Abstract: A one-part curable epoxy adhesive composition is provided. The adhesive comprises curable epoxy resin, a latent curative system comprising (a) at least one first curative encapsulated in thermoplastic polymeric microcapsules and (b) a second latent curative admixed in the curable epoxy resin, and sufficient particulate thermoplastic polymeric material to at least partially regionally plasticize the cured epoxy resin wherein up to all of the particulate thermoplastic polymeric material may be provided by the walls of the microcapsules. A method of curing the adhesive by heating the composition is also provided. A joint made by adhering members together with the adhesive composition and a method of making the joint are also provided.

Abstract: Microporous material comprising a polypropylene polymer having at least 20 percent crystallinity; and a compatible, amorphous, glassy polymer, wherein said polymers are miscible in a compound when heated above the melting temperature of the polypropylene polymer and wherein a polypropylene polymer phase separates from the compound when cooled below the crystallization temperature of the polypropylene polymer. Microporous material is made by a thermally induced phase separation process using a compound such as mineral oil to form one phase containing both polymers. The pores of the microporous material resist collapse during processing. Membranes made of this material are useful as battery separators having a good combination of strength, porosity, and ionic resistance when imbibed with an electrolyte.

Abstract: Disclosed is a method for making a substrate coated with an adhesive, comprising applying an electron beam modifiable adhesive layer onto a repeatably reusable transfer surface, irradiating the adhesive layer with an electron beam to chemically modify the adhesive layer, and transferring the irradiated adhesive layer to a substrate. Also disclosed is an adhesive coated web, comprising a substrate having at least one component susceptible to electron beam radiation degradation having no electron beam radiation modification and an adhesive layer having an electron beam modified composition and having no chemical, thermal, or ultraviolet crosslinking agent.

Abstract: A die apparatus, a method of using the die apparatus to produce co-extruded polymeric articles, and co-extruded polymeric articles produced using the die apparatus and method are disclosed. The die apparatus includes a hollow vane configured to extrude a material into a chamber within the die, thereby producing a co-extruded web. The co-extruded web has a plurality of distinct, discontinuous phases in the cross-web direction, the phases having a uniform width as shown by a coefficient of variation of less than 8 percent for, any three consecutive phases. The phases are substantially continuous down-web and are surrounded by a matrix having two or more layers.

Abstract: Patterned articles, such as RFID antenna, are made by subablation, a process comprising the steps of: A. providing a substrate having a coating, such as a metal or metal oxide, and an interface comprising the thin region where the coating and the substrate are closest to each other; B. exposing at least one part of the total area of the coating to a flux of electromagnetic energy, Such as a focused excimer laser beam, sufficient to disrupt the interface but insufficient to ablate the coating, and C. removing the parts of the coating in registry with the portion of the interface area that was disrupted, by means such as ultrasonic agitation. The process has advantages over photo-resist processes in that there is no residual chemical resist left on the product and no undercutting of the pattern or image. It has advantages over laser ablation processes in that higher throughput is possible at the same energy level and there is no microscopic debris left on the product surface.

Abstract: Disclosed is a composite pressure-sensitive adhesive comprising from about 95 to about 5 parts by weight of an acrylic pressure-sensitive adhesive; from about 5 to about 95 parts by weight of an at least partially soluble (in a solvent) polymer, and a compatibilizer present in the composite pressure-sensitive adhesive in an amount greater than 0 to about 10 parts by weight of the composite pressure-sensitive adhesive. The polymer is selected from the group consisting of a butadiene-containing polymer, an isoprene-containing polymer, a saturated olefin-containing polymer, and a styrene-containing polymer.

Abstract: Curable coating compositions containing melamine precursors comprising: (a) a compound of the formula  wherein R is each, independently, H, CH2OH or CH2OR2, and R1 and R2 are each, independently, alkyl having 1 to 4 carbon atoms; (b) an alcohol, preferably a polyhydric alcohol; and (c) either (i) a perfluoroalkyl alcohol of the formula  in which Rf is CnF2n+1 or where x is 1-12; n is 3-20, and R3 is H, alkyl of 1-4 carbon atoms or —CH2)x—OH, or (ii) a polyvalent salt. These compositions can be cured thermally with a catalyst and provide unique advantages as coatings for porous materials.

Abstract: Vapor coating apparatus comprising a chamber having a liquid inlet, atomization means, and chilled substrate support. Carrier gas and coating liquid (e.g. monomer or polymer) are contacted under conditions that vaporize the liquid. Nozzle near chamber inlet has liquid and carrier gas inlets, outlets, and passageways through which liquid and gas streams flow. The outlets and passageways are shaped so that the liquid and carrier gas streams collide outside the nozzle, and the liquid is atomized and then vaporized due to conditions within the chamber. The vapor flows to a substrate at the chamber outlet where it is condensed. The gas discharged from the nozzle is at high velocity and can be shaped as a cone surrounding the liquid discharged from the nozzle in the interior of the gas stream cone.

Abstract: Patterned articles, such as RFID antenna, are made by subablation, a process comprising the steps of: A. providing a substrate having a coating, such as a metal or metal oxide, and an interface comprising the thin region where the coating and the substrate are closest to each other; B. exposing at least one part of the total area of the coating to a flux of electromagnetic energy, such as a focused excimer laser beam, sufficient to disrupt the interface but insufficient to ablate the coating; and C. removing the parts of the coating in registry with the portion of the interface area that was disrupted, by means such as ultrasonic agitation. The process has advantages over photo-resist processes in that there is no residual chemical resist left on the product and no undercutting of the pattern or image. It has advantages over laser ablation processes in that higher throughput is possible at the same energy level and there is no microscopic debris left on the product surface.

Abstract: Disclosed is a container having top, bottom, and side walls that comprises first and second substantially identical halves, each of which has a major surface that has a polygonal shape defined by at least six sides and at least one substantially vertical side wall, substantially orthogonal to the major surface, that forms a portion of the side walls of the container when the halves are assembled, an at least double wall construction, the two substantially identical halves matingly engage when the halves are assembled to form the container, and means integral to each half for securing the two halves together. In another aspect, the container of the invention comprises a major surface having a curved periphery and is otherwise as summarized above.

Abstract: Coated porous materials that exhibit air permeability and repellency to liquids as well as coated, nonporous breathable materials are described as suitable for making ileostomy vent filters, transdermal drug substrates, agricultural and medical apparel, as well as paint and chemical protective garments. The coating composition is applied as a curable composition containing cross-linkable melamine, polyol and fluorocarbon alcohol precursors. Hydrophilic coatings may be prepared by incorporating a polyvalent salt with the curable composition.

Abstract: A continuous, preferably counter-current, extraction process that can be used to significantly reduce the concentrations of residual monomers, residual catalyst, undesired solvents, and other impurities in polymer compositions. The invention is particularly beneficial for extracting residual monomers and other impurities from viscous, sticky polymer solutions, such as solutions of PSAs and low cohesive strength polymer compositions that phase change during extraction (i.e., change from liquid to solid, or precipitate), in a continuous manner. The polymer composition can be extruded into an extraction solvent as fibers in a vertical extraction column, under conditions such that at least a portion of an impurity is extracted from the polymer into the extraction solvent.

Abstract: A method of making embossed optical polymer films and embossed optical polymer films made are described. The embossed optical polymer films have substantially the same optical properties as unembossed optical polymer films. The method includes providing an optical polymer film having first and second major surfaces, softening at least one of the first and second major surfaces to produce a softened surface, embossing the softened surface to produce an embossed optical polymer film, and cooling the embossed optical polymer film.

Abstract: The present invention provides unified multilayer films having at least one internal layer that includes a pressure sensitive adhesive material. Preferably, multilayer films of the present invention are no greater than about 250 micrometers (.mu.m) thick. In particularly preferred embodiments of the present invention, multilayer films include layers that include a pressure sensitive adhesive material alternating with layers that include a material that is not a pressure sensitive adhesive. In other preferred embodiments, multilayer films include alternating layers of different pressure sensitive adhesive materials.

Abstract: Coating system and method that allows coatings to be formed from a wide variety of coatable compositions that are entirely free of any solvents or, alternatively, have relatively little solvent in minor amounts effective to help dissolve one or more components of such compositions. A fluid composition is atomized and contacted with a carrier gas. The contacting occurs under conditions such that vaporization of substantially all of the atomized fluid composition occurs so as to form a vapor having a condensation temperature. The vapor is caused to flow to the surface of the substrate. The surface is at a temperature below the condensation temperature of the vapor. Consequently, the vapor condenses onto the surface to form the coating.

Abstract: Apparatus controllably breaks hollow spheres stored in an enclosure. A first screen is disposed within the enclosure on a screen support. The screen has holes that are no larger in mesh size than the smallest hollow spheres. The screen support provides support to the first screen and has void areas to allow debris from broken spheres to pass through. An impeller is in contact with the first screen such that movement of the impeller across the first screen breaks the hollow spheres in contact with the first screen.

Abstract: Apparatus suitable for atomizing and vaporizing at least a first liquid by colliding at least one gas with the first liquid. The apparatus includes a gas inlet through which the gas enters the apparatus and a first liquid inlet through which the first liquid enters the apparatus. A discharge end of the apparatus includes at least one first liquid discharge outlet through which at least one stream of the first liquid is discharged from the apparatus. The discharge end also includes at least one gas discharge outlet through which at least one stream of gas is discharged from the apparatus to collide with and thereby atomize the discharged stream of the first liquid. A first liquid passageway interconnects the first liquid inlet with the first liquid discharge outlet. A gas passageway interconnects the gas inlet with the at least one gas discharge outlet.

Abstract: Microporous materials formed by thermally induced phase transition from a crosslinkable oil in combination with a thermoplastic polymer providing covalent bonding and immobilization of the oil diluent. Such materials are useful in graphic imaging substrates and fluid-repellent diapers and garments.

Abstract: Coated porous materials that exhibit air permeability and repellency to liquids having a surface tension at least equal to or greater than 20 dynes/cm which are suitable for making ileostomy vent filters, transdermal drug substrates, agricultural and medical apparel, as well as paint and chemical protective garments. The coating for the porous material is applied as a curable composition containing fluorocarbon urethane precursors which are cross-linked in situ.