Abstract: A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of powder material, applying a liquid reagent to the powder layer in a pattern corresponding to the digital model, and repeating these steps to form successive layers. The powder comprises a first reactive component and the liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers.

Abstract: A non-woven fabric which is excellent in thermal resistance, mechanical strength, and thermal dimensional stability for applications exposed to high temperature circumstance and has an extremely large surface area and exhibit an excellent filter performance is obtained. The non-woven fabric is composed of polyimide fibers which are obtained by polycondensation of at least an aromatic tetracarboxylic acid and an aromatic diamine having a benzoxazole structure and have a fiber diameter in the range of 0.001 ?m to 1 ?m. The non-woven fabric is obtained by the steps of preparing a polyamic acid by polycondensation of an aromatic tetracarboxylic acid and an aromatic diamine having a benzoxazole structure, and electro-spinning the polyamic acid to form a polyimide precursor non-woven fabric; and imidizing a polyimide precursor fiber bundle.

Abstract: The invention relates to a modified strontium ferrite of the general chemical formula: Sr1-xLaxFe12-yCoyO19; in which x=y=0.01-1.00 or x=0.15 and y=x/1.6n to =x/2.6n, where n is the Fe2O3:SrO ratio used and may be 5-6. According to the invention, lanthanum and cobalt are added in an amount such that 0.14?x?0.145 and 0.14?y?0.145. The modified strontium ferrite thus prepared has excellent magnetic properties with regard to the remanence BR, the coercive force HCJ and the ratio of HK to HCJ.

Abstract: Nanometer scale structures, and methods of making the same are disclosed.

Abstract: The present invention relates to a process for melting and adhering material to produce three-dimensional objects by means of selective heating via microwave radiation. Unlike selective laser sintering, the present process uses simple microwave radiation commonly available in any household. The selectivity of heating is achieved by applying one or more susceptors to selected regions of a layer composed of a pulverulent substrate, and then heating the susceptor by means of microwave radiation. The heated susceptor transfers the energy present therein to a pulverulent substrate surrounding the susceptor, and the substrate is thereby melted, providing firm adhesion within the substrate after cooling.

Abstract: A method for manufacturing a dental restoration, including: determining an external form and dimensions available for a completed restoration; obtaining an image of a natural tooth to be replaced with the restoration or a tooth corresponding therewith, wherein the image comprises at least the external surface visible in use of the to be replaced or corresponding tooth, with variations in the appearance therein; defining locally on and at least to visible depth below the surface of appearance-determining properties of at least one material to be applied for the restoration in accordance with the obtained image and the variations in the appearance therein; constructing the restoration, including the steps of: providing at least one material to be applied in non-cohesive form; and providing cohesion to the material in accordance with the available form and dimensions.

Abstract: A method of moulding products made of expanded polymer beads using steam. The steam is generated by introducing a quantity of water into a mould that is capable of being pressurized. Steam is created by way of exposing the mould to microwave irradiation and the temperature of the steam is directly controlled by the pressure inside the mould.

Abstract: A fully curable jettable composition having a viscosity less than 30 cps at a temperature within the range of 15-180° C., more preferably at a temperature of 15-100° C., e.g. 60-80° C. the composition comprising: (A) at least one low viscosity reactive resin selected from the group consisting of compounds containing an oxetane ring, cycloaliphatic epoxy resins, tetrahydrofurans, hexahydropyrans and mono-functional (meth)acrylates, said resin having a molecular weight of not greater than 300 Daltons, e.g. 250 Daltons or less, and a viscosity at a temperature in the said range of less than 30 cps, e.g.

Abstract: A task often encountered in very recent times is the rapid provision of prototypes. Particularly suitable processes are those based on pulverulent materials and in which the desired structures are produced layer-by-layer through selective melting and solidification. The invention provides the constitution, production and use of a copolyamide powder which was produced using the following monomer units: a) laurolactam or ?-aminoundecanoic acid, and also b) dodecanedioic acid, and either c) decanediamine or dodecanediamine, in shaping processes, and also to mouldings produced through a layer-by-layer process which selectively melts regions of a powder layer, using this specific powder. Once the regions previously melted layer-by-layer have been cooled and solidified, the moulding can be removed from the powder bed. The mouldless layer-by-layer processes for the production of components using the copolyamide powder result in simplified and more reliable conduct of the process and better recyclability.

Abstract: A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of powder or liquid material, applying a liquid reagent to the layer in a pattern corresponding to the digital model, and repeating these steps to form successive layers. The powder or liquid material comprises a first reactive component and the applied liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers. The characteristics of the layers vary across those layers and/or the properties vary from layer to layer.

Abstract: A method of fiber production relating in general to electrospinning and specifically to MEMS (Micro ElectroMechanical Structures). Utilizing integrated circuit manufacturing processes, a nanoscale, self-contained device has been developed to execute the process of electrospinning large arrays of fibers and fiber arrays. One of the benefits of using the disclosed MEMS device is that the voltage required to produce a “so called” Taylor Cone would is substantially reduced and the requirement of a hydrostatic feed negated through the use of passive capillarity based wick surface treatment.

Abstract: The present invention provides a method of manufacturing a porous chemical mechanical polishing pad comprising focusing a laser beam from a laser into a sintering nozzle and injecting the fluidized thermoplastic particles into the sintering nozzle via an injection port. The method further provides sintering the thermoplastic particles with the laser beam and selectively depositing the sintered thermoplastic particles onto a table to form the polishing pad.

Abstract: Chemically cross-linked polymeric particles are formed using mechanical rather than chemical processes, facilitating production of small-diameter particles in a manner largely independent of the viscosity or density of the polymer. For example, an uncross-linked resin may be provided in particulate form, agglomerated, and compressed into a mass of a desired shape with a desired diameter, and subsequently cross-linked.

Abstract: A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of powder material, applying a liquid reagent to the powder layer in a pattern corresponding to the digital model, and repeating these steps to form successive layers. The powder comprises a first reactive component and the liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers.

Abstract: A process of producing a three-dimensionally shaped object comprising a layer forming step of forming a powder material having a refractive index n1 into a layer having a prescribed thickness on a support, a cross-sectional shape forming step of binding the layer of the powder material formed in the foregoing step into a prescribed cross-sectional shape with a binding agent having a refractive index n2; and repeating these steps successively, wherein n1 and n2 satisfy the relationship of ?0.1?(n1?n2)?0.1.

Abstract: In an investment casting procedure using microwave energy as the heat source virgin wax models are attached to a spree of wax-type pattern material incorporating a susceptor, the spree having a pour cup also of a wax-type pattern material, the pour cup material having a higher percentage of the susceptor than the material of the spree. In use the pour cup will melt first and the spree second, unblocking the path of the virgin wax so that its expansion will not crack ceramic with which it has been coated.

Abstract: A method of producing a high-density abrasive compact material includes the steps of providing an electrically conductive mixture of a bonding powder material and abrasive particles or grit; compressing the electrically conductive mixture; and subjecting the compressed electrically conductive mixture to one or more high current pulses to form the abrasive compact is provided.

Abstract: Chemically cross-linked polymeric particles are formed using mechanical rather than chemical processes, facilitating production of small-diameter particles in a manner largely independent of the viscosity or density of the polymer. For example, an uncross-linked resin may be provided in particulate form, agglomerated, and compressed into a mass of a desired shape with a desired diameter, and subsequently cross-linked.

Abstract: The present invention relates to a sinter powder composed of polyamide which also comprises PMMI, PMMA, or copolymers with PMMI, in particular PMMI-PMMA copolymers, to the use of this sinter powder for laser-sintering, and also to moldings produced from this sinter powder. The moldings made from the powder of the invention have marked advantages over conventional products in their appearance and in their surface quality, especially as far as roughness and dimensional stability during selective laser sintering (SLS) are concerned. In addition, moldings produced from the sinter powder of the invention also have better mechanical properties than moldings based on conventional nylon-12 powders, in particular in terms of modulus of elasticity and tensile strength. These moldings also have a density close to that of injection moldings.

Abstract: The invention relates to a rapid prototyping apparatus for the manufacturing of three dimensional objects by additive treatment of cross sections comprising a wholly or partially light-sensitive material, said apparatus comprising at least one light source for illumination of a cross section of the light-sensitive material by at least one spatial light modulator of individually controllable light modulators, wherein at least one light source is optically coupled with a plurality of light guides arranged with respect to the spatial light modulator arrangement in such a manner that each light guide illuminates a sub-area of the cross section. According to the invention, it is possible to obtain a significant simplification of an RP design system, just as the apparatuses designed are essentially capable of creating prototypes of any size, according to the invention.

Abstract: Chemically cross-linked polymeric particles are formed using mechanical rather than chemical processes, facilitating production of small-diameter particles in a manner largely independent of the viscosity or density of the polymer. For example, an uncross-linked resin may be provided in particulate form, agglomerated, and compressed into a mass of a desired shape with a desired diameter, and subsequently cross-linked.

Abstract: A method for producing a capillary bead array comprises the steps of: dispensing beads into a liquid pool, outside a capillary, having a depth of almost the same length as the particle diameter of a bead; leveling the excessive beads by moving a leveling member which is in contact with and relatively capable of be moved to the liquid pool to remove excessive beads that the liquid pool cannot contain; aligning the beads in the liquid pool one- or two-dimensionally; bonding adjacent individual beads to each other; producing a structure having the plurality of beads bonded and aligned one- or two-dimensionally; removing the structure from the liquid pool; and disposing the structure in the capillary formed of soft resin, so that the beads comprising the plurality of beads retaining the one- or two-dimensional alignment can be introduced simultaneously into the capillary.

Abstract: Heat-settable epoxy resin mixtures are provided that can be used alone or in combination with fibers to form large composite material structures without the need for high consolidation pressures. The heat-settable resin mixture is composed of a resin component, curing agent component and a particulate component. The particulate component includes rigid-rod polymer particles that dissolve when the heat-settable resin is heated to temperatures within a predetermined processing window. After heating to the processing temperature, the resulting heat-set resin is cooled to form a curable solid resin. The curable solid resin may be stored indefinitely or re-heated to curing temperatures to form a cured product.

Abstract: A method for forming an article in which thermoplastics materials are used as the binding agent. Materials (21) are shredded in a shredder (1), compressed in a compressing chamber (15) and moulded in a moulding chamber (16, 17, 19, 20, 26, 27). The thermoplastics material is heated whilst the material is held under compression and then cooled to bind the material together. In one embodiment superheated steam is supplied via tubes (31) having apertures there along. In another embodiment superheated steam is supplied via apertures in side walls of the mould (58, 59). Blocks (62, 72) formed by the method and apparatus of the invention may find application as construction materials etc. and have good structural, thermal and acoustic properties.

Abstract: A process for producing fused alumina-zirconia grits includes mixing raw materials suitable to produce grits with the following chemical composition, in % by weight: ZrO2+HfO2: 10–60%, Al2O3: 38–90%, SiO2: <0.8%, and Impurities: <1.2%. The process also includes adding carbon and aluminum metal to the mixture of raw materials to obtain a charged batch containing, in % by weight,: Carbon: 0.4–1% Aluminum metal: 0.5–2.5%. The process further includes melting the charged batch in an electric arc furnace with a voltage of 175–205 V and a delivered specific electrical energy of 2.5 to 4 kWh per kg of charge.

Abstract: The present invention relates to a method for fabricating a functional dental element, such as a crown. According to the invention, use is made of a three-dimensional printing technique. The major advantages of the invention are that no mold is needed anymore, which entails a considerable saving of costs, that a great accuracy is achieved, and that the element can be made of different materials.

Abstract: A backing or an intermediate layer for a surface covering is described which comprises a fused recycled material, wherein the material comprises a thermoplastic material, for instance, a vinyl material from a vinyl backed carpet or vinyl backed carpet manufacturing waste or both. Surface coverings containing the backing or intermediate layer of the present invention are also described as well as methods of making the backing or intermediate layer and methods of making the surface coverings containing the backing or intermediate layer of the present invention.

Abstract: To provide a three-dimensional molding technique capable of generating a three-dimensional molded article in short time. In a three-dimensional molding apparatus, a powder material is allowed to drop via an opening while moving a thin layer formation section in the +X direction, thereby forming a powder layer on a molding stage. With respect to a selected region in the powder layer, a binder of ultraviolet-ray hardening resin is discharged from a head section. Then, the powder layer is irradiated with ultraviolet rays from an ultraviolet irradiation section, making the ultraviolet-ray hardening resin applied on the powder layer harden to thereby bind the powder material. By repeating this operation with respect to the powder layer which is sequentially formed, a three-dimensional molded article is formed.

Abstract: A process for recycling of powder coating waste comprising the steps of (1) compressing powder coating waste to powder coating compacts having a volume of 0.5 mm3 to 15 cm3 by applying pressing forces; (2) placing the formed powder coating compacts into a vessel, rotating the vessel about a rotational axis inclined at an angle of 20 to 70 degrees relative to the horizontal and (3) heating the powder coating compacts while being moved in the rotating vessel until through-glassed powder coating bodies are formed.

Abstract: A process for producing a honeycomb structure, which comprises adding water to a mixed raw material of a raw material powder and a binder, kneading the mixture to obtain a plastic mixture, molding the plastic mixture into a honeycomb shape to obtain a green honeycomb structure, drying the structure by a step including hot-air drying, and firing the resulting dried honeycomb structure, wherein the binder contains hydroxypropyl methyl cellulose as a major component. The process can produce a crack-free high-quality honeycomb structure rapidly at a low cost.

Abstract: A method for forming a stabilized airlaid layer (86) can include an airforming of a substantially unbonded fibrous layer (66) which includes absorbent fibers and binder-fibers. The fibrous layer (66) is exposed to high-frequency electromagnetic energy during a distinctively short activation period to activate the binder-fibers to provide the stabilized, airlaid layer (86). In a particular aspect the activation period can be not more than about 3 sec.

Abstract: The present invention relates to a process for melting and adhering material to produce three-dimensional objects by means of selective heating via microwave radiation. Unlike selective laser sintering, the present process uses simple microwave radiation commonly available in any household. The selectivity of heating is achieved by applying one or more susceptors to selected regions of a layer composed of a pulverulent substrate, and then heating the susceptor by means of microwave radiation. The heated susceptor transfers the energy present therein to a pulverulent substrate surrounding the susceptor, and the substrate is thereby melted, providing firm adhesion within the substrate after cooling.

Abstract: Electrically conductive, thermoset molding compositions are disclosed which comprise an unsaturated thermosetting resin, an olefinically unsaturated monomer which is copolymerizable with the thermosetting resin, a thermoplastic additive and carbon black. The carbon black is incorporated in a conductive additive which comprises the thermoplastic additive, the carbon black and, preferably, a lubricant. The electrical resistance of articles molded from the disclosed molding compositions is typically less than about 108 ohms/cm2.

Abstract: A moisture-absorption sheet includes a small fraction of an organic polymer having a high weight-averaged molecular weight and a large fraction of particles of a moisture absorbing substance. In spite of the high content of moisture-absorbing material, the moisture-absorption sheet is not susceptible to crack formation and disintegration, and may have a high porosity. Due to these properties, the moisture-absorption sheet is particularly useful in an organic electroluminescent device.

Abstract: The present invention is a method of forming a compressed product. The method includes introducing a material into a press. The material has a flow direction through the press. The press is arranged to have at least one platen oscillating between a compression phase and a release phase. The at least one platen is configured to impart a compressive force onto the material during the compression phase such that the force is applied initially at an acute compression vector angle relative to the material flow direction. As a function of the angled compressive force, the material is transported a distance through the press and then released during the release phase.

Abstract: The present invention is a method of forming a compressed product. The method includes introducing a material into a press that is oscillating between a compression phase and a release phase. The material has a compression recovery response time when compressed and released. The compressed product is formed by repeatedly compressing the material during the compression phase and releasing the material during the release phase.

Abstract: Proposed is a process for producing non-woven fabric materials in which nano- and/or microfibers are produced by an electrostatic spinning process from a polymer melt or a polymer solution and deposited to form a non-woven fabric, wherein a carrier material in web form is arranged or is passed through between at least two spraying devices which are in the form of electrodes for producing an electrical field and each side of the carrier material is coated with the nano- and/or microfibers of opposite polarity, which are produced by means of the spraying devices. A non-woven fabric material produced by that process and the use of the material are also subject-matter of the present invention.

Abstract: A method is provided for forming a plastic prosthesis bearing, net-shape bearing, near net-shape bearing or plastic stock from which such a bearing can be formed. The method includes the steps of providing plastic resin in powdered form, subjecting the powdered resin to irradiation to cross-link the resin, and molding the irradiated powder. The irradiated powder is molded by applying heat and pressure to form the powder into a desired solid plastic shape, the heating being sufficient to melt the powder.

Abstract: A bed of particulate solids including some hydrated materials can be converted by controlled irradiation with subinfrared electromagnetic radiation into a unitary porous solid that is mechanically strong enough for easy handling. When the particulate solids include typical mildly acid to alkaline cleaner materials, a block or tablet especially suitable for automatic cleaning machinery, with a very fast dissolution rate in water, can readily be obtained.

Abstract: A method of fabricating a three-dimensional heterogeneous small-scale device includes the steps of depositing a fine heterogeneous materials (such as dry powders and biological materials) towards a substrate. In addition, the method includes sintering/cladding the material with a laser so as to produce a pattern. Then, the pattern is micro machined according to the particular design. The depositing step preferably includes providing a feed mechanism having an input to receive the material, an output, and a source of ultrasonic vibration to discharge the material from the output.

Abstract: A PTFE seal and method of fabrication therefor includes preparing a mixture of PTFE resin powder and a susceptor material which is then compacted and sintered by exciting the susceptor material with microwave energy. Preferably, the compaction and sintering of the mixture is carried out in a continuous process and a vacuum is drawn on the mixture in the heating zone to extract any air from the mixture. The sintered mixture is advanced, preferably continuously, to a cutting zone where PTFE wafers are cut from the sintered mixture, preferably while the mixture is still warm.

Abstract: According to a molding method for a conductive plate of this invention, a substrate having through holes each corresponding to each protruded portion is employed and the substrate is sandwiched between both dies. Then raw powder is filled into each housing portion provided opposing each through hole in the substrate provided in each of both dies, through the through hole in order to form each protruded portion. Then the protruded portion is formed integrally with the substrate by heating the raw powder under pressure.

Abstract: Thermally shrinkable films or labels having coated thereon a radiation curable adhesive; and a process for applying thermally shrinkable films or labels to containers comprising the steps of a) coating at least a portion of a thermally shrinkable but unshrunken film or label segment with a radiation curable adhesive; b) applying the film or label to the longitudinal surface of the container; c) subjecting the radiation curable adhesive to a radiation source to effect curing thereof and, d) subjecting the container to heat to shrink the film or label onto the container so as to permanently affix it thereto.

Abstract: A particulate silicone based material and method for forming a heat resistant composite is provided. The particulate silicone based material is heated to a temperature between about 200° F. and about 400° F. The particulate silicone based material is cooled until a solid composite is formed. The solid composite is resistant to melting and thermal decomposition when heated to temperatures of at least 3000° F. The particulate silicone based material may be formed by mixing liquid silicone resin with a catalyst and powdered silicone molding compound.

Abstract: Methods for making ceramic aggregate particles comprising forming a plurality of ceramic aggregate precursor particles from a composition by forcing the composition through at least one orifice in a substrate, at least partially curing the ceramic aggregate precursor particles, and heating the ceramic aggregate precursor particles to provide ceramic aggregate particles wherein solid particulates are bonded together by ceramic binder.

Abstract: A method for forming a product from cellulosic material and thermoactive material is described. A mat is formed from a mixture having cellulosic material and thermoplastic material. The mat is consolidated and pressed to a final thickness. At least a portion of a surface of the mat or product may be surface modified. Consolidating the mixture may include forming a first face layer, forming a core layer on the first face layer, and forming a second face layer on the core layer. Forming the core layer may include depositing mixtures of wood flakes and plastic flakes according to mixture flake size in successive layers such that the core layer has larger flakes adjacent the first face layer and adjacent the second face layer, and smaller flakes in a middle portion of the core layer. Consolidation can occur as a mat or composite moves through a hot-gas consolidation zone.

Abstract: An ETFE powder having a viscosity factor &phgr; of at most 1×104 Pa·sec, an anelasticity factor &egr; of at most 5×10−4 Pa−1, an average particle diameter of from 5 to 1,000 &mgr;m and an apparent density of at least 0.5 g/cc, is deposited on a substrate surface, followed by heat melting and cooling for solidification to form a film.

Abstract: A method for forming a stabilized airlaid layer (86) can include an airforming of a substantially unbonded fibrous layer (66) which includes absorbent fibers and binder-fibers. The fibrous layer (66) is exposed to high-frequency electromagnetic energy during a distinctively short activation period to activate the binder-fibers to provide the stabilized, airlaid layer (86). In a particular aspect the activation period can be not more than about 3 sec.

Abstract: A particle board, a fiberboard or an oriented strand board (25) is formed by the process according to the invention from a mixture of a comminuted cellulose material and a binder, especially a synthetic resin containing an unsaturated oligimer, that is hardenable by electron radiation. The process of the invention includes first forming a loosely scattered layer (4) of the mixture, e.g. on a conveyor belt, then compressing the layer in a press device (16), after performing a pre-compression in a pre-press in Some embodiments, and rapid setting of the layer (4) by means of electron radiation from an electron radiation device (22). Unlike the known processes that only use a thermosetting binder, the inventive method is hindered neither by heat transfer to the center of the board nor by a non-uniform humidity profile. High quality boards may be produced at a high yield without splitting and these boards require no conditioning storage.

Abstract: Apparatus suitable for vitrifying nuclear waste comprises a tunable microwave cavity connected by a first wave guide to a source of microwave energy; cooling coils for cooling the exterior of the cavity; a hopper for loading particulate fusible material to the interior of the cavity; within the cavity a crucible made of melted and re-solidified fusible particulate material; an exit-chamber connected by a second waveguide to a second microwave source; and a pipe for supplying argon gas to the exit chamber so that a plasma torch can be generated. The separating of the crucible form the cavity walls by unmelted material gives significant advantages in case of cleaning and reduced energy consumption.