Abstract: A method of making light weight flame resistant structures from bonded polyimide macroballoons and products thereof. An aromatic tetracarboxylic acid dianhydride is reacted with an oxoimine to produce an N-substituted imide, which is then esterfied with a suitable alcohol. The resulting liquid is dried and the dry residue is reduced to a uniform powder having particles with diameters generally in the 0.5 to 10 mm. range. The powder is preferably further dried, either before or after final size reduction, in a moderate vacuum at moderate temperature to remove any excess residual alcohol. The powder spontaneously expands to form a closed cell foam when heated to a temperature in the range of about 90.degree. to 150.degree. C. for a suitable period. When the powder is expanded in a closed mold, a well consolidated, uniform, closed cell foam product results. The closed cell foam produced has excellent flexibility and resistance to heat and flame, and does not shrink appreciably when exposed to flame.

Abstract: A mixture of vinyl plastisol, suspension grade resin and expanded perlite is prepared in a manner such that the particles of perlite are not significantly damaged. The mixture is placed on a substrate and fused, thereby producing a foam-like material which is usable as a decorative covering. Alternatively, the mixture can be cast on a release surface and allowed to stand until the majority of the perlite particles have migrated to the top surface, thus leaving a layer of material containing substantially no perlite along the lower surface which interfaces with the release surface. Upon fusing this stratified mixture and separating the release surface, the fused material is inverted. The layer of material which contains substantially no perlite becomes the protective surface and the remaining portion of the fused material, which is foam-like in nature, becomes the resilient support. Such syntactic foams may be used as replacements or substitutes for mechanically frothed or chemically blown foams.

Abstract: A method of adjustably tailoring the effective bulk density of a solid material in which a mixture comprising the solid material, a film-forming polymer and a volatile solvent are sprayed into a drying chamber such that the solvent evaporates and the polymer dries into hollow shells having the solid material captured within the shell walls. Shell density may be varied as a function of solid/polymer concentration, droplet size and drying temperature.

Abstract: A material suitable for thermosetting includes a collection of hollow particles adhesively mixed with a thermosetting resin in such proportions that the mixture exists in a granular form and may be converted by thermosetting into a fused solid mass having a density not greater than 0.5 grams per cubic centimeter.The particles may be glass microbubbles or phenolic microballoons and the resin may be a hardenable Friedel-Crafts resin. The material according to the invention is more suitable for packing into shaped cavities than known resins including those containing filler particles.

Abstract: Alkali metal borohydride concentrates are prepared by dry blending alkali metal borohydride powder with a dry non-reactive plastic resin, melting and extruding the blended mixture to form an encapsulated alkali metal borohydride concentrate, and then chopping the extrusion into pellets. The pellet concentrate may then be blended into other materials.

Abstract: Alkali metal borohydride concentrates are prepared by dry blending alkali metal borohydride power with a dry non-reactive plastic resin, melting and extruding the blended mixture to form an encapsulated alkali metal borohydride concentrate, and then chopping the extrusion into pellets. The pellet concentrate may then be blended into other materials.

Abstract: The present invention relates to a process for drying and expanding microspheres whereby first a dispersion of the microspheres in an inert liquid is prepared. This dispersion is then atomized in a hot inert gas. The process of the invention is advantageously carried out in a spray dryer.

Abstract: Alkali metal borohydride concentrates are prepared by dry blending alkali metal borohydride powder with a dry non-reactive plastic resin, melting and extruding the blended mixture to form an encapsulated alkali metal borohydride concentrate, and then chopping the extrusion into pellets. The pellet concentrate may then be blended into other materials.

Abstract: Alkali metal borohydride concentrates are prepared by dry blending alkali metal borohydride powder with a dry non-reactive plastic resin, melting and extruding the blended mixture to form an encapsulated alkali metal borohydride concentrate, and then chopping the extrusion into pellets. The pellet concentrate may then be blended into other materials.

Abstract: A lightweight preformed stable gel composition formed by admixing a gel mixture of silicon gels and catalyst with glass microspheres, pouring the mixture into a mold and reacting the mixture. The resulting composition is a preformed stable silicon gel with glass microspheres dispersed throughout.

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

Abstract: Hollow plastic microspheres made from thermoplastic or thermosetting plastic compositions are described.The hollow plastic microspheres are made by forming a liquid film of thermoplastic or thermosetting plastic composition across a coaxial blowing nozzle, applying a blowing gas at a positive pressure to the inner surface of the plastic film to blow the film and form an elongated cylinder shaped liquid film of plastic. A transverse jet is used to direct an entraining fluid over and around the blowing nozzle at an angle to the axis of the blowing nozzle. The entraining fluid as it passes over and around the blowing nozzle fluid dynamically induces a pulsating or fluctuating pressure field at the opposite or lee side of the blowing nozzle in the wake or shadow of the coaxial blowing nozzle.

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: The strip comprises a tubular section of thermoplastic material, e.g. PVC, and a fill comprising a matrix of methylmethacrylate with silicate spherules as a filler, reinforced by glass filaments under tension. In production, cold methylmethacrylate is pressed in the extruded section while it is still hot.

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

Abstract: The method of making a reinforced composite structure utilizing an initially amorphous foam core element containing a high volume of macro and micro spheres mixed in a thermosetting resin with said core element being contained between resin-impregnated, fibrous reinforcing layers such that the resin of the core element remains in the core element when the composite is molded under heat and pressure.

Abstract: Viscous, flowable, pressure-compensating fitting materials or compositions suitable for a variety of uses and applications, including, but not limited to, fitting pads for footwear or the like.

Abstract: A method is disclosed comprising in-mold coating a structural foam part made from a thermoplastic aromatic polycarbonate resin or a thermoplastic ABS polymer resin with a thermosetting in-mold coating composition at a pressure of from about 25 to 50 p.s.i. and at a temperature not in excess of about 200.degree. F. for from about 1 to 10 minutes, preferably for from about 1 to 3 minutes, to provide hard, smooth and adherent coatings, said thermosetting in-mold coating composition comprising an ethylenically unsaturated polyester resin and an ethylenically unsaturated monomer(s) catalyzed with an organic perioxide initiator including an accelerator for the initiator.

Abstract: This invention provides a method for producing porous elastomeric sheet material, wherein ungelled elastomer liquid material is admixed with hollow spherical filler particles and then spread to form a sheet, which is then dried and gelled. The dried and gelled sheet of filled elastomer is subjected to rigorous biaxial stretching, wherein the elastomeric material surrounding at least some of the particles is stretched and ultimately broken by the rigorous stretching, to form a porous sheet material.

Abstract: A photographic carrier material comprising a cellulose sheet which is coated on both surfaces with a polyolefin resin and in which hollow, thermoplastic microspheres are uniformly mixed therein in an amount of from 0.5 - 5.0 weight percent.

Abstract: When producing insulating units, in particular building units, plaster of Paris was previously poured into the mold, bloated polystyrene pearls being prekneaded into said plaster. Plaster of Paris has also been poured into molds, wherein a lining of an aggregate of fused, bloated polystyrene pearls were prearranged. The bloated polystyrene pearls according to the invention are first densely packed in the mold, whereupon plaster of Paris, cement or another hydraulic binding material is filled into the mold through a net or a perforated plate, said net or perforated plate keeping the pearls densely packed during the casting so as to ensure that they do not reposition as a consequence of their buoyancy in the cast, liquid binding material.

Abstract: Methods involving the use of high frequency heating means and temperature-compensating means to expand hollow, thermoplastic resinous microbeads in a controllable manner. The heat-expanded microbeads are suitable for use, for example, in providing viscous, flowable, pressure-compensating fitting materials or compositions.

Abstract: In a process for rapidly producing a substantially uniform, elongated, cellular thermoplastic article comprising rapidly discharging from a vessel a pressurized gel of a solid thermoplastic amorphous polymer and a gaseous solvent in an amount in the range of from about 25-100% by weight of said polymer, said solvent being capable of forming a flowable gel with the polymer when subjected to superatomospheric pressure, the improvement for shaping the article comprising restraining sufficiently the speed of flow of the gel from the vessel through a die to form the desired shaped article with the gel at ambient temperature in said vessel.

Abstract: There is disclosed herein improved packages, and methods of forming same, of the type wherein a container, such as for example a glass container, like a bottle or jar, is provided externally thereof with a heat-shrunk, cellular thermoplastic member, circumferentially and snugly engaging a sidewall portion of the container; the improvement resides in employing, as the thermoplastic member, a composite structure, or laminate, having a closed cellular polymeric layer preponderantly of polystyrene having incorporated therein from zero weight percent up to compatible amounts of a copolymer of ethylene and an alkyl ester of alpha-beta monoethylenically unsaturated carboxylic acid or a copolymer of ethylene and vinyl acetate or a copolymer of ethylene and an alpha-beta monoethylenically unsaturated carboxylic acid, or mixtures thereof, and, in adhered relationship to said cellular layer, a layer of a non-cellular polymeric material preponderantly of ethylene moieties having incorporated therein moieties of vinyl ace

Abstract: A snow ski having a plastic foam core formed in situ between preformed top and bottom subassemblies.

Abstract: Foam-encapsulated laser fusion targets are fabricated by suspending fusion fuel filled shells in a solution of cellulose acetate, extruding the suspension through a small orifice into a bath of ice water, soaking the thus formed shell containing cellulose acetate gel in the water to extract impurities, freezing the gel, and thereafter freeze-drying wherein water and solvents sublime and the gel structure solidifies into a low-density microcellular foam containing one or more encapsulated fuel-filled shells. The thus formed material is thereafter cut and mounted on a support to provide laser fusion targets containing a fuel-filled shell surrounded by foam having a thickness of 10 to 60 .mu.m, a cell size of less than 2 .mu.m, and density of 0.08 to 0.6.times.10.sup.3 kg/m.sup.3. Various configured foam-encapsulated targets capable of being made by the encapsulation method are illustrated.

Abstract: A typical embodiment of the resinous foam sandwich construction that characterizes the invention has face sheets of fiber reinforced thermoplastic resin laminates. The foam core is a mixture of hollow glass spheres and resin, in which the resin in the core is the same as the resin used to form the face sheets.

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: Method of preparing an insulated negative buoyancy conduit wherein a jacket is placed around the conduit and an insulating material comprising a porous filler and a resin-forming composition is positioned in the annulus between the jacket and the conduit.