Abstract: The method of forming rigid panel assemblies of this invention eliminates the requirement for mechanical fasteners and may be used to bond wall boards to studs, floor joists to wood flooring such as plywood or OSB boards and trusses to ceiling panels. The method of this invention includes applying a thin bead of a thoroughly mixed two-component liquid polyurethane foamable resin adhesive on the surface where the components are to be joined. The foamable resin is formulated to provide a long tack time or delay curing until the assembly is complete. The foamable resin is then allowed to cream and rise before bonding. Where the bead is applied to the side faces of the support members, the support members are preferably turned to orient the foam beads over the fibrous panel, which is preferably supported on a flat horizontal support surface.

Abstract: An insulation material comprising the double salt of aluminum potassium sulphate and method of producing such. Aluminum sulphate materials and potassium sulphate materials are combined to form aluminum potassium sulphate which is then dehydrated to remove the water of hydration. Porous forms are made by mixing the hydrated aluminum potassium sulphate with a binder before dehydration. The resultant dehydrated sulphate expands greatly to provide an insulative material which is of lightweight and inorganic.

Abstract: Method of making a layered carpet construction suitable for use for the automotive industry as a "deck lid" wherein the backing of the carpet construction is specially processed to adhere to the backside of the exposed carpet face and a separate layer of foamed material is then secured to the backing.

Abstract: The present invention provides a polyethylenic foaming composition comprising (a) 100 parts by weight of an ethylenic copolymer having glycidyl groups consisting of 20 to 99.9% by weight of ethylene units, 0.1 to 30% by weight of a unit of a glycidyl ester of an unsaturated carboxylic acid or an unsaturated glycidyl ether, and 0 to 50% by weight of ethylenically unsaturated ester units other than a glycidyl ester, (b) 0.1 to 30 parts by weight of a carboxylic acid having 2 or more carboxyl groups and a molecular weight of 1500 or less, and (c) 0.1 to 20 parts by weight of a foaming agent of a thermal decomposition type. The present invention also provides a polyethylenic foam molded from said foaming composition.

Abstract: The heat insulator of this invention comprises a thermoformed open cell rigid polyurethane foam core enclosed in a gas barrier material and evacuated. The method of this invention comprises heating an open cell rigid polyurethane foam at a temperature not lower than the temperature at which its storage modulus of elasticity begins to decrease and enclosing the thus-thermoformed polyurethane foam in a gas barrier material and evacuating the interior of the enclosure. The heat insulator of the invention is highly heat-insulating and can be snugly applied to irregular surfaces.

Abstract: A method of making an interior panel of an automotive vehicle door having an exterior surface which is to face toward the interior of the automotive vehicle when installed therein which comprises the steps of forming a bolster laminate including a textile outer layer, a flexible imperforate layer and an inner surface layer of a material which becomes tacky when heated, mounting the bolster laminate in a vacuum mold part, heating a sheet of predetermined material content presenting a vinyl surface, vacuum forming the heated sheet in the vacuum mold part so that the vinyl surface bondingly interengages the tacky material of the film inner layer of the bolster laminate, molding material between the vacuum mold part with the bolster laminate and the sheet therein and a cooperating opposed mold part to form an integrally molded panel having a content between an exterior bolster and vinyl surface and an opposed surface which includes a relatively hard substrate defining the opposed surface, a layer of sheet vinyl p

Abstract: A method for fabricating plastic interior trim components having an insert with openings therein joined to a composite member including a shell and a foam layer, the method including die punching a hole through the shell and foam layer and die punching an edge extension on the shell to a predetermined parametric form; providing a press that is operable to compress a part therebetween and including a first platen and a second platen moveable between opened and closed positions with respect to one another; providing an insert having an opening; supporting the insert on one of said first and second platens and applying adhesive on a surface of the insert; loading the composite member on the other of said first and second platens so that the foam layer thereof is facing the adhesive sprayed insert inboard of the die cut edge extension; closing the press to compress the adhesive sprayed surface against the foam layer of the composite member for adhering the insert only to the foam layer without leakage of foam thr

Abstract: An improved cushioned carpet fabric is provided. The cushioned carpet comprises a primary carpet having a primary base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the primary base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and embedded in, a cushion layer of a polymer such as a polyurethane. There is preferably no additional adhesive between the cushion layer and the layer of reinforcement material since the primary carpet fabric is mated in-situ to the polyurethane-forming composition without preheating the polyurethane-forming composition. An apparatus and process for forming the cushioned carpet fabric of the present invention are also provided.

Abstract: A method of manufacturing a carpet pad and the apparatus for the same are shown. A frame is provided to which is mounted a conveyor belt. The conveyor belt feeds a first liner sheet along a conveyor path from a forward end to a rearward end. A foam spray assembly is connected to an uncured polymeric foam supply having a spray nozzle mounted adjacent to the forward end of the conveyor path. The spray nozzle dispenses uncured, resilient polymeric foam as a generally uniform layer on a surface of the first liner sheet. A second conveyor belt mounted to the frame is located along the conveyor path and spaced apart from the second conveyor belt a selected distance. The second conveyor belt is parallel to the first conveyor belt and feeds the second liner sheet along the conveyor path so that the second liner sheet is positioned over the layer of foam.

Abstract: A process and apparatus are described for extruding a soft, low density elastomeric thermoplastic foam. A single screw extruder having a very large screw length to diameter ratio is provided to thoroughly mix the thermoplastic elastomer with a blowing agent. A thin, substantially taperless die is also provided to form extruded profiles. By using such a process and apparatus, a variety of complex-shaped extruded profiles may be easily produced.

Abstract: An cut-resistant seat or seating material is disclosed together with methods of forming such a material. The material comprises at least one layer of flexible metal or non-metal matrix material embedded within a compressed flexible foam material. The foam material may be a fire retardant flame material.

Abstract: A lightweight warp knitted textile fabric suitable for use as the loop component of a hook-and-loop fastener is formed of a set of ground yarns knitted in a relatively stretchable construction with a set of loop-forming yarns formed in a stitch pattern producing elongated underlap loops extending outwardly from the technical back of the fabric which can be readily interengaged with the hook elements of a mating hook component without any necessity for brushing, napping or mechanically raising the loops. In one embodiment, a second set of loop-forming yarns is formed in a stitch pattern producing elongated loops extending outwardly from the technical face of the fabric which can be adhered to a backing material such as a carpet backing. In another embodiment, filling yarn is inserted weftwise in every fabric course.

Abstract: A manufacturing method of a ski which includes a first preparation step of a solid core made of synthetic foam and a second assembly step of the core with the various component elements of the ski. The first step includes injecting or pouring in a mold having the final shape of the core to be obtained, the components of a hardenable and expandable foam and during which a solid adhesive film having good adhesive properties with the foam as well as with the elements adapted to enter into contact during the second assembly step, is located against the walls of the mold.

Abstract: The method of forming rigid panel assemblies of this invention eliminates the requirement for mechanical fasteners and clamps and may be used to bond wall boards to studs, floor joists to wood flooring such as plywood or OSB boards and trusses to ceiling panels. The method of this invention includes applying a thin bead of a thoroughly mixed two-component liquid polyurethane foamable resin adhesive on the surface where the components are to be joined. The foamable resin is formulated to provide a long tack time or delay curing until the assembly is complete. The foamable resin is then allowed to cream and rise before bonding. Where the bead is applied to the side faces of the support members, the support members are preferably turned to orient the foam beads over the fibrous panel, which is preferably supported on a flat horizontal support surface.

Abstract: A foamed adhesive insulation, consisting of a mixture of a foamed adhesive material and a fibrous insulation material, is provided which adheres to a desired surface without the need for a retaining means to hold the mixture in place. While in the flowable state, the foamed fiber insulation can be molded to a desired shape and texture. The foamed fiber insulation adheres and can be applied to substantially any surface, such as wood, metal, masonry, concrete, or urethane, with virtually any orientation. The compression and tensile strengths of the layer of foamed fiber insulation can be selected by adjusting the mixture of foamed adhesive material and insulation particles. The foamed fiber insulation can include additives such as a dye to produce a substantially rigid insulation layer of a desired color, or a fire retardant material to produce a fire retardant insulation layer.

Abstract: In the production of slabstock polymeric foam, foam reactants are delivered to a vessel (1), the reacting foam mixture passes over an overflow outlet (2) from the vessel and along a downwardly inclined fall plate (3) to a conveyor (4), two separate covering layers, namely a lower flaccid plastics film (26) and an upper relatively stiff paper foil (28), are applied over the reacting foam mixture near the overflow outlet (36), a blanket (40) weighted by free floating plates (46) is positioned over the cover layers in the foam expansion zone to press down lightly on the foam. The separate plastics film and paper foil are provided by delaminating a composite sheet (21), and are delivered to the foam surface in substantially tension-free condition by a take-off mechanism (22) which draws the composite sheet from a supply roll. Improved economy is achieved as a result of improved characteristics at the top of the foam block produced.

Abstract: Foamable thermoplastic resin compositions are provided having vinyl chloride polymer, a graft copolymer having a superstrate grafted to a substrate wherein the superstrate has alphamethyl styrene, unsaturated nitrile, and unsubstituted styrene therein, and the substrate is a butadiene rubber, a rubber-free copolymer having alkylmethacrylate, vinyl aromatic, and unsaturated nitrile therein, and a chemical blowing agent. The foamable thermoplastic resin composition may be coextruded with a non-foamed thermoplastic resin skin to produce a coextruded rigid foamed structure by a process of coextruding the skin and foamable thermoplastic composition. The composition and process are useful for making coextruded rigid foam structures which are useful in rigid foam applications such as foamed pipe and foamed sheet.

Abstract: A method and apparatus for simultaneously insulating cavity portions and securing batt insulation in the cavity to be insulated. The present invention provides a system for using a mixture of insulating material, a dissipating foam, and an adhesive to hold the batt insulation in a frame that defines a cavity to be insulated. In one embodiment the mixture is applied only to the border of the cavity. In another embodiment the insulating material comprises fly ash particles.

Abstract: A method of making an elastomeric, hot-melt adhesive foam is disclosed. The method involves melting an adhesive material, mixing a gas with the adhesive material under pressure to form a solution of the gas in the adhesive material, reducing the pressure to cause evolution and/or expansion of the gas to form a foam, and stabilizing the foam by causing the adhesive material to solidify. The relatively low melt-viscosity of the adhesive material which is used to form the foam provides desirable processing times and the ability to form foams having desired physical properties, e.g., caliper and cell structure.

Abstract: A water-permeable and fire-resistant product and the preparing method thereof is disclosed. The waterpermeable and fire-resistant product is made of a fabric layer and a purous film adhered thereon. The porous film of this invention comprises polyurethane resin; a first fire-resistant agent; a second fire-resistant agent, an inorganic fire-resistant agent and an additive agent. The first fire-resistant agent used is selected from the group consisting of paraffine chlorinated, decabromodiphenyl oxide, hexachloro benzene, hexabromo benzene, pentabromo ethyl benzene, pentabromo diphenyl oxide and octabromo diphenyl ether. The second fire-resistant agent used is selected from the group consisting of Sb2O3 and Sb2O5. The surface of the product produced is smooth.

Abstract: A method of bonding a roof tile to a roof substrate utilizing a two component polyurethane foam. The method includes the step of applying under low pressure a stream of a two component foamable liquid polyurethane on a roof substrate. Preferably, the foamable liquid polyurethane has a density in the range of about one and one-half to about two pounds per cubic foot and a reactivity period in the range of about one and one-half to about four minutes. Preferably, the foamable liquid polyurethane is applied at a rate of about two to about three pounds per minute. The roof tile is placed into contact with the foamable liquid polyurethane during the reactivity period of the foamable liquid polyurethane.

Abstract: A method is provided for bonding an adhesive to a polyolefin foam, and preferably a non-crosslinked polyethylene foam. The foam is useful as a liquid-impervious backing in a disposable absorbent article, such as a panty liner, a sanitary napkin, a diaper, a adult incontinent garment, a training pant, and the like. The adhesive is applied to a substrate which is then brought into intimate contact with one side of the foam's surface. Optionally, heat and pressure may be applied to enhance bonding.

Abstract: According to the present invention, a surface of a molding is provided with soft touch feeling by making a sheet for covering a substrate having a soft touch layer adhere to the surface of the molding. A covering film having soft touch feeling can easily be formed even on surfaces of products with unevenness and curves. This sheet for covering a substrate has a soft touch layer formed from a resin composition containing at least one substrate selected from the group consisting of elastic beads and a porous inorganic material, and a urethane resin as its main components. This sheet is placed in a mold and a resin is molded in the mold, whereby a molding having soft touch feeling can be obtained. The sheet for covering a substrate has extensibility and is not likely to be broken during the molding.

Abstract: This invention is directed to coating press fabrics to achieve a controlled void volume. More particularly, this invention is directed to a method of modifying a press fabric for a papermaking machine which comprises the steps of:(a) applying a thin layer of a polymeric foam to the surface of a press fabric;(b) drying said foam to form a coated press fabric; and(c) curing said coated press fabric.

Abstract: A barrier foam tray contains recycled reclaim of barrier foam. The tray comprises a sheet of foamed polystyrene (PS) having laminated to it a flexible barrier film. The foamed polystyrene part can have admixed therein from 0.0001% up to 30% by weight of the flexible barrier film. The barrier film contains a barrier polymer such as ethylene vinyl alcohol copolymer (EVOH). The tray is made by grinding laminate scrap and extruding reclaim therefrom with virgin polystyrene.

Abstract: The disclosed method relates to the formation of a relief pattern on the surface of a shaped object through the expansion of an expandable ink. The ink is applied on a support web and then dried. A varnish which polymerizes under UV radiation may be applied on the printed, dried support web. The printed, dried, and possibly varnished, support web is then rolled in to a coil. Afterwards, the coiled web is transformed into the desired shaped objects, such as filled and closed packages or security documents. The relief pattern may then be formed upon the surface of the object by irradiating the expandable ink. In particular, a laser beam may scan the surface of the object to form the relief pattern.

Abstract: A cut-resistant seat or seating material is disclosed together with methods of forming such a material. The material comprises at least one layer of flexible metal or non-metal matrix material embedded within a compressed flexible foam material. The foam material may be a fire retardant flame material.

Abstract: An approved roofing shingle (10) and a method for its manufacture, are disclosed. The shingle incorporates an upper layer (12) of conventional asphaltic composite roofing material and a lower layer (14) of a polymer foam having a thickness between 1/16 inches and one inch. The foam effectively thickens the shingle to give a layered appearance to a roof using the shingle. The polymer foam can be applied by a free blown or froth process, or preformed and adhered to the composite material sheet by adhesive techniques.

Abstract: The invention is directed to an unfoamed foil of at least one thermoplastic resin, said foil being capable of serving as an adhesive when softened and having included therein at least one blowing agent, and to the use thereof in preparing laminates.

Abstract: A manufacturing method for an article having a foamed layer, comprising the steps of: retaining and fixing an adherent portion having a resin-made reinforcing layer and a foamed layer, the reinforcing layer having an integrally formed design surface; and vibration welding, with a low-frequency wave, the reinforcing layer and a base portion together so as to be integrally bonded while the base portion, formed of resin which can be welded to the reinforcing layer, is in contact with the reinforcing layer. Thus, it is possible to reduce the processes which require a great deal of man-hours, such as the applying and drying of an adhesive material, sewing and mechanically affixing. Consequently, an attractive article can be produced while reducing manufacturing man-hours and providing for automated manufacture.

Abstract: A composite plastic article is provided which includes an improved boss for fastening the article to a supporting structure. The composite article includes a decorative outer skin co-molded to a reinforced foam layer. The foam layer is formed from a foaming resin such as polyurethane in an exothermic reaction. The boss is formed as a part of the foam layer and protrudes through the insert. A metallic fibrous material such as steel wool is molded into the boss to give the boss added structural integrity and to remove heat generated during formation of the boss and foam layer to thereby reduce cracking of the boss and localized blistering and delamination of the outer skin. A method for making such a boss is also provided.

Abstract: A sheathing board capable of transmitting water vapor while retaining good thermal conductivity properties. The board is formed of a core comprising rigid foamed plastic interspersed with spaced areas of water vapor permeable insulating material that extend from one major face of the core to the other. The major faces of the core are preferably faced with a water vapor permeable sheet, allowing water vapor to travel through the spaced areas of insulating material and the facing sheets. By aligning the spaced areas of material with the insulation in a wall cavity, the strength of the board and its thermal conductivity are maintained within acceptable limits.

Abstract: A power door sensing strip incorporates a pair of electrical conductors positioned in a sealed plastic tube and supported in a molded foam block so that external forces result in contact between the conductors. Reliable operation is afforded by the absense of internal supports between the conductors. Further, short circuits caused by moisture and contaminants entering the foam through breaks in an outer jacket are eliminated. Trimmable tails and electrical connections on the ends of the strip enable the strip to be used with doors of varying widths and for non-handed installation.

Abstract: A process for the production of a headrest with an articulated insert, comprises casting in situ polyurethane foam (7) within an external cover in which is disposed an insert (5) having articulated legs (4) that protrude from the cover, then hollowing out, by means of heating elements (2), swinging spaces (3) for the articulated legs (4) of the insert (5) by hot fusion of the external cover (6) and of the polyurethane foam (7) at the corresponding locations (8) of the headrest (1), and simultaneously heat sealing the external cover (6) and the surface of the polyurethane foam (7) bordering the swinging spaces (3).

Abstract: A method of substantially completely filling elongated channels with foam, such as the channels in an extruded lineal used by the window industry. The method includes first orienting the channel in an upwardly angled orientation preferably greater than 30 degrees and less than 90 degrees, with a preferred angle of about 60 degrees. Where the channel has open ends, the lower end may be temporarily sealed. A thin, relatively high-pressure high-velocity stream of liquid foamable resin is then directed into the elongated channel open end generally parallel to the inside walls, such that the high-pressure liquid stream is carried at least partially down the length of the elongated channel, prior to contacting the channel inside walls and creaming. The liquid foamable resin then rises upwardly through the elongated channel, substantially completely filling the channel with resin foam.

Abstract: A process for producing a bicycle frame of a fiber-reinforced plastics (FRP) including the steps of: forming parts of a bicycle frame such as an upper pipe, a lower pipe, a vertical pipe, a chain stay and a rear fork, or a combination thereof, with an FRP; arranging the bicycle frame parts in a structure of the bicycle frame; forming, with an FRP, lug portions onto the arranged bicycle frame parts at a required position whereat the bicycle frame parts are to be connected and fixed to each other; and curing all of the lug portions at one time, to thereby simultaneously accomplish an assembling of the bicycle frame.

Abstract: A barrier foam tray contains recycled reclaim of barrier foam. The tray comprises a sheet of foamed polystyrene (PS) having laminated to it a flexible barrier film. The foamed polystyrene part can have admixed therein from 0.0001% up to 30% by weight of the flexible barrier film. The barrier film contains a barrier polymer such as ethylene vinyl alcohol copolymer (EVOH). The tray is made by grinding laminate scrap and extruding reclaim therefrom with virgin polystyrene.

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 hot melt gasket or liner is applied to a portion of a manually operated dispenser having a closure cap for coupling the dispenser to a container. The material may contain a predetermined amount of gaseous fluid to form a foamed hot melt material having a predetermined density. After the material cools to room temperature, it forms an anti-slip gasket seal which, upon coupling the cap to the container neck, the hot melt material is compressed for restricting movement of the dispenser about the central axis of the container and for preventing formation of a leak path between the container rim surface and the dispenser.

Abstract: An evaporable first foam pattern portion adapted to be glued to a second foam pattern portion including a glue surface having thereon a fill gun boss, the first foam pattern portion comprising a glue surface adapted to be glued to the glue surface of the second pattern portion, and a recess in the glue surface of the first foam pattern portion for receiving the fill gun boss on the glue surface of the second pattern portion.

Abstract: The invention provides a heat-shrinkable foamed composite film which is a film laminate composed of: (A) a laterally monoaxially-oriented foamed film of an olefin polymer having a thickness of about 40 to about 400 .mu.m and being heat-shrinkable predominantly in a lateral direction, (B) a laterally monoaxially-oriented film of an olefin polymer having a thickness of about 5 to about 50 .mu.m and being heat-shrinkable predominantly in a lateral direction, and (C) a laterally monoaxially-oriented printed polyester film having a thickness of about 5 to about 50 .mu.m and being heat-shrinkable predominantly in a lateral direction, the film laminate being formed by laminating the films (A), (B) and (C) in this order so that the printed surface of the film (C) is faced with the film (B), and the film laminate having a heat shrinkage factor of about 25 to about 50% in a lateral direction and about 0 to about 10% in a longitudinal direction under the conditions of 100.degree. C.

Abstract: Floating containment booms for containing petroleum and similar product spills on a water surface such as at sea, in harbors, rivers and the like, and methods for forming the same. In accordance with the method, an elongate sheet of flexible material and components for mixing to form a plastic foam or a foam forming or expanding material together with apparatus for forming the containment boom therefrom are stored for use when required. In operation on a boat, the apparatus forms a loop or opens a preformed loop or loops in the material, at the same time injecting the foam forming material in the loop so formed to expand and fill the same with foam at the same is played out from the boat while traversing the region to be surrounded by the oil boom. The portion of the elongate sheet opposite the loop is preferably weighted, either prior to use or as the oil boom is formed and played out from the boat.

Abstract: There is provided an imitation stone counter material and a method of making the same. In one embodiment, the material consists of a layer of gel coat over a stone matrix layer. The matrix layer mixture consists of a hardenable resin, a thickening agent, and a crushed stone aggregate. To the stone matrix layer is applied a layer of fiberglass and curable resin. In an alternative embodiment, alternating layers of foam and fiberglass are applied to the stone matrix layer to provide the desired structural integrity to the final imitation stone counter material.

Abstract: The invention relates to a high-integrity closure, sift-proof carton [10], a method and an adhesive dispensing apparatus for producing same. Foamed hot melt adhesive is dispensed in parallel strips from dispensing guns onto the flaps [20], [22], [30], [32] of the carton [10], which are thereafter folded down to close the carton [10]. The strips can be spaced so that a continuous tight adhesive seal is formed, especially by providing a strip pattern interdigitating when the flaps contact each other. Since all strips are provided in parallel, while the carton is moved with respect to the dispensing apparatus, application of adhesive is fast and reliable.

Abstract: An anatomical multilayer seat for use on a bicycle or the like. The seat comprises a formed substantially rigid shell covered by a flexible cover sheet and having a layer of soft encapsulated gel material provided between the cover shell and the seat shell. The encapsulated gel layer is constrained against any appreciable lateral movement while permitting only limited deflection of the gel during use by a lower formed foam layer provided between the shell and the cover sheet to produce a controlled graduated support for the rider. If desired, a second upper layer of a resilient material can be advantageously provided between the gel layer and the cover sheet of the seat for encapsulating the gel layer. The invention also includes a method for making the anatomical multilayer seat.

Abstract: In a seat for use in an automotive vehicle, a trim cover is bonded at least at its seat base partly only to a molded polyurethane foam functioning as a seat cushion member and is not substantially bonded at its flap and side parts to the molded polyurethane foam, so that an internal defect can be easily repaired by merely stripping off a corresponding portion of the trim cover. The trim cover may consist of a cover member only, or a filler pad may be only locally bonded to the cover member. The molded polyurethane foam may be formed by foaming and molding a polyurethane resin solution or may be supplied in the form of a slab.

Abstract: A method for producing a laminated material including a lower layer of highly-expanded plasticized polyvinyl chloride with cross-linking and a surface layer of thermoplastic resin sheet laminated on an upper surface of said lower layer, said method including the steps of: heating and kneading raw materials for the lower layer in an extruder, the raw materials excluding a cross-linking agent and a blowing agent; adding the cross-linking agent and the blowing agent; heating and kneading the obtained material at or less than a reacting temperature of the cross-linking agent and a decomposition temperature of the blowing agent to obtain a sheet; heating the sheet to cross-link and expand the sheet to form the lower layer of cross-linked highly-expanded plasticized polyvinyl chloride; and laminating the surface layer of the thermoplastic resin on the upper surface of the lower layer.

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: A method of making a foam filled polymer article includes the steps of compressing an expandable foam material (12) and containing the compressed expandable material (12) in a degradable container, such as a polyethylene bag (16). An outer polymer shell (10) is formed while degrading the container (16) therewithin, such as by rotation molding. The shell (10) is filled with the uncontained expandable foam material (12).