Abstract: This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories. The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized post-consumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.

Abstract: The present invention related to a method of manufacturing of a contamination control sheet, the method comprising the steps of: passing a web of support material from a supply roller to a coating station, and applying a coating of polymeric material to one surface of the support material; passing the coated support material through an oven to cure the polymeric material; and passing the coated support material around a cooling roller to a take up roller; characterised in that a nip roller is provided adjacent to the cooling roller so that the coated surface of the support material is pressed onto the cooling roller by the nip roller, and further characterised in that the cooling roller has a surface roughness of 0.2 to 1 Ra.

Abstract: Thermoformed polymeric foam articles are described herein In some embodiments, the articles are made by a manufacturing method (e.g., a continuous process) which involves the extrusion and subsequent thermoforming of a blowing agent containing thermoplastic sheet. The thermoformed polymeric foam articles may have a lower density than the precursor sheet from which they are formed. In some but not all embodiments, the precursor sheet is a multi-layer sheet which includes at least one foam layer. In such embodiments, the thermoformed articles also include multiple layers and at least one foam layer.

Abstract: The present invention provides a laminated plate capable of not only achieving a reduced weight and an increased rigidity but also improving a sound absorbing performance, and a method for manufacturing the same. A laminated plate (1) is supposed to include a core layer (2) including a plate-shaped paper honeycomb structure (4) and a pair of fiber reinforcement layers (3) sandwiching the paper honeycomb structure (4) from both sides in a thickness direction and integrated with the paper honeycomb structure 4. The through-holes (5) of the paper honeycomb structure (4) are filled with a foam resin (6), and the core layer (2) is made up of the paper honeycomb structure 4 and the foam resin (6) filled in the through-holes (5). When the foam resin (6) is filled in the through-holes (5) of the paper honeycomb structure (4), the foam resin plate (6A) is pushed into the through-holes (5) as a filling material by utilizing a compression force of a mold (11).

Abstract: Lithium-treated calcium aluminate cement (CAC)-based products, concretes, and related techniques are disclosed. In accordance with some embodiments, a lithium-treated CAC mixture may be produced by intergrinding ground-down CAC, class C fly ash, a lithium compound, and a polycarboxylate material. In accordance with some embodiments, a cementitious material may be produced by intergrinding said lithium-treated CAC mixture with class C fly ash, sodium citrate, and a polycarboxylate material. In accordance with some embodiments, a concrete may be produced by mixing said cementitious material (including said lithium-treated CAC mixture) with rock, sand, and water.

Abstract: A system and method for forming plastic sheet into a three-dimensional shape. The plastic sheet may include one or more sheet-mounted components, such as electronics, that must be shielded from excessive heat, pressure, and/or crushing when the formation of the sheet occurs. A recess will be formed to protect against directly contacting sheet-mounted component. The recess may be aligned along the heating plate and/or the form core and/or along a protective blanket which may be set over (and under) sheet prior to heating/forming. The sheet is registered (with or without a blanket) onto a base plate, and preferably over a form core. The sheet is then raised to contact with a heating plate, and then placed downward over the (optionally heated) form core. Recess(es) align in locations corresponding to mounted component to protect same.

Abstract: An embodiment includes a system comprising: a monolithic shape memory polymer (SMP) foam having first and second states; wherein the SMP foam includes: (a) polyurethane, (b) an inner half portion having inner reticulated cells defined by inner struts, (c) an outer half portion, having outer reticulated cells defined by outer struts, surrounding the inner portion in a plane that provides a cross-section of the SMP foam, (d) hydroxyl groups chemically bound to outer surfaces of both the inner and outer struts. Other embodiments are discussed herein.

Abstract: A novel material for producing auxetic foams is disclosed. The material comprises a multiphase, multicomponent polymer foam with a filler polymer having a carefully selected glass transition temperature. Novel methods for producing auxetic foams from the material are also disclosed that consistently, reliably and quickly produce auxetic polyurethane foam at about room temperature (25° C.). This technology overcomes challenging issues in the large-scale production of auxetic PU foams, such as unfavorable heat-transmission problem and harmful organic solvents.

Abstract: A substantially spherical hollow body, having a diameter of from 37 mm to 45 mm, in particular a diameter of 39.7 mm to 40.75 mm, and a weight of from 2.5 g to 3.5 g, in particular a weight of 2.6 g to 2.85 g, comprising a shell and an inner hollow space, wherein the shell has a wall thickness of 0.2 mm to 1.3 mm, in particular 0.3 mm to 0.8 mm, characterized in that the shell is free of celluloid and comprises at least one styrene-containing copolymer.

Abstract: A plasticized PVC formulation for foam extrusion including polyvinyl chloride, at least one plasticizer, at least one nucleating agent and a chemical blowing agent, wherein the plasticized PVC formulation is a dry blend containing 0.5 to 5% by weight of one or more nucleating agents and 0.1 to 3% by weight of the chemical blowing agent, wherein the blowing agent is sodium bicarbonate and the nucleating agent is talcum, and a foam extrusion method using said formulation. The extruded plasticized PVC foam is particularly suitable for rock shield pads used for pipeline protection. The foams are lightweight and require less consumption of materials with comparable properties to corresponding solid articles.

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.

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.

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.

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.

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.

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.

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.

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.

Abstract: A formulation for producing a polymeric material including high-density polyethylene, a chemical blowing agent, and other optional components is described.

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).

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.

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.

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.

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.

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.

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.

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.

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).

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.

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.

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.

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.

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.

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.

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.

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.

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, . . . ).

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.