Abstract: Microporous articles formed by thermally induced phase separation from a diluent in combination with a thermoplastic polymer and a fluorochemical additive providing novel fluid repellent articles. Such articles are useful in clothing, barrier membranes, optical films in electronic devices (such as light reflective and dispersive films), and protective garments.

Abstract: A material and method for providing a laminate of at least two layers to provide breathability and moisture barrier properties without appreciably reducing elastic properties. A first material comprises a woven or nonwoven web and a second material comprises a cellular elastomer film or fiber. Such materials may be integrated into a laminate by forming said first material onto said second material, or by joining the two materials through chemical or physical means such as the use of adhesives. The second material can be prepared by mixing a cell opening agent with the elastomeric polymer resin and extruding the mixture at appropriate conditions whereby the cell opening agent decomposes or reacts to release a gas that forms cells in the elastomer film.

Abstract: A method of making an interior trim system for a vehicle includes providing a trim assembly having a cover layer and a backing layer attached to the cover layer, the backing layer including a polymeric material and a blowing agent. The method further includes activating the blowing agent to form fluid cells in the backing layer that expand and burst, such that the backing layer is an air-permeable layer after the activating step.

Abstract: A process of making a nanoporous substrate, such as the matrix in an electrical laminate, by grafting onto an organic resin backbone a thermolabile functionality by reacting hydrogen active groups of the organic resin with a compound containing thermolabile groups; then thermally degrading the thermolabile groups grafted on the organic resin to form a nanoporous laminate. Advantageously, the nanoporous electrical laminate has a low dielectric constant (Dk) because of the nanopores present in the laminate matrix.

Abstract: A microporous polyolefin membrane is formed by fine fibrils, comprising (A) a polyolefin having a weight-average molecular weight of 5×105 or more or (B) a composition containing component (A), connected to each other, and has micropores of 0.05 to 5 &mgr;m in average pore size and crystal lamellas of component (A) or (B) being in a specific orientation state. The membrane is produced by extruding a solution of component (A) or (B) in a solvent, into a gel-like formed article; thermally setting the article, with or without stretching, at least at the crystal dispersion temperature of component (A) or (B), but at melting point of component (A) or (B) plus 30° C. or lower; and removing the solvent.

Abstract: Polymeric films including a layer of propylene polymer resin having microvoids therein, the microvoids having been formed by stretching a web containing the beta-form of polypropylene, have shown low static cling when being unwound from rolls in labelling operations and also during destacking of pre-formed labels. The invention provides labels formed from such films.

Abstract: The present invention relates to gas separation membranes including a metal-based layer having sub-micron scale thicknesses. The metal-based layer can be a palladium alloy supported by ceramic layers such as a silicon oxide layer and a silicon nitride layer. By using MEMS, a series of perforations (holes) can be patterned to allow chemical components to access both sides of the metal-based layer. Heaters and temperature sensing devices can also be patterned on the membrane. The present invention also relates to a portable power generation system at a chemical microreactor comprising the gas separation membrane. The invention is also directed to a method for fabricating a gas separation membrane. Due to the ability to make chemical microreactors of very small sizes, a series of reactors can be used in combination on a silicon surface to produce an integrated gas membrane device.

Abstract: The present invention relates to a multi-component composite separate membrane and a method for preparing the same, and to a multi-component composite membrane comprising a support layer and active layers, wherein the support layer is located between the active layers.

Abstract: The present invention provides a process for producing a three dimensionally texturized liquid resistant laminate having a fibrous nonwoven layer and a liquid resistant layer. The process has the steps of placing the fibrous layer and the liquid resistant layer in juxtaposition to form a laminate, attaching the fibrous layer and the liquid resistant layer at a plurality of spaced-apart bond locations, heating the bonded laminate to a temperature that activates the latent shrinkability of the liquid resistant layer, and allowing the heated laminate to retract such that the liquid resistant layer shrinks and said fibrous layer forms gathers between said bond locations, thereby forming a three dimensional texture and heat annealing the laminate. The invention additionally provides a three dimensionally texturized laminate having a fibrous layer and a nonelastic liquid resistant layer.

Abstract: An anti-slip mat includes three layers, a top and a bottom layer of an expanded, closed cell elastomer and a center layer of a strong, non-stretching and waterproof fabric. The mat layers are held in place, one on top of another, by a fabric binding extending around the perimeter of the map and secured by stitching.

Abstract: The invention presents a composite profile for use in the production of windows, doors, facade elements or the like, having inner and outer metallic profiles spaced at a specific distance from each other by a plastic profile. The invention further proposes that the plastic profile contain a surface of a solid, non-porous first plastics material, in a core region, a fine-pored cellular structure of a second plastics material. Additionally, the plastic profile may either be a solid, multilayer profile or a hollow profile. Such plastics profiles are particularly adapted to absorb tensile, bending and/or pressure loads.

Abstract: A foam article for use as a masking material when spray painting a vehicle comprises a plurality of foam strips 1a, 1b, 1c joined together by a common seam 4 along at least one side edge to form a cord 6. The cord 6 can be adapted for masking across gaps of different size in different locations by superimposing the appropriate combination of foam strips 1a, 1b, 1c to provide the required thickness of cord 6. The cord 6 may be secured by wedging in the gap or by attaching an adhesive stripe 2 on at least one of the foam strips 1a to a surface on the inside or outside of the gap. The cord 6 may also be re-used by removing any painted foam strips or by re-arranging the foam strips to conceal any painted foam strips.

Abstract: A technique and device for rehabilitating or repairing waste water system components or the like, comprising a spray-applied, multi-layer liner which seals the components and imparts structural integrity. The liner comprises a primer layer, a first moisture barrier layer, a foam layer and a second moisture barrier layer. The first and second moisture barrier layers are preferably made of the same material and form a skin on both sides of the internal foam layer. The combination of the foam layer and the two moisture barrier layers imparts structural strength and rigidity to the cured liner.

Abstract: Biaxially oriented polymeric films having a core layer of a voided propylene homopolymer with a density of not more than 0.70 g/cm3, and at least one substantially non-voided layer on each surface of the core layer, the ratio of the combined thicknesses of the non-voided layers on the respective surfaces of the core layer being from 2:1 to 1:1. Films in accordance with the present invention have low curl, particularly after having been printed.

Abstract: A polymetaphenylene isophtha lamide-based polymer porous film having a satisfactory porous structure that exhibits excellent gas permeability and heat resistance. It is produced by a process which comprises casting a dope of the polymetaphenylene isophthalamide-based polymer and coagulating it in a coagulating bath. The porous film may also contain inorganic whiskers, and a composite porous film may be formed in combination with a separate thermoplastic polymer film.

Abstract: The present invention provides a porous polyolefin film abounding in air permeability and moisture permeability and having extremely high degree of light transmission and tear strength, a process for producing same and intended use thereof. This porous polyolefin film is produced, for example, by stretching an unstretched polyolefin film having a resin composition of 100 parts by weight of polyolefin, 50-150 parts by weight of an inorganic filler having a 50% median diameter of at least 2 &mgr;m but less than 7 &mgr;m measured according to the light-scattering method, and 2-20 parts by weight of a wax of polyolefin series in at least uniaxial direction at an area magnification of 1.1-1.5 times, and possesses physical properties of a water vapor transmission rate of at least 1000 g/m2·24 hrs., a light transmission of at least 65%, and a tear strength of at least 0.6 N.

Abstract: A flame retardant, electromagnetic interference (EMI) shielding gasket construction. The construction includes a resilient core member formed of a foamed elastomeric material, an electrically-conductive fabric member surrounding the outer surface of the core member, and a flame retardant layer coating at least a portion of the interior surface of the fabric member. The flame retardant layer is effective to afford the gasket construction with a flame class rating of V-0 under Underwriter's Laboratories (UL) Standard No. 94.

Abstract: The invention is a composite pad that is particularly useful in a horse trailer, exercise room, playroom, or the like. The pad has a moisture impermeable and scuff resistant outer skin layer, a cushioning layer, an impact absorbing layer, and a backing layer.

Abstract: This invention relates to labels. In one embodiment the labels comprise a polymer facestock layer, a nano-porous layer underlying the facestock, and an adhesive layer underlying the nano-porous layer. In another embodiment, the labels comprise a polymer facestock layer, a nano-porous layer underlying the facestock, and a metal layer overlying the facestock or underlying the facestock between the facestock and the nano-porous layer. These labels can be bonded to substrates of glass, plastic, or metal using a water based adhesive which is in contact with the nano-porous layer.

Abstract: A multilayer fabric for protection from aerosol and gas phase agents comprising a bilayer structure comprising an unfilled Fine fiber layer substantially free of materials within the pores of the Fine fiber layer secured to an outer shell, the Fine fiber layer acting as an aerosol filter, and an optional interior fabric layer having a reactive layer for the removal of gas phase agents.

Abstract: A heat-insulating an soundproofing lining for an engine compartment is disclosed, and a method of manufacturing the same, are disclosed. According to one embodiment of the present invention, the lining includes a first covering layer facing the engine. A duroplastic foam layer contacts the covering layer. A soundproofing layer contacts the duroplastic foam layer. A second covering layer contacts the soundproofing layer. According to another embodiment, a method of manufacturing a heat-insulating and soundproofing lining for an engine compartment is disclosed. The method includes the steps of (1) providing a first covering layer; (2) providing a duroplastic foam layer on the first covering layer; (3) providing a soundproofing layer on the first covering layer; (4) providing a second covering layer; and (5) pressing the layers together at an increased temperature and an increased pressure.

Abstract: A diamond foam article comprises diamond deposited material on a substrate having an open contiguous structure that permits the flow of fluids in at least one direction through the material. Methods for forming a diamond foam article comprise providing a foam substrate; preparing the foam substrate for diamond deposition; and depositing diamond material on the foam substrate by one of several diamond deposition methods.

Abstract: Disclosed is a process for making a two or more component foam composite obtained by adhesion of a polyurethane foam onto a substrate comprising the steps of frothing an aqueous polyurethane formulation; applying the froth to a substrate and drying the froth into a foam wherein the foam has a dry density of 35 kg/m3 to 160 kg/m3 (2.2-10 lbs/cft). The process allows the production of foam backed textiles without the need for a flame lamination step or the need for an adhesive layer between the textile and the foam layer and is optionally optimized for superior handling properties for covering polyurethane molded foam cushions.

Abstract: An elastically stretchable composite sheet including an elastic sheet and a fibrous assembly. A fibrous assembly having an inelastic extensibility is bonded to at least one surface of an elastic sheet at intermittently arranged bond regions to form a composite sheet. Component fibers constituting the fibrous assembly are long fibers continuously extending and describing curves between each pair of adjacent bond regions.

Abstract: Fibrous monolith composites having architectures that provide increased flaw insensitivity, improved hardness, wear resistance and damage tolerance and methods of manufacture thereof are provided for use in dynamic environments to mitigate impact damage and increase wear resistance.

Abstract: The present invention relates to a method for placing process survivable indicia on a support for an imaging element comprising providing a support wherein the support comprises a closed cell foam core and adhered thereto at least one flange layer, wherein the closed cell foam core layer comprises a polymer that has been expanded through the use of a blowing agent, and placing process survivable ink on at least one flange layer, wherein the process survivable ink forms process survivable indicia. The invention also relates to a method for placing process survivable indicia on a support comprising a closed cell foam core and adhered thereto an upper flange layer and a lower flange layer. The invention also includes a method for placing process survivable indicia on a support by placing process survivable indicia on said closed cell foam core.

Abstract: A laminated support for pressure-relief comprising an upper layer of visco-elastic foam, a middle layer of visco-elastic foam having a greater hardness, and a bottom layer of highly resilient polyurethane foam. These layers are sandwiched between two layers of reticulated filter polyurethane foam.

Abstract: A single-layer waterproof insulating system that is totally waterproof, windproof and an insulating high performance fabric for textile products or garments such as coats, jackets, vests, pants, blankets, hats, caps, gloves, etc., composed of three separate panels: a waterproof outer panel; a middle micro-cell membrane thermal wall film panel of polyurethane; an inner panel; wherein the three panels are sealed by the process of a permanent bond by laminating the three panels together with a permanent adhesive producing a single-layer fabric that blocks water from penetrating the insulating system, thereby providing a wearer both warmth and protection from moisture and wind.

Abstract: The invention is a composite foam structure comprising a first segment of an anisotropic thermoplastic foam part and a second foam shaped part comprising an isotropic foam wherein the anisotropic foam block and isotropic foam part intersect along at least one common surface.

Abstract: A leather covering piece for a vehicle interior lining comprises a leather piece and an intermediate layer connected with the leather piece. A hardenable mass is applied onto the intermediate layer or the leather piece. The hardened mass gives the leather covering piece such an inherent rigidity that it maintains a curved shape and can be inserted into an injection mold. The stacking of prefabricated leather covering pieces is also possible. The shape of the leather covering piece already corresponds to that of the finished product, in particular of the vehicle interior lining for which it is used. The leather covering piece is back-molded in order to obtain a stable carrier piece which gives the entire interior lining more stability.

Abstract: Microporous articles formed by thermally induced phase separation from a diluent in combination with a thermoplastic polymer and a fluorochemical additive providing novel fluid repellent articles. Such articles are useful in clothing, barrier membranes, optical films in electronic devices (such as light reflective and dispersive films), and protective garments.

Abstract: Flexible sheet materials having a foam layer and a film layer of polymer materials, at least one of the layers being formed from a filled polymer resin composition containing filler material comprising 30% to 65% by weight of the composition. The filled resin composition includes an ethylene copolymer such as ethylene vinyl acetate and may include other polymers such as polyethylene. The film layer serves a vapor barrier function. The layer having the filler provides a sound transmission loss. A preferred embodiment of an underlayment has a filler resin film layer of 6 to 30 mils thickness and a polymer foam layer of 75 mils thickness, the underlayment providing a sound transmission loss of at least about 2.5 dB at 1000 Hz.

Abstract: The invention concerns the application of a flexible melamine foam (7) having an indentation hardness stabilised to less than 300 N for 40% compression ratio, in the production of cushioning (2c, 3c, 4c). It also concerns items of upholstery (2a, 3a, 4a) for the seat base, back, headrest and legrest of a seat (1), and any other part of a seat, bed or any other element designed for comfort.

Abstract: Provided is a method of making a stretched, multilayer breathable film having the combination of properties of:

Abstract: A thermoplastic resin film (i) which has a degree of dimensional change through heating and cooling (a) in the range of from −2% to 2% as measured by thermomechanical analysis in the range of from room temperature to 135° C., or which has a degree of thermal shrinkage of 1.8% or lower upon heating at 130° C. for 30 minutes or longer; and a label paper employing the same. The label paper has suitability for heated-roll fixing type electrophotographic printers and is satisfactory in curling after printing.

Abstract: A laminate composite material comprises a layer of an open weave supporting fabric having a layer of breathable resin adhered thereto by an extruded layer of a thermoplastic resin blended with a high temperature volatile particulate. The resultant composite material is substantially impervious to air and water and permeable to water vapor and having a water vapor transmission rate exceeding one (1) perm of water vapor.

Abstract: A split resistant microporous membrane is provided for use in preparing a battery separator. The microporous membrane has a TD tensile strength to MD tensile strength ratio of from about 0.12 to about 1.2, preferably from about 0.5 to about 1. The microporous membrane is made by a process which includes the steps of preparing a film precursor by blown film extrusion at a blow-up ratio of at least 1.5, annealing the film precursor, and stretching the resultant annealed film precursor to form the microporous membrane.

Abstract: A heat-sensitive stencil including a thermoplastic resin film on which a porous resin layer and a porous reinforcing layer are formed in succession. A porous fibrous layer may be disposed between the porous resin layer and the porous reinforcing layer.

Abstract: The nonwoven composite fabric of the invention provides a barrier to blood and viral challenges, and also provides breathability for comfort. The fabric is particularly suited for use as a disposable surgical gown. The fabric comprises a first microporous ply comprising a microporous formable resin that has been extrusion coated onto a nonwoven fabric substrate and subsequently stretched to impart microporosity, and at least one additional ply positioned adjacent the first microporous ply. The nonwoven composite fabric has barrier properties passing the ASTM F1671 viral barrier test, and the MVTR of the composite fabric is at least 300 g/m2/24 hr.

Abstract: A continuous method for making foams having uniform and/or small cell sizes and articles made with these foams are described. The method allows for adjusting or controlling cell size and cell size distribution by controlling temperature and/or blowing agent concentration. The foams feature small and/or uniform cell sizes and may be comprised of amorphous thermoplastic polymers, pressure sensitive adhesive compositions, and immiscible thermoplastic polymer compositions. A method for coextruding the foams is also described.

Abstract: An opaque, oriented polymeric film structure comprising: a core layer comprising a thermoplastic polymeric matrix material wherein the core layer has a first side and a second side, the core layer having a plurality of voids, substantially all or all of the voids being free from a void-initiating particle and at least some of the voids being interconnected with an adjacent void in the polymeric matrix material, the number of voids not containing a void-initiating particle being sufficient to impart a significant degree of opacity to the film structure, wherein the core layer comprises the interior of the film structure; and a first skin layer comprising a thermoplastic polymeric material and an effective amount of a high-melting incompatible additive to suppress cavitation in said first skin layer, wherein the first skin layer is exterior to the first side of the core layer.

Abstract: A luminescent composite laminate structure for utility accessories and service hardware having luminosity for emergency and non-lighted conditions in which to illuminate the outer surface of such hardware and accessories. The composite laminate structure includes a plurality of layers for the protection of the luminescent outer surface of the laminated hardware or accessories. An outer first layer is a plastic protective covering for resistance to wear and impact; and the outer first layer is covering an inner second layer and has an inner surface wall in contact with the inner second layer. The inner second layer is a plastic micro-thin covering having a plurality of micro-hole openings for the transfer of oxygen (O2) through the micro hole openings in order to increase visibility of the luminescent outer surface; and the inner second layer is covering an inner core third layer and has an inner surface wall in contact with said inner core third layer.

Abstract: Novel gas-permeable membranes which are particularly useful in the packaging of fresh cut fruit and vegetables, and other respiring biological materials. The membranes comprise a microporous film or other gas-permeable substrate and, coated on the substrate, a layer of a block copolymer having a heat of fusion of at least 5 J/g and containing polysiloxane polymeric blocks and crystalline polymeric blocks having a melting point of −5 to 40° C.

Abstract: A laminated support for pressure-relief comprising an upper layer of visco-elastic foam, a middle layer of visco-elastic foam having a greater hardness, and a bottom layer of highly resilient polyurethane foam. These layers are sandwiched between two layers of reticulated filter polyurethane foam.

Abstract: A metal oxide coating has a nanotextured surface defined by a plurality of capillary openings arranged in a pattern on the surface of the coating. Each of the capillary openings have a diameter defined by a previously present organic macromolecule. The metal oxide coating is formed by depositing a solution containing uniformly dispersed micelles composed of amphiphilic molecules on a metal, oxide, or plastic substrate. The micelles are self-arranging, in solution, as a result of mutually repulsive electrostatic forces on the surface of the micelles, and form a uniformly patterned organic template when the solution is deposited on the surface of the substrate. A metal oxide coating is then applied to the substrate, which forms a ceramic monolayer that is a negative image of the organic template. The organic template is then removed, thereby forming a metal oxide coating having a plurality of macromolecular-sized apertures formed therein.

Abstract: A transfer laminating element for laminating ink jet prints comprising a flexible, polymeric support having thereon a porous, fusible, transferable protection layer comprising fusible, thermoplastic polymeric particles in a polymeric binder, the protection layer having a thickness of between about 2 and about 100 &mgr;m and a particle-to-binder ratio of between about 95:5 and about 70:30, the thermoplastic polymeric particles having a particle size of less than about 10 &mgr;m and a Tm or softening point of greater than about 50° C. and the polymeric binder having a Tg of less than about 20° C.

Abstract: An asymmetric support membrane can be prepared by using a phase separation method. The method includes immersing a polymer solvent solution into water. The polymer solution is made by dissolving 15 to 35% by weight of the polymer into a solvent that lets the polymer solution become a gel at a temperature of 0 to 50° C. The solution is then allowed to gel and brought into a final membrane form in water for phase separation and formation of the asymmetric support membrane. The polymer may be poly(vinyl chloride), polyethersulfone, polyetherimide and polyamic(methylester). The solvent is &ggr;-butyrolactone alone as a major solvent or is a mixed solvent with N-methyl-2-pyrrolidone as a cosolvent. The asymmetric support membrane is a porous support membrane of a sponge form having open pores that are connected to one another with a narrow pore size distribution. Thus, the asymmetric support membrane has an improved permeance and mechanical strength.

Abstract: A metal oxide coating has a nanotextured surface defined by a plurality of capillary openings arranged in a pattern on the surface of the coating. Each of the capillary openings have a diameter defined by a previously present organic macromolecule. The metal oxide coating is formed by depositing a solution containing uniformly dispersed micelles composed of amphiphilic molecules on a metal, oxide, or plastic substrate. The micelles are self-arranging, in solution, as a result of mutually repulsive electrostatic forces on the surface of the micelles, and form a uniformly patterned organic template when the solution is deposited on the surface of the substrate. A metal oxide coating is then applied to the substrate, which forms a ceramic monolayer that is a negative image of the organic template. The organic template is then removed, thereby forming a metal oxide coating having a plurality of macromolecular-sized apertures formed therein.

Abstract: A multi-purpose sheet material comprising an absorbent layer and a cut-resistant material in contact with the absorbent layer. The cut-resistant material can comprise a cut-resistant support system, such as cut-resistant support element formed in the absorbent layer for example. The cut-resistant material may alternatively comprise cut-resistant particles, such as polymer particles having an average size of at least about 100 micrometers for example. Preferably, the sheet material exhibits an absorbent efficiency of at least about 0.2 and a slice resistance of at least about 30 kgf/cm, and more preferably an absorbent efficiency of at least about 1.0 and a slice resistance of at least about 40 kgf/cm. It is also preferred that sheet material exhibit a cut-resistance of at least about 30 kgf/cm, an absorbent efficiency of at least about 0.2, and a wet abrasion loss of less than about 400 mg per 100 revolutions.

Abstract: Microporous material comprising a polypropylene polymer having at least 20 percent crystallinity; and a compatible, amorphous, glassy polymer, wherein said polymers are miscible in a compound when heated above the melting temperature of the polypropylene polymer and wherein a polypropylene polymer phase separates from the compound when cooled below the crystallization temperature of the polypropylene polymer. Microporous material is made by a thermally induced phase separation process using a compound such as mineral oil to form one phase containing both polymers. The pores of the microporous material resist collapse during processing. Membranes made of this material are useful as battery separators having a good combination of strength, porosity, and ionic resistance when imbibed with an electrolyte.