Including In Situ (e.g., Foaming) Patents (Class 264/415)
  • Patent number: 11117409
    Abstract: A stereoscopic image forming method forms a color stereoscopic image on a recording medium having a thermal expansion property. The stereoscopic image forming method includes the steps of: fixing a color image on the thermally expandable recording medium using a color material; and irradiating the fixed color image with light of a light source having a maximum emission wavelength in a wavelength range of 280 to 780 nm. This light is absorbed by a compound contained in the color material to generate heat of the compound.
    Type: Grant
    Filed: March 6, 2020
    Date of Patent: September 14, 2021
    Assignee: KONICA MINOLTA, INC.
    Inventors: Seijiro Takahashi, Kouji Sugama, Michiyo Fujita, Haruo Horiguchi
  • Patent number: 10960700
    Abstract: In a setting apparatus including a control unit, the control unit is configured to: set, by a user operation, an irradiation condition of a laser beam for a thermally expandable sheet, a surface of the thermally expandable sheet being heated and expanded by being irradiated with the laser beam; and control an output and a scanning speed of the laser beam in accordance with the set irradiation condition, and in the setting, (i) a surface state of the thermally expandable sheet after expansion is selectable from a plurality of mutually different surface states, and (ii) the irradiation condition is set by the user operation according to the surface state selected from among the plurality of surface states.
    Type: Grant
    Filed: December 17, 2019
    Date of Patent: March 30, 2021
    Assignee: CASIO COMPUTER CO., LTD.
    Inventors: Yuji Horiuchi, Kenji Iwamoto
  • Patent number: 10166784
    Abstract: A photothermal conversion image generating device that generates a photothermal conversion image for forming a three-dimensional image by causing a thermally expandable sheet having a thermally expandable layer on a base material to expand, the device including: a processor that allocates, based on a line width of a line forming the three-dimensional image, an image for forming the line to either a front surface of the thermally expandable sheet or a rear surface of the thermally expandable sheet.
    Type: Grant
    Filed: July 21, 2017
    Date of Patent: January 1, 2019
    Assignee: CASIO COMPUTER CO., LTD.
    Inventor: Koji Tamura
  • Patent number: 8961859
    Abstract: There are provided expandable polystyrene resin particles formed by granulating a polystyrene resin containing an expanding agent, wherein the weight-average molecular weight Mw of the polystyrene resin is in the range of 120,000 to 270,000, and the expanding agent contains, as an essential component, pentane at a proportion of 3 to 8 parts by mass based on 100 parts by mass of the polystyrene resin, while the composition of the pentane is in the range of isopentane:normal pentane=10:90 to 80:20 by mass ratio. These expandable polystyrene resin particles can utilize a recycled raw material, and can produce a molded foam product having sufficient mechanical strength, while the expandable polystyrene resin particles have a long bead life and excellent low pressure moldability.
    Type: Grant
    Filed: January 23, 2009
    Date of Patent: February 24, 2015
    Assignee: Sekisui Plastics Co., Ltd.
    Inventors: Ryosuke Chinomi, Hiroyuki Tarumoto, Yoshifumi Saitou
  • Patent number: 8936744
    Abstract: There are provided a fluorine-containing photocurable resin composition and a method of preparing a mold comprising the same and more particularly, a photocurable resin composition having chemical resistance, mechanical properties and high transmittance, etc. as well as being easily wetted with and released from thermosetting or photocurable resins for pattern formation regardless of additional surface treatment, as opposed to the existing polymer resin materials used for resin molds, and a method of preparing a resin mold using the same.
    Type: Grant
    Filed: July 7, 2010
    Date of Patent: January 20, 2015
    Assignee: Dongjin Semichem Co., Ltd.
    Inventors: Jae-won Yoo, Byung-uk Kim, Un-yong Kim, Eun-jin Kwak
  • Publication number: 20150011666
    Abstract: This disclosure relates generally to molded cellular foam parts and, more specifically, to methods of manufacturing cellular polyurethane foam parts. In an embodiment, a polymer production system includes an energy source configured to provide activation energy to a foam formulation to produce a foam part. The system further includes a polymeric mold configured to contain the foam formulation within a mold cavity during the manufacture of the foam part. Furthermore, the mold is configured to not substantially interact with the activation energy that traverses the mold during the manufacture of the foam part. The system also includes a semi-permanent surface coating disposed on a surface of the mold cavity that is configured to facilitate release of the foam part from the mold cavity.
    Type: Application
    Filed: January 9, 2013
    Publication date: January 8, 2015
    Inventor: James Thomas McEvoy
  • 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
  • Patent number: 8894896
    Abstract: A method of making garment material, the method having the steps: applying coagulant (34) to a substrate (32); applying a foam (38) of the polymeric material to the substrate (32); allowing the coagulant (34) to coagulate some of the foam (38); and removing uncoagulated foam (38) from the substrate (32) to leave a layer of coagulated polymeric material on the substrate (32).
    Type: Grant
    Filed: November 20, 2004
    Date of Patent: November 25, 2014
    Assignee: A T G Ceylon (Private) Limited
    Inventors: John Arthur Taylor, Agampodl Sunil Shantha Mendis, Mohamed Fazal Abdeen, Howard William Thomas Goth
  • Patent number: 8865037
    Abstract: A method of manufacturing foamed thermoplastic films and trash bags wherein a foaming agent is added to a base thermoplastic resin. The resultant foaming agent/base resin mixture is extruded to form a single-ply foamed thermoplastic film. The film may be formed into bag, such as a trash bag.
    Type: Grant
    Filed: March 10, 2008
    Date of Patent: October 21, 2014
    Assignee: VINXI, L.L.C.
    Inventor: John Charles Marrelli
  • Patent number: 8858848
    Abstract: A conductive plastic article (31) is disclosed suited for a housing that offers improved shielding against electromagnetic interference or that offers improved electrostatic discharge properties. The plastic article is made by means of low pressure injection molding. The article (31) comprises at least 0.25 volume percent of electrically conductive additives (38). The article (31) comprises a cellular structure. The cellular structure is created by the use of a blowing or foaming agent. At least 0.25 weight percent of blowing or foaming agent is used in the production of the conductive plastic article (31).
    Type: Grant
    Filed: May 26, 2011
    Date of Patent: October 14, 2014
    Assignee: NV Bekaert SA
    Inventors: Rik Dewitte, Wim Verbrugge
  • Patent number: 8852473
    Abstract: A pin or tube reinforced polymeric foam and a method of manufacture thereof. The reinforcing pins or tubes are incorporated into the polymeric foam during or after fabrication of the reinforced polymer foam and are preferably coated with an adhesive or binder layer prior to fabrication.
    Type: Grant
    Filed: September 23, 2008
    Date of Patent: October 7, 2014
    Assignee: Wright Materials Research Co.
    Inventor: Seng Tan
  • Publication number: 20140272230
    Abstract: Systems and methods for adding buoyancy to an object are described herein. A buoyant material may be enclosed inside a flexible container, heated, and inserted into a free flooded cavity inside the object. The flexible container may then be formed to the shape of the cavity. After the flexible container is formed to the shape of the cavity, the flexible container may be cooled. The flexible container may hold a pre-determined amount of the syntactic material that provides a fixed amount of buoyancy. According to another aspect, systems and methods for packing a vehicle are described herein. In some embodiments, a buoyant material may be molded into the shape of a hull of a vehicle, and a plurality of cutouts may be extracted from the buoyant material which are specifically designed to incorporate one or more instruments.
    Type: Application
    Filed: March 13, 2014
    Publication date: September 18, 2014
    Applicant: Hadal, Inc.
    Inventors: Richard J. Rikoski, Jonathan Pompa, Robert S. Damus, Dylan Owens
  • Publication number: 20140275306
    Abstract: Pellets, beads, particles, or other pieces of a thermoplastic elastomer having a maximum size in at least one dimension of 10 mm or less (collectively, “pellets”) are infused with a supercritical fluid in a pressurized container, then rapidly depressurized and heated either by immersion in a heated fluid or with infrared or microwave radiation to foam the pellets The pellets are prepared with at least two different densities. Pellets with different densities, thermoplastic elastomer compositions, or foam response rates are placed in different areas of a mold. The mold is filled with pellets, then the pellets are molded into a part. The part has areas of different density as a result of the placement of pellets of different density.
    Type: Application
    Filed: March 15, 2013
    Publication date: September 18, 2014
    Inventors: Richard L. Watkins, Hossein Baghdadi, Charles Edwards, Yihua Chang
  • Publication number: 20140176390
    Abstract: An antenna and a method of manufacturing the antenna are provided. The antenna may include an antenna surface, a ground plane, and an air layer comprising a porous structure.
    Type: Application
    Filed: October 22, 2013
    Publication date: June 26, 2014
    Inventors: Byung Hoon KO, Sang Yun PARK, Youn Ho KIM, Young Jun HONG, Kun Kook PARK, Kun Soo SHIN
  • Patent number: 8728364
    Abstract: A foam form sheet material having a first large surface comprising substantially only closed cells and an opposite large surface and an interior comprising substantially only open cells. This material comprises a cross linked olefin thermoplastic polymer or copolymer. The foam is made by mixing the polymer with a blowing agent and a cross linking agent. The mixture is maintained in a two roll mill means for a time sufficient to initiate cross linking and to initiate foaming to form closed cells. The sheet material is then disposed in a second two roll mill means having a nip that is larger than the thickness of the foamed sheet material and maintained under elevated temperature and pressure sufficient to initiate further cross linking and foaming. The fully cross linked cell foam is then compressed to rupture the closed cells that are disposed in the interior to form open cells.
    Type: Grant
    Filed: July 9, 2008
    Date of Patent: May 20, 2014
    Assignee: Senstat Products & Technologies, Inc.
    Inventor: Edward Benjaminsen
  • Patent number: 8715559
    Abstract: A tetrafluoroethylene resin molded article obtained by fusing PTFE by heating a tetrafluoroethylene resin by heating, and then executing a gradual cooling or a cooling including a holding at a temperature equal to or higher than 313° C. and lower than 321° C. for 10 minutes or longer, and having, when heated to 365° C., then cooled to 245° C. with a rate of ?1° C./min, and then heated to 365° C. with a rate of 10° C./min, a heat of fusion which, within a range from 296 to 343° C., is equal to or larger than 32 J/g and less than 47.8 J/g, a porous article obtained by expanding the molded article, and a composite article, a filter, an impact deformation absorber and a sealing material utilizing the molded article or the porous article.
    Type: Grant
    Filed: September 8, 2006
    Date of Patent: May 6, 2014
    Assignee: Sumitomo Electric Fine Polymer, Inc.
    Inventors: Fumihiro Hayashi, Shinichi Kanazawa, Atsushi Uno, Akira Udagawa, Shigetoshi Ikeda, Toshiaki Yagi
  • Publication number: 20140062161
    Abstract: According to various embodiments, a seat cushion includes an electrospun nonwoven polymer layer. The seat cushion may be prepared by melting a polymer, electrospinning the polymer onto a mold lid to form the nonwoven polymer layer, injecting a foam into the mold, and closing the mold lid such that the foam and the nonwoven polymer layer bond as the foam expands.
    Type: Application
    Filed: April 5, 2012
    Publication date: March 6, 2014
    Applicant: Johnson Controls Technology Company
    Inventors: Frances A. Elenbaas, Eric B. Michalak
  • Publication number: 20140039076
    Abstract: To provide a urethane foam molded product having high thermal conductivity and electric insulation and a method for producing the same. A urethane foam molded product includes a base material made of a polyurethane foam and composite particles that are blended in the base material and oriented in a mutually connected state, in which each of the composite particles includes a thermally conductive particle made of a non-magnetic body, and a magnetic particle and an insulating inorganic particle that are adhered to the surface of the thermally conductive particle through a binder. A powder of the composite particles can be produced by stirring a powder raw material containing a powder of the thermally conductive particle, a powder of the magnetic particle, a powder of the insulating inorganic particle, and the binder using a stirring granulator.
    Type: Application
    Filed: October 2, 2013
    Publication date: February 6, 2014
    Inventors: Naoki Katayama, Koji Tomiyama, Yasuo Suzuki
  • Publication number: 20130330109
    Abstract: This invention provides a process for producing a conductive rubber roller having small aspect ratios of inner and outer diameters, having a stable measure of its inner diameter, having uniform cell distribution and being free from non-uniformity of hardness and electrical resistance in the peripheral direction. The process has a step of continuously extruding a tube composed of a specific unvulcanized rubber composition from a rubber extruder in a microwave vulcanizing unit, and a step of foaming and vulcanizing the tube by using a microwave irradiator having a microwave irradiation zone 4 m or less in length while being transported at given speed. The foamed rubber tube has an inner diameter 20 to 35% smaller than the outer diameter of the conductive core material over the whole region in the lengthwise direction, and the conductive core material is press-fitted into the foamed rubber tube without using any adhesive.
    Type: Application
    Filed: August 15, 2013
    Publication date: December 12, 2013
    Inventors: Hiroshi Imasaka, Satoshi Fukuzawa, Mitsuru Okuda, Erika Umeki
  • Publication number: 20130267623
    Abstract: Disclosed is a thermoplastic resin foam which is obtained by subjecting a thermoplastic resin composition containing a thermoplastic elastomer and an active-energy-ray-curable resin to foam molding to give a foamed structure, and irradiating the foamed structure with an active energy ray to allow the active-energy-ray-curable resin to form a cross-linked structure in the foamed structure. Also disclosed is a thermoplastic resin foam which is obtained by subjecting a thermoplastic resin composition containing a thermoplastic elastomer, an active-energy-ray-curable resin, and a thermal cross-linking agent to foam molding to give a foamed structure, irradiating the foamed structure with an active energy ray to allow the active-energy-ray-curable resin to form a cross-linked structure in the foamed structure, and heating the resulting foamed structure bearing the cross-linked structure to thereby allow the thermal cross-linking agent to form another cross-linked structure in the foamed structure.
    Type: Application
    Filed: June 3, 2013
    Publication date: October 10, 2013
    Inventors: Hironori Yasuda, Takayuki Yamamoto, Mitsuhiro Kanada, Kaori Ozawa
  • Patent number: 8551374
    Abstract: The invention relates to a novel, innovative industrial method for producing polystyrene (EPS) foam parts of arbitrary length and having a constant cross-section, with mixed densities located in accordance with the mechanical and thermal properties required for each application. The invention also relates to a machine (apparatus) for producing said solid parts having localized densities defined by the mechanical and thermal requirements of the application. The aforementioned products are produced by joined both longitudinally and transversely. The invention can be used to reduce the standard method to three steps, thereby resulting in a significant saving in terms of production. Moreover, unlike with the standard method, variants can be produced using the above-mentioned method, thereby increasing the range of application said type of products.
    Type: Grant
    Filed: August 30, 2007
    Date of Patent: October 8, 2013
    Assignee: Universidad de Guanajuato
    Inventors: Héctor Plascencia Mora, Luz Antonio Aguilera Cortés
  • Publication number: 20130161874
    Abstract: There are provided a method and apparatus for forming a three-dimensional image. The method and apparatus form an arbitrary colored image on the surface of a thermally expandable sheet by using surface image data. The method and apparatus form a mirror image, of which the density of a black component is adjusted in consideration of the influence of the density of the colored image on a bulge height of a thermally expandable layer so that an originally scheduled bulge height can be achieved, on the back of the thermally expandable sheet. The method and apparatus can achieve an intended bulge height by expanding the thermally expandable layer with thermal energy that is generated in the mirror image and the colored image when the thermally expandable sheet is irradiated with light including infrared wavelengths from the back of the thermally expandable sheet.
    Type: Application
    Filed: December 11, 2012
    Publication date: June 27, 2013
    Applicant: CASIO COMPUTER CO., LTD.
    Inventor: CASIO COMPUTER CO., LTD.
  • Publication number: 20130127092
    Abstract: A molded multilayer plastics component (1) with continuously reinforced fiber plies (2, 2?), which has a sandwich structure made of an internal structure (3) made of a foam material, embedded between at least two outer plies of fiber composite plastic. Around the periphery of the embedded internal structure (3) the component (1) has a coherent edge made of the fiber composite plastic, formed through peripheral overdimensioning (2?) of at least one of the fiber plies (2, 2?) with respect to the internal structure (3). Two alternative production processes are also disclosed for producing the multilayer plastics component (1).
    Type: Application
    Filed: July 26, 2011
    Publication date: May 23, 2013
    Applicant: DAIMLER AG
    Inventors: Willy Dauner, Frank Hoecker
  • Publication number: 20130082422
    Abstract: A molded article is made by first providing a starting material comprised of a support web and a layer of expandable polymer particles on the support web. This starting material is fitted as several layers into a generally closed cavity of a mold or shaping shell so as to only partially fill the cavity. Then energy, for instance microwave radiation, is applied to the starting material in the cavity so as to expand or foam the polymer particles such that the starting material generally fills the cavity.
    Type: Application
    Filed: September 28, 2012
    Publication date: April 4, 2013
    Inventors: Herbert BADER, Ralf NIEPELT
  • Publication number: 20130001460
    Abstract: The present invention provides a urethane foam molded product that has high thermal conductivity with minimal change to its physical properties. A simple method for producing the same is also provided. The urethane foam molded product includes a base material formed of a polyurethane foam, and a thermal conductive filler mixed in the base material and oriented to form mutual connections. The thermal conductive filler is formed of composite particles that include thermal conductive particles formed of a nonmagnetic material, and magnetic particles adhered to the surfaces of the thermal conductive particles.
    Type: Application
    Filed: March 24, 2011
    Publication date: January 3, 2013
    Inventors: Koji Tomiyama, Naoki Kitayama, Yasuo Suzuki, Shinji Yoshida, Katsutoshi Hashimoto
  • Patent number: 8303883
    Abstract: The invention provides foams of desired cell sizes formed from metal or ceramic materials that coat the surfaces of carbon foams which are subsequently removed. For example, metal is located over a sol-gel foam monolith. The metal is melted to produce a metal/sol-gel composition. The sol-gel foam monolith is removed, leaving a metal foam.
    Type: Grant
    Filed: June 30, 2006
    Date of Patent: November 6, 2012
    Assignee: Lawrence Livermore National Security, LLC.
    Inventors: Richard L. Landingham, Joe H. Satcher, Jr., Paul R. Coronado, Theodore F. Baumann
  • 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: 8257624
    Abstract: A method for making a porous material, includes melt-blending two or more non-miscible polymers to obtain a co-continuous melt, solidifying the melt to obtain a solid mass consisting of two co-continuous polymer phases, and selectively extracting one of the co-continuous phases thereby creating within the solid mass an essentially continuous pore network having an internal surface. The method further includes replicating the internal surface of the pore network within the solid mass by coating the internal surface with successive layers of materials, and selectively extracting the solid mass without extracting the layers of materials, to thereby yield the product porous material, formed of the layers of materials. The material has a void fraction higher than about 75%, and mainly having essentially fully interconnected sheath-like non-spherical pores and essentially non-fibrous walls.
    Type: Grant
    Filed: November 14, 2006
    Date of Patent: September 4, 2012
    Inventors: Basil D. Favis, Pierre Sarazin, Xavier Roy
  • Publication number: 20120189877
    Abstract: The claimed invention uses activated carbon fibers that incorporate porous carbon with a suitable pore size to maximize capacitance. The porous carbon material is prepared using a template, followed by incorporation into a matrix polymer and electrospinning of the mixture. Subsequent thermal treatments retain the fiber form, and a composite carbon fiber incorporating templated porous carbon is attained. The resulting electrode is binder free and 100% electrochemically active. Energy densities up to 41 Wh/kg in energy density 1.5 kW/kg in power density (electrode weight only) have been achieved.
    Type: Application
    Filed: January 24, 2012
    Publication date: July 26, 2012
    Applicants: Solarno, Inc., The Board of Regents of the University of Texas System
    Inventors: John P. Ferraris, Qiang Wu, Marilou E. Dela Cruz
  • Publication number: 20120091632
    Abstract: A selective high intensity ultrasonic foaming technique is described to fabricate porous polymers for biomedical applications. Process variables, including ultrasound power, scanning speed, and gas concentration have an affect on pore size. Pore size can be controlled with the scanning speed of the ultrasound insonation and interconnected porous structures could be obtained using a partially saturated polymers. A gas concentration range of 3-5% by weight creates interconnected open-celled porous structures. The selective high intensity ultrasonic foaming method can be used on biocompatible polymers so as not to introduce any organic solvents. The method has use in cell related biomedical applications such as studying cell growth behaviors by providing a porous environment with varying topological features.
    Type: Application
    Filed: April 7, 2011
    Publication date: April 19, 2012
    Inventors: Wei Li, Hai Wang, Vipin Kumar, Thomas J. Matula
  • Patent number: 8133419
    Abstract: Vehicle headliners are prepared with a core layer of a fiber-reinforced polyurethane foam. The polyurethane foam is prepared from a polyurethane-forming composition that uses water as a blowing agent and polyol or polyol mixture that has a high functionality and an average hydroxyl equivalent weight of 100-130. The selection of polyols permits cycle times to be reduced by allowing for faster demolding and shortened aging times before post-molding heat lamination steps can be performed.
    Type: Grant
    Filed: December 15, 2006
    Date of Patent: March 13, 2012
    Assignee: Dow Global Technologies LLC
    Inventors: Stephen R. Burks, Rogelio R. Gamboa, Richard G. McNeil, K. Joanne Bladon, Armando Esau Toledo Gonzalez
  • Patent number: 8123990
    Abstract: The object of the present invention is to provide a method for producing a fiber composite excellent in lightweight and rigidity.
    Type: Grant
    Filed: January 22, 2009
    Date of Patent: February 28, 2012
    Assignee: Toyota Boshoku Kabushiki Kaisha
    Inventor: Shigeki Watanabe
  • Publication number: 20110313073
    Abstract: Described herein are foam-like materials having substantially the same physical structure of polyurethane foams but with properties that can be tailored for a particular application. Methods of forming these foam-like materials are also described.
    Type: Application
    Filed: April 25, 2011
    Publication date: December 22, 2011
    Applicant: ALLERGAN, INC.
    Inventors: Alexei Goraltchouk, Jordan M. Thompson, Miriam M. Abiad, Kevin A. Ma, Dennis E. Van Epps, Nicholas J. Manesis
  • Publication number: 20100317759
    Abstract: Disclosed is a method for manufacturing an adhesive sheet, including the steps of: (i) forming polymer syrup using monomer for adhesive polymer resin; (ii) injecting gas into the polymer syrup to form bubbles; (iii) forming an adhesive mixture by adding a conductive filler to the polymer syrup having the bubbles and mixing the conductive filler with the polymer syrup; (iv) manufacturing the mixture in a form of a sheet; and (v) irradiating light onto at least two surfaces of the sheet to photopolymerize the adhesive mixture. Gas is injected into polymer syrup before the conductive filler is added to the polymer syrup to form bubbles, thereby obtaining an adhesive sheet capable of shielding and/or absorbing an electromagnetic radiation with dimensional stability and adhesive force superior to that of comparative adhesive sheets.
    Type: Application
    Filed: November 21, 2008
    Publication date: December 16, 2010
    Inventors: Jung-Hyun Ryu, Jeongwan Choi, Jin-Woo Park, Shin-ae Yang
  • Patent number: 7842379
    Abstract: Polymeric foams having nanocellular morphology are formed from a polymeric material having structural units derived from 2-hydrocarbyl-3,3-bis(hydroxyphenyl)phthalimidine compound. The foams include a plurality of cells having an average diameter of less than 1 micron. Processes for forming the foams include melting a polymeric material having structural units derived from 2-hydrocarbyl-3,3-bis(hydroxyphenyl)phthalimidine compounds; diffusing a blowing agent into the polymeric material to form a mixture; nucleating bubbles in the mixture is at a sufficient temperature and pressure to enable the production of cells having an average diameter of less than 1 micron; stabilizing the cells; and forming the mixture into a desired shape.
    Type: Grant
    Filed: July 5, 2007
    Date of Patent: November 30, 2010
    Assignee: Sabic Innovative Plastics IP B.V.
    Inventors: Chinniah Thiagarajan, Gautam Chatterjee, Ravi Sriraman, Santhosh Kumar Rajendran, Anand Vaidyalingam
  • Patent number: 7824592
    Abstract: A method for forming a bond between a first and a second shell of a blade is provided. The method comprises the steps of forming a cavity between said first and second blade shells and filling an adhesive into said cavity to form a bond line between said first and second blade shells.
    Type: Grant
    Filed: September 22, 2006
    Date of Patent: November 2, 2010
    Assignee: General Electric Company
    Inventors: Sjef van Breugel, Willem Bakhuis, Andy Billen
  • Patent number: 7811504
    Abstract: A molded product includes a matrix formed of a polymer material and a plurality of capsules dispersed in the matrix. An unevenness is formed on a surface due to expansion of the capsules. Some of the capsules have expanded without bursting and include an exposed outer shell portion that protrudes from a surface, and/or some of the capsules have burst and include an outer shell protruding portion that protrudes outward from the surface. Finish processing is performed, which eliminates the outer shell protruding portions and/or the exposed outer shell portions from the surface. This results in a molded product in which a color difference due to frequency of contacting an object, etc. is not easily generated.
    Type: Grant
    Filed: December 23, 2008
    Date of Patent: October 12, 2010
    Assignee: Tokai Kogyo Kabushiki Kaisha
    Inventors: Yasuyuki Takeuchi, Keiji Hiroe, Hideki Iwamoto
  • Publication number: 20100178488
    Abstract: Disclosed is a thermoplastic resin foam which excels typically in strength, flexibility, cushioning properties, and strain recovery and is especially resistant to cell structure shrinkage caused by the restoring force of resin. The thermoplastic resin foam which is obtained by subjecting a thermoplastic resin composition containing a thermoplastic elastomer and an active-energy-ray-curable resin to foam molding to give a foamed structure, and irradiating the foamed structure with an active energy ray to allow the active-energy-ray-curable resin to form a cross-linked structure in the foamed structure.
    Type: Application
    Filed: May 28, 2008
    Publication date: July 15, 2010
    Applicant: Nitto Denko Corporation
    Inventors: Hironori Yasuda, Takayuki Yamamoto, Mitsuhiro Kanada, Kaori Ozawa
  • Publication number: 20100147760
    Abstract: A filter assembly for removing contaminants from a fluid includes a filter housing, a filter cartridge, and a reticulated foam fluid treatment media. The filter housing has an inlet, an outlet and a chamber extending through the filter housing. The filter cartridge is positioned in the chamber of the filter housing and is constructed from a fibrous material used to filter contaminants from a fluid. The reticulated foam fluid treatment media is disposed within a passageway of the filter cartridge. The reticulated foam fluid treatment media includes a porous polymeric substrate having surfaces, including pore walls, and particles secured to the surfaces of the porous polymeric substrate via a binder, the particles being substantially uniformly distributed throughout the porous polymeric substrate via sonic vibration of the porous polymeric substrate and particles.
    Type: Application
    Filed: October 16, 2009
    Publication date: June 17, 2010
    Inventors: David Leavitt, John Famula, Christer Broman, Jeremy Hess, Elmo Walter Geppelt
  • Patent number: 7704437
    Abstract: A compounded rubber, which is made up of an NBR polymer, an organic peroxide and a blowing agent, to which 1 to 100 parts by weight of a synthetic silicic acid serving as a reinforcing filler and 10 to 200 parts by weight of precipitated calcium carbonate having a prismatic particle shape and serving as a filler are added to 100 parts by weight of the NBR polymer, is extrusion molded by a continuous extruder, and heated by HA heating and UHF heating in combination throughout the rubber to cause vulcanization and expansion, thereby providing a thick sponge having a homogenous cell structure. The sponge is passed through press rolls, and the resulting sheet stock is cut or punched with a cutting or punching machine into pieces of a desired form to obtain an applicator for cosmetics.
    Type: Grant
    Filed: August 27, 2008
    Date of Patent: April 27, 2010
    Assignee: Nishikawa Rubber Co., Ltd.
    Inventors: Yuichi Yamato, Kenji Kurisu
  • Publication number: 20090289212
    Abstract: A process for producing porous films (2), with the film (2) having a polymer matrix (M) and discrete domains (D) being provided in the matrix (M). According to the invention, it is proposed that the film (2) be subjected to a field for selective excitation of the domains (D), that the domains (D) be heated selectively relative to the remainer of the matrix by the excitation and that the pores (12) be produced in the domains (D) or in the region of the domains (D).
    Type: Application
    Filed: December 11, 2007
    Publication date: November 26, 2009
    Applicant: EWALD DOERKEN AG
    Inventor: Joern Schroeer
  • Patent number: 7582352
    Abstract: The foamed laminate based on olefin according to the present invention is composed of a substrate layer of a foamed body made of either an ethylenic thermoplastic elastomer comprising a polyethylene resin and an ethylene/?-olefin copolymer having a Mooney viscosity ML1+4 (100° C.) of 90-250 and an ethylene content of 70-95 mole % or an ethylenic thermoplastic elastomer composition comprising 100 parts by weight of an olefinic thermoplastic elastomer and 1-20 parts by weight of an olefinic thermoplastic resin and, under lamination thereon, a skin layer made of either an ultrahigh molecular weight polyolefin resin having an intrinsic viscosity of 3.5-8.3 dl/g or made of an olefinic thermoplastic elastomer composition comprising an olefinic thermoplastic elastomer and a lubricant.
    Type: Grant
    Filed: June 29, 2001
    Date of Patent: September 1, 2009
    Assignee: Mitsui Chemicals, Inc.
    Inventors: Kyoko Kobayashi, Akira Uchiyama
  • Publication number: 20090142563
    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: Application
    Filed: February 15, 2006
    Publication date: June 4, 2009
    Inventors: Alois Zorn, Florian Nowy
  • Publication number: 20090072449
    Abstract: A method of forming a composite cohesive material. The method including mixing a two part phenolic resin along with a plurality of expandable thermoplastic microspheres. Pouring the mixture into a mould which is then subjected to microwave radiation to substantially cure the material. The microwave radiation also causes expansion of the microspheres. Subsequently the cured material may be dried in a warm room.
    Type: Application
    Filed: November 11, 2005
    Publication date: March 19, 2009
    Inventors: Simon Harry Shepherd, Peter John Mellersh
  • Publication number: 20090008829
    Abstract: A compounded rubber, which is made up of an NBR polymer, an organic peroxide and a blowing agent, to which 1 to 100 parts by weight of a synthetic silicic acid serving as a reinforcing filler and 10 to 200 parts by weight of precipitated calcium carbonate having a prismatic particle shape and serving as a filler are added to 100 parts by weight of the NBR polymer, is extrusion molded by a continuous extruder, and heated by HA heating and UHF heating in combination throughout the rubber to cause vulcanization and expansion, thereby providing a thick sponge having a homogenous cell structure. The sponge is passed through press rolls, and the resulting sheet stock is cut or punched with a cutting or punching machine into pieces of a desired form to obtain an applicator for cosmetics.
    Type: Application
    Filed: August 27, 2008
    Publication date: January 8, 2009
    Inventors: Yuichi Yamato, Kenji Kurisu
  • Publication number: 20070264484
    Abstract: Process for continuous manufacture of latex foam rest articles such as mattresses, cushions and the like comprising a part able to participate to the manufacture steps and to remain embedded in the article with consequent improvements of final performances. A flexible perforated band, preferably a flat polymeric material net with longitudinal and cross reinforcement members, is placed over a foam laying surface provided with protuberances and in continuous advancement between a foam laying station and an unlimited length article extraction station. The latex foam passes through net holes forming an upper portion and a lower portion relative to said net. The net continuously opposes contraction forces and weight force exerted from upper portion on lower portion. The unlimited length article is subjected to successive cross cuts originating rest articles wherein a foam embedded net is arranged on ends of recesses originated by the protuberances.
    Type: Application
    Filed: September 1, 2006
    Publication date: November 15, 2007
    Applicant: SAPSA BEDDING SRL
    Inventors: Luciano ABRIGO, Renzo VILLA
  • Patent number: 7026044
    Abstract: An open-celled, inorganic foam based on an aluminosilicate and having a density of less than 25 g/l can be prepared by reacting and foaming an alkali metal silicate solution with an alkali metal aluminate solution in the presence of a volatile blowing agent and an emulsifier.
    Type: Grant
    Filed: August 10, 2002
    Date of Patent: April 11, 2006
    Assignee: BASF Aktiengesellschaft
    Inventors: Frank Braun, Horst Baumgartl
  • Patent number: 6923932
    Abstract: A method of molding a composite structure of a polymeric preformed skin with tightly radiused features and a polymeric foam body is provided. The method includes providing a mold cavity having a first edge; placing the preformed skin in the mold cavity with a preformed first edge of the preformed skin adjacent to the first edge of the mold cavity; heating the preformed skin adjacent the first edge; exposing the first edge to a vacuum to reform the preformed skin first edge to be adjacent the mold cavity first edge and injecting a foam polymeric material into the mold.
    Type: Grant
    Filed: December 12, 2002
    Date of Patent: August 2, 2005
    Assignee: Intertec Systems, LLC
    Inventor: Gregg S. Evans
  • Publication number: 20040198853
    Abstract: Carbon dioxide in a supercritical state is caused to permeate into a resin composition formed by sufficiently kneading a thermoplastic copolymer having a polysiloxane structure at recurring units. Subsequently, the resin composition is degassed by cooling and/or pressure reduction. As a result of degassing, a resin foam body 1 having a fine and uniform micro-cellular foam structure is obtained. The resin foam body 1 has a cyclic structure in which a resin phase 2 and a pore phase 3 are continuous and intertwined. The resin foam body 1 shows an excellent reflectivity relative to rays of light and is highly nonflammable, while it is very strong and lightweight.
    Type: Application
    Filed: February 9, 2004
    Publication date: October 7, 2004
    Inventors: Hiromu Saito, Takafumi Oda, Hiroshi Kawato, Toshitaka Kanai, Nobuhiro Watanabe, Takehito Konakazawa
  • Patent number: 6616886
    Abstract: Methods and apparatus for eliminating or reducing a surface skin when producing a flexible polyurethane foam slab are disclosed. The top surface of the chemically reactive polyurethane foaming mixture is heated during and/or after the foaming mixture expands. The heating preferably is conducted so as to prevent a significant temperature gradient from forming between the internal temperature of the foaming mixture and the top surface of that mixture. Preferably, heat is applied so as to heat from the top surface of the foaming mixture in an escalating fashion to higher temperatures as the foam is conveyed along a conveying path away from the foaming mixture dispensing device.
    Type: Grant
    Filed: January 31, 2001
    Date of Patent: September 9, 2003
    Assignee: Foamex L.P.
    Inventors: Bruce W. Peterson, Theodore J. Bartsch