Abstract: Hollow thermoexpandable particles or microspheres are provided that contain hydrocarbon blowing agents and have a shell polymer that can be softened at the onset of the expansion temperature and solidified at a higher temperature (thermoset) in an expanded state. Preferably, the microspheres have a shell of thermally expandable and thermally crosslinkable polymer and a hollow interior that contains a hydrocarbon liquid that boils at a temperature below the heat activated crosslinking temperature of the polymer shell. The crosslinking of the shell polymer during or after expansion, which is heat activated at an elevated temperature, can solidify the shell polymer and, then, maintain the expanded volume of the microspheres. The thermoexpandable thermoset polymer particles are useful in insulation, packaging, for making foam materials such as polyurethane or polyisocyanurate rigid foams.

Abstract: A synthetic polymer foam is produced which incorporates fine particles of expandable graphite which surprisingly impart excellent fire resistant properties to the foam, particularly to foam made with a non-halogenated hydrocarbon as the primary blowing agent. For best results, the foam is produced through mixing the constituent materials, including the expandable graphite using a screw extruder. The foam can also be produced by creating a graphite/polyol or graphite/isocyanate dispersion in an extruder then mixing the remaining components in a conventional batch mixing or high pressure spraying process. Alternatively, conventional mixing can be used for the entire process, but use of a screw extruder in whole or in part is preferred.

Abstract: A polyurethane and/or polyisocyanurate foam is made using expandable microspheres which encapsulate a primary blowing agent. By expanding during the foam making process, the microspheres function as a blowing agent. The foam preferably has at least 10% by weight expandable micro spheres which encapsulate a non-halogenated hydrocarbon chemical or a non-halogenated hydrocarbon chemical blend and less than 2% by weight of any non-encapsulated blowing agents.

Abstract: A polyurethane and/or polyisocyanurate foam is made using expandable microspheres which encapsulate a primary blowing agent. By expanding during the foam making process, the microspheres function as a blowing agent. The foam preferably has at least 10% by weight expandable micro spheres which encapsulate a non-halogenated hydrocarbon chemical or a non-halogenated hydrocarbon chemical blend and less than 2% by weight of any non-encapsulated blowing agents.

Abstract: A synthetic polymer foam is produced which incorporates fine particles of expandable graphite which surprisingly impart excellent fire resistant properties to the foam, particularly to foam made with a non-halogenated hydrocarbon as the primary blowing agent. For best results, the foam is produced through mixing the constituent materials, including the expandable graphite using a screw extruder. The foam can also be produced by creating a graphite/polyol or graphite/isocyanate dispersion in an extruder then mixing the remaining components in a conventional batch mixing or high pressure spraying process. Alternatively, conventional mixing can be used for the entire process, but use of a screw extruder in whole or in part is preferred.

Abstract: A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.

Abstract: A method for preparing a thermosetting foam, such as polyisocyanurate or polyurethane foam, includes introducing polyol and isocyanate to a screw of an extruder and mixing in the extruder screw. Catalyst is then added and mixed with the already formed mixture in the extruder screw. This mixture is extruded onto a conveyor and foamed on the conveyor. Finely divided carbon black, dispersing agent and/or surfactant may be mixed with polyol before introducing to the screw of the extruder or carbon black may be dispersed in polyol in the extruder and a polyol premix made before the remainder of the polyol is added. Foam cell size is decreased when extruder speed is increased. The foaming agent, which is preferably HCFC or water, may be mixed with one of the components, preferably the polyol, before introducing to the screw of the extruder. The mixture is cooled before extruding onto a conveyor to delay the foaming step until the mixture is outside the extruder.

Abstract: Polyester resins are disclosed as the impregnant in the core sheets of heat and pressure consolidated laminates, especially decorative laminates having a core of a color complementing that of the decor sheet, and more especially those decorative laminates of unusual thickness.

Abstract: A boot pull including a frame with convergent side pieces and a pair of boot gripping members pivotably attached to the frame. The heel portion of a boot is received between the gripping members and, when the boot is lifted, the gripping members move inwardly toward each other as they pivot upwardly. In this way, the boot is grasped between the gripping members so that is is held firmly against continued upward movement. The boot pull can be held in position by placing one foot in the frame while a boot is removed from the other foot of the user.

Abstract: A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.

Abstract: Polyester resins are disclosed as the impregnant in the core sheets of heat and pressure consolidated laminates, especially decorative laminates having a core of a color complementing that of the decor sheet, and more especially those decorative laminates of unusual thickness.