By Mechanically Introducing Gas Into Material Patents (Class 264/50)
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Patent number: 7166248Abstract: A method for producing an alkenyl aromatic polymer foam structure that comprises melting at least one alkenyl aromatic polymer resin. An effective amount of blowing agent mixture is dissolved in the at least one alkenyl aromatic polymer. The blowing agent mixture comprises at least one VOC blowing agent and acetone. The majority by mole percent of the VOC blowing agent is selected from n-butane, iso-butane, propane and combinations thereof. An extrudate is formed comprising the at least one alkenyl aromatic polymer resin, the at least one VOC blowing agent, and acetone. The extrudate comprises less than about 2.7 wt. % of the at least one VOC blowing agent. The extrudate is transferred to an expansion zone and permitted to expand to produce the foam structure. The foam structure has an extruded density less than about 7 lbs/ft3 and a basis weight of less than about 20 grams per 100 in2.Type: GrantFiled: January 3, 2003Date of Patent: January 23, 2007Assignee: Pactiv CorporationInventors: Gary A. Francis, Wen P. Wu
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Patent number: 7150615Abstract: A process for injection-foaming a thermoplastic resin by using an injection molding machine with a two-stage-compression screw, injecting a physical foaming agent into the cylinder of the machine at a pressure lower than the storage pressure of the physical foaming agent, mixing it with a melted resin and expanding the volume of the cavity of the mold at the time of injection, and an injection molding machine and resin composition suitable therefore.Type: GrantFiled: August 3, 2004Date of Patent: December 19, 2006Assignee: Mitsui Chemicals, Inc.Inventors: Eiichi Sugihara, Michio Eriguchi, Masaki Misumi
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Patent number: 7144532Abstract: The present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.Type: GrantFiled: October 28, 2002Date of Patent: December 5, 2006Assignee: Trexel, Inc.Inventor: Roland Y. Kim
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Patent number: 7138079Abstract: Methods for making foamed elastomer gels are disclosed. Chemical foaming agents may be incorporated or gas may be injected into a molten gel and then using heating and cooling techniques and/or additives, gas bubbles are formed and preserved in the cooled and solidified elastomer gel.Type: GrantFiled: February 11, 2003Date of Patent: November 21, 2006Assignee: EdiZone, LCInventor: Terry V. Pearce
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Patent number: 7132023Abstract: The invention relates to a method and a device for foaming glue for the production of wood-based sheets. Gluing substance and gas are fed (1,2) into the foaming device through nozzles (3,4), which are directed to mix the gluing substance and gas to be fed to form an essentially homogenous mixture prior to foaming. After this the gluing substance is foamed mechanically in the foaming chamber (5) with the aid of gas.Type: GrantFiled: December 31, 2003Date of Patent: November 7, 2006Assignee: Raute OyjInventors: Raili Kaarina Virtanen, legal representative, Jouni Rainio, Matti Virtanen, deceased
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Patent number: 7118696Abstract: Polymeric structures produced with a controlled number and distribution of small, closed cells. The polymeric structures are characterized by an opaque, whitening appearance attributed, at least in part, to the distribution of closed cells and thus, at least in part, to light scattering resulting from the distribution of small, closed cells or voids. The light scattering thus provides an enhanced whitening effect. The whitening effect may be uniform or non-uniform along the length and width of the structure.Type: GrantFiled: June 8, 2004Date of Patent: October 10, 2006Assignee: Milliken & CompanyInventors: Kirkland W. Vogt, Daniel T. McBride, Robert M. Smith
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Patent number: 7105112Abstract: A lightweight member is provided for reinforcing, sealing or baffling structures of articles of manufacture such as automotive vehicles. The lightweight member preferably includes a carrier member having a cellular structure and an expandable material disposed thereon.Type: GrantFiled: October 16, 2003Date of Patent: September 12, 2006Assignee: L&L Products, Inc.Inventors: Michael J. Czaplicki, David Carlson
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Patent number: 7105113Abstract: A method is disclosed for flatproofing a tire and wheel assembly with a flexible, lightweight foam-fill by supplying at least two polyurethane reactive materials to a static mixer. The static mixer mixes the reactants, and a nucleating gas is supplied to the mixed reactants in the static mixer to form a liquid reactant mixture with entrained gas. The reactant mixture is injected into the tire and wheel assembly where the mixture reacts and foams replacing the air in the tire with a flexible, lightweight semi-open cell foam-fill. The resulting foam-filled tire and wheel assembly is then allowed to cure.Type: GrantFiled: October 16, 2003Date of Patent: September 12, 2006Assignee: Urethane International LLCInventors: John Danules, Steve Anderson, Van Doesburg
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Patent number: 7097438Abstract: A foaming agent charging and mixing device comprises at least one mixing device and one foaming agent metering device, wherein the foaming agent charging and mixing device may be arranged between an plasticating screw and a mold. In order to improve the foaming agent charging and mixing device in a manner that the mixing with foaming agent is facilitated and at the same time a risk of obstruction of the foaming agent metering device is avoided, the foaming agent metering device is alternately opened and closed through the mixing device during operation thereof for supplying foaming agent to the plastic melting.Type: GrantFiled: June 16, 2003Date of Patent: August 29, 2006Assignee: Demag Ergotech GmbHInventors: Erich Schuermann, Juergen Herrmann, Ansgar Jaeger, Marco Prigandt, Joerg Seidel
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Patent number: 7087200Abstract: An indirect solid free form scaffold manufacturing technique is provided. More particularly, the present invention provides a set of molds, casting methods, mold removals, and surface modification techniques that are compatible with image-based design methods and with solvent, melt, and slurry casting of polymers and ceramics.Type: GrantFiled: June 24, 2002Date of Patent: August 8, 2006Assignee: The Regents of the University of MichiganInventors: Juan Taboas, Rachel D Maddox, Paul H Krebsbach, Scott J Hollister, Tien-Min Gabriel Chu
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Patent number: 7083403Abstract: An apparatus for supplying a resin material to an injection molder comprises a vessel for storing a resin material, gas supplying means for supplying an inert gas to the vessel which is not a super-critical state, and material supplying means for supplying the resin material from the vessel to an injection molder.Type: GrantFiled: April 18, 2005Date of Patent: August 1, 2006Assignee: Canon Kabushiki KaishaInventor: Takashi Arai
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Patent number: 7077987Abstract: Disclosed is a method for foam-injection molding a thermoplastic resin, comprising: (1) providing a mold comprising a fixed mold half and a movable mold half mating with the fixed mold half to thereby form a mold cavity defined by an inner wall of the fixed mold half and an inner wall of the movable mold half, wherein the mold cavity has an inner wall which has a molten resin releasing means, (2) injecting a foamable thermoplastic resin in a molten form into the mold cavity of the mold, thereby forming a foamable molten resin mass in the mold cavity, (3) applying a pressure to the foamable molten resin mass in the mold cavity to press the surface of the foamable molten resin mass against the inner wall of the mold cavity, thereby allowing a surface portion of the foamable molten resin mass to be solidified to form a surface skin layer of the foamable molten resin mass, and (4) releasing a portion of the foamable molten resin mass under the foaming pressure exerted by the foamable molten resin mass to the outsType: GrantFiled: December 26, 2001Date of Patent: July 18, 2006Assignee: Asahi Kasei Kabushiki KaishaInventors: Hiroshi Yamaki, Yuji Tanaka
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Patent number: 7070722Abstract: A process for producing a sterile foam for medical or veterinary use is provided. A physiologically acceptable formulation for application to a body as a foam contains a foamable gelling agent. The formulation is foamed and treated with a precipitant which is calcium citrate or a calcium ion. The precipitant is combined with the foamable gelling agent before or during the foaming of the gelling agent. The foam thus obtained is allowed to cure and is then immersed in a bath of the precipitant. The treated foam is dried and sterilized by exposure to gamma-irradiation or ethylene oxide.Type: GrantFiled: October 7, 1999Date of Patent: July 4, 2006Assignee: Giltech LimitedInventors: Tom Gilchrist, Eilidh Trainer
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Patent number: 7045082Abstract: The invention relates to a process for producing foam webs by foam extrusion of a mixture of a polysulfone or polyether sulfone and a volatile blowing agent, where the blowing agent is water or a mixture of water with an inert gas or organic liquid, e.g. an alcohol or a ketone.Type: GrantFiled: December 16, 2002Date of Patent: May 16, 2006Assignee: BASF AktiengesellschaftInventors: Franz-Josef Dietzen, Dietrich Scherzer, Joachim Queisser, Swen Rück, Gerd Ehrmann, Wolfgang Kratzmüller
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Patent number: 7014801Abstract: The present invention relates to a hollow molded foam article in which a plurality of polypropylene resins are used as the base resin, and to a process for the production of this hollow molded foam article. More particularly, the present invention relates to a polypropylene resin hollow molded foam article having a foam layer, in which the base resin comprises (a) a polypropylene resin with a melt tension of at least 98 mN and a melt flow rate of 0.5 to 15 g/10 minutes, (b) a polypropylene resin with a melt tension of less than 30 mN (excluding O) and a melt flow rate of 2 to 30 g/10 minutes, and (c) a polypropylene resin with a melt tension of at least 30 mN and less than 98 mN and a melt flow rate of 2 to 15 g/10 minutes, formed by positioning in a mold a softened cylindrical foam having a foam layer obtained by extruding from the die of an extruder a foamable molten resin composition containing a foaming agent, wherein the melt tension at 230° C.Type: GrantFiled: September 23, 2003Date of Patent: March 21, 2006Assignee: JSP CorporationInventors: Daisuke Imanari, Teruyuki Akiyama, Naochika Kogure, Masato Naito
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Patent number: 7008576Abstract: Microporous ceramic materials used in structural materials, high-temperature filters, electrode materials or preform materials for infiltration by homogeneously mixing and molding a ceramic precursor powder polymer. The powder is saturated by introducing fluid to a pressure vessel. The fluid is super saturated by adjusting pressure in the vessel. Micropores are formed in the molded bodies by evolving the fluid from the molded bodies by heating and hardening the molded bodies. The hardened molded bodies are heated to pyrolysis. Pore characteristics (e.g., pore size and pore size distribution) suitable to target materials are controlled by adjusting pressure at a non-critical state without requiring additional processes or devices.Type: GrantFiled: June 17, 2003Date of Patent: March 7, 2006Assignee: Korea Institute of Machinery and MaterialsInventors: Hai-Doo Kim, Young-Wook Kim, Chul Bum Park
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Patent number: 7008202Abstract: The present invention relates to the step of plasticizing a thermoplastic resin material by rotatably driving a screw (20). Also included in the method is the step of injecting an inert gas into a screw cylinder (1) to permeate the melted resin and injecting the melted resin into a mold by driving the screw (20) in the direction of injection. Here, the inert gas has a pressure, at least in pressure, equal to or greater than a supercritical pressure or is under a supercritical state. To provide a thermoplastic resin foam by the method, electric servomotors (31, 32) are employed to drive the screw (20). After the step of plasticizing the resin material has been completed, brakes are applied to the electric servomotors (31, 32) to prevent the screw (20) from retreating. Alternatively, even after the step of plasticizing the resin material has been completed, the screw (20) is driven at low speeds in the direction of plasticization until immediately before the step of injecting the melted resin is initiated.Type: GrantFiled: March 12, 2003Date of Patent: March 7, 2006Assignee: The Japan Steel Works, Ltd.Inventors: Atsuo Teraoka, Fumiaki Tsuda, Hideo Ohyabu
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Patent number: 7008578Abstract: A method for production of an extruded, polystyrene-based foam plate wherein a polystyrene-based resin is heated and kneaded together with a blowing agent, a flame retardant and a nucleating agent in an extruder to obtain a foamable molten composition, and the foamable molten composition is extruded through a die attached to an end of the extruder into a lower pressure zone. The blowing agent comprises not smaller than 25% by weight but not greater than 65% by weight, based on the total weight of the blowing agent, of an isobutane-containing saturated hydrocarbon; not smaller than 5% by weight but not greater than 70% by weight, based on the total weight of the blowing agent, of a dimethyl ether-containing ether; not smaller than 5% by weight but not greater than 55% by weight, based on the total weight of the blowing agent, of carbon dioxide; and 0–25% by weight, based on the total weight of the blowing agent, of other blowing agent components.Type: GrantFiled: June 14, 2002Date of Patent: March 7, 2006Assignee: JSP CorporationInventors: Masato Naito, Naochika Kogure, Daisuke Imanari, Noritoshi Nishiyama
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Patent number: 7001549Abstract: A process for producing physically foamed injection molded articles is provided. The process involves feeding a propellant-free thermoplastic melt into a cavity followed by delivering a physical propellant directly into the cavity or directly into the melt flowing into the cavity. The pressure exerted on the propellant during the injection stage is greater than that exerted on the propellant during the holding phase.Type: GrantFiled: March 15, 2000Date of Patent: February 21, 2006Inventor: Ulrich Stieler
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Patent number: 6956067Abstract: Expanded, substantially non-crosslinked polypropylene resin beads capable of producing a high rigidity foamed molding at a relatively low temperature. The beads are produced by a process including a step of dispersing substantially non-crosslinked polypropylene resin particles in a dispersing medium containing an organic peroxide to obtain a dispersion, a step of heating the dispersion to decompose the organic peroxide and to modify the surface of the surface-modified polypropylene resin particles, and a step of expanding the non-crosslinked, surface-modified polypropylene resin particles using a blowing agent.Type: GrantFiled: March 6, 2003Date of Patent: October 18, 2005Assignee: JSP CorporationInventors: Hidehiro Sasaki, Akinobu Hira, Keiichi Hashimoto, Hisao Tokoro
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Patent number: 6949208Abstract: An object of the invention is to provide an injection molding process for preparing thermoplastic resin molded articles and an injection molding apparatus for use in practicing this process, the process and the apparatus being adapted to supply a blowing agent, especially a nonreactive gas such as carbon dioxide or nitrogen gas, to a thermoplastic resin continuously at a relatively low pressure with good stability to incorporate the agent or gas into the resin. As shown in FIG. 3, a resin in a cylinder (2) of an injection molding machine (1) as melted by rotating a screw (3) is mixed and dissolves carbon dioxide which is supplied to the molten resin from a gas supply opening (5) formed in the screw (3). An amount of the gas-incorporating molten resin is measured out and injected into a mold cavity to obtain an expansion-molded article.Type: GrantFiled: September 6, 2000Date of Patent: September 27, 2005Assignee: Sekisui Chemical Co., Ltd.Inventors: Hitoshi Kawauchi, Hiroshi Harada, Hiroyuki Hirano, Satoshi Shimura
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Patent number: 6946090Abstract: A method for extruding a corrugation-free polystyrene foam with up to 100% carbon dioxide as the blowing agent by extruding the extrudate through an annular die opening so that it contacts a choke ring inner surface. A foam made with the apparatus according to the invention will have no visible corrugations and an average cell size of less than 0.35 mm.Type: GrantFiled: March 28, 2002Date of Patent: September 20, 2005Assignee: Dart Container CorporationInventors: Wayne J. Myer, Blaine M. Kelley
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Patent number: 6936200Abstract: A process for producing plastic/wood fiber composite foamed structures includes the steps of pre-drying wood fiber filler; mixing it with plastic to form a mixture; feeding the mixture into an extruder; introducing and mixing a blowing agent; subject the mixture to high shear forces and extruding the mixture to produce a plastic/wood fiber composite foamed structure. The filler has a degradation temperature and an active volatization temperature. During the pre-drying step the temperature is maintained below the degradation temperature. During the mixing step the mixing temperature is maintained below the active volatilizing temperature. During the introducing and mixing step a blowing agent is introduced into the plastic/wood fiber mixture and is mixed therewith to produce a plastic/wood fiber/gas mixture. During the subjecting step the plastic/wood fiber/gas mixture is subjected to high shear forces in the presence of high pressures and the temperature is maintained below an active volatilizing temperature.Type: GrantFiled: December 7, 2001Date of Patent: August 30, 2005Inventors: Chul B. Park, Ghaus M. Rizvi, Haiou Zhang
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Patent number: 6932925Abstract: A super-lightweight ceramic foam with a cellular structure effectively reinforced by ceramic short fibers, which has a density of 0.2 g/cm3 or less and a sufficient strength. The ceramic foam is prepared by evenly dispersing ceramic short fibers throughout a nonaqueous solvent through the use of the reactivity of metal alkoxide with the surface of the ceramic short fibers, adding into the nonaqueous solvent an aqueous slurry containing ceramic powder dispersed therein, allowing the evenly dispersed ceramic fibers to move into an aqueous phase separately from a nonaqueous solvent phase so as to obtain an aqueous slurry containing the ceramic fibers evenly dispersed therein, and foaming and firing the aqueous slurry.Type: GrantFiled: October 3, 2003Date of Patent: August 23, 2005Assignee: National Institute of Advanced Industrial Science and TechnologyInventors: Kazushi Kishi, Eiji Tani, Eishi Maeda
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Patent number: 6929763Abstract: The invention provides an injection molding method comprising supplying a gas into a molten resin in a plasticizing cylinder and injecting the molten resin having the gas dissolved therein, wherein when the resin is being plasticized, a gas space with a predetermined gas pressure is formed within the plasticizing cylinder in a gas supply section and the pressure at the front end of the screw is adjusted to be at least equal to the gas pressure in the gas space and within a range where the gas space can be maintained within the plasticizing cylinder in the gas supply section. According to the invention, the necessary amount of gas can be dissolved in the molten resin with good reproducibility in a quantitative manner.Type: GrantFiled: May 31, 2001Date of Patent: August 16, 2005Assignee: Asahi Kasei Kabushiki KaishaInventor: Hiroshi Yamaki
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Patent number: 6902693Abstract: Open celled membranes from thermoplastic polymers are prepared from foamed polymer melts by extrusion through a die.Type: GrantFiled: January 22, 2002Date of Patent: June 7, 2005Assignee: Sartorius AGInventor: Rebecca Klötzer
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Patent number: 6884823Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.Type: GrantFiled: June 18, 1999Date of Patent: April 26, 2005Assignee: Trexel, Inc.Inventors: David E. Pierick, Jere R. Anderson, Sung W. Cha, Liqin Chen, James F. Stevenson, Dana E. Laing
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Patent number: 6884377Abstract: 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.Type: GrantFiled: July 27, 2000Date of Patent: April 26, 2005Assignee: Trexel, Inc.Inventors: Theodore A. Burnham, Sung W. Cha, Robert H. Walat, Roland Y. Kim, Jere R. Anderson, James F. Stevenson, Nam P. Suh, Matthew Pallaver
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Patent number: 6884380Abstract: The invention is to ensure that in injection molding a molten resin having carbon dioxide dissolved therein as a plasticizer, a sufficient amount of carbon dioxide to achieve satisfactory improvement in flowability is dissolved in the molten resin so that the flowability of the molten resin is significantly improved while enabling the production of a non-foamed molded article. Specifically, in the invention, a molten resin having dissolved therein a sufficient amount of carbon dioxide to improve its flowability is filled into a mold cavity while allowing to foam at the flow front of the molten resin, and the resin in the mold cavity is then pressurized to at least a pressure at which it does not foam.Type: GrantFiled: June 12, 2001Date of Patent: April 26, 2005Assignee: Asahi Kasei Kabushiki KaishaInventor: Hiroshi Yamaki
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Patent number: 6881365Abstract: In order to achieve an economical and trouble-free continuous extrusion of plastic hollow profiles having at least one hollow chamber that is filled with foam, the profile tool of an extrusion device is configured in the shape of a pistol. The profile tool comprises a pistol shaft (102) with a melt feed channel (166), connected to the melt discharge opening of the extruder (300) and which opens into a melt radial distributor channel (164) that surrounds the lance guide channel (150). The profile tool is also equipped with a pistol barrel (101) comprising a melt ring channel (162), which extends from the melt radial distributor channel (164) to the profile nozzle (160) and comprising a lance guide channel (150), which extends in a continuous manner from a lance inlet (152) to the profile nozzle (160).Type: GrantFiled: December 18, 2000Date of Patent: April 19, 2005Assignee: Veka AGInventor: Alfons Topp
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Patent number: 6841106Abstract: The invention provides a method for producing a foamed article comprising the steps of: heating a mixture comprising (a) 100 parts by weight of linear saturated polyester, (b) 0.1 to 10 parts by weight of a mixture as a coupling agent of 0 to 100% by weight of a compound having two epoxy groups in the molecule, and 100 to 0% by weight of a compound having two or more epoxy groups, and (c) 0.01 to 5 parts by weight of a metal salt of a carboxylic acid as a coupling reaction catalyst, at a temperature of a melting point of the polyester or more to provide a melt flow rate of 50 g/10 minutes or less and swell of 10 to 200%, whereby a polyester resin is formed; and heating and foaming the polyester resin using a foaming agent .Type: GrantFiled: October 1, 1999Date of Patent: January 11, 2005Assignee: DJK Techno Science Laboratories, Inc.Inventors: Takashi Fujimaki, Yoshitomo Urata
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Patent number: 6838488Abstract: A method for producing expanded polypropylene resin particles wherein polypropylene resin particles impregnated with a physical blowing agent are heated along with an aqueous medium and a dispersant and are released and expanded at reduced pressure from the interior of a pressure-tight vessel, wherein the aforementioned aqueous medium has an electrical conductivity of from not less than 0.00 ms/m to not more than 20.00 mS/m. The resulting particles obtained are without inconsistencies caused by differences in the amount of dispersant adhering to the particles or the amount of dispersant added to prevent the particles from fusing together during the heat treatment step of the method.Type: GrantFiled: June 7, 2002Date of Patent: January 4, 2005Assignee: JSP CorporationInventors: Hidehiro Sasaki, Kazuya Ogiyama, Akinobu Hira, Keiichi Hashimoto, Hiroki Yanagisawa, Hisao Tokoro
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Publication number: 20040262798Abstract: A method of producing a foamed synthetic resin molding article by using a mold comprising a closed space formed by a lower mold and an upper mold as a cavity to be supplied with a material, closing the upper and lower molds, foaming the material, curing the foamed body and demolding the foamed and molded body, wherein the method comprises the steps of supplying the material for foamed synthetic resin molding article under atmospheric pressure, closing the upper and lower molds so that a gas in the mold can be exhausted, causing foam molding, preliminarily measuring a cavity fill-up time required for the foamed body of the material to fill up the cavity, thereafter supplying the material into the cavity under atmospheric pressure, closing the upper and lower molds so that the gas in the mold can be exhausted, causing foaming to proceed, and perfectly closing the upper and lower molds when the cavity fill-up time has passed.Type: ApplicationFiled: April 20, 2004Publication date: December 30, 2004Inventors: Kazuhiko Hori, Takao Ishibashi, Takahisa Murata
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Patent number: 6832429Abstract: A method for creating a hot melt foamed form for an air induction system. A block of thermal mastic elastomer is melted and blended with nitrogen gas to create a foamed material. The foamed material is applied by robotic techniques over a base material on the surface of a polypropylene glass lower shell. After the foamed material cures, a polypropylene glass cover is applied over the foamed material form to create an air tight dust/water seal. The cover does not adhere to the cured foamed material and is removable when service is necessary. The foam material can also be dispensed into a mold and then transferred to the base, allowing for changes in the shape and profile of the foamed material. This method can also be employed to create an isolation pad on an air induction system to absorb engine shock. The thermal mastic elastomer can also be employed to create a seal between the cover neck of an air induction assembly and a mass air flow sensor.Type: GrantFiled: October 9, 2001Date of Patent: December 21, 2004Assignee: Siemens VDO Automotive Inc.Inventors: Gordon R. Boyes, Robert John Lidster, Boderic Cole
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Patent number: 6827888Abstract: An annular die designed to produce polymer foam using only one or more ambient gasses as a blowing agent includes an exiting channel with an exit having a cross-sectional area between about two and about ten times that of a smallest point within the exit channel. The section of the die from the smallest point to the exit is thermally isolated from the rest of the die, and the temperature thereof is independently controlled. In addition, the interior surface of the exit channel is coated with a friction-reducing coating.Type: GrantFiled: January 23, 2001Date of Patent: December 7, 2004Assignee: Genpak LLCInventor: Walter R. Harfmann
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Publication number: 20040241367Abstract: The present invention relates to light weight molded plastic articles and methods of making same. More specifically, the present invention relates to a method of manufacturing a hollow-core, foamed-plastic, film-laminate article utilizing convention gas assisted molding apparatus with corresponding high production rate capabilities. The resulting film-laminate, hollow-core, foamed-plastic part comprises a class A show-face surface. The method comprises formation of a porous mass of molten plastic in the mold cavity containing the laminate. The molten plastic is cored out or hollowed by injection of gas into the mold cavity.Type: ApplicationFiled: July 6, 2004Publication date: December 2, 2004Inventors: Daniel R Johnson, Andrew G Yorde
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Patent number: 6821464Abstract: A process for producing a polymer/filler composite material includes a mixture forming step in which there is obtained a mixture of a flake-like filler and a polymer material, and the mean area (L2), mean thickness (d) and volume fraction (c) of the flake-like filler in the mixture satisfy the following equations (1), (2) and (3): 500 nm2≦L2≦100 &mgr;m2 (1) d≦L/20 (2) 0.2d/L≦c≦4d/L (3), and a deforming step of applying deformation to the mixture at a strain rate of no greater than 10 s−1.Type: GrantFiled: May 29, 2002Date of Patent: November 23, 2004Assignee: Kabushiki Kaisha Toyota Chuo KenkyushoInventors: Hirotaka Okamoto, Naoki Hasegawa, Arimitsu Usuki, Makoto Kato, Masami Okamoto
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Publication number: 20040212119Abstract: The invention relates to a process for producing foam webs by foam extrusion of a mixture of a polysulfone or polyether sulfone and a volatile blowing agent, where the blowing agent is water or a mixture of water with an inert gas or organic liquid, e.g. an alcohol or a ketone.Type: ApplicationFiled: December 16, 2002Publication date: October 28, 2004Inventors: Franz-Josef Dietzen, Dietrich Scherzer, Joachim Queisser, Swen Ruck, Gerd Ehrmann, Wolfgang Kratzmuller
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Publication number: 20040201120Abstract: A method of manufacturing gypsum board includes applying compressed air to an input end of a tube, wherein the tube includes the input end, an output end, and a venturi located between the input end and the output end; admitting a foaming agent to the input end of the tube so as to form a mixture of the compressed air and the diluted foaming agent; passing the mixture through the venturi and out the output end; combining the mixture with gypsum and water to form a gypsum slurry; and casting the gypsum slurry onto a continuous web for forming a gypsum board.Type: ApplicationFiled: February 2, 2004Publication date: October 14, 2004Applicant: LAFARGE NORTH AMERICA, INC.Inventor: Elizabeth Colbert
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Patent number: 6790870Abstract: A method of producing a foamed material comprises contacting a mixture comprising a first thermoplastic polymer and a second thermoplastic polymer with a blowing agent, wherein the first thermoplastic polymer has a higher percent crystallinity that the second thermoplastic polymer; and subjecting the mixture to conditions sufficient to create a thermodynamic instability in the blend foam the mixture, wherein the mixture comprising the first and second thermoplastic polymers has a percent crystallinity lower than the first thermoplastic polymer.Type: GrantFiled: March 1, 2000Date of Patent: September 14, 2004Assignees: North Carolina State University, The University of North Carolina at Chapel HillInventors: Joseph M. DeSimone, Saad A. Khan, Joseph R. Royer, Richard J. Spontak, Teri Anne Walker, Yvon J. Gay, Srinivas Siripurapu
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Patent number: 6773640Abstract: A process for injection-foaming a thermoplastic resin by using an injection molding machine with a two-stage-compression screw, injecting a physical foaming agent into the cylinder of the machine at a pressure lower than the storage pressure of the physical foaming agent, mixing it with a melted resin and expanding the volume of the cavity of the mold at the time of injection, and an injection molding machine and resin composition suitable therefore.Type: GrantFiled: June 21, 2001Date of Patent: August 10, 2004Assignee: Mitsui Chemicals, Inc.Inventors: Eiichi Sugihara, Michio Eriguchi, Masaki Misumi
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Publication number: 20040124554Abstract: This invention relates to an isolation gasket intended to reduce the damage and wear of finishing layers, such as ceramic tiles, when installed over a rigid support layer, such as concrete. The disclosed isolation gasket prevents the propagation of cracks that may develop in the supporting layer through to the finishing layer. A preferred isolation gasket is a low-density, crosslinked polyolefin foam having a density of from about 60 kg/m3 to about 200 kg/m3, a compressive strength of from about ⅕ kg/cm2 to about 8 kg/cm2, a shear strength of at least 2 mm, and a thickness of at least 0.5 mm.Type: ApplicationFiled: September 22, 2003Publication date: July 1, 2004Applicant: Toray Plastics (America), Inc.Inventors: Jeff Lippy, Glenn Owens, Andrew Aitken, Alan Franc
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Patent number: 6733706Abstract: A plastic foamed synthetic closure for use with liquid bearing containers which closely simulates natural cork products is realized by incorporating color concentrates into the polymer melt and forming the color concentrates into elongated streaks. The desired emulation is further enhanced by arcuately pivoting the foamed plastic material during the production to form curved or sinusoidal-shaped streaks. This invention also provides manufacturing methods for mass producing individual products in a continuous motion casting system wherein fully complete products are formed in polymer casting members, which receive foam material exiting from the die and allow the foamed material to be formed in a continuous operation in the casting members. Finally, the present invention also teaches a unique system for maintaining and delivering carbon dioxide in its supercritical phase for use as a blowing agent.Type: GrantFiled: October 29, 2001Date of Patent: May 11, 2004Assignee: Nomacorc L.L.C.Inventors: Michael Allman, Eduardo Lauer
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Patent number: 6726862Abstract: The present invention relates to the step of plasticizing a thermoplastic resin material by rotatably driving a screw (20). Also included in the method is the step of injecting an inert gas into a screw cylinder (1) to permeate the melted resin and injecting the melted resin into a mold by driving the screw (20) in the direction of injection. Here, the inert gas has a pressure, at least in pressure, equal to or greater than a supercritical pressure or is under a supercritical state. To provide a thermoplastic resin foam by the method, electric servomotors (31, 32) are employed to drive the screw (20). After the step of plasticizing the resin material has been completed, brakes are applied to the electric servomotors (31, 32) to prevent the screw (20) from retreating. Alternatively, even after the step of plasticizing the resin material has been completed, the screw (20) is driven at low speeds in the direction of plasticization until immediately before the step of injecting the melted resin is initiated.Type: GrantFiled: March 8, 2001Date of Patent: April 27, 2004Assignee: The Japan Steel Works, Ltd.Inventors: Atsuo Teraoka, Fumiaki Tsuda, Hideo Ohyabu
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Publication number: 20040038018Abstract: Foams with low water absorption are provided, along with thermoplastic elastomeric foam materials and methods of forming the same. In some embodiments, the TPE foams have a low water absorption. Microcellular foams are included. Processing conditions (e.g., blowing agent type and content, die geometry, exit melt temperature, among others) may be controlled to produce foams having desirable characteristics, such as low water absorption.Type: ApplicationFiled: August 22, 2002Publication date: February 26, 2004Applicant: Trexel, Inc.Inventors: Jere R. Anderson, Kent G. Blizard, Liqin Chen, Kelvin T. Okamoto
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Patent number: 6689325Abstract: A process is described for producing foam materials from two-component reactive plastics using carbon dioxide as blowing agent by mixing at least one of the reactive components with carbon dioxide under pressure, mixing the components, at least one of which contains carbon dioxide under pressure, expanding the reactive mixture containing carbon dioxide obtained by mixing, and hardening, wherein the expansion takes place suddenly with the production of high rates of shear. Preferably the rate of flow of the reaction mixture is reduced after expansion.Type: GrantFiled: April 23, 1998Date of Patent: February 10, 2004Assignees: Bayer Aktiengesellschaft, Hennecke GmbHInventors: Ferdinand Althausen, Reiner Raffel, Wilfried Ebeling, Robert Eiben
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Patent number: 6676866Abstract: This invention is directed to golf balls including one or more foamed, microcellular materials. The invention also encompasses methods of controlling or adjusting one or more material properties or the weight distribution of a golf ball, and methods of forming golf balls including such microcellular materials.Type: GrantFiled: May 10, 2002Date of Patent: January 13, 2004Assignee: Acushnet CompanyInventors: Kevin M. Harris, Murali Rajagopalan, Christopher Cavallaro
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Patent number: 6673286Abstract: A method of making a porous biodegradable polymer is disclosed, which comprises (a) placing a biodegradable polymer and a solvent in a chamber; (b) adding a supercritical fluid to the chamber and maintaining the chamber at a predetermined temperature for a sufficient period of time to allow the supercritical fluid to dissolve into the biodegradable polymer with the help of the solvent; and (c) venting the supercritical fluid and the solvent by reducing the pressure in the chamber, thereby obtaining a porous biodegradable polymer.Type: GrantFiled: September 4, 2001Date of Patent: January 6, 2004Assignee: Industrial Technology Research InstituteInventors: Hsi-Hsin Shih, Kuang-Rong Lee, Huey-Min Lai, Chin-Chin Tsai, Yuan-Chia Chang
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Publication number: 20030236313Abstract: Methods for making foamed elastomer gels are disclosed. Chemical foaming agents may be incorporated or gas may be injected into a molten gel and then using heating and cooling techniques and/or additives, gas bubbles are formed and preserved in the cooled and solidified elastomer gel.Type: ApplicationFiled: February 11, 2003Publication date: December 25, 2003Applicant: EdiZONE, LCInventor: Terry V. Pearce
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Patent number: RE38993Abstract: There is disclosed a process for producing alkenyl aromatic foams utilizing a combination of atmospheric and organic gases as blowing agent, preferably using greater than 30% by weight of atmospheric gas, and preferably also using a predetermined about of a masterbatch mix comprising a styrenic polymer, a rubbery block copolymer, and a solid blowing agent. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased densities, increased thermoforming capabilities, increased post-expansion properties, and increased retainment of the atmospheric and organic gases.Type: GrantFiled: October 3, 2000Date of Patent: February 28, 2006Assignees: Reedy International Corporation, Genpak CorporationInventors: Michael E. Reedy, Edward W. Rider, Jr.