Abstract: A forming apparatus for forming objects by forming a sheet of thermoformable material includes a thermal conditioning station including a kiln for heating the material to an operating temperature, and a heating station positioned downstream of the thermal conditioning station and including a heating arrangement to heat set portions of the material to a temperature near a softening temperature of the material. In order to reduce reject material at the restart of the apparatus following machine downtime, the kiln and the heating arrangement are positioned near one another in such a manner that a part of the material interposed between the thermal conditioning station and the heating station is heated by the heat generated by a kiln and/or by the heating arrangement.

Abstract: A single-sided, slip resistant, self-adhesive material is produced using a blown film process which produces a film having an interior layer capable of being treated or coated to accept a pressure sensitive adhesive, a middle layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent to produce a single-sided slip resistant material. A number of in-line rollers are optionally provided after a pair of nip rollers, 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) the film prior to the film being coated on one side with a pressure sensitive adhesive.

Abstract: A foam form sheet material having a first large surface comprising substantially only closed cells and an opposite large surface and an interior comprising substantially only open cells. This material comprises a cross linked olefin thermoplastic polymer or copolymer. The foam is made by mixing the polymer with a blowing agent and a cross linking agent. The mixture is maintained in a two roll mill means for a time sufficient to initiate cross linking and to initiate foaming to form closed cells. The sheet material is then disposed in a second two roll mill means having a nip that is larger than the thickness of the foamed sheet material and maintained under elevated temperature and pressure sufficient to initiate further cross linking and foaming. The fully cross linked cell foam is then compressed to rupture the closed cells that are disposed in the interior to form open cells.

Abstract: A single-sided, slip resistant, self-adhesive material is produced using a blown film process which produces a film having an interior layer capable of being treated or coated to accept a pressure sensitive adhesive, a middle layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent to produce a single-sided slip resistant material. A number of in-line rollers are provided after a pair of rollers, 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) the film prior to the film being coated on one side with a pressure sensitive adhesive.

Abstract: The invention relates to a press felt for use in the press section of a paper machine. Said felt comprises a nonwoven layer lying on one of its surfaces, the surface of said layer being connected and fixed to the felt by a thermoplastic binding material. According to the invention, the surface of the nonwoven layer is smoothed by the application of pressure from a smooth surface during the cooling of said layer surface from a temperature in excess of the melting temperature of the thermoplastic binding material to a temperature below the melting temperature. To manufacture the press felt, an untreated press felt, which contains the nonwoven layer and the thermoplastic binding agent is first produced, the thermoplastic binding agent being distributed in the nonwoven layer in the form of thermoplastic adhesive fibres and/or a thermoplastic adhesive component of bicomponent fibres.

Abstract: The invention relates to a hydraulic binder product [12, 10] which includes a mixture of a hydraulic binder [38, 202], a polyvinyl alcohol [14, 204] and a gelling agent [54] which reacts with the polyvinyl alcohol and a method [8] of producing same.

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: An object of the invention is to provide a leather-like sheet having excellent water absorbability (sweat absorbability, defined the same hereinafter), providing a natural leather-like touch, and suitably used as a ball covering or a non-slip covering, without lowering surface wear resistance. An aspect of the invention is directed to a leather-like sheet including a base material having an entangled fiber sheet; and a porous elastic resin layer laminated on a surface of the base material. The porous elastic resin layer has a concave-convex surface. The concave-convex surface of the porous elastic resin layer includes a projection having a top surface and a side surface, and a recess having a bottom surface contiguous to the side surface. The top surface of the projection has openings with a diameter from 10 to 500 nm at a density of 1,000 openings/mm2 or more.

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: Method of encapsulating optoelectronic components, by embedding the components to be encapsulated between a first transparent polymer layer and a second polymer layer, which is filled with unactivated foaming agent, and then activating the foaming agent, so that the two polymer layers join to one another, in particular weld to one another, and the components are enclosed between the two polymer layers.

Abstract: Apparatus and methods for cutting compressible cellular polymers such as polyurethane foam, are characterized by a first die roller and a pressure roller, wherein both rollers define raised portions separated by recesses or depressions, and the raised portions on the first die roller register with the recesses of the pressure roller at a nip formed between the rollers. Portions of the polymer material extruded into the spaces between the raised portions of the first die roller are cut away, such that the cut product conforms substantially to the surface geometry of the first die roller, and the depth of cut is greater than with prior rotary cutting methods.

Abstract: A movable door panel having a front facer with opposed longitudinal edge profiles, rails secured to the longitudinal edge profiles, a rear facer secured to the rails, and foam disposed within an inner volume defined by the front facer, the rails and the rear facer is disclosed. Transverse stiffeners are disposed within the inner volume and the foam, and extend between the opposed rails. The door panel may be made by continuously providing the front facer with a rail secured thereto, continuously positioning transverse stiffeners on the front facer and extending between the metal rails, and continuously applying a foaming material on the front facer and the transverse stiffeners. The method concludes by bringing a rear facer into contact with the metal rails, and drawing the panel through a laminator. Hardware may then be attached to one or both of the facers and the stiffener.

Abstract: There are provided a foaming filler member which allows, even when the inner space of a hollow member has a protruding space, easy filling of the protruding space without using an extra member, a heat-foamable sheet used for the foaming filler member, a method for manufacturing the heat-foamable sheet, and a method for filling the inner space of the hollow member. A heat-foamable sheet which extends in one direction when heated at 100 to 130° C. for 20 minutes and has an extension ratio of 5 to 50% in the extension direction is manufactured by stretch-forming a heat-foamable material. Even when the inner space has the protruding space, the protruding space can be easily filled at low cost without using an extra member by using the heat-foamable sheet as the foaming filler member, disposing the foaming filler member in the main space of the inner space, and foaming it such that the extending direction of the heat-foamable sheet is oriented toward the protruding space.

Abstract: A method for producing a bio-based polymeric shoe component includes: preparing a blend from a composition including 5˜50 weight parts of a modified starch, 50˜95 weight parts of an ethylene vinyl acetate copolymer, 5˜30 weight parts of a filler, 1˜50 weight parts of a polyolefin, 2.0˜8.0 weight parts of a foaming agent, 0.5˜3.0 weight parts of a foaming aid, 0.5˜2.0 weight parts of a lubricant, and 0.4˜1.2 weight parts of a crosslinking agent, the modified starch being obtained by hydrolyzing and esterifying a predetermined amount of a raw starch to form a hydrolyzed and esterified starch, followed by drying the hydrolyzed and esterified starch; processing the blend into a foamable product; and forming the foamable product into the shoe component.

Abstract: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer having a density less than 6 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

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: The invention relates to a plant and a process for the production of foam in a continuous slabstock process in which the actual foam height profile is detected transversely to the feed direction and a correcting variable for the slabstock process based on deviation of the actual foam height profile from a desired foam height profile is determined.

Abstract: This invention relates to a nonslip decorative and protective coverings in order to cover and protect distinct surfaces, its composition and the manufacturing process thereof; characterized in that it consists of a foamed cellular film based on dry mixed and calendared suspension resins, defining a smooth textured and decorated upper surface, and a rough lower surface with high adherence; said film consists of a composition of: a) suspension resin of vinyl polychloride and/or copolymer of vinyl chloride; b) plasticizers in order to provide flexibility to the covering; c) other components such as elastomers, Barium/Zinc or tin stabilizers; lubricants, biocides, flame retardants, pigments and charges, in order to facilitate the processing thereof, and d) foaming agents, obtained by a process consisting of the following steps: a) Feed and homogenize the components in an intensive high speed mixer until a dry mixture is obtained; b) feed the dry mixture into mixers until plasticized; c) form the decorative film i

Abstract: The present invention relates to a process for the continuous production of polyurethane sandwich elements comprising an upper outer layer and a lower outer layer and a layer of cellular polyurethane lying in between, which is firmly bonded to the outer layers. This invention also relates to an apparatus suitable for the production of polyurethane sandwich elements as described above.

Abstract: Touch fastener, molded articles having touch fasteners and methods of making such touch fasteners and articles are provided. The touch fasteners include a sheet form base having an upper face and a lower face; a plurality of male fastener elements, each fastener element having a stem molded integrally with and extending from the upper face of the sheet form base; and a foam or fibrous non-woven material adjacent to the upper face of the sheet form base, wherein at least a portion of the foam or fibrous non-woven material is disposed between at least a portion of the fastening elements.

Abstract: A device for applying a substance, the device including an applicator member having at least one of a fibrous and cellular element. The element defines a surface for applying the substance. At least a portion of the surface includes projecting fibers. The projecting fibers are attached to a portion of the element. The portion of the element and the fibers may be made out of the same material.

Abstract: A sheet-form structure of expandable thermoplastic resin is provided which is capable of undergoing a pseudo-one-dimensional expansion in its thickness direction and which enables manufacture of thermoplastic resin foams having reduced variations in thickness and weight precisions, increased compressive strength, and excellent properties such as surface smoothness. A method of manufacturing the sheet-form structure, as well as such thermoplastic resin foams, are also provided. A sheet-form structure 1 of expandable thermoplastic resin including granules 2 of expandable thermoplastic resin arranged generally uniformly for integral connection thereof through a thin film 3 of expandable thermoplastic resin.

Abstract: The invention relates to a process for forming a laminate comprising a core of a compressed metal powder mixed with a foaming agent between two metal layers, comprising the successive steps of providing two metal strips and a stock of powder comprising a metal powder mixed with a foaming agent; applying a layer of the powder between the two metal strips; feeding the metal strips, with the powder between them, to a rolling mill; rolling the two strips with the powder between them to form a laminate of compressed powder between two metal layers. The invention also relates to an associated device and to the product formed using the process.

Abstract: A manufacturing method for a synthetic leather includes a first step of feeding materials of preset volume, a second step of materials foaming (capable to be skipped if unnecessary), a third step of material and mixing injecting to produce liquid mixed materials by instant reaction, a fourth step of conveying two basic cloths, a fifth step of compressing the two basic cloths with the liquid mixed materials producing reaction between the two basic cloths conveyed to an upper portion of two rollers to produce synthetic leather, and a sixth step of winding finished synthetic leather on two winding wheels.

Abstract: An apparatus for the continuous production of expanded plastic panels with inserts on their longitudinal edges, comprising a head for pouring a reactive mixture between a first and a second containment layers in order to obtain a foamed layer, a containment and advancement assembly for the layers being constituted by a lower slat conveyor and by an upper slat conveyor. The lower slat conveyor has lateral containment blocks at the ends of its slats. At least some of the blocks are provided thereon with the inserts to be incorporated in the foamed layer, for picking and placing the inserts on the engaging elements provided in the apparatus.

Abstract: A method of making the basic material and the facial skin of synthetic leather with one round of process includes two units of material injecting devices for respectively making a PU plastic foam layer and a face-skin layer at the same time. The PU plastic foam layer and the face-skin layer are tightly combined together when they are in a condition of half reaction and not fully becoming hardened to finish making the synthetic leather with one round of process, achieving effects of shortening a producing process, saving equipment, labor and electricity, lowering producing cost, and preventing air and water pollution.

Abstract: An opaque, oriented polymeric film structure comprising: a core layer comprising a thermoplastic polymeric matrix material wherein the core layer has a first side and a second side, the core layer having a plurality of voids, substantially all or all of the voids being free from a void-initiating particle and at least some of the voids being interconnected with an adjacent void in the polymeric matrix material, the number of voids not containing a void-initiating particle being sufficient to impart a significant degree of opacity to the film structure, wherein the core layer comprises the interior of the film structure; and a first skin layer comprising a thermoplastic polymeric material and an effective amount of a high-melting incompatible additive to suppress cavitation in said first skin layer, wherein the first skin layer is exterior to the first side of the core layer.

Abstract: A method of manufacturing a foamed article includes embossing or otherwise impressing a three dimensional pattern into a surface of an article formed from a polymer composition with a blowing agent. The three dimensional pattern is formed prior to activation of the blowing agent and curing of the article. The article is then heated to activate the blowing agent and cure the material. The final article retains the three dimensional pattern in its expanded form.

Abstract: A coextruded multilayer film laminate featuring a polyolefin based formulation which closely matches the mechanical performance criteria of a plasticized PVC film is disclosed. This film is particularly suitable for use as a replacement film for plasticized PVC in a variety of medical and non-medical applications. The multilayer films of the present invention offer a particular set of mechanical properties, normally associated with plasticized PVC, including easy stretch, high degree of recovery, low fatigue and minimal permanent set. Moreover, these polyolefin based formulations do not contain any known or suspected carcinogenic compounds and may be produced at costs that are highly competitive with the costs associated with a conventional, plasticized PVC film.

Abstract: The present invention relates to sheet materials suitable for use in or as a floor covering. The sheet materials comprise a polyalkene resin in intimate admixture with at least one additive comprising a filler, wherein the polyalkene resin has a relatively narrow molecular weight distribution (MWD), and a small amount of long chain branching and produced by a single site catalyzed polymerization of at least one, linear, branched or cyclic, alkene having from 2 to 20 carbon atoms. The present invention also extends to processes for the production of such sheet materials and floor coverings.

Abstract: A process for producing static-free synthetic rubber includes mixing acrylonitrile-butadiene, Anti-static agent, Activated zinc oxide, Zinc stearate, HI-sil (EPDM), Plasticizer, and Stearic Acid prior to a kneading process at 140 degrees Celsius for 8 to 12 minutes. (DCP) Peroxides and Blowing agents are added to the kneeing mixture two minutes before the end of the kneeding process. After the kneeding process, the resultant mixture is fed through rollers to form a sheet of the synthetic rubber. The sheet is then cut into appropriately-sized pieces and put into a mold, where the pieces are subjected to high pressure and a temperature of 160 degrees Celsius. The pieces are then left to cool, and then be used for articles such as static-free footwear.

Abstract: A method for continuously producing a rigid polymer foam in rolled form comprising (a) continuously conveying a carrier along a production line, (b) depositing on the carrier a foam-forming mixture, a regulating means being located on the production line to ensure deposition of only enough of the foam-forming mixture for production, after foaming and curing, of a rigid foam having a maximum thickness of less than 1 inch, (c) foaming and curing the deposited foam-forming mixture to produce a rigid foam, and (d) rolling the rigid foam.

Abstract: An opaque, oriented polymeric film structure comprises: (a) a core layer containing a thermoplastic polymeric matrix material which has a first surface and a second surface, the core layer having a plurality of voids, substantially all or all of the voids being free from a void-initiating particle and at least some of the voids being interconnected with an adjacent void in the polymeric matrix material, the number of voids not containing a void-initiating particle being sufficient to impart a significant degree of opacity to the film structure; and (b) at least one outer or skin layer containing a thermoplastic polymeric material and an effective amount of a nucleating agent to suppress cavitation in said at least one outer or skin layer. The film structure has a smooth surface and can be tailored to provide a controlled permeability, and is particularly suitable for food packaging.