Abstract: Polyurethane syntactic foam compositions having high glass transition temperatures and low coefficients of thermal expansion suitable for use in tooling applications as modeling stock are prepared from polymeric isocyanate, an amine-based polyol, a polyether triol, molecular sieve material and hollow microspheres.

Abstract: This invention relates to compositions for forming opaque, abrasion-removable masks on substrates. The compositions, which include a texture modifying amount of solid or hollow microspheres, have enabled depression or embossing of the surface of the printed substrates to be obscured so that they cannot be seen by the naked eye. The compositions can be based on plastisols, pigmented polymer solution, or pigmented aqueous emulsions. The invention further provides substrates, for example lottery tickets, having abrasion-removable masks formed from compositions of the invention.

Abstract: A polyarylene sulfide resin composition comprises(A) 100 parts by weight of a polyarylene sulfide resin and(B) 5 to 400 parts by weight of a hollow microspherical filler which comprises 20 to 80% by weight of SiO.sub.2 and 20 to 80% by weight of Al.sub.21 O.sub.3 as major components and has a specific gravity of 1.0 to 2.5 and an average particle diameter of 1 to 100 .mu.

Abstract: The present invention relates to a process for the production of fluorocarbon-free, rigid polyurethane foam moldings having a gross density of at least 300 kg/m.sup.3 by in-mold foaming of a reaction mixture based on(a) a polyisocyanate component containing at least one aromatic polyisocyanate,(b) a polyhydroxyl component,(c) blowing agents,(d) catalysts and(e) zeolitic adsorbents,at an isocyanate index of about 75 to 150, characterized in that(b) an organic polyhydroxyl compound or a mixture of organic polyhydroxyl compounds having an (average) hydroxyl functionality of at least 2.2 and an (average) OH number of at least 300 mg KOH/g is used as the polyhydroxyl component,(c) water and/or carbon dioxide is/are used as the blowing agent and(e) the zeolitic adsorbents have a pore diameter of at least 0.7 nm.

Abstract: A method of making thermal insulating products comprising porous, lightweight, high temperature resistant inorganic particles in a polyimide foam matrix and the product thereof. A polyimide precursor provided is mixed with about equal weight of flake-like porous inorganic particles to substantially uniformly coat the particles with powder. The mixture is placed in a mold and compressed slightly. The assembly is heated to the foaming temperature of the polyimide precursor for a period suitable to produce uniform foaming. Then the temperature is raised to the curing and crosslinking temperature of the precursor for a time period sufficient to produce complete cure. A high temperature and flame resistant, light weight, highly insulating product results. If desired, protective sheets of material may be bonded to selected product surfaces during or after the molding operation.

Abstract: Fibres, particularly glass or rock wool fibres coated with a modified polyvinyl alcohol-based polymer and suitable for use as a base material to produce a surface coating on a backing by simultaneous spraying of the coated fibres mixed with water and a cross-linking agent. A method of producing the fibres to make them suitable to be sprayed in the manner described is also provided.

Abstract: A filler composition for mixing with a resin to form a castable marble-like product comprises an inorganic filler material, such as calcium carbonate in powdered form admixed with components which considerably reduce the density of the cast product. The weight reducing components may be hollow ceramic spheres in combination with hollow plastic spheres. The plastic spheres have an average diameter significantly less than the average diameter of the ceramic spheres. The plastic spheres act as cushion to minimize break up and degradation of the ceramic spheres. When the filler composition is admixed with a resin, the resultant cast product is considerably lighter than existing cast marble-like products.

Abstract: A filler composition for mixing with a resin to form a castable marble-like product comprises an inorganic filler material, such as calcium carbonate in powdered form admixed with components which considerably reduce the density of the cast product. The weight reducing components may be hollow ceramic spheres in combination with hollow plastic spheres. The plastic spheres have an average diameter significantly less than the average diameter of the ceramic spheres. The plastic spheres act as cushion to minimize break up and degradation of the ceramic spheres. When the filler composition is admixed with a resin, the resultant cast product is considerably lighter than existing cast marble-like products.

Abstract: A composition for a pressure molded core of a composite structure, including a thermal plastic resin. The composition also includes a component to reduce the coefficient of thermal expansion, a lightweight high compressive strength filler, and a blowing agent. The thermoplastic resin may be polyetheretherketone, the component may be carbon fibers, and the filler may be hollow glass microspheres.

Abstract: A flame-retardant polymer is created by forming a first resin typically by reacting resorcinol with furfural in a ratio of one mole of the former to less than a mole of the latter in the presence of an alkaline catalyst. A resole is then formed by reacting typically phenol with formaldehyde in a ratio of one mole of phenol to more than a mole of the aldehyde in the presence of an alkaline catalyst. The first resin and resole are mixed together with a powered oxyborate compound such as zinc borate and allowed to polymerize to form the polymer.

Abstract: Masonry structures are susceptible to cracking due to distortion caused by movement of their foundation, vibration, and/or drying out subsequent to the construction of the structure. Such cracking often occurs after the structure has been painted. This results in the crack being transmitted through the coating of paint. Upon repainting of the masonry structure new cracks often develop and are transmitted through the paint coating within a short period of time.This invention discloses a crack resistant coating for masonary structures comprising:(1) a crack absorbing layer which is contiguous to the masonry structure which contains beads which are essentially spherical and which are bound by a resin binder, and(2) a conventional coating layer which is contiguous to and covers the crack absorbing layer.

Abstract: Coherent thermoplastic aggregates with very high content of pulverulent mineral materials, said aggregates comprised of the said mineral materials, further of polyolefin polymers and/or copolymers, and possibly additionally of miscellaneous known additives; characterized in that, with the aim of achieving a density near to or at most equal to the theoretical density of the pulverulent mineral materials entering into their composition, while still having excellent compatibility with the polymers of redispersion, i.e., the polymers into which the subject aggregates are to be mixed, the interparticle voids between the grains of the mineral materials, which grains are basically in contact with each other, are at most filled--in the presence of a fluidifacient agent--by at least one polyolefin polymer and/or copolymer having a fusion temperature and/or softening temperature at least equal to 60.degree. C., and having a fluidity index (ASTM 1238) of at least 50.

Abstract: The invention relates to electric insulation with a polyolefin base for medium and high voltage from about 10 kV up. In insulation of this type the formation of so-called water trees is to be prevented on the one hand and on the other hand, the dielectric losses are to be kept as low as possible. For this purpose it is provided that silicic acid prepared in the following manner is added to the insulation: SiO.sub.2 -containing mineral substances are melted with additions of aluminum oxide, boron oxide and carbonates and/or oxides of alkali and earth-alkali metals to form a homogeneous glass phase; from the glass melt, glass bodies with a large surface are made; the glass bodies are subjected to a leaching process with mineral acid; the porous SiO.sub.2 bodies produced are washed and dried and optionally milled. The electric insulation according to the invention is particularly well suited for use in cables and wires.

Abstract: A process for mixing a magma that can be used to make a structural syntactic foam of very low density includes the steps of mixing and agitating the dry ingredients of the foam, principally silica microspheres, in a slant cone mixer to break up any lumps and achieve a uniform fluffy mixture, and spraying a resin/solvent solution as a fog of fine droplets into the mixture. The resulting magma is folded and agitated within the mixer until the resin uniformly coats the microspheres, and the resin is packed into a mold. The filled mold is pressurized and heated in an autoclave until the resin is cured, and then the mold is cooled and opened and the finished syntactic foam part is removed.

Abstract: The invention primarily concerns a pressure-sensitive adhesive tape, the adhesive layer of which is filled with glass microbubbles and has a dark appearance by virtue of (1) the microbubbles are stained glass which preferably is dark, and (2) dispersed throughout the adhesive layer is a pigment or dye which preferably is dark. More broadly, the invention concerns any coherent article filled with stained-glass microbubbles. The glass of the microbubbles preferably has an ultraviolet window, permitting the article to be made by photopolymerizing a matrix filled with the microbubbles.

Abstract: A trowelable ablative coating composition is disclosed. The composition comprises an epoxy resin, an amide curing agent, glass microspheres and ground cork. A method for protecting a substrate is also disclosed. The method comprises applying the trowelable ablative coating discussed above to a substrate and curing the coating composition.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermoplastic polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: Filling compounds having plastic flow behavior for electrical components and light-wave conductors comprising (a) a non-polar, water-immiscible hydrocarbon organic liquid, (b) an organic polymeric thickening agent therefor, (c) pyrogenic silica, and when used for electrical cables or optionally for optical cables, (d) hollow micro-bodies dispersed in the filling compounds.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermosetting polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: A formulation for surface coating applications, particularly surfaces which are in frequent contact with water and remain water-wet, and/or surfaces of elastomeric and plastic foams, especially foams fabricated from polyethylene and polyurethane resins. The formulation includes a vehicle consisting primarily of a block polymer of styrene/ethylene/butylene/styrene and methylmethacrylate copolymer or related block polymer with lesser degrees of ethylenic unsaturation together with a rubber tackifier, with fillers being provided including particulate colloidal or powdered silicon dioxide, and glass microspheres having an average size of less than about 70 microns. The formulation is such that it is adaptable to be applied by either air pressure spray systems or aerosol packaging techniques.

Abstract: Polydiorganosiloxane compositions useful for producing flame resistant foam of the type containing finely divided nonmetallic fibrous heat resistant material and finely divided nonmetallic cellular heat resistant material tend to separate upon long time storage. The compositions remain homogeneous upon storage when at least 0.1 weight percent of fume silica is included in the composition during the mixing of the ingredients before storage.

Abstract: The method of the present invention includes mixing a low viscosity thermoset resin and microspheres together without melting the thermoset resin and extruding the mixture to form a continuous strand of paste-like uncured material. The continuous strand is gelled on a conveyor which preferably includes a radiant heater or other means for accelerating the gelling of the continuous strands into solid form. The strands are then cut or chopped into pellet form and may be coated with an adhesive or B-staged material in preparation for forming into structural reinforcements. The pellets are filled with microspheres in the amount of 20 to 35% of resin weight. The pellets may include unexpanded thermally expandable microspheres which permit expansion of the pellets when exposed to heat to provide a pellet having a bulk density as low as 9 pounds per cubic foot.

Abstract: In a method of producing implants of bone replacement material from resin reinforced with carbon fiber at least the fibers in the parts of the surface which are to come into contact with the bone tissue are exposed by mechanical treatment. This provides for an improved unification of the bone with the implant. The fibers at the surface may be fibers of a fabric which is wrapped around a basic member shaped to conform to the desired implant.

Abstract: A method for accelerating the dehydration of aqueous dispersions and bonding the solids contained therein characterized by the addition of fly ash to the aqueous polymeric composition. The fly ash is added in an amount sufficient to significantly reduce the dehydration time of the composition and generally comprises at least a partial substitution of the mineral filler content of the aqueous polymeric dispersion.

Abstract: The use of microporous inorganic fillers in polymerizable compositions, in particular in the dental field, characterized in that the fillers have(a) an average particle size of 0.5 to 50.mu.,(b) a BET-surface area of at least 200 m.sup.2 /g,(c) a pore volume of 0.7 to 5 ml/g and(d) a pore diameter of 10 to 50 nm.Fillings made therefrom are smooth and easy to polish.

Abstract: Sulfonated copolymers of styrene alpha-methylstyrene are added to cement compositions to improve the workability and strength characteristics of the concrete, mortar or grout product derived therefrom.

Abstract: A phenolic resin composite foam is disclosed which is prepared by heating and foaming a novolak phenolic resin having a number average molecular weight of 250 to 600 and a bulk density of 0.15 to 0.5, a blowing agent, a blowing auxiliary compound and inorganic foamed particles. Additional materials for flame retardancy can be added. The foam produced has a high compressive strength, a high foaming and rapid curing rates, a low water absorption and a minimum of friability.

Abstract: A thermoplastic resin composition comprises a thermoplastic resin and a spherical, hollow filler having a wall thickness ratio of 2.5 to 10, defined as a ratio of an outer diameter of the filler to a wall thickness of the filler. It is useful for a light-weighed piece.

Abstract: An improved process for matching the color characteristics of a paint containing film forming binder, a liquid carrier, colored pigments and flake pigments to the color characteristics of a surface layer that contains flake pigments; the improvement comprises the following:adding to the paint a dispersion comprising a liquid carrier, a dispersing agent and transparent or semitransparent extender pigments or rigid or semirigid organic particles, particularly preferred are, hollow glass spheres, in an amount sufficient to match the color characteristics of the surface layer.

Abstract: The intumescent material of this invention comprises a filled polyorganosiloxane composition that is elastomeric in the cured form and up to 70 parts by weight per 100 parts by weight of said composition of hollow, thermoplastic microspheres filled with a volatile liquid. The materials are particularly useful as flame and smoke barriers in passages of partitions that are traversed by thermoplastic articles such as pipes and conduits, and can optionally contain chemical blowing agents.

Abstract: The invention provides an insulation material in the form of a cured composition comprising as components:(a) 10 to 30% w magnesium chloride,(b) 0 to 15% w of an organic resin,(c) 0 to 0.5% w of a mould-release agent,(d) 0.1 to 1% w of a surfactant,(e) 6 to 8% w of a sodium polyphosphate glass,(f) 6 to 20% w magnesium oxide,(g) 4 to 20% w inorganic filler,(h) 15 to 30% w cenospheres,(i) 1 to 3 % w orthophosphoric acid,(j) 0 to 12 % w inorganic fibres,in overall proportions to total 100%, having a density in the range 200 to 500 kg/m.sup.3 ; and its preparation.

Abstract: A self-supporting structure comprising an inorganic sorbent and method for preparing is described in which the self-supporting structure is substantially free of sorbent fines and the sorption characteristics of the sorbent particles is retained. The process for immobilizing the sorbent particles in the self-supporting structure comprises the steps of:(a) preheating inorganic sorbent particles to an elevated temperature;(b) mixing the sorbent particles with particles of a polymeric binding material to form a mixture comprising the particles of polymeric binding material adhered to the sorbent particles; and(c) heating the mixture to about the solid-liquid transition temperature of the polymeric binding material with or without pressure to form a structure which upon cooling is self supporting.

Abstract: An insulating foam and a process for producing insulating foam, wherein a foamable first component may be made of alkyl sulfate, half ester of maleic anhydride and acrylic resin in an aqueous solution is mechanically foamed with air, and to that foam is added an aqueous solution of magnesium oxide, dispersant, acrylic resin, perlite and/or precipitated calcium carbonate. To those components is added an aqueous solution of at least one of aluminum chloride, magnesium sulfate, magnesium chloride, zinc chloride, sulfamic acid, sodium silicate, zinc oxide, barium metaborate, vinyl alcohol, magnesium carbonate, calcium chloride and vinyl acetate. In another embodiment a polyvinyl alcohol and dispersant first portion is foamed with air and mixed with a second cementitious portion comprising magnesium oxide and barium metaborate.

Abstract: Process for the preparation of cellular products and laminates based on anhydrous furan prepolymers which possess free OH groups, which is carried out at normal temperature using small amounts of silicon tetrachloride and/or phosphorus oxychloride as the crosslinking and expansion agent, characterised in that a combination of a furfuryl alcohol resin and/or a furfural/phenol (phenol and/or bisphenol A) resin with a bishydroxymethylfuran resin is used as the furan prepolymers, without the use of an acid, the silicon tetrachloride and/or phosphorus oxychloride being used in amounts of 0.1 to 5% by weight, based on the resin employed.

Abstract: Masonry structures are susceptible to cracking due to distortion caused by movement of their foundation, vibration, and/or drying out subsequent to the construction of the structure. Such cracking often occurs after the structure has been painted. This results in the crack being transmitted through the coating of paint. Upon repainting of the masonry structure new cracks often develop and are transmitted through the paint coating within a short period of time.This invention discloses a crack resistant coating for masonry structures comprising:(1) a crack absorbing layer which is contiguous to the masonry structure which contains beads which are essentially spherical and which are bound by a resin binder, and(2) a conventional coating layer which is contiguous to and covers the crack absorbing layer.

Abstract: A vinyl chloride resin composition made lightweight and delustered and having a superior abrasion resistance and a good microballoon-retainability, and molded products such as steering wheel using the same are provided, which composition comprises 100 parts by weight (hereinafter "by weight" omitted) of a vinyl chloride copolymer consisting of 97.0.about.99.95% of vinyl chloride and 3.0 to 0.05% of a polyethylene glycol di(meth)acrylate having a specified number of ethylene glycol polymerization units and a specified average polymerization degree, 5 to 100 parts of microballoons having a specified s.g., particle diameter and compressive strength, 1 to 20 parts of polyvinyl acetate having a specified average polymerization degree and 30 to 150 parts of a plasticizer.

Abstract: A composition for protection of the liquid surface from heat- and mass-trfer, for example from evaporation, contains a polymer limitedly swelling in the protected liquid or a mixture of said polymer with a neutral filler having a density lower than the density of the protected liquid.A method for protection of the liquid surface from heat- and mass-transfer comprising application of said composition on the surface of a liquid, for example petroleum, in an amount of from 0.1 to 2 kg per m.sup.2. Upon contacting of the polymer with the liquid the polymer rapidly swells and forms a continuous gel-like covering which hinders the heat- and mass-transfer on the liquid surface.

Abstract: Gel-resistant composition especially suited for filling, patching or repairing plaster, gypsum board panels and the like comprising a blend of glass microbubbles containing borate, high molecular weight polyhydroxy compound such as polyvinyl alcohol functioning as a binder, water, and low molecular weight polyhydroxy compound in which at least two of the hydroxyl groups are attached to carbon atoms that are separated by one or more intervening carbon atoms.

Abstract: An insulating paint for exteriors or interiors of buildings includes glass microspheres or hollow glass extenders, having a density of about 0.22 to 0.28 grams per cubic centimeter, and a diameter of about 100 microns. The microspheres are dispersed by high speed mixing in the grind stage of the paint formulation. The paint provides insulation against heat loss.

Abstract: Expandable phenolic resin-coated composite beads comprise an aggregate having coated thereon a solid, expandable resin composition comprising a solid, phenolic resin initial condensation product, a foaming agent and, if necessary, a hardening agent. The expandable phenolic resin-coated composite beads provide composite cellular moldings in which the aggregates are uniformly dispersed in a phenolic resin-expanded layer and are firmly adhered to the expanded layer. The composite cellular moldings can be adhered to a face plate to form integral laminates.

Abstract: The invention concerns glass microbubbles having an inorganic thin-film coating not exceeding about 10 nm in thickness, especially a coating of a metal, a metalloid, or an alloy thereof. When dispersed throughout a matrix such as a polymer, the coated glass microbubbles can afford surprisingly good hiding power while also imparting esthetically pleasing colors to otherwise transparent articles.

Abstract: Open-cell foamed particles and molded shapes having up to 99% porosity are formed from fumed oxides, for example SiO.sub.2, Al.sub.2 O.sub.3, TiO.sub.2, with or without functional groups, in 30-99%, by weight, and polymers, for example polyvinyl chloride and copolymers thereof, and styrene. The resulting structures are thermally insulating. The structures can be formed by beating small amounts of a liquid polymerizable monomer into the fumed oxide or by immersing a formed shape of the oxide in a liquid monomer and thereafter polymerizing the monomer to a solid polymer. The oxide is believed to have a microfibrous nature and the polymer is believed to coat the oxide, without destroying the open-nature configuration of the oxide, and cements the oxide particles together in the microfibrous condition.

Abstract: Syntactic foam with improved processing characteristics is disclosed wherein a blend of coupling agents and alkylphenol alkoxylates are used to improve processibility and reduce cure time of the syntactic foam system.

Abstract: Syntactic foam with improved processing characteristics is disclosed wherein a blend of aminosilane and aminated alkylphenol alkoxylates are used to improve processibility and reduce cure time of the syntactic foam system.

Abstract: A pressure-resistant buoyancy material, comprising pressure-resistant hollow elements, a syntactic foam, and an empty space intervening between the pressure-resistant hollow elements and the syntactic foam, communicating with the outside of the buoyancy material. The pressure-resistant hollow elements are retained in a freely movable state in the empty space.

Abstract: Fiber-reinforced syntactic foam composites having a low specific gravity and a low coefficient of thermal expansion suitable for forming lightweight structures for spacecraft applications are prepared from a mixture of a heat curable thermosetting resin, hollow microspheres having a diameter of about 5 to 200 micrometers and fibers having a length less than or equal to 250 micrometers.

Abstract: A soft, low-resilience, cured rubber composition is prepared by mixing(a) 100 parts by weight of a polymeric material comprising a styrene-butadiene copolymer or styrene-butadiene copolymer mixture having a styrene content of 53 to 75% by weight, and 0 to 40% by weight of the polymeric material of another rubber ingredient,(b) 30 to 300 parts by weight of a filler, and(c) 5 to 100 parts by weight of a plasticizer, adding effective amounts of a vulcanizing agent and a vulcanizing accelerator to the mixture, and then heat curing the mixture. A similar composition further containing a foaming agent may be heat cured into a low-resilience rubber foam. Rubber and foamed rubber compositions have improved vibration-attenuating and shock-absorbing properties.

Abstract: An improved polyurethane lacquer for coating an elastomer containing at least one polyfunctional aromatic nitroso compound as an adhesion improver and optionally, lacquer-nonreactive spacer particles.

Abstract: A novel economical hardboard is provided which comprises (a) about 1-40 wt % of a porous additive having a particle size in the range of about 0.1-2 mm; (b) about 65-97 wt % of cellulose fibers; (c) about 2-5 wt % binder; and (d) about 1-4 wt % wax. Also provided is an efficient economical process for the production of the above described inventive hardboard comprising the steps of formulating an aqueous mixture of the above ingredients, then dewatering the aqueous mixture, and finally heating the mixture at a temperature and time sufficient to cure the binder.

Abstract: A laser shield consists essentially of a series of spherical glass bubbles densely packed within a range of 1.95.times.10.sup.3 bubbles per cubic centimeter to 1.25.times.10.sup.8 bubbles per cubic centimeter encapsulated in a matrix of silicone to provide a flexible and lightweight foam-like material to terminate CO.sub.2 laser radiation without producing a substantial carbon plume. The glass bubbles may be filled with a gas. In another embodiment, a laser shield consists essentially of water encapsulated in a matrix of silicone to provide a flexible and lightweight material to terminate CO.sub.2 laser radiation without producing a substantial carbon plume. In another embodiment, water bubbles and glass bubbles are both encapsulated within a matrix of silicone to provide a laser shield. A surgical drape, a surgical sponge and an endotracheal tube are formed of a flexible and lightweight material of a series of densely packed bubbles encapsulated in a matrix of silicone to terminate laser radiation.