Abstract: Prepare a dimensionally stable polymeric foam article by affixing first and second polymeric foams together in a layered orientation to produce an article having a thickness of at least 50 millimeters wherein at least the first polymeric foam contains an infrared absorbent and is prepared using a blowing agent containing carbon dioxide.

Abstract: Methods of producing a custom-fitted prosthetic socket device for a residual limb include covering the distal end thereof with a liner, positioning the covered end within a socket cup to maintain a spaced relationship between the exterior of the liner and the interior of the socket cup, introducing an expandable, hardenable filler material into the socket cup, expanding the material to fill the volume between the liner and the socket cup, hardening the material, and removing the socket cup, hardened filler material, and liner, from the residual limb. Some methods include a filler material that hardens into a flexible solid foam cushioning layer which may optionally form a bond between the socket cup and the liner, embedding the liner in the cushioning layer. Some methods include selecting a socket cup from a plurality of sized socket cups, and/or providing the plurality of sized socket cups.

Abstract: A structure includes a skin and a foam member. The foam member has a molded contour, the mold contour being configured to provide tooled surface for the skin. When the skin is a composite skin, the foam member provides support for the skin so that the skin can be cured under heat and pressure. A method of making the foam member for a foam stiffened structure includes creating a mold having an interior cavity which resembles a desired shape the foam member. A subsequent step involves introducing a foam mixture into the mold. Next, the foam mixture is allowed to polymerize so as to expand and distribute within the cavity of the mold. The method further includes selectively controlling a density of the foam member in the mold. The foam member is at least partially cured. The foam member is assembled with a skin to produce the foam stiffened structure.

Abstract: An insulating panel 1 comprises a first sheet 2, a second sheet 4, and a body of insulating foam 5 between the sheets 2, 4. The foam 5 has a plurality of longitudinally extending conduits 7 through which a heat exchange medium such as air is circulated. A barrier 10 is used to create an enlarged void space for air circulation. The barrier is located below profile crowns 3 to prevent foam from entering the crowns 3 and to create additional foam-free voids below the crown. Heat transfer efficiency is increased.

Abstract: It is an object of the present invention to provide a panel capable of obtaining sufficient strength, weight reduction and sound absorbing performance. A space is formed by an inner thin plate fixed to the inner surface of an outer thin plate, and a foam material is filled in the space. The foam material is preferably a highly foamable rubber sound absorbing material. In the inner thin plate, a perimetrical side part and perimetrical edge part for forming the space, and a concave part for enhancing the strength of the panel are drawn to the side of the outer thin plate. The bottom faces of the perimetrical edge part and concave part of the inner thin plate are bonded to the outer thin plate using a thermosetting adhesive.

Abstract: Methods for reducing the density of thermoplastic materials and the articles made therefrom having similar or improved mechanical properties to the solid or noncellular material. Also disclosed are improvements to foaming methods and the cellular structures of the foams made therefrom, and methods for altering the impact strength of solid or noncellular thermoplastic materials and the shaping of the materials into useful articles.

Abstract: The panel 1 comprising a backing tray 2 and an external skin 3 with a layer of foam insulation material 4 therebetween. The external skin 3 has a plurality of mountings for fixing cladding elements such as tiles 5 to the panel to form a cladding. The mountings comprise rails 10 and fasteners 12 for fastening the rails 10 to the external skin 3. Each fastener 12 comprises an internal clamping sleeve 15 and a bolt 16. A hole is first drilled through the skin 3 and the sleeve 15 is inserted. On tightening of the bolt 16, the sleeve splays and is clamped against the inside surface of the external skin 3. To enhance the peel strength of the composite panel a layer 30 of an adhesive is applied to the internal face of the external skin 3.

Abstract: A polyurethane foam for vehicles is obtained by reaction, foaming, and curing of a polyurethane-foam raw material comprising polyol, polyisocyanate, a blowing agent, and a catalyst, and is used for vehicle parts. The foam raw material comprises expanded graphite and an inorganic compound hydrate. The polyol preferably comprises polymeric polyol in which a polyether polyol is graft-polymerized with a vinyl monomer, polyether polyol having a mass average molecular weight of from 400 to 1,000, in which a polyhydric alcohol is addition-polymerized with an alkylene oxide, and polyether polyol having a mass average molecular weight of from 2,000 to 4,000 in which a polyhydric alcohol is addition-polymerized with an alkylene oxide.

Abstract: A self-sealing vascular graft with kink resistance is described. The vascular graft includes a substrate that can be ePTFE, having a self-sealing region that may include several layers of material. The central section of the vascular graft may be constructed differently from surrounding self-sealing regions, in order to provide kink resistance following the clamping of the graft. Also described is a graft with a flared cuff attached to one or both ends, the attachment or transition region including reinforcement beading.

Abstract: Surfaces are adhesively bonded by employing a highly reactive alkoxysilyl-functional foamable mixture, and pressing the surfaces together with the foam prepared from the foamable mixture between the surfaces.

Abstract: A method is disclosed for using discarded carpet segments or other recycled textiles to make wood-like material in sheets that are comparable to plywood. The carpet segments or other recycled materials are shredded, then layered across a slow-moving conveyor to form a thick, low-density belt of fibers. This belt is compressed between rollers, and then needle-punched, using needles with surface barbs that pull fibers downward and upward. This needle-punching causes fibers inside the mat to be pulled into vertical alignment (i.e., perpendicular to the top and bottom surfaces of a horizontal mat), to form a needle-punched mat that will hold together without chemical adhesives. A binder material is then applied to at least one and possibly both surfaces of the mat, by means such as spreading or spraying a liquid binder on either or both surfaces of the mat, or stretching a continuous film of the binder material across either or both surfaces of the mat.

Abstract: Modified alkoxylation products of the formula (I), their use and processes for preparing them

Abstract: A formulation to prepare a low- to medium-index (1 to 2.5) polyurethane or polyisocyanurate foam includes from 20 to 60 percent by weight of a formulated polyol comprising an aromatic polyester polyol having a functionality greater than or equal to 2 and a hydroxyl number greater than about 50 mg KOH/g; from 10 to 30 percent by weight of a Novolac-type polyol; and from 5 to 40 percent by weight of a sucrose- or sorbitol-initiated polyether polyol having a hydroxyl number greater than about 200 mg KOH/g and a functionality of at least about 4. The foams may exhibit improved processability, resulting in, for example, reduced shrinkage and deformation in sandwich panels, and improved fire behavior as tested according to German Standard DIN 4102.

Abstract: A method for producing a building board. The method includes applying synthetic-resin layers to the top side and/or the bottom side of a support board made of a wood material or a mixture of wood material and plastic. The layered structure is compressed under the impact of pressure and temperature. At least one of the synthetic-resin layers expands during compressing.

Abstract: Implants include a porous layer made from a composition including a compound wherein collagen is cross-linked to a glycosaminoglycan, the porous layer being optionally joined to a collagen film.

Abstract: An insulating panel 1 comprises a first sheet 2, a second sheet 4, and a body of insulating foam 5 between the sheets 2, 4. The foam 5 has a plurality of longitudinally extending conduits 7 through which a heat exchange medium such as air is circulated. A barrier 10 is used to create an enlarged void space for air circulation. The barrier is located below profile crowns 3 to prevent foam from entering the crowns 3 and to create additional foam—free voids below the crown. Heat transfer efficiency is increased.

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: An unmixed plastic sheet, which is made of a thermoplastic material and which is composed of a number of body segments that are adjacent to one another in a plane, interconnected and made of a closed-cell foam material. The body segments are thermoplastically welded to one another at their abutting lateral faces while forming flat weld seams. The flat weld seams form a plastic intermediate layer, which has few pores, and which is provided in the form of a web structure that, when viewed from above, is reticular and reinforces the plastic sheet. The inventive plastic sheet is preferably used as a core layer in sandwich composites.

Abstract: A system for preparing a microcellular polyurethane material, includes a froth, prepared, for instance, by inert gas frothing a urethane prepolymer, preferably an aliphatic isocyanate polyether prepolymer, in the presence of a surfactant; a filler soluble in a CMP slurry; and a curative, preferably including an aromatic diamine and a triol. To produce the microcellular material, the froth can be combined with the filler, e.g., PVP, followed by curing the resulting mixture. The microcellular material has a low rebound and can dissipate irregular energy and stabilize polishing to yield improved uniformity and less dishing. CMP pads using the microcellular material have pores created by inert gas frothing throughout the pad polymer body and additional surface pores created by dissolution of fillers during polishing, providing flexibility in surface softness and pad stiffness.

Abstract: Disclosed is a method for manufacturing a separator for an electrochemical device. The method contributes to formation of a separator with good bondability to electrodes and prevents inorganic particles from detaching during an assembling process of an electrochemical device.

Abstract: A multi-layered material and a method for making the same are provided. The multi-layered material includes a first foamed layer, a substrate, a second foamed layer, and a surface layer. The first foamed layer has a plurality of first cells. The substrate is a fabric. The second foamed layer has a plurality of second cells. The foaming method of the second foamed layer is different from that of the first foamed layer. The size of the second cells is different from that of the first cells. The variation in size of the second cells is different from that of the first cells. The surface layer is disposed on the second foamed layer. Thus, when the multi-layered material is used as a surface cover of a ball, it can provide excellent resilience and control, and improve manufacturing efficiency.

Abstract: The invention relates to the production and use of polyester polyols, formed from at least one carboxylic acid hydride and ethylene glycol, wherein a specialized reaction control stustantially suppresses the formation of 1,4-dioxane from diethylene glycol.

Abstract: A carpet is having a raschel fabric to the back face. The raschel fabric consists of wefts which are inlay-yarns and warps which are chain-stitched yarns. The warp consists of chain-stitched ground yarns 3a, 3b, and a pile yarn 4 which forms standing loop piles on specified courses and which is chain-stitched with the ground yarns except said specified courses. The pile yarn consists of two mono-filaments 5, 5. The two mono-filaments 5, 5 are twisted at least one time per the length of each loop pile. Cut piles are formed by mechanically cutting the each loop pile near the top thereof. The two mono-filaments in the cut pile are disjoining each other and standing with inclination at random direction on the raschel fabric. When the carpet is placed on the surface of a mat, each mono-filament which is formed on the back face of the carpet, bites into the surface of the mat. Therefore, it is prevented that the carpet is displaced.

Abstract: Inserts such as screw threaded receivers are provided with an activatable adhesive so they can be inserted into a cavity of an article of manufacture and the adhesive activated to secure the insert within the article.

Abstract: The invention relates to a self-inflating mat or pillow consisting of open-cell foamed material which is hermetically covered on both sides by outer layers of cloth, the outer layers being sealed on the edges and at least one valve providing a connection between the foamed material and the surrounding atmosphere. At least one layer of cloth or a mesh fabric is provided on at least one side and the cloth or mesh fabric consists of a hot-pressed yarn coated with a thermoplastic material.

Abstract: A method and apparatus for manufacturing and installing a fairing on an aircraft. In one advantageous embodiment, a composite fairing is installed on the aircraft. A composite sheet having a form of the composite fairing is formed. A plurality of cured composite tiles is created from the composite sheet, wherein spaces are present between the plurality of composite tiles. The plurality of composite tiles is cured to form the composite fairing. The composite fairing is attached to a surface of the aircraft. The spaces between the plurality of composite tiles are filled with a flexible filler.

Abstract: A process for producing a cross-linked foamed molded article using a lower mold having a tray-shaped recessed portion and an upper mold capable of closing the tray-shaped recessed portion, the process comprising the following steps: (1) a step in which a thermoplastic resin sheet (A) comprising a blowing agent and a crosslinking agent and a thermoplastic resin sheet (B) comprising a blowing agent and a crosslinking agent and differing in resin composition from the thermoplastic resin sheet (A) are stacked in the tray-shaped recessed portion and the upper mold and the lower mold are clamped to fill the tray-shaped recessed portion with the thermoplastic resin sheet (A) and the thermoplastic resin sheet (B); (2) a step in which the molds clamped are pressed and heated; and (3) a step in which the molds are opened to obtain a foamed molded article.

Abstract: The present invention is a method to manufacture shaped foam composite articles and articles made therefrom. Specifically, shaped foam articles having a laminated skin such as a solid thermoplastic sheet. The shaped foam article (10) and the skin may be made from the same or different materials. The method comprises (i) preparing a shaped foamed article with a plurality of perforations and (ii) vacuum forming a skin onto the perforated shaped foamed article.

Abstract: An unmixed plastic sheet, which is made of a thermoplastic material and which is composed of a number of body segments that are adjacent to one another in a plane, interconnected and made of a closed-cell foam material. The body segments are thermoplastically welded to one another at their abutting lateral faces while forming flat weld seams. The flat weld seams form a plastic intermediate layer, which has few pores, and which is provided in the form of a web structure that, when viewed from above, is reticular and reinforces the plastic sheet. The inventive plastic sheet is preferably used as a core layer in sandwich composites.

Abstract: A new light and durable construction for posts including an inner pre-stressed tube or pole or wire or fibre rope. The construction includes an outer cover of composite fibre material and a polymer foam that has been added to the tube profile which the outer cover has formed and the polymer foam expanded and cured in situ.

Abstract: A process for assembling a composite piece for use in the interior of an automobile. An outward facing skin of the composite piece is connected to a substrate by a foaming material, and at least one switch item is integrated seamlessly into the composite piece. Part of the process includes wrapping a visible portion of each switch item with the outward facing skin. A spare piece is placed against the surface of the visible area of each item opposite the surface located on the visible surface of the composite piece. A foaming material is injected between the skin and the substrate, and then each spare piece is removed. A control component is placed at each cavity left where the removed spare pieces blocked expansion of the foaming material.

Abstract: Planar structural element, as a portion of a foam block, the foam block being made of a foamed plastics material, containing a plurality of stacked foam bodies and/or foam bodies made of body segments, which are arranged next to one another in a plane and connected to one another to form foam bodies and which have flat weld seams at their abutting faces, and the foam bodies being welded to one another at their abutting faces with the formation of flat weld seams to form the foam block. The weld seams between the foam bodies are interrupted by recesses at a spacing from one another. The planar structural element is preferably used as the core or core layer in sandwich composites, for example in rotor vanes of wind power plants.

Abstract: Filtration devices may include a shape-memory material having a compressed run-in position or shape and an original expanded position or shape. The shape-memory material may include an open cell porous rigid polyurethane foam material held in the compressed run-in position at the temperature below glass transition temperature (Tg). The foam material in its compressed run-in position may be covered with a fluid-dissolvable polymeric film and/or a layer of fluid-degradable plastic. Once filtration devices are in place in downhole and are contacted by the fluid for a given amount of time at temperature, the devices may expand and totally conform to the borehole to prevent the production of undesirable solids from the formation.

Abstract: A framed device includes a substrate, a frame, and a seal. The substrate has a first length, a first width, and a peripheral edge. The frame has a single, contiguous lengthwise piece having a first end and a second end, wherein the lengthwise piece is configured to form three corners by bending and is substantially equal to the length of the substrate. The frame further includes an attachment means connecting the first end and second end of the frame when in the bent position and a groove that runs along a length and a width of the frame, wherein the groove is substantially engaged with the peripheral edge of the substrate. The seal is disposed within the groove of the frame, wherein the seal runs contiguously from the substrate to the frame and the seal includes a foamed polymer.

Abstract: A movable door panel having a front facer with opposed longitudinal edge profiles, rails secured to the longitudinal edge profiles, a rear facer secured to the rails, and foam disposed within an inner volume defined by the front facer, the rails and the rear facer is disclosed. Transverse stiffeners are disposed within the inner volume and the foam, and extend between the opposed rails. The door panel may be made by continuously providing the front facer with a rail secured thereto, continuously positioning transverse stiffeners on the front facer and extending between the metal rails, and continuously applying a foaming material on the front facer and the transverse stiffeners. The method concludes by bringing a rear facer into contact with the metal rails, and drawing the panel through a laminator. Hardware may then be attached to one or both of the facers and the stiffener.

Abstract: There is provided a laminate sheet which is excellent in oxygen-barrier property and moisture resistance, biodegradable as a whole and therefore suitable as a base material for packaging materials, such as food containers. The laminate sheet is formed by laminating a water-containable and biodegradable polymer substrate sheet or a precursor thereof in a water-containing state with a layer of polyglycolic acid resin having a residual monomer content below 0.5 wt. % to form a laminate, and subjecting the laminate to bonding and forming under heat and pressure.

Abstract: The foam product includes a foam body, a connection block, an accessory and an adhesive layer. The foam body is formed of expandable polystyrene (EPS). The connection block is formed of a copolymer of expandable polyolefin and expandable polystyrene, and is completely or partially embedded inside the foam body. The accessory is made of non-expandable material and is completely or partially embedded inside the connection block. The accessory and the connection block are bonded by the adhesive layer.

Abstract: Processes of making slightly sloped roofing members/products (30, 130) for drainage of essentially flat roofs and the products (e.g., sloped roofing members) produced thereby are provided. Some of the processes comprise feeding a series of mold members (50, 150) in a conveyance direction (26) toward a laminator (22) wherein the sloped roofing members are cured. In various embodiments such processes comprise feeding a bottom facer (42) in the conveyance direction toward the laminator (22); depositing a foam-forming mixture (46) on the bottom facer (42); feeding a top facer (44) in the conveyance direction toward the laminator whereby the foam-forming mixture is interposed between the bottom facer (42) and the top facer (44); feeding the series of mold members (50, 150) in the conveyance direction toward the laminator (22) and beneath the bottom facer (44); and curing the foam-forming mixture in the laminator to form a solidified web comprising the sloped roofing member (28, 128).

Abstract: A method and apparatus for manufacturing a composite structure. A filler material with a barrier material for a channel in the filler material is formed. A composite material and the filler material with the barrier material are laid up onto a tool in a shape of the composite structure. The composite material and the filler material in the shape of the composite structure are cured.

Abstract: A developer supplying member includes a foamed member formed of continuous foams for supplying developer to a developer supporting member. The foamed member has a high resistivity in terms of electrical conductivity through ion conductivity, and has a low resistivity in terms of electrical conductivity after carbon black is attached to foam cell walls thereof.

Abstract: A weatherseal adapted to be installed in a door or window opening includes a spine, a resilient foam core, an intumescent material, and a liner. The spine has first and second ends, the first end adapted for mounting the weatherseal to the door or window opening. The resilient foam core is attached to the spine, proximate the second end of the spine. The intumescent material is arranged proximate the foam core. The liner encloses the flexible foam core and the intumescent material. The weatherseal or a portion may be color-coded to identify the weatherseal for fire rated applications.

Abstract: There are provided a vehicle interior finishing laminate sheet in which a polypropylene resin foam board of high foaming extent having interconnected cells is used as a core member, a vehicle interior trim material, a method for manufacturing the vehicle interior finishing laminate sheet, and an apparatus therefor. The present invention relates to a vehicle interior finishing laminate sheet 1 provided with a core member consisting of a polypropylene resin foam board 2. The polypropylene resin foam board 2 is extrusion molded into a plate shape, and has an interconnected cell ratio of 50% or higher and a foaming extent of 10- to 50-fold. A plurality of polypropylene resin foam boards 2, 2 are joined to each other by the hot plate welding method or the laser transmission welding method, whereby a large-size core member of vehicle interior finishing laminate sheet 1, which is used for a roof lining or the like, can be formed.

Abstract: A tie foundation (1) for a railway tie (2) having at least a first elastic, preferably elastomer layer (3) and at least a second elastic, preferably elastomer layer (4), with a reinforcement layer (5) being embedded between the first elastic layer (3) and the second elastic layer (4), with the second elastic layer (4) forming an outer surface (6) of the tie foundation (1) and the reinforcement layer (5) comprising a fibrous material.

Abstract: Foamed, aqueous adhesive compositions are used to manufacture tissue laminate products including or especially as bathroom tissue, facial tissue, paper towels, and the like. Foaming typically occurs by introducing pressurized gas and adhesive flows in a nozzle chamber on demand, wherein the kinetic energy of the flows is used to provide mixing energy. The adhesive preferably is dispensed as a plurality of discrete, foamed adhesive particles. The foamed adhesive can be used for intralamina bonds, interlaminate bonds, bonding loose sheet extremities, bonding roll to roll, and the like. The invention provides a reliable, straightforward way to accomplish in-nozzle foaming of an adhesive.

Abstract: In some embodiment, a method of manufacturing an automobile floor carpet comprises a step of pressing a nonwoven fabric 4, an adhesive film 3 obtained immediately after extruding thermoplastic resin having a melt flow rate of 10 to 1,000 g/10 min from an extruder 20, and a surface skin material 2 piled together in this order with a pair of rollers 21 and 22. With this manufacturing method, an automobile floor carpet excellent in sound absorption performance and also excellent in sound insulation performance can be manufactured.

Abstract: A method for making a composite panel, wherein the composite panel has a honeycomb core sandwiched between a pair of facing sheets, includes the steps of (a) coating the interior walls of the cells with a unexpanded thermo-expandable material; (b) bonding a pair of facing sheets to the opposite sides of the honeycomb core; and (c) heating the honeycomb core while the honeycomb core is sandwiched between the pair of facing sheets with sufficient heat to cause the thermo-expandable material to expand and to substantially fill the cells.

Abstract: An electronic cover for a passport, booklet or the like includes an electronic device and a layer of cover material that are bonded together by a fill-up adhesive layer, the electronic device preferably being in the form of an RFID inlay that includes a substrate, an antenna coupled to the substrate and an integrated circuit (IC) chip module conductively coupled to the antenna. During manufacture of the cover, the fill-up adhesive layer is applied to at least one of the electronic device and the layer of cover material. Immediately thereafter, the electronic device and the layer of cover material are held spaced apart from one another a predefined distance so as to define a void therebetween. Through a suitable trigger, the fill-up adhesive layer expands to fill in the entire void and subsequently cures to bond the electronic device to the layer of cover material.

Abstract: A light weight flexible hand grip and method of making with a single piece precursor grip member having a tubular sleeve portion connected with a tubular grip portion with a wall situated therebetween. An alternate embodiment includes the tubular grip portion attached proximate an open end of the tubular sleeve portion. A core portion is disposed on an outer surface of the tubular sleeve portion and the tubular grip portion is positioned back over the tubular sleeve portion securing the core portion within an annular cavity to form the light weight hand grip.

Abstract: Composite laminated article having: a first layer of a closed cell foam of a thermoplastic material, a second layer of a fibre-reinforced resin, the resin adhering a surface of the second layer to a surface of the first layer, wherein the closed cell foam has an average cell size of from 15 to 75 microns.

Abstract: The present invention is directed to a treadmill belt with foamed cushion layer and method of making same. In one embodiment, the treadmill belt includes a fabric base layer and a foamed cushion layer foamed on and integral with the fabric base layer. The foamed cushion layer includes a thermoplastic composition and has a Shore A hardness of about 20 to about 80. In one example, the first foamed cushion layer is from about 0.05 inches to about 0.35 inches thick. The thermoplastic composition, prior to being foamed, includes about 1 part to about 5 parts of a foaming agent, e.g., a chemical foaming agent, based on 100 parts thermoplastic material, e.g., polyvinyl chloride. An outer wear layer is securely adhered on the foamed cushion layer to sandwich the foamed cushion layer between the fabric base layer and outer wear layer thereby defining the treadmill belt.