Abstract: Rigid cellular hydrous calcium silicate thermal insulating product of low density can be made by aerating an aqueous slurry containing reactive calcareous and siliceous materials, preferably in conjunction with the incorporation of a foaming agent in the slurry, and then indurating the aerated slurry by the application of heat and pressure.

Abstract: A process of producing a fibre-reinforced shaped article comprising extruding a composition comprising a settable fluid as a carrier for fibres at least 5 mm in length through a die so that relaxation of the fibres causes the extrudate to expand to form an open fibrous structure with randomly dispersed fibres as the extrudate leaves the die characterized in that the porous extrudate is compressed while the carrier is in a fluid condition into a shaped article. The process enables moulded articles to be formed having a random distribution of fibres the majority of which are at least 5 mm long.

Abstract: A process for producing urethane-modified polyisocyanurate foams in which a poly(oxyalkylene-oxyethylene)polyether polyol is used as a modifying agent having the number of functional groups and the molecular weight in specific ranges with the equivalent ratio of NCO/OH being in a specific range and containing a specific quantity of ethylene oxide. The use of this modifying agent provides urethane-modified polyisocyanurate foams exhibiting excellent fire resistance and adhesion to an object surface.

Abstract: A structural laminate comprises at least one planar facing sheet with a rigid foam attached to one surface of the facing sheet. The rigid foam may be any polymeric material which is capable of being foamed. Distributed substantially evenly throughout the foam is a mat of long glass fibers arranged in layers substantially parallel to the facing sheet. The process for producing this structural laminate comprises the steps of contacting a thin, substantially incompressible yet expansible mat of long glass fibers with a foam-forming mixture, positioning a facing sheet on each face of the mat, and passing the facing sheets having the mat and the foam-forming mixture therebetween through means for metering the amount of foam-forming mixture and causing it to fully penetrate between the fibers of said glass mat.

Abstract: A method of forming a reinforced foam structure or laminate wherein a low density, fast reacting liquid foamable resin is sprayed under pressure into a low density fiberglass mat to penetrate and wet the fibers. The foam then expands within the fiberglass mat, forming a low density foam sheet having fiberglass distributed substantially continuously therethrough. A support or cover sheet is preferably laminated to the foam-fiberglass sheet and the laminate is formed under heat and pressure in a die into a contoured shape, simultaneously curing the resin foam.

Abstract: Methods of converting essentially unpolymerized precursors into polyimides in which the precursors are exposed to microwave radiation. Preheating, thermal post-curing, and other techniques may be employed to promote the development of optimum properties; and reinforcements can be employed to impart strength and rigidity to the final product. Also disclosed are processes for making various composite artifacts in which non-polymeric precursors are converted to polyimides by using the techniques described above.

Abstract: A tubular frame structure adapted for use as a tennis racket having a rigid outer shell of composite material and an inner reinforced foam core including a foam portion and honeycomb reinforcement layers. The honeycomb reinforcement layers are oriented so that string holes passing through the frame pass through the foam core and rigid shell, but do not pass through the honeycomb layers. The use of honeycomb reinforcement layers is particularly well suited for use with elastic polymer foam cores.

Abstract: A method for making reticulated foam structure of a crosslinkable thermosetting polymer which includes the steps of dissolving the polymer in a relatively volatile solvent, forming the resultant solution into an emulsion with a relatively less volatile emulsifying vehicle, forming the emulsion into the desired structure, removing the solvent from the structure, removing the vehicle and curing the structure to form a reticulated foam structure.

Abstract: Articles having increased fire-retardant properties are obtained by surrounding a foraminous core having the desired product properties with an adherent protective layer of a hydrophilic polyurethane foam having large amounts of fire-retardant fillers. The core can be made of rigid, semi-rigid or flexible foams. Preferable cores include conventional bedding and cushioning materials. The protective layer can be sprayed or poured as a coating or molded on to the core.

Abstract: Textile quality polymeric fibers and thin films that are highly sorbent for organic and other vapors, mists and solutes. The fibers and films comprise a polymeric matrix with a system of interconnecting micropores, and are highly loaded with particulate sorbents such as activated carbon. The fibers and films are manufactured by forming a melt blend of the sorbent particles, the polymer and a selected diluent, spinning or extruding and drawing down the fiber or film, and extracting the diluent. The diluent functions to permit a high spin or extrusion draw down, to permit the subsequent cold drawing of fibers highly-loaded with active carbon, and to permit the fiber or film to be porosified. Optionally, the diluent may be extracted after or before cold drawing, or without any cold drawing. The fibers and films are highly sorbent, are strong and durable and exhibit substantial strength over an appreciable degree of elongation.

Abstract: The instant invention relates to a process and an apparatus for the production of a foamable mixture from at least two fluid, foam forming reactants and aggregates, in which the aggregate is added to one of the reactants and the resulting preliminary mixture is then mixed with the other reactant.

Abstract: A semi-permeable asymmetrical membrane, useful for water desalting by reve osmosis and comprising cellulose acetate polymer, is formed from a casting solution in which there is incorporated, as a swelling medium, organophilic bentonite, that is, bentonite (preferably Montmorillonite) which has been directly reacted with di-methyl-di-stearyl (quaternary) ammonium chloride to have had its exchangeable cations replaced by long-chain hydrocarbons. The bentonite is swelled in dioxane, and the solution also includes acetone, equal parts of cellulose diacetate and cellulose triacetate, acetic acid and methanol. The steps of casting, cold water immersion and annealing are generally conventional. Incorporation of the bentonite results in high salt restraining capacity along with high product water flow and good flow stability.

Abstract: In the cultivation of mushrooms from an underlying bed containing mushroom spores, novel compositions and processes are provided for a casing layer which is placed over the compost layer containing spawning mycelium. A hydrophilic, thermosetting prepolymer resin is mixed in with a casing substrate, preferably Canadian peat, other optional additives and sufficient amount of water to form a slurry, and the mixture is allowed to cure to a spongy block. The cured material is then pulverized and deposited as a casing layer over the compost layer. Because of the high water retention qualities of this material, watering the mushroom beds is reduced by a factor of three or more, thereby reducing operation and production costs, as also the incidence and severity of disease and displeasing blemishes.

Abstract: A microporous film which comprises a matrix comprising 40 to 90 volume percent of a polyolefin having a number average molecular weight of 15,000 or more and 10 to 60 volume percent of an inorganic filler, said matrix having therein void spaces at a rate of 30 to 75 volume percent based on the volume of the film; and 2 to 20 weight percent, based on the total weight of the polyolefin and the inorganic filler, of an organic substance which is substantially insoluble in and inert to sulfuric acid and has a solubility parameter ranging from 7.3 inclusive to 8.4 exclusive; said organic substance, in its majority, adhering to the overall surface of the film including the outer surfaces of the film and the surfaces of the polyolefin walls defining said void spaces in cooperation with said inorganic filler.

Abstract: A structural material formed of a fiber and honeycomb reinforced foamed resin is disclosed, which is constructed by arranging a honeycomb material, the voids of which contain a foamable thermosetting resinous liquid, between two fibrous layers and heating the assembly to foam the resinous liquid and simultaneously cover and impregnate the fibrous layers whereby the fibrous layers and the honeycomb material are completely impregnated with and encased in the foamed resin.

Abstract: Elastic foamed products or articles having a much better heat resistance than that of the asbestos fiber foamed mass, prepared by drying of an aqueous fiber-dispersed slurry retaining bubbles and consisting essentially of inorganic fibers, synthetic fluormica of the non-restrictive swelling type and surface active agents. In the elastic foamed products, the inorganic fibers having films of the fluormica formed therebetween are evenly entangled with each other, said films having bubbles retained therein.

Abstract: A process for the production of foamed products from an unsaturated polyester resin composition, said composition comprising polyester resin, unsaturated monomer, a promotor, initiator, physical blowing agent, and compatible surfactant whereby a known gel time "T" results, foaming said composition by exposing it to microwave radiation prior to 1 T, thereafter permitting said foam structure to exotherm to obtain a fully cured product. Preferably the resin composition is exposed to the radiation between 0.2 and 0.7 T. Due to the foamed nature of these products, they will find many uses where insulation and light weight is important. End products include foamed unsaturated polyester resins and products incorporating the same such as patio blocks containing a polyester gel-coat, the gel-coat containing sand, decorative chips, or other decorative aggregate. The foam is a mixture of polyester resin and fillers and has a density of about 35 pounds per cubic foot.

Abstract: A novel apparatus and method are provided for monitoring gas entrainment in liquid precursors for reaction injection molding (RIM). In accordance with the invention, a nucleated RIM precursor is sampled and the sample subjected to a controlled volumetric change. The measured pressure of the expanded or compressed sample is compared to that corresponding to the ideal degree of gas entrainment. The comparison is used to control the addition or withdrawal of entrained gas.

Abstract: Composite foam panels are prepared from expanded thermoplastic particles of low density by generally encapsulating the particles in a phenolic foam matrix and providing a particulate expanded mineral substance such as perlite disposed generally adjacent the major surfaces of the panel.

Abstract: A method of making a membrane comprised of a hydrochloric acid-insoluble sheet of a mixture of a rubber and a powdered ion transport material is disclosed. The sheet can be present as a coating upon a flexible and porous substrate. These membranes can be used in oxidation-reduction electrical accumulator cells wherein the reduction of one member of a couple is accompained by the oxidation of the other member of the couple on the other side of the cell and this must be accompained by a change in chloride ion concentration in both sides. The method comprises preparing a mixture of fine rubber particles, a solvent for the rubber and a powdered ion transport material. The mixture is formed into a sheet and dried to produce a microporous sheet. The ion transport material includes particles ranging from about 0.01 to 10 microns in size and comprises from 20 to 50 volume percent of the microporous sheet.

Abstract: Process for preparing, by the wet method, refractory insulating products, comprising mixing a refractory aluminous cement, a refractory aggregate, and aluminous fibers, making a stable emulsion in water of said mixture, molding and drying the product, and firing the molded product at a temperature lower than its sintering temperature.

Abstract: A method is disclosed for incorporating particulate material in reactive resin mixes produced by the RIM method in the molding of foamed or unfoamed plastic articles, wherein the particulate material is introduced into the resin mix in a manner which substantially eliminates the severe abrasive effect such particulate material produces under conditions existing in prior methods due to flow through the various passges of the mixing head. The particulate material may constitute reinforcement for a plastic article, in which case short lengths of glass, carbon, graphite or other mineral or metal fibers and the like may be used. Alternatively, granular particulates such as carbon black, metal or mineral oxides, pigments, etc. may be incorporated for coloring the product, or increasing its resistance to actinic rays, or for imparting increased rigidity to the molded product, etc.

Abstract: Foams of polypropylene resin composition having remarkably improved extrusion foaming characteristics are prepared by a non-crosslinking extrusion foaming process comprising mixing and kneading polypropylene resin and 1,2-polybutadiene resin so that 1,2-polybutadiene resin reacts under the influence of the heat and shearing stress in the extruder, and extruding thereafter.

Abstract: A polyurethane cushion material comprising incorporating fiber filament in a foamed polyurethane, and it is produced by crimping the fiber filament, setting it under heating, producing a staple fiber, filling the staple fiber thus formed with a polyurethane into a mold, forming the polyurethane and post-curing it to complete polycondensation.

Abstract: The laminates have a core of rigid isocyanurate-based foam sandwiched between two facing sheets which are preferably non-combustible. Embedded in the core, substantially throughout its thickness, are multiple layers of a mesh of continuous glass fibre strands which is readily permeable to the foam forming ingredients. Each layer of the mesh is substantially parallel to the facing sheets.The laminates show advantages over laminates reinforced with single filament surface veil mat, single filament expanded mat, single filament random swirl mat and continuous rovings.

Abstract: The instant invention is directed to a process for the production of microcellular elastomeric moldings comprising:(A) introducing a reaction mixture into a closed mold, said reaction mixture comprising:(i) an organic polyisocyanate,(ii) a hydroxyl group containing compound having a molecular weight of from 1800 to 12,000,(iii) a catalyst for the reaction between hydroxyl groups and isocyanate groups,(iv) an active aromatic diamine having at least one alkyl substituent in the orthoposition to a first amino group and two alkyl substituents in ortho-position to a second group, and(v) air and/or nitrogen dissolved under pressure in any one or more of Components (i), (ii), (iii) or (iv),(B) allowing said reaction mixture to react in said mold and(C) removing the resultant product from said mold, the improvement wherein in any of Components (i), (ii), (iii) or (iv) which does contain said air and/or nitrogen dissolved therein there is included an inorganic, finely divided, nitrogen adsorbing agent in an amount suf

Abstract: A lightweight mixed dielectric and a manufacturing method thereof is described, which is prepared by mixing metal-coated expanded particles of plastic, glass or silica, thin-wall metal pipes or metal coated thin-wall plastic pipes and uncoated expanded particles of plastic, glass or silica and then forming the resulting mixture into a desired shape by thermal expansion or by the use of binder with the provision that these uncoated expanded particles are only made of plastic when the forming step is carried out by thermal expansion.

Abstract: This invention provides a commercially advantageous process for producing a foamed article of an aromatic polyester, especially a large-sized foamed article of aromatic polyester having a high expansion ratio. The process comprises mixing an aromatic polyester, a polyepoxy compound, a compound of a metal of Group Ia, IIa or IIIa of the periodic table and a blowing agent in a melt extrusion molding machine optionally with a fibrous filler while introducing the blowing agent thereinto under pressure, extruding the molten mixture from the molding machine, further expanding the foamed unsolidified extrudate in an atmosphere maintained at reduced pressure, and solidifying it by cooling in an atmosphere maintained at reduced pressure. The resulting aromatic polyester foamed article has numerous fine cells having uniform volumes, shapes and distribution.

Abstract: Novel polyester diols are described containing aliphatically saturated divalent diacyl moieties and olefinically unsaturated divalent diacyl moieties in a mole ratio of 0.25:1 to 3:1; and divalent dioxy moieties which are linear and/or branched, preferably divalent branched dioxy moieties and divalent linear dioxy moieties in a mole ratio of 0.3:1 to 3:1, the diacyl moieties being bonded through ester linkage to the dioxy moieties in a mole ratio of at least 1.75 dioxy moieties per diacyl moiety, wherein the polyester diol is end-blocked essentially only by alcoholic hydroxyl groups and has an acid number of less than 3. The novel polyester diols are highly useful in the production of polyurethane/vinyl polymer copolymers by reaction with polyisocyanates and polymerizable ethylenically unsaturated monomers.

Abstract: Auto parts prepared from polyurethane are manufactured by a process comprising:(a) preparing a polyol component by blending a stabilizer combination of (A) nickel dibutyldithio carbamate with (B) N-mono- or dimethylphenyl-N'-mono- or dimethylphenylphenylenediamine and/or (C) N,N'-diphenyl-p-phenylenediamine with a polyol and carbon black;(b) reacting said polyol component with a polyisocyanate: and(c) molding said reacted mass.

Abstract: An improvement in low temperature distortion is realized in a composite panel comprising a cellular core and upper and lower layers of organic fibers on each of the major surfaces of the core, the panel having upper and lower outer glass layers in contact with the upper and lower layers of organic fiber, the improvement comprising a layer of inorganic fibers interposed between the cellular core and the upper layer of organic fibers.

Abstract: A field transplant system including a machine for sequentially forming groups of polymerized soil plugs having seed receiving recesses in one end thereof and supported on a carrier, and in certain cases interconnected by strips, the carrier being used to transport the soil plugs through a seeding station and then to a germination station and then to a growing station either in the flat or on a plant turning machine in a greenhouse to grow the germinated seeds to transplant size, and then using the carrier to transport the soil plugs with the transplants growing therein to the field for transplanting by an automatic transplanter; several forms of soil plugs are disclosed, and several methods for supplying seeds to the soil plugs are disclosed, as well as an improved method of mounting a mat of soil plugs on the cylinder of a plant turning machine.

Abstract: A method and composition are described for the decomposition of sodium-mercury amalgam in a reactor containing solid packing particles to form hydrogen, sodium hydroxide, and denuded mercury. The novel packing particles are comprised of a heterogeneous solid mixture of a matrix of a thermally stable polymer having embedded therein discrete particles of a surface active element. Suitable thermally stable polymers include polyphenylene sulfide and suitable surface active elements include carbon, iron, nickel, cobalt, vanadium, and molybdenum. The proportion of polymer in the packing generally ranges from about 20 to about 80 percent by volume. Preferably, the matrix is prepared in porous form which may also be coated with a surface active metal.

Abstract: Prefabricated self-supporting panels having at least two outer layers and one inner layer provided with a foamed mixture, wherein the inner layer comprises unsaturated polyester resins, hollow microspheres of aluminum phyllosilicate having an average diameter of 150 microns and density of 0.7 kg/cu.dm., and a coupling agent of the organofunctional silane type.The process for the manufacture of these panels has also been described.

Abstract: Foamed hot melt adhesives are made and employed by methods which offer significant advantages and economies. The method employs surfactant stabilizers in making hot melt adhesive foams which are very useful in bonding substrates with efficiency and superior bond strengths. Continuous and reliable foaming operations are achieved with a uniform quality and output of foamed materials. Hot melt adhesives are also capable of being foamed with relatively simple mechanical apparatus and under conditions which provide considerable savings of energy. The number of hot melts which can be foamed employing the present technique in a controlled manner is unlimited. The method of stabilization is conducted at low or ambient pressures and resulting stabilized hot melt adhesive gas dispersions may then be pumped with pressurization and dispensed with immediate foaming.

Abstract: The invention relates to a method, and an apparatus, for the production of articles which consist of filler-containing synthetic material, in particular a foam, wherein flowable reactants, at least one of which has previously been charged with filler, are injected into a mixing zone under predetermined injection pressures, wherein the reaction mixture is subsequently introduced into a mold.Cellular materials such as flexible, semi-rigid, rigid or structured foam based, for example, on polyurethane or isocyanurate, and also non-cellular materials such as elastomers, may be produced by methods of this type.

Abstract: A panel comprising fillers embedded in a closed cell expanded phenolic resin is made by making a mixture, which is initially fluid, or phenolic resin, a hardening agent, a surface active agent and a porogenic agent, which has a boiling point above ambient temperature and below the polycondensation temperature of the mixture. This liquid mixture is mixed with fillers, for example balls or microspheres of glass or expanded material such as polystyrene. The resulting mixture is placed in a mould, only partially filling the mould, and heated progressively to a temperature in the neighborhood of the boiling point of the porogene agent, while evacuating the mould, and held at that temperature until the mixture has expanded to fill the mould. The temperature is then progressively increased to the polycondensation temperature to harden the expanded mixture.

Abstract: A molded article simulating the appearance of natural plantation crepe rubber and a method for producing this article. Styrene/butadiene linear or radial block copolymer having a polymerized styrene content of the range of about 20 to about 50 weight percent of the total block copolymer and resinous polymer of vinyl-substituted aromatic compound in the range of about 10 to about 60 parts resinous polymer per 100 parts block copolymer are blended with a sufficient amount of polarizing agent to achieve rapid heating through response to microwave treatment. The composition is melted, molded against a surface mirroring the appearance of plantation crepe rubber, and removed from the mold as an article simulating plantation crepe rubber.

Abstract: The invention is a method for making reaction injection molded polyurethane of improved properties. The product comprises the cured reaction product of a high molecular weight polyhydric polyether, a low molecular weight active hydrogen containing compound of at least two functionality and a polyisocyanate. The reaction product is cured by subjecting it to an ambient temperature of from about 290.degree.-425.degree. F. for a time sufficient to achieve an improvement in properties. The invention is also the resulting polyurethane.

Abstract: A method of producing high temperature insulating foam is described. A gellable foam of glass fibre, expanded perlite and bentonite in water is shaped dried and fired at a temperature below the temperature at which a ceramic product is formed but in excess of the temperature at which the bentonite lattice hydroxyl water is lost.

Abstract: A panel comprising fillers embedded in a closed cell expanded phenolic resin is made by making a mixture, which is initially fluid, of phenolic resin, a hardening agent, a surface active agent, a finely divided hydrophilic material and a porogenic agent, which has a boiling point above ambient temperature and below the polycondensation temperature of the mixture. This liquid mixture is mixed with fillers, for example balls or microspheres of glass or expanded material such as polystyrene. The resulting mixture is placed in a mould, only partially filling the mould, and heated progressively to a temperature in the neighborhood of the boiling point of the porogene agent, while evacuating the mould, and held at that temperature until the mixture has expanded to fill the mould. The temperature is then progressively increased to the polycondensation temperature to harden the expanded mixture.

Abstract: The instant invention relates to a process and an apparatus for the production of a foamable mixture from at least two fluid, foam forming reactants and aggregates, in which the aggregate is added to one of the reactants and the resulting preliminary mixture is then mixed with the other reactant.

Abstract: The fibrous structure of a non-woven mat is disrupted by an apparatus comprising at least one roll which has one or more upraised ribs in a chevron pattern extending helically around the roll. In processing, the mat passes under tension over at least a portion of at least one chevron roll and preferably over two chevron rolls which may or may not be intermeshing. Thereafter, the mat may be crushed or crimped by being fed through to intermeshing third and fourth chevron rolls. Additional rolls may be supplied to exert tension. The mat which exits from the apparatus has a disrupted fibrous structure and is a superior skeleton within a structure such as a polymeric foam board.

Abstract: The invention relates to a process wherein A a heat curable froth or foamable mixture of polyurethane reaction components is applied to the back of a fabric, B the coated fabric is heated to form a gelled, tack-free and storable foam-backed fabric and C the fabric is shaped and cured using a hot molding process. The polyurethane formulation contains a hydroxy functional ester of an acrylic or alkyl acrylic acid and a free radical initiator.

Abstract: An automobile sound insulating panel and apparatus for and method of making same are provided wherein such panel comprises a contoured fibrous pad and a plastisol layer bonded against the pad with the plastisol layer comprising a foamed plastisol layer having randomly disposed air pockets therethrough which provide a minimum weight for the panel while improving the acoustical properties thereof.

Abstract: A process of manufacturing a microporous sheet by forming a blend of a polyolefin, silica and a water insoluble plasticizer, forming a sheet from the blend, and contacting the sheet with water for a time sufficient to render the sheet microporous. The plasticizer, being essentially insoluble in water, is easily separated therefrom and recycled. The preferred plasticizers are dialkyl phthalates and dialkyl adipates having between about two and about eleven carbon atoms in the oxo-alcohol moiety.

Abstract: Solid materials having a flash point of less than 500.degree. C. are rendered fire alarming by providing for the presence thereon of micro capsules containing a bromofluoroalkane having a critical temperature of at least 100.degree. C., the micro capsules having an external diameter of from 200 to 260 microns, and the wall of the capsules consisting of a polymer, treated to release the bromofluoralkane suddenly at a predetermined temperature to provide a detonation having a maximum sound level of 10-12 kHz.

Abstract: Embossable foam latex compositions prepared by dispersing into a foam latex from 20 to 150 parts by weight per hundred parts of latex solids of a powdered particulate material having a melting point in the range 90.degree. to 200.degree. C. Embossing of foam-backed carpet or foam sheet material prepared from these latex compositions is readily accomplished by heating the foam structure to the melting temperature of the dispersed particulate material, then passing the foam through a cold embossing roll to chill and set the foam in place.

Abstract: A method of making a microporous elastomeric material having interconnecting cavities and which may be used as an ink dispensing article is provided wherein such material is made by the steps of admixing fibrous material and particles of hydrated magnesium sulfate in an elastomeric matrix material, shaping the material, curing the elastomeric matrix material, simultaneously causing liberation of water of crystallization from the hydrated magnesium sulfate which provides a blowing effect resulting in the formation of interconnecting passages between the particles from the cured material.

Abstract: A rooting media in the form of a resilient, integral body of spongy open-celled hydrophilic polymer forming a first essentially continuous phase extending throughout the body and having passages therethrough forming a second essentially continuous phase extending throughout the body, a quantity of particles of soil mixture distributed throughout the body of spongy polymer and held thereby with a substantial portion of the surface area of the particles of soil mixture exposed and in communication with the passages, the exposed particles of soil mixture providing colloidal contact exchange surfaces in communication with the passages and having collectively a porosity maintenance capacity and a water holding capacity and an ion exchange capacity and a pH buffering capacity; also disclosed is a method of making such a body of rooting media, as well as a release agent useful in that method; there further is disclosed a particular form of rooting media for use in propagation by air layering and a method of propagat