Abstract: Polyol blend compositions are provided containing a polyester polyol, especially an aromatic polyester polyol, a compatibilizing block copolymer of ethylene oxide and at least one other alkylene oxide having three or more carbon atoms in the molecule, the block copolymer being terminated by ethylene oxide blocks, and optionally other polyols. The blends are miscible with halohydrocarbon blowing agents such as trichlorofluoromethane and suitable for reaction with polyisocyanates to give polyisocyanurate and polyurethane foams.

Abstract: A method for making a roller sleeve assembly comprising providing a metal sleeve, forming apertures extending radially through the sleeve, bonding a flexible sleeve to the exterior of the metal sleeve and permitting the flexible sleeve material to fill certain of the apertures. The invention further contemplates a method for making a roller assembly comprising sliding the above-described sleeve assembly onto a hub comprising a circular wall with ribs extending normally therefrom, and providing locking plates and cooperative pins for locking the sleeve assembly onto the hub, with the pins disposed partly in the locking plates and partly in other of the sleeve assembly apertures.

Abstract: A method of manufacturing lightweight shapes from polyimide foam in which density discontinuities such as cavities, varying cell size, or swirl marks are substantially eliminated. A block or bun of polyimide foam is prepared in a conventional manner which results in a high density rind and other discontinuities. The foam is chopped into fine flakes in a chopper with a continuous flow of air to prevent electrostatic attachment of the flakes to the chopper and ducting. The flakes are mixed with a quantity of polyimide precursor and then heated to cause the precursor to bond the flakes into a uniform mass having highly uniform and predictable density. This is a very economical process since portions of the original bun may be used which would ordinarily be discarded. An alternative method is described whereby the flakes can be bonded together by using the precursor in the form of a partially cured foam either as a binder, or by making the flakes of partially cured foam.

Abstract: A flexible laminate, such as backed tufted carpeting, is formed by bonding a fabric or polymeric backing layer to a pre-coated textile substrate. The substrate is pre-coated by advancing it past a perforated hollow transfer roller (3) containing an internal doctor member (4). Fluent settable coating material is fed to the substrate (1) so that it forms a well (6) between the substrate (1) and the doctor member (4) through the perforations of the roller (3). Coating material is deposited on the fabric (1) and is then set, for example by passing through an oven, to form the pre-coat. The spacing of the roller (3) and the substrate (1) and the pressure of the doctor member (4) on the perforated wall of the roller (3) are adjusted so that a pre-coat of desired thickness or density is obtained.

Abstract: Laminated reinforced thermoplastic sheets are made by preparing first and second porous sheets, each having 20% to 60% by weight of reinforcing fibers having a high modulus of elasticity and 40% to 80% by weight of a thermoplastic material differing from the thermoplastic material in the other sheet and applying heat and pressure to cause the sheets to consolidate and adhere together to form the laminate.

Abstract: The present invention includes metal oxide foam particles and a method of making the same. A decomposable metal salt feed solution is injected into a hot atomizing gas. The mixture of hot atomizing gas and feed solution is maintained in the reactor until the feed solution converts to metal oxide foam particles. The metal oxide foam particles have a high specific surface area.

Abstract: A process for preparing permeable adhesive tapes, which comprises dispersing water or water and a water absorptive high-molecular weight compound homogeneously in a solution of a natural or synthethic rubber or acrylic pressure sensitive adhesive agent in an organic solvent, applying the dispersion onto a releasing agent applied sheet, drying the adhesive agent applied sheet, and laminating a porous backing material on the adhesive agent applied surface to obtain a permeable adhesive tape.

Abstract: The present invention is directed to a process for the production of optionally foamed polyurethanes which are combined or fabricated with another material, comprising reacting compounds with molecular weights from 400 to 10,000 containing at least 2 isocyanate reactive hydrogen atoms with polyisocyanates in the presence of catalysts containing tertiary amino groups and combining or fabricating the resulting polyurethane with another material, characterized in that the catalysts used are diffusion resistant aminoalkanols corresponding to the general formula ##STR1## wherein R.sup.1, R.sup.2, R.sup.3 and R.sup.4 may be identical or different and represent hydrogen or a C.sub.1 -C.sub.6 alkyl group,R.sup.5, R.sup.6, R.sup.7 and R.sup.8 may be identical or different and represent a C.sub.1 -C.sub.6 alkyl group or together form a C.sub.2 -C.sub.6 alkylene group which may contain hetero atoms such as O or NR (R=C.sub.1 -C.sub.4 alkyl), and n and m may be identical or different and represent integers from 1 to 6.

Abstract: A substrate for high-frequency circuits best suited as a substrate for a flat antenna to receive satellite-broadcast microwaves or as a similar substrate, the substrate comprising (i) a porous insulator layer wherein the proportion by volume of open cells to all the cells is at least 50% and (ii) a metal foil laminated over at least one side of the insulator layer through (iii) a water-impermeable film, and a process for making such substrates.

Abstract: An improved method is disclosed for forming articles, especially airfoils, comprised of a fiber reinforced plastic bonded to a metal object. In the manufacture of a propeller blade a subassembly is made by coating a metal spar with a certain class of adhesive to a depth of 5-40 mils to compensate for dimensional variations in the spar surface, transferably coating the interior of a subassembly mold with the adhesive, then inserting the coated spar into the mold and injecting a lightweight filler material. The adhesive and filler are then precured and the subassembly removed from the mold. A fibrous reinforcing material, such as glass fiber cloth, is then used to cover or wrap the subassembly, the subassembly thus covered is placed in a second mold and a synthetic polymeric material such as epoxy resin, previously or subsequently applied, is then cured.

Abstract: A method of manufacturing a shape from a composite material by applying laminations impregnated with plastic resin to a positive mold. At least one cellular, cellular-core layer is applied into the neutral zone of the laminations and embedded into them while the laminations are being built up. The cellular layer is a rigid foam. The cellular-core or honeycomb layer has the axis of each cell radial to that of the shape and can be single, double, or multiple. If double or multiple it may have an interior connective layer consisting of plastic, foil, glass cloth, non-woven carbon-fiber fabric, polyimide, or woven or non-woven fabric impregnated with plastic resin. The cellular-core or honeycomb layer is intended to make the shape more stable and flexurally strong.

Abstract: A molded thermal insulation body having a microporous thermal insulation material encased in a sheathing. The molded body is partially evacuated to a partial air pressure of 20 mbar or less. Following the evacuation of air, the molded body may be filled with krypton, xenon, sulfur hexafluoride, carbon dioxide or a combination thereof. A process for the manufacture of the molded thermal insulation body is also provided.

Abstract: A gas diffusion composite electrode useful in an electrochemical cell comprising an electrochemically active layer and a backing layer, said active layer characterized as porous, homogeneous, hydrophilic, and electrolyte-permeable and comprising a sintered mixture of a major amount of an electrically conductive, hydrophilic, particulate material containing admixed therewith an electrochemically active catalyst, and a minor amount of a hydrophobic polymer, said particulate material being substantially coated with said hydrophobic polymer by precipitation of said hydrophobic polymer upon said particulate material.

Abstract: A cellular seal coating is provided for uses such as assembling composite packages, which cellular seal coating is formed by electrostatically depositing finely divided, electrostatically chargeable bonding agent particles onto a preassembly member. Such bonding agent particles include a chemical blowing or foaming agent or system which forms gas bubbles when heated or otherwise energized in order to alter the thickness and strength of the seal coating so that it may, for example, fill gaps along assembly locations of a package or other article.

Abstract: The disclosure is directed to preparing three-layer laminated electrodes suitable for use as oxygen (air) cathodes in chlor-alkali and other electrochemical cells, fuel cells and in other electrochemical applications.This three-layer laminate includes an active layer or sheet containing from about 60 to about 85 wt. % active carbon, the remainder being unsintered, fibrillated polytetrafluoroethylene in intimate admixture with said active carbon, said active layer laminated on its working surface to a current distributor and on its opposite surface to a porous, coherent, hydrophobic polytetrafluoroethylene-containing wetproofing layer.

Abstract: This invention relates to a method of producing a moisture-permeable artificial leather comprising transferring a water-soluble inorganic salt-containing polyurethane layer onto a base fabric and washing the polyurethane layer with water to extract out said water-soluble inorganic salt. A feature of the invention is that the inorganic salt used has a particle diameter range such that at least 90% thereof is not larger than 30 microns.

Abstract: Insulating material is formed in a continuous strip and comprises a web of flexible impervious polymeric material in which individually spaced elongate pockets have been formed transversely across the elongate strip. Insulation material is located in the pockets which are covered by a sheet of impervious foil material, such as aluminium foil, which forms one outer surface of the completed web of insulating material. The foil is heat sealed to the polymeric material so that the insulation material in the pockets is totally encompassed by impervious material, thus minimizing deteriorization of the insulation properties of the insulation material. The insulation material can be foamed in the pockets or can take the form of powder or foam granules.

Abstract: A thermoformable laminate structure with improved acoustical absorption is provided which has a first and a third layer of foamed thermoplastic material and a second layer, intermediate the first and third layers, which is a material having acoustical properties different from the properties of the material of the first and third layers. A portion of the surface area of each layer is adhesively bonded to the adjacent layer. A resin impregnated fabric is bonded to the outer surfaces of the first and third layers.

Abstract: An improved method of producing a compressible layer to be utilized for a blanket for printing operation is disclosed, wherein the improvements are that the method comprises the steps of adding to elastomer compound of oil resistant polymer pulverized material which is dissolvable in effluent, placing the elastomer compound over a base fabric in the form of a layered structure, and subjecting to vulcanization and then immersing it in the effluent at a predetermined temperature for a certain period of time. To improve compressibility one or more another compressible layers are preferably placed over the early prepared compressible layer with adhesive agent interposed therebetween so as to form an integrated structure.

Abstract: A method of forming structural board panels from short strands of bagasse or other cellulistic material. The material resinated, compressed and cured to give an open structural block. A mortar screed of portland cement and sand is then applied to penetrate interstices between the strands and is built up with rendering and facing layers of mortar. A reinforcement, such as an open mesh net of resinated nylon strands may be incorporated in the facing layer.

Abstract: Coated Prosthetic devices useful in the medical and dental fields, such as dental implants, intramedullary nails, and total hip prostheses, are provided having a porosity or density gradient in the sintered plastic coating. The higher porosity is at the outer surface which facilitates bone ingrowth while the lesser porosity which has a higher density and a more continuous plastic layer is on the inner surface and thus provides better adhesion to the load bearing component.

Abstract: Thermal insulation which contains a plurality of contiguous hollow structures such as hollow spheres and an elastomer, preferably a silicone rubber, which fills the interstices between the contiguous structures. The insulation may be molded around a pipe by filling the space between the pipe and an annular jacket which is concentrically arranged around the pipe to be insulated with hollow structures, adding a thermosetting composition to fill the interstices between the structures while the structures are retained in their original position and thereafter curing the thermosetting compositions to an elastomeric solid.

Abstract: A porous sheet comprising a flexible sheet in which a rigid substance is incorporated, wherein pores are formed in the sheet by breaking the rigid substance.

Abstract: This invention is an improved insulation means and a method of forming the same. An expanded ceramic material such as expanded perlite, with a calculated R-rating of 2.7 per inch, and urethane foam, with a R-rating of 7 per inch under American Society for Testing Methods (ASTM), are combined to more than triple the expected R-rating of the sum of the two. The methods of forming the improved insulation can be used for either original equipment insulation such as water heaters or for board or foamed in type insulation for use in building structures and similar applications.

Abstract: The process for producing a decorative surface covering having an inlaid decoration which comprises depositing a layer of fine granules of resinous composition on the surface of a backing sheet, heating to sinter the granules into a porous mass, applying a design on the surface of the sintered layer with a mixture of a pigmented dryblend of at least two contrasting colors and a transparent or translucent plastisol and then fusing the printed, sintered sheet into a non-porous sheet by the application of heat.

Abstract: This invention is concerned with a process for producing microporous coatings comprising (1) mixing an NCO-prepolymer prepared from polyisocyanates with compounds containing at least two isocyanate-reactive hydrogen atoms with about 3 to 40% by weight, based on the NCO-prepolymer, of a substantially inert, non-migrating liquid organic compound miscible with said NCO-prepolymer as a plasticizer; (2) adding about 3 to 300 weight % of water, based on the NCO-prepolymer, into the NCO-prepolymer-plasticizer mixture to form a water-in-oil emulsion; (3) adding a polyamine in a quantity substantially equivalent to the isocyanate groups; (4) applying a coating of the water-in-oil emulsion to a substrate; and (5) hardening the coating by evaporating the chemically unbound water from said coating.

Abstract: A method of forming a laminate composed of a solid polyester lamina bonded to a block. A block having a matrix composed of polyurethane foam and particles of expanded polystyrene distributed therein is prepared. A layer composed of a solution of a relatively unpolymerized polyester in styrene solvent with fiberglass embedded therein is placed in contact with a surface of the block. The styrene solution of polyester dissolves polystyrene particles adjacent such block surface, leaving recesses distributed in the block matrix. These recesses become at least partially filled with the polyester solution. The solution is then cured to produce a solid resin lamina which is joined with polymerized resin contained in the matrix recesses to secure the lamina to the block.

Abstract: Synthetic suede leather is produced by casting a mixture containing polyurethane elastomer and a solvent therefor between two sheets of a substrate fabric, immersing the resulting structure in a liquid which is a nonsolvent for polyurethane elastomer but miscible with said solvent, splitting said structure into two sheets at middle of the cast layer before it is fully gelled, and re-immersing the resultant sheets in said nonsolvent to allow complete gelation of said mixture.

Abstract: The present invention provides a process for making a water vapor permeable pressure sensitive adhesive material which comprises forming on a surface which is poorly wettable (or non-wettable) by water, a continuous coating of an aqueous emulsion based pressure sensitive adhesive having dispersed therein a water immiscible organic liquid which is more volatile than water and which does not break the emulsion; leaving the coating at room temperature until pores develop and reach a size such that the material when dried will have a water vapor permeability of from 2000 to 10,000 units as hereinafter defined; drying the coating at a higher temperature and transferring the adhesive mass to a water vapor permeable backing material. The pressure sensitive adhesive material finds use in the medical and surgical fields and especially in first-aid dressings and tapes.

Abstract: A fabric backed cellular cushioning material is produced in a mold by introducing a liquid reaction mixture into a mold cavity and then covering the mold cavity with a coposite material consisting of a fabric backing and a thin layer of preformed cellular material attached to the backing. The preformed cellular material is presented toward the mold cavity. The reaction mixture expands into a cellular cushioning material, which assumes the shape of the cavity, the expansion being sufficient to enable the molded cellular material to completely fill the cavity and diffuse partially into as well as adhere to the preformed cellular material. The air displaced by the expanding reaction mixture passes out of the mold cavity through the preformed layer of cellular material, but once the expanding cellular material reaches the preformed layer, the mold cavity is sealed.

Abstract: Disclosed is a porous sponge-like material having an improved scrubbing and cleaning ability which comprises a porous cellulose hydrate body having at least one netting attached to at least a portion of the surface of the body. In order to improve cleaning ability, the porous cellulose hydrate body contains a thermoplastic filler material. In the preferred embodiment, moreover, the filler material is comprised of a heat-sealable thermoplastic material and the netting at least partially comprised of a heat-sealable thermoplastic material to enable the facile bonding of the netting to the porous cellulose body by heat-sealing.

Abstract: A foamed polymeric material is coated with a fire protective thermal barrier product. The polymeric material, thus protected, is used for on-site application on walls, ceilings, decks and roofs of buildings. The thermal barrier product (hereafter "thermal barrier" for brevity) is also used to protect foam plastics in fire-resistant factory-made building panels, the exteriors of tanks and other vessels, and the coverings over pipes. The thermal barrier comprises a normally fluent thermosetting synthetic resinous material in which is dispersed an effective amount of hydrated magnesium sulfate and, optionally, inert inorganic fillers, pigments and the like.

Abstract: Disclosed is a method of forming an unsintered, nonwoven, wettable, microporous diaphragm of a fluorocarbon polymer. The diaphragm is prepared by maintaining a nonwoven, fibrous mat of a leachable material in contact with the external surfaces of the fluorocarbon polymer film while hot pressing the halocarbon polymer film above its flow temperature and below its thermal decomposition temperature, and thereafter leaching the fibrous mat out of the halocarbon film. Additionally, monomers having acidic or basic groups may be grafted to the pore walls. Also disclosed is a method of rendering a hydrophobic fluorocarbon polymer film wettable by compressing the film between a pair of nonwoven mats of a leachable fibrous material while maintaining the film above the flow temperature thereof but below its decomposition temperature and then leaching the fibrous material out of the film.

Abstract: A tire having a reticulated or foraminous plastic reinforcing member within an elastomeric body. This tire can be made by reticulating polyester or nylon type plastic to give a foraminous member and then injecting a liquid elastomer or elastomer precursor into a mold to fill the interstices of the foraminous body.

Abstract: An improvement in the process for producing a decorative surface covering having a multilevel embossed wear surface wherein, a layer of vinyl chloride resin dryblend which may be foamable or unfoamable, and which contains a polymerizable monomer having at least two olefinically unsaturated sites is formed. After sintering to achieve a solid but porous layer having substantial voids throughout, a plurality of resinous ink compositions, formulated to produce varying degrees of elevation in the final product, are applied in a design. Among the inks used are non-monomer-containing ink compositions which may include foamable and non-foamable inks and which may or may not include a catalyst for the monomer in the dryblend. The improvement of this invention comprises the inclusion in the plurality of inks printed in a design on the monomer-containing dryblend layer of an ink containing the same polymerizable monomer as that in the dryblend, and a catalyst for the monomer.

Abstract: Method of making a leather-like sheet material having a low bounce impact elasticity, which comprises: (a) mixing (i) a solvent solution of a polymer (A) consisting mainly of an elastomer and (ii) a dispersion in a liquid of a polymer (B) consisting mainly of an elastomer, thereby obtaining a composite solution containing fine particles of (B) dispersed in a solution of polymer (A); (b) coating a sheet or impregnating a fibrous mat substrate with the composite solution; (c) immersing the substrate in a coagulation bath to deposit and coagulate both polymers; and (d) drying said sheet or mat.

Abstract: Novel dense foam articles having a solid plastic sheet coating on at least a portion of the surface are prepared by injection molding plastic foam into a mold containing a thermoformed solid plastic sheet having the configuration of at least a part of the mold and fitted to a matching mold surface.

Abstract: An improved terrazzo floor or wall construction of reduced thickness bonded and adhesively secured to an underlying sub-surface through the medium of an intermediate liquid impermeable sheet. A frangible terrazzo veneer is bonded to the liquid impermeable sheet and the sheet in turn is adhesively secured to the underlying sub-surface by a rubberized asphalt or the like elastomeric material to permit lateral movement of the sub-surface relative to the said facing veneer to obviate cracking of the veneer due to cracking or lateral movement of the sub-surface.

Abstract: Polymeric sheets having on one or both sides a fabric texture and a network of elongated channels in the interior of the structural framework of the sheet. In one embodiment, the sheets comprise a plurality of interbonded continuous polymeric ribs extending in a direction parallel to the plane of the sheet. The ribs impart a fabric texture to both sides of the sheet and define between them recessed portions on each surface of the sheet. The elongated channels extend throughout the ribs. The open area between the ribs can vary from zero to 60%. In another embodiment, the sheets have an ultra-thin, pinhole-free silicone rubber membrane on one side and a fabric texture on the other side. The sheets are useful as burn coverings where they serve as synthetic temporary replacements for damaged or missing skin.

Abstract: This invention is an improvement in a process for making a thermosetting resin article.In the process of producing an article of thermosetting resin which comprises (a) impregnating a sheet having an open-cell structure with a curable thermosetting resin, (b) applying a layer of fibrous reinforcing material to at least one side of the impregnated sheet, (c) compressing the sheet and reinforcing layer to the extent that resin is expelled from the sheet into the fibrous reinforcing layer and (d) allowing the resin in the sheet and layer to cure while maintaining the compression, the improvement which comprises uniformly incorporating a gas release agent into the curable thermosetting resin to promote the expulsion of resin from the sheet into the reinforcing layer.The invention also includes an open-cell sheet impregnated with a mixture of a curable thermosetting resin, an effective curing agent for said resin, and a compatible gas release agent.

Abstract: Chain-extendible, sulfonated isocyanate-terminated polyurethane-type prepolymers are obtained by treating the prepolymers with a strong sulfonating agent selected from H.sub.2 SO.sub.4, SO.sub.3, CISO.sub.3 H, and mixtures thereof.

Abstract: Self-emulsified polyurethane or polyurethane-polyurea or polyurea latices formed by reacting an aromatic polyisocyanate such as a polyurethane prepolymer with a strong sulfonating agent selected from H.sub.2 SO.sub.4, SO.sub.3, ClSO.sub.3 H, and mixtures thereof, converting the sulfonated polyisocyanate to a sulfonic acid salt by reaction with a base, and mixing the polyisocyanate in water to obtain chain extension and self-emulsification thereof.

Abstract: A printing blanket especially suited for use in offset lithography is provided by permanently laminating together an oil-resistant continuous rubber ink transfer layer, a strong thin tough synthetic foundation sheet, and a layer of incompressible elastomer having dispersed and bonded therein numerous minute frangible rigid-walled bubbles that have been broken uniformly throughout the elastomer layer to make it compressible.

Abstract: A particle having superior bonding properties comprising crystalline portions connected together by a bonding material. The bonding material is relieved at the surface of the particle to provide capillaries extending into the particle between adjacent crystals. This results in the fusing material having a terminal surface recessed from the surface of the particle. The particle, when added to an elastomeric material, achieves superior mechanical, chemical and vacumatic bond strength as the elastomeric material is anchored to the particles by occupation of the capillaries, achieving increased bonding area.

Abstract: A plastic laminate and shaped article having a polyurethane film substrate, a fabric superstrate and an intermediate layer of polyurethane foam. The polyurethane foam layer is cast upon the polyurethane film to provide a substantially integral laminate. The fabric layer is also bonded to the foam layer, preferably prior to complete curing, permitting the use of unnapped fabrics.

Abstract: Patterns described with inks or colors on the surface of thermoplastic resin articles having an interconnected fine open-cell structure in the surface layer thereof are rendered durable without displacement or deformation by heating under pressure the pattern described surface to a higher temperature than that at which said thermoplastic resin becomes fluid to cover the pattern-bearing surface with a thin film formed from the original resin constituting said surface layer.