Abstract: A resilient fiber mass and method of forming the same is provided whereby a conventional batting is sprayed with a polyurethane prepolymer and is then in one embodiment rolled into a tight cylindrical shape for subsequent molding. A steam catalyst is introduced into a mold having a specific shape which causes the prepolymer to foam and polymerize. The foaming action separates the fibers at the intersections to provide resiliency to the fiber mass. The molded mass is then removed and can, for example, be attached to a chair seat and covered with decorative fabric as is standard in furniture manufacturing. The chair cushion so formed is highly resilient and durable.

Abstract: A blocking device for filling a cavity in a hollow structural member includes a foamable material, and magnetic member embedded on a surface of the foamable material, the magnetic member is secured within the hollow structural member and the foamable material is foamed and expanded by the application of heat so that the cavity is filled.

Abstract: A foamed rubber composition for tire comprises a particular amount of particles having specified hardness and average particle size and containing aluminum-bonded hydroxy group and/or silicon-bonded hydroxy group at its surface, and a particular amount of at least one specified silane coupling agent, and develops excellent performances on ice. Further, pneumatic tires contain the foamed rubber composition as a tread rubber.

Abstract: The present invention is a method of producing an extruded composite comprising the general steps of: (a) extruding a longitudinally oriented composite precursor coextrusion comprising: (1) at least one thermoplastic polymeric material and (2) a core mixture of at least one thermosetting resin and at least one filler material; whereby the thermoplastic polymeric material(s) is extruded so as to substantially enclose a space, and whereby the core mixture is pumped into the space; and (b) maintaining the composite precursor under conditions whereby the at least one thermoplastic polymeric material becomes cooled and the at least one thermosetting resin becomes cured so as to form the extruded composite of the present invention.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a particle packed, highly inorganically filled, cellular matrix are disclosed. Suitable inorganically filled mixtures are prepared by mixing together a starch-based binder, a solvent, inorganic aggregates, and optimal admixtures, e.g., fibers, mold-releasing agents, rheology-modifying agents, plasticizers, coating materials, and dispersants, in the correct proportions to form an article which has the desired performance criteria. The inorganically filled mixtures have a predetermined viscosity and are heated between molds at an elevated temperature and pressure to produce form-stable articles having a desired shape and a selectively controlled cellular, structure matrix. The molded articles may be placed in a high humidity chamber to obtain the necessary flexibility for their intended use.

Abstract: A foamed rubber composition for pneumatic tires comprises at least one diene polymer as a rubber ingredient and includes closed cells in a matrix rubber, each of these cells being covered with a coat layer made from a given amount of a resin or resin composite having a JIS-C hardness of not less than 75, a particle size of 10-200 .mu.m and a reacted conjugate diene unit content of not less than 10% by weight. In the production of the foamed rubber composition, the melting point or glass transition point of the resin or resin composite is restricted to at least 5.degree. C. lower than the vulcanizing temperature.

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. The dry resin powder in another embodiment of the invention includes unexpanded expandable powder which will expand into microballoons in the confined spaces in which they reside and effect a bonding relation with surrounding particles upon supply of heat to the mixture. The foam product is produced by thoroughly intermixing and depositing the mixture as a layer over a surface having a release agent thereover within a dimension defined region.

Abstract: The present invention is directed to a method of making a foamable film of at least one thermoplastic resin with at least one liquid blowing agent incorporated therein, said method comprising forming the thermoplastic resin and a liquid swelling agent for the thermoplastic resin into a layer, contacting the said layer with the liquid blowing agent and replacing at least part of the swelling agent in the resin by the liquid blowing agent.

Abstract: A process produces foam bodies having various properties and containing cellulose-containing materials broken up and/or partially broken up and/or not broken up, and additives, if need be. The cellulose-containing starting materials are first processed further for forming a moist pulp and subsequently subjected to a heat treatment by microwave radiation. The properties of the foam bodies so produced are predetermined by admixing certain substances intensifying the formation of gas in the pulp, increasing the adhesive bond between the particles in the pulp, or which completely or partially convert into a gas either under the influence of heat or of moisture, thus supporting the foaming. Furthermore, other residual and waste materials can be added during the production process, which may be materials of a silicate nature as well, preferably with the objective of reusing such materials in a useful way and of predetermining at the same time certain product properties of the foam bodies.

Abstract: A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.

Abstract: A unitary, monocoque, injection-molded skateboard (and method of making the same) which is characterized by an elongate composite body with a specific gravity in the range of about 0.75 to about 0.8, and including a foamed structural plastic mass having a distributed differentiated density, and contained within that mass, plural, elongate strands of reinforcing carbon fibre material.

Abstract: Disclosed is a rigid fine-celled foam composition and a method of producing it. The foam composition is nontoxic, environmentally friendly, has improved absorption/adsorption and retention of liquids, is not as hard as prior art foams, does not include polymerization by-products detrimental to flower and plant life, and is a foamed mixture of a caustic silicate solution derived from the caustic digestion of rice hull ash having diffused activated carbon particles from thermal pyrolysis of rice hulls rather than from commercial sodium silicate solutions. Valuable by-products of commodity grade are obtained including activated carbon and sodium fluoride.

Abstract: A fiber reinforced, thermoplastic foam is produced by dispersing fibers of controlled dimensions and blowing agent in molten thermoplastic and extruding the mixture with high back pressures. As the blowing agent expands, the fibers become randomly oriented and a fine cellular structure is formed in the plastic which freezes the fibers in a random spatial orientation. The resulting reinforced foam may be used as formed or compacted to collapse the foam and then shaped.

Abstract: The present invention provides a method for the semi-continuous production of microcellular foam articles. In a preferred embodiment, a roll of polymer sheet is provided with a gas channelling means interleaved between the layers of polymer. The roll is exposed to a non-reacting gas at elevated pressure for a period of time sufficient to achieve a desired concentration of gas within the polymer. The saturated polymer sheet is then separated from the gas channelling means and bubble nucleation and growth is initiated by heating the polymer sheet. After foaming, bubble nucleation and growth is quenched by cooling the foamed polymer sheet.

Abstract: An elongated, substantially rigid member suitable for use as a marine piling is formed by feeding a substantially solid plastic core into a die and continuously extruding a molten plastic into the die so that the molten plastic surrounds and bonds to the plastic core and to reinforcing bars fed into the die at positions surrounding the plastic core. The plastic core acts as a heat sink to facilitate cooling of the molten plastic and deters bending of the member while cooling.

Abstract: A unique composite material impregnated with a heat curable resin comprising a layer of conductive fibers and one or more resin carrying layers is utilized to reinforce utility poles by wrapping the material around a portion of the utility pole and causing a current to flow through the conductive fibers to resistively heat the material to the resin. The composite material can also be incorporated into molds to produce cured composite parts. The composite material is also used in the construction of large parts without the need for huge, expensive molds. The conductive fibers in composite parts are oriented in a manner to ensure that the entire part is thoroughly heated during the curing process.

Abstract: A slurry containing a precursor fiber convertible to carbon fiber and/or a carbon fiber and, based on 100 parts by weight of the fiber, 10 to 300 parts by weight of a thermosetting resin, e.g. phenol resin, is processed into a random web. This web may contain a pitch or an organic granular material. The web is hot-pressed between a pair of belts while curing of the resin is inhibited to prepare a prepreg sheet. This sheet is disposed, leaving a clearance, in a mold having ribs on a molding surface and heated over the melting point of the resin for expansion and complete cure to provide a porous composite sheet equipped with grooves. This porous composite sheet is carbonized or graphitized to produce a porous carbonaceous material for use as a fuel cell electrode material and so on. This porous carbonaceous material has high homogeneity, gas permeability, electrical conductivity, heat conductivity and mechanical strength.

Abstract: A composition useful as a casting resin is provided. The composition comprises a polyol, a polyisocyanate, a catalyst, and a suspension aid, and said catalyst and said suspension aid are present in the casting resin in such concentrations that, within 10 minutes of mixing, it flows downwards a) by at least 15 cm at 25.degree. C. and b) by 3 to 0.3 cm at 130.degree. C. The casting resin is particularly useful as a binder for a granular material in the production of open-cell moldings which are permeable to water.

Abstract: A self-supporting sheet-like structure is described, which contains a substrate layer and a structured coating on at least one surface of the substrate layer. The structured coating is produced by treating at least one surface of the substrate layer by means of an electric corona discharge, which takes place between a high voltage electrode and a grounded counter-electrode. In this procedure, an aerosol containing discrete inert particles is simultaneously introduced into the corona discharge space during the corona discharge to improve the slip characteristics and reduce friction of the substrate layer.

Abstract: A thermal barrier in the form of a base material with a plurality of microcapsules containing a phase change material forms an insulative pad, such as a shoe insole. The microcapsules are surroundingly encapsulated and embedded within the base material. In addition, substantially all of the microcapsules are spaced apart from each other, the space between neighboring adjacent microcapsules containing a phase change material. The microcapsules may be anisotropically distributed to further reduce thermal conductivity of heat through the thermal barrier.

Abstract: An improved shaped article comprising a thermoformed composite sheet, which is a layer of thermoplastic polymer attached to a surface of a lightweight conformable fabric, the other surface of the fabric being attached to a layer of rigid foam, provides the article with improved wall thickness uniformity and impact resistance.

Abstract: A porous substance containing a reactive material and the related method for making the substance is provided. The method includes establishing a thermosetting resin substance which is porous and inert to liquids in a vessel. The resin substance may then be impregnated with finer particles of a reactive material or chemicals. The reactive material is chosen such that an ionic exchange or catalytic reaction will occur when a liquid to be treated is passed through the kernels. After the reactive material is added to the resin substance, the resulting resin substance is cured by heating or by the addition of a catalyst or a combination thereof. Kernels may be formed from the thermosetting resin substance which have a sponge-like configuration and which contain the reactive particles within the supporting resin substance. Air, gases and solutions may be passed through the kernels for filtration, purification, or reactive purposes.

Abstract: The present invention relates to a sound attenuation composite and a method for making the composite. The sound attenuation composite includes a barrier layer and an open cell foam layer loaded with a sound blocking filler. In one embodiment, the foam layer is filled with a barium sulfate filler. In another embodiment, a solid polyvinyl chloride barrier layer is loaded with barium sulfate, wherein 60 parts of barium sulfate is present in each 100 parts of polyvinyl chloride.

Abstract: A process is described for the production of optionally cellular polyurethane moldings with an elevated ground material/filler content, which process broadly comprises a) mixing and reacting an aromatic di- or polyisocyanate with a di- and/or polyol of a molecular weight of 1,000 to 20,000 in a quantity insufficient to react with all the NCO groups to yield an isocyanate pre-adduct with an NCO group content of 5 to 32%, b) mixing this isocyanate pre-adduct with ground material/filler, c) mixing the resultant mixture, with a di- and/or polyol with a molecular weight of 62 to 2,000 (crosslinking agent), and optionally water and/or an organic blowing agent, in a static mixer and d) introducing the resultant mixture into a mold.

Abstract: A method of forming a plastic molded article includes expansion molding of a plastic raw material mixed with a blowing material. In a first step, a first-stage expansion molding is used to form a core. This is followed by a second step in which a second-stage expansion molding is employed to produce an outer layer around the previously-formed core, in such a manner that the outer layer is fusion bonded and integrated with a boundary region of the core, thereby forming a second-stage molded product. At least the outer layer contains randomly distributed resin fibers.

Abstract: The method of compression molding an article such as a closure wherein a thermoplastic resin is mixed with additives including a metallic pigment additive, extruded through a nozzle, cut by a blade into individual pellets, and each pellet is deposited into the cavity of a mold which is then closed to compression mold the pellet into an article, including the step of adding a blowing agent to the resin prior to extrusion in a quantity sufficient to randomize the metallic particles in the metallic pigment additive such that gaseous bubbles are provided in the extruded melt and that the gaseous bubbles are substantially expelled during the compression molding resulting in an article that is substantially free of blemishes which normally occur. Preferably, the method includes positioning a mixer plate in the path of the resin immediately prior to the nozzle.

Abstract: High quality, consistent polyurethane froth foams, both filled and unfilled, are prepared by directing polyol, isocyanate, and optionally other polyurethane-forming ingredients to a high pressure mix head prior to introducing the mixture to a froth foaming head. Changes in stoichiometry may be made rapidly without shut-down. An in-line blender incorporated filler into the polyol stream minimizing density differentials normally encountered in the holding tank, maintaining low and reproducible viscosity, and allowing for greater amounts of filler than otherwise possible.

Abstract: A liquid resin composition prepared by mixing an ionic material and/or a chargeable material into a thermosetting or thermoplastic resin is injected into a mold having a predetermined inner shape, and a DC voltage is applied to the liquid resin composition to concentrate the ionic material and/or chargeable material on a desired portion or to distribute the ionic material and/or chargeable material continuously. Thereafter, the resin composition is thermally cured when the resin composition contains the thermosetting resin, or the resin composition is hardened by cooling when the resin composition contains the thermoplastic resin, thereby obtaining a molding having a predetermined shape.

Abstract: An interior trim panel comprises a flexible polyurethane skin layer, an intermediate resilient polyurethane foam layer and a rigid polyurethane foam substrate. The flexible polyurethane skin layer and intermediate resilient polyurethane foam layer are formed as an expanded thermoplastic urethane (TPU) shell in a slush molding process. The rigid polyurethane foam substrate is then foamed in place on the shell in a substrate forming mold. This produces an environmentally friendly, long lasting interior trim panel that can be manufactured economically without any need for plasticizers or adhesive coatings.

Abstract: A method of producing a plasma treated article in a tool having electrically isolated conductive members, wherein at least one of the members has a surface closely conforming to the surface of the article which is to be treated. The method includes the steps of placing the article between the members so as to create a relatively small bounded space between the article surface and the closely conforming member surface, drawing a vacuum in the bounded space, introducing a polymerizable gas into the bounded space and applying an electric field between the members to create a plasma in the bounded space to react with the article surface.

Abstract: This invention relates to a reaction injection molding process for preparing a molded product by reaction of a mixture of(a) an organic polyisocyanate;(b) one or more compounds containing at least two isocyanate-reactive groups;(c) about 2 to about 20% by weight, based on the weight of the molded product, of rigid fibers having a diameter of from about 5 to about 10 micrometers and a length ranging from the diameter of the fiber up to about 2 millimeters, preferably in admixture with component (b);and, optionally,(d) an inert gas dissolved in at least one of components (a) or (b) in an amount sufficient to produce a molded product having a density of at least 0.80 g/cm.sup.3 ; and(e) up to 15% by weight, based upon the weight of the molded product, of a filler other than rigid fibers (c).

Abstract: The recycling of used polyurethane foam is made possible by a process in which the starting material is first dried to a moisture content of 2 to 4% and is then filled into a multi-part mold (16, 17, 18) that defines the molded part (32). The parts of the mold (16, 17, 18) are then, with generation of the necessary compression pressure of below 20 N/mm.sup.2, pressed together and locked. These molds (16, 17, 18) that are subject to the compression pressure are heated in a tunnel furnace (20) so that the molding material reaches a temperature of approximately 130.degree. C. After a predefined holding time, the molds (16, 17, 18) can be opened under pressure and the molded parts (32) can be removed. Molded parts (32) with a thickness of 42 mm and of corresponding size have been produced successfully with this process. Instead of the molds (16, 17, 18), it is also possible that a two-part tool is used.

Abstract: A particulate plastics material, a polysaccharide and water are fed to an extruder which is operated under such heat and pressure conditions that upon emergence of the extrudate from the extruder die, the extrudate assumes a cross-section greater than that of the exit orifice of the die. The extrudate is then further processed, either by shredding to produce particulate material for feeding to filter-making section of a cigarette making machine, or by forming into smoking article filter rod lengths.

Abstract: A preform for impregnation of a metal or ceramic matrix material comprising a multiplicity of reinforcement particles bonded together so as to define a three-dimensional, open-cell reticulum comprising a plurality of randomly oriented thread-like portions interconnected one to the next via a plurality of nodes. A reinforced composite made from such preform and method of making the preform is disclosed/claimed wherein the reinforcement particles are mixed with prepolymers used to produce a fugitive binder for the particles comprising a foamed polymer, and the particles align themselves with the polymer portions of the resulting foam.

Abstract: A wood type metal golf club head having a hollow metal head and the cavity within filled with a thermoplastic material produced from a thermoplastic polymer, filler and chemical blowing agent in a manner so that the material in the cavity has a dense outer skin adjacent the surfaces of the cavity and a cellular central area and the finished product reduces the undesirable metallic sound made during hitting.

Abstract: A pair of concrete coated pipe joints welded together end to end with a gap between the concrete coatings, the gap being filled with a fast setting elastomeric polymeric infill material, either solid or foamed, and a particulate filler material, and a method for molding the infill material with the mold being filled with filler material before the polymer components are injected, and with a membrane lining the mold to prevent the polymer from adhering to the mold.

Abstract: A process for the continuous production of a high modulus article comprising a composite of an oriented plastic material and an oriented particulate material, said process including the steps of:a. continuously forcing an orientable plastics material, while it is close to or at its softening temperature and in admixture with an orientable particulate material, through a converging passage of which the cross-sectional area diminishes in the forward direction of plastic flow, thereby to produce an extrudate;b. deforming the extrudate, while it is maintained at or close to its melt temperature, to produce an oriented, deformed extrudate; andc. cooling the deformed extrudate to preserve the orientation and provide said composite. The foamed and unfoamed composite articles have strength, modulus and density values comparable to typical hardwoods or softwoods.

Abstract: Process using low to medium temperature thermoset epoxy composite materials and an expandable epoxy matrix material to efficiently form high strength composite parts of divers shapes in a single-one-step process. The composite material is placed within the periphery of a mold and expandable epoxy matrix material is placed between the layers of the composite material either before or after closing the mold and, then, subjecting the mold and its contents to heat which activates the epoxy resins in both the composite material and the matrix material causing the matrix material to expand thereby compressing the composite material in order to produce a competent composite part.

Abstract: This invention relates to a reaction injection molding process for preparing a molded product by reaction of a mixture of(a) an organic polyisocyanate;(b) one or more compounds containing at least two isocyanate-reactive groups;(c) about 2 to about 20% by weight, based on the weight of the molded product, of rigid fibers having a diameter of from about 5 to about 10 micrometers and a length ranging from the diameter of the fiber up to about 2 millimeters, preferably in admixture with component (b);and, optionally,(d) an inert gas dissolved in at least one of components (a) or (b) in an amount sufficient to produce a molded product having a density of at least 0.80 g/cm.sup.3 ; and(e) up to 15% by weight, based upon the weight of the molded product, of a filler other than rigid fibers (c).

Abstract: Tubes or pipes are engaged on an insert and are fixed thereon in sealed manner by molding a plastics material at least over those zones of said tubes or pipes that co-operate with the insert. The plastics material is molded so as to form a cellular material whose expansion is performed so as to give rise to compression forces on said tubes or pipes that ensure that said tubes or pipes are fixed or sealed onto the insert.

Abstract: To manufacture high quality, fine pored silicone foam parts by the injection molding process, two reaction components A and B are used. They both contain a silicone polymer and fumed silica. The component A also contains a complexed organo-platinum catalyst and a small portion of water, whereas the other component B contains as a crosslinker polydimethyl hydrogen siloxane.At least one of the two components A and B of the mixture is pressurized with a gas, preferably air or nitrogen, in a pressure container so that the gas is dissolved into the component(s). The components A and B are mixed in the pressure process, injected into an injection mold, and heated so that the foaming process forms the silicone foam part.

Abstract: A method for preparing a thermosetting foam, such as polyisocyanurate or polyurethane foam, includes introducing polyol and isocyanate to a screw of an extruder and mixing in the extruder screw. Catalyst is then added and mixed with the already formed mixture in the extruder screw. This mixture is extruded onto a conveyor and foamed on the conveyor. Finely divided carbon black, dispersing agent and/or surfactant may be mixed with polyol before introducing to the screw of the extruder or carbon black may be dispersed in polyol in the extruder and a polyol premix made before the remainder of the polyol is added. Foam cell size is decreased when extruder speed is increased. The foaming agent, which is preferably HCFC or water, may be mixed with one of the components, preferably the polyol, before introducing to the screw of the extruder. The mixture is cooled before extruding onto a conveyor to delay the foaming step until the mixture is outside the extruder.

Abstract: A method of making a foamed building board or the like from the following components:(a) a major amount by weight of an inorganic base material selected from the group consisting of a calcium sulphate hemi-hydrate, magnesium oxychloride, magnesium oxysulphate and a hydraulic cement;(b) a suitable amount by weight of the inorganic base material of a thermosetting resin which is miscible, soluble or dispersable in water;(c) a suitable amount of a catalyst for the thermosetting resin;(d) water in an amount sufficient to rehydrate the inorganic base material with the water present in the other components;(e) a suitable amount of a plasticizer such as a melamine formaldehyde condensate;(f) a suitable amount of a polyvinyl alcohol;(g) a suitable amount of a retarder for the setting time of the inorganic base material;(h) a suitable amount of a fibrous reinforcing material; and(i) a suitable amount by weight of a foam or a foaming agent; which comprises the steps of:(1) mixing together components (a), (b), (c), (d),

Abstract: A method of making a plastic reinforced by natural fibers which comprises natural fibers and a mixture prepared by combining per 100 parts by weight of an unsaturated polyester with 30-300 parts by weight of an organic foaming agent, 0.5-3.0 parts by weight of an organic peroxidase, and a predetermined quantity of a wood powder filling agent. The method includes the steps of (a) preparing a filling agent mixture by adding a predetermined quantity of a filling agent to a foaming agent; (b) preparing an unsaturated polyester mixture by adding the filling agent mixture of step (a) and a catalyst to the unsaturated polyester; and (c) impregnating the natural fibers in the unsaturated polyester mixture of step (b) before the natural fibers are arranged in a mold cavity, which is then heated under a pressure to bring about the production of the plastic reinforced by natural fibers.

Abstract: Foam boards of high compressive strength are produced by extruding a mixture of a styrene polymer and from 5 to 16% by weight of a blowing agent which containsa) from 3 to 70% by weight of an alcohol or ketone having a boiling point of from 56.degree. to 100.degree. C.,b) from 0 to 50% by weight of carbon dioxide,c) from 0 to 88% by weight of a saturated C.sub.3 - to C.sub.5 -hydrocarbon,d) from 2 to 90% by weight of at least one fluorinated hydrocarbon which has a boiling point of from -30 .degree. to +30.degree. C.

Abstract: A process for producing a porous pipe is disclosed and includes forming an extrudable mixture comprising elastomer particles, binder component and a solid water carrier component having a composition other than the elastomer particles and the binder component and being associated with sufficient water to provide porosity to a porous pipe produced from the mixture; and extruding the extrudable mixture to conditions effective to form the porous pipe.

Abstract: A pair of concrete coated pipe joints welded together end to end with a gap between the concrete coatings, the gap being filled with a fast setting elastomeric polymeric infill material, either solid or foamed, and a particulate filler material, and a method for molding the infill material with the mold being filled with filler material before the polymer components are injected, and with a membrane lining the mold to prevent the polymer from adhering to the mold.

Abstract: The method of compression molding an article such as a closure wherein a thermoplastic resin is mixed with additives including a metallic pigment additive, extruded through a nozzle, cut by a blade into individual pellets, and each pellet is deposited into the cavity of a mold which is then closed to compression mold the pellet into an article, including the step of adding a blowing agent to the resin prior to extrusion in a quantity sufficient to randomize the metallic particles in the metallic pigment additive such that gaseous bubbles are provided in the extruded melt and that the gaseous bubbles are substantially expelled during the compression molding resulting in an article that is substantially free of blemishes which normally occur. Preferably, the method includes positioning a mixer plate in the path of the resin immediately prior to the nozzle.

Abstract: A process and device for the manufacture of plastic fiber boards made of balls of expanded glass, expanded clay, pumice granules, mica, or a similar material and a foamed organic binder, such as epoxy resin, PU phenol resin, or the like. The binder is mixed with the balls, foamed, and hardened in a matrix space formed between two mold plates (1, 2) positioned at a distance one from the other. In order to obtain a particularly light but stable plastic fiber board, uniformly distributed recesses opening toward the internal sides of the plates are provided to contain the mixture located between the two mold plates during compression and before hardening. The device employed to implement the process includes two mold plates (1, 2), which are brought together in a press to compact the introduced therebetween.

Abstract: A process for producing foamed articles containing thermoplastic aromatic polycarbonates is disclosed. Accordingly, thermoplastic aromatic polycarbonates are mixed with about 0.01 to 10% by weight of Al.sub.2 O.sub.3 (H.sub.2 O).sub.3 and the mixture is either extruded in an extruder at temperatures from 220.degree. C. to 320.degree. C. without application of a vacuum to produce foamed molded articles or it is injection molded in injection molding machines without application of vacuum at temperatures from 290.degree. C. to 330.degree. C. to produce molded foam articles.