Abstract: A lightweight ready-mix concrete composition that contains 8-20 volume percent cement, 11-50 volume percent sand, 10-31 volume percent prepuff particles, 9-40 volume percent coarse aggregate, and 10-22 volume percent water, where the sum of components used does not exceed 100 volume percent. The prepuff particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3. The slump value of the composition measured according to ASTM C 143 is from 2 to 8 inches. After the lightweight ready-mix concrete composition is set for 28 days, it has a compressive strength of at least 1400 psi as tested according to ASTM C39.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: Resin beads having an average particle size of from 0.001 mm to 10 mm and containing a continuous phase and a particulate dispersed phase are described. The continuous phase includes elastomeric polymers; the dispersed phase includes homopolymers and/or copolymers containing repeat units resulting from the polymerization of one or more aryl polymerizable monomers. The unexpanded polymer resin beads can be prepared by dispersing an organic phase containing elastomeric polymers and one or more monomers, into droplets and polymerizing the monomers in the organic droplets in a low shear flow pattern. The beads can be impregnated with blowing agents, expanded and can be used to make molded articles. Resin beads having a continuous phase comprising a nitrile rubber, and a dispersed phase comprising one or more homopolymers and/or copolymers containing repeat units resulting form the polymerization of one or more aryl polymerizable show prolonged retention of blowing agents in unexpanded form.

Abstract: Methods of constructing concrete walls that include placing a plurality of cleats along a wall perimeter, securing the cleats to a surface under the wall perimeter, placing a plurality of insulating concrete forms along the perimeter, and placing concrete into the insulating concrete forms to form the insulating concrete wall. The cleats include a base plate, a first vertical flange extending approximately perpendicular from the base plate, and a second vertical flange extending approximately parallel to the first vertical flange. The space defined by the first vertical flange, second vertical flange and the base plate, is adapted to receive a bottom portion of a form component or a bottom portion of a form. The insulating concrete forms are placed along the perimeter such that a bottom portion of the form components or a bottom portion of the form are press fit into the defined space.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate, where the particles contain an antimicrobial agent; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, dining tables, counter surfaces, bench tops, and/or examination tables as well as other articles.

Abstract: A device and method for producing labeled expanded resin containers; the method including applying a label sheet, formed from a label material capable of maintaining an electrostatic charge, to an inner wall of female portions of two-part molds, positioning one or more male portions of the two-part molds in contact with the corresponding female portions to form one or more mold cavities; adding expandable resin beads or pre-expanded resin beads to the mold cavities; applying a sufficient amount of heat for a sufficient length of time to the mold cavities to effect expansion of the expandable resin beads or pre-expanded resin beads to form labeled containers; cooling the labeled containers; and removing the labeled containers from the mold cavities. The labels on the external wall of the labeled containers present a smooth circumferential surface.

Abstract: An expandable particulate interpenetrating network polymer composition that includes as an expansion agent pentafluorobutane and optionally a minor amount of heptafluoropropane is described. The expandable particulate interpenetrating network polymer, more particularly, includes a particulate interpenetrating network polymer that includes: (i) a polyolefin polymer present in an amount of from 10 percent by weight to 80 percent by weight; and (ii) a vinyl aromatic polymer present in an amount of from 20 percent by weight to 90 percent by weight, in each case based on total weight of the particulate interpenetrating network polymer. The expansion agent resides (or is impregnated) within the particulate interpenetrating network polymer. The pentafluorobutane may be 1,1,1,3,3-pentafluorobutane, and the heptafluoropropane may be 1,1,1,2,3,3,3-heptafluoropropane. In an embodiment, the expansion agent consists of 1,1,1,3,3-pentafluorobutane, and is substantially free of any other expansion agents.

Abstract: A method of constructing a shallow pier foundation building that includes a) placing a plurality of insulating pier forms along a perimeter of the building; b) placing a plurality of insulating concrete forms between the insulating piers to form a continuous insulating surface to the surrounding soil and a continuous forming surface to provide a slab form; c) placing a concrete composition in the insulating piers and insulating concrete forms and allowing the concrete composition to cure and harden; and d) placing a concrete slab composition in the slab form and allowing the concrete composition to cure and harden.

Abstract: A method of making foamed articles that includes providing a copolymer composition, combining the copolymer composition and cellulosic fibers, applying heat, mixing energy and pressure to the copolymer composition and cellulosic fibers mixture to form a foamable mixture, and forming the foamed article by placing the foamable mixture in a molding or extruding operation. The copolymer composition includes a copolymer of 51% to 99.9% of primary monomers, 0.1% to 49% of anhydride containing monomers, and 0% to 25% of other monomers and 0% to 30% of elastomeric polymers. This is combined at 30% to 99.99% copolymer composition with 0.01% to 70% by cellulosic fibers such that the copolymer anhydride groups react with the cellulosic fiber hydroxyl groups to produce a blowing agent byproduct to form a foamable mixture. The foamed article has a density of not more than 1.3 g/cm3.

Abstract: A particulate interpenetrating network polymer that is composed of a polyolefin polymer and a vinyl aromatic polymer that includes residues of (meth)acrylic acid, is described. The particulate interpenetrating network polymer is formed by polymerization of a vinyl aromatic monomer composition substantially within the polyolefin polymer. The vinyl aromatic monomer composition includes vinyl aromatic monomer (e.g., styrene) and a comonomer that is composed at least in part of (meth)acrylic acid (e.g., (meth)acrylic acid and optionally butyl(meth)acrylate). The amount of (meth)acrylic acid present within the comonomer (and accordingly the vinyl aromatic polymer) is selected such that a molded article prepared from expanded particulate interpenetrating network polymer, has a volume shrinkage value of less than or equal to 5 percent, when subjected to a temperature of 100° C. for 24 hours.

Abstract: Labeled thin-wall containers molded from pre-expanded expandable thermoplastic particles having a label disposed over at least a portion of the outer surface of the container. The particles are coated with a composition that includes at least 2,500 ppm of a salt of a C8 to C32 carboxylic acid based on the weight of the particles. The label has a thickness of from 10 ?m to 1,500 ?m and the sidewall has a thickness of from 0.5 mm to 5 mm. An aqueous beverage at 80° C. does not leak from the container after being left undisturbed for 24 hours and the container has a rim strength of at least 0.54 kg. The containers are made by placing a label against an inner surface of a female portion of a two-part mold; closing the mold to form a mold cavity; filling the mold cavity with the particles; and fusing the particles.

Abstract: Methods for identifying defective containers that include a) providing a container having an open rim end, a closed base end, an exterior surface and an interior surface; b) directing one or more sources of electromagnetic radiation toward the exterior surface or interior surface of the container; c) positioning one or more sensors for the electromagnetic radiation opposite the exterior or interior surface not directed to in b); d) accepting the container if the amount of electromagnetic radiation detected by the one or more sensors is within a predetermined range; and e) rejecting the container if the amount of electro-magnetic radiation is not within the predetermined range. The methods can be used in devices that contain a) conveying means for moving containers; b) means for directing sources of electromagnetic radiation; c) means for detecting electromagnetic radiation; and d) means for separating containers.

Abstract: A mobile polymer system. The system includes a mobile platform and a heat generating device mounted to the mobile platform. The system also includes a polymer expansion unit mounted to the mobile platform, wherein the polymer expansion unit is adapted to expand a polymer, using heat generated by the heat generating device, at a location of the mobile polymer expansion system to create an expanded polymer that can be used to create an expanded polymeric product that is comprised of the expanded polymer.

Abstract: A method of reducing plastic shrinkage cracking in concrete compositions that includes a) combining 3-40 volume percent cement, 5-50 volume percent fine aggregate, 5-50 volume percent coarse aggregate, and 10-22 volume percent water to form a concrete mixture; b) during or after (a), adding 1.5-40 volume percent of prepuff particles to the concrete mixture to form a concrete composition; c) placing the concrete composition in a form; and d) allowing the concrete to set and harden to form a hardened concrete article substantially free of plastic shrinkage cracking. The prepuff particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3. The concrete composition has a density of from about 40 to about 135 lb./ft3.

Abstract: A method of placing a concrete compositions including a) combining 3-40 volume percent cement, 5-50 volume percent fine aggregate, 5-50 volume percent coarse aggregate, and 10-22 volume percent water; b) adding 1.5-40 volume percent of prepuff particles to form a concrete composition; and c) pumping the concrete composition to a point higher in elevation than the delivery point of the concrete to place the concrete. The concrete composition contains less than 30 volume percent of other light weighting aggregates and the prepuff particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3. The slump value of the placed concrete measured according to ASTM C 143 is greater than 1 inch and the concrete has a density of from about 40 to about 135 lb./ft3.

Abstract: A polymerization process to prepare polyolefin-clay nanocomposites from modified clay is described. Polystyrene-clay nanocomposites formed using the inventive method are highly exfoliated and show improved physical properties relative to polystyrene polymers. The process can be applied to bulk or suspension polymerization. The process provided is a two stage polymerization of monomer in the presence of a modified clay. In a first stage, monomer is polymerized within a clay gallery by an intercalated free radical initiator which is activated at a first polymerization temperature. In a second stage, monomer extrinsic to the clay is polymerized using an oil soluble free radical initiator which is activated at a second polymerization temperature.

Abstract: A sports board that includes an elongate, water impervious, thermoplastic foam core having an upper surface and an under surface; an upper layer covering at least a portion of the upper surface; and an under layer covering at least a portion of the under surface. The foam core is made of a foamed material having a water absorption (measured according to ASTM C-272) of less than 2 volume percent.

Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.

Abstract: Process for preparing polymer, e.g. polystyrene, particles that may not or may contain a water-retaining agent and that require only a one-step process for incorporating the water-retaining agent. The polymer particles may be prepared via an extrusion process, or a bulk polymerization process wherein a water-retaining agent is blended into the polymer melt. Water is incorporated into the particles by soaking them in hot or cold water or treating the particles with steam for a predetermined time depending on the desired water content in the particles. The water-retaining agent may be starch, zeolite, silica dioxide or poly (N-isopropyl acrylamide) ranging from 0.1% to 10.0% by weight. The particles can be expanded via appropriate means to form pre-expanded or expanded particles in a conventional manner.

Abstract: Articles containing a cellulosic fiber filled thermoplastic that includes about 10% to about 99.9% by weight of a copolymer; optionally 0.1% to 30% by weight of one or more elastomeric polymers; and 0.1% to 70% by weight of one or more cellulosic fibers. The copolymer contains residues formed by polymerizing a mixture that contains i) 51% to 99.9% by weight of one or more primary monomers, ii) 0.1% to 49% by weight of one or more maleate-type monomers, and iii) optionally 1% to 25% by weight of one or more other polymerizable monomers. The article has a thickness of from 0.1 cm to 12 cm. The tensile modulus, determined according to ISO 527-2, of the cellulosic fiber filled thermoplastic is at least 2,000 MPa and the DTUL at 1.82 MPa determined according to ISO-75-2, of the cellulosic fiber filled thermoplastic can be at least 85° C.