Abstract: A building block having at least one chamber therein which is filled with a foamed plastic material consisting of particles interconnected at their surfaces to form gas-permeable interstices. The block is formed by filling the chamber with a loose fill of the foamed plastic material and then fusing the particles to each other by blowing hot gas through an injection lance inserted in the fill.

Abstract: A thermally-insulating, non-flammable, air-permeable insulation for installation in the field, for example, in closed cavities between the walls of a house. A multitude of individually preformed, foamed plastic particles are initially entrained in a carrier stream, and thereupon drenched with a settable film-forming, non-flammable, liquid substance, such as a sodium silicate solution. The liquid substance sets to form a film which covers and adheres the particles to one another to form a thermally-insulating dense structural aggregate mass having structural integrity, resistance to fire, and venting capability. A method of making and installing the insulation, and a preferred apparatus therefor, are disclosed.

Abstract: A panel comprising fillers embedded in a closed cell expanded phenolic resin is made by making a mixture, which is initially fluid, or phenolic resin, a hardening agent, a surface active agent and a porogenic agent, which has a boiling point above ambient temperature and below the polycondensation temperature of the mixture. This liquid mixture is mixed with fillers, for example balls or microspheres of glass or expanded material such as polystyrene. The resulting mixture is placed in a mould, only partially filling the mould, and heated progressively to a temperature in the neighborhood of the boiling point of the porogene agent, while evacuating the mould, and held at that temperature until the mixture has expanded to fill the mould. The temperature is then progressively increased to the polycondensation temperature to harden the expanded mixture.

Abstract: A process for the production of polyolefin foam materials from crosslinked polyolefin foam scraps includes the steps of comminuting scraps of crosslinked polyolefin-containing foam; admixing the comminuted scraps with a synthetic resin on a polyolefin basis; compressing the resulting admixture at a temperature lying below the decomposition temperature of the crosslinking agent to form an aggregate product; comminuting this product to form a particulate material; plasticizing the particulate material at a temperature lying below the decomposition temperature of the crosslinking agent to form a shaped article; and crosslinking and expanding, i.e. foaming, the shaped article by heating the article to above the decomposition temperatures of the crosslinking agent and of the blowing agent.

Abstract: The instant invention is directed to a novel process for the production of bonded foam, and particularly polyurethane foam scrap. The process allows for the production of a high quality rebonded product. Significant improvements are seen in the quality of the product, reduction in density, reduction in scrap loss, elimination of density variations in the molded product and overall product consistency.

Abstract: The instant invention is directed to a novel process and apparatus for the production of rebonded foam, and particularly polyurethane foam scrap. The process and apparatus allow for the simultaneous performance of three and preferably four basic operations, i.e. mold filling, curing or steaming, boring and mold stripping, to achieve the shortest, most efficient time cycles to produce a high quality rebonded product. Significant improvements are seen in the quality of the product, reduction in density, reduction in scrap loss, elimination of density variations in the molded product and overall product consistency.

Abstract: A wear-resistant flexible sheet material, suitable for use as outer soles on footwear, is produced by pressing reconstituted polyurethane foam sheets in the substantial absence of air at temperatures above 150.degree. C. The sheets should have a density exceeding 15 lb/ft.sup.3 and are further densified by the hot pressing. The sheets are preferably pre-heated to 175.degree.-210.degree. C. and pressed under a pressure of 5 to 30 tons/ft.sup.2 for periods of up to 5 minutes. The sheets may be embossed or smooth surfaced and may contain pigments, plasticizers and other additives.

Abstract: A process is disclosed herein for the production of a composite foamed material which comprises premixing expandable polystyrene beads and a binder and adding the premix to fragments of resilient, open-celled material. The materials are combined in the proportions of about 4-15% polystyrene beads, about 6-25% binder and about 60-90% open-celled material. The combined materials are compressed to a density of about 5-30 lbs per cubic foot, preferably 5-17 lbs per cubic foot, and steam is applied to the compressed materials to cure the binder and expand the polystyrene beads, producing the desired composite foamed material.

Abstract: A process is disclosed herein for the production of a composite foamed material which comprises premixing expandable polystyrene beads and a binder and adding the premix to fragments of resilient, open-celled material. The materials are combined in the proportions of about 4-15% polystyrene beads, about 6-25% binder and about 60-90% open-celled material. The combined materials are compressed to a density of about 5-30 lbs per cubic foot preferably 5-17 lbs per cubic foot, and steam is applied to the compressed materials to cure the binder and expand the polystyrene beads, producing the desired composite foamed material.

Abstract: Method for the continuous production of a cylindrical block of reconstituted foam material. A charge of foam crumb (together with a binder) is placed in an open-ended mould, supported therein and compressed to a height of about one foot. The product is lowered from the mould and maintained relative thereto so as to provide a support to receive a further charge of foam crumb and binder. The further charge is compressed so that it unites with the first-mentioned charge. Further charges of crumb and binder are added, and the method-steps repeated, as often as necessary. An apparatus is provided in which the method may be performed.

Abstract: A method of forming a laminate composed of a solid polyester lamina bonded to a block. A block having a matrix composed of polyurethane foam and particles of expanded polystyrene distributed therein is prepared. A layer composed of a solution of a relatively unpolymerized polyester in styrene solvent with fiberglass embedded therein is placed in contact with a surface of the block. The styrene solution of polyester dissolves polystyrene particles adjacent such block surface, leaving recesses distributed in the block matrix. These recesses become at least partially filled with the polyester solution. The solution is then cured to produce a solid resin lamina which is joined with polymerized resin contained in the matrix recesses to secure the lamina to the block.

Abstract: Prefabricated building components such as panels, roofing units, and floor blocks and a method and machinery for producing the same. The prefabricated components are obtained by casting in form a mix containing granules of expanded polystyrene or other suitable light thermal and sound insulating material which is bonded to cement by adhesive. Depending upon their particular application, the components may be used for either load bearing or non-load bearing purposes.

Abstract: A mastic composition formed of a substantially homogeneous imporous mixture of a predetermined volume of low-density expanded closed-cell synthetic resin beads and a slurry prepared from calcined gypsum and water wherein the interstitial volume of the expanded beads is not substantially more than the volume of slurry. The substantially homogeneous mixture is self-adhering as a thick layer on an inverted smooth surface and yet separable therefrom as an integral layer, the mastic composition setting to a hard, strong, dimensionally stable, heat-and sound-retardant material. Methods of mixing mastic compositions, and composite structural panels utilizing mastic compositions as well as the methods and apparatus for forming such panels are also disclosed.

Abstract: Closed cell foamed polystyrene beads are shredded to form small size, open-celled foam particles. The particles are mixed with a slurry of a granulate and a liquid whereby the slurry enters the open cells to increase the density of the particles. After an even distribution of the particles throughout the slurry is obtained the mixture is dried to form granulate objects, such as boards, having an even distribution of foamed polystyrene particles therein to reduce the density of the object.

Abstract: The invention relates to a method for the production of insulating elements for the walls and ceilings, made from facing layers fitted to a frame. Between the facing layers, a perforated foam-permeable, optionally reinforced, intermediate layer is inserted. One of the two chambers thus formed is subsequently filled with foam. The other chamber is filled with a foam permeated granular material.

Abstract: A strong, expanded moulded panel or board, having a specific gravity between 0.2 and 0.8, is produced by heating dry urea formaldehyde resin containing 4% to 8% volatile materials in a mould at between 130.degree. and 160.degree. C under light restraining pressure between 30 and 300 psi which permits moderate expansion of the resin owing to the gasification of the volatile materials.

Abstract: Shaped articles are produced by heating and compressing particles of foamed olefin polymer containing crosslinked portions in molds, the pressure being reduced during compression in the mold.

Abstract: Shaped articles for construction and insulation which are water repellent are prepared by dry blending expanded perlite particles and fibers, applying to the resulting mixture a solution of a reactive synthetic organic binder in a low boiling organic solvent. The binder is capable of being cured at ambient temperatures and of reacting with hydroxyl groups present in the perlite and fibers to provide the articles with water repellent properties. The mixture containing binder is formed into the desired shape, e.g. panels, solvent is removed and the binder is cured at substantially ambient or slightly higher temperatures.

Abstract: A method for molding a protective pad or the like, and which includes a convex mold surface having a plurality of perforations therethrough, and a cooperating concave mold surface also having a plurality of perforations therethrough. The two mold surfaces are mounted for relative movement with respect to each other and such that the concave mold surface initially faces upwardly to receive the molding material therein, and then is inverted and translated downwardly into face to face relationship with the convex mold surface. The apparatus includes a vacuum system for drawing a partial vacuum beneath the concave mold surface to maintain a predetermined distribution of molding material on the concave mold surface during the movement thereof, and means is provided for introducing steam into the mold cavity to cure the molding material.

Abstract: Disclosed is a process for manufacturing elastic floor covering boards comprising a lower, water-permeable layer of natural or synthetic rubber particles bound together by an adhesive and a cover layer of non-woven synthetic textile fibers, which process comprises placing into a mold the cover layer of non-woven synthetic textile fibers, impregnating this layer with a resilient, heat-curable adhesive, placing the particles of natural or synthetic rubber which are likewise impregnated with said adhesive on top of the fibrous layer and subsequently compressing both layers in the mold at a temperature below 100.degree.C. and at a pressure of from 40 to 100 metric tons per square meter until the adhesive is cured. Advantageously, a woven reinforcing layer is interposed between the two layers prior to molding to provide an exceptionally strong and stable product.

Abstract: There is disclosed the preparation of polymer composites with porous cellulosic materials, such as wood. The process for forming such a composite involves impregnating the wood with a polymerizable complex of a monomer combination such as a complex of maleic anhydride and styrene. The polymerization is uncatalyzed -- i.e., it is conducted without employing conventional means for inducing polymerization of monomers in wood, such as high-energy radiation or the thermal decomposition of a chemical free radical precursor. There is also disclosed a solid, stable complex of styrene and maleic anhydride.

Abstract: Manufacture of molded articles of foamed ethylene copolymers containing, attached to the polymer chain, substituents having Zerewitinoff-active hydrogen atoms, and a binder mix containing isocyanate groups, wherein the components are mixed and the mixture is compressed in molds to from 80 to 20% of its original bulk volume and is cured under pressure.

Abstract: Method of preparing an insulated negative buoyancy conduit wherein a jacket is placed around the conduit and an insulating material comprising a porous filler and a resin-forming composition is positioned in the annulus between the jacket and the conduit.