Abstract: The process for producing a surface covering having a randomly embossed wear surface which comprises incorporating a blowing agent into a resinous composition, forming the resinous composition into a layer, heating to partially fuse the layer, printing a design on the surface of the layer, randomly distributing flakes of resinous composition containing an inhibitor for the blowing agent onto the printed surface of the layer, applying a clear wear layer thereto and heating the assembly to the decomposition temperature of the blowing agent.

Abstract: In a process for the manufacture of pitch foams in which pitches are expanded at elevated temperature by a porogenic agent in a mould, the pitch has a KS softening point of from 70.degree. to 210.degree. C. The initial pressure is such that, at the decomposition temperature of the porogenic agent, the external pressure is higher than the pressure which would normally exist within the pitch at the temperature of operation. After the decomposition of the porogenic agent the pressure is lowered to expand the pitch. The temperature may also be adjusted between the decomposition and decompression stages.These pitch foams can be used as floor coverings, as insulators or as surfaces for the collection of solar energy.Certain foams may be converted to carbon and graphite foams by a process of oxidation to render their surface infusible followed by carbonisation and, if desired, graphitisation.The carbon foams can be used as thermal insulation, as catalyst supports or as filters for corrosive products.

Abstract: Novel processes and compositions are provided for the preparation of foamed, crosslinked polyethylene utilizing cyclic peroxyketal crosslinking/blowing agents. The novel compositions include esters of thiodipropionic acid as activators.

Abstract: The invention relates to a foaming on foamable olefin polymer composition containing a nucleating agent and a cell size increasing agent comprising certain amino acids and/or polyhydric alcohols.

Abstract: A process for the production of foamed films of polyethylene or ethylene vinyl acetate copolymers using metal salts of aliphatic fatty acids as additives.

Abstract: Thermoplastic resin foams such as polyethylene foams having excellent appearance can be produced with high foaming stability by using a blowing agent composition comprising (a) azodicarbonamide, (b) dinitrosopentamethylenetetramine, and (c) a phenolic or propionate compound such as 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl)-s-triazine-2-4-6-(1H, 3H, 5H)trion.

Abstract: A foamed polystyrene board useful as a thermal insulating material is produced by melting a polystyrene having a melt index of from 0.5 to 5 under heat in an extruder, mixing the molten mass with a blowing agent composed of methyl chloride and dichlorodifluoromethane, and extruding the resulting foamable molten gel from the extruder. As a novel essential feature, a flowability improver having a melting point higher than 70.degree. C., such as an aromatic sulfonamide, a brominated aromatic compound, a brominated alicyclic compound or a poly(.alpha.-methylstyrene), is mixed with the polystyrene within the extruder to impart superior extrusion formability. The foam has good dimensional stability both at room temperature and higher temperature, high mechanical strength and superior thermal insulation properties.

Abstract: A composition comprising a gas-expandable polymeric material and an activated hydrazodicarboxylate blowing agent, wherein the activator is selected from nickelbis(3,5-di-t-butyl-4-hydroxybenzoate), a mixture of 2-hydroxy-4-n-octoxybenzophenone and nickelbis(2-oxy-4-n-octoxybenzophenone), nickel stearate, nickel trifluoroacetylacetonate, [2,2'-thiobis(4-t-thiobis(4-t-octylphenolato)]nickel, nickelbis [O-ethyl-(3,5-di-t-butyl-4-hydroxybenzyl)phosphonate], nickelammoniumsulfate, ethylenediaminetetra(methylenephosphonic acid), and hexamethylenediaminetetra(methylenephosphonic acid).

Abstract: The invention is a method for making reaction injection molded polyurethane of improved properties. The product comprises the cured reaction product of a high molecular weight polyhydric polyether, a low molecular weight active hydrogen containing compound of at least two functionality and a polyisocyanate. The reaction product is cured by subjecting it to an ambient temperature of from about 290.degree.-425.degree. F. for a time sufficient to achieve an improvement in properties. The invention is also the resulting polyurethane.

Abstract: Dry mixed and sintered PVC battery separators having predetermined thicknesses less than 0.012 inch, porosities greater than about 50%, and pores sufficiently small to substantially prevent interplate "treeing" (i.e., less than about 10 microns average) are produced by: mixing about 3% to about 15% by volume of leachable, pore-forming particles with the PVC particles; scraping the particle mix into a layer less than about 0.012 inch thick; sintering the PVC into a continuous strip; compressing the strip in the temperature range of about 250.degree. F.-450.degree. F. to a thickness no greater than about 50% of its as-sintered thickness; thereafter immediately allowing the strip to recover much, but not all, of its as-sintered thickness; and cooling the strip to substantially fix the separator thickness at the recovered thickness. The leachable, pore-forming particles are preferably formed in situ by the thermal degradation of a gasifiable filler such as sodium bicarbonate.

Abstract: A process for preparing a foamed product from a high-melting synthetic resin by decomposing a blowing agent incorporated in the resin, characterized in that the blowing agent is at least one zinc peroxide represented by the formula:ZnlO.sub.m.(H.sub.2 O).sub.n/2wherein l is an integer of 1 to 10, m is an integer of 2 to 20 and n is 0 or an integer of 1 to 5.

Abstract: A blowing composition comprising azodicarbonamide, a zinc peroxide and a decomposition inhibitor for azodicarbonamide.

Abstract: Cellular polyvinyl chloride products of good cell quality are made utilizing a lower fusion temperature than conventionally employed by incorporating in a polyvinyl chloride containing plastisol, which has a fusion temperature of from about 220.degree. F. to about 300.degree. F., an effective amount of a blowing agent selected from the group consisting of (1) a mixture of benzene sulfonyl hydrazide and 4,4'-oxybis (benzene sulfonyl hydrazide), (2) a mixture of toluene sulfonyl hydrazide and 4,4'-oxybis (benzene sulfonyl hydrazide), and (3) 4,4'-oxybis (benzene sulfonyl hydrazide) alone, and an organic base or oxidizing agent which acts as an activator for said blowing agent.

Abstract: A method is disclosed comprising in-mold coating a structural foam part made from a thermoplastic aromatic polycarbonate resin or a thermoplastic ABS polymer resin with a thermosetting in-mold coating composition at a pressure of from about 25 to 50 p.s.i. and at a temperature not in excess of about 200.degree. F. for from about 1 to 10 minutes, preferably for from about 1 to 3 minutes, to provide hard, smooth and adherent coatings, said thermosetting in-mold coating composition comprising an ethylenically unsaturated polyester resin and an ethylenically unsaturated monomer(s) catalyzed with an organic perioxide initiator including an accelerator for the initiator.

Abstract: Improved polyolefin foams, particularly polystyrene foams, and improved extrusion processability thereof are obtained by employing as blowing agent a mixture of from about 3 to about 70 weight percent monochloromonofluoromethane and from about 97 to about 30 weight percent of dichlorodifluoromethane.

Abstract: In a process for producing a foamed polyolefin article which comprises melting and mixing a polyolefin, a volatile organic blowing agent, a cell size-controlling agent, and an ester of a long-chain fatty acid and a polyhydric alcohol in an extruder comprising a feed zone, a compression zone and a metering zone, and extruding the resultant molten gel into an area having a lower pressure than the pressure of the inside of the extruder, the improvement wherein said ester is at least one ester of a long-chain fatty acid having 8 to 20 carbon atoms and a polyhydric alcohol having 3 to 6 hydroxyl groups, and said ester is fed in the molten state into the molten gel within the metering zone and mixed with it.

Abstract: Low density, closed cell, soft foam products having dimensional stability are made from ethylenic resin blends having low stiffness by extrusion foaming, wherein the heat plastified gel comprises the ethylene polymer blend and at least one volatile blowing agent. The blends especially comprise a copolymer of ethylene and monoethylenically unsaturated carboxylic acid and a copolymer of ethylene and at least one monoethylenically unsaturated non-ionic comonomer. The starting ethylenic resin blends are preferably blends of ethylene acrylic acid copolymers and ethylene vinyl acetate copolymers, having stiffness less than about 20,000 psi. Exemplary volatile blowing agents are 1,2-dichlorotetrafluoroethane, 1-chloro-1,2,2,2-tetrafluoroethane and 2,2-difluoropropane.

Abstract: A plastic foamed sheet of excellent quality is produced by preheating in a chamber including a conveyor means for continuously conveying a thermoplastic resin sheet containing a heat-decomposable blowing agent in the horizontally supported state and a heating means for heating the sheet to a temperature lower than the decomposition temperature of the blowing agent, and foaming in a foaming chamber connected to the preheating chamber and including a heating means for heat-foaming the sheet as it is continuously conveyed while being perpendicularly suspended from the terminal of the conveyor means.

Abstract: A process for producing a crosslinked and foamed resin sheet which comprises shaping a resinous mixture comprising a thermoplastic synthetic resin and a heat-decomposable blowing agent into a sheet form, applying a high-energy ionizing radiation to the resulting foamable resin sheet to crosslink the resin sheet, and then heating the resulting crosslinked foamable resin sheet to the decomposition temperature of the blowing agent or to a higher temperature; wherein the high-energy ionizing radiation has a range of at least 0.7 .rho.d g/cm.sup.2 in which d is the thickness in cm of the foamable resin sheet, and .rho. is the density in g/cm.sup.3 of the foamable resin sheet, and a low-energy ionizing radiation with a range of not more than 0.6 .rho.d g/cm.sup.2 in which d and .rho. are as defined is applied to the foamable resin sheet before, during or after the application of the high-energy ionizing radiation.

Abstract: In a process for producing a highly expanded polyolefin insulated coaxial cable comprising the steps of feeding a polyolefin, a nucleating agent and a volatile liquid as a blowing agent to an extruder and heat extruding said mixture through said extruder onto an inner conductor passing through said extruder to cover the outer periphery of said inner conductor thereby forming an insulation layer of a highly expanded polyolefin foam having a foaming ratio in excess of 2.5 times (60% expansion degree), the improvement which includes the step of, after extruding the foaming polyolefin mixture around said inner conductor, sizing the outer surface of said foaming polyolefin layer on said inner conductor by means of a sizing die to provide a highly expanded uniform polyolefin insulation layer of a predetermined size, said insulation layer being tightly adhered to said inner conductor.

Abstract: An extrusion foamed article with a large cross-sectional area is made by extrusion foaming a mixture of an ionomer resin and a styrenic resin utilizing a volatile blowing agent. The process permits economic production of a novel thick, foamed article having well balanced properties.

Abstract: A process of forming a surface covering having decorative effects is disclosed. The process comprises forming a foam comprising at least one polymer having at least a first phase region and a second phase region on a backing, heating the foam to the flow temperature of the first phase region of the foam, compressing the heated foam and cooling the foam while in the compressed shape, thus facilitating coating the surface of the foam which remains in the compressed shape, and reheating the foam to permit the compressed foam to return to substantially its precompressed shape.

Abstract: Blowing agents comprising urea dicarboxylic acid anhydride do not give rise to discoloring decomposition residues nor form acid or alkaline by-products. These blowing agents may be used for expanding thermoplastic resins.

Abstract: This invention relates to a novel elastomeric foamed material which has surprisingly been found to exhibit a variety of unusual and desirable features both in its physical properties and in its process of manufacture. These foamed compositions of a lightly sulfonated elastomeric gum contain a nonvolatile polar plasticizer and preferably extenders such as oil and fillers. These elastomer foams exhibit an unusual profile of physical properties including melt reprocessability of fabricated articles, and high temperature reshaping of foamed objects while maintaining a good foam structure. These novel foams can be manufactured with relatively uniform cell structures and with small cell sizes at foam densities from near bulk density to less than 0.1 g/cc.

Abstract: The present invention relates to a process for expanding thermoplastic polymer compositions, notably those containing polymers having processing temperatures in excess of 200.degree. C. and/or containing an ingredient which is susceptible to ammonia, characterized in that as the blowing agent certain carbonates (notably zinc carbonate) are used. Preferably a nucleating agent and a weak acid are present to aid cell formation.The invention also includes expandable polymer compositions and blowing agent formulations containing the carbonates.

Abstract: A method for producing a foamed plastic insulating coating in a wire. A gaseous foaming agent is mix with a resin and passed through a high pressure narrow passage and then through a lower pressure wide passage.The release of pressure, when the resin enters the wide passage, results in a foaming of the resin. The foamed resin is thereafter extruded through an orifice onto a wire. In one embodiment a chemical is added to serve as a nuclei for the gas bubbles formed during foaming. In a second embodiment, a second chemical is added to provide a smoother extruded surface. In still a further embodiment, the pressure in the wide passage is automatically controlled to remain at a predetermined preferred pressure.

Abstract: A flame-retarding additive for foamed polystyrene is composed of 40 to 56 weight percent of halogenated hydrocarbon, 9 to 15 weight percent of antimony oxide, 14 to 22 weight percent of zinc borate, and 16 to 28 weight percent of hydrated alumina.

Abstract: A method and apparatus are provided for the extrusion of a thermoplastic material in modified form in which the thermoplastic material is introduced into the barrel of a screw extruder, and is heated and forced through the barrel: the material is passed through valve means which together with the temperature of the material is effective to produce a melt transition in the material at a predetermined point and to thoroughly mix the material; subsequently, the material is forced into a low pressure zone in the barrel where a modifying agent is introduced into the material; the resultant mass is forced out of the low pressure zone, and is passed through a mixing means effective to intensify the dispersion of the modifying agent in the mass, the mass is extruded and the extruded material collected.

Abstract: A melt extrusion process for producing a low density open cell filtering element for an aerosol such as tobacco smoke from plasticized cellulose acetate. A mixture of cellulose acetate, plasticized, a volatile liquid blowing agent which is at least a partial solvent for the cellulose acetate and a nucleating agent are melt extruded under conditions wherein the melt is subjected to high shear, the loss of the blowing agent through back flow is prevented, the melt is reduced in temperature prior to extrusion and the extrudate is conditioned in a hot air chamber and then sized in a sizing die.

Abstract: Foamed, low density polymeric articles have been fabricated from a non-tacky hydrogel obtained by blending normally solid thermoplastic polymer resin with a normally liquid organic solvent and water, at lower molding temperatures and energy requirements than those conventionally used in melt extrusion foam processing.

Abstract: A very low density material is produced by extruding a composition comprising a settable fluid containing long resilient fibres through a narrow die under conditions which cause the extrudate to expand to form an open fibrous structure as it leaves the die, and then causing the fluid to set. This is applicable to both thermoplastic and thermosetting materials. Various coating layers may be applied to provide rigid light-weight panels and shaped articles for various uses including furniture and building applications.

Abstract: A method for preparing foams of chlorinated vinyl chloride polymers is provided. The foams are prepared by impregnating the chlorinated vinyl chloride polymer with an aliphatic alcohol of from 1 to 5 carbon atoms and thereafter heating the impregnated polymer.

Abstract: A method of manufacturing a fiber-reinforced thermoplastic resin of cellular structure comprises immersing bundles of filaments of fibrous reinforcing material in a bath containing an emulsion of thermoplastic resin added with a blowing agent, drying the emulsion-impregnated reinforcing filaments, preheating the dried reinforcing filaments, compressing the preheated reinforcing filaments to provide an integrally bonded block of fiber-reinforced thermoplastic resin, and allowing the block to expand. The fiber-reinforced thermoplastic resin of cellular structure is advantageously employed as a light-weight, high strength construction material.

Abstract: Unitary molded plastic hinged article and method of making in which a fluid molten mixture of heat softenable resin and a blowing agent in substantially unfoamed condition is introduced into an expandable mold cavity to fill the cavity and the mold is expanded to allow foaming of the resin to form at least one foam cored article section while the resin adjacent the mold surface is still fluid and in which the hinge structure is formed by a member adapted to form a thin, flex portion and portions transitional from the thickness of the flex portion to the thickness of a cored article section, the shaping member being slidably disposed in an aperture in the mold with portions of the walls of the aperture exposed within the mold cavity at the time the molten mixture is introduced and the exposed portions of the walls being wiped by the shaping member when the mold is expanded.

Abstract: A tough board of thermoplastic resin foam provided with skin layers on both surfaces thereof and formed of large cells elongated in the direction of the thickness of said board, wherein an intermediate high density layer thicker than 0.1mm lies substantially halfway between the upper and lower surfaces of said board. The board is formed by extruding thermoplastic resin containing dissolved foaming agent as a sheet, cooling the upper and lower surfaces rapidly to form solid skin layers and then slowly cooling while allowing controlled expansion thereof between expansion restricting members.

Abstract: Lightweight glass fiber reinforced plastic articles are produced in matched dies by combining fibrous reinforcing materials, such as glass fibers, with a foamable unsaturated polyester resin composition. The matched dies are closed and compressed so that the resin composition fills the mold cavity and wets the fibrous reinforcing material. Thereafter the matched dies are separated to increase the volume of the mold cavity by at least 50 percent greater than the closed volume. The matched dies are retained in this relationship until the unsaturated polyester resin composition has cured and expanded to fill the mold cavity. The resulting product has a density less than 67 percent of the density of a corresponding reinforced plastic article fabricated from the same composition (unsaturated polyester resin, fillers and reinforcement), which is not foamed. The unsaturated polyester resin composition preferably includes 0.

Abstract: Disclosed is a method for continuous extrusion coating of a hollow core material with a highly expanded polyolefin resin, which is characterized by subjecting an extruded molten mass of an expandable polyolefin resin to external cooling at the point at which said molten mass begins to foam and supplying said hollow core material with the surface temperature thereof kept below the softening point of said polyolefin resin for thereby enhancing the fastness of adhesion of the highly expanded polyolefin foam with the hollow core material and at the same time facilitating the release of the two materials thus joined.

Abstract: Flake- or sliver-like porous structures of a polymeric material heavily loaded with a finely divided inorganic substance are prepared by spurting a mixture of the polymeric and finely divided inorganic components in a solvent. The products have many fine, irregular voids. The thickness of walls forming such voids is 5.mu. or less. The products are especially useful for producing sheet-like structures therefrom by beating and/or refining them followed by general paper making procedures. The sheets, when calendered, have a high initial modulus and improved dimensional stability.

Abstract: A method of forming a ball core is disclosed. A flowable homogeneous mass of a thermoplastic resin and a blowing agent is injected into the spherical cavity of a mold under temperature and pressure conditions sufficient to activate the blowing agent. The mold is cooled to 32.degree. to 65.degree. F. so as to form a skin on the surface of the mass. The mass is held within the mold cavity for a sufficient time so that the skin has adequate strength to prevent its rupture by blowing agent contained within the mass, upon removal of the mass from the mold cavity. The mass is cooled at an exterior temperature of 32.degree. to 65.degree. F. A ball core for baseballs and softballs is also disclosed.

Abstract: This invention relates to an improved injection foam molding method in which a foamable mixture of molten synthetic polymer resin and a chemical blowing agent in unfoamed condition is injected into a gas-pressurized expandable mold having a mold section movable for expanding the mold cavity to a position in which the surface of that section is in registry to the surface of another mold section, in which process the mold is filled under conditions resisting foaming of the material prior to filling of the mold and a novel controlled time sequence effective to form a fine mold crease line is employed in releasing the gas pressure and expanding the mold to allow foaming of the mixture into conformity with the mold surface.

Abstract: Low density, closed cell, soft foam products having dimensional stability are made from ethylenic resins having low stiffness, especially comprising copolymers consisting essentially of ethylene and monoethylenically unsaturated non-ionic comonomers, by release to lower pressure of a flowable, foamable gel under pressure, e.g., by extrusion foaming, wherein the gel comprises the ethylenic polymer and a volatile mixed blowing agent. The starting polymers are preferably copolymers of ethylene and vinyl acetate having stiffness less than about 20,000 psi. The mixed blowing agents are particularly characterized as mixtures of dichlorodifluoromethane and at least one fluorocarbon constituent A, as defined. Exemplary mixtures contain (I) dichlorodifluoromethane and (II) from 35 to 50 percent chloropentafluoroethane, octafluoropropane or octafluorocyclobutane based on the mixtures of I and II.

Abstract: An injection molded polymer having limited surface gloss is provided by preparing an admixture of an injection moldable polymer substrate and an additive chosen from among the group consisting of finely divided textile fibers, finely divided hydrocarbon polymers, and blowing agents and injection molding an article from the admixture. In the embodiment of the invention employing blowing agents the admixing is carried out at a temperature below that at which the blowing agent is activated and the injection molding is carried out at a temperature sufficient to activate the decomposition of the blowing agent.

Abstract: A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member, said core comprising from about 25 to about 75 volume percent of a low density cellular filler material, such as chopped cork, and from zero to about 60 weight percent of a high density weight control material, such as barium sulfate.

Abstract: A poppet type check valve for controlled feeding of blowing agent into an assembly for the extrusion of thermoplastic polymeric foam material and, in particular, for controlled feeding of a blowing agent such as pentane into the barrel of an extruder assembly for extrusion of polystyrene foam; and an apparatus assembly comprising such a check valve in combination with the barrel of an extruder for extrusion of such foam materials.

Abstract: Polyester foam is formed by simultaneously cross-linking an unsaturated polyester resin and generating carbon dioxide as a blowing agent. The foam-forming components are divided into two equal volume parts which are metered together to effect the simultaneous reactions and form the foam. Apparatus is described for effecting the foam-forming method.

Abstract: Stable foams of reaction resins and/or condensation resins can be obtained by adding a blowing agent which is gaseous under normal conditions to the resin under pressure, the gas liquid interface being enlarged while dispensing with moving equipment, allowing the mixture to expand and to cure.

Abstract: Foamed articles are made by causing the cross-linking of a thermosetting in, preferably a polyester resin, concurrently with the production of carbon dioxide by the reaction of a carbonate with an inorganic acid. The carbonate is mixed with the resin and the acid then folded in in a progressively accelerated blending operation, whereupon carbon dioxide is generated to foam the resin, the carbonate, acid and setting time of the resin being selected to obtain an appropriate match between the progress of the foaming operation and the setting of the foam. The foam may be made in a mold coated with resin impregnated glass fibers, the impregnating resin becoming cross-linked with the foam. The impregnating resin may also be cross-linked with a resin gel coat, the glass fibers forming a tough layer between the gel coat and the foam.

Abstract: Thermoplastic articles with highly porous cores and less porous or nonporous skins are injection-molded with the aid of a nozzle having a flow divider disposed upstream of its aprue for splitting the oncoming plastic mass into a homogeneous outer stream and an inner stream admixed with a foaming agent, the two streams merging inside the gate of a mold cavity. The foaming agent enters through a central channel which may be provided with one or more ducts alternately usable to introduce pressure fluid and coolant into the cavity lined with coalescing layers of nonfoamed and foamed plastic. The flow divider may be axially movable within the nozzle to serve as a control valve and flow regulator.

Abstract: The invention refers to a blowing agent composition consisting of 1,4 butan-diol-bis-(carbonic acid ester-benzoic acid anhydride) and silicon dioxide. Silicon dioxide reduces the decomposition temperature of the anhydride while at the same time increasing the yield of gas substantially.

Abstract: A porous pipe primarily of rubber and synthetic rubber reclaimed from rubber tires, ground to a relatively small granular size, with metal removed; such as, for example, would pass through a 30-mesh screen, process-mixed through a pipe extruder, with a much smaller binder mix of primarily polyethylene, along with vinyl, ABS binder, and a trace of attaclay. The resulting product is useful as a subsurface irrigation buried pipe, having high structural integrity effectively resisting soil-loading pipe collapse, and it even resists collapse from moderately large rocks in the soil, and yet has a high degree of flexibility along its length. A pipe is provided with cross sectional area of pipe wall more than twice the cross sectional area of the pipe opening.