored, mineral insulating board with a gross density below 130 kg/m.sup.3 the following steps are employed:a) producing a water-solids suspension by intensive mixing of the following raw materials in an intensive mixer with a rotating mix container and a mixer mechanism rotating at a higher speed, using water and, in each case referred to the total content of solids, 40 to 48 M % (mass percent) quartz flour with a specific surface area according to BET of at least 2.5 m.sup.2 /g, 15 to 20 M % slaked lime with a specific surface area of at least 15 m.sup.2 /g, 25 to 35 M % cement, 0.3 to 0.5 M % hydrophobic medium, the rest additives, wherein the ratio of cement to slaked lime amounts to 1.5 to 2.3:1, the binder proportion lies in the range from 45 to 52 M % and the suspension has a water/solids factor (without foam) from 0.7 to 1.2,b) preparing a foam from water, air and a pore former, with a gross density from 40 to 50 kg/m.sup.

Abstract: An improved process for the preparation of a pitch foam with a microcellular structure and a uniform pore size comprises the steps of (a) pressing a quantity of a pitch to provide a pressed article, (b) placing the pressed article in a pressure vessel, (c) introducing an inert gas into the pressure vessel under an elevated pressure of about 200 to 500 psi, (d) heating the pressed article within the pressure vessel to about 10.degree. to 40.degree. C.

Abstract: The present invention provides a process for making an improved thermally insulated microwave silicate foam susceptor. The process for making the improved microwave susceptor comprises the following steps:a) preparing pourable aqueous alkali metal dielectric sodium silicate slurry,b) pouring said slurry into a smooth surface substrate mold,c) heating said poured slurry at an effective elevated temperature to foam the slurry in said mold;d) drying said foam at an effective elevated temperature to provide said dry silicate foam substrate having a substantially smooth surface;e) coating at least a portion of said substantially smooth surface with an effective amount of a flowable microwave active material coating (MAC) and drying said flowable coating at an effective temperature to form a dry layer of said MAC.

Abstract: A silicon nitride ceramic porous body having excellent acid and alkali resistance, mechanical strength, and durability can be employed as a filter or a catalytic carrier. The silicon nitride porous body contains a plurality of silicon nitride crystal grains with pores formed in grain boundary parts thereof, or includes a body part and a pore part wherein the body part is formed by a plurality of silicon nitride crystal grains and the pore part forms a three-dimensional network structure. The body part is formed by at least 90 vol. % of silicon nitride crystal grains, which are directly bonded to each other. In order to prepare the finished ceramic porous body, a porous body compact which is mainly composed of silicon nitride, is brought into contact with an acid and/or an alkali so that a component other than silicon nitride is partially or entirely dissolved and removed from the compact.

Abstract: Flexible graphite sheet is made by compressing a mixture of relatively large particles of intercalated, exfoliated, expanded natural graphite with smaller particles of intercalated, exfoliated expanded, expanded particles of natural graphite. The resulting sheet of flexible graphite exhibits increased electrical conductivity through the thickness ("c" direction) of the sheet and improved sealability perpendicular to the "c" direction.

Abstract: A method for manufacturing a tile having a desired pattern. The pattern goes through the tile in the thickness direction. For manufacturing such a tile, e.g. a partition plate 84 is disposed in a pressure forming die 91 so as to divide its inside space into an outer forming space 95 and an inner forming space 96. Light black granules and light red granules are filled respectively in the outer and inner forming spaces 95, 96. Then, the partition wall 84 is taken out from the die 91, and lining granules are filled over the colored granules. Thereafter, they are pressed into one body and burned.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria. The inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength. The articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.

Abstract: The invention relates to a process of making a light weight, cementitious, three dimensional structure such as a building panel which includes the steps of measuring a quantity of water, measuring about 425 kilograms of cement, and between approximately 40 to 60 grams of ferric chloride in 40% solution by volume per approximately 278 liters of water, mixing the quantity of water, the cement and the ferric chloride, measuring between approximately 0.620 kilograms and 1.347 kilograms of substantially pure powdered aluminum, between approximately 0.230 kilograms and 0.710 kilograms of Hexafluorosilicate, between approximately 0.560 and 0.

Abstract: Compositions and methods for manufacturing sheets having a starch-bound matrix reinforced with fibers and optionally including an inorganic mineral filler. Suitable mixtures for forming the sheets are prepared by mixing together water, unmodified and ungelatinized starch granules, a cellulosic ether, fibers, and optionally an inorganic mineral filler in the correct proportions to form a sheet having desired properties. The mixtures are formed into sheets by passing them between one or more sets of heated rollers to form green sheets. The heated rollers cause the cellulosic ether to form a skin on the outer surfaces of the sheet that prevents the starch granules from causing the sheet to adhere to the rollers upon gelation of the starch. The green sheets are passed between heated rollers to gelatinize the starch granules, and then to dry the sheet by removing a substantial portion of the water by evaporation.

Abstract: A method for manufacturing a mineral fiber panel which comprises uniformly dispersing in water 60 to 90% by weight of a mineral fiber, 2 to 19% by weight of an organic binder, 1 to 20% by weight of an inorganic microfiber, 0.5 to 3% by weight of a flocculant and 0.5 to 10% by weight of a thermally expansible resin fine particle which has a diameter after expansion of not less than 0.03 mm but less than 3.0 mm, the expansion degree of the above diameter being at least 3 times, and which has an expansion-starting temperature of 50.degree. to 105.degree. C., as the composition components, to prepare a slurry, and thereafter subjecting the slurry to wet forming and then to drying. The above production process enables the enhancement of productivity and the mineral fiber panel obtained by the above production process is light in weight and excellent in sound-absorbing qualities and fireproof properties.

Abstract: The present invention relates to mat-shaped composites having porosities above 60% and densities below 0.6 g/cm.sup.3, comprising an aerogel and fibers dispersed therein, the aerogel having cracks and the aerogel fragments enclosed by the cracks, whose average volume is 0.001 mm.sup.3 to 1 cm.sup.3, being held together by the fibers. The present invention further relates to processes for producing the composites of the invention and to their use.

Abstract: A polymer bonded sheet product suitable for use as an electrode in a non-aqueous battery system. A porous electrode sheet is impregnated with a solid polymer electrolyte, so as to diffuse into the pores of the electrode. The composite is allowed to cool, and the electrolyte is entrapped in the porous electrode. The sheet products composed have the solid polymer electrolyte composition diffused into the active electrode material by melt-application of the solid polymer electrolyte composition into the porous electrode material sheet. The solid polymer electrolyte is maintained at a temperature that allows for rapid diffusion into the pores of the electrode. The composite electrolyte-electrode sheets are formed on current collectors and can be coated with solid polymer electrolyte prior to battery assembly. The interface between the solid polymer electrolyte composite electrodes and the solid polymer electrolyte coating has low resistance.

Abstract: Methods and systems for readily and economically manufacturing hydraulically settable articles, particularly containers, from microstructurally engineered hydraulically settable mixtures wherein the mixture is extruded into a sheet that is feed through a plurality of sets of rollers so as to form the sheet into the desired thickness. The sheet is then pressed between a male die of a desired shape and a female die having a substantially complimentary configuration of the male die shape to immediately fashion a portion of the sheet into a form stable shape for the desired article. To assist in imparting form stability, the dies can be heated or cooled. Once the article has obtained form stability, the article is removed from the dies and dried under heated air to gain strength. The article can then be cut from the sheet and receive printing or a coating, if desired, prior to packaging, shipping, and use.

Abstract: Containers use in the storing, dispensing, packaging, and/or portioning of food and beverage products. The disposable and nondisposable food and beverage containers are manufactured from aggregates held together by organic binders in order to be lightweight, insulative, inexpensive, and more environmentally compatible than those currently used for storing, dispensing, packaging, or portioning such products. The food and beverage containers of the present invention are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrices of the food and beverage containers include a hydrated organic binder paste (formed by mixing the binder with water) in combination with appropriate aggregate materials, such as fibers to add flexibility and strength, glass spheres to make the product more lightweight and insulative, or clay to make the product extremely inexpensive yet strong.

Abstract: The process of controlling foam in a foam-generating system by adding to the system a foam-inhibiting effective amount of a block copolymer containing alkylene oxide units obtained by reacting a homopolymer or copolymer of alkylene oxides with a diisocyanate or a dicarboxylic acid derivative containing 2 to 44 carbon atoms.

Abstract: Disclosed is a rigid fine-celled foam composition and a method of producing it. The foam composition is nontoxic, environmentally friendly, has improved absorption/adsorption and retention of liquids, is not as hard as prior art foams, does not include polymerization by-products detrimental to flower and plant life, and is a foamed mixture of a caustic silicate solution derived from the caustic digestion of rice hull ash having diffused activated carbon particles from thermal pyrolysis of rice hulls rather than from commercial sodium silicate solutions. Valuable by-products of commodity grade are obtained including activated carbon and sodium fluoride.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a starch-bound cellular matrix reinforced with substantially uniformly dispersed fibers. High strength articles that have adequate flexibility and toughness immediately or very shortly after being demolded without the need for subsequent conditioning are molded from compositions having a starch-based binder and fibers that are uniformly dispersed by means of a high yield stress fluid fraction within the starch-based composition. In a two-step mixing process, a preblended mixture is formed by gelating a portion of the starch-based binder or other thickening agent in water to form a liquid phase having high yield stress into which the fibers are substantially uniformly dispersed. The fibers preferably have an average length of at least about 2 mm and an aspect ratio of at least about 25:1.

Abstract: A gas generating substance is added to an aqueous dispersion containing refractory particles and a polymerizable monomer and the pressure and/or temperature are adjusted so that the substance generates the gas before the polymerization gets underway; to control the formation of pores.

Abstract: The present invention provides a microwave silicate foam susceptor which comprises a dry sodium silicate foam substrate coated with an effective amount of microwave active material. The silicate is preferably a sodium silicate, but can be other suitable alkali metal silicate, and the active constituent is preferably graphite, but other actives can be used. The susceptor of the present invention is capable of quickly reaching and more importantly maintaining extremely high temperatures. This enables it to brown and crispen foods in a microwave oven.

Abstract: A ceramics porous body having high porosity as well as high strength is especially suitable for use as a filter for removing foreign matter from a fluid or as a catalytic carrier. The porous body has a porosity of at least 30% and comprises columnar ceramic grains having an aspect ratio of at least 3. In particular, the porous body comprises Si.sub.3 N.sub.4 grains, of which at least 60% are hexagonal columnar .beta.-Si.sub.3 N.sub.4 grains. The porous body further comprises at least one compound of a rare earth element in an amount of at least 1 volume % and not more than 20 volume % in terms of an oxide of the rare earth element, and optionally at least one compound of elements of the groups IIa and IIIb of the periodic table and transition metal elements in an amount of not more than 5 volume % in terms of an oxide of each element.

Abstract: An improved, rapid process is provided for making microporous and mesoporous materials, including aerogels and pre-ceramics. A gel or gel precursor is confined in a sealed vessel to prevent structural expansion of the gel during the heating process. This confinement allows the gelation and drying processes to be greatly accelerated, and significantly reduces the time required to produce a dried aerogel compared to conventional methods. Drying may be performed either by subcritical drying with a pressurized fluid to expel the liquid from the gel pores or by supercritical drying. The rates of heating and decompression are significantly higher than for conventional methods.

Abstract: The invention provides an improved method for preparing foamed gypsum products. The invention can utilize a single mixing chamber and significantly improve the efficiency of foaming agent usage. In the method of the invention the point of insertion of aqueous foam into calcined gypsum slurry is positioned such that the foam is agitated less than the calcined gypsum to thereby minimize destruction of the foam while still uniformly dispersing the foam in the calcined gypsum slurry. This is accomplished, for example, by locating an inlet for foam closer to the discharge outlet of a slurry mixing chamber than the location of the inlet for calcined gypsum or by locating the foam inlet in a discharge conduit connected to the discharge outlet of the slurry mixing chamber.

Abstract: Methods and systems for readily and economically manufacturing hydraulically settable articles, particularly containers, from microstructurally engineered hydraulically settable mixtures. The mixture is pressed between a male die of a desired shape and a female die having a substantially complimentary configuration of the male die shape to immediately fashion a portion of the mixture into a form stable shape for the desired article. To assist in imparting form stability, the dies can be heated or cooled. Once the article has obtained form stability, the article is removed from the dies and dried under heated air to gain strength. The article can then receive printing or a coating, if desired, prior to packaging, shipping, and use.

Abstract: A high-temperature ceramic filter having a three-dimensional reticulated skeleton structure is prepared by applying a ceramic slurry to a synthetic resin foam having an open cell three-dimensional reticulated skeleton structure, followed by drying and firing. The ceramic slurry contains 20-40 parts by weight of aluminum titanate, 40-60 parts by weight of mullite, 2-20 parts by weight of alumina, and agalmatolite. The filter is useful for the filtration of molten metals.

Abstract: A tile having a desired pattern is provided. The pattern goes through the tile in the thickness direction. For manufacturing such a tile, e.g. a partition plate 84 is disposed in a pressure forming die 91 so as to divide its inside space into an outer forming space 95 and an inner forming space 96. Light black granules and light red granules are filled respectively in the outer and inner forming spaces 95, 96. Then, the partition wall 84 is taken out from the die 91, and lining granules are filled over the colored granules. Thereafter, they are pressed into one body and burned.

Abstract: A three-dimensional network structure comprising three-dimensionally interconnected spherical silica particles, having specific physical characteristics including diameter, pores on the surfaces of the particles, cross-sectional areas of the bonds interconnecting the spherical silica particles, elasticity modulus, voids content, and silica content, the surfaces of the spherical silica particles being wholly or partly covered with a water-soluble polymer, the network structure being able to remain substantially intact when heat-treated and being able to undergo machining. There is also provided a method of making a three-dimensional network structure comprising spherical silica particles, comprising hydrolyzing and polymerizing a low polymer of an alkoxysilane in a mixed solution containing the alkoxysilane low polymer and a water-soluble polymer in a mixed solvent composed of water and an alcohol in the presence of an acid catalyst.

Abstract: This invention is a process and foaming system for producing foamed gypsum board which permits the production and control of large foam voids in the gypsum core by adjusting the ratio of a first foaming agent and a second foaming agent. My process includes the steps of preforming a first foaming agent which forms stable foam voids in a gypsum slurry and independently preforming a second foaming agent which forms unstable foam voids in a gypsum slurry. Independently, blending the two different foaming agents is the key to controlling void size. A greater amount of the second foaming agent and a lesser amount of the first foaming agent is preferred.

Abstract: An insulation material comprising the double salt of aluminum potassium sulphate and method of producing such. Aluminum sulphate materials and potassium sulphate materials are combined to form aluminum potassium sulphate which is then dehydrated to remove the water of hydration. Porous forms are made by mixing the hydrated aluminum potassium sulphate with a binder before dehydration. The resultant dehydrated sulphate expands greatly to provide an insulative material which is of lightweight and inorganic.

Abstract: Novel hollow beads are characterized in that they contain aluminium phosphates optionally containing boron. They can be produced by first drying, at from 20.degree. to 200.degree. C., reaction products of acid aluminium phosphates (and optionally boric acid) with amines, then comminuting them and finally subjecting them to a heat shock of from 200.degree. to 1200.degree. C. Such hollow beads can be used for a great variety of purposes.

Abstract: An improvement process for producing a coated porous ceramic, ceramic composite or metal structure, wherein the impregnation step is carried out by (a) fluidizing said slurry with steam or heated water and spraying said shape with said fluidized slurry or (b) heating said slurry so as to reduce its viscosity and spraying said shape with said reduced viscosity slurry. Manufacture of a single component which functions both as a filter and as a heating element, is made possible by the process of the present invention.

Abstract: A process for producing and curing hydraulic material to reduce its hydrophilic characteristics and increase its strength. By preventing water loss and by adding water, efflorescence is controlled and the number of and size of voids created by water evaporation and hydration are reduced. Controlling the cure environment, humidity, temperature and pressure and using fluid barriers and water, control the physical and chemical composition formed during curing. The controls can be used before and/or after the initial set or shape formation of the hydraulic material.

Abstract: The invention relates to a process for producing heat-insulating material from silicate-containing material, hydrated lime, water, foam and a reactive aluminates-containing quick-setting cement, from which a pourable raw mixture is produced which is poured into molds, the green moldings formed in the molds being demolded and autoclaved after sufficient setting. To achieve very low bulk densities, it is provided that, as silicate-containing material, a quartz powder with a specific surface area according to BET of at least approx. 3 m.sup.2 /g, in particular approx. 4 to 5 m.sup.2 /g, is used, the raw mixture is produced with a weight ratio of water/solids (excluding foam) of at least approx. 1.25 and an essentially stoichiometric amount, with respect to the virtually complete reaction of the quartz powder and the reactive aluminates, of hydrated lime with a surface area according to BET of at least approx. 15 m.sup.

Abstract: A foamed glass product and its manufacturer are disclosed. According to the present invention, crushed glass particles and a foaming agent, preferably selected from CaCO.sub.3 and CaSO.sub.4, are provided. The glass particles and foaming agent are mixed and heated to a desired foaming temperature for creating foamed glass. A nonreactive gas having desired insulative properties, preferably selected from SO.sub.2 and CO.sub.2 is provided to sweep air away from the mixture during heating.

Abstract: A method is provided for producing dense, free-flowing and non-caking alkali metal silicate-based particles which are heat expandable into lightweight particles of a spumiform character. Pursuant to the invention, one provides at a selected temperature a dilatant aqueous gel comprising an alkali metal silicate as the majority non-aqueous component, the silicate being present in the gel in a dissolved state; and the non-aqueous content of the gel being in the range of from about 38 to 65% (w/w). Shearing forces are imposed upon the gel which exceed the flow response characteristics of the gel, whereby the viscosity of the gel becomes sufficiently high to cause a discontinuity in the gel, resulting in disruption into discrete particles. The discrete particles are conditioned while being maintained as separate entities to thereby form a skin on the particles so that they will not agglomerate or coalesce with one another.

Abstract: The material contains interrelated micro- and anisodiametric macropores which latter are disposed mainly on peripheral portions. The volume ratio of micro- and macropores is 1:3-7.The process involves freezing a polymer dispersion at a temperature ensuring a 3-11:1 ratio of dispersed phase to the noncrystallized dispersion medium, seasoning the conjugate-dispersed system at a temperature and within a time sufficient for reversal of phases, followed by thawing. The used polymer dispersion contains a liquid crystallizable dispersion medium and a polymer phase capable of autohesion at temperatures below the initial melting temperature of crystals in the dispersion medium.

Abstract: A simple, environmentally benign building for on-site erection and fabrication is made of monolithic, architectural, structural walls, beams, girders, joists and panels of relatively high physical strength which exhibit great durability and resistance to fire, wind and seismic damage and which have highly desirable acoustic and thermal transfer characteristics. The wall is constructed by casting a core of flowable fibrous, foam-cement mix between two, thin panels of manufactured, exterior-grade fiberglass reinforced cement board. Particles and proteins from the core mix penetrate, migrate into and fill interstitial spaces in the cement board, forming a strong, continuous and homogenous bond between the fill material and the board itself. This imparts additional strength to the cement board by filling the interstitial voids, creating a solid, homogeneous wall. The wall, girder, etc.

Abstract: A process of molding a building panel which includes the steps of combining about 25 pounds of Portland Cement Type I, about 15 pounds of water at around 21.degree. Centigrade, added about 1 ounce of aluminum, calcium, magnesium, and silica, respectively, and about 12 ounces of synthetic fibers with about 0.1 ounce of ferro chloride in 40% solution by volume, and pouring the mixture into the lower portion of a mold to about 1/2 its depth and waiting for approximately 4 hours for the mixture to increase by about 100% of its original volume to fill the mold and thereafter stripping the mold from the form and placing it in a heated environment for curing for a period of approximately 24 hours and thereafter removing the panel from the heated environment.

Abstract: A method of making a foamed building board or the like from the following components:(a) a major amount by weight of an inorganic base material selected from the group consisting of a calcium sulphate hemi-hydrate, magnesium oxychloride, magnesium oxysulphate and a hydraulic cement;(b) a suitable amount by weight of the inorganic base material of a thermosetting resin which is miscible, soluble or dispersable in water;(c) a suitable amount of a catalyst for the thermosetting resin;(d) water in an amount sufficient to rehydrate the inorganic base material with the water present in the other components;(e) a suitable amount of a plasticizer such as a melamine formaldehyde condensate;(f) a suitable amount of a polyvinyl alcohol;(g) a suitable amount of a retarder for the setting time of the inorganic base material;(h) a suitable amount of a fibrous reinforcing material; and(i) a suitable amount by weight of a foam or a foaming agent; which comprises the steps of:(1) mixing together components (a), (b), (c), (d),

Abstract: A method for the production of structural foam from air, water, foaming agent and an aggregate, particularly cement foam, for which cement slurry is blown under high pressure into a mixing chamber and mixed with a foaming agent and the mixture immediately thereafter is conveyed to an expansion nozzle, into which metered amounts of compressed air are blown.

Abstract: A method of producing a patterned shaped article includes the steps of disposing at a prescribed position within a main form for molding the shaped article a cell form having a plurality of cells arranged in a contiguous manner, charging a prescribed amount of dry pattern-course material for forming the pattern course of the shaped article into prescribed cells of the cell form, charging a base-course material for forming the base course of the shaped article into the remaining space of the main form not filled with the pattern-course material, removing the cell form, causing the charged pattern-course material and base-course material to set into a shaped article, removing the shaped article from the main form and, optionally, sintering the shaped article.