Abstract: A manufacturing method for a synthetic leather includes a first step of feeding materials of preset volume, a second step of materials foaming (capable to be skipped if unnecessary), a third step of material and mixing injecting to produce liquid mixed materials by instant reaction, a fourth step of conveying two basic cloths, a fifth step of compressing the two basic cloths with the liquid mixed materials producing reaction between the two basic cloths conveyed to an upper portion of two rollers to produce synthetic leather, and a sixth step of winding finished synthetic leather on two winding wheels.

Abstract: Sound attenuating laminates for use within vehicles are provided that include a substrate and polyurethane attached to selected portions of the substrate. The polyurethane is non-porous and serves as a barrier to attenuate sound passing through the substrate. Additional non-porous polyurethane may be added to one or more selected portions of the polyurethane layer to enhance sound attenuation characteristics in the one or more selected portions. Sound attenuating laminates for use within vehicles are provided that include a substrate and breathable polyurethane attached to selected portions of the substrate. The polyurethane serves as an absorber of sound (e.g., sound generated within a vehicle compartment). Additional breathable polyurethane may be added to one or more selected portions of the polyurethane layer to enhance sound absorption characteristics in the one or more selected portions.

Abstract: Adhesives for bonding paper facings to aerated concrete provide increased manufacturing efficiencies and long term stability of constructs prepared therewith. Adhesives may advantageously be used in the foamed state.

Abstract: A blow molding part with a decorative coating is produced in a three-stage process. The blow molding part is initially produced without a coating in a blow mold tool cavity, and is then molded against the decorative coating material in a second blow-molding operation under low pressure and at a low temperature in a decorative coating cavity. The decorative coating material is heated up if appropriate and is placed in advance against a mold contour. The blow mold tool includes a middle part, which is provided between two movable side parts and can be moved or pivoted out. Mold contours of the middle part form with the mold contours of the side parts the blow mold tool cavity and the decorative coating cavity. The blow mold tool cavity has holding devices for the blow molding part. The decorative coating cavity has suction openings and heating elements for molding the decorative coating material and heating it up.

Abstract: A self-adhesive reinforced foam gasket comprising a release liner having an upper surface which is a release surface, a layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film, preferably polyester film, applied to the pressure sensitive adhesive layer, and a layer of flexible foam, preferably closed cell PVC flexible foam, thermally bonded to the flexible polymeric film layer. A length of material for die-cutting the gasket therefrom is provided, along with a method of making the length of material. The gasket may be used in automobiles and other applications.

Abstract: A method of manufacturing an airbag cover is set forth in which at least one recess is formed in the inner side of the cover layer at the location of the tear-open position and is substantially sealingly closed by a cover film, with foam material being applied onto the cover layer and onto the cover film.

Abstract: Flexible polyurethane, polyacrylic and polybutadiene foams can be obtained with cyclopentane as a blowing agent and are useful as coatings for leather or leather substitutes.

Abstract: A thermoplastic polyester resin is fed into a twin extruder, wherein a resin is heated for melting, thereby removing moisture in the resin by evacuating and sucking from a vent port thereof, injecting a foaming agent into the resin to which is pushed out as a foaming sheet and, after that, forming the foaming sheet which is divided into a forming body and a trimming loss, whereby the trimming loss is crushed to obtain crushed materials which are provided so as to put the materials into the twin extruder as collection materials and recycle them.

Abstract: A method for manufacturing a preservation mat board for use in framing a picture frame. The mat board includes a top facing layer and/or backing layer, each comprising a buffer and/or deacidifying agent, adhered to a middle board or layer by an adhesive containing zeolites. Another embodiment discloses mixing polystyrene pellets with zeolite using an extruder and one or more blowing agents to form a foam material. One or more paper layers comprising a buffer and/or deacidifying agent are heat-fused, without the use of adhesives, to the surface of the foam to form a preservation mat board.

Abstract: An elastomer film laminated cushion includes an elastomer having the physical properties of flexibility and compressibilities in the range of flexibilities and compressibilities of stable elastomer block polymer gels. A film is provided for encapsulating the elastomer with the film having physical properties of flexibility to enable uninhibited flexure compression of the elastomer by a user. A compatibilizing layer is provided for laminating the film to an exterior of the elastomer. The compatibilizing layer also has physical properties of flexibility to enable uninhibited flexure and compression of the elastomer by the user.

Abstract: The present invention relates to an interior automotive trim member comprising a backing substrate, a layer of elastomeric material bonded to and overlying the backing substrate, and a soft skin formed of polyolefinic material. The soft skin is bonded to and overlies the layer of elastomeric material. The soft skin is cured by electron beam curing. The present invention also relates to a method of making a soft skin for use with an interior automotive trim member comprising a backing substrate, a layer of elastomeric material bonded to and overlying the backing substrate, and the soft skin bonded to and overlying the layer of elastomeric material. The method comprises providing a polyolefinic material, and exposing the polyolefinic material to electron beam radiation to cure the polyolefinic material.

Abstract: A pressure sensitive adhesive consisting of a polyurethane foam is used for adhering decorative parts to automobiles and other vehicles. The adhesive is characterized by high tensile strength and elongation, excellent peel strength and good thermal and mechanical stress tolerance.

Abstract: A foamed resin adhesive and its use for glueing wood based panels and boards such as plywood. The adhesive comprises 40-80% of an aqueous resin solution, 2-10% of an organic filler or fillers, 1-10% of a cationic acrylamide copolymer, and 0.05-1% of a surface active agent.

Abstract: A sprayable polymeric material and a process for preparing the material which contains a fibrous material, dispersed throughout the polymeric material. A restriction free spray nozzle is provided for mixing and spraying the polymeric material having a fibrous material, the nozzle having a restriction free check valve. A reinforced structure, and a method of making the structure are provided, the structure having layers of the polymeric material (both film and foam) containing the fibrous material. A flexible liner is provided of a porous geotextile fabric and a polyurethane composition comprising the fibrous material sprayed over the geotextile fabric.

Abstract: A wall panel structure for controlling humidity within a building having a panel assembly attachable to an inner wall surface of the building including: a first panel having a surface with a first predetermined porosity to moisture; and a second panel secured to said first panel with a space for accomodating airflow between the first and second panels, the second panel having a surface with a second predetermined porosity to moisture, the first perdetermined panel porosity being greater than the second predetermined porosity to thereby absorb moisture from air being circulated between the first and second panels; whereby humidity of an environment within the building is controllable.

Abstract: A composite polyurethane foam structure and method of preparing the composite structure, which structure includes a semirigid-rigid polyurethane foam layer having bonded, free, unreacted, ethylenically unsaturated groups like allyl or acrylic groups. The structure includes a cured, unsaturated resin composition layer which is chemically bonded to one or both surfaces of the polyurethane foam layer through the polymerization of the allyl or acrylic group in the foam surface with the polyester resin composition.

Abstract: The present invention concerns foamed products having a plurality of coalesced extruded layers or layers of coalesced strands of a foamed thermoplastic composition having a low density.

Abstract: A method for manufacturing a carpet used for an automobile comprises steps of: coating a preheated liquid foamable mixture directly on a back surface of the surface material by a spray system; placing the surface material in a molding die comprising an upper portion and a lower portion, the upper and lower portions defining a space inside the die corresponding to a three dimensional shape of the carpet; clamping the liquid foamable mixture with the surface material between those portions of the molding die, when the liquid foamable mixture coated on the back surface of the surface material has completed a gas reaction thereof but is still in a visco-elastic flowing condition; and changing the liquid foamable mixture into a solid condition, thereby a foamed body layer made of the liquid foamable mixture is molded in three dimension and is connected with the surface material through the back surface thereof.

Abstract: A method and an industrial robotic device for uniformly applying coatings at appropriate thickness and pitch upon a surface moves a spray applicator foam dispenser between two parallel tracks. The uniform application of foam at each pass is assured, by accelerating the speed of the foam dispenser at the end of each pass, by providing respective curved uphill distal ends of the tracks, so that the spray applicator foam dispenser moves up the curved distal ends and returns quickly while changing speed tilt and direction at the end of each pass.

Abstract: Methods for making decorative grasses from materials wherein at least one surface of the material is modified to assimilate the appearance of cloth.

Abstract: A composite material consists essentially of a particle foam comprising expanded polypropylene (EPP), at least one fiber layer and at least one polymer introduced onto this layer. An intimate connection is secured in that the fiber layer is a mixed fiber layer comprising a fraction of fibers made from polypropylene (PP) which are welded to the EPP particles and with an additional fraction of reinforcing fibers which have a sufficient wetability for the hardening, curing or cross-linking polymer introduced onto the free surface of the fiber layer in the liquid phase. A method for producing these composite materials is also described.

Abstract: An apparatus for the continuous production of expanded plastic panels with inserts on their longitudinal edges, comprising a head for pouring a reactive mixture between a first and a second containment layers in order to obtain a foamed layer, a containment and advancement assembly for the layers being constituted by a lower slat conveyor and by an upper slat conveyor. The lower slat conveyor has lateral containment blocks at the ends of its slats. At least some of the blocks are provided thereon with the inserts to be incorporated in the foamed layer, for picking and placing the inserts on the engaging elements provided in the apparatus.

Abstract: Article of manufacture comprising (i) a sheet of a foamed mixture of starch and at least one of, a polyhydroxy ether, a poly(hydroxy amino ether), a poly(hydroxy ether sulfonamide), a poly(hydroxy ether sulfide), a poly(hydroxy amide ether), or polyvinyl alcohol and (ii) a barrier layer. Specifically, a beverage cup or ice chest with foamed starch/polymer core layer.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: A composite structure generally includes a polyolefin foam sheet and a film in adherence with the foam sheet. The film includes a blend of polyethylene and a thermoplastic elastomer. The elastomer includes a copolymer or terpolymer having a styrenic component and a rubbery component, the rubbery component having at least one carbon-carbon double bond. The rubbery component makes up at least about 70 wt. % of the thermoplastic elastomer. The resultant composite structure has a coefficient of friction ranging from about 0.5 to about 2.0, as measured at the upper surface of the film.

Abstract: A door and method for fabrication of unitary six panel steel doors wherein frames members (stiles and rails or headers) are fabricated by forming metal stock into a cross-sectional channel configuration, cutting and swaging the channels into predetermined lengths. The stiles and rails of the frame members are swaged to provide frictional interconnection at the corners thereof upon assembly of the frame members (stiles and rails) into a rectangular frame configuration. Assembly of the frame is accomplished in a shuttle having two assembly jigs. Upon assembly, each frame is moved by the shuttle into a molding press wherein a panel of foam is molded within the frame. The shuttle moves back and forth through the molding press in a manner which provides for removal of a completed panel and assembly of an additional frame from one jig of the shuttle while the molding operation is accomplished within the molding press upon a frame retained within the other jig of the shuttle.

Abstract: A flexible, metallized, polyurethane foam has, incorporated therein, particles selected from copper and copper oxide in an amount, based on metallic copper, of at least 1% by weight of the total weight of the metallized foam. The copper can be incorporated into the foam by (a) mixing the particles with a polyol and reacting the polyol with a polyisocyanate in the presence of a foaming agent to form the flexible polyurethane foam, whereby the particles are incorporated in-situ within the foam; or (b) forming a slurry of the particles in a polymer latex medium and treating the foam with the said slurry to allow impregnation of the particles into the foam. An article for alleviation of discomfort from an ailment associated with a joint, limb or muscle contains the flexible polyurethane foam covered by a fabric.

Abstract: The invention thus provides a method of making a foam-filled composite matrix having a cellular core, and the composite matrix of the method, e.g. for use as sacrificial energy absorbing structures particularly for the passenger compartments of vehicles, e.g. motor vehicles. Thus the structures may be used in head linings in automobiles and as linings and even seats in vehicles such as aircraft. Additionally the structures may form crash padding in crash helmets and body armour.

Abstract: A method and an industrial robotic device for uniformly applying coatings at appropriate thickness and pitch upon a surface moves a spray applicator foam dispenser between two parallel tracks. The uniform application of foam at each pass is assured, by accelerating the speed of the foam dispenser at the end of each pass, by providing respective curved uphill distal ends of the tracks, so that the spray applicator foam dispenser moves up the curved distal ends and returns quickly while changing speed tilt and direction at the end of each pass.

Abstract: The present invention concerns foamed products having a plurality of coalesced extruded layers or layers of coalesced strands of a foamed thermoplastic composition having a low density.

Abstract: To provide a decorative sheet which has a three-dimensional decorative effect and, in addition, is free from separation of a decorated area upon being exposed to abrasion or impact conditions. A decorative sheet comprising: a substrate (1) formed of a transparent resin composition; and, laminated thereon in the following order, a color layer (2), an expandable layer (3), and a pressure-sensitive adhesive layer (5).

Abstract: A process for the manufacturing of floor elements, which floor elements comprise an upper decorative surface and a lower surface, edges intended for joining and a core forming a carrying structure. A mixture of polyols, such as polyester or polyether, crude methylene diphenyl diisocyanate and possibly a small amount of blowing agent in a ratio forming a polymeric resin with a density in the range 600-1400 kg/m3 is injected or cast into a mold, whereby a slightly porous or solid polyurethane core is formed.

Abstract: A process for producing carbon foam or a composite is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: A floor, wall, roof, or ceiling of a building is made of specially adapted beams and overlying panels. The beams have a layer of foam material on their edges. The foam material can include a resiliently compressible material, a thermally insulating material, or a material which possesses both of these properties. The panels are positioned over the beams so that the foam material is sandwiched between the beams and the panels. When the panels are fastened to the beams, the resiliently compressible foam material partially compresses, thereby filling any gaps which may form between the beams and the panels. The resiliently compressible foam material thus prevents relative movement between the panel and the beams which would otherwise produce squeaks. When the foam material includes thermal insulating material, it forms a thermal barrier between panels and beams, especially metal beams, thereby eliminating various drawbacks of construction using metal beams.

Abstract: A process for producing a composite structural element, which includes the steps of providing a thin-section wall part, placing the thin-section wall part into a mold, applying reinforcing elements to the thin-section wall part, placing a counter-mold onto the mold for forming a mold cavity, and introducing a binder having a foaming agent into said mold cavity via one of injection cannulas and nozzles, after a set time delay a foaming of the binder occurring for encapsulating the reinforcing elements on all sides.

Abstract: A method and several exemplary apparatus for capillary dewatering of foam materials. The apparatus may include felt which is applied to an exposed face of the foam material, or a double felt arrangement applied to two opposed surfaces of the foam material. The apparatus may provide a temperature differential between the two exposed surfaces of the foam material. An alternative embodiment utilizes a roll having a capillary dewatering medium. The capillary dewatering medium may be maintained at a vacuum either above or below the breakthrough vacuum of the capillaries. The disclosed apparatus and method is particularly useful for dewatering foams having relatively fine open capillaries.

Abstract: The present invention relates to a method of applying adhesive to corrugating media to produce corrugated materials by foaming the adhesive with air prior to application to the flute tips of the corrugating media. The foamed adhesive requires less precise control of the applicator rollers, and remains in place on the flute tips, rather than migrating into the flute valleys. As a result, the same volume of adhesive can be used with decreased solids content, decreasing overall adhesive cost and increasing corrugator productivity. In addition, because of the more precise placement of the adhesive on the tips of the flutes, a stronger, higher quality board can be produced. The adhesive can be starch-based, and can be foamed by a variety of methods, such as in existing pin-rotor stator containing foaming machine used for foaming latices.

Abstract: A method of manufacturing a conveyor belt having an elongate body made of uncured rubber and/or synthetic rubber. A polymeric parting material is placed adjacent to the upper and lower surfaces of the body, and heated platens are applied to the upper and lower surfaces of the body (i.e. belt material) to soften the adjacent upper and lower layer portions of the belt. This causes the softened belt material to flow into interstitial openings in the parting material. The resulting belt has the parting material squeezed into a thinner layer and embedded in the adjacent surface portions of the body of the belt. This provides a substantially uniform and reflectively soft texture surface.

Abstract: The present invention relates to a method for producing a thermoplastic material for immobilization and/or protection of a part of the body. The method includes the steps of (1) admixing a thermoplastic material with at least one foaming agent and (2) extruding the admixture at a temperature sufficient to expand the foaming agent and for a specified resident time interval.

Abstract: A self-adhesive reinforced foam gasket comprising a release liner having an upper surface which is a release surface, a layer of pressure sensitive adhesive applied to the release surface, a layer of flexible polymeric film, preferably polyester film, applied to the pressure sensitive adhesive layer, and a layer of flexible foam, preferably closed cell PVC flexible foam, thermally bonded to the flexible polymeric film layer. A length of material for die-cutting the gasket therefrom is provided. The gasket may be used in automobiles and other applications.

Abstract: Improvements in tuft bind and/or elongation of tufted carpet may be achieved by selecting, as components of a tuft bind adhesive, one or more of: i) a polyol component comprising a low or ultra-low unsaturation polyoxypropylene polyol optionally containing up to 30 weight percent oxyethylene moieties, and ii) a chain extender component comprising 2-methyl-1,3-propanediol.

Abstract: An apparatus for forming an interior panel for a vehicle door includes mandrels which hold rolls of vinyl laminate and fiberglass reinforcing mat and from which sheets of vinyl laminate and reinforcing mat are pulled in overlying relation with respect to each other. The vinyl and mat sheets are tacked together, cut to a predetermined length by a cutting mechanism, and moved into a heater by a pin-chain conveyor system. In the heater, the vinyl and mat are heated until the vinyl, which is supported at its edges by the pin-chain conveyor, sags a sufficient amount to indicate that the vinyl is sufficiently softened. The heated vinyl and mat are then moved to a vacuum mold part and thereafter a vacuum is applied to draw the vinyl to a molding surface of the vacuum mold part. A vacuum assist, carried on a carrier, engages the mat and heated vinyl within the vacuum mold part to press the mat into the heated vinyl to partially embed the mat into the vinyl to secure the mat to the vinyl.

Abstract: In order to manufacture compound composite bodies having at least two lay with a support material made completely or substantially from a polymer and with a porous layer firmly connected thereto, a substantially microwave-permeable polymer is utilized for the support material and a polymer having microwave absorbing properties is utilized for the porous layer. The polymer for the porous layer, treated with foaming agent, is heated with microwave energy up to the decomposition temperature of the foaming agent. The resulting polymer foam is sufficiently heated using microwave energy that the support material, at its bordering layer adjacent the foamed polymer, is sufficiently melted substantially due to heat conduction out of the foamed layer that, subsequent to cooling, a firm composite between the support material and the foamed polymer is effected.

Abstract: This invention relates to a method and several exemplary apparatus for capillary dewatering of foam materials. The apparatus may include felt which is applied to an exposed face of the foam material, or a double felt arrangement applied to two opposed surfaces of the foam material. The apparatus may provide a temperature differential between the two exposed surfaces of the foam material. An alternative embodiment utilizes a roll having a capillary dewatering medium. The capillary dewatering medium may be maintained at a vacuum either above or below the breakthrough vacuum of the capillaries. The disclosed apparatus and method are particularly useful for dewatering foams having relatively fine open capillaries.

Abstract: A heat insulating paper cup with improved insulation in areas where printed matter exists. The printed matter is applied using a water-based alkyd or epoxy ink. In one embodiment the cup can include a body member having an inside surface and an outside surface, and a bottom panel member having a upper surface and a bottom surface. The body member is coated on its outside surface with a foamed synthetic resin, and on its inside surface with an unfoamed synthetic resin. The bottom panel member is optionally coated on its upper surface with a foamed or an unfoamed synthetic resin. The body member and bottom panel member are oriented and joined to form a seal at an interface between a portion of inside surface of the body member and a portion of the upper surface of the bottom panel member. The printed matter is applied prior to foaming of the synthetic resin on the outer surface of the cup.

Abstract: This invention relates to a process for the production of a polyurethane backing and air frothed foam on a substrate comprising the steps of a) mixing a polyisocyanate and a polyol blend in the presence of a catalyst to form a reaction mixture, b) applying the reaction mixture to a substrate, and c) curing the reaction mixture to form a polyurethane backing an/or an air frothed foam on the substrate. Suitable catalyst compositions for the present invention include those corresponding to the formula: ##STR1## wherein: each R: independently represents a linear or branched C.sub.1 to C.sub.24 (preferably from 5 to 16 carbon atoms and most preferably from 8 to 12 carbon atoms) alkyl group, or a cyclic group containing from 4 to 24 carbon atoms (preferably from 5 to 16 carbon atoms and most preferably from 8 to 12 carbon atoms).

Abstract: A method in which a polyolefin foam layer is laminated to a sealing film having at least a first layer of a polyolefin. During the lamination a second layer is located between the first layer and the foam layer; the second layer is extruded therebetween and pressure is immediately applied. The second layer and the first layer are polyolefins each based on the same monomer as the main monomer of the foam layer. The same lamination technique may be used to laminate a sealing film to the other side of the foam layer, optionally at the same time as the lamination of the sealing film to the first side of the foam layer. Alternatively, the lamination technique may be used on one side of the foam layer, and the other side of the foam layer may be sealed by means of a coextruded layer.

Abstract: A method of fabricating a door and a door. A first step involves molding a first door skin. A second step involves molding a second door skin. One or both of the first door skin and the second door skin have molded in place rails. One or both of the first door skin and the second door skin have molded in place stiles. A third step involves integrally bonding the first door skin and the second door skin. This produces a door having a body with integrally formed skins, rails, and stiles. A lock latch area and hinge pockets can also be integrally molded into the door.

Abstract: Monolithic films are provided having controlled regional breathability with high WVTR regions and low WVTR regions. The zoned monolithic films are be made by selectively applying adhesive to the monolithic film.