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 films so that the resultant product is adpated for use for plates, cups, food containers or packaging and for labells for containers such as glass and plastic containers and for labels that are shrunk in place on a container.

Abstract: A porous waterproof film having a superior gas-permeability and waterproofness, capable of being produced under simple processing conditions, by means of simple processing equipments and at cheap cost, having superior mechanical strengths and also suitable for disposable use applications and a process for producing the film are provided, which film is obtained by subjecting a thermoplastic resin composition film comprising a thermoplastic resin and a specified quantity of a filler based on the thermoplastic resin to calender processing.

Abstract: A process in which a blowing agent dispersion is used for producing poly(vinyl chloride) that is particularly well suited for use in insulation covers and the insulation covers made from the resultant poly(vinyl chloride).

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: Carpet, or carpet tile having a tough resilient backing may be prepared by incorporating a fleece (6) into a foam backing on a carpet. The foam (5) is applied to the back of a carpet and the fleece (6) is overlaid and the foam and fleece are crushed together and gelled preferably using a drum laminator (10) then dried in a conventional oven (13). The resulting carpet may be cut into carpet tiles. The carpet or tile has lay flat properties and good abrasion resistance.

Abstract: A method for the continuous production of foam materials, wherein the foaming and/or foamed synthetic starting material is passed through the pressure zone (4) of a continuously operating press (1), and in which method at least a part of the heat required for foaming is produced in the synthetic starting material itself as dielectric heat of an electromagnetic high-frequency condenser field, wherein production of this heat in the starting material takes place at least to its greatest part within a high-frequency condenser field which is arranged in the direction of passage (8) of the material through the press (1) in front of the pressure zone (4), and that in order to supply additional heat into the foaming and/or foamed starting material or in order to prevent or delay its surface cooling, at least one of the electrodes (10, 11) between which prevails the high-frequency field and/or at least one of the pressure surfaces of the press may be heated.

Abstract: A thermally insulating structural laminate comprising a core of rigid plastic foam having two major surfaces, at least one of the major surfaces of the foam being attached to a facer comprising a fribrous sheet having at least one layer of an air- and moisture-impervious polymer disposed on the inner surface thereof and interposed between the fibrous sheet and the foam, the oxygen transmission of the polymer being a value of less than about 1 cc/100 in.sup.2 -24 hrs-atm sufficient to make the facer substantially impervious to the passage of air and water vapor, resulting in the long-term preservation of insulation value.

Abstract: A process for producing fibrous material moldings surface-coated with a decorative sheeting is described. Cellulose and/or lignocellulose fibers are mixed with binders and are compressed by single-stage or multistage moldings, so that the decorative sheeting covering the finished molded surface is used as a supporting sheet for the non-woven fabric to be shaped. The fibrous material mixture is placed on the side of the decorative sheeting provided with an adhesive, and thus, a mat fleece whose entire surface is joined to the decorative sheeting is produced therefrom. The adhesive between the decorative sheeting and the non-woven fabric can be an adhesive foam.

Abstract: The present invention is directed to a process for the production of matte, non-blocking, thin-walled molded articles, films or tubes from polyurethane elastomers prepared from high molecular weight polyols which contain dispersed polyadducts based on polyisocyanate polyaddition products. The use of these high molecular weight polyols contained dispersed polyadducts allows for the preparation of thin-walled, molded articles which have reduced surface tackiness. The present invention is additionally directed to the molded articles produced by this process and to their use for forming polyurethane foam composites.

Abstract: An aqueous frothed and filled vinyl chloride and/or vinylidene chloride polymer latex containing an emulsified plasticizer is used to coat and impregnate the back of a carpet. The carpet containing the froth is heated to drive off or evaporate the water and gel the vinyl polymer. While still hot or soft, the froth on the carpet is densified to obtain uniform dimensions or thickness. The resulting laminate is then cooled and cut to the required shape and size for carpet tiles.

Abstract: A method and apparatus for making building panels includes means for positioning upper and lower rigid sheets of material, such as paper pulp, in spaced relation so that foamable material disposed between the sheets can move into gripping engagement with both sheets as it expands and solidifies.

Abstract: A method for continuously producing an insulation board comprising a rigid plastic foam core having two major surfaces and a facing material on one or both of the major surfaces, the method including conveying a facing material along a production line, depositing a partially expanded froth foam of a plastic mixture, which contains at least one frothing agent, on the facing material, and further expanding and curing the froth foam in contact wiht the facing material to form the insulation board. The board is particularly useful as roof insulation.

Abstract: A tube is thermally insulated by helically wrapping a water-repelling spacer around the tube; longitudinally folding a paper ribbon carrying a separating medium around and onto the helical spacer; injecting a foaming material into the tube as it is being formed, and permitting the material to foam inside the folded ribbon; and further permitting the foam to cure and set. Subsequently, the ribbon is peeled off the foam and, preferably, a metal or metalized foil is wrapped around the exposed foam, which is followed by the extrusion of a thermoplastic, synthetic envelope onto the foam.

Abstract: A continuous molding machine (10) for forming two chains (55) of soil plugs (50) for use in germinating seeds or otherwise growing plants. A continuous sheet of paper (22) is corrugated to conform to a series of mold elements (14) and a reaction mixture (32) of polymerizing agent and soil slurry is added over the paper to conform to the mold element shape. Another sheet of paper (38) is added over the top of the mixture (32) and the entire assembly is then passed under a series of pressure belts (42, 44, 46) during which time the mixture (32) is cured. The chain of soil plugs (50) which emerges from the pressure belts (42, 44, 46) is encased on both sides by paper (22, 38) and may be cut to provide a pair of separate soil plug chains (55).

Abstract: A plastic foam-forming mixture (31), e.g. a polyurethane or polyisocyanurate foam mix, deposited from one or more static dispensers (19) is metered through two spaced opposed members 14 and 18 forming between them a metering gap. At least one of the members is deformable in a controlled manner such that the profile of the metering gap can be variously defined. Reduces "crowning" of foam boards while permitting foam boards of different thicknesses to be made without having to replace metering bars.

Abstract: An insulation filled building plank having two spaced apart boards held together and separated by webs having dovetail connections with the boards and being at an angle to the longitudinal axis of the plank so that any transverse cut of the plank will cut a web is produced on apparatus which first cuts matching dovetail grooves on surfaces of the boards arranged face to face after which the boards are turned to have the dovetail surfaces facing each other and the apparatus pulls dovetails of webs into the grooves in the boards from a magazine and then the apparatus fills the spaces between the webs and boards with an in situ foamable insulation.

Abstract: A buoyant fiber product and method of manufacturing same. The fiber product includes a quantity of fibers which are bound together with a binder. The binder also secures a quantity of buoyant particles, such as foam beads, to the fibers. The buoyant particles render the product buoyant. The fiber product is manufactured by adding an adhesive and buoyant particles to a quantity of fibrous material. Upon curing of the adhesive, the fibers and particles are bound together.

Abstract: A structural laminate comprises at least one planar facing sheet with a rigid foam attached to one surface of the facing sheet. The rigid foam may be any polymeric material which is capable of being foamed. Distributed substantially evenly throughout the foam is a mat of long glass fibers arranged in layers substantially parallel to the facing sheet. The process for producing this structural laminate comprises the steps of contacting a thin, substantially incompressible yet expansible mat of long glass fibers with a foam-forming mixture, positioning a facing sheet on each face of the mat, and passing the facing sheets having the mat and the foam-forming mixture therebetween through means for metering the amount of foam-forming mixture and causing it to fully penetrate between the fibers of said glass mat.

Abstract: A deformable and durable polyurethane foam molding is made from the reaction product of a polyether polyol component and a polyisocyanate component. The polyether polyol component is a polyether having at least two hydroxyl groups, a molecular weight of from 400 to 10,000 and at least 10 wt. % hydroxyl groups which are primary hydroxyl groups. The polyisocyanate component is a mixture of from 60-90 wt. % 4,4'-diphenyl methane diisocyanate and from 3-30 wt. % 2,4'-diphenyl methane diisocyanate. Such reaction mixture is prepared in each of at least two mixing heads. The index of reaction mixture is different from that in the other mixing head. The mixture is then introduced into associated zones of a mold cavity where the mixture is allowed to foam. The molding is subsequently removed from the mold cavity. These polyurethane foam moldings are particularly useful in making seat cushions.

Abstract: A process for producing a laminate of polyisocyanurate foam which is the reaction product of a polymethylene polyphenylisocyanate and a polyol which is ethoxylated trimethylol propane, ethoxylated trimethylol ethane, ethoxylated pentaerythritol or ethoxylated glycerin. Laminates of such foams exhibit improved adhesion of the facing sheet.

Abstract: A polyurethane carpet underlay having a barrier film attached to one side is prepared employing a continuous sheet of film material which serves both as the mold for the polyurethane-forming mixture and the barrier film.

Abstract: A plastics foam-forming mixture (31), e.g. a polyurethane or polyisocyanurate foam mix, deposited from one or more static dispensers (19) is metered through two spaced opposed members (14 and 18) forming between them a metering gap. At least one of the members having a plurality of faces of different profile and being rotatable to present to the other member a selected face appropriate to the thickness of foam board to be produced. Reduces "crowning" of foam boards while permitting foam boards of different thicknesses to be made without having to replace metering bars.

Abstract: The invention relates to equipment for the continuous production of foam boards, which may be laminated between facings, from a liquid foamable reaction mixture. The apparatus broadly comprises a conveyor, a foam mixture application device located at or near one end of the conveyor and a transverse foam mixture distribution device located downstream of said application device and above said conveyor, the space between said distribution device and said conveyor being adjustable.

Abstract: The invention relates to equipment for the continuous production of foam boards, which may be laminated between facings, from a liquid foamable reaction mixture. The apparatus broadly comprises(i) a conveyor,(ii) an inclined table at one end of said conveyor, the incline of said table sloping downwardly toward said conveyor,(iii) a foam mixture application device located above said downwardly sloping surface, and(iv) a transverse foam mixture distribution device located downstream of said application device and located above said downwardly sloping surface thereby forming a space therewith. When sheets or relatively thin foam boards or sandwich boards are produced, the device used is generally additionally equipped with an upper conveyor. This invention primarily relates to such double conveyors. The liquid reaction mixture must be applied over the entire width in a particularly uniform layer in order to obtain a perfect final product.

Abstract: The present invention relates to equipment for the continuous production of foam boards, and particularly rigid foam boards, which may be laminated between facings. The apparatus broadly comprises a conveyor, which at the pouring end is equipped with an inclined table and a transverse distribution device, and a foam mixture application device provided above the table.

Abstract: The fibrous structure of a non-woven mat is disrupted by an apparatus comprising at least one roll which has one or more upraised ribs in a chevron pattern extending helically around the roll. In processing, the mat passes under tension over at least a portion of at least one chevron roll and preferably over two chevron rolls which may or may not be intermeshing. Thereafter, the mat may be crushed or crimped by being fed through to intermeshing third and fourth chevron rolls. Additional rolls may be supplied to exert tension. The mat which exits from the apparatus has a disrupted fibrous structure and is a superior skeleton within a structure such as a polymeric foam board.

Abstract: Machines and process for making in a continuous operation a prestressed glass reinforced, thermally insulating panel, structurally stiff, and totally impervious, of indefinite length and with a cross-section shaped as an elongated parallelogram.Steps for manufacture include making the surface of the panel out of a tubular envelope of knitted or woven glass fabric, stretched over a special holding frame, to give it the desired parallelogram shape. Fastened by a continuous knitting process to the opposite faces of the glass fabric envelope, other glass fibers are stretched inside the envelope and arranged according to three principal directions, all of them oblique with respect to the panel faces. The glass fabric envelope is then coated with a plastic resin to make it impervious to gas and covered on one face at least with a metal liner. This liner, made of cryogenic alloy, has its edges upturned and folded, so as to be fastened to the glass reinforced plastic envelope.

Abstract: The manufacture is carried out by impregnating bundles of filaments of fibrous-reinforcing material in a bath made up of an emulsion of a thermoplastic resin and a blowing agent. The emulsion-impregnated reinforcing filament bundles are then squeezed and dried to form resin coatings, and then collected to provide a single bunch of the fiber-reinforced thermoplastic resin material. This bunch is subsequently heated and allowed to expand in a tunnel and also cooled in a tunnel to produce a fiber-reinforced thermoplastic resin of a cellular structure. During the impregnation with the emulsion in a bath, the bundles are slackened and repeatedly beaten in the condition of free tension to cause the filament bundles to be substantially frayed to facilitate the impregnation. An apparatus utilizable in the practice of the above method is also disclosed.

Abstract: A method and apparatus for directing a foamed material, such as a foamed binder, across the lateral dimension of a moving surface in a uniform and controlled metered flow. In accordance with the method the foamed material is fed into an interior compartment of an applicator unit and is spread laterally as it moves through the compartment toward a laterally extending metering flow gap. After being laterally spread the foamed material is metered in a uniform, controlled manner across the lateral dimension of the moving surface. The applicator unit of this invention has a housing that includes a body portion and a door portion movable relative to each other to form, in a closed condition, the interior compartment that receives the foamed material. The body portion and door portion also aid in forming the laterally extending metering flow gap in communication with the interior compartment, and a passage extends through a wall of the housing to permit the foamed material to be introduced into the applicator unit.

Abstract: An apparatus is disclosed for making foam plastic insulating panels. The apparatus has a lower conveyor band forming a support surface and a first continuous form belt on the support surface and an upper conveyor band forming a limiting surface and a second continuous form belt on the limiting surface. The conveyor bands are supported for rotation between conventional tires, the inflation of at least one of the tires controls the pressure on the form belts adjacent their initial point of contact. Resilient metal clips are provided which lock the support and limiting surfaces together during curing of the foam plastic panel.

Abstract: Continuous foam blocks with rectangular cross-section are produced on a side-limited conveyor band by feeding a foamable mixture to a cover foil travelling with said conveyor band and covering the free surface of the mixture with a bearing layer not earlier than immediately after the supply of the mixture and not later than before the zone in which a skin would be formed on the free surface of the block.

Abstract: A method of applying foamed insulation to pipe is contemplated by the present invention. The pipe is moved longitudinally while being rotated about its longitudinal axis. A sprayable, foamable liquid is directed onto the surface of the pipe from a stationary location and is allowed to partially rise before a protective outer jacket is wrapped around the rising foam. The wrapping step includes application of sufficient pressure to the foam to increase the final density thereof, at the outer surface, by from 10% to 25% above the density if the foam was allowed to rise uninhibited.

Abstract: A method for producing continuous polyurethane blocks having a planar upper surface and a rectangular cross-section is disclosed. The method includes a pressure regulating stage in which pressure is gradually exerted along entire transverse directions of the foamed material to prevent a crowning thereof. The pressure is applied transversely in a plurality of longitudinally discontinuous non-fixed locations.

Abstract: In the continuous production of rectangular foam slabs wherein a foamable reaction mixture is foamed on a forwardly moving floor web and lateral confining webs, and in which a cover web is applied during the foaming process to the surface of the rising foam, the improvement which comprises supplying said cover web from a supply to the surface under controllable tension, thereby exercising a controllable pressure on the surface of the rising foam, removing the cover web from the foam surface beyond the point at which the rising mixture has substantially reached its maximum height and passing the web rearwardly and then forwardly to serve as the floor web for receiving further foamable mixture.

Abstract: A structural laminate comprises at least one planar facing sheet with a rigid foam attached to one surface of the facing sheet. The rigid foam may be any polymeric material which is capable of being foamed. Distributed substantially evenly throughout the foam is a mat of long straight glass fibers arranged in layers substantially parallel to the facing sheet. The process for producing this structural laminate comprises the steps of contacting a thin, substantially incompressible yet expansible mat of long straight glass fibers with a foam-forming mixture on each face of the mat, and passing the facing sheets having the mat and the foam-forming mixture there between through the nip of two rotating rolls.

Abstract: Insulation board comprising a urethane foam core sandwiched between a thin flexible membrane and a thicker inflexible panel is made by dispensing foam forming materials onto a moving continuous sheet of the thin flexible membrane and depositing individual panel segments onto the foam as it expands. The manufacturing apparatus includes a conveyor press for transporting the flexible membrane past a foam dispensing device and means for consecutively depositing the individual panel segments onto the expanding foam. The panel depositing means comprise a suction apparatus for suspending the panel over the foam and a friction drive mechanism for simultaneously impelling a leading end of the panel against a trailing end of an immediately preceding panel to prevent the formation of gaps between consecutive panel segments. The resultant laminate is then passed through the conveyor press that acts as a forming and curing zone for the laminate which is thereafter cut to size at a cutting station.

Abstract: A shaped synthetic resin article varying in cross-sectional area and shape of longitudinal section along at least a part of the length is continuously produced by introducing a molten synthetic resin composition, extruded from an extruder die, between at least one pair of rolls rotating in the direction of extrusion so that the rolls of each pair contact each other on their periphery, the peripheral surfaces of the rolls being engraved so as to form a cavity corresponding to the shape of said shaped article when the rolls of each pair contact each other while being rotated, in which cavity the molten resin composition is remolded into an article having the desired shape and at the same time the surplus resin composition overflowing from said cavity is cut off by the edges of said rolls contacting each other, and then cooling the molded article to solidify the same.

Abstract: Apparatus for producing continuous polyurethane blocks is disclosed. The apparatus includes pressure regulating members to prevent a crowning of the upper surface of the foamed material. The pressure regulating members comprise a plurality of surface elements each of which is rigid and fixed with respect to an axis taken along the width of the foam. The plurality of elements is arranged or utilized so that the entire width of the foamed material is superposed. The surface elements may be in the form of shoes or rollers. The width of the foamed material may be adjusted by adjusting the apparatus side walls. In such a case, the plurality of surface elements will be arranged or utilized to superpose the entire width without the necessity of shutting down the process or manually adjusting the width of the elements. The shoes or rollers are pivoted or suspended from a common frame so that they are freely movable along the surface of the foamed material in the forward or reverse direction of foam movement.

Abstract: A process for the production of artificial leathers having excellent air permeability and resembling a natural leather is provided, which comprises incorporating a catalyst, a foam stabilizer and, optionally, a pigment and other additive into an isocyanate-terminated polyurethane prepolymer formed by compounding a polyester diol derived from an aliphatic dicarboxylic acid with an organic polyisocyanate so that the [NCO]/[OH] ratio is within a range of from 2.0 to 4.0, to thereby form a substantially solvent-free paint having a viscosity adjusted to 70 to 1000 poises, coating the paint on a release paper in an amount of 50 to 400 g/m.sup.2, applying the release paper to a substrate, allowing foaming and polymerization reactions to proceed in an atmosphere of a dry-bulb temperature of 40.degree. to 95.degree.C.

Abstract: A method for making a cellular article in which at least some of a plurality of extruded, generally parallel streams of strand-forming organic, thermoplastic, polymeric material are periodically expanded to provide bulbous portions along the lengths thereof, with such bulbous portions contacting and bonding with adjacent streams during their expansion, after which the streams are set to provide an integral article.

Abstract: Forming a plastic containing paper product by introducing expandable plastic pellets between two partially dewatered webs of cellulose fibers, pressing together and heating.

Abstract: An improvement in a process for preparing a foamed thermoplastic article in which a foamable thermoplastic resin is passed through an orifice of a die and is permitted to expand after passing through said orifice. The improvement includesA. passing the foamable thermoplastic resin through an orifice, the outer periphery of which contains a plurality of recesses,B. allowing the resin to expand to form a soft-surfaced porous shaped article having peaks and valleys corresponding to the recesses of the orifice, andC. pressing the surface of said article so as to level the peaks.A smooth-surfaced shaped article is produced having a surface structure characterized by high density portions corresponding to the peaks and low density portions corresponding to the valleys and resembling natural wood.