Abstract: Apparatus for and methods of forming, from a single column of fibers, an airlaid fibrous web having a multiplicity of components.

Abstract: Apparatus for and methods of forming airlaid fibrous webs having a multiplicity of layers and/or discrete particles of absorbent gelling material dispersed through at least a portion of the web. The apparatus is of the type which includes a laydown drum having a foraminous forming element, a primary vacuum chamber, and a dusting layer vacuum chamber; a primary hood; and a dusting layer hood. The dusting layer of fibers formed on the laydown drum acts to block the passage of particles or fibers entrained in a first fiber stream which is airlaid over the dusting layer so as to minimize equipment plugging problems and the loss of particles or fibers through the foraminous forming element. The primary vacuum chamber of the laydown drum preferably spans the primary hood and a portion of the dusting layer hood so that the dusting layer is not sheared off, damaged, or destroyed as the laydown drum rotates to the position where the first fiber stream is deposited over the dusting layer.

Abstract: An apparatus permitting formation of a flanged product with the wider flanged portion in engagement with a foraminous transporting device. The apparatus uses a mold-like former having a narrower or smaller portion separated from the foraminous surface by a wider flange forming portion. The flange forming portion is adjacent to the foraminous surface and is separated from the foraminous surface after pad formation leaving the formed pad behind.

Abstract: A tangled fibrous material from cut glass fibre bundles, with the cut glass fiber bundler being fed into a compressed air flow and a glass fibre-laden air being deflected into a turbulent eddy flow of varying direction, so that a tangled fibrous material of wadding-like consistency is formed. Through the simultaneous addition of dry polymer-based binder powder, it is possible to obtain a tangled fibrous material as a starting product for a production of glass fibre-reinforced plastic moundings, which can be compressed to a felt. This can be packed as an intermediate or further processed in a heated belt press to glass fibre-reinforced plastic plates.

Abstract: An improved, continuous airlaying apparatus for making airlaid articles such as discrete absorbent fibrous cores for catamenial napkins and disposable diapers and the like having high structural integrity, and good edge definition. The articles are airlaid in discrete cavities as they pass through a deposition zone of the apparatus, and are compacted a predetermined amount prior to their being removed from their respective deposition cavities. An exemplary mechanism for effecting the compacting comprises a lugged cylinder having circumferentially spaced lugs which are configured and pitched to mesh in a quasi gear-like manner with the deposition cavities.

Abstract: A method for producing press-molded articles having a plurality of cavities therein includes a mold cavity which can be filled with a particulate molding compound, which mold cavity contains rods sheathed with expandable tubes which can be expanded by means of a fluid under pressure conveyed into the space between the rods and the tubes: this causes compaction of the molding compound to form the pressed article, which can be removed from the mold after reduction of the fluid pressure to allow detumescence of the expandable tubes and withdrawal of these from the mold cavity so that the mold cavity can be opened to remove the shaped pressed article.

Abstract: An absorbent member, suitable for a tampon, is produced by ejecting a liquid against a sheet of water-absorptive fibers in order to interlace the fibers with each other and molding under a pressure the sheet to form the absorbent member.

Abstract: A molded article, for example, a filter or a preform used in the manufacture of fiber-reinforced composites, is manufactured from an air laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into the desired shape of the molded article in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting article retains the desired shape. If the article is to be used as a fluid filter, it can be used either as it is removed from the mold if a filter of uniform density is desired, of the article can be further processed in a compression mold to densify portions of the article to thereby form, for example, a fluid impervious portion used as a gasket. If the article is to be used as a preform for a structural composite, it is then to be transferred to a resin injection mold.

Abstract: Polyester fiberfill having spiral crimp that is randomly-arranged and entangled in the form of fiberballs with binder fibers, preferably with a minimum of hairs extending from the surface of the fiberballs, so as to be air-transportable on account of the low cohesion between the balls. A process for making such fiberballs by repeatedly air-tumbling small tufts of such fiberfill/binder/blend against the wall of a vessel. Improved bonded batts or molded articles or other bonded articles obtained by bonding such fiberballs.

Abstract: A process and apparatus for producing a dry-pressed molding from a particulate or granular molding material such as a ceramic molding composition in which the composition is initially drawn into a loading cavity by applying a vacuum thereto. The loading cavity is formed by a first mold half and a shooting head having a molding surface the shape of which determines the shape of a premolding which is formed upon entry of the composition into the loading cavity and sufficiently compressed to retain its shape after the shooting head has been removed to allow a second mold half to be positioned over the first mold half.

Abstract: Polyester fiberfill having spiral-crimp, especially in the form of an omega (.OMEGA.), that is randomly-arranged and entangled in the form of fiberballs with a minimum of hairs extending from their surface, and having a refluffable characteristic similar to that of down on account of the low cohesion between the balls. A process for making such fiberballs by repeatedly air-tumbling small tufts of such fiberfill against the wall of a vessel.

Abstract: Apparatus for and methods of providing a multiplicity of streams of air-entrained fibers. The apparatus is of the type which includes a splitting member having multiple ports disposed in and along the surface of the splitting member; a first conduit duct in communication with a first port for directing a column of air past a first port to cause a portion of the column of fibers to split off and be drawn into the first conduit duct; and a second conduit duct in communication with a second port for directing a column of air past a second port to cause a second portion of the column of fibers to split off and be drawn into the second conduit duct.

Abstract: Apparatus for and methods of forming, from a single column of fibers, an airlaid fibrous web having a multiplicity of components.

Abstract: There is disclosed a process and apparatus for melt blowing at an initial velocity of from 500 to 1000 feet per second a molten thermoplastic condensation polymer at a temperature less than 50.degree. C. above the melting point thereof to form fibers of high molecular orientation, and collecting the fibers to form a non-woven web. In one aspect of the present invention, the fibers are collected on a rotating mandrel and heat treated during collection or subsequent to collection.

Abstract: Methods and apparatus for producing three-dimensional structural members having one flat side from wood fibers utilizing flow deposition of the fibers onto a support. The support includes resilient deformable mold inserts. The mold inserts are formed of silicone rubber and may be blocks of the material, or may be a membrane which can be inflated to form the mold inserts. Pressing is done with a force normal to the support, and the mold inserts create response forces at varying directions to thus shape and hold the three-dimensional finished part. Heat drying also may be used.

Abstract: Dry laid board comprising peat moss is provided and made by harvesting peat moss having a degree of decomposition of H-1 value as measured by the Modified Von Post Scale, individualizing the harvested peat moss, drying the individualized peat moss and entraining the peat moss in a gas stream. The entrained peat moss is then condensed to form a low density peat moss containing board which is subsequently calendered for use in such products as dressings, diapers and sanitary napkins.

Abstract: A dense, resilient, non-woven staple polymer fiber batt is formed of either of a plurality of overlayed, relatively thin webs or at least one relatively thick web. The web or webs comprise at least first and second staple polymer fiber constituents blended to form a homogenous mixture. The first fiber constituent has a relatively low melting temperature and the second fiber constituent has a relatively high melting temperature. The fibers of the first fiber constituent are fused by heat to themselves and to fibers of a second fiber constituent to interconnect the fibers while in a vacuum-compressed state. The heat is sufficient to melt the fibers of the first fiber constituent but not high enough to melt the fibers of the second fiber constituent.

Abstract: Apparatus and process for forming a laid fibrous article includes a foraminous forming surface for depositing thereon of fibers under the influence of a pressure differential imposed on the surface, wherein the improvement comprises the provision of a concavely contoured portion of the forming surface to yield a non-stepwise gradation in basis weight of the laid fibrous article. The concavely contoured surface portion is bounded by walls defining angles of from about 45.degree. to 68.degree., whereby the laid fibrous article is readily removable from the forming surface, which may comprise the cylindrical surface of a rotating drum.

Abstract: The present invention discloses a process of forming glass, glass-ceramic or ceramic matrix, fiber reinforced composite articles. The method comprises preparing both the matrix and the reinforcement into fibers, which are then chopped into relatively short lengths. These chopped fibers are then formed into hybrid felt papers comprising a mixture of both reinforcing fibers and matrix fibers. These felt papers are then cut into preforms and stacked one on top of the other to form a lay-up. The lay-up is then placed in a die and densified to form the composite article.

Abstract: The invention relates to a method and an apparatus for producing layers of dry fibres and/or particles on a forming surface pervious to air. According to the invention, the material is distributed in air and passed to a forming unit where a turbulence with high intensity is effected in that air is injected through separate nozzles.

Abstract: Polyester fiberfill having spiral-crimp that is randomly-arranged and entangled in the form of fiberballs with a minimum of hairs extending from their surface, and having a refluffable characteristic similar to that of down on account of the low cohesion between the balls. A process for making such fiberballs by repeatedly air-tumbling small tufts of such fiberfill against the wall of a vessel.

Abstract: To produce a panel of variable thickness, a stratified assembly of a layer of fibers containing a non-polymerized binder and at least one cover sheet is placed between the mold and mold-backing of a molding press. The stratified assembly is caused to conform to the interior surface of the mold or mold-backing by forcing the cover sheet against the mold or mold-backing interior. Hot air is blown into the fiber layer from the mold surface opposite the cover sheet, into at least the region that will correspond to the area of greater thickness. The direction of the heated air is reversed after a period of time, the blowing of the air being maintained and adjusted in order to secure polymerization of the binder. At the same time, the portions of the panel corresponding to areas of lesser thickness, generally the edges of an acoustical panel, are cured (the binder polymerized) by contact heating means.

Abstract: An apparatus for making airlaid articles such as discrete absorbent cores for catamenial napkins and disposable diapers and the like. Apparatus embodying the invention preferably comprises a laydown drum having a plurality of formation cavities having foraminous bottom walls, which cavities are circumferentially spaced around the perimeter of the drum. The apparatus also preferably includes means for directing a high velocity stream of air-entrained matter such as, for example, fibers or particulate matter, substantially radially towards a relatively short circumferential span of the perimeter of the drum; and a hood having sufficient circumferential span of the drum to enable excess entrainment air to be drawn by vacuum through the foraminous bottom walls of substantially empty cavities, and to enable recirculation of the excess scarfed fibers.

Abstract: A selectively stable latex has discrete polymer particles which have present as bound charges both a pH independent charge (such as sulfonium) and a pH dependent charge of opposite polarity of the pH independent charge (such as carboxyl), wherein the two charges are present in such proportion that the latex is stable in at least one pH range and controllably unstable in at least one pH range. The latexes of the invention are extremely useful in the preparation of fibrous composites such as highly-filled composite paper and fine printing paper.

Abstract: A hot isostatic pressing system including a hot isostatic pressing station having a high pressure container constituted by a vertical pressure-resistant cylinder closed at the top end thereof and a lower lid detachably fitted to the bottom of the pressure resistant cylinder and a treating chamber internally provided with a heater and enclosed by a heat insulating wall, and a mechanism for adjusting an atmospheric gas pressure and temperature of the pressing station into a condition suitable for the hot isostatic pressing of a work item accommodated in the treating chamber; a plurality of auxiliary stations each provided with an opening for receiving from beneath thereof the heat insulating wall of the treating chamber accommodating the internal heater and a work item, a support structure for supporting the heat insulating wall, and a mechanism for cooling the work item and internal heater in an inert gas atmosphere; a carriage for transferring the lower lid and work item or the lower lid, work item, heat insu

Abstract: The invention relates to a process for preparing flat articles which are moulded in any desired shaped in dry moulds from defibrated components of wood. In this process, the moisture required to give good felting remains a constituent of the wood fibres until the moulding stage. These wood fibres are mixed with fibre- and/or moisture-reactive binders and, if appropriate, auxiliaries, are metered by means of a gravity-compensating air stream onto a preform sieve, and are then compression-moulded without a cooling cycle in sieve-free moulds between two surfaces which are smooth or embossed in any desired pattern.

Abstract: The invention provides an improved method for producing a filler-loaded thermoplastic resin composite by mixing a thermoplastic resin with a filler, making it possible to be applied to molding machine such as extrusion and injection molding machines without the disadvantage of segregation between the resin and the filler otherwise inevitable leading to inferior uniformity of the shaped articles. The invention is characterized by the presence of a fibrillatable polytetrafluoroethylene during the mixing under mechanical shearing forces, wherein the thermoplastic resin is melted in one case and not melted in other case. The invention is also effective for shaping cellular foamed bodies of a filler-loaded thermoplastic resin with fine and uniform cellular structure.

Abstract: A dimensionally stable asbestos diaphragm is formed by direct coating on the foraminous cathode of an electrolytic cell from an asbestos fiber-particulate polymer slurry, followed by fusion of the thermoplastic polymer.

Abstract: In a method of manufacturing dry-pressed molded articles from essentially dry, pourable ceramic metal or carbon-containing molding compound in a mold of one or more parts, it is proposed to generate a negative pressure through the mold wall in the hollow space of the mold and, by means of the pressure difference generated as a result, to propel molding compound which is under pressure, for example, atmospheric pressure, through an injection opening into the hollow space of the mold and to precompress the molding compound in the mold while deaerating the molding compound, and that subsequently, the pneumatically precompressed molding compound is compression molded into a molded article having the desired final density.

Abstract: A method for making acoustical tile having a pattern of raised portions and portions in relief on the tile surface is provided by contacting deformable, acoustical tile fiber composition pulp with a hollow embossing roll containing the pattern in reverse and interstices communicating from the surface of the roll into the hollow interior of the roll; pressing the roll against the deformable pulp with sufficient force as to dispel the pulp; vent air, between the roll and the pulp surface, through the roll and produce the reversed pattern of the roll upon the pulp surface; and releasing the pulp from the surface of the roll by rotation of the roll.

Abstract: A method of manufacturing an expanded graphite gasket comprises the steps of taking co-operating male and female mould members, the female mould member comprising a channel extending through a block from one face to a directly opposite face, the channel as seen in plan having a width and configuration corresponding to a desired gasket shape, presenting a substrate to one face of said block with said channel in register with said locations, filling the channel with a charge of expanded graphite particles, followed by pressing the charge with the male mould member onto the substrate to form a gasket thereon and thereafter removing the mould members.

Abstract: A flat gasket incorporating a metallic reinforcement layer which is enclosed within the gasket in relation to one edge thereof is formed from relatively uncompacted, i.e. loose, expanded graphite particles by a method comprising the step of pressing such particles onto the opposed faces of said reinforcement substantially simultaneously to form compacted graphite foils in situ thereon while at the same time pressing some of said particles relative to said one edge to form a single unreinforced graphite foil portion extending from and integral with the other foils to enclose said one edge.

Abstract: A molding mixture comprising a filler, such as wood particles and a resin binder, is pressed under light pressure on a flat bed to produce a mat with a density between 1/15 and 1/3 of the material in the finished article to be made by pressure molding. A molding preform is then made from a piece of such mat having a suitable contour, by sculpturing one side of the mat with suction devices to provide a thickness variation over the mat area corresponding to the requirements of the molding step.

Abstract: A method of applying a vermicular expanded graphite composite material to the interior surface of a conduit by a two-step in situ compression process is disclosed.

Abstract: A process of manufacturing molded parts using a mold with relatively movable parts enclosing a mold cavity which is fed with plasticizable material, comprises directing grains of the plasticizable material into a vertically elongated vestibule having a lower end connected to the feed of the mold cavity and directing hot gases into the lower end of the vestibule and upwardly through the plasticizable material therein to make the material weldable and, thereafter, directing the weldable material into the cavity under pressure. The device for carrying out the process includes a feed conduit which is connected into the cavity which is disposed below a vertically elongated vestibule which has a closed top and a bottom opening into the conduit.

Abstract: A method is disclosed of molding a cementitious material within a mold having a filler material bed, the configuration of which is maintained by means of suction applied through a filter disposed within the mold frame. A shield layer can be formed upon a surface of the filler material bed having air permeability so as to impart a desirable shape thereto, and the filler material is fixed under reduced pressure conditions within the mold so as to form a molding mold, whereupon the cementitious material may be charged into the mold so as to set therein. It is also possible to achieve the method of the present invention by charging a cementitious material within a molding mold having a desirable configuration, forming a filler material bed having good air permeability with or without a shield layer disposed upon the cementitious material, and preparing a hardening mold, under reduced pressure conditions, beneath the filler material bed.

Abstract: In manufacturing of a mold for metal casting via the vacuum molding process, the cover for the original pattern is made of a synthetic film including, at least partly, ionomer resin component and, further preferably, the exposed surface of the cover set to the pattern is coated with a solution of an initial condensate of a thermosetting resin.High fidelity in patterning, excellent vacuum retainability, enhanced surface stability and high resistance against thermal decomposition of the ionomer cover film accompanied with considerably reduced casting defects assures high quality of the castings obtained.