By Direct Application Of Vacuum Or Pneumatic Pressure Patents (Class 264/87)
  • Patent number: 6261493
    Abstract: A method and system for molding a tissue or substitute tissue product in a mold having an exterior surface, and an interior surface, wherein at least one portion of the interior surface is porous and whose pores are in continuous communication with the exterior surface, and wherein said mold can be fabricated using solid free-form fabrication techniques is disclosed.
    Type: Grant
    Filed: March 20, 1998
    Date of Patent: July 17, 2001
    Assignee: Therics, Inc.
    Inventors: Christopher M. Gaylo, Walter Flamenbaum, Miles J. Flamenbaum
  • Patent number: 6257546
    Abstract: A method of slip casting wherein reduced pressure is applied to the mold during casting by virtue of a network of piping extending through the mold. The mold has an impermeable outer coating. Heat may also be applied to the mold during casting, by for example a heated fluid passing through piping located in the walls of the mold.
    Type: Grant
    Filed: July 21, 1999
    Date of Patent: July 10, 2001
    Assignee: British Ceramic Research Limited
    Inventors: Robert Norman Deakin, Andrew Watson
  • Patent number: 6225246
    Abstract: The invention disclosed is a self-supporting porous ceramic material, which is typically used in ceramic filters as a substrate prior to coating with a thin dense membrane layer of additional ceramic material. Conventional ceramic support structures are not necessarily designed as membrane support substrates. They are typically made with monosized particles and have a uniform cross section. The present support structure is made via a polydisperse slurry method where a functionally gradient structure is achieved by a colloidal destabilization technique. The key for achieving this structure is to colloidally unstable or metastable suspensions of a controlled and broad particle size distribution, so that segregation based on particle diameter will occur during consolidation. This produces a continuously finer mean particle diameter axial profile from one major surface to the other on the cross section of the consolidated structure.
    Type: Grant
    Filed: May 3, 1999
    Date of Patent: May 1, 2001
    Assignee: National Research Council of Canada
    Inventor: Ken Darcovich
  • Patent number: 6214102
    Abstract: A method of vacuum forming of aqueous, fibrous slurries and products produced thereby are disclosed. The method entails forming an aqueous slurry of ceramic fiber, cationic starch and silica sol. The silica has, based on total weight of the sol, about 50% silica having a particle size range of from about 7 nm to about 200 nm and a specific surface area of about 100 m2/gm to about 10 m2/gm. The slurry is passed through a porous screen under a vacuum pressure deposit the solids content onto the screen to produce high strength products.
    Type: Grant
    Filed: June 1, 1999
    Date of Patent: April 10, 2001
    Assignee: Wes Bond Corp.
    Inventor: John Vandermeer
  • Patent number: 6197235
    Abstract: An improved method for texturing gypsum fiber panels and producing surface textured panels, edge tapers, and deeper patterned wainscot-type panels, involving the use of a flexible die with a textured surface. The die is pressed onto the panel in its slurry state just after the onset of an exothermic rehydration reaction. Partial hydration and setting occur during pressing by the die to form a textured mat. The mat is removed from contact with the die at a point along the rehydration temperature curve about at or less than one-half of the rise to the greatest rehydration temperature.
    Type: Grant
    Filed: February 9, 1999
    Date of Patent: March 6, 2001
    Assignee: United States Gypsum Company
    Inventors: David Paul Miller, Matthew Huss
  • Patent number: 6190151
    Abstract: A method of making a three-dimensional object from fibers includes attaching a mold made at least in part of elastomeric material to a porous support. The mold comprises a first mold member defining at least one channel in fluid communication with the porous support. Each channel has within it at least one second mold member. A mixture of fibers and fluid carrier is poured onto the mold. Thereafter, a pressure differential is created across the mold to create a flow of the mixture toward the porous support via the second mold members. This flow causes the fluid carrier to pass through the porous support, thus depositing the fibers within the recessed parts of the second mold members in the mold. Thereafter, the mold is compressed sufficiently to deform the mold and to provide uniform, normal pressure to the fibers which have been deposited in the second mold members.
    Type: Grant
    Filed: July 9, 1998
    Date of Patent: February 20, 2001
    Assignee: The United States of America as represented by the Secretary of Agriculture
    Inventor: John F. Hunt
  • Patent number: 6165398
    Abstract: A method of slip casting using a casting mold provided with a water-absorbent layer that has a self-water-absorbent ability, substantially has a water resistance, and is controlled in the saturated water content thereof, the slip casting being conducted by employing mainly a capillary sucking force as the driving force of the water-absorbent layer of cast formation. An open-cell porous body usable as the water-absorbent layer is produced by agitating a mixture comprising a compound having at least one epoxy ring in its molecule, a curing agent which cures the epoxy compound by reaction, a filler developing for a self-water-absorbent ability and a mold release property, and water to prepare an O/W emulsion slurry and curing the slurry, as such in a hydrous state.
    Type: Grant
    Filed: February 26, 1998
    Date of Patent: December 26, 2000
    Assignee: Toto Ltd.
    Inventors: Akio Matsumoto, Takeshi Sato, Yoshifumi Misumi, Akira Hirayama, Katsuhiro Hasebe, Yoshinori Yamashita
  • Patent number: 6149845
    Abstract: A method of manufacturing paper coffin for use in cremation including the steps of forming a box and a cover for a coffin from prepared pulp by vacuum molding, drying the molded box and cover, compressing walls of the box and of the cover in a die casting machine to consolidate them and give them enhanced structural strength, and painting the box and the cover so that the coffin has beautified outer surfaces. Dies for compressing the walls of the box and the cover may be provided with patterns so as to form raised or depressed patterns on outer wall surfaces of the coffin.
    Type: Grant
    Filed: March 29, 1999
    Date of Patent: November 21, 2000
    Inventor: Shieh Chwan Ren
  • Patent number: 6139620
    Abstract: A method of manufacturing a calcium silicate board having a bulk specific gravity of approximately 0.5 to 0.8, which method achieves a decrease in the bulk specific gravity and an increase in the matrix strength of the board without impairing productivity, and the calcium silicate board obtained by this method. The method is characterized in that a material slurry comprising 5 to 30 wt % of calcium silicate hydrate slurry as a solid component, 17 to 50 wt % of calcareous material, 13 to 45 wt % of silica containing material, 2 to 8 wt % of fiber material, and 5 to 40 wt % of inorganic fillers is formed through conventional processes and the obtained molded body is subjected to a hydrothermal reaction in a pressure container.
    Type: Grant
    Filed: February 18, 1998
    Date of Patent: October 31, 2000
    Assignee: ASK Corporation
    Inventors: Seishiro Suzuki, Masato Sakiyama, Takuya Asami, Tomoki Iwanaga, Yasuhide Oshio, Shigemitsu Shiromoto, Toru Sugiyama, Masaaki Oda
  • Patent number: 6123878
    Abstract: The present invention has as its object self-supporting, highly porous molded parts produced by the methods of powder metallurgy from solids, processes for their production, and the use of the molded parts obtained in accordance with the invention.
    Type: Grant
    Filed: July 15, 1996
    Date of Patent: September 26, 2000
    Assignee: Cerasiv GmbH
    Inventors: Alwin Nagel, Dirk Rogowski
  • Patent number: 6123882
    Abstract: A fiber reinforced thermoplastic resin sheet which has no warpage, higher fiber orientation or randomized fiber orientation, manufactured by supplying a dispersion containing reinforcing fibers and a thermoplastic resin from an inlet onto a moving endless mesh belt and by continuously forming a web in the shape of a sheet while subjecting the dispersion to suction and filtration, is disclosed. The method and apparatus of manufacturing the same by means of controlling the speed ratio and the distribution of the suction amount of the aqueous medium are also disclosed.
    Type: Grant
    Filed: August 19, 1996
    Date of Patent: September 26, 2000
    Assignee: Kawasaki Steel Corporation
    Inventors: Yuichi Uchida, Fumiaki Yoshikawa, Seiji Hanatani, Osamu Nishimura, Masahiko Kajioka
  • Patent number: 6103155
    Abstract: A fiber reinforced thermoplastic resin sheet which has no warpage, higher fiber orientation or randomized fiber orientation, manufactured by supplying a dispersion containing reinforcing fibers and a thermoplastic resin from an inlet onto a moving endless mesh belt and by continuously forming a web in the shape of a sheet while subjecting the dispersion to suction and filtration, is disclosed. The method and apparatus of manufacturing the same by means of controlling the speed ratio and the distribution of the suction amount of the aqueous medium are also disclosed.
    Type: Grant
    Filed: January 12, 1999
    Date of Patent: August 15, 2000
    Assignee: Kawasaki Steel Corporation
    Inventors: Yuichi Uchida, Fumiaki Yoshikawa, Seiji Hanatani, Osamu Nishimura, Masahiko Kajioka
  • Patent number: 6103179
    Abstract: The invention relates to a method and an arrangement for manufacturing a fiber product. The method and the process are characterized in that a first male mold (6) is immersed in stock in a molding tank (2a). By means of a vacuum, fibers are induced to form a fiber layer of predetermined thickness on the male mold (6). The male mold (6) is thereafter removed from the molding tank (2a) and a female mold (8) is brought under force against the male mold (6) in order to express the stock water, following which the fiber product (P) is transferred to the female mold (8). A second male mold (10) is brought under force against the female mold (8) so that the fiber is subjected to pressing in order to increase the dry solids content of the fiber product and give this a predetermined external structure, following which the fiber product (P) is released and subjected to final drying under the effect of microwave or IR radiation.
    Type: Grant
    Filed: June 12, 1998
    Date of Patent: August 15, 2000
    Assignee: Celtec Development AB
    Inventor: Johan Peter Larsson
  • Patent number: 6083447
    Abstract: An apparatus and method for molding articles from a fibrous slurry. The apparatus comprises a forming die manufactured from a water insoluble, porous, relatively rigid and easily shaped material having molding surface shaped to the contour of the article to be molded, a vacuum vessel for receiving the forming die, and an opening through the vacuum vessel for communicating with a vacuum means for applying suction through the forming die to draw the slurry against the molding surfaces to form a fiber layer having the configuration of the article to be molded.
    Type: Grant
    Filed: June 17, 1997
    Date of Patent: July 4, 2000
    Assignee: Cin-Made Packaging Group, Inc.
    Inventor: Todd Thomas Turner
  • Patent number: 6077467
    Abstract: A process for making an artificial mineral or ceramic fiber log representation having areas of enhanced thermal texturing that can be used in gas fireplaces to simulate the burning of real wood logs. The process uses a screen mold having simulated wood pattern elements to impart a realistic exterior surface to the artificial log and thermal reactive textured surface areas applied to said screen mold. A slurry of mineral fibers is injected under pressure into the mold forcing excess water therethrough leaving the fibers impinged within the mold. The log thus formed is dried in an oven and processed for additional decorative coatings.
    Type: Grant
    Filed: October 5, 1999
    Date of Patent: June 20, 2000
    Inventor: Wayne Sinsley
  • Patent number: 6053998
    Abstract: A method of manufacturing a rust-preventing cover in which sufficient strength during mounting is ensured and which can be easily removed when not needed. The method of manufacturing a rust-preventing cover is carried out by a WFM manufacturing method rather than a conventional DFM manufacturing method. A mixed aqueous solution having paper fibers as a main material thereof is stored in a water tank. A porous rust-preventing cover mold is immersed therein. Then, the mixed aqueous solution is sucked by a vacuum pump. In this way, a paper fiber surface layer, which later becomes a rust-preventing cover, is formed on a surface of a mold main body of the rust-preventing cover mold at portions to which masking has not been applied. By adjusting a suction time of the vacuum pump, a rust-preventing cover of an arbitrary thickness which corresponds to a thickness required during mounting can be obtained.
    Type: Grant
    Filed: January 22, 1997
    Date of Patent: April 25, 2000
    Assignees: Toyota Jidosha Kabushiki Kaisha, Nihon Sekiso Industries Co., Ltd.
    Inventors: Makoto Nitta, Haruyuki Yamazaki
  • Patent number: 6015513
    Abstract: A method of manufacturing disposable, single-use lipstick samplers by means of a dipping process. In a preferred form, a reservoir containing molten lipstick wax material is provided, and a spindle which is disposed above the reservoir is advanceable toward and retractable away from the reservoir. A plastic cup-shaped form having an apertured tip is applied to the spindle, which is thereafter advanced so as to submerge the tip of the form into the molten liquid wax material. The spindle and coated form are then removed from the reservoir, and a vacuum is applied through the spindle to the aperture of the tip of the form, so as to draw lipstick wax material therefrom and into the interior of the spindle. The form is allowed to cool so as to solidify the wax, and thereafter is fitted with a cover, removed, and suitably packaged.
    Type: Grant
    Filed: June 10, 1998
    Date of Patent: January 18, 2000
    Assignee: Charles Chang
    Inventors: Robert J. Sheffler, Charles Chang
  • Patent number: 6013214
    Abstract: In a filter manufacturing method, during a time period from the start of the suction of the slurry to a point in time when fibers in the slurry accumulate on the outer peripheral surface of the protector to a prescribed thickness, the protector and its leg portions are held spaced away from each other. The leg portions are moved toward the protector so that the leg portions are disposed at a position spaced by a uniform distance from the outer peripheral surface of the protector and the suction operation is continued. Thus, the slurry containing the fibers therein can be easily caused to flow deeply into recess portions of a fin-like portion with no fiber being caught between the protector and the leg portions, thus reducing non-walled portions.
    Type: Grant
    Filed: November 13, 1997
    Date of Patent: January 11, 2000
    Assignee: Denso Corporation
    Inventors: Satoshi Inukai, Ichihiro Kato, Takeharu Maekawa
  • Patent number: 6013215
    Abstract: A method of compression-molding a slurry of a hydraulic inorganic material such as cement or slag, a light-weight aggregate, a reinforced fiber material and other filler material kneaded with water so as to manufacture an inorganic molded product. The slurry is put into a molding frame having a filtering cloth placed over the bottom surface thereof and is then compression-molded in the molding frame by using a molding die while it is suction-dehydrated from on both sides of the molding die surface and the filtering cloth surface. The molding die has a number of vent holes for sucking-dehydration each of which vent holes comprises a small-diameter hole and a large-diameter hole continuous therewith.
    Type: Grant
    Filed: March 10, 1998
    Date of Patent: January 11, 2000
    Assignee: Mitsui Wood Systems, Inc.
    Inventors: Yoshimi Iwamoto, Kiyohisa Kitagawa, Kazuhiro Kurihara, Masahiro Hirao
  • Patent number: 6004493
    Abstract: A mineral fiber mat is formed from a slurry of a known fiber material and a binder in a vacuum mold. The mold includes a porous screen through which a vacuum is drawn to remove water from the slurry while leaving the mat on top of the screen. A cover is pressed down on the mat under the vacuum. The fiber mat or layer is formed to include a simulated surface, such as tree bark, or a brick wall. To form a hollow log the uncured layer is placed over a core to provide a partial enclosure around the core that is of a sufficient size to permit a gas burner to be placed in the enclosure and hidden from view. Panels that are to be used flat are cured while held flat.
    Type: Grant
    Filed: September 2, 1997
    Date of Patent: December 21, 1999
    Assignee: Hussong Manufacturing Co., Inc.
    Inventor: Dudley D. Hussong
  • Patent number: 5989473
    Abstract: A molding process in which a material with an open cell, porous structure 10 is placed, aligned or supported inside a suitable enclosed holding device. Another molding material 20 is subsequently injected into the said holding device while gas and/or pressure is sequentially applied to the said holding device, causing a synergistic interaction and joining between the said materials to take place. During the processing phase, gas is evenly dispersed throughout the porous core, effectively equalizing cavity pressure and permitting an even flow pattern to exist, encapsulating or sandwiching the said porous structure, thus forming a composite material with physical properties which are substantially greater than the individual components.
    Type: Grant
    Filed: July 29, 1997
    Date of Patent: November 23, 1999
    Assignee: David G. Haverty
    Inventor: David G. Haverty
  • Patent number: 5945049
    Abstract: A method of vacuum forming of aqueous, fibrous slurries and products produced thereby are disclosed. The method entails forming an aqueous slurry of ceramic fiber, cationic starch and silica sol. The silica has, based on total weight of the sol, about 50% silica having a particle size range of from about 7 nm to about 200 nm and a specific surface area of about 100 m.sup.2 /gm to about 10 m.sup.2 /gm. The slurry is passed through a porous screen under a vacuum pressure deposit the solids content onto the screen to produce high strength products.
    Type: Grant
    Filed: November 17, 1997
    Date of Patent: August 31, 1999
    Assignee: Wes Bond Corporation
    Inventor: John Vandermeer
  • Patent number: 5900119
    Abstract: The present invention comprises a method for forming a biodegradable, thin-walled packing chip from an aqueous pulp of recycled newsprint by contacting the pulp with a mold comprising: (a) a solid core having substantially the shape of the article to be formed and having a minimal number of holes through which air may be evacuated and (b) an air permeable, stretchable fabric which covers the exterior of the core. After forming the chip on the fabric through application of a vacuum, the fabric is separated sufficiently from the solid surface to cause release of the chip from the fabric. The dried packing chip has enhanced packing qualities, is environmentally friendly and provides a significant new use for recycled newsprint.
    Type: Grant
    Filed: October 9, 1996
    Date of Patent: May 4, 1999
    Assignee: E-Tech Products, Inc.
    Inventors: John Lawrence Goers, Thomas S. Warda, William H. Oliver
  • Patent number: 5866062
    Abstract: A shaped body of amorphous silicon dioxide, which has a chemical purity of at least 99.9% and a cristobalite content of at most 1% and which is impermeable to gas, is known. To provide shaped bodies of amorphous silicon dioxide which have a high precision, which can be small or large in size and of simple to complicated shape, which have a chemical purity of at least 99.9%, are impermeable to gas above wall thicknesses of 1 mm, which have a high cold flexural strength, low thermal conductivity and low radiation of heat, which are thermal shock resistant and can be exposed repeatedly or also long-term to temperatures in the range from 1000.degree. to 1300.degree. C. and which can be welded in a sharply delineated manner without spreading joins and which have a low spectral transmission from the ultraviolet to the middle infrared spectral region, the shaped body is opaque, contains pores, at a wall thickness of 1 mm has a direct spectral transmission which is virtually constant in the wavelength range from .
    Type: Grant
    Filed: March 11, 1997
    Date of Patent: February 2, 1999
    Assignee: Heraeus Quarzglas GmbH
    Inventors: Stephan Moritz, Wolfgang Englisch
  • Patent number: 5853634
    Abstract: A building material and a method for its manufacture is provided wherein cellulosic, polymeric and acid wastes are treated and combined to produce a building panel which demonstrates low weight, high strength and good fire resistance.
    Type: Grant
    Filed: August 13, 1997
    Date of Patent: December 29, 1998
    Inventor: Orville M. Ontkean
  • Patent number: 5833805
    Abstract: A unique method of producing a reinforced moulded sheet having one continuously planar face and having a plurality of ribs or thickened areas which provide a corresponding plurality of prominences directed outwardly of the other face, said prominences having predetermined shapes, locations and dimensions to serve as reinforced areas for said sheet. And a series of new or improved composite hollow moulded panels, each comprised of at least two co-extensive elements, each of said panels being reinforced and improved by the provision of at least one of said reinforced moulded sheets as an external element of said at least two co-extensive elements, the ribs or thickened areas of said reinforced sheet being glued internally of said hollow panel to the adjacent co-extensive element thereof.
    Type: Grant
    Filed: November 19, 1996
    Date of Patent: November 10, 1998
    Inventor: Roy William Emery
  • Patent number: 5817262
    Abstract: A process is described for making a gypsum board having improved water resistance. The resulting gypsum board products are also described. The process comprises adding an aqueous siloxane emulsion to an aqueous slurry of a calcium sulfate material and host particles, where the siloxane emulsion is stable under the condition in which the slurry is maintained. The process further includes passing said siloxane containing slurry onto a flat porous forming surface to form a filter cake; removing a substantial portion of the water from the filter cake through the porous surface; pressing the filter cake to form a board and remove additional water; and drying the board to remove the remaining free water and to cause the core of the board to reach a temperature sufficient to cure the siloxane.
    Type: Grant
    Filed: December 20, 1996
    Date of Patent: October 6, 1998
    Assignee: United States Gypsum Company
    Inventor: Mark H. Englert
  • Patent number: 5800875
    Abstract: A process for making a mineral fiber artificial log that can be used in vented and unvented gas fireplaces, fireplace inserts, and free-standing gas fire room heater to simulate the appearance of a real burning log. The process utilizes a screen mold formed from a pattern that can be made to give the desired exterior configuration and size for the formed log. The screen mold is placed in an outer porous jacket and then in a vacuum chamber. A slurry of the formulation containing mineral wool fibers, a suitable high temperature binder, and water is drawn into the mold while contained in the vacuum chamber, so liquid is drawn through the mold and mineral fibers are trapped in the mold. The log is formed to the size and shape of the mold. Once molded, the log is removed from the mold, dried in an oven, treated with a suitable rigidizing exterior coating, and again oven dried. The log is painted suitably, dried again, and packaged for sale.
    Type: Grant
    Filed: December 8, 1995
    Date of Patent: September 1, 1998
    Assignee: Hussong Manufacturing Co., Inc.
    Inventor: Dudley D. Hussong
  • Patent number: 5776392
    Abstract: A method for producing insulating panels based on mineral fibers and paper fibers is disclosed. The panels are formed by preparing a suspension of mineral fibers, binders and conventional additives in water, forming the insulating panel by applying the slurry on a screen, drying and consolidating the insulating panel. Due to the use of surface active siloxanes, which contain betaine or quaternary groups, a more rapid and better dewatering of the filter residues, which are intended for the drying process, is attained.
    Type: Grant
    Filed: March 14, 1997
    Date of Patent: July 7, 1998
    Assignee: Th. Goldschmidt AG
    Inventor: Manfred Schmuck
  • Patent number: 5753163
    Abstract: A method of producing a self-sustaining body of refractory boride from the group consisting of the borides of titanium, chromium, vanadium, zirconium, hafnium, niobium, tantalum, molybdenum and cerium. This body includes a refractory boride and a dried colloid from the group consisting of colloidal alumina, silica, yttria, ceria, thoria, magnesia, lithia, monoaluminium phosphate and cerium acetate and is obtained from a slurry of the refractory boride in one or more of said colloids by casting the slurry on a porous plaster layer, and drying the cast slurry by draining through the plaster, or by pressing/drying. Subsequently, the dried body is subjected to heat treatment to bond the refractory boride in the dried colloid. The bodies are useful as components of aluminium electrowinning cells.
    Type: Grant
    Filed: August 28, 1995
    Date of Patent: May 19, 1998
    Assignee: Moltech. Invent S.A.
    Inventors: Jainagesh A. Sekhar, Jean-Jacques Duruz, Vittorio De Nora
  • Patent number: 5746954
    Abstract: An improved process for forming a thin, durable coating of a perfluorosulfonated, salt- or acid-form ionomer on a selected substrate, which comprises contacting the substrate with an aqueous, surface active dispersion of the thermoplastic, sulfonyl fluoride precursor of the perfluorosulfonated, salt- or acid-form ionomer, contacting the dispersion-wetted substrate with a salt solution or a strongly ionizing acid solution of a sufficient ionic strength to cause a thin, adherent coating of the precursor particles in said dispersion to be formed on the substrate, then removing excess dispersion and excess salt or acid solution, annealing the coated substrate at an elevated temperature and thereafter converting the precursor to the desired acid or salt form ionomer.
    Type: Grant
    Filed: September 7, 1995
    Date of Patent: May 5, 1998
    Assignee: The Dow Chemical Company
    Inventor: Robert E. Aikman, Jr.
  • Patent number: 5741388
    Abstract: The apparatus according to the invention for the slip casting of ceramic parts has essentially a bell which is arranged on a holding device and is vertically displaceable and a plurality of mold parts. The latter together with a base part form a mold which stands on a rigid plate. During operation of the apparatus, the mold and the bell covering it form an intermediate space in which are arranged a plurality of inflatable inflatable bladders air pockets which can cooperate in order to clamp the mold and prevent it from moving during the entire casting process. For this purpose, the inflatable bladders are connected to a compressed air source. In addition, a slip supply pipe which communicates with the stated compressed air pipe leads into the mold cavity of the mold, so that pressure equilibration between the mold cavity and the inflatable bladders can be brought about by means of the apparatus according to the invention.
    Type: Grant
    Filed: June 29, 1995
    Date of Patent: April 21, 1998
    Assignee: Keramik Holding AG Laufen
    Inventors: Thomas Gerster, Gerold Spieler, Konrad Dublin, Stefan Bitter
  • Patent number: 5700409
    Abstract: A method of molding at article capable of enduring temperatures of at least 1250.degree. F. without deformation or deterioration. High temperature resistant fibers cut to a length of one eighth of an inch are mixed with water to create a pool of slurry. A flexible mold having an article-forming cavity affixed to a suction chamber having means for injecting slurry into the cavity and means for the flow of liquid out of the cavity when the flexible mold and the suction chamber are under vacuum to create within the mold cavity an article of compacted high temperature resistant fibers. The mold is flexed causing the molded article to be released from the cavity within the mold.
    Type: Grant
    Filed: November 13, 1996
    Date of Patent: December 23, 1997
    Inventor: Arthur A. Corry
  • Patent number: 5693274
    Abstract: The present invention relates to a manufacturing method of preform for composite material of automobile, in particular, to an economical and easy mass-production manufacturing method of preform including the steps of manufacturing a wet sheet by pouring a suspension prepared by adding inorganic binder, organic binder and cohesion agent to reinforced fiber, into vacuum suction equipment, and forming the sheet into a cylindrical shape with cylindrical press and deforming the sheet form before drying.
    Type: Grant
    Filed: November 13, 1995
    Date of Patent: December 2, 1997
    Assignee: Hyundai Motor Company
    Inventor: Jun-Su Kim
  • Patent number: 5662944
    Abstract: A sealing assembly for molds used for casting sanitary fixtures including at least one female die which is capable of defining the molding cavity of the item as well as at least one male die which is designed to be introduced into and withdrawn from said molding cavity, and which is provided with a mating surface capable of interacting with an associated mating surface of at least one female die. The sealing assembly includes a tubular elastic body of annular shape which is placed within a peripheral groove recessed in the mating surface of at least one male die, and which is connected to an assembly capable of alternately deflating and inflating said elastic tubular body so that the latter assumes a first transverse shape which is completely accommodated within the corresponding transverse-shape of the groove, and a second transverse shape which projects beyond the mouth of the groove, where it comes to rest against the facing associated mating surface of at least one female die.
    Type: Grant
    Filed: October 5, 1995
    Date of Patent: September 2, 1997
    Assignee: American Standard Inc.
    Inventor: Toffolo Renato Petrucco
  • Patent number: 5647951
    Abstract: An agricultural growth control device (2) includes an organic, biodegradable, layer (6) and an impermeable sheet (4) affixed to the underside of the organic layer to form a unitary ground collar (8). The ground collar defines at least one hole (10) to allow growth of a plant (P) therethrough while suppressing the growth of weeds or grass around the plant. The impermeable sheet is preferably formed from a slurry of cellulosic fiber and water and the organic layer is preferably formed from a slurry of fiber, water and finely chopped organic material, such as straw, manure, leaves or almond wood chips. The fiber and chopped organic material provide a semi-rigid mulch cover for suppressing weeds around the plant. The mulch cover is easily positioned around the plant and, once it is so disposed, will be relatively impervious to severe weather, such as heavy rainfall and winds. The chopped organic material, particularly almond wood chips, enhance the appearance of the mulch cover.
    Type: Grant
    Filed: May 7, 1996
    Date of Patent: July 15, 1997
    Inventor: John Bayer
  • Patent number: 5611980
    Abstract: An apparatus for slip casting includes a pouring pipe for supplying slip, to which each mold is connected by way of a pouring hose having a pouring valve. A slip discharge pipe is provided in the vicinity of the pouring pipe. The pouring pipe and the slip discharge pipe are connected by a by-pass pipe which includes a rising pipe, a traverse pipe, a connecting pipe and an atmosphere pipe. Slip is fed from the pouring pipe to each mold. After a body is formed with a predetermined thickness in each mold 1, pressurized air is fed to the slip discharge spaces to discharge surplus slip to the slip discharge pipe. The height of the rising pipe is set so that the pressure of discharging the surplus slip and the head pressure of the slip within the rising pipe balance each other when the surplus slip is discharged to the slip discharge pipe. This allows the pressure within the slip discharge spaces to be stabilized.
    Type: Grant
    Filed: June 5, 1995
    Date of Patent: March 18, 1997
    Assignee: Toto Ltd.
    Inventors: Mamoru Eto, Masaharu Yasui, Hidetoshi Ohtani, Taiichi Aso
  • Patent number: 5580505
    Abstract: Unusually strong and highly perforated plates are formed by pressurized filtration of a suspension of chopped ceramic fibers in an aqueous dispersion of colloidal alumina or colloidal silica through a mold having a perforated filter base and a pin support base having pins that extend through and beyond the perforations of the filter base. Pressurized filtration is preferably conducted by applying vacuum on the downstream side of the mold. When the layer of chopped fibers deposited on the perforated filter base has the desired thickness, filtration is stopped. The perforated filter base and pin support base are moved apart to retract the pins from contact with the perforated layer of chopped fibers which is transferred to a drier for conversion into a strong perforated plate.
    Type: Grant
    Filed: June 6, 1995
    Date of Patent: December 3, 1996
    Assignee: Alzeta Corporation
    Inventor: Martin G. Carswell
  • Patent number: 5569423
    Abstract: A process for making light, fibrous heat insulating materials wherein the silica fibers used in the process are quartz fibers formed by spraying quartz. The fibers are predispersed in water until there is formed a homogeneous flowing slurry from which is molded a green fibrous block, with simultaneous partial removal of water. This green fibrous block is dispersed in water and mixed with an aqueous emulsion containing an organosilicon binder, a boron-containing sintering adjuvant and a surface-active agent. A green billet is molded from the suspension thus obtained, a portion of the water being simultaneously removed by suction. The green billet is compressed until the desired height is obtained and then it is dried, in the compressed state, at a temperature of up to 300.degree. C. The billet is released from pressure and fired at high temperature.
    Type: Grant
    Filed: February 17, 1995
    Date of Patent: October 29, 1996
    Assignees: Aerospatiale Societe Nationale Industrielle, VIAM - All Russian Institut of Aviation Materials
    Inventors: Ludmila V. Belunova, Vladimir N. Gribkov, Andre I. Chernyak, Galina T. Mizyurina, Oleg A. Mordovin, Elena E. Mukhanova
  • Patent number: 5556587
    Abstract: A porous mold for manufacturing ceramics comprises a porous mold body including a mold central portion and a mold outer peripheral portion and having mold surface of a shape corresponding to an outer shape of a suspension insulator and other similar ceramics to be manufactured having a small diameter hollow cylindrical central core portion with a closed head portion and a large diameter shed portion extended from the core portion in a radial direction, wherein water absorption percentage of a mold surface side portion of the mold outer peripheral portion is larger than that of the mold central portion. The water absorption percentage of the mold surface side portion of the mold outer peripheral is 20-30%, and that of a mold head portion of the mold central portion is 10-20%. A difference of the water absorption percentage between the mold surface side portion of the mold outer peripheral portion and the mold head portion is 5-20%.
    Type: Grant
    Filed: May 26, 1995
    Date of Patent: September 17, 1996
    Assignee: NGK Insulators, Ltd.
    Inventors: Yoshio Funahashi, Masao Kogai, Katsura Kasugai, Hideki Kato
  • Patent number: 5536533
    Abstract: A process for producing fibrous composite materials from feed stock formed reliminarily from a gypsum binder and chopped cellulose fibers, and saturating the mixture with water to the extent of at least 1.2 times its normal hydrated state, and beating the material to provide a fleece that is then spread on a flat surface and subjected to pressure for a sufficient length of time to drive out a substantial portion of the moisture from the product. The compression step is carried out long enough to achieve a bulk density of approximately 9/10 the dry bulk density of the components prior to hydration.
    Type: Grant
    Filed: March 19, 1993
    Date of Patent: July 16, 1996
    Assignees: Fraunhofer-Gesellschaft zur Forderung der angewandten Forschung e.V., Goldbach GmbH
    Inventors: Heinz Sattler, Volker Thole, Sebald Pallhorn, Bernhard Schmelmer
  • Patent number: 5514316
    Abstract: A ceramic article such as a sanitary pottery ware is produced by slip casting using a porous composite mold. A green ceramic body of a part such as a trap of sanitary ware is separately formed in advance by, for example, slip casting. The green ceramic body is placed in the mold cavity of the porous composite mold. Then, a slip as the material of the main part of the sanitary ware is supplied into the mold cavity to form deposit integral with the green ceramic body, whereby an integral sanitary ware is obtained by slip casting.
    Type: Grant
    Filed: May 28, 1993
    Date of Patent: May 7, 1996
    Assignee: Toto Ltd.
    Inventors: Tatsuhiro Kosugi, Mitsuru Saka, Akio Matsumoto, Minoru Inoue, Toshiaki Nogami, Takazi Naotsuka, Masao Yamasaki, Hiroyuki Suzuki
  • Patent number: 5498383
    Abstract: A slip casting process and apparatus for producing parts with graded properties across the thickness of the body of the parts. A number of slips is combined at a varying predetermined ratio and passed continuously through a casting mold between its inlet and outlet. The process can be carried out under elevated pressure. The casting mold can be positioned vertically or horizontally.
    Type: Grant
    Filed: May 18, 1994
    Date of Patent: March 12, 1996
    Assignee: National Research Council of Canada
    Inventors: Basil Marple, Jean Boulanger
  • Patent number: 5489408
    Abstract: A method for producing ceramics reinforced with three-dimensional fibers, which entails: a) setting a filter plate in contact with one surface of a three-dimensional fiber preform and a porous metallic plate in contact with said filter plate; b) setting a slurry in contact with a surface of the preform opposite to the one surface; c) exerting pressure on the slurry and, at the same time, subjecting the preform to vacuum aspiration through the filter plate, thereby obtaining a composite having an impregnated preform, the impregnation being effected in a single step; d) heating the composite; and e) firing the resultant composite.
    Type: Grant
    Filed: March 3, 1994
    Date of Patent: February 6, 1996
    Assignees: Agency of Industrial Science & Technology, Ministry of International Trade & Industry
    Inventors: Kikuo Nakano, Akira Kamiya
  • Patent number: 5474724
    Abstract: This method is to mold a ceramic port liner from a ceramic material by drain casting. The slurry of the ceramic material is subjected to a pressure of 5 kgf/cm.sup.2 or higher in a mold. The method is also to mold under the condition that the mold is transformed by reducing a certain volume within the range of 0.3%-1.0% in the direction of constriction applied. According to this method, a ceramic port liner without deformation and unevenness in thickness can be obtained.
    Type: Grant
    Filed: May 31, 1994
    Date of Patent: December 12, 1995
    Assignee: NGK Insulators, Ltd.
    Inventor: Kaname Fukao
  • Patent number: 5474635
    Abstract: A method of joining adjacent, non-coplanar, fiber reinforced composite structures includes machining a plurality of serrations (4) into an edge (6) of a consolidated first fiber reinforced composite structure (2) such that reinforcing fibers continue from a main body (14) of the first fiber reinforced composite structure (2) into the serrations (4). One or more reinforcing fiber plies (16) are then laid up around the serrations (4) to form an unconsolidated second structure such that the serrations (4) protrude through at least one reinforcing fiber ply (16). In addition to the one or more reinforcing fiber plies (16), the unconsolidated second structure also includes a matrix precursor. Sufficient heat and pressure are applied to the unconsolidated second structure and the serrations (4) to consolidate the second structure into a fiber reinforced composite structure (8).
    Type: Grant
    Filed: March 7, 1994
    Date of Patent: December 12, 1995
    Assignee: United Technologies Corporation
    Inventors: Bernarr A. Jacob, John E. Holowczak, Philip H. McCluskey, Willard H. Sutton
  • Patent number: 5468135
    Abstract: A process for manufacturing containers that are suitable for containing materials that are to be heated by microwave radiation or other heating equipment includes making a dilute liquid dispersion of quartz and/or glass fibers (very preferably microfibers), depositing them on the interior of a permeable female mold or form, from the dispersion by way of a pressure differential across the female mold, with the liquid passing through the mold, moving a male mold or form which matches the female mold, into and against the container in the female mold, terminating the pressure differential across the female mold, applying a pressure differential across the male mold to release the container from the female mold and press it against the male mold exterior, withdrawing the male mold, with the container held to it, releasing the container from the male mold and sintering the container, to make it form retaining.
    Type: Grant
    Filed: October 4, 1993
    Date of Patent: November 21, 1995
    Assignee: CEM Corporation
    Inventor: James E. Thomas
  • Patent number: 5451152
    Abstract: A porous mold for manufacturing ceramics comprises a porous mold body including a mold central portion and a mold outer peripheral portion and having mold surface of a shape corresponding to an outer shape of a suspension insulator and other similar ceramics to be manufactured having a small diameter hollow cylindrical central core portion with a closed head portion and a large diameter shed portion extended from the core portion in a radial direction, wherein water absorption percentage of a mold surface side portion of the mold outer peripheral portion is larger than that of the mold central portion. The water absorption percentage of the mold surface side portion of the mold outer peripheral is 20-30%, and that of a mold head portion of the mold central portion is 10-20%. A difference of the water absorption percentage between the mold surface side portion of the mold outer peripheral portion and the mold head portion is 5-20%.
    Type: Grant
    Filed: December 16, 1993
    Date of Patent: September 19, 1995
    Assignee: NGK Insulators, Ltd.
    Inventors: Yoshio Funahashi, Masao Kogai, Katsura Kasugai, Hideki Kato
  • Patent number: 5447666
    Abstract: A method of forming a burner for a gaseous mixture of fuel and an oxidant mixes a random mix of refactory fibers, the fibers being predominantly alumina and silica, and then forms a burner body from the fiber mix. Passageways are then formed in the burner body by perforating the burner body with pins. This is achieved by providing comb assemblies each having a plurality of pins, which are pressed into the body from either side and then removed, and the body is then indexed for further sets of holes to be formed. The burner body can be treated with colloidal silica and subsequently baked to bond and preshrink the fibers, both before and after the forming of ports or passageways.
    Type: Grant
    Filed: November 19, 1993
    Date of Patent: September 5, 1995
    Assignee: Canadian Gas Research Institute
    Inventor: Robert D. LaFontaine
  • Patent number: 5441681
    Abstract: A process for manufacturing containers for holding heated materials includes the steps of depositing a dispersion of fibers in a liquid onto the interior of a liquid permeable female mold, removing liquid from the deposited dispersion by applying a pressure differential across the mold, with the higher pressure being in the interior of the mold, moving a liquid permeable male mold into the female mold, terminating the pressure differential across the female mold, applying a pressure differential across the male mold, with the higher pressure being on the exterior thereof, to press the container onto the male mold exterior, withdrawing the male mold from the female mold, with the container being held to the male mold, and releasing the container from the male mold.
    Type: Grant
    Filed: October 4, 1993
    Date of Patent: August 15, 1995
    Assignee: CEM Corporation
    Inventor: James E. Thomas