Abstract: Novel sp3 rich diamond-like carbon (DLC) nanorod films were fabricated by hot filament chemical vapor deposition technique. The results are indicative of a bottom-up self-assembly synthesis process, which results in a hierarchical structure that consists of microscale papillae comprising numerous nanorods. The papillae have diameters ranging from 2 to 4 ?m and the nanorods have diameters in the 35-45 nm range. A growth mechanism based on the vapor liquid-solid mechanism is proposed that accounts for the morphological aspects in the micro- and nano-scales.

Abstract: The present invention relates to a method for producing three-dimensional objects based on computer data by repeated application in layers of a medium containing particulate material and selective solidification of the medium, whereby a feedstock made of medium in a build space is provided and a layer application of the medium takes place on a surface of the feedstock bordering the build space at an angle ? and a solidification according to computer data occurs by use of a solidification unit, characterized in that the feedstock is not moved during build-up of the object.

Abstract: This disclosure provides methods of flash sintering and composition created by these methods.

Abstract: An apparatus for forming at least one three-dimensional article by fusing parts of a powder bed layer-wise. The apparatus comprising a powder distributor and an energy beam for fusing the powder layer. Said powder distributor comprises a first part being an elongated rod provided movable at a predetermined distance above the powder bed and with its central axis in parallel with a top surface of said work table and second part being a metal foil having at least a first and a second opposite edge portions. Said metal foil is provided between said elongated rod and said work table, said first and second opposite edge portions are attached to said elongated rod so that a distance between said first and second edge portions is smaller than the distance between said first and second edge portions of said metal foil when said metal foil is in a flat position.

Abstract: The present invention relates to methods for making oxidation resistant medical devices that comprise polymeric materials, for example, ultra-high molecular weight polyethylene (UHMWPE). The invention also provides methods of making antioxidant-doped medical implants, for example, doping of medical devices containing cross-linked UHMWPE with vitamin E by diffusion, post-doping annealing, and materials used therein.

Abstract: This publication discloses a method for creating nanoscale formations. According to the method, a filler matrix and first nanoparticles embedded in the filler matrix, and two conductive electrodes are superimposed on the insulating material layer. According to the invention, a voltage is applied between the conductive electrodes, a filler matrix is used and first nanoparticles have substantially different electrical properties in order to induce self-organized localized contact creation when said voltage is applied. Potential applications of the invention include e.g. parallel-plate capacitor structures based on metal-oxide nanoparticles, such as memory cells, and high-permittivity/tunable capacitors.

Abstract: The invention concerns an apparatus (1) for producing a three-dimensional object (6) layer by layer using a powdery material which can be solidified by irradiating it with an energy beam (4), said apparatus (1) comprising an electron gun (3) for generating said energy beam (4) and a working area (5) onto which the powdery material is distributed and over which the energy beam (4) sweeps during irradiation. The invention is characterized in that the apparatus (1) is provided with a system (12, 14, 16, 18) for feeding controlled amounts of a reactive gas into the apparatus (1) such as to contact the reactive gas with material positioned on the working area (5), said reactive gas being capable of, at least when having been exposed to the energy beam (4), reacting chemically and/or physically with the material positioned on the working area (5). The invention also concerns a method for operating an apparatus of the above type.

Abstract: A process for producing carbon nanotubes includes carbon plasma generation with microwave energy, plasma stabilization, and product deposition. Stabilization homogenizes the plasma energy density and concentration, leading to a more efficient reactor. A transition metal catalyst and associated catalyst support are used to form the end product. The formation region may have variations of geometry and supporting equipment that will affect the rate and purity of production. The formation region is immediately downstream from the plasma stabilization region such that the apparatus may be mounted on a robotic arm for direct deposition of product.

Abstract: The invention concerns a method for producing three-dimensional objects (3) layer by layer using a powdery material (5) which can be solidified by irradiating it with a high-energy beam.

Abstract: Chemically cross-linked polymeric particles are formed using mechanical rather than chemical processes, facilitating production of small-diameter particles in a manner largely independent of the viscosity or density of the polymer. For example, an uncross-linked resin may be provided in particulate form, agglomerated, and compressed into a mass of a desired shape with a desired diameter, and subsequently cross-linked.

Abstract: Chemically cross-linked polymeric particles are formed using mechanical rather than chemical processes, facilitating production of small-diameter particles in a manner largely independent of the viscosity or density of the polymer. For example, an uncross-linked resin may be provided in particulate form, agglomerated, and compressed into a mass of a desired shape with a desired diameter, and subsequently cross-linked.

Abstract: Chemically cross-linked polymeric particles are formed using mechanical rather than chemical processes, facilitating production of small-diameter particles in a manner largely independent of the viscosity or density of the polymer. For example, an uncross-linked resin may be provided in particulate form, agglomerated, and compressed into a mass of a desired shape with a desired diameter, and subsequently cross-linked.

Abstract: A method for making agglomerate particles from a composition comprising at least a radiation curable binder and solid particulates. The method comprises the steps of forcing the composition through a perforated substrate to form agglomerate precursor particles which then separate from the perforated substrate. Then, the particles are irradiated to form soldified, handleable agglomerate particles before being collected.

Abstract: Methods for making ceramic aggregate particles comprising forming a plurality of ceramic aggregate precursor particles from a composition by forcing the composition through at least one orifice in a substrate, at least partially curing the ceramic aggregate precursor particles, and heating the ceramic aggregate precursor particles to provide ceramic aggregate particles wherein solid particulates are bonded together by ceramic binder.

Abstract: The invention is embodied in an electrical device which includes at least a layer of a ferroelectric polyvinylidine flouride polymer that has been processed to exhibit an electrostrictive strain of 4% or more when an electric field gradient of 50 megavolts per meter or greater is applied thereacross. The processing of the polymer preferably involves subjecting it to either electron beam radiation or gamma radiation. The polyvinylidine flouride polymer is selected from the group of: polyvinylidine fluoride, polyvinylidine fluoride-trifluoroethylene P(VDF-TrFE), polyvinylidine fluoride tetrafluoroethylene P(VDF-TFE), polyvinylidine fluoride trifluoroethylene-hexafluoropropylene P(VDF-TFE-HFE) and polyvinylidine fluoride-hexafluoropropylene P(VDF-HFE).

Abstract: A method for forming a product from cellulosic material and thermoactive material is described. A mat is formed from a mixture having cellulosic material and thermoplastic material. The mat is consolidated and pressed to a final thickness. At least a portion of a surface of the mat or product may be surface modified. Consolidating the mixture may include forming a first face layer, forming a core layer on the first face layer, and forming a second face layer on the core layer. Forming the core layer may include depositing mixtures of wood flakes and plastic flakes according to mixture flake size in successive layers such that the core layer has larger flakes adjacent the first face layer and adjacent the second face layer, and smaller flakes in a middle portion of the core layer. Consolidation can occur as a mat or composite moves through a hot-gas consolidation zone.

Abstract: A particle board, a fiberboard or an oriented strand board (25) is formed by the process according to the invention from a mixture of a comminuted cellulose material and a binder, especially a synthetic resin containing an unsaturated oligimer, that is hardenable by electron radiation. The process of the invention includes first forming a loosely scattered layer (4) of the mixture, e.g. on a conveyor belt, then compressing the layer in a press device (16), after performing a pre-compression in a pre-press in Some embodiments, and rapid setting of the layer (4) by means of electron radiation from an electron radiation device (22). Unlike the known processes that only use a thermosetting binder, the inventive method is hindered neither by heat transfer to the center of the board nor by a non-uniform humidity profile. High quality boards may be produced at a high yield without splitting and these boards require no conditioning storage.

Abstract: A method for making abrasive agglomerate particles from a composition comprising at least a radiation curable binder and solid particulates. The method comprises the steps of forcing the composition through a perforated substrate to form agglomerate precursor particles which then separate from the perforated substrate. Then, the particles are irradiated to form soldified, handleable agglomerate particles before being collected.

Abstract: A solid freeform fabrication method and related apparatus for fabricating a three-dimensional, multi-material or multi-color object from successive layers of a primary body-building powder, at least a modifier powder and a binder powder in accordance with a computer-aided design of the object, the method including: (a) feeding a first layer of the primary body-building powder to a work surface; (b) operating an electrophotographic powder deposition device to create at least a modifier powder image and a binder powder image in accordance with this design; (c) transferring these powder images in a desired sequence to the first layer of a primary body-building powder; (d) applying energy sources to fuse the binder powder, forming a binder fluid that permeates through the first layer of a primary body-building powder for bonding and consolidating the powder particles to form a first cross-section of the object; (e) feeding a second layer of a primary body-building powder onto the first layer and repeating the ope

Abstract: An apparatus and method for continuously forming composites comprising filler materials and thermoactive materials, particularly waste cellulosic materials and waste thermoplastics, are described. One embodiment of the apparatus includes either a batchwise or continuous mixer, such as a cyclone, for forming mixtures comprising filler and thermoactive material. The mixtures are conveyed to a continuous consolidation apparatus. Alternatively, the mixtures may be densified in a densifying apparatus before entering the consolidation apparatus. The consolidation apparatus includes a hot-gas distribution system having plural paired gas cells, such as rollers or hoods, for applying hot air to the charge. A first cell of each pair applies gas to the mixture. The second cell of each pair operates at a pressure less than that of the first cell, thereby creating a pressure differential across the charge.

Abstract: A process for forming carbon nanofibers by means of pyrolyzation with plasma in a reactor is disclosed. The process includes the steps of: providing, in a reactor, a first catalyst in the form of solid catalytic particles; applying a vacuum to the reactor to create a reduced pressure in the reactor; feeding a first mixture of gases including a carbon-based gas into the reactor; forming, from the carbon-based gas, a plasma containing carbon free-radical species; and forming, in the presence of the catalytic particles, carbon nanofibers.

Abstract: A method of manufacturing an articulating bearing surface for use in an orthopaedic implant uses a supply of ultra-high molecular weight polyethylene particles which are irradiated with sufficient radiation energy to crosslink at least a portion of the ultra-high molecular weight polyethylene. The irradiated particles are then formed into an orthopaedic bearing surface.

Abstract: A method in which a polyolefin foam layer is laminated to a sealing film having at least a first layer of a polyolefin. During the lamination a second layer is located between the first layer and the foam layer; the second layer is extruded therebetween and pressure is immediately applied. The second layer and the first layer are polyolefins each based on the same monomer as the main monomer of the foam layer. The same lamination technique may be used to laminate a sealing film to the other side of the foam layer, optionally at the same time as the lamination of the sealing film to the first side of the foam layer. Alternatively, the lamination technique may be used on one side of the foam layer, and the other side of the foam layer may be sealed by means of a coextruded layer.

Abstract: A battery separator is made from a microporous polyolefin membrane having a thickness of less than or equal to 0.5 mil. The separator is made by extruding a parison, collapsing the parison to form a flat sheet comprising two plies, annealing the sheet, stretching the sheet, and winding the sheet.

Abstract: A capsule is formed from a pre-expanded foam core in a compressed condition with a thermoplastic outer covering completely enveloping the foam core to maintain it in the compressed condition. The outer covering is made of a material capable of softening sufficiently when heated to permit the foam core to expand toward its original expanded uncompressed condition. Preferably, the outer covering adheres to the foam and then is carried by the expanding foam into intimate contact with the inner surface of a hollow structural member so as to form a seal for the hollow structural member.

Abstract: A method is provided for manufacturing a diamond-like carbon (DLC) coated optical phase-change recording medium for use with near-field optical head devices and which exhibits superior wear resistance and improved lifetime. According to the method, the surface of a composite optical phase-change media structure deposited onto a substrate is subjected to ion beam deposition of a DLC over-coat to a thickness of no greater than about 450 .ANG.. Preferably the DLC is ion beam deposited onto the phase-change recording layer at the surface of the medium structure or onto a germanium-containing adhesion-promoting interlayer to achieve the desired adhesion of the DLC to the surface of the medium structure.

Abstract: There is provided a biodegradable filter tow or filter material from renewable raw materials for the use as a tobacco smoke filter element of cigarettes, cigars or pipes as well as a method for preparing it, wherein fibers, films or foams prepared in an extrusion method from biopolymers based on thermoplastic starch or its polymer compositions are processed to the filter tow or filter material according to the present invention.The advantages of this invention reside in the use of mainly renewable raw materials, a fast and complete biodegradability of the natural biopolymer filter material, a pollutant-reducing flavor-increasing filtering effect and an economically favorable preparation method.

Abstract: A foamed cellular material which can be obtained from foamed aromatic polyester resins with a bulk density of 50 to 700 kg/m3 by heating in vacuum to temperatures which are higher than the Tg of the material and lower than its melting point. The foamed material, generally in the form of a sheet or panel, has high-level characteristics in terms of flexibility and dimensional thermostability depending on the degree of crystallinity after the vacuum treatment.

Abstract: A method of the invention can produce a fiber-reinforced thermoplastic resin foamed product having less unevenness in a thickness of a surface layer and excellent mechanical strength. In the method, a fiber-reinforced thermoplastic resin sheet is continuously shaped into a hollow member, and a foaming resin composition containing a thermoplastic resin and a foaming agent is supplied into an interior of the obtained hollow member. The foaming agent is foamed so that the hollow member is shaped into a desired form by the foaming pressure.

Abstract: In a process for extruding polymer melts (25) to form hollow chamber sections (21) by pressing the polymer melt through a shaping tool (24) with an internal shaping mandrel (26) and by subsequently sizing and cooling the hollow chamber section strand in a sizing and cooling unit (31) it is provided for the sizing and cooling of the hollow chamber section strand to be carried out in the sizing and cooling unit under extrusion pressure. A device for carrying out this process is characterized in that shaping tool (24) and sizing and cooling unit (31) are rigidly connected to form a closed system so that the strand extrusion pressure prevailing in the shaping tool can be propagated into the sizing and cooling unit, and that the shaping mandrel (26) protrudes out of the shaping tool (24) into the sizing and cooling unit (31).

Abstract: The invention relates to the field of providing coatings for articles, said coatings provided to enhance the visual appearance of the articles such as doors, for furniture, sporting goods and in general any articles where the appearance can be enhanced by providing a coating thereon. Typically the coatings can be provided to give the appearance that the article has been manufactured from a more expensive material, to provide advertising material thereon or generally to provide a more pleasing appearance to the eye. The invention provides a coating formed of a plastic sheet material to which has been applied at least one ink pattern which is viewable and said ink pattern is applied and the sheet material is of sufficient flexibility to enhance the appearance of the article and also to mimic the effect of contour changes of the articles.

Abstract: The invention relates to a process for the manufacture of new shaped parts, preferably made from chipboards, wherein a mass formed from at least a binder and a small-particled material brought into contact with this binder is subjected to extrusion at elevated temperature and pressure. In the process according to the invention, a mass possessing a total moisture content of 6 to 25 wt. % or adjusted to the stated moisture content and made up of at least one biopolymeric preferably starch-containing binder, which converts into a melt and/or gel at extrusion temperatures and pressures, and further made up of the small-particled material, is subjected to extrusion and immediately thereafter undergoes decompression and spontaneous expansion.

Abstract: A panel including a starch foam core which is composed of starch, which is one of resilient foam or hardened foam; and which has a form selected from the group consisting of a plurality of strands which are straight and in essentially parallel alignment with one another, and a plurality of strands which are bent and arranged in an undulating path; and at least one outer layer composed of sheet material and provided directly on a surface of the starch foam core in engaging contact therewith; wherein the panel is prepared in a continuous process.

Abstract: The invention provides a polyglycolic acid sheet obtainable by melt-extruding a thermoplastic resin material into a sheet in a temperature range of from the melting point, Tm of the polymer to 255.degree. C., wherein the thermoplastic resin material comprises polyglycolic acid having a repeating unit represented by the following formula (1): ##STR1## and the following physical properties: (a) the melt viscosity, .eta.* ?as measured at a temperature of (the melting point, Tm of the polymer+20.degree. C.) and a shear rate of 100/sec! being 500-100,000 Pa.s;(b) the melting point, Tm being at least 150.degree. C.;(c) the melt enthalpy, .DELTA.Hm being at least 20 J/g; and(d) the density being at least 1.50 g/cm.sup.3 as measured in an unoriented, crystallized form, and the sheet has tensile strength of at least 60 MPa, and a production process thereof.

Abstract: The present invention relates to a plastic article formed from several foamed thermoplastic elastomers, such as a thermoplastic polyolefin elastomer based on polypropylene and a vulcanized elastomer at least one of an elastomeric styrene/ethylene/butylene/styrene block copolymer, an elastomeric styrene/butadiene/styrene block copolymer, a thermoplastic elastomer based on polypropylene and an elastomeric styrene/ethylene/butylene/styrene block copolymer and a thermoplastic elastomer based on polypropylene and an elastomeric styrene/butadiene/styrene block copolymer. The present invention further provides plastic articles based on a blend of thermoplastic elastomers and thermoplastic elastomer olefins. The invention further provides a process for making these articles.

Abstract: A composition containing thermoplastic elastomer and elastic fine particles is extruded into a sheet-like shape from an extruder. Then, by expanding this sheet-like shape member, a covering sheet having minute unevenness attributable to the elastic fine particles formed on the surface is produced. The covering sheet may have an adhesive layer, a substrate layer, a foamed resin layer, etc., on the opposite side to the surface having a matt feeling. Such covering sheet can be produced with good productivity without creating environmental problems such as a problem related to solvent, etc. By molding using the covering sheet, a molding having matt feeling can be obtained.

Abstract: The present invention provides a method of producing high-strength and high-conductance copper and silver materials comprising the steps of combining a predetermined ratio of the copper with the silver to produce a composite material, and melt spinning the composite material to produce a ribbon of copper and silver. The ribbon of copper and silver is heated in a hydrogen atmosphere, and thereafter die pressed into a slug. The slug then is placed into a high-purity copper vessel and the vessel is sealed with an electron beam. The vessel and slug then are extruded into wire form using a cold hydrostatic extrusion process.

Abstract: A composite camel structure includes an elongate hollow, rigid cylindrical core, opposite ends of the core having respective caps sealingly connected thereto, a buoyant material of cured urethane foam substantially filling the core and being sealingly enclosed therein. A cushion is thermally bonded to and sealingly surrounds the core, the cushion having a substantially unbroken outside surface, being formed of a polymeric component consisting of polyethylene being at least 80 percent low-density polyethylene, and a process additive component including an effective amount of an ultraviolet inhibitor. A pair of parallel-spaced, transversely oriented guides extend between opposite sides of the cushion in axially spaced relation to the core, each guide defining a guide opening through the cushion for receiving hawser chains whereby the camel structure rides up and down with the tide.

Abstract: A synthetic reinforcement having surface features that facilitate adhesion of the reinforcement to another surface and a process for making the same is disclosed. The synthetic reinforcement is comprised of a plurality of continuous fibers that are maintained in position by a resin encasement. An external surface of the synthetic reinforcement can be characterized by micro-recesses that are located in a generally random pattern, which increases the surface area of the resin encasement.

Abstract: A method of making ornamented elongate members, for example for picture frames, uses the steps of extruding a first material and cooling it so that it is substantially solid, extruding a second material along a surface of the first material, which is arranged to undergo a change enabling a firm bond to be formed between the materials, shaping the second material to produce surface ornamentation and cooling the first and second materials. This provides an inexpensive and quick way of producing ornamented members.

Abstract: A coextruded block composite which includes a porous first block. The block is permeable to fluids and includes a granular component and a binder component. The block has interconnected pores therethrough having a first average diameter. The composite also includes a second block. In addition, at least one of the first block and the second block is continuous and at least a portion of the second block is contiguous with at least a portion of the first block. The second block also may be permeable to fluids. Additional blocks may be present, if desired. One or more of the blocks other than the first block may be a porous block having a granular component and a thermoplastic binder component. The coextruded block composite may be employed as a filter medium.

Abstract: An apparatus 1 for widening a foam sheet S obtained immediately after heating and foaming a foam sheet which has not been yet widened, while the foam sheet S is continuously received or supplied. The sheet widening apparatus 1 comprises: a pair of chains 2 constructed in the form of endless chains composed of links 22 having pin parts 21 and a driving device 3 meshing with these chains 2 and driving the chains 2 along such loci as to widen the space between the chains 2 from sheet receiving start points to sheet receving end points. A method for widening a foam sheet by the sheet widening apparatus 1 comprises the steps of piercing both the side parts of the foam sheet S with the pins 21 at the sheet receiving start points; widening the space of width between the pins 21 along gently curved loci by drying the chains 2 while the pins 21 penetrating the foam sheet; and receiving the foam sheet S from the sheet receiving start points to the sheet receiving end points while the foam sheet is widened.

Abstract: A process for producing an automotive molded roof material is provided which comprises sheeting a foamable sheet forming composition comprising a specified propylene resin, a glass fiber, a radical initiator, a crosslinking auxiliary and a foaming agent in specific proportions into a foamable sheet, lining one side of the foamable sheet with a backing sheet so as to integrate these and irradiating the foamable sheet with ionizing radiation to thereby crosslink the propylene resin, followed by heating the foamable sheet so as to cause the foamable sheet to foam, placing a cover sheet on the other side of the foamed sheet before the sheet cools to solidify and press molding the cover sheet on the foamed sheet to cover. There is also provided an automotive molded roof material produced by the above process. An automotive molded roof material is obtained which can be recycled, is lightweight and has high rigidity.

Abstract: This invention produces three-dimensional shapes such as window lineals by first lining a foam die with a continuously moving reinforcing veil. Once the veil is in the foam die, a foam is blown into the die. The foam expands in the die forcing the veil against the die wall. The veil is selected so that the foam never fully penetrates the veil, but adheres to it. The material exiting the foam die is now properly shaped to enter the curing die. Resin is then injected onto the foam core where it penetrates the veil, is cured in the heated curing die and exits as a finished product of a plastic skin adhered to a foam core with a veil sandwiched therebetween.

Abstract: A method of producing and the product of heat-proof laminate boards are disclosed. Each laminate board cut from a continuous laminate has a corrugated upper layer, a middle foam layer produced by spraying foam agent onto one side of the upper layer which will expand into shape automatically, a bottom layer having opposite edges folded in conformance to the corresponding edges of the upper layer so as to sealedly confine the foam in between the upper layer and bottom layer. The upper layer can be made of one of the materials including steel plate, PVC, PC, PP, aluminum plate, iron sheet. The bottom layer is made of materials including PVC film, PP film, papery film, fabric film, nylon film or wooden fiber sheet.

Abstract: A white-colored porous polymer film having elongated spherical pores, which is characterized in that said pores exposed on a surface created by cutting the film along longitudinal direction satisfy the following formulae, possesses a low density, good surface and mechanical property and good processability: ##EQU1## wherein, P.sub.L,90 is an average length of longer axes of 90% or more of the exposed pores;P.sub.D,90 is an average length of shorter axes of 90% or more of the exposed pores;P.sub.L/D,50 is an average of the longer axis to the shorter axis length ratios of the exposed pores;P.sub.N is the number of exposed pores per 1000 .mu.m.sup.2 of the exposed surface; andP.sub.A is the ratio of the exposed pore area to the exposed surface area.The polymer film of the present invention comprises a polyester and polyolefin resin mixture, inorganic particles, a metal sulfonate and a hindered phenol.

Abstract: Foam forming techniques capable of permitting foaming of biodegradable resin to be positively and uniformly accomplished to provide a biodegradable resin foam with satisfactory quality. The biodegradable resin foam is made of biodegradable resin consisting of a main biodegradable resin ingredient of 100.degree. C. or more in melting point and a low-melting biodegradable resin ingredient of 100.degree. C. or less in melting point. The biodegradable resin foam is produced by placing a starting material consisting of at least biodegradable resin and a substantial amount of moisture in a heated and pressurized environment, releasing the starting material from the environment to foam the biodegradable resin, and subjecting the foamed resin to forming by means of a forming mold. An apparatus for producing the foamed biodegradable resin foam includes a pressure adjusting chamber, an air-permeable forming mold, a pressure reducing tank and an injection machine.

Abstract: There is disclosed a method for making a vibration dampener, the dampener cluding a body for disposition between two relatively movable members, the body being formed from a carrier of a gel material and particles having electrorheological properties embedded in the carrier with the particles electrically aligned and pseudo-bonded. The dampener is made by passing a current through a mixture of the particles and the carrier while the carrier cures into a gel material.

Abstract: A synthetic reinforcement having a plurality of recesses on a surface to facilitate adhesion to wood structural members and a process for making the same is disclosed. The synthetic reinforcement is comprised of a plurality of continuous fibers that are maintained in position by a resin encasement. The surface of the synthetic reinforcement is characterized by recesses that are located in a generally random pattern, which increases the surface area of the resin encasement. The synthetic reinforcement is connectable to wood laminae or itself with commercial grade adhesives such as the resorcinol resins, which are suitable for adhering the wood laminae together.

Abstract: The method of making polystyrene foam for foam products which includes utilizing atmospheric gases as the blowing agents or preferably mixing one or more of these gases and a blending agent which is non-volatile at the extrusion temperatures, introducing the mixture to a molten thermoplastic polystyrene resin containing nucleating agents such as sodium bicarbonate and citric acid and extruding the thermoplastic in the form of a foam. The resultant foam has substantially no residual blowing agent, is dimensionally stable at ambient temperatures and when used with a non-volatile blending agent can be made with small amounts of blowing agent permitting cooling of the melt without high loading on the extruder. The foam may be coextruded with one or more layers of thermoplastic film so that the resultant product is adapted for use for plates, cups, food containers or packaging and for labels for containers such as glass and plastic containers and for labels that are shrunk in place on a container.