Abstract: A polymer composition for forming spunbond fabrics offers a unique combination of simplicity and processability, while allowing fabrics formed therefrom to exhibit suitable elasticity and/or tensile strength. The polymer composition includes an propylene-based elastomer component exhibiting a particular combination of MFR and comonomer content, so as to allow for improved processability with minimal, if any, need for blending partners in the polymer composition, while still permitting fabrics formed therefrom to exhibit improved elasticity and/or tensile strength.

Abstract: The invention relates to a novel process for commercial production of bulk functionally graded materials (FGM) with a per-determined axial, radial, and spherical gradient profiles. The process is based on the reiterated deformation of the layers of variable cross-section thicknesses made of different materials. That allows significant savings of time, energy and materials. Metals, ceramics, glasses and polymers in different combinations can be brought together with a continuous or stepwise gradual change from one material to another. The invention can be applied to industrial production of functionally graded materials with different types of gradient profiles, which cannot be produced by the existing technologies and which are sought by many key industries. The mechanical, thermal and optical responses of materials produced by the proposed methods are of considerable interest in optics, optoelectronics, tribology, biomechanics, nanotechnology and high temperature technology.

Abstract: The present invention relates to an easy-to-apply, but versatile method for modifying the physical and chemical resistance properties of expanded polyester products, such as fire retardancy and hydrolysis resistance, by melt-modification of the surface layer(s) of said foams and sponges, the manufacturing of such products and the use of such products.

Abstract: A method for making a shapeable article from poly(lactic acid) includes treating solid poly(lactic acid) that results in the solid poly(lactic acid) having a crystallinity of at least 20% by weight based on the weight of the solid poly(lactic acid) and a gas concentration of 6% to 16% by weight based on the weight of the solid poly(lactic acid); and heating the solid poly(lactic acid) having said minimum crystallinity and gas concentration to produce a cellular poly(lactic acid) article that is shapeable. The shapeable cellular poly(lactic acid) article is advantageous in that the article can be further shaped by heat and/or pressure (or vacuum), such as via thermoforming, into a variety of useful products.

Abstract: A system for kneading and extruding a material includes a crusher for crushing the material into coarse particles, an extruder for conveying and extruding the material crushed by the crusher, a gear pump for receiving and discharging the material extruded from the extruder, and a kneading and extruding apparatus for kneading the material discharged from the gear pump and continuously extruding the kneaded material. Therefore, a material is accurately quantified and highly uniform, resulting in reduced product variations and ensured consistent quality.

Abstract: There are provided a forming device capable of drying at a high speed and of manufacturing a thermosetting resin foam plate more efficiently and stably without multilayering any unnecessary surface material, and a method of efficiently manufacturing a thermosetting resin foam plate therefor. A thermosetting resin foam plate is manufactured by: mixing a resin composition containing at least a thermosetting resin, a foaming agent and a curing agent in a mixer; continuously discharging the resin composition on a traveling air-permeable and flexible surface material, and at the same time covering the upper surface of the resin composition with an air-permeable and flexible surface material; and passing the covered resin composition through a forming device equipped with conveyors having apertures having an aperture area ratio of 15% or more and 80% or less to form and cure the resin composition.

Abstract: A method of manufacturing foamed thermoplastic films and trash bags wherein a foaming agent is added to a base thermoplastic resin. The resultant foaming agent/base resin mixture is extruded to form a single-ply foamed thermoplastic film. The film may be formed into bag, such as a trash bag.

Abstract: A method of forming a filter with uniform pore sizes includes synthesizing a moiety so as to form a plurality of like platelets having a precisely sized pore extending therethrough, distributing the plurality of like platelets about a membrane having apertures therethrough, and bonding the plurality of platelets around the apertures to form precisely sized pores through the membrane. A filtration membrane is also disclosed which provides a porous membrane having a plurality of apertures therethrough, and a plurality of platelets, wherein each platelet has a pore therethrough. The platelets are positioned over or in the apertures.

Abstract: The present invention relates to a multi-layered microporous polyolefin film for a battery separator and a method for preparing the same. The microporous multi-layered film of the present invention has a characteristics to have both the low shutdown temperature conferred by the polyethylene and the high melt fracture temperature conferred by the polypropylene and heat-resistant filler. In addition, it has the high strength and stability conferred by the micropores prepared under wet process and the high permeability and high strength conferred by the macropores prepared under dry process. Therefore, this multi-layered film can be used effectively to manufacture a secondary battery with high capacity and high power.

Abstract: A system for continuous High Internal Phase Emulsion (HIPE) foam production. A (HIPE) is produced then extruded onto a carrier sheet positioned on a belt surface.

Abstract: A process for manufacturing a self-extinguishing cable including at least one transmissive element and at least one flame-retardant coating in a position radially external to the at least one transmissive element, wherein the at least one coating includes an expanded flame-retardant polymeric material having (a) at least one expandable polymer; (b) at least one expanding agent; (c) at least one flame-retardant inorganic filler, in an amount of 100 parts by weight of 250 parts by weight with respect to 100 parts by weight of the at least one expandable polymer. The process includes the following steps: (i) feeding the flame-retardant polymeric material to an extruding apparatus, therein melting and mixing it; (ii) passing the flame-retardant polymeric material obtained in step (i) through at least one static mixer; and (iii) depositing by extrusion the flame-retardant polymeric material obtained in step (ii) onto the at least one transmissive element conveyed to the extruding apparatus.

Abstract: A foam form sheet material having a first large surface comprising substantially only closed cells and an opposite large surface and an interior comprising substantially only open cells. This material comprises a cross linked olefin thermoplastic polymer or copolymer. The foam is made by mixing the polymer with a blowing agent and a cross linking agent. The mixture is maintained in a two roll mill means for a time sufficient to initiate cross linking and to initiate foaming to form closed cells. The sheet material is then disposed in a second two roll mill means having a nip that is larger than the thickness of the foamed sheet material and maintained under elevated temperature and pressure sufficient to initiate further cross linking and foaming. The fully cross linked cell foam is then compressed to rupture the closed cells that are disposed in the interior to form open cells.

Abstract: The present invention relates to a continuous process for producing an insulated pipe comprising at least one medium pipe, an outer pipe, a layer of at least one polyurethane between the at least one medium pipe and outer pipe and a film tube between the at least one polyurethane and the outer pipe, which comprises at least the steps (A) provision, in a jaw band, of at least one medium pipe and a film tube formed continuously from a film, where the at least one medium pipe is arranged within the film tube in such a way that a gap is formed between the at least one medium pipe and the film tube, (B) introduction of a polyurethane system comprising at least one isocyanate component (a) and at least one polyol (b) into the gap, (C) foaming and allowing to cure of the polyurethane system and (D) application of a layer of at least one material to the film tube in order to form the outer pipe, where the polyurethane system has thixotropic properties.

Abstract: A single-sided, slip resistant, self-adhesive material is produced using a blown film process which produces a film having an interior layer capable of being treated or coated to accept a pressure sensitive adhesive, a middle layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent to produce a single-sided slip resistant material. A number of in-line rollers are provided after a pair of rollers, which form part of a machine direction orienter (MDO) that is used in line in the manufacturing process to heat, and then cool and condition (anneal and relieve any stresses and/or thickness inconsistencies) the film prior to the film being coated on one side with a pressure sensitive adhesive.

Abstract: A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on fibers and on a crosslinkable resin, by continuous winding and superposition of several layers of a tape of reinforcement fibers embedded in a matrix based on a composition comprising a crosslinkable resin. The process comprises from upstream to downstream, the following steps: producing a rectilinear arrangement (12) of reinforcement fibers (11) and conveying this arrangement in a feed direction (F); degassing the arrangement (12) of fibers by the action of a vacuum (13); after degassing, impregnating said arrangement (12) of fibers under vacuum with said resin composition in the liquid state (17); passing the pre-preg thus obtained through a die (20) to make said pre-preg into the form of a tape (21) composed of reinforcement fibers (11) in their liquid resin (17) matrix, the thickness of said tape being less than 0.

Abstract: The invention relates to a hydraulic binder product [12, 10] which includes a mixture of a hydraulic binder [38, 202], a polyvinyl alcohol [14, 204] and a gelling agent [54] which reacts with the polyvinyl alcohol and a method [8] of producing same.

Abstract: The present invention provides a method for manufacturing a film for a film capacitor making it possible to produce a film for a film capacitor which has a thickness of 10 ?m or less and which is excellent in a heat resistance and a voltage resistance at a high thickness accuracy by using a polyetherimide resin and provides as well a film for a film capacitor.

Abstract: Asymmetric membranes comprising a first asymmetric porous zone including a first porous asymmetry that increases from the first exterior surface through the first porous zone of the bulk, and a second asymmetric porous zone including a second porous asymmetry that increases from the second exterior surface through the second porous zone of the bulk, wherein the first average pore size is larger than the second average pore size, as well as methods of making and using the membranes, are disclosed.

Abstract: Continuous manufacture of at least a layer of latex foam with recesses of unlimited length to be divided in a plurality of blocks of latex foam by transverse cuts. The layer has a thickness between 10 and 20 cm and more. The process includes advancing along a predetermined longitudinal direction a metal laying surface provided with protuberances, gelating, curing. The process includes: a) Before depositing the latex foam inserting, by interference fit, supporting elements of resilient deformability having a predetermined thickness between pairs of protuberances of horizontal rows, the supporting elements of unlimited length; b) Carrying away the supporting elements with the advancing laying surface between an injection latex foam station and a layer extracting station; c) Embedding with latex foam the supporting elements. Advantageously the process forwards the blocks to a washing station and squeezes the blocks to a thickness reduction between 3% and 5% of their initial thickness.

Abstract: A double-sided, slip resistant material is produced using a blown film process which produces a film having an interior heat sealable layer, a core layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent and optionally grit to produce a double-sided slip resistant material. A number of rollers are provided after nip rollers have fused the film together, and which form part of a machine direction orienter (MDO) that is used in line in the manufacturing process to heat, and then cool and condition (anneal and relieve any stresses and/or thickness inconsistencies in the film) prior to the film being wound onto a roll for storage.

Abstract: A method and apparatus for providing an evenly mixed additive enhanced gypsum slurry to a web. Calcined gypsum and water are inserted into a mixer through at least one inlet of the mixer. The contents are agitated to form a slurry. The slurry is passed from an outlet of the mixer into a conduit. An additive is introduced into the slurry along a length of the conduit to achieve a flow stream of a slurry/additive mixture. A cross section of the flow stream is expanded in the conduit while not changing direction of the flow stream and a direction of the flow stream is changed while not expanding the cross section of the flow stream and conduit, all prior to the flow steam exiting from an outlet of the conduit.

Abstract: A composite includes a first preform and a second preform spaced from and in overlying relationship to the first preform. The second preform defines at least one first opening extending therethrough along an axis transverse to the first preform. A first surface layer is disposed adjacent to the second preform and on an opposite side of the second preform from the first preform. A polymeric composition including the reaction product of an isocyanate component and an isocyanate-reactive component is disposed between the first preform and the second preform. The polymeric composition adheres the first surface layer to the second preform through the at least one first opening. The surface layer is adhered to the second preform during molding of the composite article and in the absence of additional adhesive, thereby reducing production time and cost of the composite article.

Abstract: Process to manufacture a composite foam including at least two foams with cellular structure, at least one of them being a latex foam. The present process avails itself of the steps of preparing separately the forming mixtures of the foams of cellular structure; mixing independently the one from the other forming mixtures; foaming separately each of the forming mixture; sending separately the foams obtained into a single mixing installation; mixing the foams until to manufacture the composite foam. Preferably the composite foam is deposited on a laying surface to form rest articles for example mattresses provided with recesses.

Abstract: A disclosed method of manufacturing an image display element structure includes a coating step of coating a substrate surface including a plurality of recessed portions arranged at predetermined intervals, with a coating material that is plastic-deformable, in such a manner as to maintain spaces in the recessed portions; and an expanding step of forming gaps in the coating material coating the substrate surface by expanding gas in the spaces, wherein the gaps correspond to the recessed portions; and a peeling step of peeling off the coating material in which the gaps have been formed, from the substrate surface.

Abstract: A porous membrane may be manufactured with a high content of filler material and a polymer binder. After forming the membrane, the membrane may be post processed to reform the polymer binder into a stronger yet still porous membrane. The post processing may include bringing the membrane above the melt temperature of the polymer or by immersing the membrane in a solvent. Photomicrographs show that the structure may change, yet the performance of the material in batteries and other electrochemical cells may remain the same or even improve.

Abstract: Process for the preparation of a superhydrophobic film comprising the steps of applying a hydrophobic polymer in the liquid phase on a surface so as to form a layer of hydrophobic polymer, applying on said layer of hydrophobic polymer a membrane having a porosity of between 105 and 6×108 pores/cm2 in which the pores have a diameter smaller than or equal to 3 ?m, subjecting said layer of hydrophobic polymer to a thermal treatment so as to form a superhydrophobic film, and removing said membrane.

Abstract: The invention relates to an acoustic absorber comprising an absorption layer (1a, 1b) composed of an open-pored porous material. According to the invention, the open-pored porous material is flexurally stiff in such a way that the absorption layer (1a, 1b) is stimulated to flexurally oscillate when sound waves impinge on the absorption layer and the absorber can absorb sound waves of a first frequency range because of the inflow of air into the open-pored porous material of the absorption layer and can absorb sound waves of a second frequency range that comprises lower frequencies than the first frequency range because of the stimulation of flexural oscillations of the absorption layer. The invention further relates to an acoustic transducer and to a method for producing an acoustic absorber or an acoustic transducer.

Abstract: Provided are, among other things, systems, methods and techniques for manufacturing sheet material. In one representative embodiment, a sheet of fabric material is positioned across a patterning template that has a number of openings; and the sheet of fabric material and the patterning template are fed through an extrusion device in which extrusion material coats the fabric material and forces the fabric material into the openings in the patterning template, thereby producing a composite sheet material.

Abstract: A method for producing foam insulation board, the method comprising forming a foam product as part of a continuous process, where said foam product includes at least one side edge, monitoring on-line the compressive strength of the foam product, along said at least one side edge, and adjusting said step of forming a foam product in view of data obtained from said step of monitoring.

Abstract: Embodiments of the invention relate to microporous membranes that include first and second layers. The first layer includes ?20.0 wt. % polymethylpentene and the second layer includes a compatibilizer. The invention also relates to methods for making such membranes and the use of such membranes as battery separator film.

Abstract: An oriented polymer composition containing thirty to 95 weight-percent inert inorganic filler and a continuous phase of at least one orientable polymer contains void spaces due to cavitation and has a density of less than 0.8 grams per cubic centimeter, a flexural modulus of 1.4 gigapascals or more, cross section dimensions all greater than 1.5 millimeters, a delamination force value of 44.5 Newtons (ten pounds force) or more and little or no blowing agent.

Abstract: Methods of fabricating a substantially interconnected model vasculature, as well as compositions formed from such methods are provided. In some embodiments, the methods may comprise forming a non-woven fiber network comprising a plurality of fibers and a void space; backfilling the void space of the fiber network; and removing the fibers to form a substantially interconnected vascular network.

Abstract: The object of the present invention is to provide a method for producing a fiber composite excellent in lightweight and rigidity.

Abstract: A plant for manufacturing a continuous latex foam layer (2) to form mattresses (6) provided with cells (5). The plant comprises a plurality of laying planes (7) provided with a plurality of separate tables (13) separately arranged side by side to form a surface for the foam deposit. Each table comprises protuberances (14) and the arrangement of the protuberances on a table can differ from that of the juxtaposed tables in order to create supporting areas for the different body parts of the user. Preferably the tables (13) with their protuberances (14) are slidably fitted onto the laying planes (7) and can be easily and quickly replaced with separately provided tables having protuberances (14) differently arranged in order to meet the support capacity values required by different users.

Abstract: The present invention provides a process for making an integrally skinned asymmetric polybenzoxazole hollow fiber membrane comprising spinning a dope solution via a dry-wet phase inversion technique to form a porous integrally skinned asymmetric o-hydroxy substituted polyimide or an o-hydroxy substituted polyamide hollow fiber membrane comprising microporous inorganic molecular sieve followed by thermal rearrangement at a temperature from about 250° to 500° C. to convert the polyimide or polyamide membrane into a polybenzoxazole membrane. These membranes contain microporous inorganic molecular sieve materials that can have a particle size from about 20 nm to 10 ?m.

Abstract: A method for producing a microporous polyolefin membrane formed by fine fibrils, the membrane comprising (A) a polyolefin having a weight-average molecular weight of 5×105 or more or (B) a composition containing Component (A), connected to each other, and having micropores of 0.05 to 5 ?m in average pore size and crystal lamellas of Component (A) or (B) being in a specific alignment state. The method includes extruding a solution of Component (A) or (B) in a solvent into a gel-like formed article; thermally setting the article, with or without stretching, at least at the crystal dispersion temperature of Component (A) or (B), but at melting point of Component (A) or (B) plus 30° C. or lower; and removing the solvent.

Abstract: The present invention relates to a multi-layered microporous polyolefin film for a battery separator and a method for preparing the same. The microporous multi-layered film of the present invention has a characteristics to have both the low shutdown temperature conferred by the polyethylene and the high melt fracture temperature conferred by the polypropylene and heat-resistant filler. In addition, it has the high strength and stability conferred by the micropores prepared under wet process and the high permeability and high strength conferred by the macropores prepared under dry process. Therefore, this multi-layered film can be used effectively to manufacture a secondary battery with high capacity and high power.

Abstract: It is an objective of the present invention to provide a method for producing an air-permeable composite sheet which has excellent mechanical strength and compression resistance as well as PTFE's innate property such as air-permeability, water repellency, heat resistance and chemical resistance; and a filter and a fabrics material containing the air-permeable composite sheet produced by the method as a constituent material. The method for producing an air-permeable composite sheet according to the present invention is characterized in comprising steps of filling pores of a porous PTFE sheet with a hardenable material solution; hardening or semi-hardening the porous PTFE sheet filled with the hardenable material solution; and expanding the hardened or semi-hardened porous PTFE sheet.

Abstract: Plastic sheeting with a rough surface to increase the coefficient of friction, whereby at least one side of the sheeting is equipped with a layer (2, 22, 32), which layer contains the rough surface. This surface can be produced either by the coextrusion process or the coating method, and may also be provided on both sides.

Abstract: A microporous separator film for electrochemical cells and a method of making such films is disclosed. The microporous separator film includes an intimate mixture of an electrically insulating matrix phase and a self-switching voltage activated conductive phase, wherein the voltage activated conductive phase provides a plurality of conductive paths from a first face of the microporous separator film to a second face of the microporous separator film. The method for making the composite microporous separator film includes the steps of forming an intimate mixture of at least an insulating matrix phase and a self-switching voltage activated phase, forming a film from the mixture, and generating pores within the film.

Abstract: A filtration filter including a cartridge, which contains a crystalline polymer microporous membrane having a plurality of pores, where the average pore diameter of a first surface of the crystalline polymer microporous membrane is larger than that of a second surface thereof, and the average pore diameter of the crystalline polymer microporous membrane continuously changes from the first surface thereof to the second surface thereof, wherein at least part of the crystalline polymer microporous membrane forming the cartridge is subjected to surface modification after the crystalline polymer microporous membrane is formed into the cartridge.

Abstract: The presently described technology provides a low cost multilayer elastomeric film containing at least one layer of styrene block copolymer and at least one elastomer layer substantially free of styrene block copolymer such that the resultant film has a low permanent set substantially equal to or less than a film comprised of styrene block copolymer only. The elastomeric film may be used in elasticized features of various articles, such as disposable absorbent articles. Methods for producing the low cost elastomeric film having a low permanent set are also described.

Abstract: There are provided a foaming filler member which allows, even when the inner space of a hollow member has a protruding space, easy filling of the protruding space without using an extra member, a heat-foamable sheet used for the foaming filler member, a method for manufacturing the heat-foamable sheet, and a method for filling the inner space of the hollow member. A heat-foamable sheet which extends in one direction when heated at 100 to 130° C. for 20 minutes and has an extension ratio of 5 to 50% in the extension direction is manufactured by stretch-forming a heat-foamable material. Even when the inner space has the protruding space, the protruding space can be easily filled at low cost without using an extra member by using the heat-foamable sheet as the foaming filler member, disposing the foaming filler member in the main space of the inner space, and foaming it such that the extending direction of the heat-foamable sheet is oriented toward the protruding space.

Abstract: A method for producing a solid and/or porous film Includes preparing a suspension of solid particles in a solvent and spreading the suspension as a uniform layer of powder particles on a high melting point support. The solvent is eliminated so as to dry the uniform layer of powder particles into a dried porous uniform layer and surface melting/sintering of the dried uniform layer is carried out by direct contact with a concentrated heat source having a controlled gas composition so as to melt/sinter the layer into a solid/porous film.

Abstract: There are provided a foaming filler member which allows, even when the inner space of a hollow member has a protruding space, easy filling of the protruding space without using an extra member, a heat-foamable sheet used for the foaming filler member, a method for manufacturing the heat-foamable sheet, and a method for filling the inner space of the hollow member. A heat-foamable sheet which extends in one direction when heated at 100 to 130° C. for 20 minutes and has an extension ratio of 5 to 50% in the extension direction is manufactured by stretch-forming a heat-foamable material. Even when the inner space has the protruding space, the protruding space can be easily filled at low cost without using an extra member by using the heat-foamable sheet as the foaming filler member, disposing the foaming filler member in the main space of the inner space, and foaming it such that the extending direction of the heat-foamable sheet is oriented toward the protruding space.

Abstract: The invention provides composite porous materials in which a second material is fused to and/or is in the pores and/or is fused directly to some of the pore walls of a porous first material. The invention also provides methods of filtering a fluid using these composite porous materials and methods of manufacturing the composite porous materials.

Abstract: Polyurethane shapes containing a core layer of a water soluble polymer such as polyethylene oxide (PEO) are produced by casting onto a surface an aqueous mixture containing a pre-polymer of a hydrophilic polyurethane as a first layer of uncured polyurethane, covering the uncured first layer with release paper and compressing the layer, uncovering the uncured first layer and distributing PEO on the uncured surface, applying a second layer of uncured polyurethane on top of the PEO while the polyurethane is still uncured, then covering the resulting mass with release paper and compressing it to form an integrated, layered shaped article containing a core region enriched in PEO that when wetted releases PEO over an extended period.

Abstract: Process for continuous manufacture of an unlimited length latex foam block including at least two layers to form after successive cross cuts resting articles such as mattresses, cushions and parts of such articles. At least a first and second latex foam mixture with different characteristics among them are separately prepared and sent consecutively at a predetermined distance from each other on a laying surface in continuous progress. The second mixture is deposited on the already shaped first layer. The first and the second layers are gelatinized concurrently at the same place. The two layers are directly joined to each other along the contact surface by mechanical co-penetration of appendices of the one into micro-cavities of the other and by reciprocal tack of the two layers latex particles following breaking of the protective barrier between particles during gelatinizing.

Abstract: Solid state draw a polymer billet, wherein at least 50 percent of all polymers in the billet is a continuous phase of polyethylene polymer having a density of 0.941-0.959 grams per cubic centimeter and a weight-average molecular weight that is 110,000 grams per mole or greater, at a drawing rate of 1.2 meters per minute or faster using a tensile force to create an oriented and cavitated polymer composition whose cross section dimensions all exceed two millimeters.

Abstract: The object of the present invention is to provide a method for producing a thermally expandable base material for vehicle interior enabling production of an interior material for vehicle that is lightweight and has sufficient sound-absorbing properties, high stiffness and the like, and a method for producing a base material for vehicle interior. The present method for producing a thermally expandable base material for vehicle interior is characterized by comprising: mixing a synthetic resin emulsion, a thermally expandable microcapsule emulsion, and a resin-based adhesive emulsion; impregnating an inorganic fiber mat with the emulsion mixture; drying the mat at a temperature lower than a thermal expansion starting point of the thermally expandable microcapsule; heating the mat at a temperature at which a synthetic resin powder melts and which is lower than the thermal expansion starting point of the thermally expandable microcapsule; hot-pressing and cooling the mat.