Abstract: In a casting method comprising casting a slip containing water or an organic solvent as the medium into a mold and removing the mold after solidification of the slip, use of a mold formed with an organic binder soluble in the medium of the slip allows the slip to quickly solidify and afford a green body due to absorption of the medium in the slip by the mold. In this case, the mold softens with loss of the binding power thereof simultaneously with the absorption of the medium. Therefore, no cracks appear at all in the green body, and removal of the mold is very easy.

Abstract: A method for manufacturing a microporous plate, a filter plate obtained from the method, and suction drier apparatus utilizing such filter plates. According to the method, a casting mix is introduced into the interior of a gypsum mold whereupon water is absorbed from the casting mix into the gypsum so that a crust remains on the inner surface of the mold. The crust is allowed to develop to an appropriate thickness whereupon the remaining casting mix is drained from the mold. The inner surfaces of the crust are allowed to dry whereupon the interior space defined between opposed crust wall portions is filled with a granular material which preferably has the same composition as the crust material. A filter plate comprises a pair of opposed suction walls defining an interior space between them which is filled with a granular material. The suction drier apparatus includes at least one of the filter plates which is mounted to be moved into and out of a basin or the like in which material to be dewatered is present.

Abstract: A shuttering used for forming concrete comprises a plate with a plurality of through holes opening on both its face and reverse, and a double woven fabric consisting of a face tissue which permits passage of water but prevents concrete from passing and a reverse tissue opposed to the face of the plate and relatively displaceable with respect to the face of the plate; the surplus water oozing out of placed concrete flows through gaps formed by the reverse tissue between said plate and the face tissue as well as the through holes of said plate.

Abstract: Herein disclosed is a method of making a porous mold by using an upper case which bears lines for forming channels for water and air communications.

Abstract: A process for the production of reinforced refractory composite structures which may be of high density and shaped in desired three dimensional configurations. The shaped composite structures are produced by forming a suspension of particulate materials including a colloidal refractory power, colloidal sintering aid, and refractory reinforcement whiskers in a carrier liquid. The colloidal suspension is conformed to a desired configuration and brought into contact with a semipermeable membrane. A pressure is imposed on the suspension in the desired configuration to expel liquid from the suspension through the membrane to arrive at a green composite having a density of at least 40% of theoretical density. After drying, the green composite is then sintered under conditions to form an intergranular liquid phase in the composite providing further densification. A specific composite is a silicon carbide reinforced silicon nitride composite.

Abstract: The present invention is directed to a water-soluble organic binder suitable for a ceramic molding method in which a ceramic slurry containing water as a dispersion medium is utilized and with this binder, a ceramic sheet can be prepared which has smooth surfaces, contains no flocculating material, and possesses excellent flexibility and mechanical strength.

Abstract: A method of producing a high density and high strength silicon carbide member for a heat treatment furnace to be used in the manufacture of a semiconductor device. In this method, SiC powder, carbon powder, deflocculating agent and water are mixed to form a slip. Then the slip is formed into a desired shape, cured under a nonoxidizing atmosphere, and removed of any impurity contained in the shaped body. Finally, the shaped body is immersed in a molten silicon to convert the carbon in the shaped body into silicon carbide.

Abstract: A method of making a porous mold used in pressure casting for forming ceramic articles, which includes the steps of: removably attaching a plurality of apertured holding members in an array at a desired interval to the inner face of an upper case made of a rigid material; threading a flexible line into the apertures of the holding members in each row to hold it at a predetermined spacing from the inner face of the upper case, at least one of the two ends of the flexible line being extended to the outside of the upper case; casting slurry into a mold cavity which is defined between the upper case and a lower basic case joined to the former case to form a porous mold; removing the upper case from the porous mold after the slurry has cured, while leaving the holding members together with the flexible lines in the porous mold; and extracting the flexible lines from the porous mold to form channels in the porous mold.

Abstract: A porous body consisting of a felted fibrous skeleton covered with and bonded together by a ceramic material is provided. Also provided are methods for making such a porous body which comprise the use of ceramic polymer solutions.

Abstract: Ultralight carbon-bonded carbon fiber composites of densities in the range of about 0.04 to 0.10 grams per cubic centimeter are fabricated by forming an aqueous slurry of carbonaceous fibers which include carbonized fibers and 0-50 weight percent fugitive fibers and a particulate thermosetting resin precursor. The slurry is brought into contact with a perforated mandrel and the water is drained from the slurry through the perforations at a controlled flow rate of about 0.03 to 0.30 liters per minutes per square inch of mandrel surface. The deposited billet of fibers and resin precursor is heated to cure the resin precursor to bind the fibers together, removed from the mandrel, and then the resin and fugitive fibers, if any, are carbonized.

Abstract: Suspensions of ceramic or metallic colloidal particles having a high volume fraction (greater than about 55 vol. %) solid particles are provided in a pourable form. The pourable suspension includes at least about 55 vol. % ceramic or metallic colloidal particles, an aqueous vehicle, and an acrylic acid-based polymeric polyelectrolytic dispersant. Such suspensions can be prepared by mixing the colloidal particles in a staged order of addition and under a high shear rate with the other components. The suspensions are suitable for making ceramic or metallic articles, and can exhibit a low viscosity.

Abstract: Stable slip casting composition having a total solids content of from 50 to 80 percent by weight on a base of finely divided, AlN-containing powders. It contains as liquid dispersion medium, water mixed with a water-soluble, aliphatic, polyvalent alcohol and admixtures for adjusting the viscosity required for slip casting. The liquid dispersion medium can contain, for instance, from 1 to 20 percent by weight of an alcohol such as glycerin calculated on the total weight of water and alcohol.

Abstract: A method of producing a reinforced ceramic which includes a step of aggregating ceramic fibrous material of 0.5 .mu.m or more in diameter; a composite step in which the fiber aggregate obtained is placed on a filter and a dispersion liquid in which ceramic powder having a particle size of not more than one-tenth of the diameter of the ceramic fibrous material is dispersed in a dispersion medium is transferred through the fiber aggregate from a side opposite to the filter to the other side, for passing the dispersion medium through said filter and introducing the ceramic powder in a gap between the fibrous material of the fiber aggregate to form a composite of the fibrous material and the ceramic powder; and a step of sintering the composite.

Abstract: A cast article having a complicated shape of the appearance and the hollow can be obtained by forming a coating film on the surface of a pattern from a solvent-insoluble material to prepare a mold pattern, filling and hardening a molding material around the mold pattern, dissolving the pattern with a solvent, and removing the residue of dissolution and the coating film outside the mold.

Abstract: A fiber- and filament-containing ceramic preform comprises of a mixture of discontinuous fibers and particulates surrounding a layer of continuous filaments extending substantially through the mixture is procduced and infiltrated with a molten ceramic to produce a composite.

Abstract: A method for modifying a surface to a desired contour by pressing a flexible molding plate, having holes for releasing trapped fluids and excess molding compound, is pressed on a molding compound by a plurality of ordered pressure points which are set to define a shaped plane corresponding to a desired contour. The pressure points are adjustably included in a support frame, or are provided by shaped rollers. Compound extruded through the holes by the operation is removed from the plate which is then removed. Nubs resulting from excess molding compound in the holes are removed by sanding or other finishing means.

Abstract: A molded composite material comprising a plural number of constituents is provided in which at least two of the constituents are distributed with a relative existing ratio varying at least in one direction in the composite material. A process for producing the composite material is also provided.

Abstract: A casting installation for casting slip into ceramic product by use of at least one unique casting mold. The casting mold is formed of a plurality of separate mold parts each having a plurality of channels therein and having its respective outer face treated to be fluid-tight and inner molding surface. The casting installation includes a pressure-resisting container having a surrounding wall formed along the inner surface thereof so as to define an opening through the container, the mold parts, when assembled, being dimensioned to define a molding cavity of the casting mold; the space being in communication with the molding cavity of the mold. The casting installation further includes a clamp for clamping the casting mold firmly; the channels are operatively connected for depressurizing the channels; a source of slip operatively connected to the molding cavity of the casting mold; and a source of fluid operatively connected to the space surrounding the casting mold.

Abstract: Concrete forms comprising a first cloth sheet permitting surplus water and air contained in concrete cast in the form to pass therethrough but capable of blocking the passage of the concrete, a second cloth sheet permeably secured to the first sheet, permitting the surplus water and air to pass between and through the first and second sheets and to be absorbed into the second sheet as well as the first sheet, and a support plate to which the second sheet is bonded as by adhesive or thermal bonding acting through only part of the thickness of the second sheet, leaving as water and air permeable throughout the remainder of the second sheet, all of the first sheet, and the interspace therebetween, such being effective as flow paths for surplus water and air to exhaust from the concrete cast in the form to thereby shorten the cure time and improve the strength of the concrete when cured.

Abstract: Process for forming a multilayer blood vessel prosthesis. Each layer is formed from bioreplaceable materials which include those produced by contacting collagen with an aminopolysaccharide and subsequently covalently crosslinking the resulting polymer, polymers of hydroxyacetic acid and the like. Cross flow filtration molding and wet extrusion molding are two processes which are particularly useful for forming the inner layer of the blood vessel prosthesis. The outer layer of the blood vessel prosthesis is preferably formed by freeze drying a dispersion of the bioreplaceable material onto the inner layer(s). The disclosed blood vessel prosthesis is a multilayer structure with each layer having a porosity and other physicochemical and mechanical characteristics selected to maximize the effectiveness of the blood vessel. The prosthesis functions initially as a thromboresistant conduit with mechanical properties which match those of the adjacent natural blood vessel.

Abstract: A method of manufacturing a metallurgical addition agent, especially an agent comprising silicon carbide fines, comprises a first step of forming a mix of at least 30% fines, cement and at least 20% water. The next step comprises pressing the wet mix in a mold while squeezing out excess water but leaving sufficient water for hydration of the cement. The pressed shapes are cured at ambient temperatures.

Abstract: A process for producing a filter with multiple folds from an aqueous fiber mixture that is applied to a porous form, in which a paper-like filter mat is produced on the form under the action of pressure, and it is carried out without mechanical deformation of the rough casting. This is achieved pursuant to the invention by the fact that the aqueous fiber mixture is deposited on the porous form having the contour of the filter, from loading chambers separate from one another, and the filter is built up of adjacent fold sections in layers on the form by separate introduction of the fiber mixture to the fold sections connected to one another.

Abstract: Non-asbestos brake pads made of reinforcing, temperature resistant, web-forming fibers such as aromatic polyamide pulp, optionally including other fibers and friction and wear modifiers is described. The brake pads have an actual density not greater than 88% and not less than a 60% theoretical density. The pads are made by the slurry process in which the pad-forming constituents are fed as a slurry into a mold, dewattered and compressed, dried to a preform then heated and pressed to consolidate the preform to substantially the finished density without completely curing the binder. The consolidated pad is then baked to fully cure the binder.

Abstract: A process for preparing a water repellent calcium silicate shaped product, which comprises dispersing a siliceous source and a calcareous source in water, mixing a water repellent composition thereto, reacting the mixture under heating to obtain an aqueous slurry containing a calcium silicate hydrate, pressfilter-molding the aqueous slurry, followed by drying or drying after steam-curing.

Abstract: The invention relates to a process for manufacturing an insulating fibrous piece based on fibers resisting high temperature, which consists in: preparing a first suspension containing a first type of fibers resisting high temperature; preparing at least one second suspension containing a second type of fibers resisting high temperature; then pouring each suspension into a distinct compartment of a vat of which the bottom comprises a momentarily obstructed filtering sieve and of which the elementary compartments are separated from one another by a removable plate, said process being characterized in that: each suspension also comprises a minority proportion of ceramizable particles; whilst withdrawing the removable separating plate, the medium is stirred locally at least in the vicinity of this separation plate, on the one hand, and, simultaneously, the water is drained through the filtering sieve, on the other hand, in known manner; and, after having dried the piece obtained, it is heated to a temperature cap

Abstract: A sculptured structural fiberboard product is formed using a mold that includes porous forming areas which, in one embodiment, are porous forming mandrels movably mounted on the mold, and liquid impervious thimbles which removably cover the porous areas. A fiber network is formed as water is drained off through the porous areas and the thimbles are moved to gradually unveil the porous areas during the mat formation. When mandrels are used, the mandrels are withdrawn in cooperation with a pressing force applied to the mat to consolidate and dry the web. The porous areas can also act as heat and mass transfer means during consolidation and drying. An alternative embodiment permits formation of laminated products and another alternative embodiment permits close control over the product density during consolidation and drying.

Abstract: Process for the production of refractory shapes of ceramic fiber-containing mateial, wherein a slurry of refractory fibers and particulate refractory materials is produced in water, the particulate refractory materials are flocculated on the fibers by use of a flocculant, and the desired shape is produced by dewatering the slurry in a suitable mold that enables the water to be removed, and the shape is dried. At least 90% of the fibers have a maximum length of not more than 500 .mu.m; flocculant is added as an aqueous solution to the dispersion of the fibers and particulate refractory material; and pressure is applied to the shape being formed during the dewatering of the slurry to form the desired shape in order to compress the shape.

Abstract: Method for the production of light-weight molded articles wherein, in a first embodiment, a dispersion of ceramic fibers is flocculated with a cationic flocculating agent, a dispersion of finely divided refractory material and inorganic bonding agent is flocculated with an anionic flocculating agent, the flocculated dispersions are mixed together, and following settling of the mixture and optional removal of excess liquid, the mixture is filled into molds, converted by dewatering into molded articles, and dried. According to a second embodiment, a dispersion of ceramic fibers is flocculated with a cationic flocculating agent, finely divided refractory material and inorganic bonding agent which may be stirred in with water are added to this flocculated dispersion, an aqueous solution of an anionic flocculating agent is mixed into this mixture, and following settling of the mixture and optional removal of excess liquid, the mixture is filled into molds, converted by dewatering into molded articles, and dried.

Abstract: A form for forming concrete comprises a first sheet permitting surplus water contained in the concrete cast in the form to pass through the first sheet, but capable of blocking the passage of the concrete, a second sheet secured to the first sheet, permitting the surplus water to be absorbed into it, and a plate secured to the second sheet. The first sheet provides paths for the surplus water by the existence of the second sheet. The paths for the surplus water are ensured by a spacer provided between the first sheet and the plate in lieu of the second sheet or together with the second sheet.

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: As the aluminum nitride component of a sintering aid for powdered silicon nitride, either a spinel type compound having oxygen dissolved in aluminum nitride to form a solid solution or a poly-type aluminum nitride is used. Since the compound is highly stable in water, it can be effectively used in the form of an aqueous slurry mixture. As the sintering aid, this compound is used as effectively as aluminum nitride.

Abstract: A spacer core for use in constructing hollow concrete walls by introducing the core between and spaced from a pair of vertical mold plates before casting the wet concrete, and subsequently removing the spacer core, the lower end of the spacer core including a water permeable wall and a bottom chamber for accumulating water permeating the wall. Also described is a method of constructing hollow concrete walls by the use of the above spacer core by: introducing the spacer core between and spaced from a pair of vertical mold plates; casting wet concrete into the spaces between the spacer core and the mold plates, whereby the water from the concrete permeates through the bottom of the spacer core into the bottom chamber; after a first time interval, lifting the spacer core a first predetermined distance to draw water from the concrete into the bottom chamber; and subsequently removing the spacer core from the concrete.

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 thermal heating and insulating unit is manufactured by molding in situ a block of thermal insulating material about an electrical resistance element. The resistance element is first made from a continuous wire of electrical resistance material and formed into a serpentine configuration with a plurality of segments interconnected by bends at the ends of the segments. In a preferred construction, the segments are straight and the bends at the ends of the segments are in opposite directions. The resistance element is positioned in a mold on a plateau above a porous bottom, the bends overlapping the plateau, and a slurry of inorganic fibers, water and a binder is introduced into the mold to a lever above the plateau, the liquid component of the slurry passing through the porous bottom, and the fibers and a portion of the binder collecting on the porous bottom to form a block with a slot confronting the resistance element, the bends of the resistance element being embedded in the block.

Abstract: A method of manufacturing a ceramic body having continuous three-dimension through-out holes which can be preferably employed as a filter for filtration of non-metallic inclusions in a molten metal and as a porous plug for introducing a gaseous medium for floating up the non-metallic inclusions. An organic body having a three-dimensional construction is placed in a casting mold, a slip of a ceramic material is poured into the mold, and after drying, the molded body is baked to effect decomposition of the organic porous body. Thus the ceramic body is provided with through-out holes communicating with to each other three-dimensionally together with a high mechanical strength.

Abstract: In a forming method and a mold wherein a slip is cast into the mold and wherein the mold is removed after hardening of the slip, the mold is patterned by the use of a water-soluble binder. The mold absorbs a water content in the slip to soften and to become easy of removal, while the slip has the water content absorbed to harden promptly. Therefore, the forming method and the mold are especially suited to produce a cast article of complicated shape.

Abstract: Filter pads, which are made inherently stable by binders and by removal of the binders can be converted in packings to be maintained under substantially constant surface pressure between rigid filter brackets, are produced first as molded bodies from a suspension of filter aids in liquid by depositing granular, fibrous, or fiber-containing filter aids or mixtures of those filter aids in a casting mold, there being used high rates of flow while avoiding turbulences, and adding binders to the suspension so that the molded body can be stabilized by activation of the binder while drying. It is possible in this process also to manufacture multi-layered filter pads, it having been surprisingly found in those multi-layered filter pads that the layer assembly is kept intact during the filtration even in the filter packing that no longer contains binders.

Abstract: A method for producing a fabric item comprising the steps of producing a perforated substrate in the shape of the desired fabric item, supplying fibers to the perforated substrate, causing the fibers to engage the perforations in the substrate, and retaining the fibers in the perforations.

Abstract: Method and apparatus is provided for reinforcing a structural member of a vehicle body by the use of adhesively bonded together glass macrospheres of 3 to 9 mm. in diameter. The adhesive is not more than about 40% by weight of the mixture so that voids remain between the adjacent macrospheres to permit airflow through the reinforcement and the reinforced structural member upon curing adhesive. The adhesive may be curable at ambient temperature or may be a high temperature curable adhesive which is cured in a vehicle body paint curing oven to bond the macrospheres to one another and to the structural member. The adhesion of the macrospheres to the structural member may be facilitated by an epoxy coated flexible sheet material lining the walls of the structural member. The adhesive coated macrospheres may be closely packed into the structural member by pouring or blowing.

Abstract: Cement matrix composites of improved flexural toughness are prepared with polyethylene fibrids of high orientation from plexifilamentary structures as reinforcement.

Abstract: A method for making an electrolyte permeable diaphragm, and the diaphragm thus produced, wherein an aqueous slurry, containing as its principal particulate ingredient a water-wettable, insert, micron-size, inorganic material, along with both polyfluoroethylene fibers and polyfluoroethylene dispersion, is drawn through a foraminous structure to form a diaphragm thereon.

Abstract: Concrete structures consist of fabric containers which are filled with concrete through an opening in the top thereof while the top of the container is suspended from a portable support frame placed over the container. The support frame supports the container in an open and upward position with the bottom wall of the container resting on the ground while concrete is pumped or chuted into the container through the top opening.

Abstract: A method of producing ceramic items which does not necessitate the use of high vapor pressure organic solvents, aqueous solvents, binders or plasticizers. A monomer is used as a vehicle for deflocculation of the ceramic powder and, after forming, is polymerized to form a matrix which binds the ceramic particles together.

Abstract: Novel aqueous inorganic particle slurries, wherein some of the particles have had their charge potential altered to a sufficient extent to prevent segregation or settling of the particles, are described, along with a method for their preparation. The method of forming slurries of negatively charged particles comprises treating some of the particles with a cationic agent to reduce their charge and mixing these treated particles with the remainder of the particles to form a thick, cream-like flowable composition of a thixotropic nature. When slurries of positively charged particles are to be formed, an anionic agent is used instead of a cationic agent.

Abstract: A method of producing decorative ceramic ware is disclosed. In the first step, a flocculant is added to an aqueous suspension containing as main solid components a fibrous material and a ceramic raw material clay, followed by preparing ceramic raw material sheets from the suspension by the ordinary paper-making method. Prepared are at least two kinds of ceramic raw material sheets differing from each other in color after firing. Then, the stacking-cutting operation of the sheets is performed at least once, in which the different kinds of sheets are alternately stacked, followed by cutting the stacked mass in a direction not parallel with the surface of the raw material sheet. The cut piece is formed into the desired shape and, then, dried and fired to produce a striped or checkered decorative ceramic ware. This particular method permits industrial production of ceramic ware.

Abstract: A method of making a silicon metal containing article is characterized in the following steps. A water vehicle first slurry is formed which contains silicon metal particles, this first slurry being substantially free of ions which would cause a flocculation of the silicon metal particles. An organic vehicle based second slurry is formed which contains a compound which has an ion which would cause flocculation of silicon metal particles contained in a water vehicle slurry. The organic vehicle of said second slurry, however, is effective to suppress formation of ions by the ion forming compound. The first and the second slurries are added to form a castable silicon metal particle containing slurry in which the compound contained in the organic vehicle can form ions when in contact with the water vehicle. The castable silicon metal particle containing slurry is introduced into a casting mold.

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: A process of moulding a product (and a product thus formed) wherein particulate ligno-cellulose such as shredded paper, flour, Portland cement, a small amount of caustic soda, and water are mixed together, placed in a mould, and subjected to both pressure and heat until set, and the moulded product is then removed from the mould.

Abstract: A method of making a densified silicon nitride/oxynitride composite is disclosed. The method comprises: (a) shaping a substantially homogeneous powder mixture of silicon nitride, 6-18% yttrium silicon oxynitride of the Y.sub.10 Si.sub.6 O.sub.24 N.sub.2 phase in an amount to form a viscous solution with at least a portion of the silicon nitride, and (b) densifying the body by heat fusion, with or without the use of mechanical pressure, to a density and a dimension required for the final product.

Abstract: An improved electrically conductive current collector suitable for use in high temperature applications in the presence of corrosive environments comprising: (A) a high strength, noncorrosive electronically conductive ceramic member which serves as the primary load bearing element for said current collector; and (b) a highly electronically conductive metal cladding intimately attached to a substantial portion of ore surface of said ceramic member and adapted to direct current flow through said ceramic member and to shunt said current between said member and an external contact. The disclosed current collectors are ideally suited for use as current collectors and current collector/containers for electrical conversion devices such as the sodium/sulfur battery and the like. Also disclosed are two processes for preparing tantalum or niobium doped rutile titanium dioxide.