Abstract: A process for continuously forming a fibrous element in an elongate closed foraminous former during movement of the former through fluid extraction means, and which includes the steps of forming a fibrous dispersion, injecting the dispersion into said former, generating a pressure gradient across an extraction zone within said fluid extraction means and injecting the fibrous dispersion into the former at an injection velocity relative to the speed of the former (efflux ratio) to cause some of the fibres to build up as a fibrous mat on the inner surface of the former and the remainder to pack together to form a core so as to produce a continuous fibrous element having a fibrous core which is enclosed by a crust of greater density.

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

Abstract: An apparatus is connected directly on-line with an extruder to inject fluid into or to remove fluid from a fresh extrusion on a continuous basis as the latter is extruded. In one case the fluid injected is a catalyst that causes curing of a mixing of particulate matter and resin binder. In the method one part of a two part binder mechanism is mixed with a particulate material, and the mixture is extruded on a continuous basis. The second part of the binder then is injected into the fresh extrusion on a continuous basis downstream of the extruder output to cure the extrusion. The extruder die also may include fluid injecting paths, on the one hand, for injecting lubricant or, on the other hand, for injecting of the second binder part, e.g. catalyst, into the relatively less dense material near the upstream end of the die.

Abstract: A rigid building component such as a door, table top or the like, is formed of coarse wooden particles mixed with adhesive, and a solid wooden edge frame, positioned between a pair of damp, substantially parallel, cellulosic fiber webs. A heated press is employed to compact the combination, particularly between the edge frame and the cellulosic fiber webs where the coarse wooden particles are greatly compressed to provide a durable edge. Under the heat and pressure applied in the press the particles are consolidated into a solid structure, while the damp cellulosic fiber webs are converted to tough exterior skins bonded to the coarse wooden particles. The sides of the rigid building component are suitably deeply embossed to provide a decorative paneled appearance.

Abstract: A solvent extraction coal conversion process is provided wherein the effluent slurry product is subjected to vacuum distillation to yield distillate and extrudable still bottoms. The latter are removed from the vacuum still by means of an extrusion screw which is operatively associated with the still.

Abstract: During thermal processing of saturated polyesters in the molten state gaseous oxygen is excluded and as a result acetaldehyde formation is minimized.

Abstract: An improved method of pulp or pressure molding a multilayer container is disclosed wherein the inner layer consists of fused water dispersible polyolefin fibers whereas the outer layer consists of a mixture of cellulosic fibers bonded together by fused water dispersible polyolefin fibers. The containers are useful because the polyolefin layer is resistant to the passage of liquid such as lubricating oils and semi-solids such as greases while the mixed layer of cellulosic fibers and the polyolefin fiber supplies sufficient strength to permit the stacking of the containers when filled.

Abstract: Apparatus for the refinement of colloidal asbestos dispersions comprises a horizontally disposed cylindrical tube having a plurality of closely spaced holes around the periphery thereof, a helical screw disposed within the tube, and a flanged jacket concentric with and spaced outwardly from the tube. A slurry of unrefined dispersion is continuously fed into the tube to fill it. Refined slurry is drawn through the holes by a suction pump connected to the jacket while contaminants are retained in the tube and moved by the screw to the outlet end of the tube where they are compacted and removed as sludge through a spring loaded discharge door.

Abstract: A method is disclosed for forming a porous shaped body from rubber-like particles. The resulting shaped body is capable of retaining relatively large amounts of a liquid, such as ink, within its pores. Retained liquids can be controllably dispensed from the porous body by bringing it into pressure contact with a receptor surface.

Abstract: The specification discloses a novel composite coalescing filter tube and the method of making the same. In contrast to previous coalescing filters, which had layers of filter material sandwiched between relatively rigid support members, the present invention provides for a completely unitary coalescing filter tube wherein the various layers of the filter are successively vacuum formed one over the other on a forming fixture which is submerged in an appropriate glass fiber slurry mix, with the various layers being air dried, epoxy dipped, and cured as needed for the particular application. Since, during the vacuum forming process, glass fibers from one layer will interlock with glass fibers from the previously formed layer, a completely unitary coalescing filter tube is formed, preventing the problems of filter layer separation, channeling, pressure collapse and vibration damage which have occurred in past coalescing filters.

Abstract: Reinforced cement panels are produced between a fixed lower mould and a movable upper mould each having a moulding surface covered with filter cloth. Suction is applied through ports in the lower mould to extract air and residual water, reinforcement is placed on the lower mould, a layer of slurry of uniform thickness is applied by traversing a depositor over the lower mould, and the upper mould is rested on the surface of the slurry. Vacuum is applied through arched connections from upper parts of manifolds on the upper mould and through passages in the upper mould to the filter cloth thereof to withdraw moisture from the slurry to create an uncured panel. Water-containing foam is admitted through the ports in the lower mould to release the uncured panel, whereupon the upper mould is raised with the uncured panel held thereto, traversed to a different position to rest the uncured panel on a support.

Abstract: A method of making a cast article from a composition which contains a hydraulic binding agent comprising by weight from 90% to 10% calcined gypsum and from 10% to 90% Portland cement comprises mixing the composition with water to produce a fluid mixture, either the water or some at least of the components of the composition or both being heated so that the mixture has a temperature of from 70.degree. to 130.degree. F, and pouring the fluid mixture into a mould or other supporting device where the reaction of the calcined gypsum with the water causes the mixture to set and the heat of this reaction causes the temperature of the mixture to begin to rise. As soon as the mixture has set sufficiently to be self supporting, the set mixture, which forms the cast article, is removed from the mould or other supporting device and then the dissipation of both heat and moisture from the cast article is controlled so that the temperature of the article continues to rise to from 90.degree. to 180.degree. F.

Abstract: A method for manufacturing carbon-carbon composite bodies consisting essentially exclusively of carbon, of about 20 to about 96 weight percent from carbon fiber, from 0 to about 72 weight percent from a carbonaceous flour, and from about 4 to about 15 weight percent from a carbonized resin, which consists in forming a mat by allowing a mixture of the solid ingredients to settle to equilibrium height by the force of gravity or by centrifugation in a solution of the resin and an appropriate solvent, then pressing the settled solids at up to about 100 psi and removing the excess liquid therefrom. Heating the formed and pressed mat to cure the resin, and then baking and optionally graphitizing the cured mat completes the process.

Abstract: A fluid-releasable mold for forming shaped ware including a porous mold body comprising at least 70% alumina, up to 15% ball clay and up to 15% talc is disclosed. A mold face is formed on one surface of the mold body and fluid-permeable conduit is provided in communication with a second surface of the mold body with means for sealing the fluid-permeable conduit to the second mold body surface to prevent the escape of fluid from the conduit other than through the mold body and out the mold face. The arrangement obviates the problem of gradual loss of porosity which has heretofore limited the service life of fluid-release molds of alumina, ball clay, and talc.

Abstract: A process for producing an electrical heating unit by filter molding an inorganic refractory fiber to form an insulating body about a heating element wherein a layer of insulating fabric is placed on the filter mold screen and the heating element positioned on the fabric prior to filter molding so that the heating element becomes completely embedded in the insulating body and is at a controlled depth below the surface of the insulating body as defined by the thickness of the fabric.Also disclosed is a sleeve heater having integral vestibules as may be made according to the method of the present invention.

Abstract: A shaped article of refractory heat insulating material is made by forming a mixture of inorganic refractory fibrous material and a binding agent which may be soluble or dispersible in a suitable liquid medium, forming the mixture to the desired shape, drying the shape in a first drying step, impregnating the so-dried shape in a second drying step, one of the drying steps being an homogeneous drying step and the other being a non-homogeneous drying step.

Abstract: This invention relates to a process for continuously producing a dense board of cement-like material reinforced by glass fiber, which comprises (1) preparing a slurry of cement-like material; (2) simultaneously spraying the cement-like slurry and short lengths of glass fiber on a suction conveyor in such a manner that the cement-like slurry stream and the glass fiber stream intersect on the suction conveyor to form a dense mat of an intimate mixture of the two; and (3) dehydrating the mat by pulse-like intermittent suction using one or more suction boxes before the cement-like material begins to set, and to an apparatus used in carrying out the process.

Abstract: A fiber reinforced composite tube is molded by applying an annular, liquid-resin-impregnated layer of reinforcing fibers to a cylindrical mold or mandrel; placing in contact with the exposed surface of the fiber-resin layer a compression sleeve which is split lengthwise to permit circumferential contraction or expansion of the sleeve into pressurizing relation with the layer; pressurizing the compression sleeve with fluid pressure to compress the fiber-resin layer and thereby compact the reinforcing fibers and expell entrapped air and excess resin from the layer; and curing the resin while the fiber-resin layer is so compressed.

Abstract: A process for preparing fire-resisting moldings having an improved mechanical strength by admixing gypsum with crystalline calcium silicate in an amount of 5 to 100 % by weight to the gypsum and water to give a slurry, molding the slurry under pressure and drying the raw articles. The water resistance of the moldings can be improved by the further addition of cement.

Abstract: Aligned fibre mats are produced by passing a continuously accelerating or decelerating stream of fibre dispersion over a permeable surface and simultaneously withdrawing a limited proportion of the dispersion liquid through the permeable surface to deposit aligned fibres thereon. Mats having a wide variety of shapes and alignment patterns may readily be produced and may subsequently be impregnated with resins, metals etc. to form fibre-reinforced composite materials.

Abstract: An insulative material comprises a random network of ceramic fibers and a binder for holding the fibers together. In addition, it may include a filler material composed of hollow ceramic spheres which locate at the interstices of the fibrous network and increase the strength of the network. The insulative material can withstand extremely high temperatures and thermal shock without degradation, has an extremely low density, has excellent insulating properties, and has reasonably high compressive strength. The material is formed by making a slurry which contains the ceramic fibers, with or without the filler, and the binder; felting the slurry; subjecting the felt so formed to microwave energy for drying; and firing the dried felt at 2300.degree.-3200.degree.F. to increase its strength.