Abstract: A cellular thermoplastic polyolefin foam comprising at least one particulate additive in admixture with a polymer matrix is disclosed, along with a process and foamable gel for manufacturing the same, wherein the polyolefin matrix comprises at least one polymer resin graft-modified with at least one polar group selected from the group consisting of acid, acid ester, and acid anhydride, and salts thereof. The invention facilitates the manufacture of macrocellular foams useful for acoustic absorption having increased amounts of particulate additives that provide certain desired properties difficult to achieve without the particulate additives, such as improved flame retardancy.

Abstract: A macrocellular foam is described having improved cell size and Fire-test-response Characteristics, among other features, which is obtained by selecting a particle size less than 1 micron for the flame retardant adjuvant. The inventors found that the amount of fire retardant adjuvant can be increased for a given foam cell size or the foam cell size can be increased for a given amount of fire retardant adjuvant, allowing the production of foams having exceptionally large, well-formed, cells that have excellent Fire-test-response Characteristics. The benefits are especially noteworthy in relation to thermoplastic foams and inorganic flame retardation adjuvants, due to the unexpected reduction in the nucleation effect of the adjuvant. The foams are useful for improving the acoustic performance of products that are required to meet certain Fire-test-response Characteristics.

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: Thermoplastic polymer foams having sound deadening properties satisfactory for demanding applications are provided which have mechanical strength, which are economical to manufacture, and which are hydrolytically stable. Methods of preparing these foams are also provided. The foams are useful in sound management, cushion packaging, filtering, and fluid absorption and exhibit one or more of the following properties: 1) average cell size greater than about 2 mm; 2) substantially open-cell structure and 3) relatively large pores connecting the cells. In order that the foam be acoustically active, the foam should possess a substantially open-cell structure and a relatively low airflow resistivity. Foams with substantially open-cell structure and relatively low airflow resistivity are prepared by mechanically opening a foam having an average cell size greater than about 2 mm. In most cases, such mechanical opening creates relatively large pores connecting the cells.

Abstract: Thermoplastic polymer foams having sound deadening properties satisfactory for demanding applications are provided which have mechanical strength, which are economical to manufacture, and which are hydrolytically stable. Methods of preparing these foams are also provided. The foams are useful in sound management, cushion packaging, filtering, and fluid absorption and exhibit one or more of the following properties: 1) average cell size greater than about 2 mm; 2) substantially open-cell structure and 3) relatively large pores connecting the cells. In order that the foam be acoustically active, the foam should possess a substantially open-cell structure and a relatively low airflow resistivity. Foams with substantially open-cell structure and relatively low airflow resistivity are prepared by mechanically opening a foam having an average cell size greater than about 2 mm. In most cases, such mechanical opening creates relatively large pores connecting the cells.

Abstract: A macmocellular foam is described having improved cell size and Fire-test-response Characteristics, among other features, which is obtained by selecting a particle size less than 1 micron for the flame retardant adjuvant. The inventors found that the amount of fire retardant adjuvant can be increased for a given foam cell size or the foam cell size can be increased for a given amount of fire retardant adjuvant, allowing the production of foams having exceptionally large, well-formed, cells that have excellent Fire-test-response Characteristics. The benefits are especially noteworthy in relation to thermoplastic foams and inorganic flame retardation adjuvants, due to the unexpected reduction in the nucleation effect of the adjuvant. The foams are useful for improving the acoustic performance of products that are required to meet certain Fire-test-response Characteristics.

Abstract: Thermoplastic polymer foams having sound deadening properties satisfactory for demanding applications are provided which have mechanical strength, which are economical to manufacture, and which are hydrolytically stable. Methods of preparing these foams are also provided. The foams are useful in sound management, cushion packaging, filtering, and fluid absorption and exhibit one or more of the following properties: 1) average cell size greater than about 2 mm; 2) substantially open-cell structure and 3) relatively large pores connecting the cells. In order that the foam be acoustically active, the foam should possess a substiantially open-cell structure and a relatively low airflow resistivity. Foams with substantially open-cell structure and relatively low airflow resistivity are prepared by mechanically opening a foam having an average cell size greater than about 2 mm. In most cases, such mechanical opening creates relatively large pores connecting the cells.

Abstract: A process for making a macrocellular acoustic foam is disclosed in which a foamable gel made of a blowing agent and a polymeric resin composition is subjected to an extrusion process at a die pressure greater than the prefoaming critical die pressure but less than or equal to four times that of said prefoaming critical die pressure and macrocellular foams obtainable by that process are also disclosed which are made of: A) one or more homopolymers of ethylene, one or more C3-C20 &agr;-olefin polymers, or a combination thereof; B) one or more halogenated flame retardants; C) optionally, one or more polymers other than that of Component A; and D) optionally, one or more flame retardant synergists.

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: 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: 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.

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: An extruded, coalesced foam strand propylene polymer material that is either open-celled and useful for sound insulation applications or close celled and useful for thermal insulation applications. An apparatus suitable for preparing such foams with an expanded cross-section.

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: 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: Thermoplastic foams with an average cell size of greater than one and one-half millimeters and an average noise reduction coefficient in excess of 0.3 have improved sound attenuating properties when they include a Helmholtz resonator, a quarter-wave attenuator or both.

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.

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.

Abstract: Foams made from a ternary blend of a alkenyl aromatic polymer such as polystyrene, an &agr;-olefin polymer such as polyethylene, and a compatibilizer, are used as acoustical insulation in building constructions. These foams exhibit an unusual combination of low creep and low dynamic stiffness. They are especially useful in floating floor installations.

Abstract: A latex or fiber comprising a blend of polymeric materials consisting of one or more &agr;-olefin/ vinylidene monomer non-crosslinked substantially random interpolymers, wherein the distribution of the monomers of said interpolymers can be described by the Bernoulli statistical model or by a first or second order Markovian statistical model, and one or more homopolymers or copolymers of monomer components comprising aliphatic &agr;-olefins having from 2 to 20 carbon atoms, or aliphatic &agr;-olefins having from 2 to 20 carbon atoms and containing polar groups.