Abstract: An apparatus and method for producing a conveyor belt made of urethane having reinforcement embedded therein which reinforcement permits the stretching of the belt under controlled conditions. The reinforcement consists of a fabric or a plurality of aligned strands that are embedded in the urethane body of the belt proper that allow for a controlled stretch in the conveyor belt until such fabric or cords limit the stretching of such belt.

Abstract: A strippable film for adhesive coating and laminating comprising:a base paper, andan extrusion coated thermoplastic resin layer, wherein said film has the property that upon coating an adhesive onto said resin layer and assembling the adhesive coated strippable film with a base member, said base paper can be stripped from said resin layer and said resin layer can be subsequently stripped from said adhesive coating.

Abstract: The present invention provides a method and apparatus for taking up and winding a strip of material which is advancing at a selected velocity from a moving casting surface. Generally stated, the apparatus includes a take-up web supply mechanism for supplying a flexible, take-up web, and a winding mechanism, which has a reel for taking up and concentrically winding the strip and take-up web thereon in a laminated configuration. A connection mechanism connects the take-up web to the reel, and a reel drive mechanism rotates the reel to provide a peripheral velocity at a winding surface on the reel that substantially matches the velocity of the advancing strip. A directing mechanism directs the advancing strip onto the take-up web for transport to a winder nip region between the take-up web and the winding surface of the reel means to initiate winding.

Abstract: A process and product by process of making a polishing sheet material especially useful in the polishing of silicon wafer is disclosed. There is known a process of producing a poromeric suede-like polyurethane layer which comprises applying a solution of polyurethane on an impermeable synthetic resin film, subjecting the polyurethane layer to wet coagulation to form a honeycomb-like cellular structure of polyurethane on the synthetic resin film, removing the synthetic resin film from the cellular polyurethane layer, and abrading a thin surface skin of the cellular layer to form the poromeric suede-like polyurethane layer. In the present invention, a supporting layer made of a non-poromeric, soft synthetic resin sheet having good flatness is joined to a reverse side of the suede-like polyurethane layer to form a polishing sheet material.

Abstract: A method of backing carpeting material 19 with hot-melt compositions such as atactic polypropylene (APP) or bitumen (with or without additives) comprises carefully doctoring selected thicknesses of the composition to the undersurface of the material 19 with the wear surface of the material uppermost. In one arrangement (FIG. 3) this is achieved using a lick roll arrangement 20 incorporating a doctor blade, cooling the backed product at cooling zones 28, 29 and applying the material to a nip formed by rollers 21. In another arrangement (FIG. 1) this is achieved by doctor box 16 applying the composition to a carrier 13, the carpeting material 19 then being laminated at roll 21 to the layer of composition, the laminate then being cooled before being stripped from the carrier (13). In a further arrangement (FIG. 2) the carrier is in the form of sheet material 15 which is supported by endless belt 13 and which is bonded into the hot-melt composition to become an integral part thereof.

Abstract: A thin tough glossy surface may be applied to a flexible substrate in a one step process comprising: applying an aqueous thin film of a compound of a polymer to an endless carrier belt made of a material having a low adhesion to said polymer, contacting the flexible substrate and coated carrier belt and keeping them together while they pass around a hot drum laminator at a temperature of from about 100.degree. to about 150.degree. C.The process is suitable for applying impermeable surfaces to non wovens, and foam backed carpet.

Abstract: The process for fabricating a reusable artifical fingernail which enjoys a tight tolerance complimental fit with the natural nail substrate as a result of the method of fabrication. The process may involve the use of, (A) the natural nail [Direct Technique], of (B) a model of the natural [Indirect Technique] as a substrate in conjunction in each case with a secondary substrate forming an extension of the nail, and digit to accept in a continuous fashion a release agent and a coating of a curable material forming an artifical nail curing the acrylic material, preferrably by blue light source in the visible spectrum. The preferable material is an acrylic and removing the artifical nail so created, trimming flash and shaping it to the desired final configuration and reapplying with a non-permanent adhesive material.

Abstract: In the present publication a method is described for encapsulating of components (3), in particular of semiconductor components, mounted on a carrier tape (6) by means of a polymer in order to prevent access of moisture into the component (3). According to the invention a polymer film (24, 25) is pressed onto the support area (2) of each component (3) from both sides of the carrier tape (6), and the carrier tape (6) treated in this way is subjected to warm-air blasting (14). Thereupon, an encapsulating tape (9) that has been moistened with polymer (13) and subjected to a warm-air treatment (15) is connected to one side of the carrier tape (6), and the combination tape (6, 9) in this way obtained is heated in a pre-heating oven (16).

Abstract: The process of the invention concerns the manufacture of an interposed support of semipermeable microfiltration membranes, the support composed of a permeable mesh and a sealed border of elastomeric material. After deposition of an elastomeric film on a transfer support 2, the assembly which is obtained is cut into one or more elements 3 reconstituting the border; this or these elements 3 are applied on the mesh with their support(s) 2 and the elastomer is turned toward the mesh; then the mesh thus equipped is treated with pressure at a temperature of between 100.degree. and 150.degree. C. to cause the elastomer to penetrate into the mesh and to obtain a smooth border surface on each side of this mesh, allowing for a sealed joint. The product which is obtained is applied to the manufacture of microfiltration units, whether it has to do with ultrafiltration, with gas permeation or with hemodialysis.

Abstract: A process of manufacturing an element for electrophotresis which comprises steps of: sticking a spacer continuously to both side portions of a support web which is rolled back continuously from the rolled condition; casting on said support a solution for forming a medium membrane for electrophoresis; subjecting the support to hardening treatment to form a medium membrane; cutting off a portion of the medium membrane and support web; and sticking a cover sheet onto the medium membrane. An apparatus advantageously employable for performing the above process is disclosed.

Abstract: A process for coating polyvinyl fluoride layers on one or both sides of a textile material in the form of a coalesced gel which is subsequently cured by heating.

Abstract: An improved process suitable for continuously producing tiles which have the sharp and vivid coloring characteristics of ceramic tiles. In accordance with this process, a release paper is coated with a clear liquid plastisol layer. The clear liquid plastisol layer is given a completely smooth upper surface. A decorative design is then applied to the smooth upper surface by transfer printing. The printed plastisol is then covered with an opaque plastisol backing layer to form a cast wear layer comprising the clear plastisol layer, the printed pattern, and the opaque plastisol backing layer. The cast wear layer is then transferred to a continuous plastic base web that has been made previously so that the backing layer is in contact with the base web. The cast wear layer is laminated onto the base web, and this laminate is embossed using an engraved roll having raised sections which are images of the printed design.

Abstract: An improved bipolar membrane, a precursor for said membrane and a process for preparing bipolar membranes and precursors are described. In the process a precursor is formed by laminating at least two polymeric layers at least one of which is non-ionic. After the formation of the precursor, the non-ionic layer or layers are chemically treated to form a stable bipolar membrane having high permselectivity and low potential drop. The novel bipolar membrane contains an interfacial layer having anionic and cationic domains.

Abstract: Preformed, energy-absorbing, scratch resistant, optical, flexible, and self-healing polyurethane sheets, which are adhesive under the influence of heat and pressure; bilayer glazing laminates and bilayer safety windshields including said sheets; wherein said polyurethane sheet is prepared preferably by reactive-casting on a horizontal support and formed preferably from a polyisocyanate monomer including about 2 to about 10 wt. % of urea groups.

Abstract: A helical band is produced by applying a layer of heat-settable material on to a rotating support to one side of the axis of rotation. Heat is applied to the layer, as by the support while it rotates, for a length of time sufficient for the material in the layer to set to a required extent to form the band. The band is removed before it comes into contact with the material being applied on the support. The band is preferably made of electrically-insulating material so that it can be wound helically round and bonded to a cylindrical rod of electrically-insulating material to form a helically flanged insulator for use in an overhead electric power transmission line, the flange-forming band defining along the rod a helical leakage path of substantially uniform width.

Abstract: A process and apparatus are described wherein a honeycombed sheet of plastic is extruded from an extruder and at least one protective film of plastic is joined onto at least one of its surface layers, the protective film having a softening temperature lower than that for extruding the sheet. The protective film, combined with the auxiliary film or support film, is laid onto the surface of the sheet leaving the extruder; then the sheet, protective film and support film are subjected to the calibrating and cooling stage; and lastly the support film is separated from the sheet. The protective film has now been made an integral part of the sheet, thereby to produce, for example, a protected honeycombed sheet.

Abstract: A method for preparing a sliding face of a machine tool, comprising the steps of: providing a flat surface as a slide surface to a slide component of a machine proper by gluing a plastic material prepared from a kneaded mixture of sintered metal powder and a synthetic resin binder to the slide component; and thermally dissolving out said synthetic resin binder contained in the plastic material and sintering said metal powder.

Abstract: The invention concerns a top cloth, especially a top cloth cut for clothes, which top cloth or cut is coated on one side with a patterned coating serving to stabilize it. Inventively this coating comprises a lower adhesive layer (2) of patterned heat-sealable plastics elements which are not interconnected and which adhere to the back of said top cloth or cut (1), and an upper covering layer (3) of non-hot sealable or substantially non-hot sealable material. The covering layer can extend substantially or fairly continuously, i.e. pattern-free, over the lower patterned adhesive layer and optionally beyond it and can in its areas between the pattern points of the lower layer not adhere to the top cloth or only slightly adhere thereto, while being easily wiped off. But it can also be directly patterned and congruent with the adhesive pattern beneath it. The invention concerns a process for the manufacture of such a top cloth and a transfer unit for implementing said process.

Abstract: A casting composition for making dielectric green tapes comprising a dispersion of finely divided solids of (a) a noncrystallizable glass and (b) a mixture of refractory oxides in a solution of (c) organic polymer, which is readily depolymerizable at 825.degree.-1025.degree. C. in a nonoxidizing atmosphere, dissolved in (d) volatile nonaqueous solvent.

Abstract: Processes for the preparation of random-fiber thermoset composite sheets by employing a latent curing agent thermoset resin formulation or a coreactant thermoset system such that uncured thermoset composite sheets are formed which can be subsequently formed and cured into articles of manufacture.

Abstract: A dielectric composition comprising an admixture of finely divided solids comprising (a) a noncrystallizable glass of which the deformation temperature (T.sub.d) is 580.degree.-625.degree. C. and the softening point (T.sub.s) is 630.degree.-700.degree. C., and (T.sub.s -T.sub.d) is 50.degree.-75.degree. C., and (b) a refractory which is substantially insoluble in the glass at temperatures of 825.degree.-900.degree. C.

Abstract: The present invention provides a method and apparatus for taking up and winding a strip of material which is advancing at a selected velocity from a moving casting surface. Generally stated, the apparatus includes a take-up web supply mechanism for supplying a flexible, take-up web, and a winding mechanism, which has a reel for taking up and concentrically winding the strip and take-up web thereon in a laminated configuration. A connection mechanism connects the take-up web to the reel, and a reel drive mechanism rotates the reel to provide a peripheral velocity at a winding surface on the reel that substantially matches the velocity of the advancing strip. A directing mechanism directs the advancing strip onto the take-up web for transport to a winder nip region between the take-up web and the winding surface of the reel means to initiate winding.

Abstract: An integument which contributes to the maintenance of surface integrity is disclosed, particularly a sheet for use in preparing laminates, such as vehicle windshields, in which an energy absorbing ply, for example, a ply of poly(vinyl butyral), is sandwiched between two glass plies, the sheet of this invention being applied to an exposed surface of one of the glass plies and having one surface layer comprising a thermoplastic polyurethane capable of adhering to a glass or plastic substrate and the other surface layer comprising a thermoset polyurethane having anti-lacerative, self-healing and anti-ablative properties; there is further disclosed the manufacture and application of such a sheet as a ply facing the interior of a vehicle, thereby forming a windshield the inwardly exposed surface of which comprises a thermoset polyurethane which protects the vehicle occupants from facial lacerations caused by windshield impact and which has self-healing properties.

Abstract: A filter for use in combination with a cathode ray tube screen to transmit light and absorb other types of energy comprises a translucent plastic substrate onto which is applied a wire mesh impregnated with a thin layer of a bonding agent which constitutes one surface of the filter. In manufacturing the filter, a thin layer of the bonding agent is deposited on the topside of a platen, and the mesh is pressed into the bonding agent to cause it to impregnate the mesh. The translucent plastic substrate is placed on the impregnated mesh, and pressure is applied between the substrate and the platen to form a laminate. Thereafter, the laminate is cured and separated from the platen, after which it may be placed in a mold and formed into a curved shape.

Abstract: A method for making a decorative product is provided which includes forming on a top layer of polymeric material (e.g., polyvinyl chloride) a relief pattern, and bonding said top layer to a base layer of a thermoplastic ethylene interpolymer (e.g., an ethylene-vinyl acetate copolymer).The product is useful as a floor or wall covering.

Abstract: A method for producing a fibrous board having a decorative, textured surface comprising the steps of:(a) forming a wet mat of entangled mineral fibers;(b) pressure molding said fibrous mat while it is still wet to create a decorative textured surface thereon; and(c) drying said board.

Abstract: A water-absorbing laminate comprising a water-absorbing film and a non-woven fabric, in which the water-absorbing film is formed by film-forming a mixture of (A) a water-soluble polymer containing, as the monomer component, at least 40 mole % of an .alpha.,.beta.-unsaturated compound containing one or two carboxyl groups or groups from which a carboxyl group can be easily derived and in which 5% to 50% of the carboxyl groups and/or groups from which a carboxyl group can be easily derived are in the form of a salt, and (B) polyvinyl alcohol in a weight ratio of (A)/(B) of not less than 1/99 to less than 1/9. This water-absorbing can be produced by laminating the water-absorbing film on the non-woven fabric under pressure either in a hydrous and heat-softened state of the film or through an adhesive and, optionally, heat-treating the resultant laminate.

Abstract: A unitized indirect gravure coating process for forming magnetic disks. Transfer pads coating techniques are applied to conventional magnetic coating materials to form high density, longitudinal, perpendicular or annual magnetic coatings for floppy or rigid disks.

Abstract: Continuous strips of a first material, e.g., elastic strips, are continuously supplied to flexible strip supports in a supply zone while the strip supports are in a linear configuration. The strip supports are carried on respective transfer members which are mounted on a rotatable support so that individual transfer members follow a closed (orbital) path upon rotation of the support. The continuous strips are cut into discrete strips adhered to respective flexible strip supports whose configuration, and that of the discrete strips adhered thereto, is then changed to a desired curvilinear configuration. The transfer members are then brought into transfer contact in a transfer zone with a moving web of second material, which may comprise the backing sheet of a disposable diaper construction, and the curvilinear strips are transferred to the web.

Abstract: A plywood is manufactured by applying an aqueous plywood adhesive fluid to the peripheral surface of a heating roll rotating at a given speed by means of a roll coater to form an adhesive fluid film, drying the adhesive fluid film into a tacky-dry film while it is carried on the surface of the heating roll, stripping the tacky-dry adhesive film from the roll surface by pulling it under tension with or without the aid of a stripping knife, interposing the adhesive film between a pair of veneers, and pressing the veneers to each other to bond them.

Abstract: A substantially non-overlapping tightly packed layer of plastic chips is formed and attached to the surface of a substrate by a method in which the chips are dispersed onto the surface of a liquid, flowing from a first location to a second location. The rate of flow of the surface of the liquid is reduced at the second location to cause the chips to pack together in a single-chip-thickness layer. The layer of chips is then removed from the liquid by passing a porous web upward at an angle from below the liquid surface through the chip layer-liquid interface. The chip layer is then transferred to a heat-sensitive transparent adhesive coating on a suitable prepared substrate and secured thereon by means of heat and pressure. A resinous wear layer which is transparent after fusion is then applied.

Abstract: A process for bonding surfaces together comprises(i) exposing to actinic radiation a layer of a liquid composition containing an epoxide resin, photopolymerizable compound, and a heat-activated curing agent for epoxide resins until the composition solidifies to form a film adhesive while the epoxide resin remains substantially heat-curable,(ii) sandwiching the film adhesive between the surfaces to be bonded, and(iii) then heating the assembly so that the epoxide resin component of the film adhesive is cured.Surfaces which may be so bonded may be metal, glass, ceramic, or wood.

Abstract: A laminating film product for applying a sealed protective cover to a document such as an identification card has a cover film of an unoriented polyester resin extruded onto a surface of a transfer film of an oriented thermoset polyester resin that has been coated with a release agent such as a soap; a film of a thermoplastic adhesive resin may be extruded onto the exposed surface of the cover film. In use, the laminating film product is laminated to a document under heat and pressure, the transfer film is stripped away, and the exposed cover film is embossed. Magnetic strips, pigment strips, and the like may also be applied to the cover film by hot stamp transfer.

Abstract: Process for the continuous production of single-ply or multi-ply laminates, comprising feeding from below and at an obtuse angle, a web uniformly coated with resin, on to a fiber web or reinforcing web which is under tension, so that the resin penetrates the fiber web or reinforcing web in a bubble-free manner, and then passing the fiber web or reinforcing web uniformly impregnated with resin, either by itself or conjointly with one or more separating films or decorative films or resin-impermeable covering films, through a heating zone and pressure zone, whereby a single-ply or multi-ply laminate is produced. Apparatus for carrying out the process is also described.

Abstract: Edge-supported and fully supported membranes having substantially uniform thickness, and substantially parallel surfaces, and having the capacity to transmit at least about 90% of incident light with very little diffraction, dispersion or absorption of incident light are made by forming a polymer/solvent mixture, spin-coating a film of the polymer from the mixture onto a rotatable surface, which may have a release agent thereon, and, where a release agent is present, joining a frame or other support to the membrane and removing the membrane with its attached support from the surface. Apparatus for making such membranes includes a dispenser for dispensing a polymer/solvent mixture onto a rotatable support; a device for spinning the rotatable support at gradually increasing speeds from a first to a second speed; and a device for maintaining the speed of rotation of the support at the second speed until the membrane forms.

Abstract: A conductive structure in which conductive fibers a.sub.1 are sticked to the substrate B by melting thermally fusible fibers a.sub.2 entangling with said conductive fibers a.sub.1. This structure is manufactured by sticking conductive fibers a.sub.1 to the surface of the substrate B to which the cloth-like material A containing conductive fibers a.sub.1 and thermally fusible fibers a.sub.2 is sticked under pressure at a temperature not lower than a melting point of said thermally fusible fibers a.sub.2.

Abstract: Glass fiber strands are produced which have a reduced tendency for strand to strand adhesion and good dispersibility or wettability in uncured polymeric materials for the production of glass fiber reinforced plastics. The glass fibers have a dried residue of an aqueous chemical treating composition. The aqueous chemical treating composition has a film forming polymeric system, gamma methacryloxy alkyltrialkoxy silane and a glass fiber lubricant in an effective lubricating amount. The film forming polymeric system has an epoxy-containing polymer or copolymer, a non-tacky film forming polymer, and polyvinyl pyrrolidone of which are aqueous soluble, dispersible or emulsifiable.

Abstract: A method is described for the continuous manufacture of inlaid vinyl sheeting using different colored plastisols and rotary screen printing equipment. The printing equipment comprises an unwind stand, an accumulator, a plurality of printing stations, a coating station, an oven, a second accumulator, and a wind up stand. Optionally an embossing station may also be used. Each printing station comprises (i) a rotary screen through which a different colored plastisol is squeezed to form a colored pattern on a base layer and (ii) a hot air dryer for partially drying the plastisol deposited on the base layer. In accordance with the invention, the viscosity of the plastisol and the rate of drying is such that plugs of plastisol are deposited on the base layer by each screen to form discrete portions of the total pattern created. Several different rotary screens are used to deposit these plugs of colored plastisols on the base layer so as to build up a pattern from the different colored plastisols.

Abstract: A method of forming perforations in composite laminates by impregnating the material with a modified epoxy resin by means of hot melt or solvent methods. The resin is then allowed to dry. The epoxy impregnated material is then warmed to around 165.degree. F. and forced by a resilient pressure pad over a tool having a plurality of upstanding studs or pins. While in position on the pin tool, the laminate is then partially cured by combined heat and pressure to minimize resin flow while retaining the ability to be formed to a final contour in a contoured curing fixture after removal from the pin tool. Controlled partial cure and selected low flow resin systems prevent resin flow into the formed apertures formed by the pin tool during final resin cure.

Abstract: A plywood is manufactured by applying an aqueous plywood adhesive fluid to the peripheral surface of a heating roll rotating at a given speed by means of a roll coater to form an adhesive fluid film, drying the adhesive fluid film into a tacky-dry film while it is carried on the surface of the heating roll, stripping the tacky-dry adhesive film from the roll surface by pulling it under tension with or without the aid of a stripping knife, interposing the adhesive film between a pair of veneers, and pressing the veneers to each other to bond them.

Abstract: A method is disclosed for sealing edible capsules comprised of telescopically engaged tubular capsule halves that define a junction seam between them. The method comprises adhesively applying against at least a portion of the seam a frangible, edible label adapted to cover the seam at the point of intersection therewith, and to fracture upon slight displacement of the capsule halves with respect to each other. In one embodiment, the present method comprises the preparation of individual labels, the application to such labels of a quantity of adhesive and the subsequent application of the labels to the capsule. In an alternate embodiment, the labels, comprising a film forming material, are directly applied to the capsule by the projection of a hot melt of the film forming material onto the capsule at the location of the seam.

Abstract: In order to manufacture molded bodies by pressing finely divided material with a binder while the binder sets, such as to avoid problems caused because of contact of the binder or vapors therefrom with oxygen, the pressing and setting is carried out in a gas atmosphere different from air.

Abstract: A method for making polymer bonded electrode (PBE) structures wherein the particulate and particles of perfluorocarbon copolymer are combined with a solvent for the copolymer at a temperature where significant solvation of the perfluorocarbon does not occur. The resulting blended dispersion is spread to form the PBE, and the solvent removed. The PBE is then fused under heat and pressure for use.

Abstract: The invention refers to a process of coloring (printing) of track-like objects (2), especially ski coverings of thermoplastics, such as olefins, especially high and low pressure polyethylene where, the layer is brought continuously as a hot foil, essentially in a state of fusion, in contact with a print carrier (3), on which there has been deposited a print pattern first of sublimation type and then of diffusion type dye stuff. A transfer of the dye onto foil (2) occurs in a short time and only essentially along a small areal strip perpendicular to the common direction of conveying of layer (2) and print carrier (3). It is preferred that the transfer of dye occurs in the gap between rollers (5, 6) through which the foil and the print carrier are guided. This allows the obtainment of warpage-free print patterns on relatively thin-walled track-like objects in a continuous process, where it is assured that no warpages occur after cooling or reheating of the printed layer.

Abstract: An apparatus for forming foil shapes having a cast plastic cap such as decorative inlays, emblems or automobile body side moulding wherein the apparatus comprises(a) means for advancing a continuous foil member along a horizontal path,(b) means for cleaning and priming at least one surface of the foil member,(c) means for providing an adhesive composition to one surface of the foil member,(d) means for affixing a release liner to the surface of the foil member provided with adhesive,(e) means for printing the foil member with a plurality of decorative patterns in one or more colors,(f) means for embossing said foil member in registry with the decorative patterns,(g) means for cutting foil shapes from the foil member in registry with the decorative patterns,(h) means for casting a clear fluent plastic material onto the foil shapes, and(i) means for curing or otherwise hardening the plastic.

Abstract: A method of making an elastomeric coated fabric container utilizing cured elastomeric coated fabric and adhering the edges of each layer of fabric to the other with an adhesive film and curing the adhesive film under heat and pressure to form said container.

Abstract: A novel plaster comprising a thermoplastic elastomer, an oil or higher fatty acid, a tack-providing resin and a medicinal ingredient. The plaster may be easily released therefrom without giving appreciable irritation or pain to the skin and body hairs of human bodies after applied thereto, while it may nevertheless exhibit satisfactory tackiness and adhesive strength when applied to human bodies.

Abstract: The invention relates to a method of reproducing plastics record carriers, in particular duplicating video records. According to the invention, a metal die is used which is provided with a thin-liquid molding resin of a particular composition which can be polymerized by radiation. A radiation-pervious substrate which is manufactured from synthetic material, for example polymethylmethacrylate, is provided on the molding resin. The molding resin is exposed to light via the substrate after which the cured molding resin together with the substrate connected thereto is removed from the die. The molding resin used in the process comprises low-molecular monomers or oligomers which contain on an average 25-70% by weight of hydrocarbon groups and/or phenyl groups. The molding resin is aprotic and has a functionality as regards unsaturatedness which is between the values 2 and 6. A suitable molding resin contains mono-, tri- or tetra esters of acrylic acid.

Abstract: A method of manufacturing a thin net by a polycondensation reaction is disclosed. One of the reactants is deposited upon a template and subsequently the second reactant is also deposited on the template. An embossed structure is obtained which can then be biaxially oriented to form a net sheet if desired.

Abstract: A process for preparing an open-cell structure from a vinyl chloride resin. The process includes mixing a vinyl chloride resin, stabilizer, plasticizer, surface active agent, azodicarbonamide and 4,4'-oxybisbenzenesulfonyl hydrazide to form a vinyl chloride resin paste. The vinyl chloride resin paste of step (a) is rendered alkaline, and mixed to form a uniformly-mixed paste. The paste is permitted to expand, and then heated to cause gelation.