Abstract: The invention relates to a process for producing foam webs by foam extrusion of a mixture of a polysulfone or polyether sulfone and a volatile blowing agent, where the blowing agent is water or a mixture of water with an inert gas or organic liquid, e.g. an alcohol or a ketone.

Abstract: The method includes the step of forming a solid epoxy member on a substrate, the epoxy member having an upper surface of desired configuration. A first metal layer is deposited on the epoxy member with the upper surface thereof conforming to the desired configuration. A layer of epoxy is deposited on the first metal layer and epoxy material from the epoxy layer is removed to create a well, exposing the metal layer on the epoxy member. A metal impression layer is then deposited in the well. The metal impression layer is then removed from the well and affixed to a mounting member as a mold component for injection molding of small structures.

Abstract: A method and apparatus for making a dome-shaped sealing element for a vaginal speculum from an annular workpiece of closed cell polyethylene foam sheet material is described.

Abstract: The invention relates to a process for forming a laminate comprising a core of a compressed metal powder mixed with a foaming agent between two metal layers, comprising the successive steps of providing two metal strips and a stock of powder comprising a metal powder mixed with a foaming agent; applying a layer of the powder between the two metal strips; feeding the metal strips, with the powder between them, to a rolling mill; rolling the two strips with the powder between them to form a laminate of compressed powder between two metal layers. The invention also relates to an associated device and to the product formed using the process.

Abstract: Manufactured articles and methods of producing such articles are disclosed where the article has a thermoplastic polymer component and a curable polymer component. The curable polymer may be moisture-curable polymer, or microwave, dielectric or radio frequency curable polymer. The articles may be manufactured by a variety of polymer processing methods including extrusion, co-extrusion, co-molding, injection molding and calendering. A variety of articles and shapes may be made by the method including electric wire and cable, and weatherstripping.

Abstract: A molded shipping pallet is set forth as well as a process for molding and composition therefore. The process includes pre-heating and mixing various meshes of ground, crumb rubber with other polymers and agents and introducing the composition into a mold to mold the pallet. The pallet is molded to have a shape and construction which minimizes weight yet provides strength.

Abstract: In a process for producing a polyurethane-foam product molded integrally with an insert, wherein a molded body, including a substrate and a polyurethane-foam molded body being molded integrally with the substrate, is produced, the substrate being disposed in an expansion-molding mold as the insert, a fine groove-shaped polyurethane-foam relief groove and a polyurethane-foam adjuster are formed in an end of the substrate and/or a mold surface of the expansion-molding mold which contacts with the substrate. The relief groove communicates with a cavity of the mold. The adjuster communicates with the relief groove, and has a volume larger than that of the relief groove. The relief groove and the adjuster can control the pressure exerted within the cavity. Polyurethane foam, which is formed by the relief groove and the adjuster, adheres to molded product. Therefore, it is possible to obviate the deflashing operation. An expansion-molding mold therefor is also disclosed.

Abstract: Resin or pitch is melted in a melt blender apparatus (11) and then loaded, into a heated jacketed holding tank (12). A pair of feed lines (14, 16) receives resin from the holding tank (12) and feeds an upper gear pump (15) and a lower gear pump (17). A mixing enhancement such as a static mixer (18, 19) is located in each of the feed lines (14, 16) between the gear pumps (15, 17) and the resin delivery ends (25, 26) of the feed lines. The resin-melt feed lines may be equipped with pressure indicators (27, 28, 32, 34) and pressure relief valves (23, 24). The resin-melt feed lines may also be equipped with pump accumulators (31, 33). Resin melt pressure created by the gear pumps (15, 17) forces a piston inside the accumulator back to the desired position. The accumulators (31, 33) can also be used to maintain constant pressure in the feed stock. Resin can be recycled from the accumulators (31, 33) into the melt blender (11).

Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: The invention provides release agents and methods for preparing textiles and molded articles there from. Lignocellulosic materials, concrete and polyurethane foam can be molded with these release agents. The release agents comprise the salt of tall oil fatty acids, preferably of very high purity. A synthetic wax and/or silicone resin is used with the tall oil fatty acids in preferred embodiments. The tall oil fatty acids contain less than 10 wt % , based on the total weight of the tall oil fatty acid, of unsaponifiables and less than 1 wt %, based on the total weight of the tall oil fatty acid, of rosin acid.

Abstract: Polymer foams having a good balance of high sound absorption, low thermal conductivity and generally low water absorption are disclosed which are obtainable by perforating (i.e., hole punching) a polymer foam having a moderately large cell size (1.5 mm to 4 mm) and an open content not greater than 40 percent to increase the open cell content of the foam by at least about 10 percent relative to the non-perforated foam, the polymer foam matrix preferably made of a thermoplastic foam, such as a low-density polyethylene (LDPE) resin, a high melt strength (HMS) polypropylene resin (PP), or a blend of an HMS PP resin and an LDPE resin, optionally containing a cell size enlarging agent such as glycerol monostearate, an antioxidant, carbon black and/or flame retardant additives, using a volatile organic compound, e.g. isobutane, as blowing agent.

Abstract: A method of fabricating a stamping mold suitable for use in the formation of a tapered waveguide structure includes defining a stamping pattern upon the surface of a silicon wafer, and removing portions of the silicon wafer surface in accordance with the stamped pattern, thereby creating tapered vertical surfaces within the wafer.

Abstract: The present invention relates to a hollow molded foam article in which a plurality of polypropylene resins are used as the base resin, and to a process for the production of this hollow molded foam article. More particularly, the present invention relates to a polypropylene resin hollow molded foam article having a foam layer, in which the base resin comprises (a) a polypropylene resin with a melt tension of at least 98 mN and a melt flow rate of 0.5 to 15 g/10 minutes, (b) a polypropylene resin with a melt tension of less than 30 mN (excluding O) and a melt flow rate of 2 to 30 g/10 minutes, and (c) a polypropylene resin with a melt tension of at least 30 mN and less than 98 mN and a melt flow rate of 2 to 15 g/10 minutes, formed by positioning in a mold a softened cylindrical foam having a foam layer obtained by extruding from the die of an extruder a foamable molten resin composition containing a foaming agent, wherein the melt tension at 230° C.

Abstract: A method for making a surface covering is disclosed which includes providing a surface covering having a backing layer, a foamable layer, and a design layer, wherein the design layer includes a portion of a pattern printed with at least one retarder composition. A wear layer is then provided on the design layer and the wear layer is cured. The foamable layer is thereby expanded to form a foam layer, and the pattern printed with at least one retarder composition is chemically embossed. The cured product is subsequently cooled to ambient temperature and then the top surface of the wear layer is subjected to a sufficient temperature to soften the wear layer. After being softened the wear layer is mechanically embossed with a surface texture, the embossed surface texture is set in the wear layer, and a top coat may then be provided on the embossed set wear layer. A surface covering having the various features described above is also disclosed.

Abstract: A method for production of an extruded, polystyrene-based foam plate wherein a polystyrene-based resin is heated and kneaded together with a blowing agent, a flame retardant and a nucleating agent in an extruder to obtain a foamable molten composition, and the foamable molten composition is extruded through a die attached to an end of the extruder into a lower pressure zone. The blowing agent comprises not smaller than 25% by weight but not greater than 65% by weight, based on the total weight of the blowing agent, of an isobutane-containing saturated hydrocarbon; not smaller than 5% by weight but not greater than 70% by weight, based on the total weight of the blowing agent, of a dimethyl ether-containing ether; not smaller than 5% by weight but not greater than 55% by weight, based on the total weight of the blowing agent, of carbon dioxide; and 0–25% by weight, based on the total weight of the blowing agent, of other blowing agent components.

Abstract: An extrusion head for the manufacture of tubes including at least one layer of expanded plastic by extruding a stream of molten plastic containing a blowing agent through an annular passage cross section made in the extrusion head. The stream of molten plastic containing the blowing agent spreads out circumferentially and welds itself to itself by the recombining of the two stream fronts. The extrusion head is equipped with a special-purpose thermal regulation device allowing the molten plastic containing the blowing agent to be heated or cooled after the stream fronts have recombined.

Abstract: A method for forming an integrated trim plate in a single processing step. An appliqué section is reversibly securing to the lower section of a mold. A layer of thermoplastic covering is applied onto and over the appliqué section and lower section of the mold. A layer of foam is then injected between the thermoplastic covering and a substrate used to secure the integrated trim plate within a structure such as an automobile frame. The appliqué section may be magnetically secured to the lower section of the mold or may be physically secured within a forming section of the lower section.

Abstract: A method for manufacturing a mold component having a conformal thermal management system comprises forming a first mold segment and a second mold segment, each comprising a surface having a profile defined by the surface. A channel pattern is disposed beneath the profile defined by the surface in at least one of the first mold segment and second mold segment. The first mold segment and second mold segment are aligned to form a network of channels. The first mold segment and second mold segment are joined together to form the mold component.

Abstract: A molding station has a housing support and a housing. The housing has a generally horizontal axis, a plurality of mold cavity enclosures and a plurality of sides. The housing is rotatably mounted to the housing support about the generally horizontal axis. The mold cavity enclosures are circumferentially positioned about the axis in at least some of the sides. Each mold cavity enclosure defines at least one mold cavity.

Abstract: The present invention relates to a method of manufacturing an interior trim panel assembly having an integrated soft-touch area for improved aesthetic trim component quality. The method of manufacturing a trim panel assembly for the interior of a vehicle having an integrated soft-touch area of the present invention includes placing a molded trim panel including a coverstock having an exposed outer surface and a foam backing disposed opposite the outer surface and a rigid substrate having at least one aperture bonded to the coverstock into a mold cavity. The method of manufacture further includes separating the bonded coverstock and rigid polymer substrate in a localized area to define an internal chamber accessible by the aperture. The method of manufacture also includes injecting soft foam into the internal chamber through the aperture so as to be juxtaposed between the coverstock and the rigid polymer substrate in at least one predetermined location to define an integrated soft-touch area.