Abstract: Structured polyolefin coated substrates and processes for making the same are disclosed. A chill roll is used to impart a plurality of peaks which protrude outwardly from the polyolefin coating of the structured substrate. In addition, the chill roll surface is treated to impart a matte finish and thus to transfer a matte finish to the area surrounding the peaks of the polyolefin coating.

Abstract: Calender including a roll stack having a plurality of rolls that rest against one another in a press direction. At least one of the rolls has an elastic surface. A vibration recording device determines in an uninterrupted manner a vibration of at least one of the rolls. A mechanism displaces the at least one roll crosswise to the press direction based on the vibration. The process includes determining in an uninterrupted manner a vibration of at least one of the rolls and displacing the at least one roll crosswise to the press direction based on the vibration.

Abstract: A polyester resin composition is calendered to produce a film or a sheet. The polyester resin composition is a polyester having a crystallization half time from a molten state of at least 5 minutes combined with an additive for preventing sticking of the polyester to calendering rolls.

Abstract: High strength polyethylene yarns useful in ballistic-resistant, cut-resistant and other applications, fabrics produced from these yarns and the methods by which the yarns and fabrics are made. An untwisted yarn of the invention comprises a plurality of filaments in essentially parallel array and from about 0.5 to 5 weight percent of a water-dispersible binder material covering less than half the surfaces of the filaments.

Abstract: An object of the present invention is to provide an apparatus and a method for manufacturing a windable carbonaceous material sheet, which is obtained by continuously curing a long uncured fiber sheet which is obtained by using short fibers to make paper and which contains uncured resin to produce a resin-impregnated cured sheet, and then continuously carbonizing it, and its production process.

Abstract: A high density microwall ePTFE structure and a method for making, involving the manipulation of a standard extruded ePTFE graft. The final product has the desired characteristics of high density, reduced wall-thickness, above-average radial strength and enhanced suture retention.

Abstract: Diffuse reflective materials proximate to a structure formed by thermally induced phase separation of a thermoplastic polymer and a diluent providing enhanced flexibility and reflectivity especially in the visible wavelengths of 380-730 nanometers are described. Such materials find a wide variety of application among combinations with other reflective layers. The diffuse reflective articles are useful in backlight units of liquid crystal displays, lights, copy machines, projection system displays, facsimile apparatus, electronic blackboards, diffuse white standards, photographic lights and the like.

Abstract: An apparatus and a method for producing a thermoplastic resin continuous laminated sheet are provided. The continuous laminated sheet has at least one thermoplastic resin continuous film laminated on a thermoplastic resin continuous sheet by heat welding, and can be produced by a method comprising extruding a heat-fused thermoplastic resin continuously to be in a sheet form; rolling the extruded resin to form a thermoplastic resin continuous sheet; heating at least one lamination surface of the sheet while flatly holding the sheet; and laminating at least one thermoplastic resin continuous film onto the heated sheet.

Abstract: There is provided an acrylic resin film having good matted appearances and good printing characteristics, e.g., little suffering missing prints when printed. There is provided an acrylic resin film having a differential 60° surface gloss of 5% or more between the front and back sides, and thickness of 300 &mgr;m or less; a method of producing the above-described acrylic resin film, where a molten acrylic resin composition is extruded, and then rolled between a mirror-ground roll and rubber or embossed roll into the film; and a laminate (formed article coated with the acrylic resin film) with a side having a higher 60° surface gloss coming into contact with a base.

Abstract: Nonwoven substrates suitable for use as wet wipes are disclosed. The nonwoven substrates comprise at least one first region and at least one second region. The second region comprises reinforced protruding elements. In a preferred embodiment, the second region of the nonwoven substrate is reinforced by means of thermal bonding during the creation of the protruding elements of the second region. A liquid can be added to the nonwoven substrate prior to packaging or prior to use to make wet wipes. The reinforced second regions of the nonwoven substrates of the present invention make it possible to retain thickness of the wipe when wet without increasing the dry basis.

Abstract: A method of forming a thermally bonded, nonwoven polypropylene fabric is provided and includes passing a web of thermally bondable skin-core polypropylene fibers through a calender nip under heat and pressure to produce a nonwoven fabric having elongation. The patterned calender roll is embossed with a plurality of spaced and staggered lands particularly dimensioned, configured and oriented to provide the desired bonding spot size and spacing between the bonding spots such that when utilized in the calender roll, an improved soft polypropylene fabric or cover sheet having a high elongation results.

Abstract: Plastic panels for exterior use on buildings are made by forming a plastic sheet at an elevated temperature, overlaying an exterior surface portion of the formed sheet with a coloring sheet having a preselected color, and thermally bonding the coloring sheet to the formed sheet. The coloring sheet preferably comprises a vinyl resin plastisol and pigment particles. Both the formed sheet and the vinyl resin in the plastisol preferably comprise polyvinyl chloride (PVC). Use of the coloring sheet enables color changes to be accomplished quickly and inexpensively so that manufacturers are able to maintain smaller inventories of the finished product while still satisfying customer needs.

Abstract: This invention is directed to a process for the rapid in-situ curing of polymerizable materials to provide macromolecular networks and articles of manufacture that are “morphology-trapped”; that is, they exhibit a fixed phase morphology and/or molecular orientation that is locked in by the curing step. The process includes the steps of mixing together a dead polymer, a reactive plasticizer and an initiator to give a polymerizable composition; further processing the mixture in order to achieve a desired phase morphology and/or molecular orientation of the polymeric constituents; shaping the polymerizable composition into a desired geometry; and exposing the polymerizable composition to a source of polymerizing energy, without mixing, to give a final product with the desired phase morphology and/or molecular orientation locked in place.

Abstract: A method provides for full or partial infusion of resin into three-dimensional, woven textile preforms. Resin film is placed at selected locations adjacent the preform, and the resin film may be separated from other areas of the preform using separator sheets or other materials. The preform is heated and may be vacuum-bagged to apply pressure, or may be rolled or fed through a die. The heat and pressure cause the resin to infuse into the selected areas of the preform adjacent the resin films. The amount of resin in the partial infusion is the same as is necessary to fully infuse the preform, but the resin remains localized in the selected areas until heated again at cure to cause the resin to flow throughout the preform. The method may also be used to fully infuse the preform with resin by providing sufficient temperature and time at that temperature during the initial infusion.

Abstract: A process of making a pigmented shaped article comprising: (a) providing polytrimethylene terephthalate chips and two or more colored pigmented chips each containing at least one different color pigment; (b) heating the polytrimethylene terephthalate chips and colored pigmented chips to a temperature of about 200-about 280° C. to melt the chips and form a polymer composition comprising the polytrimethylene terephthalate and at least one color pigment; and (c) forming a shaped article from the polymer composition.

Abstract: This invention is directed to a process for the rapid in-situ curing of polymerizable materials to provide macro-molecular networks and articles of manufacture that are “morphology-trapped”; that is, they exhibit a fixed phase morphology and/or molecular orientation that is locked in by the curing step. The process includes the steps of mixing together a dead polymer or a prepolymer, a reactive plasticizer or a diulent, and an initiator to give a polymerizable composition; further processing the mixture in order to achieve a desired phase morphology and/or moelcular orientation of the polymeric constitutents; shaping the polymerizable composition into a desired geometry; and exposing the polymerizable composition to a source of polymerizing energy, without mixing to give a final product with the desired phase morphology and/or moelcular orientation locked in place.

Abstract: Process for producing an elastomer substrate web, comprising the following process steps: a) feeding in a polymer mixture, in particular into a mixer, b) conveying the ready-prepared polymer mixture to a calender, comprising at least two rollers, c) forming the polymer mixture out in the calender into a web, d) applying an auxiliary substrate in web form by means of a pressure-exerting roller, which is in contact with the last forming calender roller, for receiving the web, and e) if appropriate, cooling, crosslinking and/or winding up the web located on the auxiliary substrate.

Abstract: The object of the present invention to provide a method for producing a extruded ethylene copolymer that can provide a film having excellent melt tension and fluidity as well as excellent impact strength and appearance (haze and transmittance). This object is achieved by a method for producing a extruded ethylene copolymer, comprising extruding an ethylene copolymer of ethylene and an &agr;-olefin having 4 to 20 carbon atoms under specific conditions, and obtaining the extrudate.

Abstract: An apparatus for reducing wrinkles in a film includes a first pair of cylindrical rollers including a first roller and a second roller, the first and second roller each in parallel juxtaposed relation to each other, and each having a substantially smooth surface; and a second pair of cylindrical rollers including a third roller and a fourth roller, the third and fourth roller each in parallel juxtaposed relation to each other, and at least one of the third and fourth roller having a chevron pattern disposed on the surface thereof; the first pair of rollers being adjacent to and spaced apart from the second pair of rollers. A method for reducing wrinkles is also disclosed herein.

Abstract: The present invention describes an advantageous way of lubricating polyvinylchloride during an extrusion process.

Abstract: A process of manufacturing of shoes insole is disclosed. In the present method, a high-density thermoplastic material and a low density thermoplastic material are undergone a rolling process of the rollers of the pressing machine. The top and the bottom of the materials are together pressed with plastic woven cloth and non-woven cloth such that a layer of dual density rubber board is adhered in between the plastic woven cloth and the non-woven cloth to form into an integrally formed dual density complex rubber board. The present process reduces the fabrication time and the production cost is reduced as the capital for equipments is greatly reduced. The present invention also allows the lowering of cost for shoes insole.

Abstract: The present invention is directed to an adhesive article and methods of manufacturing the adhesive article. The adhesive article comprising at least one major surface comprising a microstructured surface, the microstructured surface comprising microstructured elements, the microstructured elements comprising walls and at least one wall has variable height with a maximum height and a minimum height along the wall length.

Abstract: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet of material is provided with a variable resin concentration across its width, and the position of the variable resin concentration is correlated with the position of embossing features which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers to accommodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

Abstract: A method of manufacturing thermoplastic flexible transparent PVC film (sheet) without flow marks and air pit is capably provided with high efficient production to upgrade the quality of plastic film (sheet), which is included the following steps: calendering melted plastic material by calenders into melting plastic film (sheet) with predetermined thickness, quickly chilling and setting the melting plastic film (sheet) with chilling water, removing water from the cooled plastic film, heating the plastic film to dry out any residual water and controlling the plastic film again to a temperature from 30° C. to 85° C., and applying a pressure ranging from 1 kg/cm2 to 8 kg/cm2 on the plastic film (sheet) while winding it into a roll. Plastic film (sheet) produced with this method has good transparency and smooth surface without flow mark and air pit.

Abstract: A manufacturing method for environment-friendly food container is disclosed. The process employs paddy husk or vegetative plant stalks to be crushed or ground into powdery form. These materials are then mixed and stirred with water, oil, surfactant and adhesive. The product is then proceeded to a second stirred mixing process and is then proceeded to a squeezing device to form into plate-like material directly leaded to a pressing device. The plate-like material is then proceeded to a first drying process, a glue-containing process and a second drying process. The material after the second drying process can be used for the fabrication of containers for food.

Abstract: The present invention provides a process for the production of a transparent flat film from thermoplastic polyurethane (TPU) by introduction of the thermoplastic polyurethane between sheets of a higher-melting material. The transparent flat film may find use in optical applications.

Abstract: A thermoplastic olefin composition comprises, based on the total weight of the composition: about 20 wt % to about 40 wt % polypropylene; about 30 wt % to about 50 wt % ethylene copolymer; and about 20 wt % to about 30 wt % linear low density polyethylene.

Abstract: A method (110) of manufacturing footprint tiles (10) having the steps of: rolling (112) tile base (12) to a predetermined uniform thickness; imprinting (114) by utilizing a plate or roller with a plurality of convex footprints and exerting pressure upon the rolled tile base (12) forming a plurality of concave footprint impressions (14) into the tile base (12); cutting (116) by utilizing a plate or roller with a plurality of blades complementarity positioned to the plurality of concave footprint impressions (14) and exerting pressure upon the rolled tile base (12) forming individual foot print tiles (10); and drying (120) the individual foot print tiles (10).

Abstract: A process for producing multilayered thin plasters with a carrier material based on polyurethane with the steps of applying at least one layer of uncured polyurethane to a transfer layer, applying an adhesive composition to a release layer, laminating the uncured polyurethane on the transfer layer and the adhesive composition on the release layer together using a doctor blade, passing the laminate through nip rolls downstream of the doctor blade, and rolled out the uncured polyurethane and adhesive composition to the ultimate thickness.

Abstract: The present invention provides a method of making a carbohydrate foam composition. The method produces a foam composition is highly wettable, resilient and has a uniform pore structure suitable for use in products such as absorbent personal products, health care products, and products suitable for fluid distribution and transfer. The foam of the present invention may also be made into sheets suitable for products such as tissue and paper towels. In one embodiment the foam is made from a carbohydrate and zinc chloride. In a further embodiment the carbohydrate is cellulose, and in a further embodiment the carbohydrate is chitin. The method of the present invention allows control over various properties of the foam carbohydrate composition.

Abstract: An insulated packaging material includes a thermal insulating layer, which may a fiberfill batt. The batt is laminated to at least one facing layer of film, paper or fabric. The packaging material can be used as a container, such as a pouch. A food-contacting polymer material is applied to the facing layer to form the inner surface of the pouch. The packaging material may be coated on the outer facing layer with a coating material so that it is printable, thus imparting both insulating properties and print capability to the pouch.

Abstract: A process for producing a polycarbonate film suitable for optical media applications having a birefringence of less than about 50 nm and low stress wherein the polycarbonate has a weight average molecular weight of about 30,000 or less and preferably 13,000 to about 25,000, extruding the polycarbonate film at a temperature of about 275° C. to about 360° C., the polycarbonate has a melt viscosity of about 100 to about 275 Pascal and a thickness of about 100 to about 600 &mgr;m, advancing the melted polymer film into a gap between two calendering rolls which calendaring rolls are at a temperature below the glass transition temperature, advancing the melted polycarbonate film through the gap and cooling the polycarbonate film wherein the polycarbonate film is extruded at the rate of about 10 to 100 feet per minute; and to a polycarbonate film prepared by the process above described.

Abstract: From about 50 to about 90% by weight of fibers, in particular wood fibers, and/or pellets made from cellulose or from wood, are mixed with from about 10 to about 50% by weight of a hot-curing resin, each of the percentages by weight being based on the total weight of the mixture. Instead of a single resin it is also possible to use a mixture made from two or more hot-curing resins. The mixture made from fibers and/or pellets and resin is kneaded and homogenized and then passed on to an extruder which has various heating zones in which the mixture is heated. Care has to be taken here that the maximum temperature, arising at the extruder exit, does not exceed about 120° C., since above this temperature the resin(s) begin(s) to cure.

Abstract: The present invention is directed to the realization that the dimensions and basis weight of an electrode active admixture such as a transition metal oxide, and particularly silver vanadium oxide, formed into an electrode structure from an admixture paste subjected to a calendering process are influenced by the calender direction. To obtain electrode structures of a desired low basis weight requires a secondary calendering step performed in a direction reverse or orthogonal to that used to form the initial sheet tape. Orthogonal or reverse feed of the electrode active admixture provides for fibrillation of the fluoro-polymeric binder in other than the initial direction. This lets the binder spread in directions transverse to the initial direction to form the low basis weight electrode active structure.

Abstract: The present invention is directed to a method of producing a cable protecting material. The method can include mixing and kneading an olefin-type polymer and suitable additives to prepare an olefin-type polymer composition, transforming the composition into pellets, and extruding the pellets at a temperature of from about 190° C. to about 250° C. The cable protecting material has a smoothly flowing skin and a well balanced material distribution. The cable protecting material also has good wear resistance.

Abstract: A process of calendering a sheet or a film having at least one textured surface entailing passing a web of polymeric resin through a nip between a rigid roll and a resilient roll is disclosed. The inventive process comprises slowing down the cooling rate of the web by rolling its textured surface about the resilient roll. The rate of cooling is in comparison to a corresponding process where the web is rolled about said rigid roll. Products thus produced are suitable for making thermoformed articles having low gloss.

Abstract: Flexible graphite article of manufacture made by compressing a mixture of expanded graphite particle and a fluoro-resin including ethylene-tetrafluoroethylene (ETFE) copolymers after additional heat treatment. An article of manufacture of a gasket material made shows enhanced mechanical properties especially after oil immersion and reduced leakage.

Abstract: A polyester resin composition is calendered to produce a film or a sheet. The polyester resin composition is a polyester having a crystallization half time from a molten state of at least 5 minutes combined with an additive for preventing sticking of the polyester to calendering rolls.

Abstract: The present invention relates to a sheet (1, 2) of absorbent paper, in particular made of cellulose cotton and of a specific surface weight between 10 and 40 g/m2, comprising a first embossed zone such as is provided by embossing between an undeforming cylinder (A12) fitted with protrusions and a cylinder fitted with a resilient cladding (C) in such manner that the sheet (1, 2) comprises on one side in particular frustoconical salients (120, 110) of which the tops are situated substantially in one plane. The salients (110, 120) corresponding to recesses on the opposite side, the sheet being characterized in that the first embossed zone (110) constitutes a background base pattern of which the number of salients of height H1 relative to the plane is greater than 30 per cm2, and in that it comprises at least a second pattern (G) constituted of salient-free zones of which the height H2 relative to the plane is greater than H1.

Abstract: A shaped rubber body with improved uniformity in terms of weight and/or physical properties is produced by extruding a rubber strip by a positive displacement extruding system that includes, as seen from an upstream side of the rubber strip, a screw extruder unit, a gear pump unit and an extrusion head unit with an extrusion nozzle, which are connected in series with each other. The rubber strip is fed to a rotating support along a substantially straight passage extending from the screw extruder unit to the extrusion nozzle of the extrusion head unit, passed through a gap defined between a pair of pressure roll, and applied onto an outer surface of the support by one of the pressure rolls.

Abstract: A multicolored, patterned floor covering is disclosed along with a method for its manufacture. The floor covering is made of a sheeting which has a first color, and a granular material dyed differently from the sheeting which is embedded in the sheeting along at least in the area of the top side. The sheeting and the granular material consist of cross-linkable, elastomeric materials, the granular material comprising particles which have at least two subregions dyed differently from each other and from the sheeting. The quantity and color of the fractions of each component as selected so that the mixed color resulting from an homogeneous intermixing of all the components contained in the floor covering agrees with the first color.

Abstract: An insulating label stock includes a thermal insulating layer, which may a fiberfill batt. The batt is laminated to at least one layer of film, paper or fabric. The label stock can be wrapped around a container, such as a can, bottle or pouch. The label stock may be coated with a coating material so that it is printable, thus imparting both insulating properties and print capability to a container.

Abstract: A method of manufacturing thermoplastic flexible transparent PVC film (sheet) without flow marks and air pit is capably provided with high efficient production to upgrade the quality of plastic film (sheet), which is included the following steps: calendering melted plastic material by calenders into melting plastic film (sheet) with predetermined thickness, quickly chilling and setting the melting plastic film (sheet) with chilling water, removing water from the cooled plastic film, heating the plastic film to dry out any residual water and controlling the plastic film again to a temperature from 30° C. to 85° C., and applying a pressure ranging from 1 kg/cm2 to 8 kg/cm2 on the plastic film (sheet) while winding it into a roll. Plastic film (sheet) produced with this method has good transparency and smooth surface without flow mark and air pit.

Abstract: A method of manufacturing flexible sheets of expanded graphite material from recycled materials, comprising providing source materials in the form of flexible sheets of expanded graphite; comminuting the source materials into particles; re-expanding the particles; and preparing a mat from the re-expanded particles. Also described herein is a process of manufacturing a graphite material comprising grinding a cured resin impregnated graphite material into particles; removing at least part of the resin from the particles; and expanding the resin removed particles.

Abstract: Processes are provided for formation of complex shapes by embossing of a sheet of flexible graphite material. In one approach, a sheet of material is provided with a variable resin concentration across its width, and the position of the variable resin concentration is correlated with the position of embossing features which will result in thinner areas in the embossed articles. In a second approach, recesses are provided in the embossing rollers to accommodate material flow during embossing. These recesses result in protrusions formed on the articles, which protrusions must then be removed in a machining operation.

Abstract: In a process and apparatus for producing long plastic sheets by pressing molten plastic materials between the forming roller and the forming drum unit, the forming drum unit including a thin cylindrical sleeve supported from inside by a drum support unit and pressed against the outer surface of the forming roller to deform elastically in a curve along the outer surface of the forming roller as it rotates, thus maintaining a relatively long contact length.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: This invention provides a flexible polymer modified waterproofing cement material which can be used on a substrate or in concealed areas of construction engineering, water conservancy projects, municipal works, and its making process. The waterproofing material is made by kneading a hydraulic cement, a polymer dispersion, a water-soluble polymer or re-dispersible resin and water at a weight ratio of cement/polymer of about 100:15 to about 100:150 under conditions of about 25° C. to about 120° C., about 20 rpm to about 80 rpm until the water content of the kneaded materials reaches about 5% to about 20%. The kneaded material is mixed with a toughening polymer at a weight ratio of about 100:10 to about 100:50, then is calendered into sheets. These materials can adhere to dry or wet substrates firmly. They can be used in cold or hot and wet climate areas. After application, the waterproofing structure formed can bear retractive stress and deformation of the base or can resist outer impact.

Abstract: The invention concerns a process for preparation of light weight objects comprising calendering, extrusion, blow or injection moulding a resin of polypropylene, polystyrene, HD polyethylene or copolymers thereof and, admixed therein, thermally expandable microspheres including a thermoplastic polymer shell encapsulating a propellant, at a temperature sufficient to result in expansion of the microspheres, wherein said polymer shell is made of a homo- or co-polymer from ethylenically unsaturated monomers comprising more than 80 wt % of nitrile containing monomers. The invention further concerns light weight objects obtainable by the process.

Abstract: A method for grounding reinforcement (12) and composites (17) on a calender line reduces static build up on the composite (17), and makes it possible to subject a wire reinforced composite to electron beam processing (EBP). The method employs a slip ring (36) attached to rolls which contact composite (17) on the calender (11), and reinforcement (12) before it reaches the calender (11), wherein the slip ring (36) rotates with the rolls while the rolls are working polymer into the reinforcement, and a terminal (34) connected to the slip ring (36) remains stationary, and the terminal (34) is attached to ground (27). The method effectively grounds the composite as well as the reinforcement to prevent electrical discharge during EBP.