Abstract: A melamine molded foam is produced by heat-compressing a melamine foam to a thickness of {fraction (1/1.2)} to {fraction (1/12)} to cause plastic deformation and temporarily fixing the shape; the heat-compression is performed under the conditions of from 210 to 350° C. for 3 minutes or longer; the heat-compression is preferably performed at a temperature within the range of lower than the decomposition temperature of the melamine monomer by 140° C. or less; in some of such molded foams, the shape recovery in the direction of thickness with the lapse of time is observed depending upon the heat-compression conditions; and the dimensional recovery ratio is 40% or less when allowed to stand at 23° C. for 200 hours.

Abstract: An article is made by co-curing a lay up on a composite bond jig of fiber-reinforced composite materials having a lower layer, at least one elongated hollow mandrel of a stiffened graphite fabric having its lower surface adhered to the upper surface of the lower layer, and an upper layer adhered to the top and side surfaces of the hollow mandrel and at least portions of the upper surface of the bottom layer.

Abstract: A flexible graphite sheet exhibiting enhanced isotropy is provided. In addition, an apparatus, system and method for continuously producing a resin-impregnated flexible graphite sheet is also provided.

Abstract: An object constructed of a thermoplastic polymer foam is heated above the polymer softening temperature, compacted to a desired reduced volume and reduced to a temperature below the critical softening temperature for storage. On the object being subjected again to a temperature above the polymer softening temperature, it assumes its original shape and volume. The object can additionally include flexible polymer sheets, fabrics or liners.

Abstract: A method of prescoring foam board for making composite panels includes impressing a pattern of ridges projecting from a surface of a die into at least one face surface of the foam board. The pattern of ridges on the die forms a pattern of indentations having three series of parallel linear indentations, each series being angularly offset from each series other by 60°. The ridges on the embossing die are pressed into the foam sufficiently deep that the the pattern of indentations impressed in the board surface after whatever springback occurs remain deep enough to enable volatiles generated in an interior zone of a panel to escape when drawn out by a vacuum pump when the foam board is heated under pressure between two face sheets of resin-preimpregnated fabric to form a composite panel.

Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam, a foaming agent and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.

Abstract: A method for manufacturing an E.V.A. foamed sports equipment includes preparing and stirring an E.V.A. foamable mixture, then integrally forming the foamable mixture into a sports equipment blank with a constantly reduced scale, the constantly reduced scaled sports equipment blank being placed in a reduced scaled heat forming mold to be heated at the temperature of 180° C., then opening the reduced scaled heat forming mold after a pre-determined period of time, the constantly reduced scaled sports equipment blank in contact with the air being expanded into a foamed sports equipment blank, then, placing the foamed sports equipment blank and ornamental strips into a constantly scaled pattern generating mold to be heat pressed and melted into a unity, the generating mold being evacuated so that the periphery of the foamed sports equipment blank is attached to the pattern generating mold so as to form a foamed sports equipment product with a precise knurl pattern being formed thereon.

Abstract: A process is proposed for producing non-combustible moulded articles from blown vermiculite, the blown vermiculite granules being mixed with an inorganic binder and then pressed. The blown vermiculite granules are mixed with a solution of an inorganic binder, the vermiculite granules once mixed are pre-pressed, cut to the shape required and the cut blanks are pressed non-continuously at at least room temperature and preferably at temperatures of at least 100° C. and pressures of at least 0.3 N/mm2 to ensure that all solvent residues are removed from the finished non-combustible moulded article.

Abstract: Structural members for doors and the like can be manufactured from plastic foamed composites containing wood flour by the steps of (1) dry mixing a blend of powders including PVC powder, wood flour, powdered thermal stabilizers, powdered foaming agent and a powdered gelatinization agent, (2) adding the mixed powder to a thermal stirring mixer to obtain a homogeneous dispersion of the several powders (3) transferring the homogeneous dispersion of powders to a cold stirring mixer and stirring at speeds sufficient to avoid agglomeration of the homogeneous dispersion of the several powders and (4) placing the non-agglomerated homogeneous dispersion of the several powders in a feeding hopper of an extrusion machine and extruding shapes for the desired components. The vacuum venting of the extrusion machine can be controlled to achieve components with more desirable surface features. Lubricants can be added to the homogeneous dispersions of the several powders to aid in the extrusion process.

Abstract: A shape memory foam material is obtained by impregnating a base foam material in a thermoplastic substance, heating and compressing the same at a temperature the same as or higher than the softening temperature of a thermoplastic substance as well as less than the softening temperature of the base foam material, cooling down while retaining the compressed state, and releasing the pressure after the cooling operation. The compressed state of the shape memory foam material is retained in a room temperature by a hardened product of a thermoplastic substance existing at least in the surface layer part thereof. The compressed state is released by softening the hardened product by heating. Moreover, a soundproof cover for an automobile engine is obtained using this shape memory foam.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A method for the production of molded bodies comprising foam particles is proposed in which the foam particles are shaped and welded together using microwave energy. The foam particles are accommodated in a foil-like bag and the bag is manually shaped or shaped through the use of a shaped mold with simultaneous change of the shape of the foam particles, and evacuated into a dense package. Microwave energy is subsequently used to melt together at least the surfaces of the foam particles. The method in accordance with the invention is particularly well suited as an economical manufacturing technique for packaging, in particular specialized packaging for models, small production runs, prototypes and the like.

Abstract: A pair of form keys and a method for forming reverse drafts in foam parts are disclosed. A male form key is reciprocally mounted in a first mold half in a retracted position. A female form key is rotatably mounted in a second mold half in a neutral position. The first mold half includes a first drive pin that when engaged, moves the male form key into engagement with a foam sheet to form an undercut as the first and second mold halves are closed. The first mold half also includes a second drive pin that engages the female form key as the first and second mold halves close rotating the female form key into engagement with the foam sheet and the male form key. After closure of the mold and the product is formed, the mold is opened. As this occurs, the drive pins are disengaged and the male form key retracts and the female form key rotates to their neutral positions. The formed product may then be stripped from the mold while maintaining the reverse draft or undercut.

Abstract: A susceptor-impregnated thermoplastic foam is molded by heating the susceptor-impregnated thermoplastic foam, preferably by induction; imprinting an object against the foam; and allowing the foam to cool into a hardened form conformed to the object.

Abstract: Method for producing an evacuated insulation panel comprising the steps of enveloping an open celled (semi-)rigid insulating foam in a substantially gas impermeable flexible vessel, evacuating the whole and sealing, wherein the panel is compressed during or after evacuation and sealing to a thickness of 10 to 90% of its initial thickness prior to compression.

Abstract: A method is disclosed that makes a open cell cellular body of polyethylene resin material in non-crosslinked structure, which has a maximum degree of cell interconnection, is good in recyclability and excellent in heat resistance or resistance to heat distortion. The method includes the steps of adding 4,4′-oxy bis (benzene sulfonyl hydrazide) to a polyethylene resin material to form a foamable composition and shaping the foamable composition of polyethylene resin material, heating the shaped foamable composition of polyethylene resin material to be foamed under an atmospheric pressure to form a cellular body thereof with cells therein, and mechanically deforming the cellular body of polyethylene resin material to cause the cells therein to be interconnected, thereby producing the open cell cellular body desired. The produced continuous cellular body is rendered heat resistant by irradiating the same or the formed cellular body with a beam of electrons.

Abstract: The invention concerns a method for preparing macro-porous synthetic ceramics designed in particular for bone substitution. The invention also concerns macro-porous synthetic ceramics comprising pores of controlled dimensions, distributed in number and in surface in a predetermined manner, the interconnection between the pores thereof being controlled.

Abstract: A method for re-using unneeded expanded styrene and an apparatus for preparing comminuted expanded styrene that can be used as a starting material for injection molding. The expanded styrene is rendered re-usable through a first step of comminuting expanded styrene, a second step of illuminating far-infra-red light to the expanded styrene comminuted by the first step to reduce its volume, a third step of further comminuting expanded styrene, reduced in volume by the second step, to prepare a granulated material, and a fourth step of injection-molding the granulated material from the third step to prepare a regenerated article.

Abstract: A shape memory foam member is disclosed. A coefficient of water absorption of the shape memory foam member is in the range between 0.01 g/cm3 and 0.2 g/cm3 in a non-compressed state. The shape memory foam member is compressed with heating; cooled with keeping the shape memory foam member in the compressed state; and released from the compressive pressure on the shape memory foam member after cooling. The original shape of the shape memory foam member is substantially recovered by heating.

Abstract: Angular blocks of foam flocks can be produced by the composite process with angular edges and a homogeneous density distribution over the entire cross-section in a molding box by first extending the filling cross-section in the comers of adjoining mold walls before the flocks are introduced, and, after the flocks have been introduced, reducing it to the envisaged cross-section of the slab to be produced and thus filling hollow spaces, and compacting the flock filling to the desired density in the comers, so that the slab has a homogeneous density over the entire cross-section.

Abstract: A pair of form keys and a method for forming reverse drafts in foam parts are disclosed. A male form key is reciprocally mounted in a first mold half in a retracted position. A female form key is rotatably mounted in a second mold half in a neutral position. The first mold half includes a first drive pin that when engaged, moves the male form key into engagement with a foam sheet to form an undercut as the first and second mold halves are closed. The first mold half also includes a second drive pin that engages the female form key as the first and second mold halves close rotating the female form key into engagement with the foam sheet and the male form key. After closure of the mold and the product is formed, the mold is opened. As this occurs, the drive pins are disengaged and the male form key retracts and the female form key rotates to their neutral positions. The formed product may then be stripped from the mold while maintaining the reverse draft or undercut.

Abstract: A method for re-using unneeded expanded styrene and an apparatus for preparing comminuted expanded styrene that can be used as a starting material for injection molding. The expanded styrene is rendered re-usable through a first step of comminuting expanded styrene, a second step of illuminating far-infra-red light to the expanded styrene comminuted by the first step to reduce its volume, a third step of further comminuting expanded styrene, reduced in volume by the second step, to prepare a granulated material, and a fourth step of injection-molding the granulated material from the third step to prepare a regenerated article.

Abstract: A flexible, low density thermoplastic foam and a method for lowering the density and increasing the flexibility of a thermoplastic foam having a melting temperature and being either amorphous with a softening temperature or semicrystalline with a glass transition temperature.

Abstract: A mold assembly and method for molding a substantially hemispherical construct from pre-expanded polystyrene beads. The mold assembly includes a female half mold; a mating male half mold; a first male mold insert mountable on the male half mold and having a continuous, peripheral, beveled edge; and a second male mold insert mountable on the first male mold insert. For forming a construct having an impact-resistant exterior layer and an energy-absorbing interior layer, such as a motorcyclist safety helmet, the beads are initially molded under heat and compression between the female half mold and the first insert to form a first intermediate product of a first volume having a continuous, peripheral, beveled edge; said product is thereafter molded under heat and compression between the female half mold and the second insert to a second, reduced volume to form a compressed, second intermediate product, the beveled edge of the first intermediate product serving to uniformly distribute the force applied thereto.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A method for making an improved absorber entails the loading of reticulated foam loaded with radar absorbing material and the forming and curing of the loaded foam in a mold on which vacuum is impressed prior to curing of the foam so that the foam expands and thereby experiences a substantial reduction in density of the resulting absorber structure.

Abstract: A material is disclosed which produced by a process in which a mold is filled of deformable shaped bodies, after which the mold is filled with a base material. The bodies are removed and the solidified base material forms a material of shell-like structures and an interconnecting pore system between the skeleton structures. The material produced by the process can be used as bone replacement materials, implants, filters and drug delivery systems.

Abstract: The inventive method serves for producing open containers from a flat sheeting (4) consisting of a foam material or containing at least one layer of such a material, by drawing the sheeting with the help of a female (2) and a male tool (1) and by expanding the foam material with the help of a pressure reduction. The action sequence of one cycle of the inventive method is e.g.

Abstract: A method of molding, from porous material, a low-density product having an impermeable surface. A mold is provided which has a cavity, the outline of which defines the outline of the product. The starting material is a flat sheet of plastic foam. The first step of the process, in some cases, is a pre-heating procedure, which softens the material. Then, from this sheet there is stamped a blank having substantially the outline of the desired product, which is then inserted into the mold cavity. The mold is then heated with the blank therein to form the blank permanently into the desired product, after which the mold is quenched in cold water with the product still inside. The product is subsequently removed from the mold and frozen. The result of this molding method is a low-density product having an impermeable surface integral with the foam interior which is suitable for receiving various types of brightly colored finished.

Abstract: A manufacturing method of diaphragms for use in electroacoustic transducers simultaneously joins an edge and a diaphragm body upon molding the diaphragm body through an injection molding with a set of mating molds for forming the diaphragm body, with the edge of a cell-structure disposed on one of the mating molds, the edge being preliminarily molded and cut into a predetermined shape, and with the other mold mated with the one mold.

Abstract: Methods for continuously shaping a compressible or cellular polymer material such as polyurethane foam, by cutting portions of the material from a surface of one or more slabs of material (180) include (a) compressing one or more slabs of cellular material between a pair of compression rollers (146, 146a) and two moving patterned platforms (132, 132a) interposed between the compression rollers, and (b) transversely cutting the slab or slabs with a blade or blades (76) just as the cellular material emerges from between the compression rollers. At least one of the moving patterned platforms, preferably an endless belt, defines a recess or pattern of recesses. When a single slab or multiple slabs of material are fed and compressed between the compression rollers, a portion of the material from one side of the slab or slabs fills the recess or recesses in one of the moving patterned belts. The blade then transversely cuts the cellular material.

Abstract: Flexible graphite sheet is made by compressing a mixture of fine particle of intercalated, exfoliated, expanded natural graphite with fine particles of intercalated, unexpanded, expandable particles of natural graphite, the unexpanded particles being more finely sized than the expanded particles. The resulting sheet of flexible graphite exhibits improved fire retardant and sealability properties.

Abstract: A method for shaping a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from one surface uses a compression roller, a support surface, a blade and a moving patterned platform interposed between the compression roller and the support surface. The moving patterned platform, preferably an endless belt or a series of interconnected panels, defines at least one recess, and may define a pattern of recesses of complex or simple shapes and at various depths. When the slab of cellular polymer material is compressed between the compression roller and the support surface, a portion of the material fills the recess or recesses in the moving patterned belt. At least a portion of the compressed material within the recesses is then cut from the surface of the slab by the blade just as the slab emerges from between the compression roller and the support surface.

Abstract: Thermoplastic foam is converted into useful products by simultaneously compressing and agitating particles of the foam. The particles are formed into a substantially unitary mass of hot softened material which can be immediately formed, cast or extruded into useful particles.

Abstract: PET foam is processed into flakes. The flakes are densified in a pellet mill at between about 300.degree. F. and about 350.degree. F. to produce pellets. The pellets are then dried in a desiccant dryer at about 350.degree. F. for about 6 hours, so that the dew point of the pellets reaches about -40.degree. F. The dried pellets have an intrinsic viscosity about equal to virgin PET and a crystallinity greater than 20%. This material can be reused as if it were virgin PET.

Abstract: A plastic sheet capable of being shaped by a cold room temperature tool, said sheet being a semi-rigid thermoformable plastic foam doped with carbon black having a concentration within a range of 0.0000081 to 0.0081% by weight of the foam. And a method of forming a product from such sheet by heating it to its thermoforming temperature range by infrared (IR) heat and placing and compressing the sheet between mold parts of a cold tool, the IR heat preferably being generated by quartz lamp electric heaters.

Abstract: A method for making shaped articles at room ambient temperatures without the addition of extraneous heat comprising the sequential steps:(1) forming a plurality of particles comprising a foamed admixture of starch, biodegradable polymer and water;(2) at room ambient temperature, applying to the surface of the particles finely divided drops of unheated water to effect wetting and softening of the outer surfaces of the particles;(3) without the addition of heat, compressing the surfaces of the surface softened particles to effect cohesion between the wetted outer surfaces of the particles, densification of the particles and formation of a shaped article; and(4) without the addition of heat, maintaining the particles under such compression for a time sufficient to render the outer surface of the particles nontacky by adsorption of water into the particles and by evaporation of water from the surface of the particles and(5) forming a protective skin on the outer surface of the compressed, non-tacky particles by h

Abstract: Open-cell plastic foam sheets with smooth, closed surfaces are heated up to a predetermined temperature after extrusion, are thermoformed in a thermoforming unit with the aid of a vacuum on both sides and are thermoset. One of the two closed surface skins of the plastic foam sheet is perforated with the aid of needles 4 arranged movably in a mold block 11. The mold block 11 is a component part of a thermoforming unit 10 and, together with a further mold block 9, forms the mold of this thermoforming unit. The mold block 11 for the inner side 13 of a plastic foam sheet 16 includes a male mold 1, a cooling plate 2, a vacuum plate 3, the movable needles 4, a needle plate 5, springs 6 for the return of the needle plate and also diaphragms 7 and a mounting plate 8, which are held together by screws 30.

Abstract: A flexible, open-pored cleaning body having at least one scouring surface (2) provided in at least one subregion with continuously formed, raised projecting ridges (3), wherein the ridges (3) have regions C,D of different heights in the direction of their extension.

Abstract: Flexible graphite sheet having embedded ceramic fibers extending from its surfaces into the sheet to increase the permeability of the sheet to resin.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: An extrusion profile is formed of foamed plastic, which includes a filler of wood flour or wood fiber. The foamed plastic may include polyvinyl chloride, chlorinated polyvinyl chloride or polystyrene in combination with the wood flour filler.

Abstract: According to the present invention, a three-dimensional cloth molding which has superior feel and durability, and a method for three-dimensionally molding cloth which offers low production cost and high productivity are provided. Cloth layer 85 having a print pattern, foam 87, and fabric 88 having one surface on which a plastic film is laminated are locationally placed on an elastic sheet 86. While foam 87 is still in a viscoelastic fluid state, cloth 85, foam 87, fabric 88, and elastic sheet 86 are integrally pressurizingly compressed for a predetermined time duration by upper metal mold 80 and lower metal mold 82. Thereby, foam 87 is fixedly adhered to the back surface of cloth 85 to support a print pattern of the cloth, and is three-dimensionally molded so as to conform to the profile of the print pattern.

Abstract: By employing a unique manufacturing process, unique manufacturing equipment, or a unique combination of materials, a fully integrated, multilayer foamed thermoplastic or elastomeric member or profile having a core member peripherally surrounded by an outer protective layer is attained which is virtually incapable of being removed from said core member. By effectively melting the adjacent surfaces of the foamed layers being interengaged, a core member having any desired cross-sectional shape is produced and is peripherally surrounded with an outer layer integrally bonded thereto. In one aspect of the present invention, metallocene catalyzed plastic material is employed in forming the core member to impart desirable physical attributes thereto.

Abstract: A flexible polyurethane foam is prepared by reacting a polyol with an isocyanate in the presence of water, a catalyst, a foam stabilizer and other aids. A polyol containing a hydrophilic organic acid metal salt and/or a polymer thereof is used as the polyol. The polyurethane foam is compressed to a thickness of 5 to 80% of its initial thickness. The resulting polyurethane foam has a water absorption comparable to PVA foam.

Abstract: A roller stamp includes a stamp case and a stamp roller mounted to the stamp case for rotation. The stamp roller is made of foamed polyolefin having pores capable of being impregnated with ink. A stamp pattern is formed on the stamp roller after the stamp roller is mounted to the stamp case. After the stamp roller is mounted to the stamp case, a stamp pattern is formed on the stamp roller by using a thermal head to selectively heat and close the pores in accordance with the stamp pattern.

Abstract: A method of producing a three-dimensional shaped plastic foam part comprises the steps of mixing plastic foam granules of a predetermined range of sizes and of different hardness in a predetermined mixing ratio to obtain a mixture of the plastic foam granules, mixing the mixture of the plastic foam granules with a liquid primary material until the granules are coated with the liquid primary material and a mixture of coated plastic foam granules is obtained, feeding a preset quantity of the mixture of coated plastic foam granules into a mold cavity of a mold closed on all sides, reducing the volume of the mold cavity at least in partial regions thereof after it has been filled with the mixture of coated plastic foam granules, triggering a reaction of the liquid primary material by applying pressure and heat until a continuous cellular structure of plastic foam has been formed and the plastic foam granules have been interconnected by the cellular structure of plastic foam after the volume of the mold cavity has

Abstract: A foamed polyester resin article is made by a method which includes forming a molten resin mixture containing poly (ethylene terephthalate) having an intrinsic viscosity greater than 0.7 and a moisture content of not greater than 0.03%, a melt viscosity modifier which comprises a multi-stage emulsion graft copolymer of methyl methacrylate and a lower alkyl acrylate monomer, and a heat activatable decomposition-type foaming agent. The mixture is heated in the barrel of an extruder and extruded through the die of the extruder. The method can be used to produce extruded poly (ethylene terephthalate) sheet having a foamed structure suitable for subsequent thermoforming into packaging articles and food containers such as those used in dualovenable food trays used for reheating foods in microwave or conventional ovens. The articles produced by the method have a density which may be 35-40% less than that of similar articles made from conventional non-foamed poly (ethylene terephthalate).

Abstract: A sectional door (20) having a plurality of panels (21,22,23,24) including, a body portion (25) of the panels spacing and joining longitudinal edges (40, 50), one of the edges (40) between adjacent panels on a first panel having a substantially concave curvilinear surface (45) in vertical cross-section, the other of the edges (50) between adjacent panels on a second panel having a substantially planar surface (52) in vertical cross-section, longitudinally-spaced hinges (65) interconnecting the first and second panels for pivotal movement. A panel (22) for sectional door (20) having a generally rectangular foam core (140, 240, 340), an inner surface (145, 245, 345) extending the longitudinal length of said foam core, and a recess (150,250,350) in the inner surface and the foam core extending the longitudinal length of the foam core.

Abstract: The present invention provides a heat insulated vessel (A) which is suitable for containing convenience food which can be cooked by hot water, or food or drink which is desired to be eaten or drunk while it is hot, and also a method of producing the vessel. The heat insulated vessel (A) of the present invention is made of a formed product of a foamed synthetic resin. An annular flange is continuous with an opening edge of a bottomed cylindrical portion, and a curled portion which is thinner than the bottomed cylindrical portion and which has a curved section shape is continuous with the annular flange. Preferably, the thickness of the curled portion is 1.5 mm or less.