Sponge-like Or Foamed Work Patents (Class 264/321)
  • Patent number: 10308747
    Abstract: To obtain a modified polypropylene-based resin which shows specific viscoelasticity and from which an expanded sheet having a low open cell ratio can be obtained.
    Type: Grant
    Filed: September 29, 2015
    Date of Patent: June 4, 2019
    Assignee: SEKISUI PLASTICS CO., LTD.
    Inventors: Kohei Tazumi, Eiji Fukuyama, Michihiro Hayashi, Shota Endo, Masashi Yamashita
  • Patent number: 10307944
    Abstract: There is described a method of creating a hinge in a body of expandable material, said body being substantially flat and having at least two planar regions connected by said hinge to facilitate folding of the planar regions about said hinge, comprising: expanding said expandable material to form said body; creating a region of excess expandable material in said body adjacent said hinge; and compressing said region of excess expandable material into the hinge of said body after the expandable material has fused to create a hinge having a concentrated volume of expanded material when compared to said at least two planar regions of said body.
    Type: Grant
    Filed: August 12, 2015
    Date of Patent: June 4, 2019
    Assignee: ICEE Holdings Pty Ltd.
    Inventors: Leslie John Skinner, Hamish Hingston
  • Patent number: 10297840
    Abstract: A film member stacking device includes a block having a bottom surface portion provided with an outer end configured to contact with an inner end of an opening of a first film member. The outer end of the bottom surface portion of the block is larger than the inner end of the opening of the first film member. The film member stacking device further includes a member configured to uniformly force the first film member in a direction of the bottom surface portion of the block. The inner end of the opening of the first film member is positioned by the block, and the first film member is stacked on a second film member. The block is configured to resist deformation upon contact between the outer end of the bottom surface portion of the block and the inner end of the opening of the first film member.
    Type: Grant
    Filed: June 20, 2013
    Date of Patent: May 21, 2019
    Assignee: NISSAN MOTOR CO., LTD.
    Inventors: Kei Ono, Masaya Yamamoto, Norifumi Horibe, Kenichi Toyoshima, Takayuki Terasaki
  • Patent number: 10245773
    Abstract: A method for molding a two-piece blow molded hollow tank by using auxiliary male molds includes the following steps: 1) blanking two parisons; 2) closing mold halves of a mold and a pre-molding template; 3) pre-stretching the molten parisons by using auxiliary male molds in the pre-molding template; 4) performing internal high-pressure blow molding, and pre-molding two housing portions; 5) opening the mold, and withdrawing the pre-molding template; 6) moving in a component built-in mechanism to perform built-in component connection; 7) moving out the component built-in mechanism; 8) closing the mold for the second time and finally blow molding a hollow tank; and 9) opening the mold and taking out the product.
    Type: Grant
    Filed: June 8, 2013
    Date of Patent: April 2, 2019
    Assignee: YAPP AUTOMOTIVE PARTS CO., LTD.
    Inventors: Yan Sun, Lin Jiang, Songjun Xu, Liang Liu, Dejun Gao, Ye Wang, Lushun Wu, Jie Li, Weidong Su, Changru Wang, Xiaojun Li, Quanzhou Yang
  • Patent number: 10245615
    Abstract: A method of protecting a polymer surface against fouling, which method comprises embedding in the polymer surface particles having antifouling properties, wherein the particles are embedded in the polymer surface by a spray mechanism in which the particles are accelerated and sprayed onto the polymer surface with a suitable velocity such that the particles become embedded in the polymer surface, wherein the particles are embedded in the polymer surface without an adhesive or binder and wherein the particles do not form a continuous layer on the polymer surface.
    Type: Grant
    Filed: July 15, 2011
    Date of Patent: April 2, 2019
    Assignees: COMMONWEALTH SCIENTIFIC AND INDUSTRIAL RESEARCH ORGANISATION, JAMES COOK UNIVERSITY
    Inventors: Andrew James Poole, Rocky De Nys, Peter King, Stefan Gulizia, Mahnaz Jahedi
  • Patent number: 10240394
    Abstract: A slip-resistant support base and method of making and using such a support base. A slip-resistant support base may include a resilient pad having an exposed lower expanse opposite an upper pad surface, the lower expanse being characterized by a two-dimensional distribution of downwardly open concave recesses having rims forming a lower extremity of the support base. The lower expanse may be made by shearing off a layer of a first major face of a pad of resilient closed cell foam to expose an expanse of cut cells. In some examples, the support base includes a body and the resilient pad as a resilient substrate. The body is preferably configured to support an external object positioned on a body upper surface. The resilient substrate is preferably attached to and extends along at least a portion of a body lower surface. The resilient substrate lower expanse is opposite the body lower surface.
    Type: Grant
    Filed: February 14, 2018
    Date of Patent: March 26, 2019
    Assignee: WORKING CONCEPTS, INC.
    Inventor: Richard H. Crampton
  • Patent number: 10183423
    Abstract: A compound for protection of an object from a blast or shock wave. The compound include a matrix material and at least a first and second sets of inclusions in the matrix material that differ in size, quantity, shape and/or composition in a direction through the impact-absorbing material, the combination of which contributes to the ability of the material to exhibit at least one property that changes as the inclusions are deformed in response to a blast or shock wave.
    Type: Grant
    Filed: February 1, 2015
    Date of Patent: January 22, 2019
    Assignee: Purdue Research Foundation
    Inventors: Eric Nauman, Anne Dye Zakrajsek, Andrew Zakrajsek, Steven Forrest Son, Evan Louis Breedlove
  • Patent number: 9956729
    Abstract: A method of manufacturing a foam having a Poisson's ratio which varies across at least a region of the foam in a gradient distribution involves the steps of: a) providing a housing defining an internal space having an inlet aperture and an outlet aperture; b) providing an open-cell foam of a size and shape configured to fit inside the internal space of the housing; c) positioning the foam inside the internal space of the housing; d) establishing a flow of air through the foam via the inlet and outlet apertures; e) heating the foam to a predetermined temperature while maintaining the flow of air through the foam; and f) subsequently cooling the foam while continuing to maintain the flow of air through the foam. A foam of such a type is also presented.
    Type: Grant
    Filed: September 23, 2014
    Date of Patent: May 1, 2018
    Assignee: ROLLS-ROYCE plc
    Inventors: Matteo Bianchi, Fabrizio Scarpa
  • Patent number: 9937652
    Abstract: A formulation for producing a polymeric material including high-density polyethylene, a chemical blowing agent, and other optional components is described.
    Type: Grant
    Filed: March 3, 2016
    Date of Patent: April 10, 2018
    Assignee: Berry Plastics Corporation
    Inventors: David Dezhou Sun, Philip A Driskill, Tony Cain, Diane E Marret, Debra R Wilson, Timothy S Ponrathnam
  • Patent number: 9770854
    Abstract: The present invention is directed to a deep draw microcellularly foamed polymeric container comprising a polymeric sidewall integrally connected to a polymeric base along a bottom edge. The polymeric sidewall and base are contiguous with each other and define a shape of an open top container. The polymeric sidewall and base have a contiguous inner microcellular foam structure (having average cell diameters ranging from about 5 to about 100 microns) surrounded by a smooth outer skin layer integrally connected therewith. The polymeric sidewall defines a container height and a top opening, wherein the top opening defines a top opening width, and wherein the polymeric base defines a container base width, and wherein the area defined by the top opening is greater than the area defined by the polymeric base, and wherein the ratio of the container height (h) to the top opening width (w) is greater than about 1:1 (h:w).
    Type: Grant
    Filed: November 26, 2013
    Date of Patent: September 26, 2017
    Assignee: Dart Container Corporation
    Inventor: Gregory L. Branch
  • Patent number: 9758293
    Abstract: An insulated sleeve is provided to be coupled to an outer surface of a cup. The sleeve is formed from an insulative cellular non-aromatic polymeric material having an area of plastic deformation. There are no fractures in the insulative cellular non-aromatic polymeric material so that a predetermined insulative characteristic is maintained in the material.
    Type: Grant
    Filed: April 25, 2016
    Date of Patent: September 12, 2017
    Assignee: Berry Plastics Corporation
    Inventors: Chris K Leser, Charles T Wallace, Philip A Driskill, John B Euler, Jason J Paladino, Milan C Maravich, Daniel O Davis, Jeffrey A Mann, Randy A. Bowlds
  • Patent number: 9745468
    Abstract: The present invention relates to a polyurethane resin composition for a support pad including a polyurethane resin, a DMF solvent, an anionic surfactant, and polyethylene glycol (PEG), and a polyurethane support pad including the polyurethane resin composition for a support pad. According to the present invention, long and large pores may be uniformly formed therein, and thus a support pad having an excellent compression rate and compression recovery rate may be provided.
    Type: Grant
    Filed: August 17, 2012
    Date of Patent: August 29, 2017
    Assignee: LG CHEM, LTD.
    Inventors: Dong-Mok Shin, Na-Ri Kim, Byeong-In Ahn, Sang-Soon Choi, Young-Ji Tae, Keong-Yeon Yoon
  • Patent number: 9713906
    Abstract: A cup-forming machine includes having a male mandrel and a female receiver. The male mandrel uses a cup body blank and a floor blank to form a body of a cup. The female receive receives the body and forms a rolled brim on the body to establish a cup.
    Type: Grant
    Filed: August 7, 2013
    Date of Patent: July 25, 2017
    Assignee: Berry Plastics Corporation
    Inventors: Kody A Chapman, Randy A Bowlds, Charles T Wallace
  • Patent number: 9698126
    Abstract: A method of integrating a first substrate having a first surface with a first insulating material and a first contact structure with a second substrate having a second surface with a second insulating material and a second contact structure. The first insulating material is directly bonded to the second insulating material. A portion of the first substrate is removed to leave a remaining portion. A third substrate having a coefficient of thermal expansion (CTE) substantially the same as a CTE of the first substrate is bonded to the remaining portion. The bonded substrates are heated to facilitate electrical contact between the first and second contact structures. The third substrate is removed after heating to provided a bonded structure with reliable electrical contacts.
    Type: Grant
    Filed: October 9, 2015
    Date of Patent: July 4, 2017
    Assignee: ZIPTRONIX, INC.
    Inventors: Paul M. Enquist, Gaius Gillman Fountain
  • Patent number: 9663625
    Abstract: The present invention relates to processes for producing melamine-formaldehyde foams, said processes comprising the steps of: a) producing an aqueous mixture M1) comprising 100 parts by weight of at least one melamine-formaldehyde precondensate, 2 to 4 parts by weight of at least one curative, 0.2 to 5 parts by weight of a surfactant mixture, 0.
    Type: Grant
    Filed: August 23, 2013
    Date of Patent: May 30, 2017
    Assignee: BASF SE
    Inventors: Bernd Gross, Horst Baumgartl, Jens-Uwe Schierholz, Bettina Wester, Peter Wolf, Bernhard Vath, Peter Nessel, Klaus Hahn, Tobias Heinz Steinke
  • Patent number: 9596848
    Abstract: The present disclosure provides diphenyl-impregnated compositions that are capable of delivering diphenyl into an environment for extended periods of time. In some embodiments, the compositions include a melamine copolymer foam, with formaldehyde-melamine-sodium bisulfite copolymer foams being particular effective. The present disclosure also provides methods for the manufacture of diphenyl-impregnated compositions and methods of using those compositions to achieve effective odor and mold/other fungi control.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: March 21, 2017
    Assignee: Ideaz, LLC
    Inventors: Cliff Zlotnik, Harry Velgich
  • Patent number: 9456656
    Abstract: An article with a sole structure including a midsole component and an outer sole member are described. The sole structure includes a set of holes arranged in an auxetic configuration that permit the sole to expand in an auxetic manner. The set of holes extends through the midsole component and the outer sole member and both the midsole component and the outer sole member are exposed on an outer surface of the sole structure.
    Type: Grant
    Filed: March 10, 2015
    Date of Patent: October 4, 2016
    Assignee: NIKE, Inc.
    Inventor: Tory M. Cross
  • Patent number: 9296126
    Abstract: The present invention is directed to a deep draw microcellularly foamed polymeric container comprising a polymeric sidewall integrally connected to a polymeric base along a bottom edge. The polymeric sidewall and base are contiguous with each other and define a shape of an open top container. The polymeric sidewall and base have a contiguous inner microcellular foam structure (having average cell diameters ranging from about 5 to about 100 microns) surrounded by a smooth outer skin layer integrally connected therewith. The polymeric sidewall defines a container height and a top opening, wherein the top opening defines a top opening width, and wherein the polymeric base defines a container base width, and wherein the area defined by the top opening is greater than the area defined by the polymeric base, and wherein the ratio of the container height (h) to the top opening width (w) is greater than about 1:1 (h:w).
    Type: Grant
    Filed: March 9, 2010
    Date of Patent: March 29, 2016
    Assignee: Microgreen Polymers, Inc.
    Inventor: Gregory L. Branch
  • Patent number: 9233490
    Abstract: A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel.
    Type: Grant
    Filed: August 1, 2014
    Date of Patent: January 12, 2016
    Assignee: Century Plastics, Inc.
    Inventors: Joseph W. Marchesano, Calvin A. Saur
  • Patent number: 9186822
    Abstract: A mold 20B for foam molding which allows efficient production of the foam molded product with accurately finished outer surface, and easy release of the molded product from the mold in the foam molding method is formed of an upper mold portion 21B and a lower mold portion 22B. The gas feed means 23 formed of the valve box 25, the valve element 26 and the like is attached to an opening formed in the bottom surface of the lower mold portion 22B. The recess portions 51 are formed in each part of the opposite side surfaces 50a and 50c of the cavity 50. The protruding portions 52 are formed on the lower surface of the upper mold portion 21B so as to be fit to the corresponding recess portion 51. Upon completion of curing, the upper mold portion is separated to open the mold, air is supplied into the valve box 25 such that air is fed to a space between the molded product 31B and the bottom surface of the lower mold portion 22B to push up the molded product 31B so as to be released from the mold.
    Type: Grant
    Filed: March 5, 2007
    Date of Patent: November 17, 2015
    Assignee: BRIDGESTONE CORPORATION
    Inventors: Masatoshi Sato, Toshiyuki Horimatsu
  • Patent number: 9168708
    Abstract: A method of forming a closed cell thermoplastic foam duct and a method of forming a duct and attaching it to an aircraft environmental control system. The environmental control system includes a duct made of closed cell thermoplastic foam, such as polyvinylidene fluoride foam.
    Type: Grant
    Filed: June 20, 2013
    Date of Patent: October 27, 2015
    Assignee: THE BOEING COMPANY
    Inventors: Walter Forrest Frantz, Jayant D. Patel, Douglas Dean Maben, Bruce Whitman, Douglas E. Freeman
  • Patent number: 9051879
    Abstract: A thermal barrier coating method forms a thermal barrier coating by spray coating over the surface of a component where cooling holes are made. The thermal barrier coating is formed by spray coating after masking pins, which do not protrude above the surface of the component, are inserted into the cooling holes or masking pins protruding above the surface of the component are inserted and get shrunk due to heat while spray coating, obtaining the protruding amount equal to or less than the thickness of the thermal barrier coating after shrinkage, which characterizes the method. By way of this method, a thermal barrier coating can be formed all over the surface without clogging the cooling holes.
    Type: Grant
    Filed: July 8, 2013
    Date of Patent: June 9, 2015
    Assignee: Mitsubishi Heavy Industries, Ltd.
    Inventor: Minoru Ohara
  • Patent number: 9011749
    Abstract: An example tooling system for processing a workpiece includes a base, disposed about an axis. A press is axially aligned with the base. The press defines a pressing surface. A mandrel extends along the axis from the base toward the press. The mandrel is disposed at least partially in a first cavity defined by one of the base or the press. The first cavity defines a profile different from the workpiece and is arranged to receive the workpiece. The mandrel is arranged to be inserted into at least one pocket in the workpiece.
    Type: Grant
    Filed: December 11, 2012
    Date of Patent: April 21, 2015
    Inventor: Joseph Wycech
  • Publication number: 20150105482
    Abstract: A method of manufacturing a foam having a Poisson's ratio which varies across at least a region of the foam in a gradient distribution involves the steps of: a) providing a housing defining an internal space having an inlet aperture and an outlet aperture; b) providing an open-cell foam of a size and shape configured to fit inside the internal space of the housing; c) positioning the foam inside the internal space of the housing; d) establishing a flow of air through the foam via the inlet and outlet apertures; e) heating the foam to a predetermined temperature whilst maintaining the flow of air through the foam; and f) subsequently cooling the foam whilst continuing to maintain the flow of air through the foam. A foam of such a type is also presented.
    Type: Application
    Filed: September 23, 2014
    Publication date: April 16, 2015
    Inventors: Matteo BIANCHI, Fabrizio SCARPA
  • Patent number: 8992813
    Abstract: A component made of at least one thermoformable material, having a first layer made of a first material, a second layer made of a second material, and a third layer made of the first material. The three layers form a sheet, which is formed to various shapes, depending upon the part that is to be created. The sheet may be formed to produce the bumper of an automobile, a door panel for an automobile, a flotation device, such as a pontoon for a pontoon boat, or the like. The first and third layers are SMC, and the second layer, or “core,” is disposed between the first and third layers, allowing the strength of the first and third layers to be used more efficiently, compared to a sheet having only the first and third layers, and no core.
    Type: Grant
    Filed: December 20, 2010
    Date of Patent: March 31, 2015
    Assignee: Magna International Inc.
    Inventors: Jeffrey R. Robbins, Jeremy Alan Panasiewicz, Louis Dodyk
  • Patent number: 8932504
    Abstract: A method of making an absorbent structure having a three-dimensional topography includes placing at least a portion of the absorbent structure between opposed mold surfaces. At least one of the mold surfaces has a three-dimensional topography. The three-dimensional topography of the mold surface is imparted onto the absorbent structure so that the absorbent structure has a three-dimensional topography corresponding to the three-dimensional topography of the mold surface.
    Type: Grant
    Filed: October 7, 2013
    Date of Patent: January 13, 2015
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Andrew Thomas Baker, Theresa Michelle McCoy, Stephen Avedis Baratian, Charles Wilson Colman
  • Publication number: 20150002352
    Abstract: The invention concerns a manufacturing method of a new type of dielectric material having a predefined variable permittivity resulting from the manufacturing process. Main characteristic of the manufacturing method is that in a first step homogeneous dielectric material (100) is shaped in at least a direction and subsequently at least a part thereof is formed so that the resulting dielectric material body (102) has the predefined variation in permittivity in said at least one direction. Said forming step may advantageously comprise sub-steps of deforming at least a part of the shaped dielectric material body and fixing the so deformed dielectric material body. The manufacturing steps are adapted so to induce a predefined variation in permittivity corresponding but not limited to a certain law (e.g. Luneburg, Maxwell, . . . ).
    Type: Application
    Filed: December 7, 2012
    Publication date: January 1, 2015
    Inventors: Hervé Merlet, Phillippe Le Bars, Olivier Lafond, Mohammed Himdi
  • Patent number: 8911656
    Abstract: Methods for manufacturing a composite fan inlet housing are disclosed. The methods include inserting a first piece of composite material and a second piece of composite material into a molding tool, inserting an inflatable bladder between the first piece and the second piece, and pressurizing the inflatable bladder to a curing pressure for a length of time sufficient to allow the first piece and second piece to cure.
    Type: Grant
    Filed: January 6, 2012
    Date of Patent: December 16, 2014
    Assignee: Honeywell International Inc.
    Inventors: William H. Doddman, Robert Saunders Murray
  • Publication number: 20140323604
    Abstract: A polymer foam having high bonding strength and improved compressive hardness characteristics is accomplished by the polymer foam comprising cavities formed by microballoons, and also 2 to 20 vol. %, based on the total volume of the polymer foam, of cavities surrounded by the polymer foam matrix.
    Type: Application
    Filed: April 17, 2014
    Publication date: October 30, 2014
    Applicant: tesa SE
    Inventors: Axel Burmeister, Franziska Czerwonatis
  • Patent number: 8852486
    Abstract: A molded discrete low stress gasket is constructed of restructured filled PTFE for use in corrosive or severe chemical environments under relatively low bolt loads. The gasket has a gasket surface and includes a raised outer sealing ring and a raised inner sealing ring. The gasket may constructed from a restructured filled PTFE material, with the sealing rings deforming at lower pressures than the remaining portions of the gasket.
    Type: Grant
    Filed: November 6, 2007
    Date of Patent: October 7, 2014
    Assignee: Garlock Sealing Technologies, LLC
    Inventors: T. Scott Tanner, Stefan Pitolaj
  • Patent number: 8845945
    Abstract: A method of forming a fan blade includes the step of positioning a piece of low density filler in a cavity of an inner exposed surface of a fan blade body. An upper surface of the piece of low density filler is located above the inner exposed surface of the fan blade body, and the low density filler has a density lower than a density of a material of the fan blade body. The method further includes the steps of positioning the fan blade body in a lower die of a press and applying pressure to the inner exposed surface of the fan blade body with an upper die of the press to compress the low density filler such that the upper surface of the piece of low density filler is approximately flush with the inner exposed surface of the fan blade body.
    Type: Grant
    Filed: February 29, 2012
    Date of Patent: September 30, 2014
    Assignee: United Technologies Corporation
    Inventor: Michael Parkin
  • Patent number: 8814556
    Abstract: A method for manufacturing a sheet having a shape transferred thereon, in which a sheet-like base made of a thermoplastic resin is placed between an imprint mold and an intermediate base and the sheet-like base is then pressed by a pair of pressing plates to imprint the shape of surface irregularity of the imprint mold to the sheet-like base. The sheet-like base is pressed such that, when pressing force of the pressing plates is maximum, an imprinting pressure difference is present in an imprinting surface of the imprint mold, a maximum imprinting pressure section is present in the imprinting surface, and a portion where the imprinting pressure is minimum is not present in the imprinting surface. The method achieves uniform and highly accurate shape transfer without trapping of air.
    Type: Grant
    Filed: September 22, 2008
    Date of Patent: August 26, 2014
    Assignee: Toray Industries, Inc
    Inventors: Yuma Hirai, Kiyoshi Minoura, Fumiyasu Nomura
  • Patent number: 8784710
    Abstract: A method of making an expanded polytetrafluoroethylene (ePTFE) membrane including the steps of: providing an unsintered or partially sintered ePTFE membrane; matting the unsintered or partially sintered ePTFE membrane; and immediately thereafter, sintering the matted ePTFE membrane. A method for making ePTFE tubes includes the steps of: providing an unsintered or partially sintered ePTFE membrane; wrapping the ePTFE membrane around a mandrel or form tool to form an ePTFE tube; matting the ePTFE tube; immediately thereafter, sintering the matted ePTFE tube; and removing the sintered ePTFE tube from the mandrel or form tool.
    Type: Grant
    Filed: March 18, 2010
    Date of Patent: July 22, 2014
    Assignee: Phillips Scientific Inc.
    Inventors: Douglas R. Hansen, James V. Phillips
  • Patent number: 8765043
    Abstract: The invention relates to a method of producing a foam product (1), whereby a body (2) of expanded closed-cell foam, in particular expanded polystyrene particle foam, is subjected to a non-melting heat treatment at a temperature above the glass transition temperature of the plastic used to form the foam, in particular polystyrene.
    Type: Grant
    Filed: February 15, 2006
    Date of Patent: July 1, 2014
    Inventors: Alois Zorn, Florian Nowy
  • Patent number: 8617449
    Abstract: A method of making an absorbent structure having a three-dimensional topography includes placing at least a portion of the absorbent structure between opposed mold surfaces. At least one of the mold surfaces has a three-dimensional topography. The three-dimensional topography of the mold surface is imparted onto the absorbent structure so that the absorbent structure has a three-dimensional topography corresponding to the three-dimensional topography of the mold surface.
    Type: Grant
    Filed: May 24, 2012
    Date of Patent: December 31, 2013
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Andrew Thomas Baker, Theresa Michelle McCoy, Stephen Avedis Baratian, Charles Wilson Colman
  • Patent number: 8574483
    Abstract: A method of deforming a component includes the step of forming the component from thermosetting, elastomeric microcellular polyurethane. The method further includes the step of heating at least a first portion of the component to a first temperature. The method further includes the step of compressing the first portion of the component while maintaining the first portion at the first temperature and while maintaining the second portion of the component at an undeformable state. The method of deforming the component shapes the first portion of the component. Preferably the method shapes the first portion of the component into a thin and/or complexly shape. The method of deforming the component also increases the first portion of the component relative to the second portion of the component, i.e. to densifying the component such that the component has varying density.
    Type: Grant
    Filed: July 17, 2006
    Date of Patent: November 5, 2013
    Assignee: BASF Corporation
    Inventors: Daniel G. Dickson, Gary M. Lawrence
  • Publication number: 20130277887
    Abstract: Provided is a process for thermoforming a gas and liquid permeable layer of thermoplastic material (12, 32) having an average thickness of less than 0.50 mm, the process comprising the steps of bringing the layer into contact with a layer of deformable non-gas permeable material (10, 30) to form a separable laminate of the two materials, arranging for the thermoplastic material to be at a thermoformable temperature and thermoforming the separable laminate, thereby thermoforming the thermoplastic material.
    Type: Application
    Filed: December 21, 2011
    Publication date: October 24, 2013
    Inventors: James Robert Stirling Howarth, Adrian Michael Woodward
  • Publication number: 20130277888
    Abstract: Provided is a process for thermoforming a gas and liquid permeable layer (10) of thermoplastic material having an average thickness of less than 1.0 mm, the process comprising the steps of bringing the layer of thermoplastic material, at a temperature below that required for thermoforming, into contact with a mould (16) at a temperature above that of a thermoforming temperature of the thermoplastic material; pressing the mould into contact with the layer of thermoplastic material, the contact between mould and thermoplastic material causing heat to transfer from the mould to the thermoplastic material and raising the temperature of the thermoplastic material to a thermoformable temperature; such pressing thereby causing thermoforming of the thermoplastic material to conform to the shape of the mould.
    Type: Application
    Filed: December 7, 2011
    Publication date: October 24, 2013
    Inventor: Adrian Michael Woodward
  • Patent number: 8545786
    Abstract: Methods for producing porous tricalcium phosphate net-shaped material are provide. The methods involve preparing a reactant mixture comprising calcium oxide and phosphorus pentoxide in a mole percent ratio that allows the mixture to form tricalcium phosphate upon combustion thereof, forming this mixture into a desired final shape in a die with compression, and carrying out a combustion synthesis therewith. Net-shaped TCP materials of the combustion synthesis, comprising alpha tricalcium phosphate or mixtures of alpha and beta tricalcium phosphate, are optionally further treated to effect transition of the alpha phase to the beta phase. The net-shaped TCP materials can have a uniform or non-uniform porosity.
    Type: Grant
    Filed: July 16, 2003
    Date of Patent: October 1, 2013
    Assignee: Colorado School of Mines
    Inventors: Reed A. Ayers, Steven J. Simske, John J. Moore, Martin Castillo, Guglielmo Gottoli
  • Patent number: 8540921
    Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.
    Type: Grant
    Filed: November 25, 2008
    Date of Patent: September 24, 2013
    Assignee: The Boeing Company
    Inventors: Simon D. Senibi, Barry P. Van West, Juan Carlos Guzman, Douglas A. McCarville, Daniel M. Rotter
  • Patent number: 8518313
    Abstract: Disclosed herein is a process for heat treating a foamed copolyester thermoplastic sheet structure in order to achieve a sheet structure having a compression set resistance (as determined according to ISO 1856, 22 hours, 70° C., 30% compression) of less than 11%. Heat treating involves annealing followed by at least two cycles of pre-compression at approximately the annealing temperature.
    Type: Grant
    Filed: April 25, 2011
    Date of Patent: August 27, 2013
    Assignee: E I du Pont de Nemours and Company
    Inventor: Peter Laszlo Szekely
  • Patent number: 8426006
    Abstract: An exemplary method for manufacturing and reinforcing a corner in an object made from a sandwich structure, having a thermoplastic core layer (18), which is arranged between two cover layers (16), at least one of which is a plastic cover layer, which method includes the steps of: producing an object including a corner between two object parts; positioning a thermoplastic core part (24) and an additional fiber-reinforced thermoplastic layer (26) in the corner, which thermoplastic core part has a shape adapted to the corner, in such a manner that the additional fiber-reinforced thermoplastic layer (26) substantially covers the exposed surface of the core part (24); and connecting a cover layer (16) of the sandwich structure to the additional fiber-reinforced thermoplastic layer (26).
    Type: Grant
    Filed: May 21, 2008
    Date of Patent: April 23, 2013
    Assignee: FITS Holding B.V.
    Inventor: Martin Th. de Groot
  • Patent number: 8428488
    Abstract: A cleaning roller cleaning a surface of a cleaning component, wherein the cleaning roller is provided in a roller configuration having a cylindrical shape and has a portion in contact with the cleaning component, the portion being made of a melamine resin foam having a continuous foam structure, the melamine resin foam being provided by heating compression from an original configuration in a radial direction, and wherein the portion in contact with the cleaning component has a continuous foam structure and a tensile strength in a range of 1.7±0.5 kg/cm2, and an image forming apparatus incorporating the same.
    Type: Grant
    Filed: June 30, 2011
    Date of Patent: April 23, 2013
    Assignee: Ricoh Company, Ltd.
    Inventors: Haruji Mizuishi, Tokuya Ojimi, Toshio Koike, Takeshi Shintani, Yuji Arai, Takuzi Yoneda, Ken Amemiya, Takaaki Tawada, Masami Tomita, Masanori Kawasumi, Takaya Muraishi, Hiroomi Harada, Hiromichi Ninomiya
  • Patent number: 8337188
    Abstract: An apparatus for making a shingle, together with the shingle made thereby, is provided, in which one or more thermoplastic materials are extruded or co-extruded to form an extrudate, with the extrudate being cut into a preliminary shingle shape, which is allowed to dissipate heat, and then is delivered to a compression mold, wherein the preliminary shingle shape is compression molded to substantially its final dimensions and is then discharged from the mold and allowed to cool.
    Type: Grant
    Filed: March 5, 2010
    Date of Patent: December 25, 2012
    Assignee: CertainTeed Corporation
    Inventors: Thomas Kevin MacKinnon, Robert E. Dodd, Joong Youn Kim, Douglas H. Wylie
  • Patent number: 8333858
    Abstract: A fabrication method of forming curved thermoplastic composite laminate parts with tailored and varying thickness in a continuous process. Automated equipment or hand lay-up are used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.
    Type: Grant
    Filed: October 20, 2006
    Date of Patent: December 18, 2012
    Assignee: The Boeing Company
    Inventors: Alexander M. Rubin, James R. Fox, Randall D. Wilkerson
  • Patent number: 8313682
    Abstract: A method of manufacturing a foam having a negative Poisson's ratio comprising the steps: placing a pad 12 of open cell polyurethane foam on a moulding surface 4; placing a flexible membrane 18 over the exposed surface of the foam to create a sealed chamber 20 between the moulding surface 4 and the flexible membrane 18 in which the foam pad 12 is disposed; applying an isostatic pressure difference between the inside and the outside of the chamber 20 thereby collapsing the foam pad 12 between the flexible membrane 18 and the moulding surface 4; heating the foam pad 12 to a predetermined temperature, and subsequently cooling the foam pad 12 while collapsed.
    Type: Grant
    Filed: October 8, 2010
    Date of Patent: November 20, 2012
    Assignee: Rolls-Royce PLC
    Inventors: Matteo Bianchi, Fabrizio Scarpa
  • Publication number: 20120258526
    Abstract: The invention relates to a packing material for biofilters, having a polyurethane polymer and starch. The packing material is resistant to compaction, can sorb pollutant organic compounds and reduces the start-up time of the biofilter. The packing material can be used as a substrate in the biofiltration of volatile and/or semi-volatile organic compounds present in gaseous or liquid effluents.
    Type: Application
    Filed: December 16, 2010
    Publication date: October 11, 2012
    Inventors: Olga Brígida Gutierrez Acosta, Vladimir Alonso Escobar Barrios, Sonia Lorena Arriaga Garcia
  • Patent number: 8277719
    Abstract: A process for the preparation of thermoplastic auxetic foams comprising the steps of: a) taking conventional thermoplastic foam; b) subjecting said foam to at least one process cycle wherein the foam is biaxially compressed and heated; c) optionally subjecting the foam to at least one process cycle wherein the biaxial compression is removed and the foam mechanically agitated prior to reapplying biaxial compression and heating; d) cooling said foam to a temperature below the softening temperature of said foam; and e) removing said compression and heat.
    Type: Grant
    Filed: November 6, 2006
    Date of Patent: October 2, 2012
    Assignee: Auxetic Technologies Ltd.
    Inventors: Andrew Alderson, Kim Lesley Alderson, Philip John Davies, Gillian Mary Smart
  • Patent number: 8227060
    Abstract: To provide a lactic acid polymer composition excellent in transparency, heat resistance and productivity, a molded article, a sheet and a multilayer sheet each of which comprises the composition, a thermoformed article obtained by secondary-forming the sheet or the multilayer sheet, and a process for producing the thermoformed article with excellent productivity. The lactic acid polymer composition of the invention comprises 100 parts by weight of a lactic acid polymer (A), 0.1 to 3 parts by weight of an organic crystal nucleating agent (B) comprising an aliphatic carboxylic acid amide having an amide bond, and 0.1 to 7 parts by weight of a crystallization accelerator (C). The thermoformed article of the invention is obtained with excellent production efficiency by thermoforming the sheet comprising the composition of the invention at a temperature of 60 to 130° C.
    Type: Grant
    Filed: May 9, 2006
    Date of Patent: July 24, 2012
    Assignee: Mitsui Chemicals, Inc.
    Inventors: Shoji Obuchi, Masaaki Iijima, Takayuki Kuroki, Masahiro Sugi
  • Patent number: 8202077
    Abstract: A Styrofoam densification machine for melting used Expanded Polystyrene (Styrofoam) products. It includes a hopper for holding the disposed Styrofoam and a hopper discharge area for melting the used Styrofoam. The Hopper discharge area contains a heated tray compartment which holds a receiving tray for collection of melted Styrofoam. The compartment shall have two or less access area doors for the retrieval of the collection tray. The discharge and compartment tray areas have silicone heating pads on the outside of the panels for heat. The hopper is surrounded by a paneled cabinet which includes up to two inches of installation. The machine is loaded by way of mechanical hopper lid(s) which includes up to two lid panels, high temperature seals, hinges and handles for ease of opening. The machine sits on up to four (4) casters along with anchoring plates. The machine operates on 120 volts, 208 volts and 240 volts.
    Type: Grant
    Filed: April 7, 2009
    Date of Patent: June 19, 2012
    Inventor: William C. Major