Abstract: A microphone enclosure for a vehicle exterior component includes a housing, and a microphone disposed within the housing. The housing also includes a first outer portion defining a sound channel for conveying sound to the microphone. The microphone enclosure includes a membrane of elastomeric material, such as silicone, disposed over the sound channel and configured to prevent contaminants, such as moisture and dust, from entering the sound channel. The sound channel has at least one dimension configured to provide a specific frequency response or acoustic sensitivity. A protective mesh may be disposed below the first membrane and configured to limit deflection of the first membrane. The housing includes an outer surface defining an aperture and a passageway providing auditory communication between the aperture and the microphone. In some embodiments, the passageway is configured as a tortuous path impeding straight-line access from the aperture to the membrane.

Abstract: A thermoplastic olefin composition including (a) an elastomer having a melt flow rate of less than 1.0 dg/min and a high melt strength, in combination with (b) a polypropylene with a melt flow rate of greater than 35 dg/min; a process for making the above composition; and an article made from the above composition.

Abstract: A composition for forming crosslinked polyolefin particles of micron or submicron size dispersed in an aqueous phase including: (i) water for forming an aqueous phase; (ii) a polyolefin polymer; and (iii) a curing agent for crosslinking the polyolefin polymer to form polyolefin particles of micron or submicron size dispersed in the aqueous phase of component (i); an aqueous dispersion crosslinked polyolefin particles of micron or submicron size dispersed in an aqueous phase; a powder material made from the above aqueous dispersion; a thermoplastic vulcanate (TPV)-like material made from the above powder; and an article made from the above TPV-like material

Abstract: A process for producing a sealed stitched skin structure including the steps of: (a) providing a stitched skin member; (b) providing an aqueous thermoplastic polyolefin dispersion sealant coating composition; (c) applying the aqueous thermoplastic polyolefin dispersion sealant coating composition from step (a) to at least a portion of the surface of at least one side of the skin member to form a wet film or coating of the thermoplastic polyolefin dispersion sealant coating composition on the surface of the skin member; (d) drying the wet coating from step (c) on the skin member surface; and (e) heating the dried skin member from step (d) at a temperature sufficient to form a film or coating of the aqueous thermoplastic polyolefin dispersion sealant coating composition on the stitches of the seam in the skin member; wherein the film or coating seals the stitches in the skin member; a sealed stitched skin structure made by the process above; and a polyurethane foamed article.

Abstract: An aqueous acrylic emulsion sealant coating composition used for sealing stitched skins against leakage from polyurethane foam which has been applied to stitched skins, the composition including: (a) a first soft acrylic polymer phase component; and (b) a second aqueous phase component; a process for producing the sealant coating composition; a sealed stitched skin structure; a process for producing the sealed stitched skin structure; a polyurethane foamed article; and a process for producing the polyurethane foamed article.

Abstract: The present invention relates to a method for producing a composite part comprising a textured skin and a rigid or foam substrate layer, in particular a composite automotive trim part. The method comprises the steps of spraying or casting an aqueous thermoplastic dispersion onto a rigid or foam substrate composite followed by forming the composite into a composite part comprising a textured skin and a rigid or foam substrate layer. Preferably, the dispersion is derived from the extrusion melt blending of thermoplastic polymer, a dispersing agent, and water.

Abstract: A polyvinyl chloride-based composition including (a) a polyvinyl chloride resin, (b) a flexible acrylic resin; and (c) a plasticizer; an article made from the above composition wherein the article has (i) a cold temperature ductility at a temperature of less than ?30° C. after heat aging at a temperature of 120° C.

Abstract: The present invention relates to method to make a spray skin from an aqueous polyolefin dispersion composition comprising a an olefin block copolymer, a dispersing agent, preferably an ethylene acrylic acid, and water, wherein said aqueous dispersion preferably has a pH less than 12 and is derived from the melt blending. The method comprises the steps of spraying the aqueous polyolefin dispersion onto a heated mold forming the skin and then allowing it to dry.

Abstract: The present invention provides a method comprising rotational molding a powdered polyolefin elastomer composition to form a skin, the composition formed by spray drying an aqueous polyolefin dispersion composition which is itself formed by melt blending a polyolefin composition comprising an olefin block copolymer, a dispersing agent, and water, wherein said aqueous dispersion preferably has a pH less than 12.

Abstract: The present invention relates to a method for producing a composite part, preferably an automotive trim composite part, comprising a textured skin and a rigid or foam substrate layer. The method comprises the steps of forming the skin by spraying or casting an aqueous thermoplastic dispersion which is derived from the melt blending of thermoplastic polymer, a dispersing agent, and water onto a textured mold and molding the rigid or form substrate onto the skin.

Abstract: A vulcanized rubber is formed by a method comprising blending a halogenated unsaturated polymer into a rubber comprised of cis 1-4 polyisoprene to form a vulcanizable polymer blend, adding a vulcanization material to the vulcanizable polymer blend, and vulcanizing the vulcanizable polymer blend to form a homogeneous vulcanized rubber. The method may be used to form a vulcanized rubber comprised of polyisoprene uniformly crosslinked with a halogenated unsaturated polymer that is a reaction product of (i) an unsaturated polymer miscible with polyisoprene and having conjugated dienes that undergo a Diels Alder reaction and (ii) a polyhalogenated cyclopentadiene.

Abstract: The present invention relates to a method to make a rotational molded skin from a powdered polyolefin elastomer composition derived from spray drying an aqueous polyolefin dispersion composition wherein the aqueous polyolefin dispersion composition is derived from melt blending a polyolefin composition comprising an olefin block copolymer, a dispersing agent, and water, wherein said aqueous dispersion preferably has a pH less than 12.

Abstract: A vulcanized rubber is formed by a method comprising blending a halogenated unsaturated polymer into a rubber comprised of cis 1-4 polyisoprene to form a vulcanizable polymer blend, adding a vulcanization material to the vulcanizable polymer blend, and vulcanizing the vulcanizable polymer blend to form a homogeneous vulcanized rubber. The method may be used to form a vulcanized rubber comprised of polyisoprene uniformly crosslinked with a halogenated unsaturated polymer that is a reaction product of (i) an unsaturated polymer miscible with polyisoprene and having conjugated dienes that undergo a Diels Alder reaction and (ii) a polyhalogenated cyclopentadiene.

Abstract: Flexible polyurethane foams are made using certain hydrolysable silane compounds in the foam formulation. The hydrolysable silane compounds contain at least one isocyanate-reactive group and at least one hydrolysable silane group. The presence of the hydrolysable silane compound in the foam formulation leads to improved tensile, tear and elongation properties without an adverse effect on other important foam properties such as resiliency and hysteresis loss.

Abstract: Flexible polyurethane foams are made using certain hydrolysable silane compounds in the foam formulation. The hydrolysable silane compounds contain at least one isocyanate-reactive group and at least one hydrolysable silane group. The presence of the hydrolysable silane compound in the foam formulation leads to improved tensile, tear and elongation properties without an adverse effect on other important foam properties such as resiliency and hysteresis loss.

Abstract: A process (2) for manufacturing a shaped article (17), comprising the steps of: dry blending (8) a plurality of different particulated ingredients (11) to form a uniform particle blend; reblending the particle blend by substantially defining a mass flow in a discharge unit (19) including an insert (39, 60) and shaping the particle blend in a part shaping machine (15) to form the shaped article (17).

Abstract: The present invention relates to articles and heat storage devices for storage of thermal energy. The articles include a metal base sheet and a metal cover sheet, wherein the metal base sheet and the metal cover sheet are sealingly joined to form one or more sealed spaces. The articles include a thermal energy storage material that is contained within the sealed spaces. The sealed spaces preferably are substantially free of water or includes liquid water at a concentration of about 1 percent by volume or less at a temperature of about 25° C., based on the total volume of the sealed spaces. The articles include one or more of the following features: a) the pressure in a sealed space is about 700 Torr or less, when the temperature of the thermal energy storage material is about 25° C.

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: A process (2) for manufacturing a shaped article (17), comprising the steps of: dry blending (8) a plurality of different particulated ingredients (11) to form a uniform particle blend; reblending the particle blend by substantially defining a mass flow in a discharge unit (19) including an insert (39, 60) and shaping the particle blend in a part shaping machine (15) to form the shaped article (17).