Abstract: Foam for making pads and belts with controlled, reproducible microcellular structure and method of making such foam in a fast and efficient manner. Under constant pressure and temperature, a prepolymer is mixed with the nucleation surfactant in a tank in the presence of a frothing agent metered into the tank by way of a dip tube or sparge. The nitrogen gas is sheared into small bubbles and is drawn off from the headspace of the tank creating a continuous flow of nitrogen. The pressure of the tank may vary from any absolute pressure down to near complete vacuum, thereby all but eliminating the pressure requirement. The froth of the present invention has a more consistent cell structure and increased cell count.

Abstract: The present invention relates to a light-reflecting member including a polyolefin resin foam as a light-reflecting layer, the polyolefin resin foam being obtained by foam molding a resin composition containing a polyolefin resin. According to the light-reflecting member of the invention, since it has the above-mentioned constitution, the light-reflecting member is excellent in light reflection, impact-absorbing property, and lightness in weight. Moreover, the process for producing a light-reflecting member of the invention can provide a light-reflecting member excellent in light reflection, impact-absorbing property, and lightness in weight by using a polyolefin resin foam.

Abstract: A cosmetic applicator is made of a rubber latex foam which has been solidified by microwave irradiation. The foam satisfies (i) a bubble fineness corresponding to 9 bubbles/mm2 or more, (ii) flexibility of 0.7 N/cm2 or less in initial Young's modulus indicated by 50% compressive stress, and (iii) bulk density of 0.14 g/cm3 or less.

Abstract: The disclosure provides a composition or set of compositions and method for producing cellular, foamed, or blown fluoropolymers such as perfluoropolymers and other thermoplastics to create a lower cost communications cable, conductor separator, conductor support-separator, jacketing, tape, wire insulation and in some cases a conduit tube as individual components or combined configurations that exhibit improved electrical, flammability and optical properties. Specifically, the foamable or blown perfluoropolymer cellular insulation composition comprises; talc and the selected fluoropolymers such as perfluoropolymers. Compounded pellets including inorganic and organic fillers resulting in products in cellular or foamable form with and without solid skin surfaces has also been realized by providing melt combinations within the pellets primarily comprising talc and a perfluoropolymer, and additives as needed to provide desired property differentiation.

Abstract: Disclosed herein are methods for making expanded foamed polymeric panels from solid monolithic semi-crystalline thermoplastic material sheets having a first thickness, density, and volume. In one embodiment, the method comprises: absorbing an effective amount of a plasticizing gas into the semi-crystalline thermoplastic material sheet to yield a reversibly plasticized semi-crystalline thermoplastic material sheet that is differentially impregnated with the plasticizing gas to define a non-uniform gas concentration gradient across the initial first thickness; and heating the plasticized semi-crystalline thermoplastic sheet to yield the foamed polymeric panel, wherein the foamed polymeric panel comprises (1) a second thickness that is at least about three and half times greater than the first initial thickness, and (2) a non-uniform second density level that is less than the first density level.

Abstract: The present invention relates to an open-cell foam, and to a process for producing this open-cell foam by melting a thermoplastic, or a mixture comprising a thermo-plastic, giving a melt, mixing the melt with at least one blowing agent under pressure, and foaming the melt comprising the blowing agent via extrusion into the free atmosphere, the temperature of the melt during the foaming process being greater than the melt temperature at which a closed-cell foam is formed, and/or adding a pulverulent solid, and/or adding a foreign polymer. The present invention further relates to the use of the foam of the invention for sound deadening or for producing materials by sound deadening.

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: A mat (12) of impervious material for incorporation in an article, such as an article of footwear, for enabling airflow has a plurality of passageways (14) extending in a plane of the mat (12). At least one of the passageways of the plurality (14) is interconnected with at least one further passageway which extends substantially transversely to the plane of the mat (12). Air in passageways of the plurality can therefore flow to the further passageway(s) and air in the further passageway(s) can flow to passageways of the plurality. Air can therefor flow within the mat in two substantially transverse directions. Such a mat can be incorporated into an article to enable air flow into and out of the article.

Abstract: A method for modifying a surface of a polymer such as a thermoplastic resin is provided, in which a supercritical fluid, especially carbon dioxide in a supercritical state is used as a solvent, and the polymer surface is further converted to have highly advanced function or high performance in a short period of time. In the method for modifying the polymer surface of the present invention, a solute is previously applied to the polymer surface. Accordingly, the solute can be permeated into the surface of the polymer swelled by the contact of the supercritical fluid. When this method is used, it is possible to permeate the solute into the polymer at a high concentration in a short period of time.

Abstract: A buoyant plant habitat and a process for manufacturing it. In one embodiment, the invention is a buoyant plant habitat comprising: a nonwoven matrix comprising fibers; and a plurality of buoyant foam units into said nonwoven matrix to produce a buoyant mass; wherein said buoyant foam units envelope a portion of said fibers. In another embodiment, the invention is a process for making a buoyant plant habitat comprising: providing a nonwoven matrix comprising fibers; and injecting a plurality of buoyant foam units into said nonwoven matrix. In another embodiment, the invention is a buoyant plant habitat comprising: a top layer of nonwoven matrix material; a bottom layer of nonwoven matrix material; a plurality of edge pieces of nonwoven matrix material that are attached by means of polymer plugs to said top layer and said bottom layer; and a plurality of closed-cell polymer foam pieces that are disposed between said layers.

Abstract: An elastic membrane is provided for use in a flow-control device comprising a housing with a seat of a predetermined shape and dimensions for the membrane such that when the membrane is mounted in the seat, the membrane is deflected by a pressure differential between its two opposite sides. The elastic membrane has a predetermined shape and dimensions matching the seat and is made of foamed elastomer with closed cells of predetermined cell density and morphology.

Abstract: Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.

Abstract: A cushion body which has a force to support a large load and both a soft touch feeling and can maintain an undulation shape of a groove portion and the like provided on a contact surface with a seat occupant favorable, a seat using the same, and a manufacturing method thereof are provided.

Abstract: Apparatus and methods for producing a foamed material. Pressurized gas is introduced into a multiple-component mixture that contains a catalyst-containing component and a crosslinker-containing component. The multiple-component mixture may be directly mixed and combined with the gas in a mixing device. Alternatively, the multiple-component mixture may be combined in a first mixing device and this mixture may be subsequently combined with the gas in a second mixing device. When dispensed onto an application target, the gas entrained in the multiple-component mixture expands to form the foamed material.

Abstract: A solid state foaming process permits the use of up to 100% recycled pre- and post-consumer polymer for the manufacture of foamed polymer material and thermoformed foamed polymer articles. The process enables the optional formation of integral unfoamed skins of controllable depth and crystallinity on foamed polymeric materials suitable for a wide variety of applications. Because this process does not alter the underlying chemistry of the material all scrap from the manufacturing process may be reused without additive to form new foamed polymeric materials and articles.

Abstract: A process of producing a foamed molding, wherein expanded, substantially non-crosslinked polypropylene-based resin beads are heated in a mold to fuse-bond the beads together into a unitary body. Each of the expanded beads has been surface-modified with an organic peroxide.

Abstract: A process for varying the appearance of a container is disclosed, the process comprises injection molding a polymer preform having a non-reactive gas entrapped within the walls thereof, cooling the preform to a temperature below the polymer softening temperature, reheating the preform to a predetermined temperature greater than the polymer softening temperature, and blow molding the reheated preform, to prepare a container consisting essentially of a micro cellular foamed polymer having a non-reactive gas contained within the micro cellular foam cells, wherein the appearance of the container is varied based on the predetermined temperature.

Abstract: A production method comprising the step of charging prepolymer, a foaming agent and an active hydrogen-containing compound in specified amounts into a tank and foaming/mixing them for a specified time by a mixer, and the subsequent step of pouring the mixture liquid into a metal mold.

Abstract: Methods for reducing the density of thermoplastic materials and the articles made therefrom having similar or improved mechanical properties to the solid or noncellular material. Also disclosed are improvements to foaming methods and the cellular structures of the foams made therefrom, and methods for altering the impact strength of solid or noncellular thermoplastic materials and the shaping of the materials into useful articles.

Abstract: The present invention provides a polyester foamed sheet composed of a resin composition comprising 50 to 100 weight % of a polyalkylene terephthalate, wherein the resin composition has an isothermal crystallization peak time of 5 to 60 seconds at any temperature of 100 to 150° C., and wherein the sheet has (A) an apparent density of 0.05 to 1.25 g/cm3 and (B) a temperature at which an exothermic peak derived from crystallization is observed of 0 to 150° C. when thermal analysis is performed using an input compensation type differential scanning calorimeter.

Abstract: A traditional steam chest molding apparatus for the manufacture of products from expanded plastic materials requires excessive amounts of steam to properly expand and fuse pellets of plastic together A molding apparatus is provided wherein a pair of complementary molds (100, 300) are provided with a steam manifold (110) to introduce steam into the mold cavity by way of steam lines (160, 162, 164, 166) The steam manifold (110) allows for direct injection of steam into the manifold and hence a reduction in the total steam required for a molding operation The amount of steam necessary for the production of a particular article is predetermined in dependence upon a geometry and a size of the article to be produced Thus if desired, the amount of steam provided to the mold cavity is measured prior to injection

Abstract: It is an object of the present invention to provide a foam molding method for foaming and molding a foamable material, which is free from problems, such as deformation of or continuation between closed cells. To achieve this object, there is provided a foam molding method for foaming a foamable material, comprising the steps of providing a mold having a cavity, placing the cavity of the mold under a pressurized condition, foaming the foamable material in the cavity of the mold under the pressurized condition, thus appropriately controlling foaming of the foamable material, and releasing the pressurized condition of the cavity of the mold.

Abstract: A method of making a hollow foaming member is to utilize the foaming agents with various decomposition speeds or gas issued into the rubber sheet in the die while vulcanization and foaming. As a result, the foaming member made by the method of the present invention has an air cell therein.

Abstract: A low-pressure CO2 tank or an air compressor with a refrigerated air dryer is attached to the vent zone of a standard twin-screw extruder. During extrusion, the gas is dissolved in the wood-plastic melt. The CO2 expands which foams the wood-plastic material.

Abstract: Methods to produce a pitch foam from a hydrocarbon carbonaceous precursor material. A gaseous blowing material is dissolved in the carbonaceous precursor material, and the resultant solution is pressurized in a vessel. As the solution is exhausted from the vessel, the gaseous blowing agent and the hydrocarbons of the carbonaceous precursor material evaporate from the pressurized solution to form a foam-like solution. The pitch foam is formed from the foam-like solution by directing the foam-like solution onto a surface, whereupon, the foam-like solution solidifies into the pitch foam.

Abstract: The object of the present invention is a forming device for producing a bar of synthetic material, for example of expansible plastic material, intended for the production of synthetic caps. The device comprises a first chain of half-moulds and a second chain of half-moulds that couple along the common portion of an annular path. The half-mould is delimited by a front face and by a back face and the half space inside the half-mould is free from projections and/or grooves between the faces. The forming device allows producing a bar of constant diameter of expansible material, then cut for producing synthetic caps.

Abstract: A method for generating foam for gypsum product manufacturing includes injecting water through a conduit and injecting a foaming agent through the conduit to form a first solution comprising the water and the foaming agent. The method includes straining the first solution in the conduit and injecting air through the conduit to form a second solution comprising the water, the foaming agent and the air. The method also includes straining the second solution in the conduit to form foam and communicating the foam to a gypsum product manufacturing device.

Abstract: A process for sequestering carbon dioxide from the flue gas emitted from a combustion chamber is disclosed. In the process, a foam including a foaming agent and the flue gas is formed, and the foam is added to a mixture including a cementitious material (e.g., fly ash) and water to form a foamed mixture. Thereafter, the foamed mixture is allowed to set, preferably to a controlled low-strength material having a compressive strength of 1200 psi or less. The carbon dioxide in the flue gas and waste heat reacts with hydration products in the controlled low-strength material to increase strength. In this process, the carbon dioxide is sequestered. The CLSM can be crushed or pelletized to form a lightweight aggregate with properties similar to the naturally occurring mineral, pumice.

Abstract: The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.

Abstract: A wedging apparatus including an outer polygonal surface configured to secure a screen to a shaker, the outer polygonal surface having a bottom surface, a top surface opposite the bottom surface, and at least one end surface joining the top surface and the bottom surface, and an inner core defined by the outer polygonal surface, wherein the inner core defines a cavity is disclosed. A method of forming an apparatus for securing a screen to a shaker is disclosed, the method including forming a mold of a wedging apparatus configured to secure a screen to a shaker, wherein a shape of the mod is an inverse of an outer polygonal surface having a bottom surface, a top surface opposite the bottom surface, and at least one end surface joining the top surface and the bottom surface, and an inner core defined by the outer polygonal surface, wherein the inner core defines a cavity, injecting a liquid resin into the mold, allowing the liquid resin to solidify, and removing the wedging apparatus from the mold.

Abstract: A piston pump has a piston and cylinder. A gas is supplied into the cylinder during and/or after a suction stroke of the piston pump, and a high-viscosity material is supplied into the cylinder after the suction stroke. A discharge stroke of the piston pump is effected after completion of supply of the high-viscosity material to thereby discharge the gas and high-viscosity material into a pipe. Use is made of piston pumps 45A and 45B, each including a cylinder and a piston which reciprocally moves within the cylinder to effect the suction stroke and discharge stroke, and a membrane gas generator 10 to which compressed air is supplied to generate a gas. A low-pressure gas generated by the membrane gas generator 10 is supplied into each piston pump and the high-viscosity material is introduced into the gas.

Abstract: A continuous process for manufacturing a sound absorbing tile made from a slurry including, quick setting cement, water, fibers and foaming agent, the process including the steps of (i) mixing cementitious material, water, foaming agent but without incorporation of prefabricated foam with fibers into a slurry; subsequently; (ii) injecting and distributing air into the slurry of step (i) to form a cellular slurry; subsequently; (iii) forming tiles or precursor products of tiles from the cellular slurry; and finally; (iv) allowing the cellular slurry to set into the desired tile or a precursor thereof.

Abstract: A method for manufacturing resin films includes steps of mixing PU resin and hydroxyl compound to become a first-kind first-phase mixture, and of mixing a pigment with a foaming agent to become a second-kind mixture, of injecting the first-kind mixture into a kneading device to get mixed and kneaded to become a first-kind second-phase mixture, of sending the first-kind second-phase mixture into a second kneading device to get a first-kind third-phase mixture, and the second-kind mixture and the first-kind third-phase mixture both sent into a conveyer to get a third-kind mixture, and the final step is to send the third-kind mixture into a coating device for coating the third-kind mixture on a substrate cloth to get a resin film of an original color and fresh brilliance.

Abstract: The invention relates to a membrane that consists of a polymer or a polymer mixture. The aim of the invention is to produce membranes, especially planar membranes or hollow fiber membranes that have an as high a separation efficiency as possible while simultaneously having a high membrane efficiency. To this end, the membrane has a gas- or liquid-permeable bicontinuous foam structure with orifices in the interior whose diameters do not exceed 500 nm.

Abstract: A method 10 to selectively produce an article of manufacture 20 having desirable properties and which may replace many “ceramic based” articles. Particularly, the article of manufacture 20 is made by selectively combining an epoxy structural foam material 110 with a catalyst 111 and a drying agent 200. The mixed material is then selectively dispensed within a mold 16 and allowed to harden in order to form the article of manufacture 20. Alternate formulations may be utilized. Other various non-limiting embodiment of the invention are also disclosed.

Abstract: Prepare a foam structure that includes hollow coalesced foam strands and, optionally, solid coalesced foam strands using an extrusion die block equipped with apertures that promote forming the hollow strands and, optionally, the solid foam strands.

Abstract: A process for the production of foamed plastic bodies, including the steps: introducing a physical foaming agent into the plasticised plastic material which is in the plasticising unit and which is to be foamed, wherein the physical foaming agent is introduced into the plasticised plastic material at a pressure of more than 180 bars, preferably more than 300 bars, particularly preferably more than 350 bars, injecting the plastic material provided with physical foaming agent into the tool cavity of the injection moulding machine, and decompression of the molten plastic material by expansion of the tool cavity.

Abstract: While steam is supplied to flow channels to heat inner cavity surfaces to a temperature equal to or higher than the heat distortion temperature of a molding resin, the resin mixed with a supercritical fluid is injected from an injection molding machine into a mold cavity. When the injection of a predetermined quantity of the resin is completed, the supply of the steam to the flow channels is stopped, and cooling water starts to be supplied to the flow channels. The inner cavity surfaces are thus quickly switched from a heated state to a cooled state, cooling and solidifying the resin into a molded product of good appearance which is free of broken cell marks on its surface.

Abstract: A low molecular weight polyphenylene ether having a reduced viscosity of 0.04 to 0.18 dl/g as measured at 30° C. in a 0.5 g/dl chloroform solution, and a molecular weight distribution of 1.5 to 2.5; or a low molecular weight polyphenylene ether powder comprising the low molecular weight polyphenylene ether exhibits high thermal resistance and excellent electric properties, and thus is useful as electric materials such as printed circuit board and as modifiers of other resins.

Abstract: A method and device for forming a cross-linked foam and a cross-linked foam are provided. The method includes the steps of preparing at least one foaming material for cross-linked foaming, the foaming material processed to have a plane or three-dimensional shape; forming at least one interfacing pattern on a surface of at least one of the foaming material using at least one interfacing material that prevents chemical and physical interaction between the foaming materials; and forming a cross-linked foam by foaming the foaming material having the interfacing pattern thereon, the cross-linked foam having a foam body and an internally-formed surface.

Abstract: A controllable microscopic bubble nucleation in fluid polymer material production method and apparatus utilizing a gas pipe disposed in the conveyance screw shaft of an injection or extraction forming mechanism and a microbubble generating component, such as a microscopic perforation vented metal head or a microscopic perforation ceramic head, installed at the front extremity of the conveyance screw shaft. At the rear extremity of the gas pipe, a pressurization pump or a high pressure gas storage tank is admitted from an air intake opening, enabling the gas to be indirectly heated by an electric heater on the materials pipe. The high temperature gas is thereafter outputted from the microscopic perforations of the microbubble generating component such that high temperature microscopic bubbles are directly admitted into the section of liquid polymer material which is then uniformly amalgamated by the conveyance screw shaft and then deposited into a forming die.

Abstract: A process for an extruded resin foam, comprising extruding a foamable composition comprising a melted polystyrene resin and a physical blowing agent through a die to obtain a polystyrene resin foam having a thickness of at least 10 mm and a transverse cross-sectional area of at least 50 cm2, wherein said extrusion is performed so that the ratio Mz/Mn of a Z average molecular weight Mz of the polystyrene resin foam to a number average molecular weight Mn of the polystyrene resin foam, each measured by gel permeation chromatography, is 8.0 or more.

Abstract: A method of making a sponge device is provided. This method includes introducing a curable liquid sponge forming material into a form, placing a handle into the material before it is fully cured, heating the form to cure the material, removing the cured material from the form, and rinsing the cured material. Another aspect of the present invention is the assembly for making this sponge device. This assembly includes a runner for joining a plurality of handles, plates that are spring-biased together to support the handles, a chase formed of heat conductive metal having a shelf where the plates can be set, and a silicone form having a plurality of cavities therein for receiving the sponge forming material.

Abstract: The present invention relates to light weight molded plastic articles and methods of making same. More specifically, the present invention relates to a method of manufacturing a hollow-core, foamed-plastic, film-laminate article utilizing convention gas assisted molding apparatus with corresponding high production rate capabilities. The resulting film-laminate, hollow-core, foamed-plastic part comprises a class A show-face surface. The method comprises formation of a porous mass of molten plastic in the mold cavity containing the laminate. The molten plastic is cored out or hollowed by injection of gas into the mold cavity.

Abstract: Process for the manufacture of plasterboards exhibiting a core density of less than 0.77 comprising the stages of the formation of a foam from water and a surfactant composed of at least one alkyl sulphate of formula H(CH2)nOSO3?M+, in which n is a number between 6 and 16, M is a monovalent cation and the mean number of carbon atoms nm is from 9 to 10, and the introduction of the foam obtained into a plaster slurry, characterized in that the amount of surfactant introduced does not exceed 0.32 g/l of plaster slurry. Application to the manufacture of lightened plasterboards.

Abstract: A molded article includes thermoplastic resin, and an organic material different from the thermoplastic resin inside said molded article, the organic material being located on and near a surface of said molded article.

Abstract: A method for preparing a poly(arylene ether) with a reduced level of powder fines is described. In one embodiment, the method comprises oxidatively coupling a monohydric phenol in the presence of a solvent and a complex metal catalyst, to produce a poly(arylene ether) resin; and then removing a portion of the solvent to produce a concentrated solution having a cloud point Tcloud. The concentrated solution is then combined with an anti-solvent to precipitate the poly(arylene ether) in the form of a precipitation mixture. The concentrated solution usually has a temperature of at least about (Tcloud?10° C.) immediately before it is combined with the anti-solvent. The precipitation mixture has a temperature of at least about (Tcloud?40° C.) after its formation. Related poly(arylene ether) copolymers are also described.

Abstract: Provided is a method for manufacturing a foam-molded article by molding between molds a parison with a foam layer formed by extruding an expandable molten resin composition, obtained by melt-kneading a polyethylene resin and a physical foaming agent, to an area of low pressure from a die, wherein the polyethylene resin is selected from those having a melt flow rate of 0.1 to 25 g/10 minutes and a melt tension of not less than 1.5 cN, and wherein the apparent density of the foam layer in the foam-molded article is about 0.04 to 0.3 g/cm3.

Abstract: Foamed thermoplastic polymeric mechanical planarization polishing pads (“MP pads”) made with supercritical fluids are presented. A supercritical fluid foaming agent is dissolved in a thermoplastic polymer. A rapid change in the solubility and volume of the supercritical fluid foaming agent in the thermoplastic polymer results in foaming of the thermoplastic polymer. Foamed thermoplastic polymeric MP pads are advantageously both significantly and uniformly porous.