Abstract: A laminated printing blanket having compressible and resilient properties and a method for its production are provided. The compressible characteristics are provided by disposing an intermediate layer having substantially uniformly distributed voids of substantially uniform size between the base ply and the working surface of the printing blanket. The voids of the compressible intermediate layer are formed by introducing high melting point microspheres formed from thermoplastic resins into an elastomeric matrix, coating said microsphere containing elastomeric matrix upon an upper surface of the base ply and then vulcanizing the coated base ply at a temperature of between about 80-150.degree. C. for between about one and six hours to form the compressible layer having substantially uniform compression characteristics. Once all of the layers of the blanket are stacked, a final vulcanization treatment at between about 132-160.degree. C.

Abstract: A shaped article composed of an aromatic polyimide has a hollow, essentially spherical structure and a particle size of about 100 to about 1500 .mu.m, a density of about 1 to about 6 pounds/ft.sup.3 and a volume change of 1 to about 20% by a pressure treatment of 30 psi for 10 minutes at room temperature. A syntactic foam, made of a multiplicity of the shaped articles which are bounded together by a matrix resin to form an integral composite structure, has a density of about 3 to about 30 pounds/ft.sup.3 and a compression strength of about 100 to about 1400 pounds/in.sup.2.

Abstract: A solid, single-pour synthetic weapon stock comprises polyurethane and an equal amount by volume of a spacing material of silica-alumina ceramic microspheres blended into the polyurethane. For additional strength, a U-shaped bar having spaced apart bores is disposed within the weapon stock. A process for manufacturing the polyurethane weapon stock, comprises the steps of blending polyurethane with the spacing material to form a polyurethane reactant, placing the U-shaped bar into a mold having a void of a shape of the weapon stock, pouring the polyurethane reactant into the void and allowing the polyurethane reactant to react to form a polyurethane object having the shape of the void, curing the polyurethane object and removing the polyurethane object from the mold.

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. Resin powder collected as a waste by-product from resin coating materials can be recycled in the production of the desired product.

Abstract: The invention is directed to a lightweight barrier and armor materials and, ore particularly, to a method of using a syntactic foam for protecting a desired portion of a fixed structure (e.g., building) or movable structure (e.g., armored vehicle or ship) from ballistic impact. The method of the present invention includes the following steps: (1) providing a mold defining therein a predetermined shape or an enclosed space in a fixed or movable structure; (2) providing a mixture of between about 40 percent and about 80 percent by volume of microspheres and between about 60 percent and about 20 percent by volume of an uncured binder material; (3) pouring the mixture into the mold; (4) curing the mixture to form a syntactic foam barrier material in the form of the predetermined shape; and (5) placing the barrier material in a relationship with the structure to be protected wherein the desired portion of the structure is protected from ballistic impact.

Abstract: An apparatus for consolidating a workpiece includes an oven having a heating cavity and a consolidation press received within the heating cavity of the oven. The consolidation press includes a base, a pressure platen disposed in facing relation to the base, and an expandable bellows operatively connected to the pressure platen to force the pressure platen toward the base. The bellows is expanded by a gas pressure supplied by a pneumatic source. In operation, a workpiece is placed between the base and the platen, and a force is applied to the workpiece by operation of the bellows.

Abstract: For the manufacture of breast prostheses from a shell-shaped body made from an addition-vulcanising two-component silicone rubber mass, which body is enclosed in a plastic sheet sheathing said body, a filler of fairly low density composed of hollow spheres or microspheres is added to the two-component silicone rubber mass. The mixture is filled into a sheath of plastic sheet and is cured in a mould under the effect of heat. To obtain the most uniform distribution possible of the filler in the prosthetic body, the mould filled and degassed in the customary way is turned continuously through one or two axes before and during the curing of the two-component silicone rubber mass until the silicone rubber is vulcanised to such an extent that any rising of the filler materials is prevented.

Abstract: A process for the production of a composite molded article having two surface layer (skin) portions of a fiber-reinforced resin (FRP) and a core portion of a porous resin layer between the two surface layer portions, all of which portions are integrated. More specifically, the invention relates to a process for the production of a light-weight and tough composite article having a foamed core-sandwiched structure in which two dense surface layer (skin) portions of a fiber-reinforced resin and a core portion of a porous resin layer having numerous air foams are integrally molded such that the core portion is integrated between the above two dense surface layer portions. This process can be carried out at a low cost by a batch or continuous method.

Abstract: A process for producing solid surface material is provided with a thin layer of filled polymer integrally formed with a backing of bubble-filled polymer, without an interface or transition zone in the polymer mix, using one-step casting, with vibration to aid separation of filler and bubbles.

Abstract: The present invention relates to a sound attenuation composite and a method for making the composite. The sound attenuation composite includes a barrier layer and an open cell foam layer loaded with a sound blocking filler. In one embodiment, the foam layer is filled with a barium sulfate filler. In another embodiment, a solid polyvinyl chloride barrier layer is loaded with barium sulfate, wherein 60 parts of barium sulfate is present in each 100 parts of polyvinyl chloride.

Abstract: A submarine buoyant cable antenna having positive buoyancy comprising a cunications antenna electronics package encased in a polymer composition, the polymer composition comprising from about 80 percent to about 85 percent by weight of a room temperature curable thermosetting polymer having a viscosity, before curing, in the range of from about 700 to about 900 centipoise, and from about 15 percent to about 20 percent by weight of microballoons of a size ranging from about 20 to about 100 microns in diameter, the specific gravity of the composition being in the range of from about 0.51 to about 0.65 grams per cubic centimeter to provide the positive buoyancy.

Abstract: A wood type metal golf club head having a hollow metal head and the cavity within filled with a thermoplastic material produced from a thermoplastic polymer, filler and chemical blowing agent in a manner so that the material in the cavity has a dense outer skin adjacent the surfaces of the cavity and a cellular central area and the finished product reduces the undesirable metallic sound made during hitting.

Abstract: A method of making a boat includes the steps of forming an integral hull having a rear outer wall by applying successive layers of an outer smooth coating, resin and fibers to a female mold, and allowing the hull to cure, separately forming a rear inner wall by applying sucessive layers of an inner smooth coating, resin and fibers to a male mold and allowing the inner wall to cure, attaching the rear inner wall to the inside of the hull at a position spaced away from the rear outer wall, injecting a syntactic foam comprising a plurality of microspheres encapsulated in resin between the rear inner wall and the rear outer wall to form a core between them, which core bonds throughly to the inner and outer walls forming a strong, sandwich structure after the foam core cures.

Abstract: It was found that a combination of thermoplastic microspheres containing a volatile hydrocarbon and water could be used as effective co-blowing/density reducing agents in low density, integral skin polyurethane foams.

Abstract: An interior-finishing material for use in automobiles including a substrate made of a needled glass-fiber sheet containing a thermoplastic resin binder, with the said needled glass-fiber sheet being mainly composed of glass fiber, a heat-fusible adhesive layer with air permeability disposed on the substrate, and a surface layer with air permeability disposed on the adhesive layer, and the substrate further contains expanded microbeads.

Abstract: A process for the production of an integral composite molded item including(i) a surface portion having a synthetic resin phase containing a fibrous reinforcing material,(ii) a core portion having the synthetic resin phase containing bubble-containing particles, and(iii) a separation layer positioned between the surface portion and the core portion, the process including the steps of:providing in a substantially sealed mold (1) a separation layer which does not substantially pass therethrough bubble-containing particles but which is capable of passing a synthetic resin or its precursor that is liquidized at the time of molding; (2) a synthetic resin or its precursor on either or both sides of the separation layer; (3) a fibrous reinforcing material between the separation layer and the mold, and (4) an aggregate of bubble-containing particles on the side of the separation layer opposite to the mold;causing volume expansion of the aggregate;causing the resin to flow through the separation layer to thoroughly di

Abstract: A method of protecting acoustic and damping tiles from fire damage by placing a fire barrier silicone foam sheet on the inner surface of a mold, mounting the mold at a selected distance from the surface of a hull of a vessel with the fiberglass cloth side of the silicone foam sheet facing the hull and spaced therefrom, injecting a polyurethane foam into the space between the hull surface and the silicone foam sheet, curing the polyurethane foam, and removing the mold. The porosity of the polyurethane foam is imparted by incorporation of 5-50% by volume of Saran.RTM. microspheres.

Abstract: An insulating composition comprises a polyolefin, preferably polypropylene, and hollow microspheres, at least some of which have been pre-treated with a chain-scission agent and, optionally, a functionalizing agent for the polyolefin, before addition to the polyolefin melt. The provision of the chain-scission on the microspheres enables the microspheres to be compounded substantially without breakage with low Melt Flow Index polyolefins, with the result that the resultant composite material can be employed in rigorous application areas, for examples as an extruded flowline insulation.

Abstract: A wood-type metal golf club head comprising a hollow metal head body and a core material filling the inside of the metal head body, wherein the core material is an aggregate prepared by fusing expandable beads comprising a microcapsule of a synthetic polymer and an expanding gas enclosed therein to each other by the expansion of the gas and has a bulk specific gravity of 0.05 to 0.15 g/cm.sup.3.

Abstract: A gasket which contains microspheres which expand inside the gasket sheet material after the gasket sheet is formed. Such gaskets are especially useful to provide a seal against fluid leaks at significantly lower pressures due to the presence of the microspheres. Some microspheres can expand during use.

Abstract: A method for fabricating in a mold a rotatable recording drum. Initially, the mold is rotated and a predetermined quantity of a flowable substance is poured into the mold cavity and is centrifugally flung against the mold wall to form a mold layer with a smooth inner surface. Next, a surface substance is poured into the mold cavity and is allowed to harden against the mold layer. A core outer layer substance is then poured into the mold cavity and allowed to harden against the surface substance, and rotation of the mold is stopped. The mold layer fluid is removed, and the cavity inside the outer layer is filled with a core inner layer substance which is allowed to harden before the drum core is removed from the mold cavity. Following removal of the core from the mold cavity, the hardened surface substance may be vacuum coated, and a protective overcoat applied to the core. The drum core and the surface substance can also be formed separately.

Abstract: An in situ polymerized thermplastic resin incorporating hollow glass spheres, which are incorporated during polymerization of the resin, and a method of making a concentrate of hollow glass spheres dispersed in a thermoplastic resin with minimal sphere fracture by adding the spheres during polymerization of the resin.

Abstract: A golf club head composed of an outer shell made of a fiber-reinforced resin and a core made of a syntactic foam and formed in the outer shell, wherein the syntactic foam comprises a matrix resin with glass microballoons as a main component and whiskers mixed therein.

Abstract: A soft, flexible, microporous film is provided having high tensile strength and good air and water vapor transmission rates therethrough while being substantially impenetrable to liquid water. This film is prepared by stretching a casting of a composition of a polyolefin and high levels of CaCO.sub.3 or glass beads and calcium stearate in two directions from 1.5-7 times in each direction to produce a film having a Gurley porosity of from 0.1 to 85 seconds. This film is especially useful for disposable items such as feminine panty liners, diapers, bed sheets, and hospital gowns. When glass beads are substituted for the CaCO.sub.3, the film is useful for battery separators.

Abstract: A two-part for reinforcing a hollow strucutral members and its method of use are provided. A method of reinforcing a structural member having a hollow cavity comprises the steps of preparing a first dough which includes a thermal setting resin, a first filler and unexpanded, thermally-expandable microspheres. A further step includes preparing a second dough which includes a curing agent, a colorant and a second filler. The curing agent is compatible with the thermosetting resin to promoter cross-linking of the thermosetting resin upon contact with the curing agent. The hollow structural member may be preheated to enhance the rate at whcih the thermosetting resin cross-links. The two dough are blended together until a reactive third dough of substantially uniform mixture is formed. The uniformity of the blending is confirmed when the reactive third dough attains a uniform color intermediate the color between the colors of the first and second doughs.

Abstract: To produce a layer in a multi-layer circuit structure, a "green ceramic tape" (16) comprising a sheet of particles of ceramic, glass ceramic, or a glass/ceramic composite in an organic binder is applied to a ceramic substrate (12) on which conductive paths (14) have been deposited. A slurry of hollow microspheres (20) is then deposited onto the green ceramic tape (16), and pressure is applied to drive the spheres into the tape. A further tape layer (22) is then applied, and the resultant structure is fired.

Abstract: A soft, flexible, microporous film is provided having high tensile strength and good air and water vapor transmission rates therethrough while being substantially impenetrable to liquid water. This film is prepared by stretching a casting of a composition of a polyolefin and high levels of CaCO.sub.3 or glass beads and calcium stearate in two directions from 1.5-7 times in each direction to produce a film having a Gurley porosity of from 0.1 to 85 seconds. This film is especially useful for disposable items such as feminine panty liners, diapers, bed sheets, and hospital gowns. When glass beads are substituted for the CaCO.sub.3, the film is useful for battery separators.

Abstract: A method for manufacturing lightweight structural elements, for example, in form of plates which, at low density, have high mechanical strength and good insulating properties, wherein 70-95 parts by weight of open porous blown glass spheres have a grain fraction of 0.2 to 20 mm and a gross density between 0.2 and 0.55 g/cm.sup.3 are mixed with 4-30 parts by weight of an epoxy binder. The epoxy binder consists of a bisphenolic resin, to which 0.5-5 parts by weight of a polysiloxane are added, and an amine hardner. The blown glass spheres are thereby wetted on their surfaces. They are poured into a mold corresponding to the shape of the lightweight structural element, after which heat is added, as a result of which the amine hardener reacts with the polysiloxane and epoxy resin and an epoxy foam results between the blown glass spheres.

Abstract: A spincasting technique for forming a syntactic insulation layer around a pipeline includes rotating a drum while or after injecting components for forming syntactic insulation material into said drum. In this manner a syntactic material is formed in which larger, low density, microspheres are biased towards the inner surface of the insulation layer.

Abstract: A method of forming a shaped article from a stock of preformed, thermoplastic, syntactic foam material of hollow microspheres in a thermoplastic polymer matrix, comprising heating the preformed syntactic foam to a temperature above the softening point of thermoplastic polymer matrix and applying differential pressure over at least one surface of the foam material through the medium of a plastically deformable diaphragm member to cause the foamed material to conform to a desired shape. Shaped articles of syntactic foam material, optionally having a surface coating of unfoamed, preferably fibre reinforced thermoplastics materials are provided in a more versatile and convenient manner than curing or sintering syntactic foam material in a mould.

Abstract: A method for preparing a dielectric ceramic composition containing hollow microspheres which is castable on a substrate in the form of a tape or sheet for multilayer circuits in which crushing or breaking of the microspheres is avoided, and a multilayer sheet structure formed from said tape.

Abstract: There is disclosed a one-piece short distance golf ball which is formed by foam molding a thermoplastic polymer and a filler. The resulting golf ball has a dense outer skin and a cellular core structure. The golf ball is approximately half the weight of and plays approximately half as far as a conventional golf ball, but its performance characteristics are otherwise comparable to a conventional golf ball. In addition a bramble surface pattern is provided on the ball to reduce the effects of wind on the ball's flight.

Abstract: A process for mixing a magma that can be used to make a structural syntactic foam of very low density includes the steps of mixing and agitating the dry ingredients of the foam, principally silica microspheres, in a slant cone mixer to break up any lumps and achieve a uniform fluffy mixture, and spraying a resin/solvent solution as a fog of fine droplets into the mixture. The resulting magma is folded and agitated within the mixer until the resin uniformly coats the microspheres, and the resin is packed into a mold. The filled mold is pressurized and heated in an autoclave until the resin is cured, and then the mold is cooled and opened and the finished syntactic foam part is removed.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermoplastic polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: A process for fabrication of refractory insulating materials wherein essentially pure silica shells are mixed with a polymeric graphite precursor dissolved in a solvent. The resulting slurry is placed in a forming mold, and the solvent is evaporated to form a polymeric matrix containing the shells as a dispersion. This matrix is pyrolized under an inert or reducing atmosphere to decompose the polymer and form a first product consisting essentially of a carbon matrix containing a dispersion of silica shells. To enhance refractory characteristics, such first product is fired at high temperature in an inert or reducing atmosphere to form a second product consisting of a carbon matrix containing a dispersion of SiC-lined voids, or in a nitrogen atmosphere to form a third product consisting of the carbon matrix containing a dispersion of Si.sub.3 N.sub.4 -lined voids.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermosetting polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: The method of the present invention includes mixing a low viscosity thermoset resin and microspheres together without melting the thermoset resin and extruding the mixture to form a continuous strand of paste-like uncured material. The continuous strand is gelled on a conveyor which preferably includes a radiant heater or other means for accelerating the gelling of the continuous strands into solid form. The strands are then cut or chopped into pellet form and may be coated with an adhesive or B-staged material in preparation for forming into structural reinforcements. The pellets are filled with microspheres in the amount of 20 to 35% of resin weight. The pellets may include unexpanded thermally expandable microspheres which permit expansion of the pellets when exposed to heat to provide a pellet having a bulk density as low as 9 pounds per cubic foot.

Abstract: The invention relates to foams for insulating cavities and structures, such as spaces between walls in houses. The inventive foam compositions are prepared in separate portions, generally comprising (A) cement and (B) foam. Air is added initially to foam one of the components or a mixture of components.In a first embodiment, the first component comprises an aqueous solution of polyvinyl alcohol and a dispersant. This component is mechanically foamed by injection of air, for example. After the mechanical foaming a second, cement component is added to the first component. This second component comprises an aqueous solution, mixture or suspension of magnesium oxide and barium metaborate, and a dispersant.In a second, preferred embodiment, the first component comprises an aqueous solution of polyvinyl alcohol and calcium chloride, which component is mechanically foamed by injection of air.

Abstract: Method and apparatus is provided for reinforcing a structural member of a vehicle body by the use of adhesively bonded together glass macrospheres of 3 to 9 mm. in diameter. The adhesive is not more than about 40% by weight of the mixture so that voids remain between the adjacent macrospheres to permit airflow through the reinforcement and the reinforced structural member upon curing adhesive. The adhesive may be curable at ambient temperature or may be a high temperature curable adhesive which is cured in a vehicle body paint curing over to bond the macropsheres to one another and to the structural member. The adhesion of the macrospheres to the structural member may be facilitated by an epoxy coated flexible sheet material lining the walls of the structural member. The adhesive coated macrospheres may be closely packed into the structural member by pouring or blowing.

Abstract: A decorative tile having a front face with a design thereon varies in density so that the front face of the tile presents a solid appearance, but the overall weight of the tile is less than for a comparable conventional plaster tile. The tile of the invention can be made from a mixture including a binder, fiber strands, and a bulk enhancing agent. The decorative tile of this invention is particularly useful for ceiling decoration.

Abstract: A gypsum plaster and chopped glass fiber tile having increased insulation values, reduced weight and reduced density due to the presence of vermiculite and perlite.

Abstract: A process for continuously molding a plate for an electrical printed circuit board wherein a resin containing uniformly distributed hollow microspheres having a specific gravity different from that of the resin is extruded into a vertically disposed moving double belt press maintained at a temperature which allows the extruded plate to harden almost completely. The plate exists the vertically disposed press maintaining a flexibility sufficient to be passed around a roller into a horizonal position where subsequent processing steps may be applied, such as lamination of reinforcing fiber and coating with a conductive material.

Abstract: A tool for use in a latex dip process for producing a latex skin in a given configuration, the tool being formed by producing an electro-formed female mold from a sculpture of the desired configuration, casting a vinyl skin from the electro-formed female mold, removing the vinyl skin to expose a hollow interior, and stuffing the vinyl skin with a composition of materials, having the characteristics of providing rigidity to the vinyl skin and approximately zero buoyancy in a latex bath.

Abstract: Expandable phenolic resin-coated composite beads comprise an aggregate having coated thereon a solid, expandable resin composition comprising a solid, phenolic resin initial condensation product, a foaming agent and, if necessary, a hardening agent. The expandable phenolic resin-coated composite beads provide composite cellular moldings in which the aggregates are uniformly dispersed in a phenolic resin-expanded layer and are firmly adhered to the expanded layer. The composite cellular moldings can be adhered to a face plate to form integral laminates.

Abstract: The invention is a method of forming a composite structure which begins with the formation of a syntactic foam core having internal communication passages that terminate with a plurality of openings in the outer surface of said core. After being wrapped with a plurality of layers of porous material, the wrapped core is positioned in a cavity of a mold having an inlet communicating with one of the openings. A source of uncured resin mix then is connected to the inlet and the mold is evacuated. After being forced through the inlet and the passages to fill the mold and impregnate said fibrous material, the resin mix is cured to provide with the core and the fibrous material a rigid composite structure.

Abstract: A handgrip, such as a golf club grip, having improved non-slip features is shown which is formed from a silicone rubber composition. The silicone rubber composition comprises an organopolysiloxane gum, a silica filler material, as organosilicone processing aid, a texturizing material, and a quantity of hollow spheres. The texturizing material and spheres are first blended into the composition while heating the composition. The rubber composition is then placed in a suitable mold and cured with a peroxide catalyst to form the handgrip. The external surface of the cured handgrip is buffed to fracture the hollow spheres nearest the surface and improve the non-slip character of the handgrip.

Abstract: Large, uniform hollow spherical shells are produced by forming uniform size drops of heat decomposable or vaporizable material, evaporating the drops to form dried particles, coating the dried particles with a layer of shell forming material, and heating the composite particles to melt the outer layer and decompose or vaporize the inner particle to form an expanding inner gas bubble which expands the outer layer. By cycling the temperature and pressure on the hollow shells, spherical shells with uniform walls are produced.

Abstract: A method of making hard surface prototypes or styling concept models by assembling a contoured polystyrene foam pattern and applying an epoxy clay-like material in two steps to replace the surface of the polystyrene foam pattern. The polystyrene foam pattern is first assembled from blocks cut out to design drawing specifications. The pattern is then shaped to the design contour. The surface of the pattern is then grooved and the grooves filled with the epoxy clay. The remainder of the pattern surface is then removed and replaced by more epoxy clay which is then sanded and finished with paint and suitable trim pieces.

Abstract: A process and apparatus for the internal gating of molds used to make a shaped article of aggregate filler infiltrated with a curable binder, including preparing a mold having a cavity and having gating tubes extending through the mold cavity and spaced from its surfaces, and the gating tubes having walls with multiple openings therethrough which are located inside the mold cavity, the cavity being dry-packed outside of the tubes with aggregate filler and the interstitial spaces therebetween being pumped full of liquid binder to form a matrix, the binder entering through the tubes and their openings and progressively expanding through the interstices while expelling air from breather holes, the binder then being cured in the mold either with the tubes still in place or with the tubes removed and the spaces filled with similar aggregate and binder before curing is completed.

Abstract: A method and a composition are provided for molding low density desiccant syntactic foam articles. A low density molded desiccant article may be made as a syntactic foam by blending a thermosetting resin, microspheres and molecular sieve desiccant powder, molding and curing. Such articles have densities of 0.2-0.9 g/cc, moisture capacities of 1-12% by weight, and can serve as light weight structural supports.