Abstract: The mold release properties of a molded polyurethane foam are improved by including in the foamable reaction mixture to be molded a reaction product of a ricinoleic acid and a long chain fatty acid.

Abstract: An improved process is provided for producing cigarette filters comprised of a substantially open-cell foamed thermoplastic polypropylene resin wherein a mixture comprising a thermoplastic polypropylene resin, a volatile blowing agent and a nucleating agent is extruded through a die to produce a strand of foamed resin with the strand then being cut into individual filter elements. The improvement comprises employing as a primary nucleating agent from 0.1 to 40 percent by weight, based on the weight of the resin, of a particulate compound of a metal selected from Groups IIA, IIIA or IVA of the Mendeleef periodic table of elements together with from 0.01 to 5.0 percent by weight, based on the weight of the primary nucleating agent, of a synergist consisting of an organic compound having a hydrophobic group and a hydrophilic group. A particularly effective combination is the use of calcium carbonate as the primary nucleating agent and potassium benzoate as the synergist compound.

Abstract: A method and apparatus are provided for employment in thermoplastic foam extrusion utilizing a direct-injection extrusion process. Thermoplastic foam material is produced which is characterized by having relatively smooth external skin surfaces, and an internal cellular structure, by providing intensive cooling of the foam material immediately upon its issuance from an extrusion die orifice. Means are also provided for controlling the cooling rate utilizing an adjustable device which controls the rate of cooling air flow and air temperature within the extended foam tube.

Abstract: A method of making a non-slip plastic film comprises extruding separate plasticized plastic materials in two streams so that one stream abuts against and adheres to the other to form a combined plastic layer. The combined plastic layer is then stretched by directing air centrally into a tubular formation of this layer. One of the plastic materials comprises a material having an expanding agent or a foaming agent and the stretching causes the breaking of the voids of the foam plastic to form a rough, irregular net-like formation on the exterior of the other plastic. The apparatus includes two separate nozzles arranged to extrude plastic material so as to intersect and form a combined plastic.

Abstract: The invention relates to sheet-like plastic packaging particles formed with a normally curved configuration having two spaced apart, curved coextensive surfaces, one of said surfaces being a substantially unfoamed skin and the remainder of said particle including the other surface being foamed, and to methods for producing packaging particles which comprise warped or distorted, foamed sheet particles suitable for use as packaging particles from an extrudable, expandable synthetic plastic material, such as, a polymerized vinyl aromatic monomer, e.g.

Abstract: Shaped articles comprising a polymeric frame of uniform density having one or more substantially non-foamed skin layers over all, or only a part of, its surface are produced according to the disclosed method which includes forming a foamable mixture of a photopolymerizable ethylenically unsaturated material, such as vinyl acetate, acrylonitrile, unsaturated polyester resins or the like, and a foaming agent therefor in a mould, subjecting part or all of the surface of the mixture retained in the mould to radiation of a wavelength such that photopolymerization of the material occurs forming a non-foamed or non-foamable skin layer or layers. The thus treated foamable mixture is then foamed and the ethylenically unsaturated material in the foam is polymerized. Shaped articles so produced having an open shell structure are also disclosed.

Abstract: According to the proposed method for producing solid-porous synthetic rubber articles, a preselected portion of a molded blank of a raw V-like polymeric elastomer compound containing a blowing agent is subjected to ionizing radiation at a temperature below the decomposition temperature of the blowing agent, after which said blank is subjected to heat treatment at a temperature higher than, or equal to the decomposition temperature of the blowing agent.Despite its simplicity, the disclosed method provides for producing solid-porous rubber-like articles featuring high strength of their solid portion and excellent sealing qualities of their porous portion.

Abstract: Typically, injection molded expandable thermoplastics exhibit imperfect surfaces in the form of mottled areas, visible flow lines, and pin holes; these imperfections are caused by the quick chilling of the surface of the expanded thermoplastic as it contacts the mold surface. This invention is a method of injection molding expanded thermoplastics free of these defects by injecting a short-shot of the expandable thermoplastic into an elastic membrane positioned within a cooled mold cavity, containing the short-shot within the membrane until a skin forms on the thermoplastic in contact with the membrane, and then permitting expansion of the thermoplastic in the cavity to form a smooth skin or surface on a substantial portion of the article.

Abstract: A form molded synthetic foam roofing section having a relatively broad undersurface and an exposed surface configured to resemble interlocked and overlapping roofing shingles which is united to a support surface such as wood, metal, etc. during molding process. This section may be affixed by any conventional means such as nails and adhesives to roof boards, rafters or over old existing roofing structure.

Abstract: A method of forming a spring cushion construction comprising a foamed pad having a generally flat inner surface with a depending peripheral edge, the flat inner surface including a dense outer crust. A spring assembly is disposed so that the terminal face portions thereof contact the outer crust and with the depending edge of the pad confiningly receiving the spring assembly to prevent lateral displacement therebetween. The pad is formed by a method which includes foaming a foamable material in an open top mold while leveling the upper surface of the foamable material in a manner which does not interfere with the formation of a dense outer crust thereon. The depending foam edge may then be formed by adding additional foamable material along the periphery of the pad, or by suitably attaching a preformed foam strip therealong.

Abstract: An improved process for preparing foamed articles of thermoplastic resin having a hard, mar-resistant surface that is flat and smooth and resembles natural wood, and an extrusion die therefor. In the process a softened thermoplastic is extruded through apertures of the extrusion die of the invention which is a fiered die having a resin discharge plate having a peripheral recessing portion and a protruding interior portion which are formed on the resin discharge plate by one or more step-ups. Each of the peripheral and interior portions of the resin discharge plate is provided with a plurality of apertures, the aperture density of the peripheral portion being greater than that of the interior portion. A longitudinally extending cooling frame is mounted adjacent the resin discharge plate and extends in the direction of extrusion to at least the forward face of the interior portion of the plate.

Abstract: A process for molding foam products substantially free from flaws caused by air bubbles in the foamable reaction mixture wherein a foamable reaction mixture having a viscosity .eta. in cP between 100 cP and 2500 cP is introduced into a mold cavity through an opening in the mold wall and against the wall of the cavity opposite the opening of a mold in which the thickness of the cavity and the thickness s of the resulting molded product adjacent to the opening at the time the mixture is introduced into the cavity is maintained at 0.5 mm to 15 mm under conditions whereby the radial distribution rate w.sub.radial in m/sec., .eta.

Abstract: A process is disclosed for producing a structural foam article having a surface that reproducibly and faithfully replicates the surface of the mold within which the article was made. The process is an improvement in the "low pressure" process for producing structural foam, wherein the improvement resides in introducing the molten mixture of foamable thermoplastic material and blowing agent into the mold under such conditions that a no-slip boundary condition is maintained at an interface between the flowing thermoplastic and a predetermined portion of the interior surface of the mold, and by maintaining the temperature at said interface at or above a certain temperature (termed "replication temperature"), while the thermoplastic is flowing in the mold.

Abstract: Pencils made with a resin-based sheath to replace wood sheaths. A sheath material consisting essentially of a resin binder, a fibrous filler and a metallic soap is extruded around a marking core. The resulting extrudate is immediately chilled after leaving the die, and cut into pencil lengths. The apparatus includes core feeding and transport means, core preheating means and chilling means. The resulting pencils possess the physical qualities associated with wood-sheathed pencils due to the fine, closed cell structure of the sheath material. The surface of the sheath is smooth and may be coated with a pigmented resin or painted.

Abstract: A rigid or semi rigid self-skinned cellular plastic structure which is heat recoverable and thermoelastic is prepared by a process wherein a plastisol or pregelified dry-blend of a homo- or copolymer of vinylchloride (PVC dispersion resin), a polymerizable polyfunctional allyl or vinyl monomer (o-diallyl phthalate), and a peroxide catalyst is prepared, and the plastisol or dryblend is heated so that the reacting mass is free to expand without restraint in at least one direction with a temperature rise of 10.degree.-30.degree.C/minute at least up to the temperature at which expansion of the reaction mass starts. This cellular structure is rigid at normal temperatures and behaves like an elastomer at high temperatures. The product can be subjected to fabrication techniques such as sheet molding, encapsulation expansion from compressed foam etc.

Abstract: An article, such as a door, is made from a colored water-extended thermoplastic polymeric material, and is provided with a decorated pattern by fusion of a surface layer to form a non-cellular layer, the depth of fusion being different in different parts so that the depth of color is correspondingly different. The variation in color intensity provides a decorative pattern, and fusion of the cellular material is effected by pressing with a die in the shape of the desired pattern.

Abstract: A hollow structural member formed of thin sheet steel is formed with one or more longitudinal joints and the interior is filled with a rigid lightweight synthetic plastics foam such as polyurethane. Each joint includes folded lips or flanges which are designed to provide a restricted clearance or gap into which the foaming material penetrates and changes from a cellular to a non-cellular composition and also provides an adhesive bond at each joint and a moisture proof seal.

Abstract: A method for producing an improved molded thermoplastic polymeric resinous article comprising: introducing a heat plastified thermoplastic polymeric resinous material into a mold in the presence of a finely divided inorganic material; cooling said heat plastified thermoplastic polymeric resinous material; removing from said mold said cooled mold shaped thermoplastic polymeric resinous material having finely divided inorganic material incorporated therein.

Abstract: A method of and apparatus for the molding of foamed thermoplastic bodies with integral skins wherein, for each mold operation after the first, a portion of previously foamed material produced by expansion in the mold cavity, is temporarily accumulated behind a body of unfoamed thermoplastic and the foamed and unfoamed material are then forced into the mold cavity and permitted to expand therein.

Abstract: Apparatus for molding a composite styled wheel for use on automotive passenger vehicles and the like, a method of constructing such a wheel employing the molding apparatus and a method of constructing such molding apparatus, wherein a portion of the mold comprises a conventional metal vehicle wheel having a drop center rim secured to a central disc or body having the usual bolt circle holes and a central aperture so that the disc can be mounted on an axle, drum or disc brake assembly. The metal wheel is employed in conjunction with an upper back-up clamp and lower mold part to define therewith a sealed cavity for molding and attaching a three-dimensional contoured plastic overlay, the overlay thus being molded in situ and permanently attached to the outboard side of the wheel in the mold apparatus.

Abstract: Sheets of cellular polymeric material are cast from a water-in-oil emulsion in a mould subdivided by one or more partitions.

Abstract: A shaped, elongated board having shaped face surfaces is formed of a foamed thermoplastic material and may be substituted for wood or composite moldings which are now used in the manufacture of frames for pictures and the like. The molded board has a cellulated interior and a density that varies continuously between a greatest density at the outer surface of the board to a least density at the greatest spacing inwardly of said surface and without discreted delineation between the relatively denser surface and the lesser dense interior of the board. The average bulk density of such a product is in the range of between about 24.7 and 33.5 lbs. per cubic foot, which is approximately equivalent to that of natural wood. The board has a good quality surface finish and where appropriate can accurately replicate an ornamental surface design for the finished frame. The molded board can be subsequently processed in the same manner as present wood moldings with existing production tooling and equipment.

Abstract: The invention involves the use of aluminum salts of a fatty acid mixture of fatty acids having 12 to 22 carbon atoms consisting ofA. from 42% to 50% by weight of mono-olefinically unsaturated fatty acids, wherein at least 42% by weight are oleic acid,B. from 42% to 48% by weight of saturated fatty acids, wherein at least 42% by weight are saturated fatty acids having 16 to 18 carbon atoms, andC. from 2% to 10% by weight of poly-olefinically unsaturated fatty acids,As a mold releasing agent for the release of polyurethane foams from molds.

Abstract: A method for producing an improved molded thermoplastic polymeric resinous article comprising: introducing a heat plastified thermoplastic polymeric resinous material into a mold in the presence of a finely divided inorganic material; cooling the heat plastified thermoplastic polymeric resinous material; removing from the mold the cooled mold-shaped thermoplastic polymeric resinous article having finely divided inorganic material incorporated therein.

Abstract: A process for producing a swirl-free, indent-free foamed thermoplastic structural article in which water is utilized as a foaming agent. Water and a melted thermoplastic resin are mixed together in an extruder to form a pressurized foamable mixture. The foamable mixture from the extruder is collected in an accumulator and from there is delivered to a cavity in a mold in a suitable clamping device. The pressure in the cavity is lower than the pressure of the foamable mixture in the accumulator or extruder therefore when the foamable mixture enters the cavity the foaming agent is released and the thermoplastic resin is frothed and expands to completely fill the cavity. The melted foamed thermoplastic resin cools in the mold and solidifies to form a foamed thermoplastic structural article. The quantity of water introduced into the extruder is between about 0.1 weight percent to about 0.5 weight percent of the thermoplastic resin charge in the extruder.

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.

Abstract: A process for the manufacture of profiled products by extruding in a substantially non-expanded state an expandable styrene polymer composition through a die orifice having the desired profile and subsequently passing the extruded material through a sizing member wherein it expands to the desired profile and cross-section to produce an article having a porous inner cross-section and a solid, non-foamed outer layer and wherein the styrene polymer composition employed is one containing from about 0.2 to 1.0 parts by weight of an alkaline earth metal carbonate blowing agent and from about 0.2 to 1.0 parts by weight of an organic acid per 100 parts by weight of styrene polymer.

Abstract: In molding polyurethane integral-skin foam the foam tends to stick to the mold surface. Conventional mold release agents have not been found effective; they fail to provide full release of the molded product, are not durable enough to withstand more than one molding cycle, interfere with development of the integral skin, or plate onto the integral-skin thus necessitating solvent washing of the molded foam product. This invention is a method of preparing a mold to release flexible polyurethane integral-skin foam, free from skin damage and other defects, that is durable, i.e., that will permit many molding cycles before requiring replacement, and that permits the molded foam to be merely water washed to remove all traces of the mold release agent.