Abstract: Processes for producing alkenyl aromatic foams utilizing a cycloaliphatic gas as blowing agent, are described. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased thermal insulation properties.

Abstract: The present invention provides a process for producing a foamed resin article, the process comprising: a step (the first step) of impregnating any one crystalline thermoplastic resin or resin composition containing, as an elementary ingredient, a crystalline thermoplastic resin selected from a certain group, under an elevated pressure which is not lower than the critical pressure of a substance with which the selected crystalline thermoplastic resin or resin composition is to be impregnated, with a fluid of the substance, and a step (the second step) of releasing the resin or resin composition impregnated with the substance from the foregoing pressurized condition in a period of less than 10 seconds.

Abstract: Macrocellular polyolefin foams that can withstand temperatures above 110° C. are described for use in sound absorption and insulation applications, especially in elevated temperature and/or moist environments. These foams have a large cell size (≧1.5 mm), are open or closed-cell foams, and preferably have at least one perforation per square centimeter and/or a density less than 25 kg/m3. They are obtainable by extruding a high melt strength (HMS) polypropylene resin (PP), or preferably a blend of a HMS PP resin and a free radical polymerized ethylene polymer present in the blend in a weight ratio of at least 35:65, optionally another polymer such as a substantially random interpolymer, a cell size enlarging agent such a glycerol monostearate, an antioxidant, carbon black and/or flame retardant additives, using a volatile organic compound, e.g. isobutane, as blowing agent.

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: This invention describes grafted blend compositions, processes for their preparation and fabricated articles, especially foams therefrom. The blends exhibit enhanced melt strength, melt elongation greater than or equal to about 20 mm/s, increased upper service temperature, increased modulus, and increased hardness. The grafted blend compositions have little or no high shear viscosity increase over a corresponding polymer of the same chemical composition absent the coupling agent.

Abstract: In a process for preparing expandable polymer beads based on a mixture made from A. a biodegradable aliphatic/aromatic copolyester and B. a biodegradable naturally occurring polymer, the mixture A+B is melted in an extruder, mixed with a volatile organic blowing agent, extruded and pelletized.

Abstract: A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid N-aliphatic alcohol amide of the general formula R—CON(R′)R″. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R′ typically is hydrogen. R′ can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R″ is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R′ is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA).

Abstract: This invention provides an expanded open-cell foam polymer composition comprising at least one linear or modified linear polyolefin, at least 50% of the cells being open, and the cells having an average size of at least 1 millimeter. It is desirable that the composition have a sound absorption coefficient as determined by ASTM D 1050 at 1,000 Hz which is greater than 0.15. In preferred foams the composition has an airflow resistivity of less than about 800,000 Rayls/m.

Abstract: An object is to provide a synthetic thermoplastic resin extruded foams having excellent thermal insulating properties and a method for producing the same, in which environment friendly water is used as a blowing agent in the most effective way while reducing the amount of blowing agents that affect the environment, and it is feasible to improve the production ratio of small cells in foams made up of large cells and small cells. A synthetic thermoplastic resin extruded foams having a foam density of 15 to 50 kg/m3 and an excellent cell structure which has an average call size of 0.7 mm or smaller or which mainly comprises small cells having a cell size of 0.25 mm or smaller and large cells having a cell size of 0.3 to 1 mm; and a method for producing the foams are provided, wherein the foams contains 0.2 to 10 parts by weight of bentonite, and water is used as a blowing agent.

Abstract: A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid Naliphatic alcohol amide of the general formula R—CON(R′)R″. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R′ typically is hydrogen. R′ can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R″ is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R′ is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA).

Abstract: The present invention provides a process for producing a foamed resin article, the process comprising:

Abstract: This invention relates generally to foamable crystalline propylene polymers obtained from metallocene catalysis and to their methods of production. The foamed crystalline propylene polymers have molecular weight distributions and densities that fall within broad ranges. The crystalline propylene polymers may be prepared in a multiple stage polymerization process using a combination of metallocene components in at least two stages.

Abstract: The invention concerns nucleating agent systems for foamable polymer compositions, preferably fluoropolymer resins, having foam cell nucleation sites using titanium dioxide based nucleating agents, and foamable polymers comprising the nucleating agents. The nucleating agent systems comprise TiO2, certain inorganic salts, and, optionally, sulfonic acid salts and/or phosphonic acid salts. The invention also concerns foamable composition concentrates and foamed thermoplastic insulation material comprising fluoropolymer and the nucleating agent systems.

Abstract: The invention concerns nucleating agent systems for foamable polymer compositions, preferably fluoropolymer resins, having foam cell nucleation sites using titanium dioxide based nucleating agents, and foamable polymers comprising the nucleating agents. The nucleating agent systems comprise TiO2, certain inorganic salts, and, optionally, sulfonic acid salts and/or phosphonic acid salts. The invention also concerns foamable composition concentrates and foamed thermoplastic insulation material comprising fluoropolymer and the nucleating agent systems.

Abstract: A foam includes a blend of low density polyethylene and polypropylene having a melt tension of greater than about 20 centinewtons at 200° C.

Abstract: The melt of polyvinyl aromatic polymers comprising from 10 to 45 weight % of star branched polymer prepared using a combination of thermal and tetra functional peroxide initiation has an improved melt strength permitting better foam formation for extrusion foam blown with conventional blowing agents and inert gases including CO2.

Abstract: The present invention provides a process for producing a foamed resin article, the process comprising: a step (the first step) of impregnating any one crystalline thermoplastic resin or resin composition containing, as an elementary ingredient, a crystalline thermoplastic resin selected from a certain group, under an elevated pressure which is not lower than the critical pressure of a substance with which the selected crystalline thermoplastic resin or resin composition is to be impregnated, with a fluid of the substance, and a step (the second step) of releasing the resin or resin composition impregnated with the substance from the foregoing pressurized condition in a period of less than 10 seconds.

Abstract: This invention describes grafted blend compositions, processes for their preparation and fabricated articles, especially foams therefrom. The blends exhibit enhanced melt strength, melt elongation greater than or equal to about 20 mm/s, increased upper service temperature, increased modulus, and increased hardness. The grafted blend compositions have little or no high shear viscosity increase over a corresponding polymer of the same chemical composition absent the coupling agent.

Abstract: The invention concerns nucleating agent systems for foamable polymer compositions, preferably fluoropolymer resins, having foam cell nucleation sites using titanium dioxide based nucleating agents, and foamable polymers comprising the nucleating agents. The nucleating agent systems comprise TiO2, certain inorganic salts, and, optionally, sulphonic acid and/or phosphonic salts. The invention also concerns foamable composition concentrates and foamed thermoplastic insulation material comprising fluoropolymer agent systems.

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: A closed-cell polymer foam having a density of less than 100 kg.m−3 is described. The cells in the foam contain a foam blowing agent comprising (a) a blend of two or more hydrofluorocarbons, (b) a blend comprising a carbon dioxide and one or more hydrofluorocarbons or (c) a blend comprising dimethyl ether and one or more hydrofluorocarbons, and the polymer is a blend comprising at least 50% by weight of an olefinic polymer(s) and up to 50% by weight of a polar polymer(s) having a lower molecular weight than the olefinic polymer which when in the heat plasticised state is able to dissolve the foam blowing agent. A process for preparing the foam is also described.

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: An acoustical insulation foam having, either with or without elastification, an Asker C hardness of less than about 65, a density of about 5 to about 150 kg/m3, a cell size of about 0.05 to about 15 mm, an open cell content of 0 to about 100 volume percent, a thickness of about 1 to about 200 mm, and a width of about 100 to about 3000 mm; comprising; (A) one or more alkenyl aromatic polymers, (B) one or more substantially random interpolymers and (C) optionally, one or more nucleating agents and (D) optionally, one or more other additives; and (E) one or more blowing agents.

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 silicone rubber sponge composition, a silicone rubber sponge, and a process for production thereof. The silicone rubber sponge composition comprises (A) 100 parts by weight organopolysiloxane gum described by average structural unit RaSiO(4−a)/2, where R is a monovalent hydrocarbon group or haloalkyl and a is 1.8 to 2.3 and having a viscosity at 25° C. of 1,000,000 mPa·s or above, (B) 1 to 400 parts by weight inorganic filler, (C) 0.01 to 50 parts by weight hollow thermoplastic resin particles, (D) 0.01 to 10 parts by weight a water-in-oil emulsion with silicone oil an oil phase, and (E) a curing agent in an amount sufficient to cure the composition.

Abstract: A surface decorated foam skin of cross-linked rubbery soft olefin resin, comprising rubbery soft olefin resin, characterizing by having (1) an average cell diameter of 50 to 400 &mgr;m, (2) a crystallinity of 5 to 40% (3) a hysteresis loss of 35% or lower, and (4) an embossing percentage of 40% or higher.

Abstract: A tapered stepped land having a choked funnel section which terminates in a lateral longitudinal section results in the formation of a foamed extrudate of a vulcanized blend of polyolefin and rubber which is a mass of closed cells having a specific gravity in the range from about 0.1 to 0.5 and the cells are sheathed in a dense non-porous, smoothly continuous skin which is formed integrally with the extrudate. The dense skin makes it possible to deposit a thin slip-coating of a low friction material longitudinally upon a chosen portion of the surface. An extruded weatherseal for the glass of an automobile's window has the slip-coating deposited as a thin film on a contacting strip of a surface which is in contact with the glass.

Abstract: Foams comprising blends of thermoplastic and thermoset materials wherein the thermoset forms a discontinuous phase in a continuous thermoplastic phase are described. Foams comprising an uncured thermoset and unreacted radiation-activatable curing agent in a thermoplastic matrix are also described. Additionally described are batch and continuous methods for making the foams. Particular uses for the foams, such as flexographic mounting tapes, are also described.

Abstract: A process is provided for the production of expanded olefinic thermoplastic elastomer product having good external appearance, flexibility and heat resistance. This process features using, as raw materials, a particular olefinic thermoplastic elastomer and carbon dioxide as a blowing agent.

Abstract: A silicone rubber sponge composition, a silicone rubber sponge, and a process for making the silicone rubber sponge. The silicone rubber sponge composition comprises (A) 100 parts by weight organopolysiloxane gum described by average structural unit RaSiO(4−a)/2, where R is a monovalent hydrocarbon group or haloalkyl and a is 1.8 to 2.3 and having a viscosity of 1,000,000 mPa·s or above at 25° C., (B) 1 to 400 parts by weight inorganic filler, (C) 0.01 to 50 parts by weight hollow thermoplastic resin particles, (D) 0.1 to 10 parts by weight liquid compound with a boiling point above room temperature, and (E) a curing agent in an amount sufficient to cure the composition.

Abstract: A silicone rubber sponge composition, a silicone rubber sponge, and a process for production thereof. The silicone rubber sponge composition, comprises (A) 100 parts by weight organopolysiloxane gum described by average structural unit RaSiO(4−a)/2, where R is a monovalent hydrocarbon group or haloalkyl and a is 1.8 to 2.3 and having a viscosity at 25° C. of 1,000,000 mPa·s or above, (B) 1 to 400 parts by weight inorganic filler, (C) 0.01 to 50 parts by weight hollow thermoplastic resin particles, (D) 0.1 to 10 parts by weight thermally decomposable blowing agent, and (E) a curing agent in an amount sufficient to cure the composition.

Abstract: Method and composition for making an expanded polyethylene material by forming a foamable melt of polyethylene, a nucleating agent, a material which retards migration of alkanes, and a blowing agent which comprises 10 to 100 mole percent ethane. In one disclosed embodiment, the melt is passed through an annular extrusion die to form an elongated tube of extruded material which is then expanded, slit lengthwise and laid flat to form a sheet of the expanded material.

Abstract: Semi-crystalline microcellular foams that include a midlevel amount of nucleating agent, and methods of their production, are provided. The microcellular foams can be produced in typical polymer processing techniques such as extrusion, injection molding and blow molding. The foams exhibit excellent mechanical properties and can be formed over a broad range of density into a number of different foam articles.

Abstract: The present invention provides a process for producing uncrosslinked polypropylene-based resin foam sheets which is characterized by using an extrusion foaming apparatus having a gear pump which is interposed between the extruder and the die and which is linked by means of adapters, wherein the pressure (Pg) at the inlet of the gear pump is within the range specified by the following formula (Formula 1) and the extruder is controlled so that the value of Pg is constant. Formula 1 Pc≦Pg(atm)≦Pc+90 Pc=(&khgr;−1)/H &khgr;: theoretical expansion ratio when the foaming agent added is 100% held H: coefficient of solubility of the foaming gas in the resin at the resin temperature in the gear pump inlet (cm3(STP)/cm3·atm) and the like.

Abstract: Processes for producing alkenyl aromatic foams utilizing a cycloaliphatic gas as blowing agent, are described. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased thermal insulation properties.

Abstract: The melt of polyvinyl aromatic polymers comprising from 10 to 45 weight % of star branched polymer prepared using a combination of thermal and tetra functional peroxide initiation has an improved melt strength permitting better foam formation for extrusion foam blown with conventional blowing agents and inert gases including CO2.

Abstract: The present invention generally relates to methods for preparing extruded foam products and more particularly to a methods for producing such products with a blowing agent containing 134a and an alcohol.

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: There is provided a foamed article having a low density, large thickness, a high closed cell ratio and a small average cell diameter. A foamed extrusion article having a density of 50 to 10 kg/m3 and a closed cell ratio of at least 40% is obtained by mixing a mixed resin comprising (a) 50 to 95 parts by weight of a polypropylene resin having a melt tension at 230° C. of at least 0.05 N, (b) 50 to 5 parts by weight of a polystyrene resin, and (c) 0.5 to 15.0 parts by weight of a hydrogenated block copolymer of styrene, isoprene and styrene based on 100 parts by weight of the polypropylene resin (a) and the polystyrene resin (b) with a foaming agent in an extruder, and then releasing into a low-pressure zone.

Abstract: Process for producing alkenyl aromtic foams utilizing a cycloaliphatic gas as blowing agent, are described. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased thermal insulation properties.

Abstract: A composition including, by weight: from 40 to 80% of at least one uncrosslinked composition (A) including at least one polyolefin (PA); from 60 to 20% of at least one crosslinked composition (B) including at least one propylene polymer (PB) and at least one ethylene-vinyl acetate (EVA) copolymer. The composition B has preferably been obtained beforehand by processing a composition including from 10 to 49% of at least one propylene polymer (PB), from 90 to 51% by weight of at least one ethylene-vinyl acetate copolymer, and from 100 to 1500 ppm by weight of at least one crosslinking agent. This composition makes it possible especially to manufacture foam sheets which can be employed in the motor vehicle industry, which are thermoformable, HF weldable and recyclable.

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 material for the production by extrusion or molding or calendering of light articles has a chemical formulation comprising at least a thermoplastic polymer. A predetermined amount of polymeric microspheres containing isopentane is added to said at least a thermoplastic polymer. A process for producing said material comprises a first step during which the thermoplastic polymer is mixed to further components (such as thermal stabilizers and/or costabilizers and/or additives) and a second step during which the mixture is granulated in order to obtain a granular compound. At the end of the first step, and advantageously immediately before the beginning of said second step, a predetermined amount of polymeric microspheres containing isopentane is added to the mixture. Said material is used for the production by injection molding or extrusion or calendering of light articles in the shoe industry, particularly of shoe soles.

Abstract: Method and composition for making an expanded polyethylene material by forming a foamable melt of polyethylene, a nucleating agent, a material which retards migration of alkanes, and a blowing agent which comprises 10 to 100 mole percent ethane. In one disclosed embodiment, the melt is passed through an annular extrusion die to form an elongated tube of extruded material which is then expanded, slit lengthwise and laid flat to form a sheet of the expanded material.

Abstract: The invention relates to a process for preparing a foamed thermoplastic elastomeric article,comprising the following steps: heating a mixture comprising a thermoplastic elastomer selected from the group comprising styrene based thermoplastic elastomers and thermoplastic polyolefin elastomers, and an effective amount of a water releasing chemical compound, to a temperature at which the water releasing chemical compound releases water, which is above the melting point of the thermoplastic elastomer, and releasing the resulting heated mixture to atmospheric conditions. The invention also relates to a foamable polymeric composition as well as to a foamed thermoplastic elastomeric article.

Abstract: A method of producing a substantially open-cell, expanded polystyrene sheet, comprising the steps of: forming a mixture comprising from 30 to 95% of polystyrene incorporating an aliphatic hydrocarbon with 4-6 carbon atoms, from 0 to 65% of polystyrene, and from 0.2 to 10% of a nucleating agent, mixing the mixture obtained and melting it by heating inside an extruder, bringing the mixture to a temperature of 130-150° C. in the final portion of the extruder, extruding the mixture in a lower-pressure atmosphere to produce an expanded sheet, which has a low density and a high capacity to absorb aqueous liquids, particularly if a surfactant is added to the starting mixture, and which, when coupled with two films of plastics material gives rise to a laminate suitable for the production, by thermoforming, of trays for foods which may release aqueous liquids.

Abstract: A soft foam having an Asker C hardness of less than about 65, comprising; (A) from about 30 to about 70 percent by weight (based on the combined weight of Components A and B) of one or more alkenyl aromatic polymers and wherein at least one of said alkenyl aromatic polymers has a molecular weight (Mw) of from about 100,000 to about 500,000; and (B) from about 30 to about 70 percent by weight (based on the combined weight of Components A and B) of one or more substantially random interpolymers having an I2 of about 0.1 to about 50 g/10 min, an Mw/Mn of about 1.

Abstract: A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid N-aliphatic alcohol amide of the general formula R—CON(R′)R″. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R′ typically is hydrogen. R′ can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R″ is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R′ is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA).

Abstract: Polyolefin foam materials of high dimensional stability at elevated temperatures are produced from modified polypropylenes and unmodified polypropylenes. The modified polypropylenes used are produced by mixing polypropylene particles with thermally decomposing free radical-forming agents, absorbing readily volatile bifunctional monomers and heating and melting the mixture. Areas of application for the polyolefin foam materials of high dimensional stability at elevated temperatures are the packaging sector, motor vehicle parts, sports and leisure equipment, industrial applications, as well as applications in the building sector.

Abstract: A method of producing a substantially open-cell, expanded polystyrene sheet, comprising the steps of: forming a mixture comprising from 30 to 95% of polystyrene incorporating an aliphatic hydrocarbon with 4-6 carbon atoms, from 0 to 65% of polystyrene, and from 0.2 to 10% of a nucleating agent, mixing the mixture obtained and melting it by heating inside an extruder, bringing the mixture to a temperature of 130-150° C. in the final portion of the extruder, extruding the mixture in a lower-pressure atmosphere to produce an expanded sheet, which has a low density and a high capacity to absorb aqueous liquids, particularly if a surfactant is added to the starting mixture, and which, when coupled with two films of plastics material gives rise to a laminate suitable for the production, by thermoforming, of trays of foods which may release aqueous liquids.