Abstract: Pearls based on expanded polymers are produced by extruding an expandable composition containing a thermoplastic polymer and an expanding agent, and thereafter cooling and chopping the expanded material thus obtained.

Abstract: The present invention provides a method for manufacturing a film for a film capacitor making it possible to produce a film for a film capacitor which has a thickness of 10 ?m or less and which is excellent in a heat resistance and a voltage resistance at a high thickness accuracy by using a polyetherimide resin and provides as well a film for a film capacitor.

Abstract: A double-sided, slip resistant material is produced using a blown film process which produces a film having an interior heat sealable layer, a core layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent and optionally grit to produce a double-sided slip resistant material. A number of rollers are provided after nip rollers have fused the film together, and which form part of a machine direction orienter (MDO) that is used in line in the manufacturing process to heat, and then cool and condition (anneal and relieve any stresses and/or thickness inconsistencies in the film) prior to the film being wound onto a roll for storage.

Abstract: The invention consists of a method for manufacturing a vehicle trim panel so that the sheet of thermoplastic foam that forms the central core of the trim is made from a mixture of thermoplastic material, additives and fibre reinforcement, where the fibre reinforcement forms an integral part of the sheet thermoplastic foam.

Abstract: Embodiments disclosed in the detailed description include a unitary or monolithic composite or hybrid cushioning structure(s) and profile(s) comprised of a cellular thermoplastic foam and a thermoset material. The thermoset material may also be provided as cellular foam as well. In one embodiment disclosed herein, the unitary composite cushioning structure is formed from a cellular thermoplastic foam and a thermoset material. The cellular thermoplastic foam provides support characteristics to the unitary composite cushioning structure. The thermoset material provides a resilient structure with cushioning characteristics to the cushioning structure. A stratum is disposed between at least a portion of the cellular thermoplastic foam and at least a portion of the thermoset material to secure the at least a portion of the thermoset material to the at least a portion of the cellular thermoplastic foam to provide a unitary composite cushioning structure.

Abstract: The present invention relates to a microcellular foam of a thermoplastic resin and a method for preparing the same, and more particularly to a microcellular foam comprising a skin layer having a porosity of below 5% and a core layer having a porosity of at least 5%, wherein the thickness of the skin layer accounts for 5 to 50% of the entire foam, and a method for preparing the same. The microcellular foam of the present invention is advantageous in that it has a thicker skin layer and smaller and uniform micropores in the core layer, compared with conventional microcellular foams, while having mechanical properties comparable to those of conventional non-foamed sheets.

Abstract: The invention relates to the preparation of a crosslinked polymeric film bearing ionic groupings. The process consists in extruding a material comprising at least one prepolymer, in polymerizing said material after extrusion, and in subjecting the extruded material to a chemical reaction for grafting ionic groupings. The prepolymer comprises repeating units each comprising at least one aromatic group GA and at least one functional group GF; it bears at least one group GP which is polymerizable thermally at a temperature greater than the extrusion temperature, or photochemically, and also at least one reactive group GR which allows the grafting of ionic groupings. The films are useful as a membrane for fuel cells or electrodialysis, as an electrolyte of a lithium battery, of a supercapacitor or of an electrochromic device, or as an ion exchange membrane.

Abstract: A method for supplying molten polymer and expanding agent flows to a mixing area, by dispersing the expanding agent in a polymer melt by a rapid dividing mixing in a first static mixer, holding and intensively dividingly mixing the thus obtained mixture in a second static mixer, cooling the mixture, during mixing, in a third static mixer to an intermediate temperature, cooling the mixture to a granulation temperature, extruding polymer threads and subsequently quenching and granulating them. During processing, a weight ratio between the polymer melt flow Gp and the expanding agent flow GBA ranges from 13.0 to 19.0, a temperature in the first static mixer for rapid dividing mixing is calculated according to formula (I), in the second and third static mixed according to formulas (II) and (III), respectively, wherein GBA max. is the quantity of a maximum possible expanding agent flow, GBBct.

Abstract: The invention relates to a method for making articles having a veined aspect that includes the steps of (a) extruding a layer of substantially transparent PMMA including pigmented granules in a first extruder, (b) extruding a polystyrene layer including a foaming agent in a second extruder, wherein the extrusions of steps (a) and (b) are carried out simultaneously as a co-extrusion.

Abstract: A die comprising two die cavities, with each capable of supplying polymeric material, and a distribution plate interposed between at least a portion of each of the two die cavities. The distribution plate has a dispensing edge and a plurality of extrusion channels. First and second extrusion channels extend from entrance openings at the first and second die cavities, respectively, to exit openings on the dispensing edge. The exit openings of the first and second extrusion channels are disposed in alternating positions along the dispensing edge. A method of extruding with such a die and an extruded article made therefrom are also disclosed. The method includes co-extruding a first polymeric composition and a second polymeric composition. The extruded article comprises a plurality of longitudinal first stripes of the first polymeric composition alternating with a plurality of longitudinal second stripes of the second polymeric composition.

Abstract: A method of producing a laminated body of structural thermoplastic foam, the method comprising the step of successively extruding a plurality of foam layers from an extrusion die, each next layer being extruded onto a previously extruded layer to form a stack of mutually bonded layers.

Abstract: The invention relates to foamed polyvinylidene tubular structures—and particularly those for use as conduit. The tubular structures may be corrugated, and are especially useful for fiber-optic plenum conduit. The polyvinylidene foam may also be directly applied to fiber optic cable.

Abstract: A process for producing a plastic rod, in particular round rods, suitable for machining is provided. The process includes extruding a plastic profile of a first plastic molding composition which forms the outermost layer of the plastic rod, and inserting a second plastic molding composition as a rod core into the profile within a calibrator downstream of the extruder. The first plastic molding composition contains at least 50% by weight of a semicrystalline thermoplastic and the first plastics moulding composition has the following properties: a) crystallite melting point Tm in accordance with ISO 11357 of at least 170° C., b) crystallization temperature Tk in accordance with ISO 11357 of at most 70 K below T. and c) enthalpy of fusion AH in accordance with ISO 11357 of at least 20 J/g.

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.

Abstract: A gas exchange membrane is for use in an artificial lung. The membrane consists of a foamed, closed-cell material, in particular of silicone rubber. The membrane is produced by extruding a basic material which contains a foaming agent. The extrudate is then foamed. The result is a gas exchange membrane which has an increased gas exchange performance compared to known material due to the high permeability of the surface.

Abstract: The invention relates to a production method for a foam wound dressing with an outer germ barrier, in particular a film layer, and to a wound dressing obtained by such a method. In the method according to the invention, the germ barrier is generated by means of extrusion directly on the foam support. This results in a more reliable union between foam layer and germ barrier, without thereby compromising the absorbency of the foam in respect of wound exudate. The proposed method is simple and inexpensive and is able to satisfy all the requirements of the medical sector (e.g. freedom from solvents).

Abstract: The present invention discloses an approach for making mixed matrix membranes (MMMs) and methods for using these membranes. These MMMs contain a continuous polymer matrix and dispersed microporous molecular sieve particles. This invention also pertains to control of the thickness of the thin dense selective mixed matrix membrane layer that is equal to or greater than the particle size of the largest molecular sieve particles for making large scale asymmetric MMMs. In particular, the invention is directed to making asymmetric flat sheet MMM by a phase inversion technique. The MMMs of the present invention exhibit at least 20% increase in selectivity compared to the polymer membranes prepared from their corresponding continuous polymer matrices. The MMMs of the present invention are suitable for a variety of liquid, gas, and vapor separations.

Abstract: Provided are, among other things, systems, methods and techniques for manufacturing sheet material. In one representative embodiment, a sheet of fabric material is positioned across a patterning template that has a number of openings; and the sheet of fabric material and the patterning template are fed through an extrusion device in which extrusion material coats the fabric material and forces the fabric material into the openings in the patterning template, thereby producing a composite sheet material.

Abstract: An extruded, low-density, ethylenic polymer foam including from about 86% by volume to about 98% by volume open cells and a continuous, impervious surface skin is disclosed. The foam possesses superior compression recovery and lower compression resistance when compared with similarly comprised ethylenic closed-cell foams and superior moisture resistance and handling characteristics when compared to open-cell foams. A precursor composition and method for making the extruded, low-density, ethylenic polymer foam are also disclosed.

Abstract: Medical device (?) comprising at least one part (?) consisting of a polymer material (M) comprising at least one kinked rigid-rod polyarylene (P) of which more than 50 wt. % of the recurring units are recurring units (R) of one or more formulae consisting of an optionally substituted arylene group which is linked by each of its two ends to two other optionally substituted arylene groups via a direct C—C linkage. The recurring units (R) are a mix (?) consisting of (i) between 0 and 75 mole %, of rigid rod-forming arylene units (Ra) and (ii) between 25 and 100 mole % of kink-forming arylene units (Rb), both contents being based on the total number of moles of the recurring units (R). Arylene units (Ra) and/or (Rb) may be optionally substituted by at least one monovalent substituting group.

Abstract: The invention relates to microporous membranes comprising polymer and having well-balanced permeability, shutdown temperature, and pin puncture strength. The invention also relates to methods for making such membranes, and the use of such membranes as battery separator film in, e.g., lithium ion secondary batteries.

Abstract: A microporous membrane comprising layers, wherein at least one layer comprises a first polymer having a Tm in the range of 115.0° C. to 130.0° C. and an Mw of from 5.0×103 to 4.0×105, and the membrane has a shutdown temperature ?130.5° C. and a rupture temperature ?170.0° C.

Abstract: Composite coated wood products, and methods to produce such products, are described by embodiments of the invention. Composite layers may comprise polymer and fillers, such as organic fillers and inorganic fillers. The composite layers may also be foamed in some embodiments of the invention. Such composite coated wood products may be structural or non-structural pieces that may provide safe, economical, easy to manufacture construction products that may be utilized with wood composites, and other plastic composites. Such products may also promote uniformity of appearance in objects constructed with the composite coated wood products in a variety of applications.

Abstract: A thermally insulated conduit pipe (22) is produced in that an inner pipe (2), onto which an outer pipe (13) has been extruded and which is enclosed by foam, is worked downstream of the extruder (12) with molding tools (16-21) in order to achieve deep undulation. This results in a conduit pipe having a small bending radius.

Abstract: A method for producing a microporous polyolefin membrane formed by fine fibrils, the membrane comprising (A) a polyolefin having a weight-average molecular weight of 5×105 or more or (B) a composition containing Component (A), connected to each other, and having micropores of 0.05 to 5 ?m in average pore size and crystal lamellas of Component (A) or (B) being in a specific alignment state. The method includes extruding a solution of Component (A) or (B) in a solvent into a gel-like formed article; thermally setting the article, with or without stretching, at least at the crystal dispersion temperature of Component (A) or (B), but at melting point of Component (A) or (B) plus 30° C. or lower; and removing the solvent.

Abstract: A porous membrane that includes a first zone, the first zone including a crystallizable polymer; and a first nucleating agent, the first nucleating agent having a first concentration in the first zone, the first zone having a first average pore size; and a second zone, the second zone including a crystallizable polymer; and a second nucleating agent, the second nucleating agent having a second concentration in the second zone, the second zone having a second average pore size, wherein the crystallizable polymer is the same in the first zone and second zone, wherein the first average pore size is not the same as the second average pore size, wherein the first nucleating agent and the second nucleating agent are the same or different, wherein the first concentration and the second concentration agent are the same or different and with the proviso that the first nucleating agent and the first concentration are not the same as the second nucleating agent and the second concentration.

Abstract: A hose for use in bio-pharmaceutical applications includes an innermost tubular layer made from a fluoropolymer material. The tubular layer has an inner, relatively smooth and pure surface that defines an opening for transfer of various media. A layer of silicone is disposed next to an outer surface of the innermost tubular layer through use of, for example, an extrusion method. The outer surface of the tubular layer may first be modified by various treatments or chemicals to facilitate the adhesion of the silicone layer thereto. The silicone material may be solid or foamed. A reinforcement layer may be disposed adjacent to an outer surface of the silicone layer. The reinforcement layer may be formed of a wire braid having gaps. An outer jacket of silicone may be attached to the reinforcement layer and to the inner silicone layer through the gaps in the reinforcement layer.

Abstract: A waterproof and breathable lining structure includes a sheet-like waterproof and breathable foaming cushion layer made of a composition of a predetermined amount of low density polyethylene (LDPE) and a predetermined amount of foaming agent such as azodicarbonamide (ADCA), and a fabric lining layer integrally adhered to one side of the cushion layer to form the lining structure. The cushion layer is made by a process including the steps of: (a) palletizing raw materials including the low density polyethylene and the foaming agent such as Azodicarbonamide (ADCA); (b) extruding the palletized raw material to make a solid sheet; (c) cross-linking the solid sheet by an E-beam to form an irradiated matrix; (d) foaming the irradiated matrix into the sheet-like foaming cushion layer.

Abstract: Aeration pipe for diffusion of a gas into a liquid medium, the pipe having a flexible microporous tubular wall of thermoset polymer particles and a thermoplastic binder for melt bonding said thermoset polymer particles and dispersing an antimicrobial compound substantially uniformly throughout the wall. The aeration pipe is useful in various environments such as aquaculture and waste water treatment.

Abstract: The invention relates to a production process for a foam wound dressing having an external germ barrier, more particularly a film layer, and also to a wound dressing thus obtained, having, where appropriate, a pressure-sensitive adhesive layer. In the process according to the invention the germ barrier is produced by means of extrusion directly on the foam base. This results in a more reliable bond between foam layer and germ barrier, without detriment to the absorptiveness of the foam for wound exudate. The process presented is simple and cost-effective, and all of the requirements from the medical sector (e.g. absence of solvent) can be met.

Abstract: The present invention relates to an insulation material for thermal and sound insulation with high mechanical strength, thus providing structural integrity from its own, and its composites with other building materials, such as concrete, for providing pre-insulated building elements, the manufacturing of such material and its composites and the use thereof.

Abstract: Useful composites and methods of using such composites are provided. The composites include an outer layer containing a first polymeric material, an intermediate layer circumscribed by the outer layer and containing a second polymeric material, and an inner layer circumscribed by the intermediate layer and containing a third polymeric material. The inner layer, in combination with the intermediate layer, is structured and effective to reinforce the composite relative to a substantially identical composite without the inner layer. The present composites can be produced using co-extrusion processing.

Abstract: A synthetic wicker yarn capable of simulating a rolled leaf style, while being adapted to facilitate weaving. The yarn has an extruded, elongated body fabricated from a blend of a plurality of foamed polymers. The body has a surface of a first color, an x-axis and y-axis along a cross-sectional portion of the elongated body, and a longitudinal z-axis along its length. The x-axis has a first effective diameter and the y-axis has a second effective diameter. The body includes at least two rounded, foamed polymer folds, which project transversely from the x-axis and run longitudinally along a portion of the body. These folds simulate the margins of a leaf wrapped into a roll. Between the folds is a substantially concave crease within the surface of the body, also oriented longitudinally. The effective diameters are configured to form a substantially elliptical cross section that is easy to weave.

Abstract: The presently described technology provides a low cost multilayer elastomeric film containing at least one layer of styrene block copolymer and at least one elastomer layer substantially free of styrene block copolymer such that the resultant film has a low permanent set substantially equal to or less than a film comprised of styrene block copolymer only. The elastomeric film may be used in elasticized features of various articles, such as disposable absorbent articles. Methods for producing the low cost elastomeric film having a low permanent set are also described.

Abstract: The invention relates to a microporous membrane having a relatively low heat shrinkage values along planar axes of the membrane. The invention also relates to a battery separator formed by such microporous membrane, and a battery comprising such a separator. Another aspect of the invention relates to a method for making the multi-layer, microporous polyolefin membrane, a method for making a battery using such a membrane as a separator, and a method for using such a battery.

Abstract: Methods for forming foamed polyurethane composite materials in an extruder including a vacuum section are described. One method includes introducing a polyol, a di- or poly-isocyanate, and an inorganic filler to a first section of an extruder and mixing the components. After mixing, the composite material is advanced to a second section of the extruder, which is maintained at a vacuum pressure. The composite material can begin foaming in the second section and then be extruded from the output end of the extruder. The vacuum pressure of the second section removes non-foaming related gasses entrained in the composite material. A further method includes directing the extruded composite material into a mold.

Abstract: The invention relates to microporous polymeric membrane having a good balance of rupture temperature and air permeability. The invention also relates to a battery separator formed by such a microporous membrane, and a battery comprising such a separator. Another aspect of the invention relates to a method for making the microporous polymeric membrane, a method for making a battery using such a membrane as a separator, and a method for using such a battery.

Abstract: The invention relates to polyolefin membranes and membrane precursors comprising polyethylene and polypropylene. The polyolefin membrane can be a microporous polyolefin membrane comprising a first microporous layer and at least one second microporous layers where the first and second layers contain polypropylene and polyethylene, and the amount of polyethylene in the first layer is at least about 80 wt. % and the amount of polyethylene in the second layer is at least about 50 wt. %. The amount of polyethylene is higher in the first microporous layer than in the second microporous layer, and the total amount of the polyethylene in the first and second microporous layers is at least about 61 wt. %, based on the weight of the multi-layer, microporous polyolefin membrane.

Abstract: The present invention relates to an image receiver element comprising a single low density layer, wherein the single low density layer comprises non-crosslinked aliphatic polyester containing non-interconnected void space, and wherein the single low density layer does not absorb more than 3 weight % moisture at 80% RH and 21.3° C. as compared to the weight % moisture of said single low density layer at 20% RH and 21.3° C. The invention relates to a method of forming such an image receiver element, a printing system comprising an imaging material and the image receiver element, and a method of printing comprising obtaining an imaging material comprising a colorant layer; obtaining the image receiver element; superposing the colorant layer with the receiver element; and transferring colorant from the imaging material to the image receiver element.

Abstract: A process for producing a rubber composition, which comprises the step of kneading at least (A) 100 parts by weight of a pellet containing an ethylene-?-olefin-non-conjugated diene copolymer rubber, the pellet having a covering layer comprising a thermoplastic resin, (B) 10 to 200 parts by weight of a reinforcing material, and (C) 1 to 200 parts by weight of a softener; and a process for producing a vulcanized (further foamed) molded article of the rubber composition.

Abstract: Foamed materials, and methods and systems of producing the same. At least one of the methods includes forming a composite material including paper powder having a maximum particle size between about 30 to about 100 ?m 30 and being between about 20 and 40 weight percent (%) of the composite material, starch powder having a maximum particle size between about 5 to about 30 ?m and being between about 20 and about 40 weight % of the composite material, a polypropylene resin being between about 30.0 and 49.5 weight % of the composite material, and a vapor solution being between about 10 and about 20 weight % of the composite material; and forming the foamed material from the composite material by producing an abrupt expansion of vapor in the composite material.

Abstract: A composite tube formed by covering an outer surface of a tube with a foam, characterized in that: the foam is formed of layers composed of bar-shaped foams; and in a section perpendicular to a longitudinal direction of the foam, each of 40% or more of the bar-shaped foams is formed as a substantially fan-shaped figure formed by long and short arc portions of two large and small concentric circles, respectively, and two linear portions extending radially toward an outer periphery from the center of the concentric circles, with the figure satisfying the condition of formula (1): 0.5<a/b<2.5 ??Formula (1) where a is a length corresponding to ½ of the sum of the lengths of the long arc portion and the short arc portion of a substantially fan-shaped figure, and b is the length of each of the linear portions of the substantially fan-shaped figure.

Abstract: A method for combining materials (such as impregnating materials with functional materials) uses a combination of supercritical fluid technology and polymer melt processing technology. The functional material is soluble in a near supercritical or supercritical fluid, which dissolves in the matrix/bulk material during melt processing. Controlling the processing conditions facilitates a change of state for the fluid, which results in the precipitation of the functional material in the bulk material. The impregnated bulk material may be shaped using conventional polymer based processing techniques such as extrusion and injection moulding.

Abstract: The invention relates to a production method for a foam wound dressing with an outer germ barrier, in particular a film layer, and to a wound dressing obtained by such a method. In the method according to the invention, the germ barrier is generated by means of extrusion directly on the foam support. This results in a more reliable union between foam layer and germ barrier, without thereby compromising the absorbency of the foam in respect of wound exudate. The proposed method is simple and inexpensive and is able to satisfy all the requirements of the medical sector (e.g. freedom from solvents).

Abstract: A microporous film comprises a first component comprising a super high molecular weight polyolefin resin, wherein the weight-average molecular weight of the super high molecular weight polyolefin is about 1×106 to about 6×106. The microporous film also comprises a second component comprising a polyolefin resin, wherein the weight-average molecular weight of the polyolefin resin is less than about 5×105. A method of producing a microporous film comprises melting a first polyolefin resin which is a super high molecular weight polyolefin resin in a solvent to form a first mixture, and adding to the first mixture a second polyolefin resin having a weight-average molecular weight of the less than about 5×105 to form a second mixture.

Abstract: The disclosure provides a composition as well as a set of compositions and method for producing cellular or foamed or blown fluoropolymers such as perfluoropolymers and other thermoplastics articles allowing for the creation of a lower cost communications cable, conductor separator, conductor support-separator, jacketing, tape, wire insulation and in some cases a conduit tube as individual components or combined configurations that exhibit improved electrical, flammability and optical properties. Specifically, the foamable or blown fluoropolymer such as a perfluoropolymer cellular insulation composition comprises; talc and the selected fluoropolymer such as perfluoropolymers. Compounded pellets or products resulting in cellular or foamable products using these pellets has also been realized by providing the melt combination in the pellets of only talc and a perfluoropolymer.

Abstract: A polylactic acid resin foamed molding obtained by placing in a mold a cylindrical body having a foamed layer, which is formed by extruding a foamable molten resin composition prepared by kneading together a polylactic acid resin and a physical blowing agent from a die into a low-pressure zone, and molding it, wherein the molding's foamed layer constituting the foamed molding has a difference (?Hendo:2° C./min??Hexo:2° C./min) between the endothermic calorific value (?Hendo:2° C./min) and the exothermic calorific value (?Hexo:2° C./min) obtained by heat flux differential scanning calorimetry (heating rate of 2° C./min) of 10 J/g or more and a melt tension at 190° C. of 2 cN or more.

Abstract: Provided are, among other things, systems, methods and techniques for manufacturing sheet material. In one representative embodiment, a sheet of fabric material is positioned across a patterning template that has a number of openings; and the sheet of fabric material and the patterning template are fed through an extrusion device in which extrusion material coats the fabric material and forces the fabric material into the openings in the patterning template, thereby producing a composite sheet material.

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.

Abstract: Pressure sensitive adhesives comprising a linear block copolymer having a rubbery block and at least one glassy block; a multi-arm block copolymer having at least three arms, each having both a rubbery block and a glassy block; a first high glass transition temperature tackifier compatible with the rubbery blocks; a second high glass transition temperature tackifier having compatible with the glassy blocks; and at least one of a low Tg tackifier, a plasticizer, and combinations thereof, are disclosed. Tapes that include such adhesive, methods of making such tapes, and bonded composites using such adhesives and tapes are also disclosed.