Abstract: It is an object of the present invention to provide a method for manufacturing a high-quality foam that can be produced stably on an industrial scale and that affords excellent thermal insulation as a foam with thin cell membranes, which method ensures uniform molten mixture fluidity, which is an essential condition for achieving consistent foam quality, in the manufacture of a foam by mixing starch as one molten polymer compound with another polymer compound having a different melt viscosity, and to provide a foam manufactured by this method. Water is added to and mixed with a plant-derived fibrous material and starch to manufacture a foam of a plastic resin containing as compositional components starch and a plant-derived fibrous material such as pulverized paper, pulverized wood, or the like.

Abstract: A method of manufacturing a fan from a plurality of fan blades (12), comprising the steps of: providing an injection moulding tool (30) which defines a fan hub section (14); assembling a predetermined number of preformed fan blades with the injection moulding so that inner ends (16) of said blades extend into moulding cavities (32) within the tool, injecting synthetic plastics material into the tool, and allowing the injected material to cool or cure to thereby form a moulded hub with the inner ends of the blades bonded therein.

Abstract: A method for forming a solidified granular material (15), in which granules (16, 17) are charged into a tubular frame member (11) and then heated together with the frame member, to solidify the granules. The granules include a mixture of first granules (16) and second granules (17), each of which second granules has a thermoplastic resin shell enclosing a solid or liquid which expands by vaporization. The mixture is charged into the frame member and heated together with the frame member. The heating causes the second granules (17) to expand and the surfaces of the second granules to melt for bonding with the first granules (16). The mixture, upon cooling, becomes a solidified granular material (15), filling the frame member with no space therebetween.

Abstract: Syntactic polyurethanes are prepared by mixing hollow microspheres with polyurethanes by a process in which, in a first step, the polyurethane system components are reacted and, in a second step, the feeding of the hollow microspheres is effected in a mixing apparatus, the mixing apparatus being free of dead space and comprising i) a mixing pot, ii) a feed for polyurethane, iii) a feed for hollow microspheres, iv) a stirring element and v) an outlet orifice.

Abstract: A process for producing plastic/wood fiber composite foamed structures includes the steps of pre-drying wood fiber filler; mixing it with plastic to form a mixture; feeding the mixture into an extruder; introducing and mixing a blowing agent; subject the mixture to high shear forces and extruding the mixture to produce a plastic/wood fiber composite foamed structure. The filler has a degradation temperature and an active volatization temperature. During the pre-drying step the temperature is maintained below the degradation temperature. During the mixing step the mixing temperature is maintained below the active volatilizing temperature. During the introducing and mixing step a blowing agent is introduced into the plastic/wood fiber mixture and is mixed therewith to produce a plastic/wood fiber/gas mixture. During the subjecting step the plastic/wood fiber/gas mixture is subjected to high shear forces in the presence of high pressures and the temperature is maintained below an active volatilizing temperature.

Abstract: A slip casting mold includes a water absorption layer having self water absorption capability and substantial water resistance. With the water saturation percentage of the water absorption layer being controlled, a slurry layer is deposited in the slip casting mold mainly under capillary attractive forces of the slip casting mold. The water absorption layer comprises an open porous body which is manufactured by stirring a mixture of an epoxy compound having at least one epoxy ring in one molecule, a hardener for reacting with the epoxy compound to harden the epoxy compound, a filler for developing self water absorption capability and mold releasability, and water into an O/W-type emulsion slurry, and casting the emulsion slurry into a mold impermeable to water, hardening the emulsion slurry in the mold while containing water.

Abstract: The present invention provides a cushioned floor covering having a backing material formed from waste polymeric material and a blowing agent wherein the blowing agent may be activated either before or after the backing material is adhered to the floor covering. The waste polymeric material includes from about 0 to 40 percent aliphatic polyamide material and is granulated, densified and extruded at a temperature that does not exceed the temperature at which the blowing agent would be activated.

Abstract: A method of producing a vehicle steering wheel including a steering wheel rim comprises the following steps: A foaming mold with a top part and a bottom part is used; two different foam components, namely, a central carrier component as well as a soft component surrounding the latter, are injected into the bottom part which is not closed by the top part; the foaming mold is closed by closing the bottom part with the top part, and; the foaming mold is heated.

Abstract: The object of the present invention is to provide a plastic molded material having uniform foamed structure at a low price. To attain said object, a method comprising; mixing particle containing 30 to 70% by weight of water in thermoplastic resin, heating and melting said thermoplastic resin in which said particles containing water are mixed under a high pressure, releasing said high pressure to form foamed structure and cooling to solidify said foamed thermoplastic resin.

Abstract: A process for producing a polymer/filler composite material includes a mixture forming step in which there is obtained a mixture of a flake-like filler and a polymer material, and the mean area (L2), mean thickness (d) and volume fraction (c) of the flake-like filler in the mixture satisfy the following equations (1), (2) and (3): 500 nm2≦L2≦100 &mgr;m2  (1) d≦L/20  (2) 0.2d/L≦c≦4d/L  (3), and a deforming step of applying deformation to the mixture at a strain rate of no greater than 10 s−1.

Abstract: A method is disclosed for using discarded carpet segments or other recycled textiles to make wood-like material in sheets that are comparable to plywood. The carpet segments or other recycled materials are shredded, then layered across a slow-moving conveyor to form a thick, low-density belt of fibers. This belt is compressed between rollers, and then needle-punched, using needles with surface barbs that pull fibers downward and upward. This needle-punching causes fibers inside the mat to be pulled into vertical alignment (i.e., perpendicular to the top and bottom surfaces of a horizontal mat), to form a needle-punched mat that will hold together without chemical adhesives. A binder material is then applied to at least one and possibly both surfaces of the mat, by means such as spreading or spraying a liquid binder on either or both surfaces of the mat, or stretching a continuous film of the binder material across either or both surfaces of the mat.

Abstract: A polymeric sponge includes cellulose fibers imbedded therein. The sponge is made by mixing water and cellulose fibers with a water-catalyzing prepolymer for chemical reaction thereof. The mixture is cured and granulated to size. The cellulose fibers enhance both the manufacturing process and the resulting sponge for increasing strength, durability, and performance thereof.

Abstract: A method for recycling wasted tires comprises the steps of: A. Mixing pellets of the wasted tires and natural rubber and pressing the mixture repeatedly till the mixture is heating. B. Stirring the mixture to make it well mixed. C. Rolling the mixture to a piece-like element. D. Adding some sulfur into the mixture and foaming the mixture to a foamed pad, whereby an air pressure is produced in the foaming procedure to force the pellets of the wasted tires fixedly fastening to the foamed rubber. E. Cooling the foamed pad.

Abstract: In producing a product foamed molding by molding into a specified shape a foamed product obtained by foaming a kneaded product obtained by kneading a fibrous material with an aqueous solution, followed by drying, an aqueous solution in which a binder mainly composed of gelatin and/or glue having a jelly strength of 130 Bloom or more is dissolved is used as the aqueous solution, whereby the generation of depressions in a pockmark form on a surface of the product foamed molding can be prevented to increase the yield of the product, and the specific gravity of the product can be reduced, thus being able to produce the foamed molding such as a cushioning material excellent in elastic performance economically, continuously and in large amounts.

Abstract: The invention provides a blow molding and a method for producing it. The blow molding is lightweight; its strength and rigidity per the unit weight thereof are high; and its heat resistance, sound absorption, heat insulation and sound insulation are all good. The blow molding is produced inexpensively, and is useful for the parts of inlet systems for internal-combustion engines, etc. The blow-molding method is for fiber-containing thermoplastic resins, and comprises holding a parison made of an inorganic fiber-containing, melt-expandable thermoplastic resin, between a pair of facing splits of a mold, blowing the parison to shape it, and thereafter optionally reducing the gaseous pressure inside it to thereby expand the wall of the shaped article. The blow molding is made of a thermoplastic resin, and it contains from 15 to 70% by weight of inorganic fibers having a mean fiber length of from 1 to 20 mm, and has a porosity of from 10 to 90%.

Abstract: A composite porous media for either gas or liquid flow is strong and efficient, and can readily be formed in or into a wide range of different shapes and configurations. In particular, the porous media is a composite of a metal, aerogel or ceramic foam (i.e., a reticulated inter-cellular structure in which the interior cells are interconnected to provide a multiplicity of pores passing through the volume of the structure, the walls of the cells themselves being substantially continuous and non-porous, and the volume of the cells relative to that of the material forming the cell walls being such that the overall density of the intercellular structure is less than about 30 percent theoretical density) the through pores of which are impregnated with a sintered powder or aerogel. The thickness, density, porosity and porous characteristics of the final composite porous media can be varied to conform with what is demanded by the intended use.

Abstract: The use of a plastic foam system, which contains at least one filler capable of swelling in the presence of water, for sealing openings in buildings, which are in contact with the outside, especially wall, floor and ceiling channels of pipes and/or cables.

Abstract: A method and apparatus for efficiently forming individual building units is provided, generally includes providing a plurality of molds, each capable of simultaneously forming a plurality of building units. Batches of cementitious slurry are individually mixed in order to control the density of each building unit formed. The ingredients are individually measured and combined into the mixing device. The cementitious slurry is then conveyed or transported and poured into one of the molds. The method provides the ability to control the amount of cementitious slurry in each batch in order to control to the extent possible the quantity of cementitious slurry poured into each mold and the ability to precisely control the dimensions of each building unit produced.

Abstract: An article of manufacture comprising an expandable sag-resistant nucleus-forming monolithic composite capable of being located within a hollow interior portion of a structural material and being expanded therein. Also, articles of manufacture comprising open-cellular structural material containing within the open-cell or cell thereof, at least one expandable sag-resistant nucleus-forming monolithic composite. The composite is desirably in the shape of a plug that is similar or close to similar to the shape of the hollow interior. In addition, there is described a process that comprises forming a pre-shaped expandable sag-resistant nucleus-forming. monolithic composite for use in reinforcing and stiffening a normally open-cellular structural material.

Abstract: A combination fastener and foam sheet having enhanced fastener retention and methods of forming a foam sheet are provided so that the fastener is not easily removed from the foam sheet when an outward force is applied thereto. The combination preferably includes a foam sheet including a fibrous material and urethane foam material abuttingly contacting and substantially surrounding the fibrous material so that the fibrous material is substantially contained within and retained by the urethane foam material. The combination also, preferably includes a fastener having threaded portions positioned within the foam sheet so that the threaded portions are retained in the foam sheet and are not easily removed when an outward force is applied thereto. The foam sheet preferably also has a strengthening material such as glass also substantially surrounded by the urethane foam.

Abstract: A fiber-reinforced, polymeric implant material useful for tissue engineering, and method of making same are provided. The fibers are preferably aligned predominantly parallel to each other, but may also be aligned in a single plane. The implant material comprises a polymeric matrix, preferably a biodegradable matrix, having fibers substantially uniformly distributed therein. In preferred embodiments, porous tissue scaffolds are provided which facilitate regeneration of load-bearing tissues such as articular cartilage and bone. Non-porous fiber-reinforced implant materials are also provided herein useful as permanent implants for load-bearing sites.

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 fowning 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 process for producing a cushioning article, which comprises: providing an injection molding apparatus having plural injection orifices, said orifices each having a discharge angle from 5° to 45° inclining from the vertical direction; injecting a thermoplastic polymer material in the form of strand from said plural orifices into a mold; and cooling said mold followed by demolding. The discharge angles of said orifices as projected into a horizontal plane each preferably has a phase difference of from 5° to 120° relative to those of adjacent orifices. Also disclosed is a cushioning article molded by the production process.

Abstract: A method for manufacturing products with a blown foamy structure, starting from a mass comprising at least natural polymers such as starch and fibers, in particular natural fibers, wherein the mass (M, S) is passed under pressure into or through a mould (23, 63) and the mass (M, S) is heated in the mould (23, 63) in a manner such as to give rise to gelatinization and cross-linking of the natural polymers, with the fibers extending through the product, while the mass prior to the introduction into the mould has temperature which is below the gelatinization temperature and in the mould is brought at least to the baking temperature.

Abstract: A method for injection-molding a plastics propeller fan by using a fixed-side mold section and movable-side mold section, comprises the steps of providing a movable core at an area corresponding to a thicker portion of a blade section of the propeller fan; after a predetermined amount of plastics material has been injected into a blade space of a mold cavity defined by the fixed-side mold section, movable-side metal section and movable core and conforming to the propeller fan, pushing out the movable core into the mold cavity and, after this step, bringing the movable core back to a normal position conforming to a mold shape defining the blade space and forming a proper fan.

Abstract: A method for producing an opaque polymeric film comprises: (a) extruding a base layer comprising a polymeric matrix and at least one cavitating agent; (b) coextruding at least one additional layer on at least one side of the base layer; (c) cooling the coextruded multi-layer film; and then (d) orienting the film in at least the machine direction (MD); wherein at least said base layer contains polybutylene terephthalate (PBT) and polycarbonate.

Abstract: A method for manufacturing a board includes step 1 to mix 49.8% to 97.8% of polyethylene, 50% to 2% of calcium carbonate and 0.2% of foaming agent, and step 2 to roll or press the mixture to become a board. The board can be burned without producing sticky remains.

Abstract: A polyurethane chip molded product having improved properties and a method for manufacturing the same are provided. The polyurethane chip molded product is manufactured by press-molding polyurethane chips and a binder together, wherein at least some of the polyurethane chips are split polyurethane chips made by splitting foamed polyurethane.

Abstract: A high performance structural foam is used for stiffening parts such as plastic parts. The foam could be formulated for in-mold use at elevated temperatures or at ambient temperatures for use with previously molded parts. Various ingredients are used to control the properties of the foam.

Abstract: There is disclosed a method for manufacturing products through the use of waste materials of various kind, such as heterogeneous plastic materials, wood, minerals, etc., derived from recycling processes, differentiated waste collection systems, solid urban wastes, industrial processing scraps or by-products, and the like, such products being adapted to be used in a wide range of most varied applications, particularly though not exclusively for manufacturing structural parts and decorative finishes for office furniture as well as furniture for cinematoghraph theatres, communities, concert halls and the like.

Abstract: The present invention provides a method for producing an expanded fiber-reinforced thermoplastic resin molding, the method using a mold comprising a female and male dies and comprising processes for supplying a molten thermoplastic resin containing reinforcing fibers whose average fiber length is maintained at 1 mm or more to between the female and male dies to charge a mold cavity with the molten thermoplastic resin, opening a part or the whole of the mold in the thickness direction of a molding after the charging, and cooling a molding while maintaining a cavity clearance at the thickness of a final molding, the method wherein the mold cavity of the mold is interconnectable to the atmosphere, the method further comprising steps for (a) forming a solidified layer in the surface of the molten thermoplastic resin charged in the mold cavity, followed by (b) breaking at least a part of the solidified surface layer, introducing the air through the broken part concurrently with or after the breakage, and opening a

Abstract: Disclosed is a rigid fine-celled light-weight foam composition and a method of producing it which has improved retention of liquids by absorption/adsorption which improves the thermal insulation and fire retardant properties of the fine-celled foam particularly suited for use in double walled tanks and hollow canopies, building panels, profiles, and the like.

Abstract: Provided is a polyolefin base porous film comprising a polyolefin composition in which calcium carbonate particles, preferably calcium carbonate particles subjected to surface treatment with chain carboxylic acid having 3 to 6 carbon atoms are dispersed. This polyolefin base porous film is characterized by that the leached solution with water has a pH which falls in the vicinity of neutrality and has a low stimulation to the skin, and therefore it is useful for goods contacting human bodies, particularly a back sheet for a sanitary napkin.

Abstract: An absorbent structure in an absorbent article such as a diaper, incontinence guard, sanitary napkin, dressing or the like. The structure being useful for the absorption of bodily fluids or discharges, e.g., urine and blood. The absorbent structure containing a carrier material in the form of an open-cell foam having hydrophilic fibers deposited within the pore structure of the open-cell foam.

Abstract: A method for production of cores for doors, partitions, furniture and the like. A filling material is mixed with a binding agent and the core is form-pressed in a desired shape, preferably as a plate-shaped item, where biomass is used as filling material, for instance, in the form of straw and stalks. A binding agent is used, mainly consisting of either UF-glue (urea-formaldehyde) or MUF-glue (melamin urea-formaldehyde). Preferably, the core further contains a foaming agent. A core may be provided as a form-pressed, mainly plate-shaped item, where the filling material consists of biomass, for instance, in the form of disintegrated straw and stalks, and where the binding agent mainly consists of UF-glue or MUF-glue, to which a foaming agent preferably is added.

Abstract: A foam body structure formed of plastic foam with one or more flame retardant reception cavities formed in the main body either simultaneously with an initial foam body formation process such as expandable plastic bead molding or subsequent to the foam body formation such as by melting, drilling or cutting. A solid flame retardant such as one in granular form is preferably supplied in sufficient quantity as to entirely fill the volume defined by the reception cavities. A covering or coating is provided over the flame retardant material to fix the material within the cavities. The volume and distribution of the reception cavities and the amount of the chosen flame retardant received in the cavities is sufficient to provide an essentially common flame retardation quality or characteristic over the entire volume of foam body (or at least the volume that could be exposed to a flame in its intended use).

Abstract: A method of producing artificial fossil coral which is an artistic replica of a natural coral reef formed from a slurry of cement, sand, ground PVC chips, colorant and water admixed with artistic rigid lightweight sponge or Styrofoam. Fiber glass strands are used to provide a plant like look to the artificial fossil coral and coloring of the artificial fossil coral duplicates the colors found in natural coral reefs.

Abstract: A process for manufacturing an insulation board comprising a rigid polyisocyanurate foam core having two major surfaces and a facing material on at least one of the major surfaces, comprising (a) conveying a facing material along a production line for attachment to one major surface of the core; (b) applying a foam-forming mixture of polyisocyanurate to the facing material such that the mixture is applied along the entire width of the facing material; (c) optionally conveying a second facing material along the production line for attachment to the other major surface of the core; (d) conveying the facing material with applied foam-forming mixture into a laminator which comprises a gap for foam expansion and allowing the mixture to foam and expand to fill the gap within the laminator; and (e) curing the foam. The process provides excellent boardstock thickness control, minimal wasted densification at the foam/facer interface, greater compressive strength and high line speed.

Abstract: Advanced structural components comprising a foamed thermoplastic that can be used in virtually any application where wooden components have a use. Such structural components can comprise sized lumber, shaped trim, posts, beams or shaped structural members. An advanced profile composite structural component comprising an exterior capping layer with an interior comprising a foamed thermoplastic can be used in the assembly of fenestration units adapted to residential and commercial structures. Preferably the profile structural component can be used in a window or door assembly. The profile member is adapted for ease of construction of the fenestration units, can be easily installed in a rough opening to framing members, and can be trimmed and adjusted on site. The profile is structurally strong, thermally stable, shrink resistant and will accept and retain the insertion of fasteners such as staples, nails and screws permanently with substantial retention and little or no damage to the units.

Abstract: A method for making a resilient material includes providing a particulate polymer, discrete pieces of foam 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 of increasing the amount of entrained vapor in fiber-reinforced resin composite materials, and in particular filament wound composites, wherein a particularly effective chemical foaming or blowing agent is incorporated into the resin matrix composition used to form the composites. The foaming agent creates vapor-filled voids throughout the resin matrix of the composite as it cures. The superior composites containing these vapor-filled voids demonstrate high burst strength retention and excellent resistance to cyclic fatigue. The invention also relates to composite materials and articles thereof.

Abstract: A method for manufacturing a plastic object may include the steps of: (a) providing an injection moulding device with a mould that includes two mould parts which in a closed position define a mould cavity; (b) providing foaming means for causing foaming in the mould cavity of plastic injected into the mould cavity; (c) providing blocking means for temporarily rendering the foaming means effectively inactive; (d) energizing the blocking means; (e) choosing as plastic a mixture of two plastics, wherein the first plastic is a non-type A plastic and the second plastic is a type A plastic that constitutes a maximum of roughly 30 percent by mass of the mixture, wherein the type A plastic is a plastic with high melt strength compatible with the first plastic, for instance HMS PP which is high-melt-strength polypropylene; (f) causing a formed object to cool to a chosen temperature, opening the mould cavity and removing the cooled object.

Abstract: Disclosed is a fibrous absorbent structure that is wet stable and has large void volume with a density below the critical density of the fiber employed. In one embodiment, the fibrous absorbent uses open-celled foam technologies to keep the fibrous structure expanded and bonded. In other embodiments, the resulting fibrous structure resembles an open-celled polymeric foam, with fibers serving as struts stabilized by binder material. In another embodiment, the resulting fibrous structure is filled with hydrophilic open-celled foams with the cell size substantially smaller than the fibrous pores. Such a wet-stable, high void volume fibrous absorbent can be used in a disposable product intended for the absorption of fluid such as body fluid, including extensible absorbent articles.

Abstract: A method for suppression of weld line weakening by virtually eliminating weld lines is disclosed. The process involves the near explosive injection of a metered amount of foamed thermoplastic molding material into an enclosing compartment formed by partly closing a compression type mold followed immediately by compression molding of the well mixed foamed material. The process finds particular utility in the manufacture of very long fiber reinforced parts. Variations on mold design and clamping cycles yield a variety of parts having foamed regions surrounded by more dense un-foamed regions. The method is particularly well adapted to the manufacture of large, very long fiber reinforced, foam-centered, hard surfaced, light weight, rigid parts.

Abstract: A system and a method for generating die swell/draw down information for a profile extrusion die design. A rheometer having a slit die and a puller mechanism coupled thereto provide the die swell/draw down information of a polymer resin material in two dimensions—in the thickness direction and in the width direction. A processor uses the die swell/draw down information to generate a die design chart that contains representations of shear rate, draw rates, and thickness. A designer uses the die design charts to design a profile extrusion die.

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 method for rapidly manufacturing “green-state” ceramic matrix composite components, components made from this method, and a resin/catalyst precursor mixture used in the method. The method includes manufacturing a component by preparing the precursor mixture by mixing a requisite quantity of a polymer-derived ceramic precursor resin, a catalyst, a discontinuous reinforcing fiber and filler material, and then loading this precursor mixture in a preheated mold. The precursor mixture then is cured in the mold to form the component which is porous. Thereafter, the component is reinfilitrated with a resin to at least partially fill the pores of the component. This method yields a ceramic matrix composite component that is cured in approximately one minute as well as a resin/catalyst precursor mixture that can be stored in excess of four weeks.

Abstract: The invention describes a method for producing reactive plastics molded bodies with a high proportion of coarse-grained filler, in which the coarse-grained filler is heated to an elevated temperature before being fed into the mold.

Abstract: A tonneau cover assembly for the open box of a pick-up truck includes a cover which is manufactured using an injection molding process. The cover is molded from a rigid polyurethane foam reaction injection molding (RIM) system. The cover is reinforced by a reinforcement frame and is attached to a mounting bracket using a hinge assembly. A slam action bracket secures the cover in its closed position and a pair of gas struts supports the cover in its open position. The mounting bracket is adapted to be secured to the pick-up box.

Abstract: The present invention relates to a method for producing a thermoplastic material for immobilization and/or protection of a part of the body. The method includes the steps of (1) admixing a thermoplastic material with at least one foaming agent and (2) extruding the admixture at a temperature sufficient to expand the foaming agent and for a specified resident time interval.