Abstract: A method comprising: a) determining the bow (28) in the extension direction of one or more linear paths on an outer surface or outer surfaces (11,13,14,16) of an extruded ceramic part (10) so that maximum extrusion direction bow (28) of the one of more linear paths or outer surfaces (11,13,14,16) may be determined of the extruded ceramic greenware part (10); b) identifying the linear path on the outer surface or the outer surfaces (11,13,14,16) having maximum convex bow; c) placing the greenware part (10) on a carrier with the linear path on the outer surface or the outer surface location having the maximum convex shape in contact with the carrier; and d) processing the greenware part (10) while disposed on the carrier with the linear path on the outer surface or the surface having the convex shape on the carrier, such that the bow (28) is reduced as a result of the process.

Abstract: A method comprising: a) determining the bow (28) in the extension direction of one or more linear paths on an outer surface or outer surfaces (11,13,14,16) of an extruded ceramic part (10) so that maximum extrusion direction bow (28) of the one of more linear paths or outer surfaces (11,13,14,16) may be determined of the extruded ceramic greenware part (10); b) identifying the linear path on the outer surface or the outer surfaces (11,13,14,16) having maximum convex bow; c) placing the greenware part (10) on a carrier with the linear path on the outer surface or the outer surface location having the maximum convex shape in contact with the carrier; and d) processing the greenware part (10) while disposed on the carrier with the linear path on the outer surface or the surface having the convex shape on the carrier, such that the bow (28) is reduced as a result of the process.

Abstract: A building structure includes a framework of: (a) metal studs having walls that define an interior channel; (b) a cellular backing material extending lengthwise within the interior channel of at least a portion of the metal studs; (c) a thermally insulating layer extending over multiple metal studs; (d) fasteners extending through the thermally insulating layer, through a wall of a metal stud and into the cellular backing material within the interior channel of the metal stud; and (e) a cladding attached to the framework of metal studs by means of the fasteners.

Abstract: A building structure includes a framework of: (a) metal studs having walls that define an interior channel; (b) a cellular backing material extending lengthwise within the interior channel of at least a portion of the metal studs; (c) a thermally insulating layer extending over multiple metal studs; (d) fasteners extending through the thermally insulating layer, through a wall of a metal stud and into the cellular backing material within the interior channel of the metal stud; and (e) a cladding attached to the framework of metal studs by means of the fasteners.

Abstract: The invention relates to an improved method of cold forming a shaped foam article from a foam having a vertical compressive balance equal to or greater than 0.4 and one or more pressing surface and articles thereof. The improvement comprises the use of a stamping press to form the shaped foam article. Preferably, the stamping press is operated by mechanical or hydraulic means. The shaped foam article may be shaped on one or more surfaces.

Abstract: Prepare an article by providing an extruded thermoplastic polymer foam having a cavity defined therein and placing a vacuum insulation panel entirely within the cavity.

Abstract: The invention relates to an improved method of cold forming a double-sided shaped foam article wherein the improvement is using a double-sided foam blank cut from a foam plank having a vertical compressive balance equal to or greater than 0.4 to produce the double-sided shaped foam article. The double-sided foam blank has a first pressing surface and a second pressing surface wherein the difference in compressive strength between the first and second pressing surfaces is equal to or less than 200 percent, most preferably, the compressive strength of the first pressing surface is the same as the compressive strength of the second pressing surface.

Abstract: Prepare an article by providing an extruded thermoplastic polymer foam having a cavity defined therein and placing a vacuum insulation panel entirely within the cavity.

Abstract: The invention relates to an improved method of cold forming a shaped foam article having a shape with a high degree of draft with improved surface aesthetics, specifically reduced surface cracking and articles made therefrom. The improvement is using a mold with a reduced-slip cavity surface, preferably a textured cavity surface.

Abstract: The invention relates to an improved method of extracting a shaped foam article from a mold cavity after being formed, specifically by imparting a vacuum sufficient enough to hold the shaped foam article to one side of the mold, preferably the core half of the mold, when the mold opens.

Abstract: The invention a method of forming complex shape of styrenic polymer foams in which a pressing surface is created, for example, by planing/machining a layer of an as formed extruded styrenic polymer plank, contacting said plank with a contoured die face and pressing the foam to form the complex shape.

Abstract: The present invention is a method to manufacture one or more shaped foam article. Specifically, the present invention is a method of extruding a thermoplastic polymer with a blowing agent to form a foam polymer plank having a density gradient. Preferably, shaped articles are prepared from the surface of the foam plank having the lowest density. The article is shaped by a mold comprising one or a plurality of cavities wherein the periphery of each cavity is defined by a trimming rib, said mold concurrently shapes the foam article and trims the resulting shaped foam article from the surrounding continuous unshaped foam plank. Preferably, the foam has a vertical compressive balance (Rv) equal to or greater than 0.4 and more preferably, the foam has a cell gas pressure less than 1 atmosphere and/or an open cell content of equal to or less than 20 percent.

Abstract: The present invention is a method to manufacture shaped foam composite articles comprising a foam core and one or more skin and shaped foam composite articles made therefrom. Specifically, cold formed shaped foam articles having an upper and lower surface having a skin applied to one or both of the surfaces. Preferably the foam comprises a styrenic polymer foam and the skins may independently be mono-layered or multi-layered. The shaped foam article and the skin may be made from the same or different materials. In the case where there are more than one skin, the skins may comprise the same or different materials.

Abstract: Cushions for dynamic impact applications include anisotropic cellular polymers made in an extrusion, expanded bead or reactive foaming process. The anisotropic behavior represented by CE/CT, CV/CT and CH/CT, wherein CE, CV and CH represent the compressive strength of the cellular polymer in each of three orthogonal directions E, V and H, respectively, as measured by compressing a 25-50 mm thick sample of the cellular polymer at a strain rate of 0.08 s?1 to 25% strain, CT represents the sum of CE, CV and CH, and at least one of CE/CT, CV/CT and CH/CT has a value of at least 0.40, up to about 0.80. The cellular polymer also preferably has density of 1.75 to 2.35 pounds/cubic foot and a compressive stress in the direction of maximum compressive strength of 290-600 kPa at 25% strain when used for headliner countermeasure applications. The cushions are useful in automotive applications such as automotive headliners, door panels, knee bolsters, pillars, headrests, seat backs, load floors or instrument panels.

Abstract: An improved energy absorbing member comprising, an thermoplastic cellular polymer in contact with a structural element such as a metal guard rail or automotive door, wherein the cellular polymer has an average cell size of at least about 0.75 mm and at least one of CE/CT, CV/CT and CH/CT is about 0.25 to about 0.4 said one of CE/CT, CV/CT and CH/CT having a compressive efficiency of at least 70% at a 60% strain, CE, CV and CH being the compressive strength of the cellular polymer in each of three orthogonal directions E, V and H where one of these directions is the direction of maximum compressive strength in the foam and CT equals the sum of CE, CV and CH.

Abstract: The invention relates to an improved method of cold forming a shaped foam article wherein the improvement is using a near net-shaped foam blank cut from a foam plank having a vertical compressive balance equal to or greater than 0.4 to produce the shaped foam article.

Abstract: The invention is an energy absorbing member comprising, an amorphous thermoplastic cellular polymer in contact with a structural element, wherein at least about 50% of the cells of the amorphous cellular polymer are closed cells and the closed cells have a gas pressure that is about 0.5 atmosphere to about 1.4 atmospheres at ambient temperature.

Abstract: The present invention includes an article of manufacture with a layer with a plurality of corrugations to form an energy absorbing structure, where each corrugation has a floor and two walls connecting the floor to the base layer and the length of each corrugation is longer than the widest width of the corrugation. The present invention also includes an energy absorbing structure with a multi-layer energy absorber having a layer with a plurality of surface features and a second layer with a second plurality of surface features wherein the surface features of one layer are nested within the surface features of the other layer such that the base layers are adjacent to each other. The present invention also includes a single step method of manufacturing the energy absorbers including forming a two layer material in a single step. Further, the present invention includes a method of absorbing impact energy that involves generating heat through friction between surface features on a pair of base layers.

Abstract: The invention a method of forming complex shape of styrenic polymer foams in which a pressing surface is created, for example, by planing/machining a layer of an as formed extruded styrenic polymer plank, contacting said plank with a contoured die face and pressing the foam to form the complex shape.

Abstract: An improved energy absorbing member comprising, an thermoplastic cellular polymer in contact with a structural element such as a metal guard rail or automotive door, wherein the cellular polymer has an average cell size of at least about 0.75 mm and at least one of CE/CT, CV/CT and CH/CT is about 0.25 to about 0.4 said one of CE/CT, CV/CT and CH/CT having a compressive efficiency of at least 70% at a 60% strain, CE, CV and CH being the compressive strength of the cellular polymer in each of three orthogonal directions E, V and H where one of these directions is the direction of maximum compressive strength in the foam and CT equals the sum of CE, CV and CH.