From Porous Material Containing Articles (e.g., Sponge, Foam, Etc.) Patents (Class 264/916)
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Patent number: 8277719Abstract: A process for the preparation of thermoplastic auxetic foams comprising the steps of: a) taking conventional thermoplastic foam; b) subjecting said foam to at least one process cycle wherein the foam is biaxially compressed and heated; c) optionally subjecting the foam to at least one process cycle wherein the biaxial compression is removed and the foam mechanically agitated prior to reapplying biaxial compression and heating; d) cooling said foam to a temperature below the softening temperature of said foam; and e) removing said compression and heat.Type: GrantFiled: November 6, 2006Date of Patent: October 2, 2012Assignee: Auxetic Technologies Ltd.Inventors: Andrew Alderson, Kim Lesley Alderson, Philip John Davies, Gillian Mary Smart
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Patent number: 8257624Abstract: A method for making a porous material, includes melt-blending two or more non-miscible polymers to obtain a co-continuous melt, solidifying the melt to obtain a solid mass consisting of two co-continuous polymer phases, and selectively extracting one of the co-continuous phases thereby creating within the solid mass an essentially continuous pore network having an internal surface. The method further includes replicating the internal surface of the pore network within the solid mass by coating the internal surface with successive layers of materials, and selectively extracting the solid mass without extracting the layers of materials, to thereby yield the product porous material, formed of the layers of materials. The material has a void fraction higher than about 75%, and mainly having essentially fully interconnected sheath-like non-spherical pores and essentially non-fibrous walls.Type: GrantFiled: November 14, 2006Date of Patent: September 4, 2012Inventors: Basil D. Favis, Pierre Sarazin, Xavier Roy
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Patent number: 7998380Abstract: A method of fabricating a highly porous structure is provided. The method includes the step of compounding a biodegradable polymer, a water-soluble polymer and a porogen to form a composite blend. A foaming agent is dissolved into the composite blend and the composite blend is injected into a mold so as to form the structure. Thereafter, the structure is removed from the mold and leached in a fluid.Type: GrantFiled: July 13, 2007Date of Patent: August 16, 2011Assignee: Wisconsin Alumni Research FoundationInventors: Lih-Sheng Turng, Adam J. Kramschuster
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Patent number: 7767122Abstract: Foam sheets are continuously produced by metering foam particles, which are free of any added binder or adhesive, from a storage location onto a moving conveyor at a controlled volumetric rate so as to continuously form a layer of the particles on the conveyor, heating the layer of particles to a temperature sufficient to render the particles tacky such that the particles adhere to one another so as to form a substantially integral sheet, compressing the sheet with a compression device that applies pressure on the advancing sheet so as to compress the sheet to a smaller thickness and enhance the integrity of the sheet; and cooling the compressed sheet.Type: GrantFiled: April 25, 2007Date of Patent: August 3, 2010Inventor: Fred Svirklys
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Patent number: 7641829Abstract: Methods are provided for mechanically chopping nanotubes and other nanoscale fibrous materials. The method includes forming a macroscale article which include the nanoscale fibers, and then mechanically cutting the macroscale article into a finely divided form. In one embodiment, these steps are repeated. The nanoscale fibers may be carbon nanotubes, which optionally are aligned in the macroscale article. The macroscale article may be in the form of or include one or more buckypapers. In one embodiment, the macroscale article further includes a solid matrix material in which the nanoscale fibers are contained or dispersed. The forming step can include making a suspension of nanoscale fibers dispersed in a liquid medium and then solidifying the liquid medium to form the macroscale article. After the mechanical cutting step, the medium can be dissolved or melted to enable separation of the chopped nanoscale fibers from the medium.Type: GrantFiled: July 20, 2005Date of Patent: January 5, 2010Assignee: Florida State University Research FoundationInventors: Zhiyong Liang, Zhi Wang, Ben Wang, Chun Zhang
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Patent number: 7258291Abstract: A destructive device, wherein treated material (1) including a foam body is pre-compressed in thickness direction and fed to the opposed part of a pair of compression rolls (21, 22), partition walls forming independent air bubbles in the foam body is destructed by the compression rolls (21, 22) and foam gas is arrested into a cover (3) installed on the outlet side of the compression rolls (21, 22), the foam gas is liquefied and separated by a cooling and liquefying device (6) through a cooling device (15) after pressurized, together with medium gas (41) for collection, by a pressurizing device (5), and the medium gas for collection from which the foam gas is separated is returned into the cover (3), whereby, since the foam gas is liquefied and separated in pressurized state by the cooling and liquefying device (6) by arresting the foam gas in high density inside the cover (3), the device can be remarkably downsized and simplified, and a device cost and an operation cost can also be remarkably reduced.Type: GrantFiled: January 22, 2003Date of Patent: August 21, 2007Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Mikio Yotsumoto, Yutaka Matsuda, Susumu Saitou, Masayuki Makino, Kazuo Kimura, Yasuo Sasaki
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Patent number: 7157131Abstract: A lidded semiconductor device has a first layer applied to the lid, which first layer is chosen of a material which fluoresces upon application of non-visible electromagnetic waves thereto, for example, ultraviolet light. A second layer is provided over the first layer. Openings extend through the second layer and further extend to a substantial depth into the first layer, for example, generally halfway into the first layer, to expose portions of the first layer.Type: GrantFiled: August 6, 2002Date of Patent: January 2, 2007Inventors: Richard C. Blish, II, John James Slevin
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Patent number: 7144534Abstract: The invention relates to a method of producing rebonded foam blocks in a box mould having a base, a plurality of mutually adjacent mould side walls standing thereupon and a plunger movable in the direction of the base, in which at least one of the mould side walls may be swiveled about a substantially horizontal swivel axis mounted on the base between an outwardly directed position and a substantially vertical position, the method involving mixing the foam flakes with a binder, swiveling at least one of the mould side walls outwards such that the cross-sectional area of the box mould increases from the bottom upwards, introducing the foam flakes into the box mould, adjusting the at least one mould side wall so that the cross-sectional area of the box mould is substantially constant over its height, compressing the foam flakes by means of the plunger to the desired density or foam block height, thereby bonding together the foam flakes and removing the finished foam block from the mould.Type: GrantFiled: November 22, 2004Date of Patent: December 5, 2006Assignee: Hennecke GmbHInventors: Bodo Büchel, Jürgen Wirth, Horst Klahre
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Patent number: 6958127Abstract: Coated moldings coated, on surfaces of moldings, with paint constituted of a thermoplastic resin having affinity for a thermoplastic resin used as a main constituent of the moldings. Method and apparatus for recycling the coated moldings are also described in which the coated moldings are crushed by means of a crusher and the crushed moldings are molded in a mold to provide fresh moldings, followed by coating, by means of a coating device, the fresh moldings on surfaces thereof with a paint constituted of a thermoplastic resin having affinity for the thermoplastic resin for the moldings.Type: GrantFiled: April 10, 1997Date of Patent: October 25, 2005Assignees: Suzuka Fuji Xerox Co., Ltd., Tohpe Corporation, Kowa Tokyo Co., Ltd.Inventors: Yasuhiro Suzuki, Hidetoshi Oido, Keiri Umezawa
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Patent number: 6623676Abstract: A continuous process for reusing scrap polyurethane involves the following stages: Chips of thermoset polyurethane foam are supported as a bed; the bed of chips while moving is heated; the bed of chips while moving is subjected to pressure or compression; and a web is formed. The resulting material is useful in many industrial applications, including padding, gaskets, and insulation.Type: GrantFiled: July 14, 1999Date of Patent: September 23, 2003Assignee: Wm. T. Burnett & Co.Inventors: Gregory B. Davis, Walter Greenhouse, George Tolen
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Patent number: 6576176Abstract: The invention involves recycling scrap material having a thermoplastic. The invention includes a method of forming a thermoplastic pre-preg sheet for use in a subsequent molding operation. The method includes shredding a first scrap material having a thermoplastic to form fluff. The fluff has at least about 20 percent weight of thermoplastic. The method further includes sufficiently compacting the fluff into a thermoplastic state sufficient for forming the thermoplastic pre-preg sheet.Type: GrantFiled: March 16, 2000Date of Patent: June 10, 2003Assignee: Lear CorporationInventors: Girma M. Gebreselassie, Harold G. Wolf, Jr., Vahid Sendijarevic, Qavi Anjum, Daniel Klempner, Kurt C. Frisch
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Publication number: 20020093116Abstract: A waste PVA foam recycling process to crashes the waste PVA foam into evenly distributed grains, then grains are placed into a molding die while a PVA mixing agent is added into grains. Both of the agent and grains are polymerized, heat dehydrated and hardened into an integral compound to create friction resistance between soft and hard components for removing pollutants. The PVA foam grains can be further admixed with color grains to create merchandisable patterns. Therefore, the present invention, by reclaiming the waste PVA foam and to producing zero pollutant recycled PVA foam with economic value.Type: ApplicationFiled: January 18, 2001Publication date: July 18, 2002Inventor: Ming-Ti Hsieh
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Patent number: 6372173Abstract: Process for production of three-dimensional objects by stereolithography in which a laser hardens particular areas of constantly succeeding layers of resin fluid. Prior to or during laser light action, the particles, which define physical or mechanical qualities of the object-to-be-produced, will be added into, and/or alternatively, will be produced within the resin fluid, leading to a resin-fluid-particle-mixture. The particles are integrated into the resin and/or compound with resin and/or other particles by means of laser light action or ultrasonic mixing.Type: GrantFiled: February 16, 2000Date of Patent: April 16, 2002Inventor: Klaus-Jürgen Peschges
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Publication number: 20010030387Abstract: A method for re-using unneeded expanded styrene and an apparatus for preparing comminuted expanded styrene that can be used as a starting material for injection molding. The expanded styrene is rendered re-usable through a first step of comminuting expanded styrene, a second step of illuminating far-infra-red light to the expanded styrene comminuted by the first step to reduce its volume, a third step of further comminuting expanded styrene, reduced in volume by the second step, to prepare a granulated material, and a fourth step of injection-molding the granulated material from the third step to prepare a regenerated article.Type: ApplicationFiled: June 18, 2001Publication date: October 18, 2001Inventor: Syuzo Tanaka
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Patent number: 6299811Abstract: A method for recycling materials including a significant portion of polyurethane foam includes forming the foam into a fluff of particle sized 0.25-1.0, and most preferably 0.25-0.50 inch. The material is moved to a mold and molded at an elevated temperature and pressure. Preferably, the glass transition temperature of the foam is exceeded. Other filler materials may be mixed with the fluff material. The invention recycles scrap which includes polyurethane foam, but greatly reduces the complexity of re-utilizing the scrap.Type: GrantFiled: April 23, 1999Date of Patent: October 9, 2001Assignee: Lear CorporationInventors: Girma M. Gebreselassie, Harold G. Wolf, Jr., Kurt C. Frisch, Daniel Klempner, Vahid Sendijarevic
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Patent number: 6248283Abstract: A method for re-using unneeded expanded styrene and an apparatus for preparing comminuted expanded styrene that can be used as a starting material for injection molding. The expanded styrene is rendered re-usable through a first step of comminuting expanded styrene, a second step of illuminating far-infra-red light to the expanded styrene comminuted by the first step to reduce its volume, a third step of further comminuting expanded styrene, reduced in volume by the second step, to prepare a granulated material, and a fourth step of injection-molding the granulated material from the third step to prepare a regenerated article.Type: GrantFiled: April 7, 1999Date of Patent: June 19, 2001Assignee: Sony CorporationInventor: Syuzo Tanaka
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Patent number: 6237208Abstract: A process for the manufacture of section material composed of thermoplastic material, such sections being suitable for the production of door and window jambs and frames. A thermoplastic material component and a second component containing additives are mixed and compacted to form a strand-forming mixture. In so doing, the thermoplastic component is thermally plasticised. The strand-forming mixture is formed into section material, which may then be further machined, shaped and coated to form the final product.Type: GrantFiled: February 17, 1998Date of Patent: May 29, 2001Inventor: Ernst-Josef Meeth
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Patent number: 6228478Abstract: For manufacturing a composite foam, having acoustic properties, foam flakes (8) of differing sizes, differing origins, and/or differing material compositions are wetted with a small quantity of a polyurethane dispersion binding agent. The mixture is subsequently combined to a molded part (1) or to continuous web and under the effect of hot (water) steam or microwave energy is cured and subsequently dried. The composite foam can be used for sound insulation purposes in vehicles and in general machinery construction, and also in building construction.Type: GrantFiled: December 16, 1996Date of Patent: May 8, 2001Assignee: Stankiewicz GmbHInventors: Carsten Kliwer, Christoph Kittel
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Patent number: 6132655Abstract: Thermoplastic foam is converted into useful products by simultaneously compressing and agitating particles of the foam. The particles are formed into a substantially unitary mass of hot softened material which can be immediately formed, cast or extruded into useful particles.Type: GrantFiled: December 27, 1994Date of Patent: October 17, 2000Inventor: Sam W. Ray
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Patent number: 6042764Abstract: A method of producing a three-dimensional shaped plastic foam part comprises the steps of mixing plastic foam granules of a predetermined range of sizes and of different hardness in a predetermined mixing ratio to obtain a mixture of the plastic foam granules, mixing the mixture of the plastic foam granules with a liquid primary material until the granules are coated with the liquid primary material and a mixture of coated plastic foam granules is obtained, feeding a preset quantity of the mixture of coated plastic foam granules into a mold cavity of a mold closed on all sides, reducing the volume of the mold cavity at least in partial regions thereof after it has been filled with the mixture of coated plastic foam granules, triggering a reaction of the liquid primary material by applying pressure and heat until a continuous cellular structure of plastic foam has been formed and the plastic foam granules have been interconnected by the cellular structure of plastic foam after the volume of the mold cavity hasType: GrantFiled: December 9, 1998Date of Patent: March 28, 2000Assignee: C.A. Greiner & Sohne Gesellschaft m.b.H.Inventors: Bernhard Eder, Franz Reitinger, Hans-Michael Sulzbach, Horst Klahre
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Patent number: 5906779Abstract: Expanded or foamed plastic material is fed into a hopper containing a first auger having a cutting function. The first auger is driven by an electric motor and cuts the plastic material into pieces which are discharged from the hopper into a vertical chamber. The vertical chamber contains a second auger driven by an electric motor. The pieces of plastic material are compressed by the second auger and delivered into a chamber which serves as the inlet end of a horizontal friction chute. The plastic material in the chamber is compressed by a hydraulic ram which forces the compressed plastic material along the friction chute.Type: GrantFiled: August 27, 1997Date of Patent: May 25, 1999Assignee: Middleton Engineering LimitedInventor: Ashley Paul Middleton
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Patent number: 5882558Abstract: In a process for recycling of gas-containing synthetic plastics material, this material at first is comminuted, molten, degased and filtered. The degased synthetic plastics material is supplied in the same plant before its solidification for gas introduction, and in order to homogenize the gas content, the gas amount introduced into the synthetic plastics material per time unit is controlled in dependence from the synthetic plastics material amount supplied per time unit to the gas introduction, and preferably the pressure of the synthetic plastics material to which gas is to be added, is kept almost constant. The apparatus suitable for performing this process comprises an extruder (12,13) for plasticizing and degasing the synthetic plastics material, the outlet (15) thereof is connected by means of at least one line (16) to a mixer (25), to which also a device (29) for supplying gas is connected.Type: GrantFiled: November 27, 1996Date of Patent: March 16, 1999Assignee: Sunpor Technology A/SInventors: Helmut Bacher, Helmuth Schulz, Georg Wendelin