Abstract: This invention consists of a method to produce a composite wet-press papermakers felt by which one side of a textile base fabric can be given a uniform, smooth coating of polymeric resin particles fused together to provide a porous, elastic surface. Its distinguishing feature is the application to the textile base fabric of a homogeneous foam, composed of resin particles, a binder material, and a solvent, in a uniformly thick coating. The textile base fabric is then subjected to heat, which evaporates the solvent and fuses the resin particles to each other and to the fabric base.

Abstract: Polyurethanes which have been prepared or combined with another material are made by combining or applying a polyurethane-forming reaction mixture or polyurethane to another material such as a PVC foil or textile. The polyurethane-forming mixture or polyurethane is made up of an organic polyisocyanate, a high molecular weight isocyanate reactive material, a catalyst and a stabilizer against thermolysis and contact discoloration. The required stabilizer is an epoxide having an epoxide equivalent weight between 57 and 10,000. Other additives commonly used in polyurethane chemistry such as blowing agents, chain extenders and surfactants may also be employed. The polyurethane composites thus produced are characterized by improved thermal stability and reduced discoloration.

Abstract: A thermally insulating structural laminate comprising a core of rigid plastic foam having two major surfaces, at least one of the major surfaces of the foam being attached to a facer comprising a fribrous sheet having at least one layer of an air- and moisture-impervious polymer disposed on the inner surface thereof and interposed between the fibrous sheet and the foam, the oxygen transmission of the polymer being a value of less than about 1 cc/100 in.sup.2 -24 hrs-atm sufficient to make the facer substantially impervious to the passage of air and water vapor, resulting in the long-term preservation of insulation value.

Abstract: Porous metal deposits especially useful in gas turbine engines as compressor seals are made by thermal spraying a metal powder and a meltable polymer powder mixture, wherein the spraying process and a subsequent polymer removal process are chosen to produce less than 30 weight percent oxide. Oxide contents of 4-25% are typical. When 86 weight percent nichrome is sprayed with 14 weight percent polymethylmethacrylate the polymer is removed by heating in air to about 315.degree. C. The resultant porous structure will have an oxide content of 7% and an apparent density of about 32%. A meltable polymer additionally produces a more desirable pore structure.

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.

Abstract: A polyester polyol suitable for use in a foam-forming reaction with an organic polyisocyanate in the manufacture of a polyurethane or polyisocyanurate foam, the polyester polyol being the reaction product of polycarboxylic acid and polyol components, wherein the polyol component solely or partially comprises an oxyalkylated polyol selected from the group consisting of(a) at least one oxyalkylated polyol having at least one primary and at least one secondary hydroxyl group, and(b) an oxyalkylated polyol mixture containing at least one oxyalkylated polyol having at least one primary and at least one secondary hydroxyl group.

Abstract: Aluminum coated ferritic base metal foil formed by cold reduction of hot dip aluminum coated ferritic steel strip containing from 10% to about 35% chromium, up to 3% aluminum, and up to 1% silicon, the foil having a ratio of aluminum coating thickness on both sides to base metal foil thickness of at least 1:10, with at least 4% by weight total aluminum. The method of production includes heating the foil in an oxidizing atmosphere within specified temperature and time limitations to provide a porous surface having a thin layer of aluminum oxide. The foil is adapted for fabrication into monolithic support structures for catalytic converters for internal combustion engine exhaust systems.

Abstract: The present invention relates to a poromeric article of manufacture comprising a felt sheet of fibers impregnated with microporous elastomer having a work surface, side surfaces joining the work surface and a support surface joining the side surfaces, wherein a majority of the fibers are oriented primarily transverse to the work surface such that the majority of fiber ends adjacent to the work surface form an angle of between about 45.degree. and about 135.degree. with respect to the work surface, and preferably, wherein the fibers have a uni-directional orientation substantially perpendicular to the work surface. The present invention also includes a plurality of such articles bonded together and oriented such that the work surfaces of adjacent articles are substantially coplanar to form a laminated article of manufacture. Further, processes for making the basic and laminated articles are set forth as other aspects of the invention.

Abstract: A reinforced, anti-fatigue foam floor tile module which comprises first and second resilient foam layers, and in between the foam layers, at a distance of about 55% to 65% of the thickness from the back surface of the mat, is a dimensionally-stabilizing, fibrous, particularly glass, scrim sheet material. The foam floor tile module has a foam density ranging from about 20 to 40 pounds per cubic foot, comprises a substantially closed cell foam and has an embossed face surface having a decorative or non-slip pattern thereon with the foam layer densified under the embossed areas.

Abstract: Rigid polyisocyanurate foams are prepared by (a) bringing together on a continuously advancing conveyor an organic polyisocyanate, a minor amount of a polyester polyol, a blowing agent and, in an organic solvent, a catalyst mixture comprising: (i) a salt of a low molecular weight carboxylic acid selected from the group consisting of an alkali metal salt and an alkaline earth metal salt and mixtures thereof, and (ii) a tertiary amine, the amount of the salt of the low molecular weight carboxylic acid being sufficient and the molecular weight of the carboxylic acid of the salt being sufficiently low to provide a firm foam having a non-friable surface, and (b) foaming the foam-forming mixture.

Abstract: A base web is prepared which has two parallel layers of nonwoven fiber glass webs, each impregnated with a solidified resinous composition and separated from each other by a core layer of an expandable solidified resinous composition which is bonded to the resinous composition used to impregnate the fiber glass webs by a thin integral layer of nonexpandable resinous composition. Additional layers of resinous material, expandable and nonexpandable, and decorative effects may be supported by the base web. The composite web is subjected to heat processing to expand the core layer and other expandable layers that may be present and to fuse the resinous composition used in the construction of the product. The processes are particularly adaptable for the production of shapes such as floor tiles and decorations that employ chemical embossing.

Abstract: A polymeric or plastic coating is provided which protects coated structures by forming an intumescent insulative fire resistant barrier. The coating is formed from the product of mixing an aromatic polyisocyanate, an aromatic polycarboxylic compound and about 1 to about 20% by weight of furfuryl alcohol. The structure to be protected is coated with the product of the mixture and the coating is dried. An intumescent polyimide fire resistant foam is formed when the coating is exposed to a (non-flame) heat source at temperature ranging from about 110.degree. C. to about 140.degree. C.

Abstract: Substrates such as aggregates, particularly for roadbuilding, are coated with asphalt by foaming the asphalt and mixing the hot asphalt foam with the aggregate. The asphalt is foamed by dispersing water in the hot asphalt as to maintain the water in the liquid phase and then vaporizing the water to form the foam structure.

Abstract: Rigid polyisocyanurate foams are prepared by reacting together an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol, the polyol comprising a sufficient proportion of at least one polyoxyalkylene polyol having (i) terminal oxypropylene oxide blocks, (ii) a molecular weight of from about 300 to 3000, and (iii) an average hydroxyl functionality of from about 2 to 5 to form a foamed polyisocyanurate whose gel time is greater than about 70 seconds and friability is less than about 20 percent, as measured by the ASTM C-421 friability test. Laminates of such foams exhibit a high degree of fire resistance, low foam friability and good facer adhesion.

Abstract: A casing for ham and sausage, has a cubic design and provides a buffer effect. Characters and other patterns are embossed on the casing surface. The characters and patterns are made using heat foamed ink, on one surface of a film to be pasted together with another film. The films each have a heat shrinkable property and together form the casing.

Abstract: The present invention relates to a sequential polymerization process for preparing a water-insoluble dispersion of core/shell particles. In one embodiment the process may be employed to produce a particulate dispersion useful in making water-based coating compositions wherein on drying the particulate dispersion serves as an opacifying agent. In another embodiment the process may be employed to microencapsulate a hydrophobic target material, such as a biocide or herbicide.

Abstract: A process for manufacturing surface coverings including the steps of printing a design on a base layer; overlying the printed base layer with a coating of substantially transparent or translucent material; printing a subsequent design using an ink including decorative particles on such transparent or translucent overlying material; and overlaying the ink printed design with a substantially transparent or translucent material prior to subsequent processing, such as heat curing to ensure an effectively fused product of the resulting surface covering. The present invention may include the required processing steps of chemical or mechanical embossing as more clearly hereinafter described.

Abstract: A method of mechanically frothing and casting an aqueous polyurethane dispersion yields a foam which, when rolled, wound or stacked, is self-releasing from the pressure sensitive adhesive layer co-cured therewith. The method includes admixing an aqueous ionic polyurethane dispersion with a stearate stabilizer and an optional aziridine crosslinking agent, frothing and casing the admixture, and co-curing the resultant foam sheet with a pressure sensitive adhesive layer. Before frothing, the polyurethane dispersion contains particles having an average size of less than one micron, and contains between 35 and 70 percent by weight of the polyurethane dispersion, between 13 and 50 percent by weight of a 33 percent by weight dispersion of a stearate salt, and up to 33 percent by weight of polyfunctional aziridine.

Abstract: The present invention relates to coatings which provide fire resistance or fireproofing of an underlying product. In particular, the invention relates to a flexible coating which provides fire resistance by the formation of two stages of fire protection.

Abstract: A polyester polyol mixture is prepared by reacting a polycarboxylic acid component-containing polyol with a terephthalic acid residue, wherein the polycarboxylic acid component has ring units with two ##STR1## groups on adjacent or alternate ring positions, the ring unit content of the polycarboxylic acid component being sufficient for viscosity reduction of the polyester polyol mixture. The polyester polyol mixture is useful in the preparation of cellular foam materials, particularly polyisocyanurate and polyurethane foams, and laminates thereof.

Abstract: A process for the production of bulky, fiber-containing textile sheet material fills a material of loose fibers with a binding agent of an aqueous polymer dispersion containing a foaming adjuvant and puffs it up to a multiple of its original volume by the action of radiofrequency radiation in the range from 30 kHz to 30 GHz. The volume increase is then made permanent by drying. Even cellulosic fibers which formerly matted down when wet can be treated in the stated manner. The puffed textile sheet material is usable as padding for articles of clothing, for sound and heat insulation soft and resilient packing materials, clothing, protective padding and the like, but especially for products which are to absorb liquids to a relatively great extent.

Abstract: A process is disclosed for the preparation of a composite mat having smooth upper and lower faces which composite mat comprises a mat of fibrous material encapsulated within a resinous polymeric gel.

Abstract: Paper sheet or board is externally sized by applying to the surface thereof a rosin-based sizing agent in the form of a foam in the production of which the sizing agent itself acts as a foaming agent. After the foam has been applied to the surface of the paper sheet or board, at least a major proportion of the applied foam is mechanically broken down to provide a substantially uniform distribution of the sizing agent over the surface.

Abstract: An industrial fabric, and particularly a papermakers dryer fabric, is proposed wherein the permeability thereof is reduced by the inclusion of a continuous layer of an elastomeric open-cell foam therein which extends to and is contiguous with at least one surface of the base structure, the base structure comprising a link belt or a woven or knitted fabric.

Abstract: A process for preparing a porous ceramic thin film which comprises applying an anhydrous solution containing an organometallic compound and a multifunctional organic compound to a substrate, and thermally decomposing the compounds. The porous ceramic thin film prepared by the process has pores of not more than 10 .mu.m in pore size, and is useable as for materials of various sensors.

Abstract: A process of preparing a fast reacting, light stable, sprayable or injectable polyester-modified polyurethane polymer reaction product to prepare coatings or molded products, which process comprises admixing and reacting together: a trimerized or biuret aliphatic polyisocyanate, such as a trimerized or biuret hexamethylene diisocyanate prepolymer; a polyamine to react as a chain extender for the prepolymer, such as for example, a diethyltoluene diamine, in an amount sufficient to react substantially with the free NCO groups of the trimerized or biuret prepolymer; an unsaturated polyester subject to cross linking by the use of a metal salt promotor, such as a cobalt salt promotor, and a peroxide initiator; the cobalt salt and the peroxide initiator present in an amount to provide for the curing of the unsaturated polyester.

Abstract: Foam applicators having specific lip configurations and substrate orientation, used for applying foamed treating compositions to substrates, including rapidly moving paper, provide uniform distribution of treating agent onto the substrate.

Abstract: An insole for shoes, with which, after having made a connection, preferably by sewing, between the insole and the shoe upper, a body of polyurethane forming the running sole and/or the foot bed is applied to the bottom side of the insole by foaming operation, consists of a fleece substantially formed of synthetic fibres and having arranged therein a reinforcing insert approximately extending in parallel relation to the upper side of the insole. At least the upper portion of the fleece, which is adjacent the upper side of the insole on which rests the foot, is impregnated with a dispersion or emulsion containing at least 1 percent by weight of hollow microspheres, the thin shell of which consists of a vinylidene chloride copolymer and the hollow core of which contains a gas.

Abstract: Foamable compositions having low concentrations of select foaming agents provide uniform distribution of paper treating agents onto moving paper, including high speed applications, and treated paper having unimpaired properties.

Abstract: Non-oxide refractory foams, possessing controlled permeability and uniformity, are prepared by impregnating an organic polymer foam material with a fluid, particulate slurry of a first refractory material, drying, applying to the dried, impregnated material a second refractory material which has a lower melting point than the first refractory material and thereafter heating, at a temperature sufficient to cause melt infiltration of the second refractory material into the impregnated material, thus producing inert and dimensionally stable composite refractory foams having broad utility as particulate filters or carriers.

Abstract: Polyisocyanurate foams are prepared by reacting together an organic polyisocyanate, a blowing agent, a trimerization catalyst, and a minor amount of a polyol blend comprising(a) about 5 percent to about 95 percent by weight of said blend of an alkylene oxide adduct of an aromatic amine of the formula ##STR1## wherein Z is a divalent aromatic radical, x, x', y, and y' each independently have an average value from about 1 to about 5, and each R is independently selected from the group consisting of hydrogen, alkyl or aryl, provided that the adduct is capped with ethylene oxide units, and(b) about 5 percent to about 95 percent by weight of said blend of an aromatic polyester polyol having a molecular weight of from about 150 to about 5,000. Laminates of such foams exhibit a high degree of fire resistance, low foam friability, high compressive strength, and excellent facer adhesion.

Abstract: A method of preparing a substrate coated with a proteinaceous foaming composition wherein the substrate is coated with the foamed composition and the foamed composition is mechanically disintegrated to form a continuous surface coating upon the substrate. The foamed composition is prepared by ingesting gas into an aqueous medium containing a proteinaceous foaming composition consisting essentially of at least one proteinaceous foaming component selected from the group consisting of vegetable protein hydrolyzate having at least two different chelating sites, egg albumen, and casein hydrolyzate; alkaline earth metal ions, and zinc ions.

Abstract: A method of impregnating a flexible, porous cellulosic sheet material involves passing the sheet through a low viscosity resin and across the resonant vibrating surface and through a cavitated zone in close proximity to at least one completely immersed ultrasonic wave generator, operating at a frequency and radiated power level effective to provide a combination vibratory pressure on the resin and cavitation effect causing degassing and heating of the resin, followed by passing the impregnated sheet through a drying means.

Abstract: A storage stable polyester polyol mixture is prepared by digesting polyalkylene terephthalate, particularly polyethylene terephthalate, with a digesting medium comprising a polycarboxylic acid component-containing polyol, wherein the polycarboxylic acid component has ring units with two ##STR1## groups on adjacent or alternate ring positions, the ring unit content of the polycarboxylic acid component being sufficient for improved storage stability of the digestion product. The polyester polyol mixture is useful in the preparation of cellular foam materials, particularly polyisocyanurate and polyurethane foams.

Abstract: A sheet material adapted for producing pressure sensitive elements includes an electrically conductive net-shaped member having projecting and recessed portions, and an electrically insulating layer in which the net-shaped member is buried such that only the projecting and recessed portions thereof are exposed out of the insulating layer, planar members are further provided on both sides of the insulating layer, while each of the planar members is provided with a resistance layer deposited on a surface thereof facing the insulating layer, so that when a depressing force is applied across the planar members, the resistance layer deposited thereon is brought into contact with the exposed portions of the net-shaped member. A method for producing the sheet material is also defined within the scope of the invention.

Abstract: A matrix coating system and method of manufacture thereof is presented wherein the matrix coating contains chemical blowing agents which permit low pressure molding and also the formation of printing plates having deep relief. The method of manufacture is such that a foamed coating is produced which at molding temperatures is highly compressible at low pressures and which also expands into the relief or nonprinting regions of the pattern plate. The unusually low molding pressures necessary result in less distortion of rubber pattern plates or made from photo polymers. In addition, the combination of high compressibility in appropriate areas, and of volume expansion in relief areas allows the board coating to conform before and during cure to pattern plates of deep relief, so that in the cured state there results a rigid, durable high fidelity mold useful for molding numerous flexographic printing plates.

Abstract: A method for applying a blown polyurethane coating to carpeting or other sheet material. The method includes the step of adding a filler to the polyurethane components to assure that the liquid does not unduly penetrate porous goods. The mixed polyurethane components are then placed in a puddle on the sheet material and leveled to a uniform coating. Steam is passed through the sheet material and the coating to initiate the reaction of the components. The steam also adds water to the coating, so the formulation is such that additional water is needed, and the needed water is added by the steaming. After the polyurethane has completed blowing, and before the polyurethane has cured beyond its plastic state, the foam may be compressed to decrease the thickness. A second sheet of material can be placed over the polyurethane to prevent the polyurethane from adhering to the compressing roller.

Abstract: A substrate, such as a roofing substrate, is protected by coating it with a low density polyurethane foam which is then coated with an essentially non-porous, dense, elastomeric polyurethane layer. The layer is formed by spraying a volatile-free spray of polyurethane precursor reactants onto the surface of the foam and rapidly reacting the precursors.

Abstract: The invention provides a novel silicone-containing curable composition capable of foaming by virtue of the blowing agent contained therein together with a curable liquid silicone composition. The composition is suitable for the water-repellent and waterproof treatment of fabric materials without decreasing the air and moisture permeability of the treated fabric material.

Abstract: Substrates having a backing of fine celled polyurethane foam are prepared by applying to the back of the substrate a frothed polyurethane forming composition containing small amounts of a silicone surfactant having an average molecular weight below about 30,000 which provides the resultant foam with a cell count value of greater than about 16 per 0.0025 square inches and wherein the unfilled, unfrothed liquid components of said polyurethane forming composition obtains a viscosity of greater than 10,000 centipoise in less than 40 minutes at 25.degree. C.

Abstract: A method for the removal of free formaldehyde from textile fabrics which have been treated with formaldehyde derived resins to make the fabrics crease-resistant is disclosed. The process comprises forming a composition composed of a foaming agent, ethylene urea and an appropriate diluent and then foaming this composition to form a stable foam. The foam is then applied to the resin treated fabric in a layer, the foam is collapsed on the fabric to force it through the fabric and then the fabric is subjected to drying and curing conditions. The process is advantageous in that it utilizes relatively small volumes of liquids and thus is energy efficient and environmentally favorable.

Abstract: Tab sealant asphalt adhesive is foamed and then dispensed through a nozzle on asphalt shingle material.

Abstract: A process for manufacturing polyurethane-coated products is disclosed. These polyurethane-coated products are manufactured by press-forming a metal material coated with a lubricant inclusive of a compound having an oxygen-hydrogen bond into a core member of a desired shape and covering necessary portions of the core member a with polyurethane foam or coating formed by reacting the compound with an isocyanate of the polyurethane forming material without degreasing steps, i.e. pretreatments for washing off the lubricant.

Abstract: A dual gloss coating is formed on a substrate by first applying to the substrate a continuous layer of curable polyurethane or PVC plastisol or organosol. After the layer is at least partially cured, a second discontinuous layer of the same or different urethane or PVC plastisol or organosol is applied to selected areas of the surface of the first layer by rotogravure printing, using a rotogravure cylinder having a number of lines per inch sufficient to produce a difference in gloss effect between the discontinuous layer and the continuous layer after complete curing of the layers, and then completing the cure of the layers.

Abstract: A fire-resistant material comprising a network of bonded expanded polystyrene beads having an organic or inorganic impregnant material incorporated in the interstices in the network so as to provide a reticulated impregnant structure which is retained upon destruction of the network of bonded expanded polystyrene beads, for example in a fire, and the structure retained upon removal of the polystyrene. The preferred impregnant material is a layer mineral, especially chemically delaminated vermiculite.

Abstract: Method of continuously treating planar textile structures by applying thereto a treatment medium in the form of foam, which includes subsequently applying underpressure to the planar textile structures at a magnitude at which the foam is completely destroyed without any appreciable flow through the material of the planar textile structures.

Abstract: Liquid treating medium is uniformly applied to a textile workpiece by foaming it, depositing the foam in a confined space atop the workpiece, applying suction to the workpiece from below and thereafter mechanically pressing additional foam into the surface layer of the workpiece.

Abstract: This application discloses open-cell foam coating compositions and open-cell coated fabrics. The foam coating comprises a fabric substrate and a breathable fine cell foam coating adhered to the substrate wherein the foam coating is comprised of an open cell foam polymer lattice and a hydrophobic material which coats substantially all the surfaces of the polymer lattice and renders the breathable foam coating water repellant and waterproof.

Abstract: A heat-insulating paper container having good heat-insulating property which can be prepared easily at low cost is disclosed. The paper container is prepared by heating a paper container comprising a body member and a bottom member, wherein one surface of at least the container body member is coated or laminated with a thermoplastic synthetic resin film and the other surface of the body member is coated or laminated with the same or different thermoplastic synthetic resin film or an aluminum foil, to thereby foam the thermoplastic synthetic resin film and form a heat-insulating layer on at least one surface of the container.

Abstract: The present invention provides a method for manufacturing a fabric-type artificial leather, wherein a nonwoven fabric is formed by using a dry method to join together hydrophobic fibers. The fabric so formed is densified by needling and the activation of shrinking forces. It is then impregnated with a mixture of a heat sensitive elastomeric bonding agent, powdered barium sulfate and a compound that reacts with acid to form a gas. The impregnated fabric is then exposed to a heated, acidified liquid which triggers coagulation of the bonding agent and liberates a gas formed by reaction of the acid and acid-reactive compound. The resulting solidified fabric is then washed, dried and ground-over on at least one side to produce a nap. Finally, the fabric is intensively fulled.