Abstract: A foam article comprising a plurality of parallel foam strips, the foam strips being integral with and secured to adjacent strips by spaced short lengths, the spacing between successive securing lengths ranging from about 80 to 260 mm. The strips are in the form of a roll, the length of the securing lengths is from about 1 to 5 mm and the width of the strips is from about 6 to 25 mm. Advantageously the strips are elliptical in cross-section, formed of polyurethane and carry a light application of adhesive of one layer of the roll to the next.

Abstract: A thermal insulating device for use as the exterior coating of a space vehicle which consists essentially of a rigid carbon-carbon foam having an elastomeric foam bonded to the rear surface thereof and having a chemically vapor deposited coating applied to the front and side surfaces thereof.

Abstract: A water-based embossing composition for use in chemically embossing a foamable polymeric material having a blowing agent incorporated therein comprising: (A) a film-forming resin dissolved or dispersed in said aqueous composition; (B) a modifier which is effective in modifying the activity of the blowing agent comprising particulate solids which are substantially insoluble and uniformly dispersible in the liquid medium of the embossing composition and which have an average particle size of no greater than about 100 microns, said modifier being present in the composition in an amount of at least about 3 wt. %; and (C) optionally, a colorant or a softening agent for the modifier solids or a mixture thereof.

Abstract: The car interior member and its molding method are offered to improve recycling and to reduce the number of parts. The instrument panel 10 as the car interior member is made by molding integrally the core member 11 organizing the main structure of certain area of car interior and the functional member 12, 13, 14 having particular function and attached to the core member 11 by the blow molding. On the occasion of then, the number of parts can be more reduced when the base layer arranging the most inside and the foamed layer and the surface layer arranging outside of the base layer are effected by the multilayer blow molding in case of the instrument panel 10 formed with the multi-layer construction.

Abstract: The invention describes a foamed material panel, in particular a shaped part composed of one or several foamed material panels. These panels consist of a soft and, if appropriate, elastic foamed material comprising cellular webs and/or cellular walls that are permanently deformed at least in some areas. A central area of the foamed material panel is plastically deformed to a higher volumetric weight than at least one intermediate area of the formed material panel.

Abstract: A product having a textured surface thereon (and its process of manufacture) is disclosed wherein the textured surface is obtained by relieving the stress in pre-stressed polymeric chips that have been distributed as a single layer throughout a polymeric layer superimposed on a substrate.

Abstract: A self-supporting convex cover for spacecraft hardware is described. In the preferred embodiment, the cover is made of a laminated material. Strips of material are inserted into the laminate in a channel shape, such that sufficiently rigid box beam structures are formed in a pattern to hold the convex shape. Ribs of foam may be placed between a layer of the laminate and the strips of material to provide the channel shape. The cover is attached to the spacecraft hardware by one or more drawstrings which are laced through the perimeter of the cover. With appropriate materials, the resulting assembly is light, inexpensive, easy to assemble, and transparent to radio frequencies, yet sturdy enough to maintain its shape during launch.

Abstract: A shaped particle for use as a loose fill material to surround and cushion an article packaged within a container includes a strip of stiff yet flexible material having a several convoluted regions for absorbing impact energy. The convoluted regions are adapted to compress together to absorb mechanical energy in response to a mechanical force such as would be encountered during an impact and act as resilient springs or bumpers to protect the article. The shaped particle has characteristics that prevents nesting and facilitates interlocking to prevent migration. The invention also provides a method for making embodiments of shaped particles according to the invention.

Abstract: This invention relates to a method for molding composite automotive trim members having a layer of a first material and a backing member made of a second thermoplastic material. The first material is introduced to the mold in the form of an elastic sheet having a show surface. This sheet is placed in the mold and the second thermoplastic material is subsequently injected into the mold cavity. This causes the second thermoplastic material to bond to one side of the sheet and forces the show surface on the opposite side of the sheet into abutting engagement with the mold surface, thereby creating the trim member. The second thermoplastic material forms a backing member that provides structural support for the sheet. The sheet forms an outer layer for the trim member. Note that the show surface on the sheet remains intact during and after injection and therefore provides a show surface for the trim member.

Abstract: This invention is directed to a resilient, flexible surface covering that has a wear surface that meets the highest standards of stain, mar, scuff, and soil resistance and a method of making the same. The improved resilient surface covering comprises (a) a resilient support surface; and (b) a resilient wear surface adhered to the resilient support surface, the resilient wear surface comprising an underlying wear layer base coat and an overlying wear layer top coat adhered to the wear layer base coat, the wear layer base coat comprising a flexible, thermoset, polymeric composition having a flexibility such that the wear layer base coat passes a 1 inch mandrel diameter face out mandrel bend test when applied at a nominal dry film thickness of 1.0 mil over a flexible 80 mil underlying substrate, the wear layer top coat comprising, a hard, thermoset, UV-curable blend of acrylic or acrylate monomers, the wear layer top coat having a glass transition temperature of greater than 50.degree. C.

Abstract: Multi-layered films are disclosed which have a barrier layer and at least one seal layer. The seal layer is made with a copolymer of ethylene and ethylenically unsaturated ester. The seal layer is radio frequency (RF) sealable and the seal layer has an anti-block matted surface. The matted seal layer surface permits a lower slip and anti-block additive level which improves RF sealing and heat sealing.

Abstract: Disclosed is a method of insulating a surface or enclosure by applying to the surface or enclosure a polymeric foam structure of a polymer material and carbon black. The carbon black is generally uniformly dispersed in the polymer matrix in the form of discrete particles substantially free of agglomeration. A preferred carbon black is thermal black. The carbon black provides a number of advantages over those previously employed commercially. Further disclosed is a process for making the foam structure. Further disclosed is an extruded, insulative foam structure of the type described above.

Abstract: A resilient panel comprising a first sheet having a plurality of pockets each having a resilient foam element located therein. Each of the foam elements is sized to substantially conform with the size of the pocket within which it is located. A second sheet is arranged over and attached to the first sheet so as to encapsulate the foam elements within the pockets in an uncompressed manner. This arrangement allows the panel to maintain a compression potential equal the entire compression range of the elastic elements. It also allows individual foam elements to be compressed without affecting adjacent foam elements.

Abstract: The present invention involves a fabric craft article and an associated method and kit for producing making the same. The disclosed fabric craft article comprises a substrate having a design depicted in the surface thereof by scored channels or grooves extending into the surface of the substrate, which design is defined by discrete design sections each having a predetermined shape and size; a discontinuous padding layer carried by the substrate; and in turn a discontinuous fabric layer which secures the padding layer to the substrate. The padding layer is defined by discrete padding sections, each of which corresponds to the predetermined shape and size of a different one of the design sections.

Abstract: A water-based embossing composition for use in chemically embossing a foamable polymeric material having a blowing agent incorporated therein comprising: (A) a film-forming resin dissolved or dispersed in said aqueous composition; (B) a modifier which is effective in modifying the activity of the blowing agent comprising particulate solids which are substantially insoluble and uniformly dispersible in the liquid medium of the embossing composition and which have an average particle size of no greater than about 100 microns, said modifier being present in the composition in an amount of at least about 3 wt. %; and (C) optionally, a colorant or a softening agent for the modifier solids or a mixture thereof.

Abstract: A compressible, flexible, resilient wedge shaped sealing strip for maintaining conforming sealing engagement with opposing spaced walls of various structures and sealing joints therebetween has a flexible resilient hollow body with an outer layer of foam both made of a material having the ability to recover from a compressed state and thus continuously exert and force the sealing strip into sealing engagement with the opposing spaced walls of the structure.

Abstract: Flat, rectangular composite insulation comprising two dissimilar insulating materials on a separate flexible backing material is described. At least one of the two dissimilar materials is rigid. V-grooves are formed in the dissimilar materials extending from the surface of the insulation opposite of the flexible backing up to, but not through the flexible backing. The V-grooving permits the rigid composite insulation to be fitted to a curved surface such as a pipe.

Abstract: An expandable structural member comprises two outer skin members, a plastically deformable reinforcing layer arranged between the two outer skin members, and a foamable polymer composition coated on at least one of each adjacent surface of the reinforcing layer and the respective outer skin member. Each adjacent surface of the reinforcing layer and the respective outer skin member contact one another and are intermittently bonded to one another, with the intermittent bonds on one surface of the reinforcing layer being non-aligned with the intermittent bonds on the other surface of the reinforcing layer. Additionally, the foamable polymer composition is foamable by application of heat to the structural member, whereby the foamed polymer resulting from application of heat to the structural member expands the outer skin members from contact with the reinforcing layer at non-bonded areas and plastically deforms the reinforcing layer into a three-dimensional reinforcing configuration.

Abstract: A flexible, breathable, composite is provided. The laminate comprises a middle layer of a padding and top and bottom layer comprising a sheet of water impermeable, moisture-vapor-permeable film bonded to the middle layer and wherein at least one outer surface of the top or bottom layer is provided with a pressure-sensitive biocompatible adhesive. Preferably the top and bottom layers comprise a composite of (a) a flexible, first sheet of hydrophobic material; and (b) a continuous hydrophilic sheet attached to or penetrating the first sheet, and forming a contamination barrier. The composite is useful in diverse applications such as a padding under orthopedic casts.

Abstract: A cushion or pad comprises a first layer of a first synthetic cellular material having a first average cell volume and a second layer of a second synthetic cellular material having a second average cell volume at least ten times greater than the first average cell volume. The first layer is attached to the second layer so that the first layer and the second layer at least partially overlap one another to form a multilayer structure. The layer with the larger average cell volume is a polymeric sheet with at least a substantially planar array of fluid-filled pockets or chambers. The layer with the smaller average cell volume is a foam material with either open cells or closed cells. Further layers of fluid-filled chambers or foam material may be attached to the first two layers.

Abstract: An apparatus and method for fabricating accurate, numerically defined curved surfaces and volumes comprising a skeleton framework having a plurality of bulkheads fixed in spaced relationship with each other, each of the bulkheads having an equal number of boreholes passing through the outer perimeter thereof so as to provide a set of selected boreholes. A flexible spline having a memory is passed through each set of mating boreholes and is secured with the boreholes after the splines have reached their static states. The resultant framework is encased in a cured polymer and the polymer is trimmed and faired between the outer edges of the splines.

Abstract: A concrete fluid structure deteriorated to the condition of removal of substance of the concrete by sulfuric acids and like corrosive material in contact therewith is restored by a substratum of epoxy foam, polyurethane foam, or a combination thereof having a relatively thin layer of polyvinyl chloride or polyethylene bonded to the outward facing surface of the foam and bonding the layer to the structure. A method for forming the substratum in the location of the deteriorated structure is described.

Abstract: A masking member consisting of a board having a projection shape on one side and a reinforcing groove on the other side, the depth of said groove being less than the thickness of said masking member.

Abstract: Improved durability and sharper chemical embossing images are obtained in a thick foamed thermoplastic floor structure by the use of an unfoamed inner layer. The floor covering is formed on a release paper and includes an unfoamed thermoplastic base coat, lower foamed thermoplastic layer, an unfoamed thermoplastic inner layer, an upper foamed thermoplastic layer and a clear coat. The enhanced chemical embossing is achieved by printing an inhibitor containing ink on the inner layer and below the upper foamed layer. Multilevel embossing is obtained by embossing both foamed thermoplastic layers or applying a growth-controlling agent to both surfaces of one foamable thermoplastic layer. The preferred embodiment includes a pearl platelet containing layer above the upper foamed layer to give the illusion of deeper embossing. The preferred embodiment also includes a wear coat of the reaction product of an aminoplast, a urethane and a polyol.

Abstract: A waterproof, thermal resistant packaging wrap, especially for large diameter cylindrical objects, such as oils of metal. The wrap comprises a layer of woven or unwoven, hydrophobic polymeric fabric, a layer of closed- or open-cell hydrophobic polymeric foam, and an intermediate layer comprising a plurality of parallel, elongated, reinforcing members. The reinforcing members comprise an extruded thermoplastic material, wrapped in a protective sheet and calendered to a thickness of at least about 1/10 inch, and width of about 3-4 inches.

Abstract: A component having a virtually rectangular force-displacement characteristic line and comprising an elongated polymer foam block (1) of rectangular cross-section having sides a and b and having a recess (2) of width d and depth c extending along the entire length of the block on one side, said dimensions satisfying certain equations.

Abstract: A sealing composition for a container closure comprising a polymeric matrix material and is modified by the inclusion therein of an oxygen scavenger. The composition can be in fluid or meltable form ready for application to a closure or it can be present as a deposit on the closure, for instance a gasket around the closure. Preferably the scavenging properties of the deposit are activated by pasteurizing or sterilizing the deposit when sealing a container with the closure. The invention is of particular value when the closure is a metal cap for a beer bottle.

Abstract: A unique housing apparatus for mounting of sensitive electronic equipment includes a polymer gasket which, when combined with the housing, isolates the electronic devices mounted therein from shock, vibration and cavitation. The polymer gasket includes characteristics wherein shock waves are dissipated along parallel planes of the polymer rather than in the normal direction of the polymer.

Abstract: Roofing systems are herein disclosed which lend themselves to simplified installation techniques and provide enhanced energy conservation over conventional roofing systems of comparable appearance. The system of this invention is based, in substantial part, upon the use of a large (typically 4'.times.8') panel of cellular structural foam as a replacement for ceramic and/or cast concrete roofing tiles ("Barrel" and "Bermuda" style tiles). In the preferred embodiments of this invention, a closed cell structural formed panel is molded or cut to simulate an array of roofing tiles. The simulated foam tile panel is further provided with a refractory (fireproofing) finish, such as stucco, or its equivalent. A finish coating is, thereafter, applied to the refractory coating to enhance water repellency and, thus, serve to further weatherproof the roofing panel. The finishing coating can be applied prior to or subsequent to installation of the foam tile panels.

Abstract: A panel type masking member comprising a foamed polystyrene panel made by expandable bead molding wherein said foamed polystyrene panel has traces of opening parts of breathing paths on both sides thereof wherein said trace(s) on at least one side is(are) dent(s), and a mold used for molding of said panel type masking member comprising a fixed molding part and a movable molding part wherein said movable molding part and said fixed molding part have opening parts of breathing paths on their surface(s) thereof and said opening part(s) of breathing path(s) of said movable molding part and/or said fixed molding part rise(s) from said surfaces thereof; are provided in the instant invention.

Abstract: A sealing composition for a container closure comprising a polymeric matrix material and is modified by the inclusion therein of an oxygen scavenger. The composition can be in fluid or meltable form ready for application to a closure or it can be present as a deposit on the closure, for instance a gasket around the closure. Preferably the scavenging properties of the deposit are activated by pasteurizing or sterilizing the deposit when sealing a container with the closure. The invention is of particular value when the closure is a metal cap for a beer bottle.

Abstract: A composite plastic article is provided which includes an improved boss for fastening the article to a supporting structure. The composite article includes a decorative outer skin co-molded to a reinforced foam layer. The foam layer is formed from a foaming resin such as polyurethane in an exothermic reaction. The boss is formed as a part of the foam layer and protrudes through the insert. A metallic fibrous material such as steel wool is molded into the boss to give the boss added structural integrity and to remove heat generated during formation of the boss and foam layer to thereby reduce cracking of the boss and localized blistering and delamination of the outer skin. A method for making such a boss is also provided.

Abstract: A multilayered molding is disclosed, which has a base molding outer layer mainly composed of a partial crosslinking type substance A obtained from polyolefin resin and ethylene-.alpha.-olefin copolymer rubber or a mixture B of polyolefin resin and ethylene-.alpha.-olefin copolymer rubber or both. The outermost layer is in direct contact with and forms a lamination with an inner intermediate layer or a base molding composed of a polyethylene resin, for instance, and is firmly bonded to the outermost layer. A method of manufacturing such multilayered molding is also disclosed, in which a composite sheet of the thermoplastic elastomer with or without the intermediate layer is preliminarily heated, followed by being suction held in close contact with a mold cavity inner surface, thus forming a surface layer. The mold is then clamped, and fluidized and plasticized polyolefin resin is injected to produce the molding. The polyolefin resin may also be injected prior to the clamping.

Abstract: A skin or shell is disclosed for use in a mold process in which the skin or shell is placed in a mold in which foam precursors are directed onto the skin for reaction thereagainst to form a foam layer thereon; the skin includes integral connector features thereon adapted to be connected to the mold for stabilizing the location of the skin within the mold so as to prevent wrinkling of the skin during the mold process.

Abstract: A coated sheet for decorative or informational applications is formed of an oil absorbing substrate and an oil permeable decorative layer. The decorative layer is a porous oleophilic membrane formed from fused polymer particles. Skin oil and certain other liquids placed on the exposed surface of the decorative layer are absorbed into the sheet so that they do not appear on that surface and do not interfere with the optical effect of diffraction gratings or holograms thereon.

Abstract: A porous sheet material is inserted into a back side of a foam base material at a convex section and forces a mat-shaped fiber reinforcing material set in a mold toward a facing material during molding. Alternatively, an impregnated sheet material is inserted between the facing material and the fiber reinforcing material at the convex section so that a molding material for the foam base material is impregnated into the impregnated sheet material during molding. Further, a concave section is molded on the back side of the foam base material at the convex portion by a mold projecting section of the mold. That is, the fiber reinforcing material set in the mold is forced toward the facing material by the mold projecting section during molding.

Abstract: A masking member presented herein comprises a sheet of a polystyrene foam provided with cutting guide lines so that said masking member consists of a plural number of units of the masking members surrounded with said cutting guide lines wherein said cutting guide lines are discontinuous and consist of a number of small grooves or short penetrating lines or small penetrating holes wherein the total length of said grooves or lines or holes is 20 to 80% of the length of said cutting guide lines. When said masking member is used, said sheet is easily and correctly broken along said cutting guide lines by hand to a piece consisting of one or more units of the masking member to have a proper size and shape corresponding with a part of an article which is necessary to be protected from a surface treatment.

Abstract: A resilient padding body which comprises an intermediate base layer and upper protruberances extending upwardly off the surface of the base layer and bottom protruberances extending downwardly off a lower surface of the base layer. The padding body includes longitudinal and lateral upper recesses which are formed between the upper protruberances. The upper protruberances have side walls which slope inwardly to form an object which is in the shape of a trancated pyramid and angled recesses. The base of the upper protruberances is essentially coplanar with the base member's upper surface. The base of each upper protruberance is separated by a slit which extends into the base member for about one half of the base member's thickness. The bottom protruberances include foundation sections which have vertical side walls. The foundation sections are spaced sufficiently to form a narrow channel between adjacent foundation section walls.

Abstract: A carrier tape comprising a strip of flexible material having a series of spaced pockets and a predetermined thickness, the size of the pockets and the predetermined thickness being adapted to receive a component between the major surfaces of said strip. In a preferred embodiment the pockets have at least a substantially closed base portion which lies between the major surfaces of the strip. The strip of flexible material comprises a layer of nonwoven thermoplastic polymeric fiber adhered together and has in the range of 20 to 70 percent air filled open spaces between the fibers. The strip of flexible material may also be composed of a thermoplastic foam.

Abstract: Imaging paper having randomly distributed fibers and uniformly dispersed throughout unexpanded synthetic thermoplastic polymeric microspheres, a method of preparation and a method of imparting an image thereto.

Abstract: A microporous polyolefin shaped article is provided. The article comprises a polyolefin substrate of substantially uniform thickness having a patterned surface, the patterned surface providing substantially skinless areas having high microporosity and skinned areas of reduced microporosity. A method for preparing the article is also provided.

Abstract: A tile product having a substantially non-porous vinyl composition base and a multilevel embossing and gloss which has a mechanically embossed mortar-line surround and which is free of gloss defects formed by pockets of air trapped between the wear layer and embossing mold during embossing is produced by applying a vacuum to the press during embossing. Preferably, the tile is laminated in a hot press heated by RF energy and cooled in a cold press to reduce the temperature of the wear layer to below its glass transition temperature.

Abstract: A method of making a composite structure, such as an aircraft wing, which has a foam core and at least one outer layer of fiber reinforced resin material. A shaped foam core is prepared by compressing a rigid, closed-cell foam to the desired shape in a closed mold under heat and pressure. A sheet of flexible open-cell foam is impregnated with a thermosetting resin. A sheet of dry fiber reinforcement material is placed on one or both sides of the impregnated foam sheet. The resulting sandwich is wrapped around the foam core and the assembly is placed in a corresponding tool cavity. The tool is heated to the curing temperature of the impregnating resin. As the temperature rises, the foam core expands, exerting pressure on the impregnated foam sheet, forcing resin into the fiber reinforcement, wetting all the fibers and forcing air out of the material. As the resin cures, void-free, strong skins are formed integral with the core foam.

Abstract: A flexible, breathable, non-linting, composite is provided. The laminate comprises a middle layer of a padding and a top and bottom layer comprising a sheet of porous water impermeable, moisture-vapor-permeable film bonded to the middle layer. Preferably the top and bottom layers comprise (a) a flexible, first sheet of hydrophobic material having a moisture vapor transmission rate exceeding 1000 gms./m.sup.2 .multidot.day; and (b) a continuous hydrophilic sheet attached to or penetrating the first sheet, the hydrophilic sheet having a moisture vapor transmission rate exceeding 1000 gms./m.sup.2 .multidot.day and forming a barrier to passage of fluids. The composite is useful in diverse applications such as a padding under orthopedic casts and as thermal insulation in wearing apparel.

Abstract: An evaporable first foam pattern portion adapted to be glued to a second foam pattern portion including a glue surface having thereon a fill gun boss, the first foam pattern portion comprising a glue surface adapted to be glued to the glue surface of the second pattern portion, and a recess in the glue surface of the first foam pattern portion for receiving the fill gun boss on the glue surface of the second pattern portion.

Abstract: A sealing composition for a container closure comprises a polymeric matrix material and is modified by the inclusion therein of an oxygen scavenger. The composition can be in fluid or meltable form ready for application to a closure or it can be present as a deposit on the closure, for instance a gasket around the closure. Preferably the scavenging properties of the deposit are activated by pasteurizing or sterilizing the deposit when sealing a container with the closure. The invention is of particular value when the closure is a metal cap for a beer bottle.

Abstract: A panel formed as a laminate with a decorative fabric at the exposed face includes a pair of foamed resin layers as backing material. Between the foamed resin layers is a fiber glass layer for strength. Means are provided to attach the panel to a substrate.

Abstract: A composite part of flexible cellular material and elastic, rubber material, wherein the cellular material is a cellular synthetic material and is compressed with the rubber material under cellular synthetic material hot-stamping conditions, the cellular material being condensed in the region of attachment.

Abstract: A breathable metallized polyolefin film is prepared by: melt embossing a highly filled polyolefin film to impose a pattern of different film thickness therein; stretching the melt embossed film to impart greater permeability in the area of reduced thickness in comparison to the areas of greater thickness; and coating the resulting stretched embossed film with a suitable metal.

Abstract: A shaped element consists of a soft and preferably elastic foamed material, comprising cellular webs which have been deformed remanently at least over areas. The shaped element is formed from a foamed material granulate, a soft foamed material having a grain size of 2 to 20 mms and filler material, for example cork granulate, rubber granulate, chalk, calcium carbonate, hard polyurethane scraps or thermoplastic plastics material scraps, with a grain size of 2 to 20 mms, which are distributed in the soft foamed material by the foaming action. The cellular webs or walls between the individual floccules of the foamed material granulate and/or of the filler material are remanently deformed over the areas concerned.