Abstract: A method for pre-treating preforms (12) made of thermoplastic plastic, before they are shaped into containers (13) by means of a stretch blow molding process and filled with liquid. The preforms (12) are tempered and sterilized for the subsequent stretch blow molding process. Tempering of the preforms (12) is carried out by means of microwave radiation and by sterilization of the preforms (12) during the pre-treatment.

Abstract: Disclosed herein is an apparatus and method with inductive heating of an electrically conductive workpiece such as a barrel used in molding or extrusion, having a layer of thermal insulation interposed between the induction windings and the workpiece, and using alternating current (AC) at an elevated frequency. Further, variable pitch induction windings may be used to generate a non-uniform and calculated heat input profile, such as to compliment the configuration of a screw for transporting material through the barrel.

Abstract: The subject invention provides a film having at least one layer comprising an interpolymer of ethylene and at least on comonomer selected from the group consisting of C3-C20 ?-olefins, dienes, and cycloalkenes, wherein the interpolymer is characterized as having a high degree of processability, good optical performance, and good mechanical properties. The subject invention further provides film fabrication processes and polymer compositions which are useful in preparing the subject films.

Abstract: A blank (2) is molded for the manufacture of a multi-layer preform (1). The blank possesses protrusions (5). After the protrusions (5) have been brought to a plasticized state under the action of heat, those surfaces that contain protrusions (5) are covered by a layer of plasticized material. The blank (2) becomes connected to the layer (6) in the area of the protrusions (5). After cooling of the preform created from the blank (2) and the layer (6), the blank (2) will be connected with the layer (6) by means of microweld positions (7) in the area of the said protrusions (5). With that, delamination of the preform (1) during further processing or use will be effectively prevented.

Abstract: A method of manufacture for producing a molded article from a polyurethane material, utilizing a spin casting apparatus, preferably a non-pneumatic tire, where a mold that is formed in sections or halves and has an inner cavity formed to have the shape of the article to be manufactured and is separable to release that article after manufacture. The mold is secured to a support plate of the apparatus that is journaled to turn axially imparting a centrifugal force into the mold. The support plate is connected to or is arranged to be connected to a motor assembly for turning, and includes a clamping arrangement for maintaining the mold halves together on the support plate. An annular trough is formed in the mold immediately adjacent to a mold interior cavity inner circumference to receive a polyurethane material liquid passed thereto, and to, in turn, pass that liquid through a trough annular opening or ports into the mold cavity.

Abstract: An enclosure for enclosing sound-producing equipment (such as a marine propulsion system), the enclosure having first and second opposing end panels, first and second opposing side panels, a base and a top panel, releasably connected to each other at corresponding mitered edge joints. The method of making the enclosure includes molding a single enclosure preform and then severing the preform into side, end and top panels. The enclosure preform may be rotationally molded, for example, and may have a layer of sound absorbing material applied to its inner surface during molding. Other, non-molded sound enclosure embodiments are also disclosed.

Abstract: New cross-linked polymeric foam compositions, and methods for making the same, are provided. The new compositions utilize novel cross-linked polyolefin copolymers and show improvements in strength, toughness, flexibility, heat resistance and heat-sealing temperature ranges as compared to conventional low density polyethylene compositions. The new compositions also show processing improvements over linear low density polyethylene. The novel polyolefins, which are essentially linear, comprise ethylene polymerized with at least one alpha-unsaturated C3 to C20 olefinic comonomer, and optionally at least one C3 to C20 polyene, and exhibit, in an uncross-linked sense, a resin density in the range of about 0.86 g/cm.sup.3 to about 0.96 g/cm.sup.3, a melt index in the range of about 0.5 dg/min to about 100 dg/min, a molecular weight distribution in the range of from about 1.5 to about 3.5, and a composition distribution breadth index greater than about 45 percent.

Abstract: Compositions and processing conditions are disclosed for the production by rotomolding of polypropylene foams, hither to satisfactorily produced only by injection molding and extrusion molding. Rheological properties of the polypropylene resin, processing conditions and choice of composition of the chemical blowing agent were found to play important roles in obtaining high quality polypropylene foam structures. High strength fine-cell polypropylene foams could in particular be formed by first melt compounding a suitable chemical blowing agent with the resin under conditions which allow for homogeneous mixing without appreciable decomposition of the blowing agent.

Abstract: Improved compositions useful for the production of rotomolded articles having a foamed interior and non-foamed exterior skin are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a chemical foaming agent, an organic peroxide and, optionally, a metal-containing activator compound and a second resin component which is a powder and can be a thermoplastic ethylene polymer or ethylene copolymer having less than 30% crystallinity. An improved one-step process for producing foamed rotomolded articles having foamed interiors and non-foamed exterior skins is also provided.

Abstract: Molded polyolefin articles of improved dimensional stability at elevated temperatures and improved stiffness and consist of mixtures of modified propylene polymers, which are synthesized by free radical coupling reactions or polymer-like reactions of functionalized polypropenes, and of unmodified propylene polymers, crystalline copolymers of propylene and .alpha.-olefins, elastic copolymers of ethylene and .alpha.-olefins, largely amorphous polypropylenes, non-isotactic propylene homopolymers, and auxiliary materials.The molded polyolefin articles, produced by blow molding or injection molding are suitable for use in the packaging industry, for use in the domestic appliances industry, to meet the requirements of laboratories and hospitals, for gardening and agricultural implements, for transporting containers for components in the automobile industry, and for components of machines and of electric and electronic equipment.

Abstract: A baluster or spindle is formed by a casting method, and has a rigid, dense, hollow outer shell forming a decoratively shaped body portion having closed, planar opposed ends. A conduit extends completely through the baluster, providing attachment means to a railing system. The hollow interior of the baluster is injected with a high density polyurethane foam to increase its weight, density, and resistance to breakage. The method of forming a baluster or spindle includes the combined method steps of placement of a mesh sheet adjacent each end of the mold, and then subsequent agitation of the mold. Agitation includes simultaneous spinning and rocking of the mold about its longitudinal axis. The mesh sheet retains the casting material against the end surfaces of the mold, and is completely encapsulated by the casting material such that the mesh sheet is not visible on the surface of the finished product.

Abstract: A process for producing pipes insulated with foams comprises providing, between an inner carrier pipe and an outer pipe arranged parallel thereto, a holder which is provided with at least one aperture and is mounted so that it can be moved axially and positions the carrier pipe in the outer pipe and introducing into the vacant space between the two pipes, via the aperture(s) in the holder, a mixture for the preparation of foams, where during the introduction of the mixture, the holder moves in an axial direction with respect to the outer pipe and the carrier pipe, then after the mixture is charged, it is reacted to give the foam and the holder and, if desired, the outer pipe are removed.

Abstract: A preform heating method for heating a preform for a stretch blow molding is executed by an apparatus which comprises an outer heating die having a cavity for the preform, a thermal-insulating pot surrounding the outer heating die and a high-frequency heating unit installed around to the thermal-insulating pot. The heating of the preformed is executed by locating the heating die around the preform, applying alternating magnetic flux to the heating die to heat the preform through the heating die, and controlling the magnitude of the alternating magnetic flux to control the temperature of the preform.

Abstract: Novel molding compositions consisting essentially of a mixture of a skin-forming component and a foam core-foaming component physically dry-blended together. The skin-forming component comprises two distinct phases blended together, a high zero-shear viscosity material and a low zero-shear viscosity material. The foam core-forming component preferably comprises a foamable polymeric material including a suitable blowing agent. In a preferred embodiment, the three materials are selected from suitable homopolymers and copolymers of ethylene.

Abstract: Improved compositions useful for the production of rotomolded articles having a foamed interior and non-foamed exterior skin are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a chemical foaming agent, an organic peroxide and, optionally, a metal-containing activator compound and a second resin component which is a powder and can be a thermoplastic ethylene polymer or ethylene copolymer having less than 30% crystallinity. An improved one-step process for producing foamed rotomolded articles having foamed interiors and non-foamed exterior skins is also provided.

Abstract: The present invention relates to the polymer composite possesses excellent mechanical properties such as restorable ability or shock resistance, coating property, and adhesiveness. It is preferred that the disperse phase is distributed homogeneously.The polymer composite of the present invention is obtained by polymerizing a vinyl monomer selected from the group consisting of a styrenic monomer, acrylonitrile, methacrylonitrile, an ethylenically unsaturated carboxylic acid, anhydride of said carboxylic acid, and ester of said carboxylic acid in the presence of a rubber-like copolymer and a thermoplastic resin selected from the group consisting of a polyolefin, a polyamide, a polyimide, a polyarylene ether, a polyacetal and a polyester without a substantial amount of a solvent. The polymer composite is preferable that a part of vinyl monomer is grafted to the rubber-like copolymer and the polyolefin, and the thermoplastic resin forms a matrix phase.

Abstract: New cross-linked polymeric foam compositions, and methods for making the same, are provided. The new compositions utilize novel cross-linked polyolefin copolymers and show improvements in strength, toughness, flexibility, heat resistance and heat-sealing temperature ranges as compared to conventional low density polyethylene compositions. The new compositions also show processing improvements over linear low density polyethylene. The novel polyolefins, which are essentially linear, comprise ethylene polymerized with at least one alpha-unsaturated C3 to C20 olefinic comonomer, and optionally at least one C3 to C20 polyene, and exhibit, in an uncross-linked sense, a resin density in the range of about 0.86 g/cm.sup.3 to about 0.96 g/cm.sup.3, a melt index in the range of about 0.5 dg/min to about 100 dg/min, a molecular weight distribution in the range of from about 1.5 to about 3.5, and a composition distribution breadth index greater than about 45 percent.

Abstract: New cross-linked polymeric foam compositions, and methods for making the same, are provided. The new compositions utilize novel cross-linked polyolefin copolymers and show improvements in strength, toughness, flexibility, heat resistance and heat-sealing temperature ranges as compared to conventional low density polyethylene compositions. The new compositions also show processing improvements over linear low density polyethylene. The novel polyolefins, which are essentially linear, comprise ethylene polymerized with at least one alpha-unsaturated C3 to C20 olefinic comonomer, and optionally at least one C3 to C20 polyene, and exhibit, in an uncross-linked sense, a resin density in the range of about 0.86 g/cm3 to about 0.96 g/cm3, a melt index in the range of about 0.5 dg/min to about 100 dg/min, a molecular weight distribution in the range of from about 1.5 to about 3.5, and a composition distribution breadth index greater than about 45 percent.

Abstract: A method of encapsulating and sterilizing waste material is disclosed. Medical waste is deposited inside of a mold. When full, the mold is charged with plastic and one of several reactants. The mold is then heated while rotated biaxially. The heat simultaneously sterilizes the waste and causes the charging materials to expand and envelop the waste, encapsulating it. The mold is then cooled while spinning biaxially, forming a hollow brick of solidified, encapsulated material in the mold. The brick of material is removed and pulverized into granules. The pulverized material is separated and readied for recycling.

Abstract: Improved compositions useful for the production of foamed rotomolded articles are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a foaming agent and a second thermoplastic resin component which is a powder consisting of a mixture of different particle size and melt index ethylene polymers. An improved process for producing foamed rotomolded articles having uniformly foamed interiors and smooth exterior skins which are substantially free of surface defects is also provided.

Abstract: An amphiphilic block copolymer including a hydrophilic internal segment and polymeric articles made therefrom.

Abstract: The invention relates to a process for drying polymeric powders and polymeric agglomerates, in particular thermoplastic aromatic polycarbonate or other thermoplastic polymers such as, for example, acrylonitrile-butadiene-styrene copolymer, in the melt, whereby thermoplastic polymeric powders or polymeric agglomerates containing water or solvent or both are freed from adhering moisture and contained solvent, accompanied by melting, in an apparatus provided with rotating baffles for cleaning the walls of the apparatus and for distribution and transport of the material being dried, by heat input through the walls or through the rotating baffles or both as well as by heat input as a result of shearing action. The process of drying and that of melting for the subsequent granulation are thereby combined.

Abstract: Improved compositions useful for the production of foamed rotomolded articles are provided. The compositions of the invention are comprised of a first thermoplastic resin component which is an ethylene polymer in pellet form containing a foaming agent and a second thermoplastic resin component which is a powder consisting of a mixture of different particle size and melt index ethylene polymers. An improved process for producing foamed rotomolded articles having uniformly foamed interiors and smooth exterior skins which are substantially free of surface defects is also provided.

Abstract: The present invention concerns a manufacturing process and a related product constituted of a tile in plastic material. The process comprises the following operative stages: crushing a thermoplastic material of recovery, injecting quality plastic material into a mold with a primary punch and a matrix associated to enable the formation of the first layer of the tile between them, rotating the mold to reverse the reciprocal position of the matrix and the primary punch, replacing the primary punch with a secondary punch to mark out, in its association with the matrix, between the first layer, supported by the matrix and the secondary punch, a cavity to contain the thermoplastic material of recovery, injecting the thermoplastic material of recovery into the cavity with the formation of a second layer of a plastic material arranged inside the tile.

Abstract: A high impact resistant rotationally molded door and process for molding the door is disclosed in which a hinge member is integrally molded to the door along one edge only. This hinge member forms to the hollow door edge without door warpage during curing and shrinking of rotationally molded plastic door body. Door warpage is avoided by delaying full integral attachment of the hinge member to the door until curing of the injected foam interior which both bonds to the interior of the door and the hinge member. An improved seal and hinge seal is disclosed together with a placed window construction that can include both placement and shaping to meet the special order needs. Further improvements including the expedient of venting a rotationally molded door during the rotational molding process through an integrally molded hinge edge reinforcing member. This same venting scheme is utilized for enabling improved cooling of the door once molding of the hollow door shell has occurred.

Abstract: A blade for a fan is formed by rotomolding around a pre-positioned support member, part of which extends out of the mold, the support member being shaped, or being provided with one or more projections, which are partly embedded in the plastic material forming a skin of the fan blade. The fan blade is made hollow by this method, but is preferably filled either during molding or subsequently with a hard foam material. A hub is also provided for mounting any fan blades, but in particular those made by the method, in which a hub includes a body portion having a first radial face associated therewith, a plate having a second radial face parallel to the first radial face and spaced therefrom, and a plurality of circumferentially equally spaced depressions facing one another on the first and second radial faces to accommodate the fan blade support members, means being provided to secure the plate to the body portion effective to clamp the fan blade and support members firmly.

Abstract: A protector made of thermoplastic resin to which a foaming agent is added is adapted such that no foams are present in the thermoplastic resin forming a predetermined volume area including lock portions mounted on a protector body for integrating the protector body and a lid element but foams are present in the thermoplastic resin forming the area other than the predetermined volume area, whereby a molded part of thermoplastic resin is provided which accomplishes weight reduction and an insured strength at a strength-required area.

Abstract: A conductive quasi-solution useful for making a homogeneously conductive single-phase polyurethane, comprising a transition metal salt, a carrier solution, and a dispersing agent, wherein said conductive quasi-solution has a transition metal salt concentration between 10 and 30% by weight, and methods of making thermoset and thermoplastic polyurethane polymers therewith.

Abstract: An anhydride-containing thermoplastic resin such as a styrene maleic anhydride copolymer is processed in a vented extruder in the present of a nitrogenous chemical blowing agent to both imidize at least a portion of the anhydride groups and remove volatile residues such as unreacted styrene monomer from the resin.

Abstract: A method for post-mold attachment of a handle to a strain-oriented plastic container body. The method utilizes thermal shrinkage of the oriented container body to engage the handle; for example, a highly-oriented recess is molded in the container body and then shrunk to engage a complimentary-shaped lug on the handle. The method is useful for both hot-fillable and pasteurizable containers, and is particularly useful for making larger-sized containers, wherein the weight of the product and size of the container make handling and pouring difficult.

Abstract: The invention is in the field of three-dimensional hollow novelty items and their manufacture, particularly items such as artificial pumpkins that the consumer desires to carve or alter after purchase. Disclosed is a carvable novelty article, such as an artificial Halloween pumpkin, comprising a polyurethane shell substantially surrounding an interior volume and having a thin, elastomeric coating, such as an acrylic, on the exterior surface of the shell. The carvable article can be formed by an inventive process in which polyurethane foam material, such as material having a nominal density of about 2.5-3.0 pounds per cubic foot, is sprayed from a nozzle rotating with respect to the inside of a mold. After the polyurethane foam article and the mold are separated, the article is coated with an elastomeric coating, such as an acrylic material that is applied as a liquid.

Abstract: Containers, which are impervious to hydrocarbon vapors, in particular to fuel vapors, and comprise an outer shell of plastic material, which is coated with a polyamide layer at least on the surface in contact with the fuel.Said containers are used in the sector of the fuel industry, in particular in the automotive industry, as tanks for automobiles and motor vehicles.

Abstract: The invention relates to a process for insulating pipes by applying a rigid polyurethane foam as an insulating layer and optionally an external top coating by the rotational casting process. The rigid polyurethane foam is obtained by a) an aromatic polyisocyanate, b) an organic polyhydroxyl compound, c) an aliphatic, cycloaliphatic or aromatic polyamine and/or polyimine having a molecular weight of from 32 to 1,000 as the cross linking agent in the presence d) a blowing agent, and optionally in the presence of e) known auxiliary substances and additives and in the presence of f) one or more compounds having a molecular weight of from about 166 to about 1,000 and being of the general formula ##STR1## wherein n represents an integer between 2 and 9, preferably 2 and 3,R.sup.1 signifies hydrogen, a C.sub.1 -C.sub.9 alkyl radical or a ##STR2## R.sup.2 signifies hydrogen, and R.sup.3 and R.sup.4 signify hydrogen or methyl.

Abstract: A process for insulating pipes comprises applying at least one layer of a polyisocyanurate plastic and then at least one layer of rigid polyurethane foam to a steel pipe. The foam is covered with an outer layer.

Abstract: For insulating pipes by application of at least one insulating layer and at least one outer surface layer by rotational molding, a rigid polyurethane foam is used as the insulating layer while a solid polyurethane is used as the surface layer.

Abstract: Methods and apparatus for molding a solid article incorporating one or more vulnerable inserts are disclosed. Centrifugal casting methods for producing a finished article composed of single or multiple curable fluid compounds utilize a self-releasing securing device for holding an insert stably and insulatedly protected within a mold.

Abstract: A cylindrical polymer fiber filter cartridge for liquid filtration is formed by applying an acrylic latex binder, diluted with water, to a batt of thermoplastic polymer fibers and winding the batt onto a core to form a hollow fibrous cylinder while applying compression with a compression roll to an outer surface of the fibrous cylinder. After the batt is fully wound onto the core, the cylindrical cartridge is rotated at a speed sufficient to cause the acrylic latex binder to foam in-situ thereby fluidizing the cartridge to allow the polymer fibers in the cartridge to reorient to form a smooth outer surface on the cartridge and to evenly distribute the acrylic binder throughout the cartridge. The binder in the cartridge is then cured to bond the fibers together at their points of intersection and annular grooves are cut in the outer surface of the cartridge to increase the surface area of the filter.

Abstract: A method and apparatus for producing foam elastomer tires for various uses including bicycle and wheel chair tires with a minimum amount of wasted material. The method involves spin casting the tires wherein a mold with suitably designed tapers on the exterior surface is placed between press plates with corresponding annular tapers which cause the mold to be accurately centered within the press plates when the press is closed. The preblended liquid foamable materials are either poured directly into the mold or onto a surface immediately adjacent to the mold gate. One or more tension members are located within the mold such that either the incoming stream of preblended liquid foamable materials wet the tension member(s), or the tension member(s) lie more or less in the path of the expanding foamable material as it fills and forces its way out of the mold, or (preferably) both.

Abstract: Process for preparing shaped bodies with integrated polyurethane skin, which process comprises:(a) charging to a closed mould for rotational moulding a first premixed reactive polyurethane system;(b) causing the mould to rotate, according to rotational moulding technology, for a long enough time to form a thin layer of partially polymerised material on the inner surface of said mould; and(c) discontinuing the rotation and charging to the mould a reactive material which will fill the inner mould hollow.

Abstract: Mobile structural unit molding and assembling apparatus includes a support portion, a raw material supplying portion, a molding portion, a unit transferring portion and a control portion. The support portion includes at least one base section with a wheeled carriage. The raw material supplying portion includes a plurality of reservoirs disposed on the base section. The molding portion includes at least one rotatable mold assembly disposed on the base section including at least two separable mold sections. A mixing chamber adjacent the mold assembly connects with raw material reservoirs through independent conduits. The unit transferring portion includes a tiltable unit positioning assembly selectively movable with respect to the molding portion. The control portion includes a programmable memory, a coordinator, sensors, actuators, a unit orienter and circuitry therefor.

Abstract: Multi-axis rotational polymeric mixture distributing apparatus includes a raw material supplying portion, a supporting portion, a raw material mixing portion, a polymeric mixture distributing portion, a polymeric mixture accepting portion and a control portion. The raw material supplying portion includes a plurality of reservoirs, each connected independently with the mixing portion. The supporting portion includes a plurality of driven frame members each with a large open central area being disposed between parallel spaced upstanding end sections and rotatably supported thereon, each being progressively smaller in size than the next larger frame member and disposed within the open central area thereof. Alternate frame members are rotatable about aligned axes with frame members therebetween rotatable about axes generally perpendicular thereto. The smallest frame member includes rotatable holding sections.

Abstract: An integrally molded plastic structural unit includes spaced support members joined by a web section disposed therebetween, each of the support members including spaced face sections and an intermediate section therebetween. Each face section includes a stressed hard outer skin. The intermediate section includes a peripheral frame section of high density. The web section includes high density connector members extending between adjoining face sections of the spaced support members. Each of the support members includes mateable sections along at least two edges thereof, with each of the mateable sections including at least five alternating raised and recessed areas forming an asymmetrical pattern along the length of each mateable section. The pattern is the same or a reverse pattern thereof along each mateable section of the same unit and of adjacent units with which it will be assembled.

Abstract: A method of making a foam filled polymer article includes the steps of compressing an expandable foam material (12) and containing the compressed expandable material (12) in a degradable container, such as a polyethylene bag (16). An outer polymer shell (10) is formed while degrading the container (16) therewithin, such as by rotation molding. The shell (10) is filled with the uncontained expandable foam material (12).

Abstract: A low-pressure inflatable article, made by rotomolding of polyvinyl chloride materials, featuring a lower weight as compared to similar articles made of the same material as well as improved physical characteristics which permit inflation of the article without the need for any inflation mechanical device, such as inflation with the mouth.

Abstract: Continuous molding apparatus includes a raw material supplying portion, a mixing portion, a molding portion, a mixture delivery portion, a supporting portion and a control portion. Each reservoir of the raw material supplying portion is independently connected to an inlet of the mixing portion. The molding portion includes a plurality of spaced rotatable mold assemblies, each with at least two retractable mold sections. The mixture delivery portion is selectively alignable with each mold assembly sequentially in a preselected repeating cycle through an indexing mechanism.

Abstract: Continuous molding apparatus includes a raw material supplying portion, a molding portion, a supporting portion, a mixing portion and a control portion. Each reservoir of the raw material supplying portion is connected independently with the mixing portion. The molding portion includes a plurality of spaced mold assemblies each with at least two separable mold sections. The supporting portion includes a plurality of the spaced mold assemblies each supported for independent rotation about more than one axis. The mixing portion includes an elongated mixing chamber disposed adjacent each mold assembly each with a plurality of deflector sections. A continuous method of molding a foamed product includes providing a plurality of raw material reservoirs and continuously moving raw material from each reservoir independently to a plurality of spaced mixing chambers each of which is located adjacent to an individual mold assembly including separable mold sections.

Abstract: A method and apparatus for forming a product, and the product, such as a buoy with a plastic outer skin or shell and a plastic foam interior are provided. A first charge including, in one exemplary embodiment, a cross-linkable resin is added to a mold component, followed by a second charge, isolated from the first, and including in the exemplary embodiment expandable polystyrene beads. The apparatus is rotated about two mutually perpendicular axes. Initially, the cross-linkable composition is rotation molded against the walls of the mold to form the outer shell. Thereafter, the second charge of polystyrene beads is released within the mold, at a sufficient temperature to cause expansion of said beads against the shell.

Abstract: Apparatus for producing articles of polyurethane or the like material including a mold of the article shape and apparatus for centrifugally discharging the polyurethane material used into the mold such that polyurethane molecules will strike the wall of the mold and break so that the article produced has a smooth, non-porous outer skin and the interior of the article has a foamed interior.

Abstract: A product and process for reconditioning abrasive stones used to sharpen metal tools such as woodworking tools. The product is a slab made up of abrasive grain bond with an organic polymer.

Abstract: A spincasting technique for forming a syntactic insulation layer around a pipeline includes rotating a drum while or after injecting components for forming syntactic insulation material into said drum. In this manner a syntactic material is formed in which larger, low density, microspheres are biased towards the inner surface of the insulation layer.