Abstract: The present invention pertains to improved alkenyl aromatic polymer foams (and processes for their preparation) having increased heat distortion temperature and improved dimensional stability while maintaining good tensile/tear, creep and environmental dimensional change properties.The closed cell low density alkenyl aromatic polymer foams exhibit increased heat distortion temperature, when substantially random interpolymers of about 21 to about 65 mol % styrene are blended in. When these same alkenyl aromatic polymer foams are made without these interpolymers, the heat distortion temperature is not improved.

Abstract: A premix composition for producing an inorganic solid foamed mass by mixing component (A) an aqueous acidic phosphate solution of mainly polyvalent cations and phosphoric acid wherein between 0.8 and 1.75 protons of the phosphoric acid molecule of said phosphate are neutralized by the cations, which also contains one or more fillers dispersed therein, with (B) an oxide, hydroxide or polyvalent salt of a weak acid as hardener and a carbonate foaming agent. A process of producing an inorganic foamed mass using the premix composition and a solid foamed mass produced by the process are also disclosed. The process produces a relatively elastic cross-linked structure due to mainly the secondary phosphates being neutralized versus the tertiary phosphate groups.

Abstract: A unitary, monocoque, injection-molded skateboard (and method of making the same) which is characterized by an elongate composite body with a specific gravity in the range of about 0.75 to about 0.8, and including a foamed structural plastic mass having a distributed differentiated density, and contained within that mass, plural, elongate strands of reinforcing carbon fibre material.

Abstract: Compositions and methods are described that relate to the use of reaction products of metal compounds and protonic acids for plasticizing and neutralizing acidic, protonated compositions comprising substituted and unsubstituted polyanilines and co-polymers and or mixtures thereof; and for reducing the percolation threshold for conductivity in blends with insulating bulk polymers.

Abstract: Cellular glass structures are made by foaming select silicone resins. A foaming agent is reacted together with the silicone resin to form a foam that carries the resin as a continuous separate phase distributed throughout the foam. The foaming agent is removed by decomposition, and the remaining silicone resin is crosslinked to retain the foamed structure. The silicone resin is then heated in a non-oxidizing atmosphere at a temperature that will pyrolize the resin. During pyrolysis, the resin densifies to foam a unique glass composition comprised of silicon, oxygen and carbon, where carbon is chemically bonded to silicon, but there are essentially no chemical bonds between carbon and oxygen.

Abstract: The invention relates to the process of the invention provides a radiation-crosslinked polypropylene foam by extrusion at a low temperature (about 170.degree. C.) below the decomposition point of the blowing agent. The resulting foamed item has by far better heat resistance than conventional ones.The raw resin can be prepared by mixing a resin in the pellet form and a blowing agent in the powder form on account of the low-temperature flowability. Heretofore, such mixing was impossible because the blowing agent does not disperse completely.This outstanding effect of the invention was not expected at all from the known prior arts.

Abstract: A process is provided for preparing propellant compositions including a film-forming synthetic polymer that are capable of forming foamed structures containing open and/or closed cells, which may optionally contain a material which is deposited in the pores and/or walls of the structure as the structure is formed, which comprises coating the synthetic polymer in particulate form with an inert solid material insoluble in the propellant and in solutions of the synthetic resin the propellant at atmospheric temperature; and then adding the propellant and dissolving the synthetic polymer in the propellant.

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: 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: 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: 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: A molding composition is disclosed for forming in a single step a natural sandwich foam product having a cellular core and a thick, densified outer layer. A hard, particulate filler material such as fly ash is admixed with an unreacted, rigid polyurethane foam system, together with a density distribution control agent such as carbon tetrachloride which lowers the viscosity of the admixture. In molding, the mold cavity is charged with the admixture and the foam reaction is permitted to occur with the mold closed. The resultant, filled foam product has a thick outer layer formed adjacent the mold surface of substantially greater density than its core. In the densified layer, both the polyurethane and filler material components of the resultant product are concentrated to provide over three times the density of the core structure. Formulations are set forth which provide substantial layer thickness and an outer surface having a durometer hardness value of 50 or greater over the entire surface area.

Abstract: A method of manufacturing a fiber-reinforced thermoplastic resin of cellular structure comprises immersing bundles of filaments of fibrous reinforcing material in a bath containing an emulsion of thermoplastic resin added with a blowing agent, drying the emulsion-impregnated reinforcing filaments, preheating the dried reinforcing filaments, compressing the preheated reinforcing filaments to provide an integrally bonded block of fiber-reinforced thermoplastic resin, and allowing the block to expand. The fiber-reinforced thermoplastic resin of cellular structure is advantageously employed as a light-weight, high strength construction material.

Abstract: A process for producing a microporous plastic member useful as a battery separator which comprises(a) forming a coherent dough by mixing a vinyl chloride resin with a plasticizing amount of a first solvent and with finely divided particles of a filler which contains volatilizable constituent releasable therefrom by heating and which shrinks substantially and irreversibly upon release of said volatilizable constituent therefrom, an example of which is hydrated silica;(b) forming the solvent-containing dough into a shaped member;(c) extracting the first solvent from the member before any substantial evaporation of solvent occurs by contacting it with a second solvent in a liquid bath at a temperature substantially below the boiling point of any liquid present, the second solvent being one which is capable of dissolving the first solvent without dissolving the resin and the filler, thereby deplasticizing the member by extractively removing the first solvent from the member; and(d) thereafter heating the member a

Abstract: Certain polymeric modifiers are surprisingly effective for injection molding and extruding thermoplastic structural foam of lower density, improved appearance, more uniform cell structure, and for lowering injection molding cycle time.

Abstract: Flake- or sliver-like porous structures of a polymeric material heavily loaded with a finely divided inorganic substance are prepared by spurting a mixture of the polymeric and finely divided inorganic components in a solvent. The products have many fine, irregular voids. The thickness of walls forming such voids is 5.mu. or less. The products are especially useful for producing sheet-like structures therefrom by beating and/or refining them followed by general paper making procedures. The sheets, when calendered, have a high initial modulus and improved dimensional stability.

Abstract: A composition of material suitable for in vivo implantation to provide an environment in which normal tissue growth is fostered which composition is a porous fibrous structure in which the critical surface tension of the fibers is 35 dynes per centimeter or higher. This composition in the preferred form is a porous structure of carbon or graphite fibers bonded together by sintered polytetrafluoroethylene in a manner to expose a maximum amount of fiber surface.Another composition of material suitable for implantation for wear surfaces includes carbon fibers and polytetrafluoroethylene resin and is processed to align the carbon fibers with the wear surfaces. The method of preparing both material includes the step of mixing, filtering, compressing, rolling, sintering and drying. The method of stabilizing appliances or implants includes bonding the ingrowth material to the appliance or implant.

Abstract: A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member, with a seamless sleeve made of a thin, flexible cellulosic film between the core and the shell.The structural member is prepared by arranging within a mold cavity an outer shell comprising at least one sheet of resin-coated unidirectionally oriented graphite fibers and a core comprising a foamable resin composition while the core is maintained within a seamless sleeve made of a thin, flexible cellulosic film, sealing the mold cavity and activating the foamable resin composition to cause expansion and generate pressure within the mold cavity and thereby provide intimate bonding of the core to the shell.

Abstract: A rigid, dimentionally stable, distortion-free article of foamed polyvinyl aromatic resin, having a solid outer skin, is formed by incorporating in a foamable polyvinyl aromatic resin a finely, divided inert solid that has been surface treated to render the solid hydrophobic and then molding the foamable composition under foaming conditions. Foamed polyvinyl aromatic resin articles molded in accordance with the present invention have physical dimensions capable of meeting tolerances in the order of .+-. 0.002 inches and are suitable for use in the manufacture of precision measuring devices and, particularly, frames for level instruments.

Abstract: A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member, said core comprising from about 25 to about 75 volume percent of a low density cellular filler material, such as chopped cork, and from zero to about 60 weight percent of a high density weight control material, such as barium sulfate.

Abstract: Stable foams of reaction resins and/or condensation resins can be obtained by adding a blowing agent which is gaseous under normal conditions to the resin under pressure, the gas liquid interface being enlarged while dispensing with moving equipment, allowing the mixture to expand and to cure.

Abstract: A process for the manufacture of a multicellular stretched sheet which comprises melt compounding a thermoplastic matrix polymer and an additive comprising a polymeric or non-polymeric organic compound or a metal salt of an organic acid, forming the blend into a shaped article and stretching the article at a temperature within the normal orientation temperature of the matrix polymer and below the glass-transition temperature of the polymeric additive or below the melting or softening point of the non-polymeric additive.

Abstract: A fiber reinforced foam having a predetermined uniform distribution of fibers throughout the skin and core is prepared by slurrying fibers with a major component of a foamable resin composition, thereafter adding the balance of the components necessary to form a foamable composition and allowing the so formed composition to foam under controlled temperatures and pressures.

Abstract: An improved process is provided for producing cigarette filters comprised of a substantially open-cell foamed thermoplastic polypropylene resin wherein a mixture comprising a thermoplastic polypropylene resin, a volatile blowing agent and a nucleating agent is extruded through a die to produce a strand of foamed resin with the strand then being cut into individual filter elements. The improvement comprises employing as a primary nucleating agent from 0.1 to 40 percent by weight, based on the weight of the resin, of a particulate compound of a metal selected from Groups IIA, IIIA or IVA of the Mendeleef periodic table of elements together with from 0.01 to 5.0 percent by weight, based on the weight of the primary nucleating agent, of a synergist consisting of an organic compound having a hydrophobic group and a hydrophilic group. A particularly effective combination is the use of calcium carbonate as the primary nucleating agent and potassium benzoate as the synergist compound.

Abstract: The present invention relates to a method of manufacture of profile-sections of any shape, including complex shapes, of structural foamed thermo-plastic material, having a density of between 0.4 and 0.9 with respect to the corresponding bulk or solid thermo-plastic material, the said method consisting in slowing-down and/or stopping the expansion at the immediate outlet of a conventional extrusion machine, at predetermined zones by blowing or spraying, in a differential manner at the periphery of the extruded product, a fluid at a temperature lower than the softening temperature of the said thermo-plastic material.

Abstract: Expanded styrene polymer sheet material is produced by extruding expandable and/or general purpose styrene polymer with a conventional blowing agent, a nucleating system and small amounts of finely divided hydrophilic silicon dioxide and alkaline earth metal oxide. The resulting product has very fine, uniformly sized pores and improved flexibility.

Abstract: Expanded styrene polymer sheet material is produced by extruding expandable and/or general purpose styrene polymer with a conventional blowing agent, a nucleating system and a small amount of finely divided hydrophobic silicon dioxide. The resulting product has very fine, uniformly sized pores and improved flexibility.

Abstract: A hard foamed material having a small specific gravity and a high mechanical strength is produced by mixing vinyl chloride resin with a large amount of inorganic powdery substances and a solvent, heating and kneading the resulting mixture in a closed kneader at a given temperature, adding a liquefied butane with a solvent thereto, and heating and foaming the resulting mixture in a mold.

Abstract: Shaped articles comprising a polymeric frame of uniform density having one or more substantially non-foamed skin layers over all, or only a part of, its surface are produced according to the disclosed method which includes forming a foamable mixture of a photopolymerizable ethylenically unsaturated material, such as vinyl acetate, acrylonitrile, unsaturated polyester resins or the like, and a foaming agent therefor in a mould, subjecting part or all of the surface of the mixture retained in the mould to radiation of a wavelength such that photopolymerization of the material occurs forming a non-foamed or non-foamable skin layer or layers. The thus treated foamable mixture is then foamed and the ethylenically unsaturated material in the foam is polymerized. Shaped articles so produced having an open shell structure are also disclosed.

Abstract: A method and apparatus for forming large fiber-reinforced foamed plastic panels is disclosed. The panels are produced by a process comprising filling a flat mold with freshly mixed foam plastic precursors, including fibrous material for reinforcement of the panels, closing the mold until the plastic precursors have foamed and set, then opening the mold and removing the finished panel. The apparatus comprises a platen mounted for traversing under the dispensing outlet of a mixing device, whereby the platen is filled with foamed plastic precursors, and a press into which the platen travels before the mixture has begun to mold. The press is provided with a novel mechanism for closing the mold by placing a cover on top of the platen before the plastic begins to foam. The same mechanism is adapted to open the mold by lifting the platen cover. Thereafter, the platen is moved in a reverse of its entry movement, returning to its starting position for removal of the finished panel.

Abstract: A strong, expanded moulded panel or board, having a specific gravity between 0.2 and 0.8, is produced by heating dry urea formaldehyde resin containing 4% to 8% volatile materials in a mould at between 130.degree. and 160.degree. C under light restraining pressure between 30 and 300 psi which permits moderate expansion of the resin owing to the gasification of the volatile materials.

Abstract: A novel cloth comprising asbestos fibers, particularly in the form of a micro-porous membrane is provided and a method of obtaining this cloth. It is characterized in that said cloth is obtained by the dry mixing of asbestos fibers and at least one filler or charge substance, then working up by malaxation in the presence of a latex, forming the cloth and, optionally, elimination of the filler substance. The invention is particularly applicable in the production of a micro-porous membrane for use in electrolysis diaphragms.

Abstract: An expanded polyvinyl chloride foam is prepared by a process characterized by admixing a polyvinyl chloride resin, which is prepared by emulsion copolymerization of a comonomer having an hydroxyl group, or a group capable of producing an hydroxyl group in the molecule under the processing conditions, with a plasticizer, a cross-linking agent, and a chemical blowing agent, introducing the admixture into a mold at a temperature lower than the melting temperature of said resin, and thereafter heating the resulting molded product to a temperature higher than the melting temperature of said resin to effect foam expansion.

Abstract: Foamed thermoset articles are produced by introducing a thermosettable organic resin, a specific class of blowing agents, inorganic particulate filler, and glass fiber in a mold at a given temperature and pressure, and then lowering the mold pressure to a predetermined reduced pressure to cause foaming, and completing the foaming before gelation. The foamed thermoset articles are also disclosed.

Abstract: Flexible polyurethane foams are anchored to themselves or to other compatible thermoplastic materials by the application of pressure and heat to such foams which contain at least 50 parts by weight per 100 parts of polyol in the foam formulation of at least one solid theromplastic resin composition having a particle size greater than 18 mesh (1.0 mm. sieve opening) and no larger than about 21/2 mesh (about 8 mm. sieve opening), preferably in the range of 16 mesh (1.2 mm. sieve opening) to 8 mesh (2.4 mm. sieve opening), in the U.S. Sieve Series.

Abstract: Plural recesses are formed on the surface of a sheet of a chemically crosslinked foam of a polyolefinic resin containing an inorganic calcium compound, the articles of food to be packaged are placed in the recesses and then the sheet is covered with a physically foamed sheet of a polyolefinic resin containing an inorganic calcium compound. Alternatively, the physically foamed sheet can be shaped to define a recessed support for the food articles and a sheet of foamed polyolefinic resin used as the covering. The polyolefinic resin has 30-60% by weight of an inorganic calcium compound incorporated therein.

Abstract: An article, such as a door, is made from a colored water-extended thermoplastic polymeric material, and is provided with a decorated pattern by fusion of a surface layer to form a non-cellular layer, the depth of fusion being different in different parts so that the depth of color is correspondingly different. The variation in color intensity provides a decorative pattern, and fusion of the cellular material is effected by pressing with a die in the shape of the desired pattern.

Abstract: A method of producing a non-combustible light-weight shaped article, which comprises shaping a mixture comprising (a) powders of silicon or a silicon alloy, (b) inorganic powders having a porous or hollow structure and (c) water glass, and maintaining the resulting shaped article at a temperature of 15.degree. to 120.degree.C. thereby to foam and cure it.

Abstract: A method for producing an improved molded thermoplastic polymeric resinous article comprising: introducing a heat plastified thermoplastic polymeric resinous material into a mold in the presence of a finely divided inorganic material; cooling the heat plastified thermoplastic polymeric resinous material; removing from the mold the cooled mold-shaped thermoplastic polymeric resinous article having finely divided inorganic material incorporated therein.

Abstract: A method of providing a structural shape includes starting with waste paper and treating the waste paper in a hammer mill to produce paper fibers. The fibers are put through a screen. The screened fibers are mixed with a binder such as a thermosetting epoxy foaming resin or with a phenolic resin in water in preferred proportions. The water or other solvent is kept to a very small value to provide a relatively dry process. The mixture is then pressed in a geometrical shape under substantial pressure (3 to 600 psi). The pressed mixture is then baked or cured at an elevated temperature (175.degree.F to 375.degree.F) for a predetermined time (three minutes to three hours).