Abstract: An automotive bumper is disclosed which comprises a shell of injection molded platable grade ABS plastic. The plastic shell is plated with chromium metal and then backfilled by injection of ethylene ionomers. The resultant composite product provides an article which has a metallic appearing external surface and is backfilled with a strong, resilient plastic core. The composite structure has a pleasing appearance, is lightweight and is easy to manufacture. It has substantial structural integrity necessary to serve as impact resistant members on automobiles. The invention also provides a novel process to bond ethylene ionomers to plastic articles of metal-platable grade plastic resin.

Abstract: A method for designing and making composite membranes having a microporous support membrane coated with a permselective layer. The method involves calculating the minimum thickness of the permselective layer such that the selectivity of the composite membrane is close to the intrinsic selectivity of the permselective layer. The invention also provides high performance membranes with optimized properties.

Abstract: A tear away seam stabilizer for a vehicle seat component is provided for use with the pour-in-place molding process. The stabilizer, or welt, has an annular body attached to a notched tab portion by a tapered portion and neck portion which is sewn between covering members to form the desired shape of a component. A mold is provided within which the sewn cover, with the seam stabilizers in place, is inserted. The stabilizers maintain alignment of the seams in the cover member during the pour-in-place process and also prevent wrinkles in the cover. The end result is a vehicle seat component with the cover member tightly adhered to the foam body and conforming to a surface of predetermined shape. Once the foam pad is adhered to the cover member, the annular body of the stabilizer is readily torn off.

Abstract: The present invention is directed to non-porous isocyanurate-crosslinked polyurethane membranes. These membranes are useful for the separation of aromatic hydrocarbons from non-aromatic hydrocarbons. The separation can be performed using any commonly accepted membrane separation technique, e.g. reverse osmosis, dialysis, pervaporation or perstraction but is preferably performed under pervaporation or perstraction conditions.

Abstract: A method of manufacturing lightweight shapes from polyimide foam in which density discontinuities such as cavities, varying cell size, or swirl marks are substantially eliminated. A block or bun of polyimide foam is prepared in a conventional manner which results in a high density rind and other discontinuities. The foam is chopped into fine flakes in a chopper with a continuous flow of air to prevent electrostatic attachment of the flakes to the chopper and ducting. The flakes are mixed with a quantity of polyimide precursor and then heated to cause the precursor to bond the flakes into a uniform mass having highly uniform and predictable density. This is a very economical process since portions of the original bun may be used which would ordinarily be discarded. An alternative method is described whereby the flakes can be bonded together by using the precursor in the form of a partially cured foam either as a binder, or by making the flakes of partially cured foam.

Abstract: A method of manufacturing lightweight shapes from polyimide foam in which density discontinuities such as cavities, varying cell size, or swirl marks are substantially eliminated. A block or bun of polyimide foam is prepared in a conventional manner which results in a high density rind and other discontinuities. The foam is chopped into fine flakes in a chopper with a continuous flow of air to prevent electrostatic attachment of the flakes to the chopper and ducting. The flakes are mixed with a quantity of polyimide precursor and then heated to cause the precursor to bond the flakes into a uniform mass having highly uniform and predictable density. This is a very economical process since portions of the original bun may be used which would ordinarily be discarded. An alternative method is described whereby the flakes can be bonded together by using the precursor in the form of a partially cured foam either as a binder, or by making the flakes of partially cured foam.

Abstract: A supported composite membrane (10) includes a porous support membrane (12) forming a first layer for structurally supporting a second membrane thereon. The porous support membrane (12) includes two sides (14,16) and a plurality of pores (18) extending therethrough providing fluid communication between the two sides (14,16). A nonporous water and water soluble substance permeating membrane (20) is disposed over each of the pores (18) for selectively permeating only water and water soluble substances through each of the pores (18). A method of making the membrane (10) includes the steps of forming a porous support material (12) into a first layer, and adhering a nonporous water and water soluble substance permeating membrane (20) over each of the pores (18) for selectively permeating only water and water soluble substances through each of the pores (18).

Abstract: An improved process for producing a laminated resin foam composed of two resin foam layers of different characteristic properties wherein the layers are integrally bonded together. A first foamable resin liquid for forming flexible foam is poured into a first space in a foam processing mold on one side of a barrier projecting from the wall of the mold and pouring a second foamable resin liquid for forming a foam less flexible than the first flexible foam into a second space in said foam processing mold on the other side of said barrier. The two foamable resin liquids foam beyond the barrier into contact with each other to form the two laminated foam layers. One improvement in the process includes wetting a substantial portion of the mold cavity with the first foamable resin liquid. Various shapes of molds and barriers will produce different shapes and characteristics of the resultant foam pad, such as for a car seat.

Abstract: A composite chromatographic sheet-like article is prepared by the steps comprising blending one or more non-swellable sorptive hydrophobic particulate materials in the presence of an amount of polar organic masking agent sufficient to allow rapid wetting of the surface of the particulate and in the presence of sufficient lubricant water to exceed the sorptive capacity of the particulate, provided that the volume ratio of water to masking agent does not exceed 3:1, adding with stirring an aqueous emulsion of polytetrafluoroethylene so that the resulting mass has a dough-like consistency, mixing the mass in an intensive mixer at a temperature between 50 C. and 100 C. for a time sufficient to cause fibrillation of the polytetrafluoroethylene particles, biaxially calendering the mass, while maintaining water at a level near the absorptive capacity of the particulate, between a gap in the calendering rolls maintained at about 50 C. to about 100 C.

Abstract: A process for preparing a polyurethane foamed article including a hard foam encapsulated by a soft foam is provided. The process provides improved encapsulation over that described in EP 68820 by frothing the hard foam formulation, with for example carbon dioxide, before it is introduced onto the rising soft foam formulation. The hard foam formulation is frothed so that is density is between 75% and 145% of the soft foam formulation.

Abstract: Disclosed are heat-resisting porous membranes or hydrophilized heat-resisting porous membranes comprising a polyolefin, especially a polyethylene or a polypropylene membrane having a crosslinked polymer held thereon, the crosslinked polymer being composed principally of (a) a polymerizable monomer containing one acid anhydride group or two esterified carboxyl groups or a monomer having at least one carboxylic group and (b) divinylbenzene, or of (a), (b) and further (c) styrene or a derivative thereof, or of (b) and (c). These membranes are prepared by thermally polymerizing some of monomer components from (a) through (c) held on at least a part of the surface of the porous membranes and optionally by further hydrophilizing the crosslinked polymer. The resulting porous membranes are useful for membrane separation requiring steam sterilization and for membrane separation of water of a high temperature.

Abstract: Laminated reinforced thermoplastic sheets are made by preparing first and second porous sheets, each having 20% to 60% by weight of reinforcing fibers having a high modulus of elasticity and 40% to 80% by weight of a thermoplastic material differing from the thermoplastic material in the other sheet and applying heat and pressure to cause the sheets to consolidate and adhere together to form the laminate.

Abstract: A method for preparation of macroporous polymeric membranes consisting in placing a mixture of monomers and a radical initiator, dissolved in a porogenic inert organic solvent selected from the group comprising alcohols, estes of carboxylic acids, ketones, and their mixtures, into a space of an adapted shape formed by two temperature-controlled plates and a distance insert having the thickness corresponding to the required thickness of membrane and heating up to 80.degree. C. for 24 hours at utmost in order to carry out the radical polymerization. Azo-bis-isobutyronitrile is advantageously used as an initiator in the amount 0.05-2 wt. % related to monomers in the polymerization mixture. Cyclohexanol or its mixture containing up to 20 vol. % dodecanol are advantageously used as a porogenic solvent in the amount 40-60 vol. % in the polymerization batch.

Abstract: A method and apparatus for forming a product, and the product, such as a buoy with a plastic outer skin or shell and a plastic foam interior are provided. A first charge including, in one exemplary embodiment, a cross-linkable resin is added to a mold component, followed by a second charge, isolated from the first, and including in the exemplary embodiment expandable polystyrene beads. The apparatus is rotated about two mutually perpendicular axes. Initially, the cross-linkable composition is rotation molded against the walls of the mold to form the outer shell. Thereafter, the second charge of polystyrene beads is released within the mold, at a sufficient temperature to cause expansion of said beads against the shell.

Abstract: A three-layer insulated concrete panel includes as the middle layer an insulating slab having grooves which provide a form for casting of concrete supporting ribs integral with a layer of concrete cast over the grooved face. A layer of material, such as particle board, is bonded to the ungrooved face of the slab. In preparing the panel, the slab is placed on a flat surface with the particle board face down. Forms are then placed in spaced-apart relation to panel edges, and concrete is cast into the forms and grooves and over the grooved panel face. The insulating slab provides a form for casting of supporting ribs and is permanently retained in the panel, giving it a high insulating value. An assembly of such panels in a roof or ceiling structure is disclosed wherein individual panels are placed in final position, and joints between adjacent panel edges are obtained by covering exposed strips along adjacent panel edges with a cap member and applying concrete over the cap member.

Abstract: A method of manufacturing an integral asymmetrical membrane for the separation of liquid or gaseous mixtures. A membrane-forming agent in the form of a polyetherimide is mixed with a solvent that is miscible with water. The resulting mixture is introduced into or accommodated in a geometrical form. The form is then brought into contact with a precipitating agent.

Abstract: A method for designing and making composite membranes having a microporous support membrane coated with a permselective layer. The method involves calculating the minimum thickness of the permselective layer such that the selectivity of the composite membrane is close to the intrinsic selectivity of the permselective layer. The invention also provides high performance membranes with optimized properties.

Abstract: A process for producing foam cushions having sections of different hardnesses using foam molding. The process broadly includes introducing a first reaction mixture into a mold, introducing a second reaction mixture into a mold, said second mixture already being in a creamed state, allowing the reaction mixtures to foam, and removing the resultant product from the mold. Prior to the introduction of the first mixture, a web with holes in it is clamped over a deepened section of the mold cavity. The first reaction mixture is then fed onto the web, with the first mixture being in a sufficiently liquid state so as to allow it to flow through the holes and into the space below the web. The second reaction mixture is then fed into the space remaining above and to the sides of the web. The second mixture is introduced at a time when itis sufficiently creamed up so that it cannot flow through the holes in the web.

Abstract: A process for producing paddings molded from polyurethane foam including several regions of different pliability, as well as the paddings thus produced.

Abstract: A method of manufacturing lightweight shapes from polyimide foam in which density discontinuities such as cavities, varying cell size, or swirl marks are substantially eliminated. A block or bun of polyimide foam is prepared in a conventional manner which results in a high density rind and other discontinuities. The foam is chopped into fine flakes in a chopper with a continuous flow of air to prevent electrostatic attachment of the flakes to the chopper and ducting. The flakes are mixed with a quantity of polyimide precursor and then heated to cause the precursor to bond the flakes into a uniform mass having highly uniform and predictable density. This is a very economical process since portions of the original bun may be used which would ordinarily be discarded. An alternative method is described whereby the flakes can be bonded together by using the precursor in the form of a partially cured foam either as a binder, or by making the flakes of partially cured foam.

Abstract: Composite membranes are disclosed having a separation layer comprised of a mixture of poly(methy methacrylate) or a copolymer thereof and at least one cellulosic derivative resulting in enhanced separation and permeating characteristics of the overall composite membrane. Processes for making these composite membranes and the methods of using them are also disclosed. The membranes are particularly useful in gas separation applications and are most suited for the separation of hydrogen from a hydrogen containing stream.

Abstract: The invention relates to a method of manufacturing permeable mineral membranes.The method of the invention is characterized in that a thin layer of gel of peptised hydroxide of at least aluminum is deposited on a permeable perous substrate and the resulting membrane is dried and fired at a temperature between 500.degree. and 1100.degree. C.The resulting membranes can be used for isotopic separation of gases or for filtration and ultrafiltration.

Abstract: Microporous polypropylene membrane or hollow fibers is formed from a melt blend of 5 to 20 weight percent polypropylene and a solvent. The melt blend is shaped and cooled to effect solid phase separation of the polypropylene from the blend. The solvent is separated from the polypropylene by extraction and the porous polypropylene is dried under restraint to prevent shrinkage.

Abstract: A process for producing a porous ceramic filter for use in the filtering of particulates from diesel exhaust gases, and the filter so produced, in which a foamable ceramic composition based upon an aluminosilicate hydrogel binder is expanded into a self-supporting, open-celled porous body of desired shape by virtue of in situ reaction between components of the composition, and thereafter treated to substantially reduce its alkali metal content and fired to produce ceramic bonds, the process further preferably providing on the intended outlet surface of the filter a thin porous ceramic membrane layer whose pores have an average diameter less than that of the pores within and at other surfaces of the ceramic filter.

Abstract: A method of manufacturing a lightweight building element comprises providing a lightweight aggregate of particles having diameters in the range of 2 mm to 20 mm, mixing the particles together to produce graduated particle size distribution of the mixture, adding a quicksetting binder to the mixture in a predetermined amount sufficiently small so that free spaces are produced between the particles after setting and drying, allowing the binder to set and dry to form a porous body of particles bound together by the binder and having free spaces between the particles, introducing expanding plastic into the free spaces, and expanding the plastic in situ to form a cellular plastic structure completely filling the free spaces.

Abstract: An improved composite polyamide membrane and methods of making the membrane are described. This improved membrane is prepared using a cationic polymeric wetting agent in an aqueous solution containing a polyfunctional amine reactant which is interfacially polymerized with an acyl halide to form a thin film polyamide discriminating layer on a microporous support. Alternatively, the wetting agent can be applied directly to the substrate and the interfacial polymerization can occur on said treated substrate. The resulting membrane exhibits an unexpected combination of high water flux, high rejection of divalent anion salts, variable sodium chloride rejection and good caustic resistance at low operating pressures. In one embodiment of this invention, a porous substrate is first treated with an aqueous piperazine solution containing a copolymer of vinylbenzyl dimethyl sulfonium chloride and methacrylic acid and then the coated microporous support is contacted with trimesoyl chloride in an organic solvent.

Abstract: Foamed products are prepared by subjecting a crosslinked polymer such as an ethylene-carbon monoxide copolymer susceptible to heating by high frequency electromagnetic radiation such as microwave or radio frequency which has been imbibed or impregnated with a suitable mechanical or physical blowing agent such as a halogenated hydrocarbon to sufficient high frequency electromagnetic radiation to cause foaming of the polymer.

Abstract: The invention concerns the production of oriented polymeric films in which a layer of a heat curable silicone resin composition is formed on a layer of a polymeric film which is thereafter stretched at an elevated temperature to effect orientation of the film. The heat curable silicone resin composition includes a volatile inhibitor for inhibiting curing of the composition while stretching is effected. Suitable inhibitors include volatile amines, alkynes and acetylene alcohols. Films so produced can be used as release films.

Abstract: A method of producing a plastic sheet with a porous surface layer suitable for use as, for example, a recording medium on which characters and images are printed by ink jet or thermal-transfer printing method. The method comprises preparing a solution by dissolving two or more kinds of plastics having low levels of miscibility to each other in a solvent, applying said solution to a substrate, passing said substrate with said solution applied thereto through a liquid which dissolves said solvent but does not dissolve said plastics thereby solidifying said plastics, and drying said substrate with the solidified plastic layer. Preferably, two or more kinds of plastics having low levels of miscibility to each other include mainly a material A which is vinyl chloride or its compolymer and a material B which is acrylonitrile or its copolymer.

Abstract: A method is provided for producing a self-supporting ceramic body comprising a polycrystalline material comprised of the oxidation reaction product of a parent metal and having therein one or more channels which inversely replicate the geometry of a configured fugitive metal. The method includes providing an assembly of the configured fugitive metal and the parent metal, optionally including a bed of permeable filler, and heating the assembly to form a body of molten parent metal. The molten parent metal is oxidized under selected conditions to grow the polycrystalline material to engulf the configured fugitive metal (and to infiltrate the filler, if the filler is present) and to cause the fugitive metal to disperse into the engulfing polycrystalline material thereby leaving behind as the one or more channels the space formerly occupied by the configured fugitive metal.

Abstract: A method of producing embossed decorative thermoplastic sheets by forming a laminate including a printable composition, having a relatively low viscosity and containing an effective amount of a blowing agent, between thermoplastic resin sheets. The printable composition is applied in a design pattern to a gelled thermoplastic resin on a support surface. A second layer of thermoplastic resin having a melt viscosity which differs from that of the first layer is applied to the printed first layer to form a composite structure. This structure is heated to decompose the blowing agent and effect foaming in selected portions of the resin layer having are established by the printed design pattern containing the blowing agent.

Abstract: Seat material having a covering member integrally provided on a foamed material and a patterned portion of the covering member formed by recessing the covering member in a stripe pattern and a method for producing such seat material comprising the steps of preparing a foaming mould having a patterning protrusion for recessing the covering member in a stripe pattern and clamping the covering member onto the patterning protrusion by a clipping member which is buried by the foamed material.

Abstract: Improved closed cell foams particularly suitable for use in packaging applications comprising a plurality of coalesced strands or profiles of a foamed thermoplastic composition.

Abstract: A method for forming a composite door to custom fit a predetermined door opening. A template is formed by spraying a quick hardening foam on a door jam of the door opening. The template is moved a base member of the tool and the base member adjusted to conform to the shape of the template. A mold is formed using the template and base member. Composite material placed inside the mold and on top of the base member forms a door to custom fit the door opening.

Abstract: A method for manufacturing a multihardness foamed article, including the steps of, placing a mold for foaming such that its bottom surface is inclined with respect to the horizontal plane, pouring a first liquid formulation which will form a portion having a certain hardness designed to constitute the surface area of the foamed article at or adjacent to a higher point of the inclined bottom surface, and allowing the formulation to flow and spread over the entire bottom surface as a continuous thin layer while sticking at its undersurface to the bottom surface, immediately after pouring of the first formulation, pouring a second liquid formulation which will form another portion of another hardness designed to constitute a portion other than the surface area of the foamed article at or adjacent to the higher point, and allowing the second formulation to flow and spread over the flowing and spreading first formulation as a second continuous thin layer which will not commingle with the first layer, and allowing

Abstract: Highly loaded improved closed cell foams comprising a plurality of coalesced strands or profiles of an alkenyl aromatic thermoplastic synthetic resin or mixture of an olefin polymer resin and a copolymer of ethylene with one or more copolymerizable comonomers having a lower melting point than the olefin polymer resin. The loading of the nucleating additive is in a range of about 0.5 to about 50 weight percent, based on total resin weight. When highly loaded with carbon black these foams are electroconductive foams.

Abstract: A method of forming a window assembly which includes a windshield and a gasket formed by curing a polymeric gasket material in situ on the windshield to encapsulate a marginal peripheral edge thereof and form an integral leaf screen and mounting tab. The gasket is formed in a mold with the windshield typically by a reaction injection molding process. The gasket-forming cavities in the mold can be separated by removable plugs and be connected to multiple inlet means for separately filling the cavities. The gasket, leaf screen and mounting tab can be formed of one material, or the leaf screen and tab can be formed of a different material then the gasket.

Abstract: A nozzle for the injection molding of thermoplastic materials includes a nozzle body having a first bore for establishing a flow path for a molten thermoplastic. A first end of the nozzle body is adapted for fluid connection with a sprue of an associated mold body, and a second end thereof is adapted for fluid connection with an end of an associated injection molding machine. The nozzle body also includes a second bore. A first valve assembly, which is adapted for reciprocating movement in the nozzle body second bore, is provided to control the flow of plastic through the nozzle body. The first valve member includes a body having a tip portion and a fluid passage formed in the body and open at one end through the tip portion. A connection member is provided for communicating the valve body fluid passage with an associated source of pressurized fluid.

Abstract: Apparatus for coinjecting a plurality of thermoplastic materials to mold an article having a layered wall structure using thermoplastic material having different optimum processing temperatures including the maintenance of the optimum temperatures in flow paths individual to each material from its source to a mold cavity.

Abstract: A method for making a foamed article having a laminated structure comprises providing a mold having a cavity therein and a rib vertically mounted from a bottom of the cavity and having a predetermined height to establish at least two blocks on the bottom, and pouring a foamable liquid compositions into the respective blocks in amounts which permit one of the foamable liquid composition to cover the other foamable liquid composition upon foaming whereby the resulting foam has a laminated structure whose boundary between the foamed layers made of the respective foamable liquid compositions is smooth and agreeable to the touch.

Abstract: A substrate for high-frequency circuits best suited as a substrate for a flat antenna to receive satellite-broadcast microwaves or as a similar substrate, the substrate comprising (i) a porous insulator layer wherein the proportion by volume of open cells to all the cells is at least 50% and (ii) a metal foil laminated over at least one side of the insulator layer through (iii) a water-impermeable film, and a process for making such substrates.

Abstract: Injection molded and injection blow molded multi-layer substantially rigid plastic articles are provided, which, in preferred embodiments, include:at least five layer plastic articles having side and bottom walls comprised of an outside surface layer, an inside surface layer, an internal layer, and first and second intermediate layers, one on either side of the internal layer, and having the terminal end of the internal layer encapsulated by intermediate layer material, whether it be solely or primarily by first or by both first and second intermediate layer material.

Abstract: A propellant is mixed with unsaturated polyester inside a first space (A) at a first pressure, for example at the atmospheric pressure. The polyester is then sprayed on the whole or parts of an open or exposed mould which is applied in a low-pressure chamber having a powerful negative pressure of 60-95% vacuum. In order to spray a first layer, polyester having a first amount of propellant is sprayed on the mould. At the initiation the propellant causes a powerful foaming effect at which bubbles are created and/or expanded in the polyester. In order to spray a second layer, which can be applied before or after the first layer, polyester having a second amount of propellant, or is without propellant, is sprayed on the mould, which causes fewer bubbles or no bubbles at all. The resulting polyester which comprises formed and expanded bubbles is bound (is allowed to tack rigid shape/is polymerized) by the use of a short tack-free time in the low pressure, said short time being preferably 5-10 minutes.

Abstract: A composite semipermeable membrane and a process for preparation thereof are described, wherein said membrane comprises (1) a porous substrate, (2) an ultrathin film as a surface layer formed by polymerization by crosslinking of polyvinyl alcohol and an amino compound having at least two secondary amino groups using a polyfunctional crosslinking reagent capable of reacting with secondary amino groups and hydroxyl groups, and (3) a porous inner layer composed of water insoluble polyvinyl alcohol which is present between the porous substrate and the ultrathin film.

Abstract: Latex may be extended with up to about 40% by weight of an emulsion of asphalt, bitumen or coal tar. The extended latex is useful in adhering scrim to carpet or in the manufacture of attached foamed carpet backing.

Abstract: A composite foam seat cushion is comprised of foams of different firmnesses which are bonded to adjacent foams without adhesives or glues. The cushion has a supportive bottom of one or more firm foams, a layer of soft foam on the top of and supported by the bottom layer, a protective front foam cap for the front edge of the layer of soft foam, a protective back foam cap for the back edge of the layer of soft foam and side walls of foam(s) of suitable firmness to provide support. A method of preparing the composite foam seat cushion is disclosed.

Abstract: A flexible polyurethane foam article with regions of different hardness is made by introducing into a mould a foam formulation giving a foam of a given hardness and then introducing a foam formulation giving a foam of different hardness directly onto the first foam formulation at a time corresponding to a volume expansion in the range 100% to 2300%.

Abstract: Apparatus for unit cavity and multi-cavity, multi-layer injection molding and injection blow-molding machines are provided, which in preferred embodiments, include one or more co-injection nozzle means each having a central channel, at least two passageways having associated orifices which communicate with the central channel and valve means operative in the central channel and movable to block and unblock the orifices. The valve means preferably comprise an elongated sleeve having an axial central passageway and a port in its side wall and an elongated pin axially-reciprocable within the sleeve central passageway. The sleeve and pin are mounted in close tolerance slip fit relationship to prevent significant accumulation of polymer melt material therebetween.

Abstract: A filter for an air cleaner is produced by impregnating a fiber web composed of one or more layers with a liquid binder in the form of solution, suspension, or emulsion. The impregnated fiber web is dried such that the solvent or dispersing medium on one side evaporates faster then that on the other side. As the result, more binder is deposited on one side than on the other side; in other words, a gradient of binder distribution is formed. The thus-produced filter has such a structure that the voids among fibers continuously change across the thickness, while fibers are bonded together by the binder. The filter thus produced can collect more dust than a conventional one.

Abstract: A glycoside compound containing one or more fatty acid ester or ether groups is used as a mold release agent in the production of molded articles from polymeric resinous materials. Said mold release agent can function as either external or internal mold release agent. The molded article also has improved tie coating properties.