Abstract: The present invention concerns a process for the preparation of foam-in-fabric articles useful in furniture and automotive applications such as car seats, arm seats and head rests. According to the present invention a flexible or semi-flexible foam formulation is frothed with a non-reactive gas when poured onto a foam hacking of a composite cover, and allowed to rise and cure.

Abstract: A method for the manufacture of paper faced foam which comprises (a) applying a foam-forming mixture to at least one advancing cellulosic sheet or composite thereof with an air- and/or moisture-impermeable material, the cellulosic sheet (i) being impregnated with cured polyisocyanate, (ii) being sufficiently flexible for unwinding from a roll for conveyance along a production line and (iii) having a moisture content which does not exceed about 10 percent and is evenly distributed throughout the cellulosic sheet, and (b) foaming and curing the faced foam-forming mixture.

Abstract: Air is blown into filter tow during or immediately after the application of plasticizer; this foams and distributes the plasticizer in the tow. Air may be delivered from a porous plate closely adjacent to the path of the tow or from nozzles in an air injecting unit. Alternatively air may be used to foam plasticizer at a location remote from the tow and foamed plasticizer subsequently conveyed to and into the tow by a roller.

Abstract: A composite fabric structure comprising a plurality of warp and fill fibers or yarns forming a fabric substrate which is impregnated with a matrix material which contains a plurality of cells which impart compressibility to the fabric substrate. This fabric may be used, for example, in a composite structure for use with one or more additional layers or coatings. Articles which may be formed from the composite structure include gaskets, packing materials, flexible diaphragms or printing blankets. In the printing blankets, one or more of a vulcanized rubber layer, a fabric layer and a compressible layer may be included.

Abstract: The disclosed method relates to the formation of a relief pattern on the surface of a shaped object through the expansion of an expandable ink. The ink is applied on a support web and then dried. A varnish which polymerizes under UV radiation may be applied on the printed, dried support web. The printed, dried, and possibly varnished, support web is then rolled in to a coil. Afterwards, the coiled web is transformed into the desired shaped objects, such as filled and closed packages or security documents. The relief pattern may then be formed upon the surface of the object by irradiating the expandable ink. In particular, a laser beam may scan the surface of the object to form the relief pattern.

Abstract: A moisture-permeable waterproof fabric having a resin layer formed on at least one surface thereof, wherein the resin layer is composed of a mixture comprising a product obtained by reacting a urethane prepolymer having isocyanate terminals with an N-carboxyamino acid anhydride and an amine, and a polyurethane having a 100% modulus of at least 40 kg/cm.sup.2, the amount of the resin product contained in the resin layer is 12.9 to 85.3% by weight of total solid resin, and the amount of the urethane/amino acid copolymer contained in the resin layer is 0.9 to 9.0% by weight of total solid resin. The fabric has both an excellent moisture permeability and waterproofness, as well as an excellent abrasion resistance and washing fastness.

Abstract: A cover layer, for example applied to a carrier sleeve (3), is volume compressible by being formed as a unitary seamless cover layer (3) of foamed or expanded or blown material resulting in micropores or microcells of less than 0.01 mm, with a percentage of closed or individual cells to total cells being greater than 50%. This cover layer will have a bounce-back or rebound elasticity of greater than 95% and preferably has a thickness of between about 1 to 5 mm. It may be covered with a polyurethane or rubber based outer cover layer of, for example, about less than 0.5 mm thickness. The cover layer is applied by providing a base substance which is made thixotropic, stirring it and applying it in liquid form as a spiral stripe on a rotating and axially moving cylinder (5), the material being free foaming and curing as it is being applied, and when still in spreadable and somewhat flowable condition to form a uniform seamless cover layer which includes individual, unconnected micropores or microcells.

Abstract: Certain fatty acid amides can be included in plastic skin clad polyurethane formulations to increase adhesion between the plastic skin and the polyurethane. These adhesion improvers can decrease or prevent blister formation in plastic skin clad polyurethanes. Additionally, the adhesion improvers can compatibilize certain extenders with base polyols and improve mold release properties.

Abstract: Alkali corrosion resistant coatings and ceramic foams having superfine open cell structure are created using sol-gel processes. The processes have particular application in creating calcium magnesium zirconium phosphate, CMZP, coatings and foams.

Abstract: A water-blown polyurethane foam is provided between two substrates in foamed-in-place applications such as cooling containers. The water-blown polyurethane foam is made dimensionally stable at low densities by adding lithium salts of a 2 to 24 carbon atom carboxylic acid to the polyol component. The dimensional stability of the foam at the low densities further results in raw material savings.

Abstract: A water-based coating composition and methods of making and using the same are disclosed. The composition includes a halogenated resin, a polyol, a surfactant, and an amine. It is suitable for coating a variety of substrates including polyolefinic substrates such as polypropylene, and operates without aromatic organic solvents.

Abstract: A stampable sheet shaped-product has a skin layer consisting essentially of a foamable thermosetting resin and formed on and in one or both of surfaces of a sheet-like open cell plastic foam. Optionally, a facing material layer of a proper material may be formed on one or both of surfaces of the skin layer. Such stampable sheet shaped-product is produced by applying a composition consisting essentially of a foamable thermosetting resin onto one or both of surfaces of a sheet-like open cell plastic foam, so that the one or both surfaces is or are impregnated with the composition. Optionally, a proper facing material is placed on one or both of the surfaces, and the resulting material is subjected to a hot pressing. Alternatively, the stampable sheet shaped-product may be produced by a process including a thermal treatment step interposed between the above-described applying and hot-pressing steps.

Abstract: An enhancement of the bulk and hand of carpeting and carpet fiber is made by treating with a terpolymer, particularly the terpolymer of (a) phenyl vinyl ether, (b) 2-(4-hydroxymethyl-phenoxy)ethyl vinyl ether, and (c) maleic anhydride.

Abstract: A method for producing a polyolefin foam sheet which includes heating a foamable base sheet comprising a polyolefin resin, a foaming agent, and a resin varnish. The resin of the varnish is selected from the group consisting of rosin, cumarone-indene resin, phenolic resin, alkyd resin, and shellac resin.

Abstract: A composite material having a substrate and an expanded, cured layer of an epoxy resin composition which is provided over a surface of the substrate and in which a major portion of the cells are present in a location adjacent to the interface between the substrate and the expanded layer and substantially no cells are present on the top surface portion of the expanded layer. The epoxy resin composition includes an acid anhydride curing agent and an alkali metal carbonate blowing agent. The composition is coated over the substrate and the coating is heated to sure and expand the composition while maintaining the top surface of the coating below the expansion temperature.

Abstract: A coated textile material, particularly for use as a durable filter fabric, is made from a textile substrate, such as a woven fabric, having a microporous coating of an elastomeric fluorocarbon polymer. The substrate may be formed from aramid or polyphenylene sulphide or glass fibres. The elastomeric polymer may be a vinylidene fluoride pentafluoropropene tetrafluoroethylene terpolymer. The microporous coating may be applied as a formed aqueous emulsion which is dried and mechanically crushed.

Abstract: A closed cell, rigid, polymer foam comprising the reaction product of a polyisocyanate and an isocyanatereactive compound in the presence of (a) a foaming agent, (b) at least about 2 percent by weight of carbon black, based on the weight of the polymer in the foam, and (c) a capped polyoxyalkylene compound which helps bring about a uniform dispersion of the carbon black throughout the foam so that the aged k-factor of the foam is below the aged k-factor of the corresponding unfilled foam.

Abstract: The invention concerns a method of using constrained layer sound damping. A composition and a laminated structure are provided for the reduction of noise coming from housings such as oil pans for automobiles. The composition comprises a rubbery polyurethane, an olefin polymer, and a filler. The laminated structure comprises the housing, the composition, and a sheet metal liner. The composition contains a blowing agent which is activated to provide a single unitary structure which dampens noise. The polyurethane and olefin polymer are thoroughly intermixed with each other, but maintain their separate identities in the blend.

Abstract: A process for the manufacture of a rigid, closed-cell polyisocyanurate foam from a foam forming mixture comprising an organic polyisocyanate, a polyol, a blowing agent, and a catalyst, utilizing a polyester polyol as the sole polyol, and chlorodifluoromethane or a mixture of chlorodifluoromethane and at least one co-blowing agent as the blowing agent.

Abstract: Polyol blend compositions are provided containing a polyester polyol, especially an aromatic polyester polyol, a compatibilizing block copolymer of ethylene oxide and at least one other alkylene oxide having three or more carbon atoms in the molecule, the block copolymer being terminated by ethylene oxide blocks, and optionally other polyols. The blends are miscible with halohydrocarbon blowing agents such as trichlorofluoromethane and suitable for reaction with polyisocyanates to give polyisocyanurate and polyurethane foams.

Abstract: A polyurethane foam comprising a convolution of connected passages and a three dimensional vesicular, porous surface structure, substantially without an outer layer skin is described. An absorbent article is further described comprising a substrate and at least a single layer of the polyurethane foam. The process to produce the polyurethane foam comprises the steps of:(a) coating a substrate with a reaction mixture capable of reacting to form a polyurethane foam;(b) immersing the coated substrate into a liquid bath comprising water and a catalyst, for a time period sufficient to effect reaction of the reaction mixture; and(c) removing the coated substrate from the liquid bath.

Abstract: Polyurethane-backed substrates such as attached cushion carpeting are prepared from a polyurethane forming composition based on a soft segment prepolymer of MDI or an MDI derivative. The use of the prepolymer provides a backing having good strength properties and good resiliency.

Abstract: A process is disclosed for imparting fire retardancy to upholstery fabrics formed principally of polypropylene fibers and involving the use of known fire retardant compositions comprised of a mixture of bromochlorinated paraffin and antimony oxide. The exceptional fire retardancy of the known composition is realized without imparting to the fabric an oily surface characteristic by further incorporating into the mixture a substantial quantity of metal hydrate, such as aluminum oxide trihydrate, in the form of a fine powder. The aluminum oxide trihydrate, in addition to having some fire retardant characteristics of its own, provides an enormous surface area for adsorption of the oily composition forming the primary fire retardant material. This new composition, advantageously in the form of a foam, is applied only to the back surface of the fabric. Two major advantages are realized: First, the oily composition is isolated from the front surface of the fabric.

Abstract: A microporous ceramic membrane comprises a porous support and a microporous layer firmly bound to each other, with a sharp geometric transition between the support and the microporous layer, the microporous layer being free of pin-holes. The microporous membrane has a predetermined average pore diameter and it is suitable for microfiltration. The membrane can comprise further microporous layers making it suitable for ultrafiltration and hyperfiltration. The membrane can be prepared by suspension coating of a support, whereby the support and/or the suspension are pretreated in order to lower temporarily the affinity between the support and the suspension.

Abstract: A method for suppressing dust in grain handling includes applying an edible foam so that it penetrates the grain to reach the dust particles.

Abstract: A method for producing an air-permeable adhesive tape comprising a substrate and a porous adhesive layer formed on said substrate is provided. The method comprises the steps of: forming a layer of a solution on a substrate, said solution containing an adhesive material in an organic solvent; applying water drops on said layer of said solution while said organic solvent remains in said layer, thereby allowing water drops to sink into said layer, the diameter of said water drops being in the range of 10 to 1000 .mu.m, and the total amount of said water drops applied onto the surface of said layer being 5 to 200 g/m.sup.2 ; evaporating said organic solvent contained in said layer of the solution, thereby forming an adhesive layer that contains said water drops; and evaporating said water from said adhesive layer, thereby forming communicating pores extending from the external surface to the inner surface of said adhesive layer.

Abstract: Disclosed are vulcanized rubber articles of foamed type and non-foamed type which are prepared by vulcanizing a vulcanizable and foamable (or a vulcanizable) molded product made of a chlorinated ethylene/.alpha.-olefin copolymer rubber, chlorinated polyethylene or chlorosulfonated polyethylene, said vulcanizable and foamable (or vulcanizable) molded product having been surface-treated with a coating solution containing at least one compound selected from alkylammonium halide, alkylphosphonium halide, amine having an acid dissociation constant (pKa) of not less than 10 and amine salt having an acid dissociation constant (pKa) of not less than 10. Also disclosed are processes for the preparation of the vulcanized rubber articles of foamed type and non-foamed type.

Abstract: A method for suppressing dust during grain handling and storage, using small bubble foam created from an edible foam-producing surfactant.

Abstract: A method for manufacturing a heat transfer surface and the surface so manufactured. The porous surface is produced by flame spraying a metal substrate with a mixture of metallic and nonmetallic powder particles. The surface is then heated, causing the nonmetallic powder particles to oxidize into gases which diffuse from the surface, leaving voids where the nonmetallic powder particles were located. The voids provide nucleate boiling sites for a liquid being heated by the surface.

Abstract: A magnetic recording medium comprising a substrate and, formed thereon, a magnetic layer comprised of magnetic particles bonded to each other with a thermosetting binder can be improved with respect to the durability by forming a number of fine pores in the magnetic layer and impregnating the fine pores with a lubricant. Particularly, when the fine pores have a diameter of 0.2 .mu.m or less and a rate of the fine pore in area of 3 to 30%, the durability can be improved while maintaining the noise during the recording and reproduction of information on a low level. In preparing the magnetic recording medium having such fine pores, it is preferred that an easily thermal-decomposable additive, such as polyalkylene oxide, be added to a magnetic layer forming paint.

Abstract: A thermoplastic or thermoset article, a porous sheet, a paint composition, and a synthetic leather which are characterized with a memory shape or a healable characteristics comprising a polyurethane resin obtained by reacting a polyisocyanate and aromatic and/or alicyclic polyol is disclosed. The polyurethane comprises at least 15% by weight in total of a ring component derived from the above polyol.The original (memorized) shape of the article or the porous sheet is reshaped into another desired form below 130.degree. C., and locked into below 40.degree. C. Those material can be reverted back to their original shape by heating above 40.degree. C. The memorized shape as an original shape of the thermoplastic article or the porous sheet can be changed by maintaining it in a desired shape at a temperature 130.degree..about.230.degree. C.When the paint or the synthetic leather is scratched or creased to its surface, they can be healed by heating above 40.degree. C.

Abstract: Expandable foam which includes a foamable polyvinylchloride (PVC) base resin combined with a glutarate ester plasticizer and stabilizing agents. The compound is cast on a release liner and heated to expand the compound into a foamed state. The resulting foam when coated with adhesive is particularly useful in adhering to plastic materials.

Abstract: The present invention provides for a process for preparing hollow polymer latexes by a one stage emulsion polymerization. The first step invloves introducing an effective amount of a first charge of a organic phase to an aqueous phase. The first charge of the organic phase comprises monomer which is vertually insoluble in the aqeuous phase and an inert-nonpolymerizable hydrocarbon. The polymer formed from polymerizing the monomer is virtually insoluble in the hydrocarbon, the hydrocarbon is virtually insoluble in the aqueous phase and the monomer is miscible with the hydrocarbon. The monomer is polymerized to produce a low molecular weight polymer such that the low molecular weight polymer will phase separate from the organic phase and conentrates at the surface of the introduced organic phase forming a low molecular weight polymer phase.

Abstract: A lightweight composite material is disclosed which comprises three-dimensionally arranged fibers of at least 50 mm length provided in a thermoplast matrix. The thermoplast matrix is thermally treated to form cavities within the matrix.

Abstract: This invention relates to a process for the manufacture of polyurethane foams which exhibit a reduced tendency to stain vinyl films with which they are in contact, such as are produced for use in automobile interiors.

Abstract: A multi-layer conductive article and method of making same wherein the article has a first layer of an organic polymer having a volume resistivity of between about 10.sup.7 and 10.sup.12 ohm-cm, a second layer, preferably in direct physical and electrical contact with the first layer of a conductive polyurethane having a surface resistance on the order of 100 to 900 ohms/square and a third layer in direct physical and electrical contact with the second layer of an organic polymer having a volume resistivity of 10.sup.7 to 10.sup.12 ohm-cm so that the article is capable of dissipating static electric charges which are impressed thereupon. The first and third layers are preferably formed of polyvinyl chloride, while the third layer can be expanded to a foam. Also, the article can be laminated to a fabric sheet to form a conductive fabric.

Abstract: A method of manufacture for producing a decorative laminate which exhibits through-color printing is provided in which a layer of absorptive PVC resin particles of substantially only one particle thickness is printed with, for example, three differently colored vinyl plastisol printing inks. The decorative article is useful as a floor covering.

Abstract: Plastic foam is applied by pushing it through or spreading it with notched spreader onto support to which it adheres and sets, forming a foam cushion in stripes that can be very close together or quite far apart. Stripes can be straight or wavy and support can be paper or plastic film such as polyethylene terephthalate. Foam can contain or be coated with antistat and/or volatile corrosion inhibitor and can be made of heat-sealable plastic or can be cold sealed by adhesives such as cohesive-nonadhesive top coatings.

Abstract: The invention relates to a cellular cellulosic wiping material consisting of a cellular cellulosic substrate covered on at least one side with an expanded latex foam obtained from an aqueous latex composition having a viscosity of between 2500 and 3500 mPa.s, measured at 20.degree. C. under 65% humidity, and giving a foam density of between 250 and 400 g/l.

Abstract: Adhesive tapes comprised of a curable composition comprising: (A) at least one polymer selected from the group consisting of ethylene/alphaolefin copolymer, ethylene/alphaolefin/nonconjugated polyene terpolymer, polyacrylate, polymethacrylate, polyisoprene, polyacrylonitrile, polymethacrylonitrile and polybutadiene, said polymer having a number average molecular weight of between about 500 and about 14,000; (B) an effective amount of curative having an activation temperature of at least about 100.degree. C; and (C) (optionally) a blowing agent possess admirable qualities for use as insulating compositions. Also disclosed are composites comprised of a substrate having cured insulating tape compositions adhered thereto.

Abstract: Substrates having successive layers of a cellular polyurethane and a noncellular polyurethane are prepared using certain siloxane-polyether block copolymers in the noncellular polyurethane formulation. The use of the block copolymer reduces or eliminates the formation of a bubble line at the interface of the polyurethane layers, thereby improving physical and cosmetic properties of the carpet.

Abstract: A method is provided whereby the setting time of a spray applied hydraulic cement-based fireproofing composition is decreased substantially while improving the yield of the composition. An acidic set accelerating agent is thus introduced into the composition effectively after conveyance through the system and in close proximity to the spray nozzle. At least about 0.5% of a basic material is provided which evolves a gas upon reaction with the accelerating agent. The invention also relates to the sprayable fireproofing compositions resulting from operation of the method.

Abstract: The invention teaches the treatment of a porous substrate such as a textile material by treating the substrate with a foam, the substrate prior to treatment having a moisture content of up to 130% of the transit water content, forcing the foam into the porous substrate to enable foam transit through said substrate, causing or allowing foam collapse both at the surface interface and at the interior interface and terminating the treatment by removing or deactivating the reagent.

Abstract: Syntactic foam graphic arts print media are provided which are particularly suitable for application to a substrate using high speed mechanical printing processes. The invention involves adding to a basic print medium a minor amount of pre-expanded, nonfriable, thermoplastic polyvinylidene chloride based microspheres substantially heat stable between about -20.degree. C. and 175.degree. C., having a particle size to about 10 to 100 microns in diameter, to produce syntactic foams having unlimited shelflife stability. The print media thereby produced may be applied to any known substrate in any desired graphic pattern.

Abstract: Enhanced hiding power for opacifiers in paints, inks, and other coatings is provided by employing the opacifiers, such as TiO.sub.2, ZnO, talc, CaCo.sub.3, and the like, adhered to or embedded in the surface of thermoplastic microspheres. The composite opacifier-microsphere material is readily formed with a preselected specific gravity, so that there is little tendency for the material to separate. In addition, the composite behaves in the coating as a opacifier-air interface, having a very high difference in refractive indices, and exceptional hiding power. The high volume to weight ratio of the composite affords very attractive economic advantages, effectively reducing the weight proportion of opacifiers required in the formulations, and other related advantages.

Abstract: Enhanced hiding power for opacifiers in paints, inks, and other coatings is provided by employing the opacifiers, such as TiO.sub.2, ZnO, talc, CaCO.sub.3, and the like, adhered to or embedded in the surface of thermoplastic microspheres. The composite opacifier-microsphere material is readily formed with a preselected specific gravity, so that there is little tendency for the material to separate. In addition, the composite behaves in the coating as a opacifier-air interface, having a very high different in refractive indices, and exceptional hiding power. The high volume to weight ratio of the composite affords very attractive economic advantages, effectively reducing the weight proportion of opacifiers required in the formulations, and other related advantages.

Abstract: A method that includes the step of spraying a foamed hot melt adhesive from the discharge nozzle of a spray gun under such conditions that elongated strands of foamed hot melt adhesive are formed in an open weave film of spider web configuration which is deposited on a first substrate. A second substrate can then be bonded to the first to form a product. Alternatively, and before the second substrate is bonded to the first, a powder, e.g., a hygroscopic powder, can be deposited within the open areas of the film's spider web configuration to form a laminate product with a special enhanced characteristic, e.g., moisture absorbency.

Abstract: A paint peeling composition contains as effective components (1) a water-insoluble high polymer compound such as unreamelamine resin, chloroprene latex, EVA latex, or polystyrene; and (2) a substance containing as an effective component thereof, a component capable of forming a group of minute bubbles in an applied coating per se, e.g., a foamed or unfoamed hollow matter, or a chemical system capable of reacting to form a gaseous foam.

Abstract: A multilayered, breathable, waterproof fabric and a process for manufacturing this fabric have been disclosed. The invention consists of a fabric substrate first coated with an adhesive foam formed from a fully reacted polymer such as polyvinyl chloride, polyurethane, acrylic, polystyrene or mixtures thereof. A microporous membrane structure is formed upon the adhesive foam from thermoplastic polymers. The microporous membrane provides the coated fabric with the properties of waterproofness and breathability. A continuous film formed from acrylic, polyvinyl chloride or polyurethane latexes, is coated on the surface of the microporous layer. The function of this continuous film is to protect the delicate microporous membrane. The process of manufacturing the waterproof and breathable fabric utilizes economical coating technology rather than costly laminating techniques used in the prior art of manufacture of breathable fabrics.

Abstract: A storage stable polyester polyol mixture is prepared by(a) digesting polyethylene terephthalate with a digesting medium comprising a polycarboxylic acid component-containing polyol derived from a digesting polycarboxylic acid component and a digesting polyol component to form a digested polyol mixture and liberate ethylene glycol from said polyethylene terephthalate, and(b) distilling from said digested polyol mixture the amount of liberated ethylene glycol sufficient for improved storage stability of the mixture.The polyester polyol mixture is useful in the preparation of cellular foam materials, particularly polyisocyanurate and polyurethane foams.