Abstract: A material system (60) contains close packed hollow shapes (50, 70) having a dense wall structure (52, 66), which are bonded together and which may contain a matrix binder material (56) between the shapes, where the system has a stable porosity, and is abradable and thermally stable at temperatures up to possibly 1700° C., where such systems are useful in turbine apparatus.

Abstract: Methods of forming a polymeric structure having a plurality of cells therein that include contacting a polymeric material that includes a first phase and a second phase with a composition comprising carbon dioxide to form the polymeric structure having a plurality of cells therein are described. Polymeric materials and microelectronic devices formed by such methods are also described.

Abstract: A method for making a resilient cushion includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.

Abstract: Weather stripping for use in sealing an interface between selected vehicle portions is made using a thermoplastic material such as TPV with a supercritical fluid introduced during the manufacturing process to provide a microcellular structure. The microcellular structure of one example implementation of this invention includes a cell density in a range from about 109 to about 1015 per cubic centimeter. Average cell sizes preferably are less than 2 microns. A preferred range in one example is between about 0.1 micron and about 1.0 micron. The inventive design provides superior performance with cost savings compared to rubber weather stripping.

Abstract: 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.

Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.

Abstract: A laminate of thermoplastic over foam is well suited for making plates to be used in a protective paint-ball vest. The vest is constructed of many such plates mounted to fabric to provide good ventilation and freedom of movement with adequate protection levels against commonly encountered hazards. The vest can be made reversible to facilitate team games and is highly suitable for use in paint ball games.

Abstract: A foamed thermoplastic resin fiber reinforced part is provided. The part comprises a member formed of thermoplastic resin, a plurality of cells and a plurality of reinforcing fibers dispersed within the member, and a skin formed on at least one exterior surface of the member. The skin is substantially devoid of cells. Here, the reinforcing fibers have a length of about 25 mm in an amount of about 10% by weight of the foamed thermoplastic resin fiber reinforced part. At least one of a cell density and a cell size of the plurality of cells is inversely proportional to the amount of the reinforcing fibers dispersed within the member.

Abstract: High-density polyethylene (HDPE) foams that are essentially free of residual chemical blowing agents and reaction-by-products of chemical blowing agent are provided. The HDPE foams can be either microcellular foams or conventional foams. The foams can be produced in extrusion, injection molding, and blow molding processes that utilize a physical blowing agent. Specific die designs useful for making high quality foams are described.

Abstract: A sprayable polymeric material and a process for preparing the material which contains a fibrous material, dispersed throughout the polymeric material. A restriction free spray nozzle is provided for mixing and spraying the polymeric material having a fibrous material, the nozzle having a restriction free check valve. A reinforced structure, and a method of making the structure are provided, the structure having layers of the polymeric material (both film and foam) containing the fibrous material. A flexible liner is provided of a porous geotextile fabric and a polyurethane composition comprising the fibrous material sprayed over the geotextile fabric.

Abstract: A vulcanized rubber comprising a rubber component containing natural rubber, in an amount of 20 to 70 parts by weight, and polybutadiene, in an amount of 30 to 80 parts by weight; a rubber matrix containing 5 to 55 parts by weight of carbon black and 5 to 55 parts by weight of silica per 100 parts per weight of the rubber component; a resin, and resin coated elongated cells having a length (L) to diameter (D) ratio (L/D) of at least 3. The vulcanized rubber can be used in the tread of tires to improve on-ice performance, wet properties and wear resistance in a well balanced manner.

Abstract: The invention relates to a thermoformable sheeting consisting of a foam material or containing at least one layer of a foam material. The inventive sheeting is particularly applicable for thermoforming cups or trays for packaging and/or consuming food stuffs, by drawing or deep drawing the sheeting and expanding the foam material. The foam material of the inventive sheeting consists of a polypropylene blend containing between 50 and 100% of high melt strength polypropylene, has a density of 0.1 to 0.7 g/cm3, preferably between 0.25 and 0.5 g/cm3, and a cell number of from greater than 300 to 3000 cells per mm3, preferably between 800 and 2500 cells per mm3. The inventive sheeting can be drawn with a high drawing ration (e.g. 1.5) and expanded to be formed into containers even with difficult shapes, whereby no drawing problems arise and the containers produced show a homogeneous opaqueness.

Abstract: The pad according to the invention can adhere to a polished surface for an extended period of time. It comprises a core support layer made of foam plastic material, for example a copolymer of ethylene and vinyl acetate, and electrostatic layer, for example comprising a polypropylene base electrostatic film, on one face of the pad. The opposite face of the pad must be capable of receiving thereon information to be displayed. The foam plastic material is characterized by having a closed cell structure and a density between 1.5 and 4, and by being capable of retaining electrostatic charges between the core support layer and the electrostatic layer after being activated.

Abstract: An anti-reflection film comprises a low refractive index layer. The low refractive index layer comprises a polymer binder and micro particles. The micro particles are so deposited to superpose at least one micro particle on another micro particle, to form micro voids surrounded by the micro particles. The micro particles have a mean particle size of 5 to 200 nm. A display device provided with the anti-reflection film is also disclosed.

Abstract: High-density polyethylene (HDPE) foams that are essentially free of residual chemical blowing agents and reaction-by-products of chemical blowing agent are provided. The HDPE foams can be either microcellular foams or conventional foams. She foams can be produced in extrusion, injection molding, and blow molding processes that utilize a physical blowing agent. Specific die designs useful for making high quality foams are described.

Abstract: A process provides a ceramic film, such as a mesoporous silica film, on a substrate, such as a silicon wafer. The process includes preparing a film-forming fluid containing a ceramic precursor, a catalyst, a surfactant and a solvent, depositing the film-forming fluid on the substrate, and removing the solvent from the film-forming fluid on the substrate to produce the ceramic film on the substrate. The ceramic film has a dielectric constant below 2.3, a halide content of less than 1 ppm and a metal content of less than 500 ppm, making it useful for current and future microelectronics applications.

Abstract: 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.

Abstract: This invention pertains to a composition and a process for preparing a closed cell alkenyl aromatic polymer foam having enlarged cell size, comprising one or more alkenyl aromatic polymers, one or more substantially random interpolymers, one or more blowing agents having zero ozone depletion potential and optionally one or more co-blowing agents, and optionally, one or more nucleating agents and optionally, one or more other additives. This combination allows the manufacture of closed cell, low density alkenyl aromatic polymer foams of enlarged cell size, when blowing agents of relatively high nucleation potential are employed. When such blowing agents are used with alkenyl aromatic polymers in the absence of the substantially random interpolymers, small cell foams result.

Abstract: A pneumatic tire which is used for a vehicle and obtained after a rubber material is formed by vulcanization. A cap portion (12A), which is an upper layer of a tread and directly contacts the road surface, is a foam rubber which includes innumerable elongated closed cells (24). The outer portion of the elongated closed cell (24) is coated by a resinous protective layer (26). During the vulcanization process of the tire, a resin whose viscosity is lower than that of a rubber matrix and a blowing agent which generates gas are kneaded with a rubber material so as to obtain a rubber composition. The rubber composition is formed in the shape of a band and adhered to a crown portion of a raw tire casing. The resin is melted by the heat of vulcanization and the viscosity of the resin is lower than that of the rubber matrix. The gas generated in the rubber moves toward and concentrates at the inner side of the resin.

Abstract: The invention relates to a thermoformable sheeting consisting of a foam material or containing at least one layer of a foam material. The inventive sheeting is particularly applicable for thermoforming cups or trays for packaging and/or consuming food stuffs, by drawing or deep drawing the sheeting and expanding the foam material. The foam material of the inventive sheeting consists of a polypropylene blend containing between 50 and 100% of high melt strength polypropylene, has a density of 0.1 to 0.7 g/cm3, preferably between 0.25 and 0.5 g/cm3, and a cell number of from greater than 300 to 3000 cells per mm3, preferably between 800 and 2500 cells per mm3. The inventive sheeting can be drawn with a high drawing ration (e.g. 1.5) and expanded to be formed into containers even with difficult shapes, whereby no drawing problems arise and the containers produced show a homogeneous opaqueness.

Abstract: AN EMI/RFI gasket with an open-celled foam substrate having a metal coating on its skeletal structure that is substantially deformable and recoverable. The gasket provides shielding effectiveness of greater than 40 dB.

Abstract: In one embodiment, the present invention relates to a process for preparing foam board or sheet including the steps of (A) forming a foamable mixture of (1) a major amount of a styrenic polymer having a high melt index, (2) a minor amount of a low melt index styrenic polymer, and (3) a blowing agent containing a major amount of carbon dioxide under a pressure sufficient to prevent prefoaming of the mixture, and (B) foaming the mixture into a region of reduced pressure to form a foam product.

Abstract: Polystyrene-based foam material for the production of for example label material, wherein the foaming has been made with a blowing agent and preferably a nucleating agent, wherein the blowing agent is for example a decomposable blowing agent (chemical blowing agent) or consists of for example carbon dioxide, nitrogen gas or even water, and with a thermoplastic elastomeric blend composition consisting of at least one styrenic block copolymer and one homogeneously branched ethylene-interpolymer.

Abstract: A heat absorbing coating having a plurality of micro-capsules each being an encapsulant shell and a heat absorbing material within the shell, and a carrier adherable to a substrate and throughout which the micro-capsules are dispersed. The heat absorbing material is preferably a phase change material and can be non-limitedly chosen from the group consisting of polyethylene, polypropylene, polywax, and combinations thereof. Shell material can be a metal such as copper, for example, or a polymer. The carrier can be a sprayable polymer mix which provides significant efficacy in uniform application to a substrate. An inventive substrate structure, such as an aircraft structure for example, has thereon the above-defined coating in an amount sufficient to absorb a sufficient amount of heat from the substrate to substantially inhibit thermal erosion in normal operating environments.