Abstract: A graphitizable carbon foam having enhanced directional thermal conductivity is provided. The mesophase portions of a mesophase pitch are aligned with each other to create an oriented mesophase pitch, which is then foamed to provide an oriented pitch foam. The pitch foam can be heated to carbonize the pitch thereby forming an oriented carbon foam. The carbon foam can be further heated to provide an oriented graphite foam.

Abstract: The invention relates to a process to foam a water-base adhesive wherein a gas is dissolved or generated under pressure in the water phase essentially without the formation of foam. To apply the adhesive in the form of foam, the pressurized adhesive is released through a valve onto a substrate at atmospheric pressure, whereby the dissolved gas separates as gas bubbles. The invention relates further to an apparatus for the implementation of said process comprising a pressure-tight container for the adhesive wherein an overpressure is provided through a first valve, and at the outlet of said container a drain valve is placed. The apparatus further comprises a pressure-tight acid vessel for the acid which is furnished with a second valve at its inlet The outlet of said vessel is connected through a third valve to the container.

Abstract: A machine for forming foam cushions comprises a web of film comprising a pair of film panels positioned face to face and having first and second lengthwise edges, and first and second foam dispensing assemblies positioned to dispense foam between the film panels, each foam dispensing assembly comprising first and second valves that dispense first and second foam components, respectively, the valves positioned so that respective foam component streams exiting the valves intersect.

Abstract: A composite component comprising at least one first and one second sheet metal plate with at least one layer of a polymer arranged between the first and the second sheet metal plates provides for a component optimized with respect to the weight thereof, and which is at the same time simple to manufacture. The polymer layer of the composite component according to the invention comprises at least one foamed polymer layer of a thermoplastic polymer, wherein the foamed polymer layer comprises gas bubbles with a volume percentage of 1% to 80%, in particular 5% to 70%.

Abstract: The invention concerns a compressible plate for flexographic printing, designed to be positioned on a support cylinder of a printing machine. The invention is characterized in that said plate (1) comprises a photopolymer layer (10) and a compressible layer (11) made of a material exhibiting voids forming between 10 and 60% by volume of said compressible layer, the material comprising at least 70% by weight of a polymer or a mixture of polymers chemically compatible with the photopolymer.

Abstract: A method for making antimicrobial rebonded carpet pad includes mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate, blending the antimicrobial polyol mixture concentrate with a binder stream, mixing the binder with foam particles and curing the binder. The percentage of zinc pyrithione mixed with the polyol and the addition ratio of the antimicrobial polyol mixture concentrate with the binder stream are selected to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm. The particles and binder are cured into a block and sliced to form carpet pad.

Abstract: The present invention describe a process and an installation for the production of stiff recyclable sandwich-type polymeric panels, preferably polypropylene-based panels, and the panel obtained, comprising three lines, in one of which a polymeric polypropylene-based foamed core is produced by extrusion (line A); the structural skins are produced in a second line (line B), which skins are formed by a polypropylene-based lamina reinforced with wood fiber, on which lamina there is applied an also polypropylene-based surface coating layer reinforced with glass fibers; in the third line the structural skins produced in line B are adhered by heat and pressure to the foamed core produced in line A. The sandwich panel produced has a thickness between 7 and 40 mm, an overall density of 400-700 kg/m3 and an elastic modulus of 5-10 GPa.

Abstract: The present invention provides a vacuum thermoforming process-combined secondary molding method for expandable polypropylene, the method comprises the steps of silk screen printing on a blister sheet, vacuum thermoforming of the blister sheet to provide a thermoforming part, foam molding of expandable polypropylene to provide a EPP foam part, spray coating the surface of the EPP foam part with ink, and integrate molding of the EPP foam part and the thermoforming part. The expandable polypropylene blister product produced by this method exhibits good impact resistance and possesses good appearance.

Abstract: A foam is disclosed that can be cured by heat having, for example, 10 to 80 vol. % of at least one gas and a compound that can be cured by heat. The foam can include at least one polyurethane polymer and at least one curing agent that can be activated by increased temperature. Foams that can be cured are suitable as flues, sealing compounds, or for the production of coatings, and can be cured by heat for structural adhesive bonds and for lining in vehicle construction.

Abstract: A multi-purpose boat has a two angle V hull with a rounded fore-aft profile and slightly convex deck. The hull has steeply angled edge portions and shallowly angled center portions. The edge portions are sufficiently sloped away from vertical to allow the boat to be lifted and not pushed by waves. The rounded fore-aft profile allows the boat to slide over waves, especially during a beach entry. The boat includes a keel having a horizontal base and separating downward from the hull at the fore and aft of the boat to resist yawing. The dry weight of the boat is about 25 pounds with a foam core with a resin coating and the keel is preferably hollow and includes ports to allow water to enter the keel to add about 25 pounds after entering the water. Approximately four inches of freeboard is provided separating riders from cold water and predators.

Abstract: A method of making a composite article includes providing an elastomeric composition with a blowing agent having an activation temperature and providing at least one structural member defining a fixed gap. The composition is formed below the blowing agent's activation temperature into a solid elastomeric member approximately the thickness of or larger than the gap. The elastomeric member is assembled into the gap, which may place the elastomeric member in a state of compression in the gap. The elastomeric member is then expanded by heating it above the activation temperature. During expansion, the escape of the gas produced is limited to increase the state of compression of the elastomer in the gap by means of confining any free surfaces or by including a platy filler such as nanoclay in the composition.

Abstract: A roofing panel, a roof, an array of roofing panels, and a method of manufacturing a roofing panel by transporting a capstock layer of the roofing panel through a moving belt mold, and forming a polymeric material in situ against the outer layer while in a mold cavity of the moving belt mold. The capstock layer is vacuum formed to shape and form a plurality of roofing shingles and to impress the shingles with surface topography features simulating natural materials.

Abstract: A nozzle assembly for conveying a flow of particles of insulation material suspended in air to a substrate to form an insulation product on the substrate is provided, including: a nozzle body defining a flow path for accommodating the flow of particles of insulation material suspended in air, wherein the nozzle body comprises an inlet for receiving the flow of particles of insulation material suspended in air; an outlet for propelling the flow from the nozzle assembly; and at least one expansion section in which the cross-sectional area of the nozzle body expands in the direction of flow, the at least one expansion section being effective to reduce the velocity of the particles flowing therethrough; and at least one binder outlet for providing a binder to the flow of particles of insulation material propelled from the outlet.

Abstract: A process for manufacturing a foamed laminar product in which the foam is obtained from thermoplastic material and additives. In order to improve the rigidity of the foamed laminar product, reinforcement fiber is added to a mixture of thermoplastic material and additives, so that the reinforcement fiber forms an integral part of the foamed laminate.

Abstract: A composite product is formed from a honeycomb panel having an array of hexagonal tubular cells which clamped between two press plates where a layer of a foaming agent is applied to only the bottom press plate such that the foaming agent expands into the cells. An array of grooves is provided in the top press plate and connected at one or both edges of the plate to a source of vacuum so as to draw air through the grooves and cells. A sheet of a polyethylene material having the characteristics that it is permeable to air, substantially impermeable to liquid and resistant to bonding to the foam is applied onto the press plate to prevent the foam entering the grooves and bonding to the press plate while allowing the air to be drawn from the cells.

Abstract: A foamed layer-laminated film or sheet having a foamed layer of a thermoplastic resin laminated on a base material such as a paper or PET, and is useful as a material for producing formed articles such as paper containers, aluminum foil containers, packing films and sheets for containing high-temperature foods, beverages and the like owing to its enhanced heat-insulating property. The foamed layer has innumerable fine elongated foamed cells, and local shades of distribution density of the cells create an appearance of vertical striped patterns on a frosted-glass-like translucent background lending the laminated film or sheet well for use as a material for ornamental articles. The invention further provides a process for easily producing the film or sheet maintaining good productivity at a low cost.

Abstract: The invention relates to a method for producing a sandwich panel, comprising the steps: providing an upper cover layer, providing a lower cover layer, providing an intermediate layer disposed between the upper and lower cover layers, compacting the upper and lower cover layers; foaming the intermediate layer, with no foaming of the intermediate layer occurring when compacting of the upper and lower cover layers begins.

Abstract: Continuous treadmill belt comprising a continuous first foamed layer (11, 12, 13, 14, 15, 16, 17, 18) made of thermoplastic foamed material, with an upper side (25, 26) and an under side (34, 35, 36), wherein a first pulling body (41, 42, 43, 44, 46, 47, 48) is arranged on the under side (34, 35, 36) and comprises a first textile layer and a pulling body under side (54, 56, 58), and wherein no layer is arranged between the continuous foamed first layer (11, 12, 13, 14, 15, 16, 17, 18) and the first pulling body (41, 42, 43, 44, 46, 47, 48), which hinders a local shearing displacement of the first pulling body (41, 42, 43, 44, 46, 47, 48) parallel to the under side (34, 35, 36) or stiffens said pulling body.

Abstract: A one-way vision film includes a white film base material; a shrinkable color tone layer on one side of the base material; and a self-adsorptive foamed layer on the base material opposite to the shrinkable color tone layer. The one-way vision film is perforated with through-holes. The self-adsorptive foamed layer has an adhesive function attachable to a surface onto which the film is attached and is printable. Since the printing ink is deposited to the bottoms of the open pores while not closing the openings of the open pores, open pores exposed to the surface of the foamed layer function like suction cups adhering onto a smooth surface. Accordingly, there is no need for forming ink-receptive and pressure-sensitive layers, unlike a conventional film, so the film can have a low cost, three-layer structure. The one-way vision and printed film is easily attachable onto a smooth and transparent substrate like glass.

Abstract: A carpet backing prepared from a polyurethane forming composition which comprises: (A) a polyisocyanate and (B) a mixture of a vegetable oil, a cross-linking agent, and a blowing agent.

Abstract: A method for preparing carpet by using polyurethane to anneal secondary backing to a greige, comprising fibers attached to a primary backing. The polyurethane monomers are mixed just prior to application to the greige primary backing allowing the relatively low viscosity polyurethane to penetrate the fibers of the primary backing to aid in fiber lock. The polyurethane is puddle between two rollers that coat a layer of polyurethane onto the greige. The polyurethane coated greige is then contacted with the secondary backing before complete polymerization to insure sufficient tack to hold the backings together resulting in a durable carpet requiring a relatively low weight of polyurethane monomers.

Abstract: A thermoplastic foil has an embossed three-dimensionally structured surface (2) in the external cover layer. The cover layer is configured as a foamed layer and has a foam density that varies across the layer thickness thereof and increases toward the surface.

Abstract: A foam product embedded with an accessory and a method of making the same are disclosed. The foam product includes a foam body, the accessory and an adhesive member. The foam body is composed of a plurality of expanded foam beads bonded with one another. The accessory is fully or partly embedded in the foam body. The adhesive member is interposed between the foam body and the accessory. In particular, the adhesive member has branches-penetrating into gaps among the expanded foam beads that surround the accessory.

Abstract: A fabric mold liner includes a flexible fabric substrate and bounded regions of cured binder encapsulating fibers of the fabric substrate and carrying magnetically attractable particles. A liquid containing ferrous particles in suspension in a binder is deposited on the substrate in discrete, selected regions arranged to correspond to magnetic liner retention points in a mold cavity. The mold liner is used in molding a foam article. The liner is inserted into a mold cavity with the liner positioned such that the bounded regions carrying the binder align with magnetic liner retention points of internal surface. A foamable resin is introduced into the mold and is caused to expand to fill the mold cavity and cover an exposed surface of the liner, such that the liner becomes bonded to, and becomes a part of, a foam body formed by the resin.

Abstract: A wound dressing comprising a backing layer and an absorbent layer, wherein the absorbent layer comprises a wound facing surface and a non-wound facing surface, said absorbent layer comprises discrete foam pads covering at least 50% of the wound facing surface of the absorbent layer and wherein the non-wound facing surface of the foam pads are attached to the backing layer. The structure of the dressing renders it possible for the foam to expand during wetting without changing the external dimensions of the absorbent layer substantially.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: Disclosed are various embodiments of a structural reinforcement system. The system reinforces hollow cavities within various products to increase the structural rigidity of the product. The system generally includes a rigid carrier, an expandable material, and an adhesive. The expandable material and the adhesive are placed within the carrier such that when the expandable material expands, the adhesive moves to be positioned to bond the rigid carrier to the cavity walls.

Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell Index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, beat or electrical insulator etc.

Abstract: A sandwich panel includes a honeycomb core of a plurality of cells. A first skin is adhered to a first surface of the honeycomb core with an adhesive. A second skin is adhered to a second surface of the honeycomb core with the adhesive. The plurality of cells extend longitudinally between the first and second skins. The first and second skins adhere to the honeycomb core to form a sandwich panel having a surface area of at least 2.25 square feet. A foam fill is disposed within the cells of the honeycomb core. The foam fill and the honeycomb core define a first gap region proximate to the first skin and a second gap region proximate to the second skin.

Abstract: An ignition composition effective to form a porous igniter substance capable of adhering to an associated inflator apparatus surface for use in an automotive inflatable restraint system and a method for preparing a porous igniter coating formed from the ignition composition are provided. The ignition composition includes a fuel, an oxidizer, a polymeric binder and a blowing agent effective, upon decomposition, to increase the surface area of the porous igniter substance. The porous igniter substance or coating is formed by heating the ignition composition to a predetermined temperature.

Abstract: A non-mutually-adhesive pellet, process for producing non-mutually-adhesive pellet, and process for producing rubber molding are provided. The non-mutually-adhesive pellet comprises a core containing a rubber composition comprising a rubber, reinforcement and softener and a coating layer which contains a thermoplastic polymer and with which the core is coated, wherein the thermoplastic polymer has the crystal melting peak temperature as measured by a DSC measuring method including the specified procedures and the Vicat softening temperature as measured in accordance with JIS K7206 at a load of 10 N and a heating rate of 50° C./h is over 40° C.

Abstract: An insulating panel comprises sheets (1, 2) with a body (3) of insulating foam between the sheets. The insulating material has a vacuum insulated panel (4) embedded therein. The panel is substantially thinner than corresponding panels without a vacuum insulated panel (4).

Abstract: A method of fabricating a door for a cover of a transport refrigeration unit includes the steps of forming first and second sheets of plastic material, forming a core member of foam material, assembling the core member of foam material between the first and second sheets of plastic material, and bonding the respective peripheral edges of the first and second plastic sheets together. A transport refrigeration unit has a front cover that includes a pair of front doors of composite structure. Each door is formed of an inner sheet and an outer sheet of plastic material bonded together at their respective peripheral edges about a core of preformed foam material between said first and second sheets.

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: Methods and apparatuses for making improved carpet are disclosed comprising the use of plasma discharge units to treat carpet backing surfaces to improve the adhesion of carpet backing layers, the adhesion of carpet backing to the carpet segments and to improve the adhesion of the exterior of the carpet backing to surfaces to which the carpet is applied.

Abstract: There is described a member for baffling, reinforcement or sealing. Typically, the member includes an internal portion and external portion wherein at least one, but typically both the internal and external portions include an activatable (e.g., expandable) material.

Abstract: Methods and systems for modularly constructed panels are described. A panel is formed by stacking and attaching together multiple layers of one or more materials. A layer of a panel may be formed completely of a single material, such as a polymer material, or of a combination of materials. One or more layers of a panel may include one or more nanomaterials.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: An adhesive material and articles incorporating the same is disclosed. The adhesive material includes at least three of epoxy resin; impact modifier; flexibilizer, blowing agent; curing agent; and filler. The adhesive material is preferably used for structural adhesion but may be used for sealing, baffling or reinforcing an article of manufacture such as an automotive vehicle.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: A concrete mixing includes a barrel having an interior surface and an exterior surface. A blade extends from the interior surface for mixing concrete and a ring is positioned about the exterior surface of the barrel for rotation of the barrel. An expandable joint is provided under compression between the ring and the exterior surface of the barrel to accommodate different thermal coefficients of expansion between the barrel and the ring.

Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.

Abstract: The height and width of a sheet-like filler material before it is placed in a cell of ahoneycomb material is set greater than those of the honeycomb material, and after the placement, peripheral edges of the honeycomb material are fringed with filler materials to prevent a filler material from falling out of an end section cell. A liquid adhesive agent is applied to the top of cell walls facing one surface of the honeycomb material, and a surface material is pressed to that surface of the honeycomb material to which the adhesive agent is applied. Then, before the adhesive agent hardens, water-absorbing foam materials are placed in cell spaces by pressing them into the cell spaces rom the other surface of the honeycomb material until they are in contact with the adhesive agent. The foam material is quickly adhered to the honeycomb material.

Abstract: A nozzle assembly for conveying a flow of particles of insulation material suspended in air to a substrate to form an insulation product on the substrate is provided, including: a nozzle body defining a flow path for accommodating the flow of particles of insulation material suspended in air, wherein the nozzle body comprises an inlet for receiving the flow of particles of insulation material suspended in air; an outlet for propelling the flow from the nozzle assembly; and at least one expansion section in which the cross-sectional area of the nozzle body expands in the direction of flow, the at least one expansion section being effective to reduce the velocity of the particles flowing therethrough; and at least one binder outlet for providing a binder to the flow of particles of insulation material propelled from the outlet.

Abstract: A method of manufacturing a blank for a floatation device is disclosed. Polystyrene material is introduced into an extruder and heated. The molten polystyrene is then blown with carbon dioxide to form a polystyrene foam that is extruded into a sizing tunnel to create a desired cross-section for a floatation device blank. The carbon dioxide pressure is preset to provide a resulting polystyrene foam having desired rigidity and density characteristics, and other softening agents may be used to achieve desired rigidity and density characteristics. The extruded polystyrene foam is then cut into blocks of predetermined length, which are then cut and shaped into a desired floatation device blank that may be finished as with conventional blanks.

Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of starting materials, thermal treatment conditions and mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold.

Abstract: The invention relates to a process for the production of sandwich elements (so-called panels), in which the rising reactive mixture is guided, when it rises, through guide elements arranged between the upper and lower outer layers. This process produces void-free panels having a regular cell structure. The invention also relates to an apparatus useful for the production of such sandwich elements.

Abstract: An apparatus and a continuous process produce composite structural insulated panels (SIPs). Lower boards are placed on a conveying system through a foam application zone and then upper boards are applied. The foam material adheres to the upper and lower boards to form a structural insulated panel after passing through a curing apparatus.

Abstract: A composite carpet cushion incorporating a film layer, a foam layer and a fiber layer and a process of forming the composite carpet cushion. The film layer of the composite carpet cushion is a polyethylene film having a lateral dimension in the range of about 0.4 to 3 millimeters. The foam layer is urethane in an amount ranging from about 20 to 90 grams per square foot of the composite carpet cushion. The fiber layer is comprised of natural or synthetic fibers or a combination thereof having a lateral dimension in the range of about 1/16 to 7/16 inches. The process of forming a composite carpet cushion comprises applying an uncured urethane foam mixture uniformly on a polyethylene film layer. The combination foam and film layer is applied to a fiber layer which is proximate the foam layer. The composite layers are moved through a heated press which compresses the layers and causes the foam layer to react and cure to form a bond with the fiber layer and the film layer.

Abstract: The invention relates to a coating for insulation material, which coating comprises a metal layer, such as an aluminum layer, and a plastic layer. The plastic layer contains plastic that crystallizes when heated. The plastic can more particularly be a polyamide.