Abstract: Methods are provided in this invention to produce wood-like boards of polyvinylchloride, which are suitable for applications, such as graphic art, construction, furniture, etc. In one of the two embodiments disclosed in this invention, the wood-like polyvinyl chloride boards have smooth surface quality, a density below 0.95 g/cm3, good dimensional stability and strong abrasive resistance. These are produced by hot mixing, cold mixing, extrusion, calibration for quenching and subsequent cutting, to produce solid skin, foamed core products. In the other embodiment, the wood-like polyvinyl chloride boards have embossed surface quality, a density below 1.0 g/cm3, good dimensional stability and surface hardness. These are produced by hot mixing, cold mixing, extrusion and subsequent slow cooling with a roller system to produce embossed products.

Abstract: An improved coat hanger extrusion die wherein the aperture of the die land widens along the extrusion axis of said die to the die exit opening, thereby forming an expansion zone, and a method for extruding foamed polypropylene sheet having an improved surface appearance.

Abstract: At least one container is disposed in contact with at least one mandrel to cause a thermoplastic polymeric film on the container to foam and become a heat insulative layer. The mandrel is heatable to a predetermined temperature and the container is in direct contact therewith or disposed thereon for a predetermined period of time, to thereby cause the foamable material on the container to foam. A method of making a web of heat insulative nonwoven material includes providing a web of nonwoven material, applying a layer of thermoplastic polymeric material to a first surface of the web to form a web laminate, placing the web laminate in contact with a heated surface, heating the web laminate and thereby expanding the layer of thermoplastic material with moisture that is vaporized from the nonwoven material. The web laminate may then be fabricated to form a container or a portion of a container.

Abstract: Writing instruments include a foam layer covering the outer surface of a preformed tubular core. The writing instruments are formed by a pultrusion process.

Abstract: A tapered stepped land having a choked funnel section which terminates in a lateral longitudinal section results in the formation of a foamed extrudate of a vulcanized blend of polyolefin and rubber which is a mass of closed cells having a specific gravity in the range from about 0.1 to 0.5 and the cells are sheathed in a dense non-porous, smoothly continuous skin which is formed integrally with the extrudate. The dense skin makes it possible to deposit a thin slip-coating of a low friction material longitudinally upon a chosen portion of the surface. An extruded weatherseal for the glass of an automobile's window has the slip-coating deposited as a thin film on a contacting strip of a surface which is in contact with the glass.

Abstract: The invention comprises a fully continuous process for shaping a high internal phase emulsion (HIPE) with a polymerizable continuous phase into dry foam, comprising 1) providing a high internal phase emulsion (HIPE) comprising (a) at least 70 percent by volume of an eternal phase comprising one or more polymerizable monomer; (b) a surfactant in an amount effective to produce a high internal phase emulsion; and (c) an internal phase; 20 depositing the emulsion onto a lower moving support substrate; 3) leveling the emulsion to a desired thickness above the support substrate; 4) polymerizing the monomers by running the emulsion and the lower moving support substrate through a heating zone for a time sufficient to polymerize at least 75% of the monomer in the HIPE by the end of the heating zone; and 5) drying the polymerized HIPE in a drying zone for a time sufficient to produce a foam having greater than 50% of the internal phase removed.

Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.

Abstract: In a process for producing a cover skin of thermoplastic polyurethane for the instrument panel of a motor vehicle, a preform is produced from thermoplastic polyurethane by extrusion and is thereafter expanded by increased internal pressure in a blow molding mold.

Abstract: A coated film comprises a thermoplastic resin support film (I), a primer coating layer (II) on at least one surface of the support (I), and an ink absorbing layer (III) comprising at least three kinds of inorganic pigments and a binder resin, coated onto the primer coating layer (II). The coated film of the present invention may be offset printed and printed with a thermal melt transfer or impact dot printer.

Abstract: Foam forming techniques are capable of permitting foaming of biodegradable resin to be positively and uniformly accomplished to provide a biodegradable resin foam with satisfactory quality. The biodegradable resin foam is made of biodegradable resin a main biodegradable resin ingredient of 100° C. or more in melting point and a low-melting biodegradable resin ingredient of 100° C. or less in melting point. The biodegradable resin foam is produced by placing a starting material of at least biodegradable resin and a substantial amount of moisture in a heated and pressurized environment, releasing the starting material from the environment to foam the biodegradable resin, and subjecting the foamed resin to forming by a forming mold. An apparatus for producing the foamed biodegradable resin foam includes a pressure adjusting chamber, an air-permeable forming mold, a pressure reducing tank and an injection machine.

Abstract: An opaque, oriented polymeric film structure comprises: (a) a core layer containing a thermoplastic polymeric matrix material which has a first surface and a second surface, the core layer having a plurality of voids, substantially all or all of the voids being free from a void-initiating particle and at least some of the voids being interconnected with an adjacent void in the polymeric matrix material, the number of voids not containing a void-initiating particle being sufficient to impart a significant degree of opacity to the film structure; and (b) at least one outer or skin layer containing a thermoplastic polymeric material and an effective amount of a nucleating agent to suppress cavitation in said at least one outer or skin layer. The film structure has a smooth surface and can be tailored to provide a controlled permeability, and is particularly suitable for food packaging.

Abstract: A method for forming an automotive instrument panel having a concealed door comprising a series of steps. A plastic parison is extruded to form the substrate layer of the instrument panel. The parison has first and second walls. The parison is placed within a mold and the first wall is contacted with the second wall to form a hinge. The area of contact forms a bond between the first and second walls. A different portion of the first and second walls are contacted to form an opening path. The opening path intersects the hinge. The opening path usually has a thickness much less than the thickness of the first and second walls to form an easily fracturable area. The door swings on the hinge to open. A elongated section of material on the second wall, enables the second wall to wrap along the hinge when the door is opened.