Abstract: A method for the production of fibrous plaster boards for which a suspension is prepared from wet-digested fiber material and calcium sulfate dihydrate, the suspension is formed into a board with removal of water, and the dihydrate is recrystallized with heating at atmospheric pressure to a hemihydrate which is subsequently converted back into the dihydrate by the addition of water. For this purpose, the suspension is dewatered from a water content of about 300 to 600% to one of about 30 to 40% in dewatering equipment, the dihydrate is recrystallized in air and without pressure to the beta form of the hemihydrate and the water, required for setting, is aspirated through the board by suction.

Abstract: A method for making a sheet of resistive material having randomly oriented conductive fibers with a density of approximately 50 to 300 milligrams per square meter. The fibers are weighed, mixed with a solvent, contained in a non-turbulent state. The solvent is withdrawn under pressure through a porous film and backing. A sticky sheet material is placed in contact with the film for transferring the fibers from the film to the sheet.

Abstract: A process for casting slip into a ceramic product using at least one unique casting mold. The casting mold is formed of a plurality of separate porous mold parts, each of which has a fluid-tight outer face, an inner molding surface and a plurality of channels therein. The mold parts are combined so that the inner molding surfaces define a molding cavity in the mold. The casting mold is positioned within a pressure container such that a space is established surrounding the casting mold within the pressure container. This space is in fluid communication with the molding cavity of the 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: 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 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 producing sulfur plates comprises producing an aqueous mixture by mixing and agitating sulfur powder, inorganic powder, fibers and water, filtering the aqueous mixture to form plates, molding the plates while dewatering, curing and drying the plates, and heating the plates at a temperature higher than the melting point of the sulfur. The sulfur plates attain a desired strength in a short time and are free from any cracks and have an excellent acid resistance.

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 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: Device for the continuous manufacture of manufactured articles reinforced with mixtures of hydraulic binders and consisting of:a conveyor belt;a plurality `A` of process stations for the formation of superimposed thin and uniform layers of a net of a hydraulic binder mix, each station consisting of:a feeder of the reinforced net 4;a wetting and degassing device 5 of the net 4;a means 2 for metering the binders mix;a section 7 for feeding and laying the net 4 on the conveyor belt 1;compacting elements 16;a means 6 for the extraction of water during the compacting state; anda second metering device 2' for the hydraulic binders mix;a levelling and sizing station 23;a final water-extracting station 26;a pressing station 27;a longitudinal and cross-cutting station 35, and a gathering station 36 for the produced plates.

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 process and apparatus for degassing high-boiling liquids, especially polymer melts and solutions, to remove low-boiling liquids and gases as impurities by feeding the polymer melt or similar high-boiling liquid under expansion into the feed chamber of a gear wheel pump to flow downwardly and only partially fill this feed chamber, preferably so as to form a thin layer or pool of the melt atop the upper crown surfaces of the gear wheels. The impurities are withdrawn separately through a suction outlet and the liquid level of the melt is preset and maintained by suitable regulating apparatus adapted to control the speed of the gear wheels and/or the speed at which melt is delivered into the pump feed chamber.

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: 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 and apparatus for solidifying a powdered cosmetic composition in a vertically held elongated hollow container to form a stick-shaped powdered cosmetic. A dispersion of the powdered cosmetic composition in a liquid phase is filled in the container. Pneumatic pressure is applied to the upper surface of the dispersion, and at the same time, the liquid phase contained in the dispersion is removed from below a screen placed at the lower end of the container.

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 ceramic article, after molding and while in a porous condition, is surface hardened not by being placed in a kiln and exposed to high temperatures, but is operatively arranged to have a combustible gas-air mixture pumped under appropriate pressure through the porosity of its molded shape. The exiting gas-air mixture is, according to the present invention, ignited, and this causes the exterior surface of the molded shape to incandesce, with the result that the external surface hardens without causing internal stresses within the article, and also avoids causing differential thermal expansion between the exterior surface and the fiber substance of the article adjacent thereto.

Abstract: In a process for manufacturing a whisker preform for a composite material, a dispersion of a whisker in water or an organic solvent is passed through a sieve and is filtered, and a residual wet whisker cake is dried, with or without prior compression, to produce a cake having a desired density based upon the relationship between the weight of the whisker in the dispersion and the volume of the residual whisker cake after filtration.

Abstract: A method for manufacturing shaped articles of organic substance is disclosed, which comprises mixing an organic substance as raw material with a binder, filling a die with the resultant binder-containing mixture, compressing the mixture in a prescribed shape in the die, and forcing a gaseous curing agent through the compressed mixture thereby curing the binder in the mixture and consequently solidifying the compressed mass. This method enables shaped articles such as noise absorbers, heat insulation panels, and plate materials to be produced efficiently and inexpensively at low energy consumption by the use of an inexpensive die.

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: Disclosed in accordance with the invention is a method for fiberboard manufacture comprising the steps of steaming and grinding woodchips to obtain a wood pulp, using said wood pulp to prepare a slurry of wood pulp in water, mixing said slurry with a binder, a cure catalyst for the binder, a water-repellent additive, peat, and carbamide to obtain a mixture, casting said mixture and dewatering said mixture to obtain a mat, and compacting said mat to obtain fiberboard which is subjected to heat treatment, in which method the peat used has a moisture content of between 25 and 70 percent and the peat content in said mixture is between 2.5 and 50 percent by mass, with the ratio of absolutely dry peat to said binder equal to between 1.0-7:1.0, respectively, while the carbamide content in said mixture is between 0.2 and 2.0 percent by mass, with the ratio of said carbamide to said binder equal to between 0.02-1:1, respectively.

Abstract: A process is provided for continuously manufacturing plates containing an open net fibrillated polymeric film reinforcement. A net having a plurality of fibrillated polymeric film layers is unwound from a continuous reel, and the net is cut into pieces having a length approximately equal to a circumference of a forming roll for forming a plate to be manufactured. The net pieces are impregnated with a cement mix and then deposited onto a conveyor belt on which a cement mix layer has been previously deposited. After contacting the net with the cement layer, the net is subjected to vibration. A vacuum is applied to the net contacting the cement layer to remove excess water and to increase the compactness between the net and the cement layer.

Abstract: The invention relates to a process for the mass-production conversion of an inorganic and/or organic material, containing a liquid fraction of between 3 and 90% by weight, to a blank by means of core casting and/or hollow casing, the material being introduced into a cavity located between at least two porous mould portions and being dewatered in contact with the adjacent mould portions.

Abstract: A flexible, microporous, hydrophobic and oleophobic protective handcovering and a process for its manufacture. The process generally comprises the steps of immersing a fabric shell having the configuration of a human hand in a liquid slurry comprised of inorganic, reinforcing microfibers and a polymeric binding agent in the form of a continuous matrix and drawing a vacuum in the interior of the fabric shell to cause the binding agent and fibers from the slurry to be deposited on the outer surface of the shell. The resulting composite structure is then cured to set the matrix in the desired shape. A treating agent, preferably a fluorinated hydrocarbon, is applied to the composite structure in an amount sufficient to render the handcovering both hydrophobic and oleophobic.

Abstract: An apparatus for drain-casting a slip comprises a mold including at least two divisible mating mold portions to form a mold cavity, a slip tank, a pump, air compressors, suction pumps, valves and tubings to connect them accordingly, supporting means of the mold portions, and a moving stand to receive the molded article thereon. The mold portion includes an air-tight vessel and a filter member inside the vessel, the filter member contains a water-drainage means, and the drainage means is communicated with the outside of the vessel. One of the mold portions has a slip supply duct and one other mold portion has an overflow duct, which ducts are communicated with the outsides of the vessels.

Abstract: The present invention relates to the steel industry and involves methods for the use of slag in forming mineral wool.

Abstract: Off-size greenware (the product resulting from the initial gelation and filter pressing of calcareous and siliceous materials in an aqueous slurry) is recycled. The greenware is pulverized into a desirable size and combined with new calcareous and siliceous materials in the initial slurrying step. The slurry containing recycled greenware gels at an improved rate.

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: The installation comprises a rectangular, parallelepipedal, leaktight steam chamber (1) provided with a gate (2) on one of the short sides, inside which a tubular fixed mold (4) of perforated steel plate is attached at a distance from the walls of the chamber, the shape of the mold corresponding to the external shape of the panel to be obtained. A first set of fixed, parallel, perforated metal tubes (5), inside the mold (4), possesses lateral holes (9) for the passage of a second set of perforated or non-perforated metal tubes (10) firmly fixed to a movable external support (11), passing through one of the short walls of the steam chamber (1) and capable of moving perpendicular to the tubes (5) of the first set, passing through the latter. The chamber (1) is provided with inlet valves (13) for the partially expanded synthetic material, an inlet (14) for steam and an inlet (15) for a cooling fluid.

Abstract: This invention is concerned with the plaster industry and, more precisely, with the elimination of excess water in objects containing hydratable calcium sulphate and water.It offers to subject the said objects to a high efficiency thermic drying before the end of the hydration of the calcium sulphate, and to stop the said drying, while allowing enough water for the continuation of hydration to remain in the objects.It is applied, more specifically, to the manufacture of plaster board.

Abstract: This invention is directed to an apparatus and method for producing a continuously molded thermoplastic sheet from heat expandable granules in a heated zone within a molding channel. The disclosed invention includes introducing a predetermined amount of water into the molding channel to wet the granules either prior to or contemporaneously with the introduction of a hot gas into the granules to expand the granules into a continuous thermoplastic sheet. The water is drained from the channel subsequent to the expansion of the granules.

Abstract: The specification discloses a shell for luggage and the like comprising wood fibers, glass fibers, paper scrap, glass beads, and plastic resin. The mixture is blended with water to form a slurry, is vacuum formed and is then molded under heat and pressure.

Abstract: In a method of casting different types of concrete products without the need of using a curing chamber or an autoclave the concrete subsequent to mixing, is casted and externally and/or internally subjected to a vacuum treatment to have it de-watered and compacted. Then carbon-dioxide gas is supplied to the mass while maintaining a sub- or under-pressure in a manner such that the gas--as a result of the sub-pressure--diffuses into the capillaries formed in the concrete mass, to quickly harden the mass. In one embodiment (cf. FIG. 2)--in which the mass (1) is de-watered and compacted by means of a mat or plate (2) placed thereupon and exposed to a sub-pressure via a pipe or a line (5)--the carbon-dioxide gas is supplied (through line 6) via said mat or plate (2) while using the under-pressure prevailing in the mass. In another embodiment (cf. FIG.

Abstract: The present invention relates to a continuous process for manufacturing articles comprised of fiber-reinforced hydraulically bound material. A layer of the fiber-reinforcing and hydraulically bindable materials are placed on a first endless carrier while a second similar layer is formed on a second endless carrier. The layer formed on the second carrier is deposited on the layer formed on the first carrier by reversing the second carrier and the composite layer formed as a result is thereafter given the desired shape and is hardened.A number of fibrous network structures are used with the hydraulically bindable material and the two are formed into a layer with the networks distributed in it. Water is removed from that layer by suction, while on the second carrier a number of fibrous networks are likewise supplied to be formed into a layer comprised of the hydraulically bindable material with the networks distributed in it and water is also removed by suction from this layer.

Abstract: A method of producing cement mortar mouldings is provided. Cement mortar material is supplied onto a lower mould. The lower mould is then brought into a vertical alignment with an upper mould. The lower and upper moulds are pressed to each other to compress the cement mortar material which is, in turn, dehydrated by suction means. While maintaining the suction, the lower mould is separated from the upper mould to leave a moulding on the upper mould. This mould is placed on a conveyor for later processing.An apparatus for producing cement mortar mouldings is also provided. The apparatus comprises upper and lower moulds, suction means, mould actuating means, and conveyor means. The suction means is provided in association with the upper mould to assure both dehydration and holding of the molding manufactured from the compressed from the moulding material.

Abstract: A light-weight thick-walled unitary burner block adapted to embrace a burner installed in the wall of a high temperature furnace. The block is formed of spun refractory fibers accreted by vacuum deposition from an aqueous slurry.

Abstract: A high rate carbon cathode is made by mixing a carbon powder having a sure area of about 1000 square meters/gram with polytetrafluoroethylene and a sufficient amount of water to form a coherent mixture. The mixture is applied to an electrically conductive screen; the cathode formed while wet to an intermediate thickness, the cathode vacuum dried at about 100 degrees C., and the cathode cold compressed to obtain a final electrode porosity of greater than 80 percent. The cathode can be used in a lithium primary cell using a solution of an inorganic lithium salt in sulfuryl chloride as the electrolyte.

Abstract: A continuous process for manufacturing composite articles, such as thin hydraulically bound boards, which are reinforced with separate layers of a stretched, fibrillated, extended plastics net reinforcing material is disclosed. An aqueous suspension of cement or other material is applied onto and into the plastics network, dewatered, taken up and rolled into a composite cylinder until the desired thickness is reached. The cylinder is then cut axially, given the desired shape and cured.

Abstract: A cross flow filtration molding apparatus and method are disclosed which are particularly useful for forming complicated shapes from dispersions of particles in a liquid medium. Dispersion is pumped through a mold which has porous walls and a sufficient pressure differential is applied to drive a portion of the liquid medium through the porous walls which results in deposition of particles on the walls to form a shaped article. The shaped article may inherently have sufficient structural integrity, or it may be post-treated to provide additional structural integrity.

Abstract: A method of making molding compounds, and particularly sheet molding compounds, wherein the reactive monomers are mixed directly with high density inorganic fillers and other ingredients of a molding compound. The monomers are converted to a resin insitu that is in or approaching the B-stage, so that the material is handleable as a solid and is moldable. Because of the amount, type, and thermal conductivity of the fillers, the resinification can be done quickly in a continuous process, by reason of the fact that the monomers are spread over a large surface area of inert fillers to provide good heat transfer, and exceedingly good process control.

Abstract: The invention relates to the removal of acetaldehyde from crystalline polyethylene terephthalate granules by passing a dry inert gas through a bed of resin at a temperature of 170.degree. C. to 250.degree. C. for a time sufficient to remove the aldehydes.

Abstract: The heat deflection temperature of amorphous thermoformed polyethylene terephthalate is increased by removing absorbed and/or adsorbed water therefrom, as by heating in an oven, or by desiccation. Following drying, the material is kept in a desiccated storage vessel until time of use.

Abstract: The invention comprises the process for making an inorganic refractory insulation article by forming a fiber mat from a fiber slurry, impregnating the mat with a conditioned colloidal silica composition comprising colloidal silica, acid, aluminum chlorhydrate and water and drying the mat to form the article. The invention further comprises an inorganic refractory insulation article comprising randomly oriented refractory fibers retained by dried colloidal silica uniformly distributed throughout the article and from about 0.001 to about 1.5 weight percent of aluminum chlorhydrate which article is manufactured in accordance with the process.

Abstract: A process for producing an organic friction article from a composition of materials in a dust free environment. Water is mixed with the composition of organic materials to produce a slurry. A fixed volume of the slurry is communicated into a first mold. The slurry in the first mold is compressed to remove up to 95% by weight of the water to form a briquette. The briquette is conveyed to a force air oven or dielectric heater where the water is further reduced to about 1% of the weight of the briquette. This dry briquette is then placed in a second mold and pressed into the shape of a friction pad. The pressed friction pad is placed in an oven and heated to cure the resin in the composition of materials to complete the manufacture of the organic friction pad.

Abstract: A method of forming a layer of material from a solution containing the material and a solvent which comprises the steps of forming the solution into a layer, contacting at least one major face of the solution layer with a wall which is permeable over the area of that face substantially to the vapor phase only of the solvent, and effecting the escape of solvent simultaneously from both major faces of the layer including the one major face by vapor diffusion through the wall so as to set the layer.

Abstract: A porous, hydrophilic, assimilable prosthesis is formed by the removal of solvent, without substantial dimensional change, from a solution of (a), an assimilable polymer composed primarily of polymerized units of an alpha or beta hydroxy carboxylic acid, preferably but not necessarily those having 1 to 4 carbon atoms, and (b), a small amount of a physiologically acceptable wetting agent that is sufficient to impart hydrophilicity to the prosthesis. The preferred assimilable polymer is a polylactic acid. The preferred process for making the prosthesis involves the lyophilization of a solution of polylactic acid having a molecular weight of at least 100,000, weight average, at a concentration of at least 31/2% by weight of the solution of the polylactic acid. A variety of physiologically acceptable wetting agents is useful, a preferred class being the alkali metal soaps of fatty acids or of alkyl aryl sulfonic acids.