Abstract: A process for producing potassium hexatitanate fibers having a tunnel structure, which comprises mixing a titanium component represented by the general formula (Ti, M)O.sub.2 where M is metal impurities with a potassium component selected from the group consisting of potassium oxide, potassium compounds capable of forming potassium oxide when heated and a mixture thereof, to obtain a mixture represented by the general formula K.sub.2 O.n(Ti, N)O.sub.2 where n is from 1.5 to 2.5 and M is as defined above; heating the mixture to obtain a melt; forming from the melt a fibrous material having a layered crystalline structure corresponding to potassium dititanate (K.sub.2 O.2TiO.sub.2); leaching a part of K.sub.2 O from the fibrous material; and heating the fibrous material at a temperature of at least 800.degree. C. and lower than the melting point of the fibrous material.

Abstract: Ceramic foams in which the open cells are connected by a three-dimensional, substantially continuous ceramic matrix formed of interconnected hollow ligaments, are made from an open-cell, reticulated precursor metal, i.e. a metal foam. The precursor metal first is treated so as to allow a support coating to form thereon, and thereafter the coated precursor is heated above the melting point of the metal in the presence of an oxidant to form an oxidation reaction product.

Abstract: The microfilter foil is made of an inorganic substance such as metal with opened pores. Each pore is formed with a channel which increases in cross-section from the crest so as to obviate clogging. The foil is produced by exposure of a photosensitive layer of paint or lacquer with the use of an interference pattern produced by monochromatic and coherent light. A skin of inorganic material is produced on the photosensitive layer and portions of the skin are thereafter removed from the coated teeth in order to produce the pores in the subsequently formed foil.

Abstract: The present invention relates to a method of producing micropores having diameters of less than 20 nanometers in straight sides in silicon film. The silicon film produced by this process may be attached to a substrate material and used as a filter in molecular separation processes.

Abstract: A process for the manufacture of shaped bodies from silicon granulates for producing silicon melts includes first incipiently melting silicon grains on their surfaces, so that they bond with their neighbors in the process and, after solidifying, form a porous compound shaped body which only then may be melted completely. Such compound shaped bodies can be manufactured continuously or semi-continuously and converted without difficulty by a subsequent step into the molten state. An apparatus for producing shaped bodies is also provided which preferably employs an electron beam, to supply energy to incipiently melt the granulate.

Abstract: Method for preparing a setting foam material containing plastic material granules, which plastic material granules are prepared from beads of plastic material. After preparing a slurry of base material it is mixed with the plastic material granules. This motar is immediately pumped after which the foam is introduced.

Abstract: The invention relates to foams for insulating cavities and structures, such as spaces between walls in houses. The inventive foam compositions are prepared in separate portions, generally comprising (A) cement and (B) foam. Air is added initially to foam one of the components or a mixture of components.In a first embodiment, the first component comprises an aqueous solution of polyvinyl alcohol and a dispersant. This component is mechanically foamed by injection of air, for example. After the mechanical foaming a second, cement component is added to the first component. This second component comprises an aqueous solution, mixture or suspension of magnesium oxide and barium metaborate, and a dispersant.In a second, preferred embodiment, the first component comprises an aqueous solution of polyvinyl alcohol and calcium chloride, which component is mechanically foamed by injection of air.

Abstract: Ceramic articles having improved fracture toughness are prepared by ion bombardment of ceramic particles by gas ions to impregnate the particles, cold compacting the gas ion-containing ceramic particles into a form, and hot pressing the gas ion-containing ceramic particle form into a ceramic article whereby gas bubbles are formed in and substantially homogeneously dispersed throughout the ceramic article.

Abstract: A separation membrane includes a glassy microporous membrane and a ceramic porous support. The separation membrane has excellent heat resistance, corrosion resistance, durability, gas-separability and high mechanical strength. The separation membrane is preferably provided with a metallic or ceramic microporous membrane vapor-deposited on the surface of the glassy microporous membrane. The separation membrane can be utilized with high efficiency in diversified fields such as microfiltration or ultrafiltration of liquidal or gaseous fluids. A process for manufacturing such a separation membrane is also disclosed.

Abstract: The present invention relates to laminated acoustical tile products which are derived from compositions that are suitable to provide rigid, water-resistant phosphate ceramic materials. The tile products comprise a decorative facing comprising a substantially open-celled character and a backing layer of higher density, the backing layer and edges of the tile comprising substantially closed-celled facing characteristics. The backing layer provides structural strength and dimensional stability to the tile product whereas the decorative, open-celled facing provides access by sound waves to the interior regions of the board. The resulting composite material provides good acoustical performance, yet is capable of withstanding conventional handling stresses.

Abstract: A method of producing hardened inorganic products is characterized in that a hydraulic material comprising slag as an effective component is mixed with gypsum and water, and mixture is then shaped and aged at an internal temperature of 50.degree. to 100.degree. C. to produce TSH therein and to cause hydration and hardening. The resulting hardened inorganic product features a light weight and improved fire resistance, freezing resistance, dimensional stability and strength.

Abstract: A process of producing ICMUs (insulated concrete masonry units) having an inner load-bearing portion and one or two outer insulating portions are disclosed. Disregarding the insulation cores, heat flows from the outer side wall or walls to the inner portion through outer end walls and, in some embodiments, webs. These outer side walls and webs are heat bridges and are thinner and of significantly lower density than the other walls of the ICMU, thereby providing improved thermal insulation.Also disclosed are ICMUs with a vertical or horizontal recess in one outer insulating portion. Electrical conduit and/or plumbing can be placed into these recesses. In addition, corner ICMUs are disclosed which provide increased structural strength when used to construct a 90.degree. corner between two structural walls because of a special mid-wall in the corner ICMU.

Abstract: A gas diffusion composite electrode is disclosed which is suitable for use in combination with an electrically conductive current collector. The electrode comprises an electrochemically active, porous and heterogeneous layer containing (1) an interconnected, hydrophilic island material comprising a blend of a major amount of an electrically conductive, particulate material, such as carbon black, in combination with an electrochemically active catalyst, and a minor amount of a hydrophobic polymer in combination with (2) a hydrophobic matrix material consisting essentially of a hydrophobic polymer rendered substantially porous by removal of a pore-forming ingredient. Methods of preparing the heterogeneous layer and the composite electrode are also disclosed.

Abstract: The process for making and the structure of a panel of light-weight, cellular concrete having at least one opening, and capable of holding at least one pane of glass or sheet of ceramic in said opening without a mounting frame.

Abstract: A novel process is provided for producing prefoam type cellular concrete articles, which uses a foamed slurry (E) consisting essentially of an aqueous slurry (A) of a calcium silicate-based cement compound, an aqueous slurry (B) of a calcium aluminate-based cement compound, a specific setting retarder (C), and an aqueous foamed liquid (D). The process is further characterized in that: (i) the foamed slurry (E) is cast and provided with hardened strength sufficient for demolding in 20 to 120 minutes after it has been poured into a mold; (ii) the demolded article is subjected to precuring under specific conditions of humidity, temperature and precuring time; and (iii) the molded article is then subjected to hydrothermal curing under high pressure.

Abstract: A method for manufacture of aerated concrete or other similar calcium silicate hydrate products. An optimal utilization of the investment for erection of the plant is achieved by keeping the time for the stiffening of one cast body shorter than the pacing time between two consecutive pourings of mix. A suitable way to achieve the short stiffening time is to use an extremely highly reactive binder.

Abstract: A wet process for the manufacture of shaped fibrous products such as acoustical ceiling board is disclosed. The ceiling board binder is foamed prior to being combined with the solids. Substantial reductions in water requirements are obtained accompanied by substantial energy savings in the drying operation.

Abstract: Compositions and processes for forming inorganic resins, including articles of manufacture incorporating these resins are disclosed. the inorganic resins are characterized by their strength, nonflammability, dimensional stability, resistance to organic and inorganic chemicals, to heat and to abrasion and their adaptability to being formed into noncellular or cellular forms. The resins are formed by reacting a liquid component A containing an aluminum phosphate or a magnesium phosphate and a liquid component B containing a source of magnesium oxide, such as magnesia, and/or wollastonite and an essentially non-reactive phosphate dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.

Abstract: A process for placing a cement composition having high strength is provided. The process comprises the steps of adding a viscosity increasing agent, vacuum de-bubbling under reduced pressure and allowing the de-bubbled cement composition to be hardened. At the vacuum de-bubbling step, relatively large foams present in the cement composition are removed and only fine bubbles are left in the composition. The strength of the cement composition is remarkably improved by the removal of large bubbles.

Abstract: A ceramic, in particular refractory product is provided comprising a matrix material which contains pores and where the pores are obtained by driving off of opening materials. The product is characterized by pores which are of a flattened shape resulting from platelet shape or flake shape voids. The invention further provides a method for the production of the ceramic product, where a platelet shaped opening material is admixed to the ceramic raw material. The resulting products are characterized by advantageous strength and thermal insulation properties.

Abstract: Molded parts having high flexural strength, based on alkali silicates, can be produced by casting and/or press-molding and curing by heating from aqueous molding compositions which are prepared from an oxide mixture containing amorphous silicic acid and aluminum oxide, as well as, optionally, as an additional component, aqueous, amorphous, disperse-powdery silicic acid, dissolved SiO.sub.2, and alkali from alkali silicate solutions, optionally alkali hydroxide or its aqueous solutions and, if desired, fillers, by means of mixing under agitation. By addition of a blowing agent inorganic foamed products can be obtained.

Abstract: A process for producing a boehmite shaped product comprises slurrying a mixture of a gibbsite powder and at least one powder selected from the group consisting of powders of pseudo-boehmite, amorphous aluminum hydroxide, alumina cement and .rho.-alumina, molding the slurry thereby obtained and subjecting the molded product to hydrothermal treatment.

Abstract: Compositions and processes for forming inorganic resins, including articles of manufacture incorporating these resins are disclosed. The inorganic resins are characterized by their strength, nonflammability, dimensional stability, resistance to organic and inorganic chemicals, to heat and to abrasion and their adaptability to being formed into non-cellular or cellular forms. The resins are formed by reacting a liquid component A containing a mono aluminum or mono magnesium phosphate and a liquid component B containing a magnesium oxide and/or a wollastonite and a dispersing agent. Various fillers may be incorporated and a blowing agent may be added to form a cellular resin.

Abstract: Lightweight gypsum wallboard produced by continuously combining a small amount of surface active agent with a liquid stream, which stream is made up of substantially all of the water to be used in the manufacture of a continuous web of gypsum wallboard, passing this mixture through a long cylindrical static mixing tube filled with one inch ceramic saddles, while adding a controlled quantity of air thereto, then passing the mixture through a shorter cylindrical static mixing tube of equal diameter filled with 3/8 inch ceramic Raschig rings, forming a uniformly dispersed foam of very small bubbles from the liquid by completely generating all of the surface active agent therein to form this foam, and mixing this foamed liquid with finely ground dry calcined gypsum in a suitable mixing device to form a foamed settable gypsum slurry, disposing the slurry between paper cover sheets, and forming a continuous web of gypsum wallboard.

Abstract: In the manufacture of cells, e.g. of the system Li-Al/LiCl-KCl/FeS.sub.x, the finely divided raw materials for the electrodes and for an included ceramic separator are respectively mixed individually with the electrolyte salt, as well as with a synthetic plastic which is decomposable without residue under heat. The mixtures are rolled into plates, and the plates are heated above the decomposition temperature of the plastic after assembly. The plastic is preferably a polyhydrocarbon such as polyisobutylene and is preferably introduced by means of a solvent. It makes the powder mixtures plastifiable and suitable for rolling. This makes it possible to produce ceramic separators, which are fundamentally composed only of loose particle accumulations, in the form of plates of uniform structure and strength and to handle these in the same way as electrode plates during cell assembly.

Abstract: A method for the production of a more water-resistant foamed element from waterglass consisting essentially of the steps of mixing together a major amount of an alkali metal silicate solution, with inorganic fillers, at least one alkali-resistant wetting agent in an amount sufficient to form a stable foam, at least one compound capable of hardening a waterglass foam in an amount sufficient to cause said alkali metal silicate to harden, and sufficient natural latex dispersion to cause the foamed element to have a greater water resistance, mechanically foaming said mixture by the incorporation of an inert gas thereon, filling the resultant foam into an element form capable of disassembly, curing said foam in said form, and recovering a more water-resistant foamed and cured element. Preferably the natural latex dispersion is employed in a 50% dispersion in an amount of from 0.2% to 30% by weight, preferably from 0.2% to 10% by weight, based on the total mixture.

Abstract: A method of producing gas concrete. Water, lime, cement and sand are pre-mixed. A calcium sulphate-containing component is subsequently mixed in and a rising agent is later admixed to form a castable mass suitable for making gas concrete by the conventional steps of pouring into a mold, permitting the mass to rise and harden sufficiently to be cut to size, and hydrothermally cured. By following the indicated procedure for making the castable mass, the calcium sulphate-containing component can be advantageously used.

Abstract: Molded products based on a two-component mineral resin are produced, starting from a mixture of magnesium oxide, magnesium chloride, and water by triggering therein through mechanical or electromagnetic vibrations an abrupt exothermic reaction, which propagates through the entire mass and causes it to set and harden spontaneously and without additional heat supply.

Abstract: Hollow fibers are prepared by spray drying a solution of a film-former in a volatile solvent. The viscosity of the solution must be 1.5 to 10 times the viscosity that usually results in spheres or microspheres. The preferred film-forming substance is a combination of sodium silicate and a "polysalt.

Abstract: A method and system whereby binder can be removed from a green body much more rapidly than in prior art systems without interfering with the integrity or aesthetics of the final part by providing a binder system having at least two components and preferably a mold release agent, the binder system having differing melting points. Each binder component can have parts with different melting temperature. When the temperature is raised to a point above the intermediate temperature at which the binder system flows, binder will proceed to exude to the surface of the green body wherefrom it can be removed.The binder is removed from the surface of the green body by blowing a non-saturated chemically inert atmosphere over the surface of the green body rapidly whereby the atmosphere at a region near the surface of the green body does not become saturated with the binder vapors.

Abstract: Rigid cellular hydrous calcium silicate thermal insulating product of low density can be made by aerating an aqueous slurry containing reactive calcareous and siliceous materials, preferably in conjunction with the incorporation of a foaming agent in the slurry, and then indurating the aerated slurry by the application of heat and pressure.

Abstract: Silicate-based composition particles are rapidly and completely expanded to form an expanded, cellular particulate aggregate of maximum density in short periods of time at particle temperatures which are comparatively low, that is, 100.degree. C., compared to existing systems by the utilization of infrared heat sources, either gas or electric, to heat the silicate particles. The use of infrared energy operates in a surprisingly advantageous fashion when the expansion process is carried out on or in the presence of a surface having the capacity to act as a thermal mirror or absorber-reflector of the infrared radiation to make maximum utilization of the radiant energy by the creation of a radiation trap. Carbonaceous materials are preferred for producing such entrapment. A further significant aspect is the discovery of a time-radiation dependency.

Abstract: A process and apparatus is provided for the production of calcium silicate-containing stone blanks which are useful in constructing building walls. A crude mixture, of a granulated silicate-containing material, lime, water, a cement and a foaming agent, is subjected to no more than a minimum application of external pressure and is subsequently hardened in an autoclave. The cement produces the necessary strength for the blank, so that the latter becomes transportable while the final strength is achieved by reaction of the silicate-containing material during the autoclave treatment. In order to arrive at acceptable molding times and in order to achieve a simplified process with slight fragment bulk density and optimal head damping characteristics, the crude mixture is rendered pourable, is filled into molds in a quantity corresponding to the fragment volume of the stone blank, and the crude mixture in the mold is heated essentially uniformly to a temperature between 45.degree. C. and 90.degree. C.

Abstract: This disclosure is directed to a non-bleeding gas electrode for operation under the rigors of high current density and to the active layer thereof. This active layer is comprised of 60 to 90 weight percent high surface area, electroconductive carbon (with or without catalyst thereon), 10 to 40 weight percent particulate polytetrafluoroethylene (PTFE) and has pores sufficiently large to relieve internal hydrodynamic pressures thus preventing liquid being forced through the electrode wetproofing layer to the air side thereof. In addition such electrodes include a PTFE-containing wetproofing or backing layer secured on one side to said active layer and on the other side to a current distributor.

Abstract: When producing building elements of lightweight concrete a viscous slurry is poured into a mould in order to form a stiff mould body. By means of parting planes this mould body is divided into individual elements of smaller sizes. According to the invention a plurality of zones having different densities and/or natures are formed in the mould body, the individual partin g plane being located within such a zone. Hereby one obtains building elements which include at least two portions having different densities and/or natures.

Abstract: Novel self-setting potassium-aluminum-phosphate compositions of matter are prepared by forming an aqueous slurry of a potassium source, an aluminum source and a phosphate source; mixing the slurry for a period of time sufficient to form a reactive, creamy mass having a viscosity of at least 2000 cps; and setting or curing the reactive creamy mass. The product is porous, can be foamed or nonfoamed, adheres well to substrates and when foamed, can be lightweight.

Abstract: Present invention provides foamed gypsum moulded articles excellent in sound absorbing property and production thereof. The foamed gypsum moulded article has many foam-cells, and the foam-cells are interconnected through fine passages. The fine passages are formed using as a decomposition catalyst of hydrogen peroxide for expansion a cobalt compound produced by pretreating a water soluble cobalt salt with hydrogen peroxide in the presence of alkali. The foamed gypsum moulded article is preferably applicable to an interial wall, ceiling panel, and the like.

Abstract: This invention provides a lightweight ceramic composition which is characterized by an average bulk density between about 10-105 PCF, and a compressive strength between about 300-10,000 psi.In a preferred embodiment, this invention provides an extruded structural cellular clay product having pores which are substantially non-interconnected and elongated in a single directional configuration, and having a density gradient in at least one cross-sectional plane, in which gradient the higher density is in proximity to the outer surfaces.

Abstract: New light, strong, non-shrinking cellular concrete having good thermal and acoustic insulating properties prepared by incorporating aluminum and an alkaline agent capable of producing a gas when reacted with the aluminum within an anhydrite binder, placing the mixture in a mold, and permitting it to expand to a cellular product and cure. The products are useful as building materials. The invention includes the production of building elements comprising the cellular anhydrite product as described above adhered to at least one layer of a substantially non-cellular or dense facing layer made with an anhydrite binder or sandwiched between and adhered to non-cellular facing layers both made with an anhydrite binder.

Abstract: Compositions comprising a thermoplastic elastomer, e.g., radial block butadiene/styrene copolymer, solid resinous polymer, e.g., vinyl-substituted aromatics, and one or more specific polar compounds. The specific polar compounds are chosen from among simple and polymeric alkaline glycols, their mono and dialkyl ethers; ethanolamines, isopropanolamines, and their hydrocarbyl-substituted derivatives; liquid acrylonitrile/butadiene polymers; acrylonitrile/butadiene blends with homopolymers of polyvinyl chloride and styrene/acrylonitrile copolymers; and mixtures thereof. A method using these compositions for producing molded objects at a molding pressure of up to about 200 psig. Molded objects produced from these compositions and molded objects produced by this method of molding.

Abstract: A method of forming a slip cast article having at least one zone of cellular construction is disclosed. The method may be utilized to make articles having zones of different cellular size as well as articles having zones of cellular construction adjacent zones of noncellular construction. In its simplest form, the method is carried out by providing a slip casting mold which has a casting volume formed therein. A stabilized casting slip is poured into the casting volume. The pH of the stabilized casting slip is increased until a hydrolysis reaction takes place between the water forming the vehicle and an oxidizable metal forming the casting material. This hydrolysis reaction results in the evolution of gases, some of which are trapped within the slip to develop a zone of cellular construction. The greater the increase in pH, the more vigorous is the hydrolysis reaction and the resulting cellular construction has larger sized cells.

Abstract: The invention relates to protective packaging of objects of a fragile nature, such as electronic components, optical components, and other delicate or fragile food objects, and comprises hollow protective container portions arranged to be positioned in a manner defining a hollow interior chamber for protectively packaging such fragile or perishable objects, with said container portions being provided with shaped inner liner parts having shaped recess portions formed in place therein in the presence of such packageable objects and at least partially engaging corresponding parts of such packageable objects, with the shaped inner liner parts comprising a multi- phase material of foamed-in-place compressible, plastic material interspersed with bubble-pack means having closely adjacent gas cells which are isolated cells.

Abstract: Method and apparatus are disclosed providing both for separation of the components of a toration fiberizing center, including separation of both the glass stream supply means and of the secondary or carrier jet from the blast, and at the same time further providing for stabilization of the feed of the glass into the system, notwithstanding the separation of the components. This is accomplished by shielding the jet flow from induced air at one side of the jet and introducing the glass stream into the influence of the induced air at the opposite side of the jet.

Abstract: A heat absorbing body made from a mixture of water, Portland cement, cellulose fibers, and a foaming agent, with or without other ingredients such as water glass and sodium sulfate. Polypropylene fibers may be used in place of part or all of the cellulose fibers. Cellulose fibers (conveniently reclaimed or recycled cellulose fibers) are preferably used because of their ability to absorb and retain relatively large amounts of water in the composition. Various formulas are given for the mixture. The material is used as a filling for the walls of fire resistant safes and storage boxes, and also for the construction of structural panels for furniture and building construction, and for cast-in-place walls and floors and roofs of buildings.

Abstract: A process for forming a solid layer of intumescent material from a fluid material which comprises the steps of pouring the fluid material onto a mold and evaporating the liquid from the fluid material while the fluid material is contained within a chamber offering a predetermined restraint to the escape of vapor from the chamber to the ambient atmosphere.

Abstract: An uncured cementitious substrate may be coated by a method which comprises applying to the substrate an aqueous emulsion of a film-forming polymeric material, wherein the emulsion contains at least one soluble soap.

Abstract: A method for producing sand-lime bricks of low bulk density and having a green strength of at least 1 kp/cm.sup.2 in which at least 1% by weight of cement is added to a mixture of sand, lime and water and the mixture is then compacted in molds by vibration or under a pressure of less than 150 kp/cm.sup.2 to form bricks which are subsequently cured.

Abstract: A method for increasing the pore volume of alumina powder produced by spray drying alumina slurries by heating the slurry to a temperature near the boiling point of water and a pressure up to the critical point of water then introducing the slurry to a spray drying chamber through a small orifice, thereby creating a backpressure in excess of slurry vapor pressure and up to the critical point of water.

Abstract: In a method of casting in a horizontal mould a hollow, reinforced tapering concrete post having a thin wall and particularly a length exceeding 10 to 15 m, there is placed in the mould a tapering reinforcing cage or basket in which a core, e.g. a steel core, is inserted to form a substantially annular mould chamber. Said mould chamber is closed with the exception of an upper filling slot. A readily pourable concrete mass is charged to the mould from above through said filling slot. The mould is then vibrated without being rotated such that concrete fills the annular mould chamber. Hardening of the concrete is accelerated by heating, and the core is withdrawn from the formed post before the concrete has completely hardened. The finished post is then removed from the mould.

Abstract: A process and apparatus is provided for the production of calcium silicate-containing stone blanks which are useful in constructing building walls. A crude mixture, of a granulated silicate-containing material, lime, water, a cement and a foaming agent, is subjected to no more than a minimum application of external pressure and is subsequently hardened in an autoclave. The cement produces the necessary strength for the blank, so that the latter becomes transportable while the final strength is achieved by reaction of the silicate-containing material during the autoclave treatment. In order to arrive at acceptable molding times and in order to achieve a simplified process with slight fragment bulk density and optimal head damping characteristics, the crude mixture is rendered pourable, is filled into molds in a quantity corresponding to the fragment volume of the stone blank, and the crude mixture in the mold is heated essentially uniformly to a temperature between 45.degree. C. and 90.degree. C.