Abstract: An air filter for an internal combustion engine comprises a composite formed of first and second layers of reticulated foam plastics material with an open-mesh substrate between them, the two layers being bonded together through the openings in the open-mesh substrate and the composite impregnated with a dust-retaining substance. This arrangement results in a reservoir of the dust-retaining substance being maintained between the first and second layers of foam plastics material.

Abstract: In accordance with the invention, compositions of matter are provided for forming visco-elastic materials to simulate the physical feel of natural human soft tissue, such as fat or breast tissue. The compositions preferred are formed from a major portion of plasticizer and a minor portion of a resin. In a preferred embodiment, about 1100 parts by weight of a dialkyl phthalate plasticizer are thoroughly mixed with about 100 parts by weight of a polyvinyl chloride resin at an elevated temperature to form the visco-elastic material of the present invention. Included in the preferred composition are minor amounts of an epoxidized soybean oil stabilizer and a metallic salt stabilizer. A method is provided for producing visco-elastic materials and for producing pad structures comprising, preferably, an outer unattached covering of an elastic closed cell neoprene material and a core of said visco-elastic material.

Abstract: According to the present invention, novel foam panels and blocks are provided which are produced by welding and/or adhering foam tubes to one another. The foam panels are used particularly as insulating and/or drainage panels, and the foam blocks are used for the production of super lightweight panels the cavities of which are optionally filled with gypsum, cement, or other material. Composite structures made therefrom exhibit excellent sound-absorbent properties.Moreover, the invention provides a process and an apparatus for welding foamed synthetic resin tubes to one another and/or to other foam materials. The synthetic resin surfaces to be welded together are guided by way of a spacer means at a distance past an electrically heated heat source to form a heating channel where the surfaces are melted and pressed together thereafter. The process and the apparatus are suited especially well for welding foams of non-crosslinked low-density polyethylenes.

Abstract: A cold weather garment is produced from inner and outer fabrics and a layer of open cell skinned foam at least 1/4 inch thick, and preferably about 3/4 inch thick. The skin may be provided on a major flat face of the foam and the other face convoluted, or both faces can be skinned, or the foam layer may include two or more thicknesses of skinned foam. The garments provide better wind resistance than garments with simple open cell foam constructions and allow the selection of a wider variety of outer fabrics while still having the desired MVT, insulation, and wind resistance properties. The skinned foam is also easier to handle, cut, and sew during the construction of cold weather garments.

Abstract: A coated plastic sheet made of non-woven polypropylene with embossed or plain surface. Since non-woven polypropylene is water impermeable and water repellent, a plastisol or a resin is applied directly for embossing on the entire surface, or partially embossing to form embossed pattern after a special treatment such as spraying with polyvinyl chloride or applying an ink or paste to form a light, plastic sheet of superior quality at low cost.

Abstract: A protective covering suitable for protecting the surface of an automobile against being injured owing to contact with a hard object during the assembling work or servicing in factories or maintenance shops, is disclosed which comprises a lamination of an outer thin flexible layer of engineering or semi-rigid plastic and a lining of elastic foamed plastic material, preferably shaped to conform to the contour of the body surface area to which it is applied for protection. Preferably, the covering has an engaging lug properly formed along an upper edge and at least part of a side thereof for engaging a seam or raised part of the applied area so that the covering has firm grip onto the surface, without accidentally coming off.

Abstract: Blocks which can be used for assembling easily and inexpensively a piece of furniture or a part of a building, such as a table, stool, gate or arch. Each block comprises a molded body of a polyolefin foam having a rectangular, circular, oval or polygonal cross-section. The body has a pair of opposite surfaces of which one is provided with a plurality of regularly spaced apart holes, while the other surface is provided with a plurality of regularly spaced apart projections of which each can be fitted into one of the holes of another block. At least one bore extends through the body between the opposite surfaces thereof. The blocks are so light in weight and easy to handle that any assembly thereof can easily be dismantled for rebuilding another assembly having a different shape or structure. They are also highly resistant to water and are, therefore, suitable for building any assembly for outdoor use.

Abstract: A container component is made from microcellular foam material, no more than approximately 30 mils thick, having a core of very small uniformity distributed cells to provide uniform opacity that is locally eliminated by the application of heat and pressure to create window areas at least 60% as thick as the surrounding material.

Abstract: An accessory floor mat designed to overlie and protect a portion of the original carpeted floor of an automobile is preformed into a tray-like configuration which also conforms to the contours of the floor portion. The mat snugly fits into the carpeted floor well on a side of the vehicle and thereby resists mat sliding. The rigidity of the mat is such that it maintains its original position in the vehicle and also retains its shape when removed for cleaning. Raised borders of the mat terminate in rolled edges which eliminate the need for surging or otherwise finishing these edges. Optionally the mat can be provided with a recessed heel pad. The composite carpet structure from which the mat is molded preferably includes a layer of carpet fibers tufted into a primary backing material which is bonded to a sheet of open-celled foam by an extruded thermoformable copolymer of polyethylene and ethylene vinyl acetate.

Abstract: An expanding and shrinking member useful as a masking member is provided in the present invention. Said expanding and shrinking member comprises a panel which consists of a thermoplastic foam having closed cells and (a) cavity(ies) is(are) formed on one side of said panel and an adhesive layer is formed on the other side of said panel.

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: 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: An interior cover assembly such as a ceiling member, a wall member, a trim cover assembly for a seat, a cushion body for a seat for use in a vehicle such as an automobile is disclosed which comprises a foam cushion member provided on the surface thereof with a large number of recesses and projections extending crosswise and alternating with one another and a covering member for covering the surface of the cushion member. The covering member is pressed and heated to be welded integrally to the recesses in the cushion member and there are formed a great number of decorative wrinkles in the covering member mainly around the welded portions of the covering member.

Abstract: Composite shaped foam articles of manufacture and method for fabricating such articles is disclosed. The articles are formed by providing a section of foam material, treating a first surface of the section of foam material with adhesive, providing a second section of flexible foam having a surface to be joined with a surface of the first section, treating at least one of the surfaces to be joined with a suitable adhesive, joining the treated surfaces of foam, deforming the joined sections of foam into a selected shape, and curing the adhesives whereby the joined sections of foam remain elastically deformed rather than restoring to their original unstressed condition thus maintaining their selected shape.

Abstract: A process for producing an expanded or foamed polyolefin panel with a decorative surface wherein a polyolefin or a mixture of a polyolefin with rubber and/or a synthetic resin miscible therewith is blended homogeneously with a crosslinking agent and a blowing agent and shaped into a panel-like matrix below the decomposition temperature of the blowing agent and the activation temperature of the crosslinking agent; a film of a thermoplastic synthetic resin, imprinted in accordance with a pattern with printing ink on one surface side, is applied unilaterally or bilaterally to the matrix, with the imprinted surface side facing the matrix; and then the matrix, with the film applied, is crosslinked and expanded by heating to a temperature above the activation of the crosslinking agent and the decomposition temperature of the blowing agent.

Abstract: A thermoformable composite article comprises a core layer made of a synthetic resin foam, a pair of adhesive layers in contact with the opposite, upper and lower surfaces of the core layer, and a pair of fabric layers superposed on the opposite upper and lower surfaces of the core layer, the fabric layers being bonded to the core layer by the adhesive layers. At least one of the fabric layers is made of a non-woven fabric which has been impregnated with a thermoplastic or thermosetting resin. The thermoformable composite articles of the present invention are useful as liners for automotive interiors.

Abstract: A cold weather garment system includes an upper body garment and a lower body garment. Each garment has three layers, an outer wind resistant shell fabric, an inner loosely knit or woven lining fabric, and a non-flat foam layer between the fabric layers. The face of the foam layer abutting the inner lining fabric is convoluted, having peaks and valleys. The peaks are disposed in a grid-like arrangement, with ridges between the peaks, and four peaks surrounding a valley, and four valleys surrounding a peak. The foam is open cell polyurethane or polyether foam, and has a thickness of at least 1/2 inch, and preferably about one inch. The thickness of the valley portions of the foam is about 1/2 that of the peak portions. The convoluted form of the foam increases flexibility and reduces material and weight, and provides added surface area for moisture transfer.

Abstract: A membrane for gas separation which comprises a silylated polyphenylene ether is disclosed. Said silylated polyphenylene ether contains a constituting unit containing an organosilane or siloxane group represented by the following formula in at least a part of the repeating unit thereof: ##STR1## wherein R.sub.1, R.sub.2, R.sub.3 and R.sub.4 each represents a hydrogen atom or a group of the formula --Si(R.sub.5)(R.sub.6)(R.sub.7), wherein R.sub.5, R.sub.6 and R.sub.7 each represents an alkyl group; l and n each represents 0 or an integer from 1 to 3; and m represent an integer of from 1 to 3; with the proviso that R.sub.1, R.sub.2, R.sub.3 and R.sub.4 do not simultaneously represent hydrogen atoms.

Abstract: The present invention relates to a method for the manufacture of moulded bodies such as cornices from foam plastics material, the visible side of these bodies being heavily textured or profiled, smooth, non-porous and free from separation elements, with a unit weight of less than 200 kg/m.sup.3. In the method, a thin, elastic, heat-deformable film (3) is inserted between two heated mould portions (1, 2) in such a way that the film edges are clamped between the superimposed mould edges of the two mould portions (1, 2), a reactive, heat emitting, foaming plastics mixture is introduced through the upper mould portion (1) in such a way that it may be distributed on the film, and the hollow chamber formed between the film and the lower mould portion is evacuated during foaming, such that the film intimately conforms to the shape of the lower mould portion.

Abstract: An article has a wall with a first, continuous region and a second, smaller region on the first region and integrally mereged with the first region thereat, both wall regions being made of PVC materials for so integrally merging by the common PVC constituent thereof in the process of forming the regions one on the other. The second wall region is preferably made harder by irradiation crosslinking after forming the regions.

Abstract: A decorative product constructed of polymeric materials is provided wherein the top layer of the product is a film or layer of thermoplastic polymer (e.g., polyvinyl chloride) having a relief pattern on one surface and bonded at its other surface to a base layer of a thermoplastic ethylene interpolymer (e.g., an ethylene-vinyl acetate copolymer).The product is useful as a floor or wall covering.

Abstract: A padded material consists of a porous resilient layer which is bonded on one side to a web of foam and on the other side to a covering web, at least the foam web and the covering web consisting of a thermoplastically softenable material, and the covering web and the resilient layer being softened by heating and compressed in a pore-free manner in closely adjacent areas, and cooled to stabilize the structure.

Abstract: A method for providing a product which has a simulated embossed effect wherein a first wear layer is applied in a pattern and a second wear layer is deposited over the total surface that receives the first wear layer so that some areas of the surface have two wear layers and other areas of the surface have one wear layer to produce an embossed impression.

Abstract: A multi-layer article having a padded appearance is disclosed. The article includes a layer of polished, highly plasticized polyvinyl chloride material suitable to adhere to a smooth high gloss surface and a padded layer. The article is produced by a high-frequency welding technique. Also disclosed are a combination of a substrate together with one or more of the multi-layer articles, and an article, in the form of a playbrick, having a padded appearance and being capable of adhering to smooth, high gloss surfaces including the surface of other such articles.

Abstract: The present invention relates to a sound absorbing member comprising a fiber grid insert disposed between and bonded to two open cell foam panels.

Abstract: A molded foam-backed carpet assembly is provided which is suitable for use in automobiles and which includes a carpet layer, a moldable thermoplastic polymer layer and a sound deadening foam cushion bonded to the thermoplastic polymer layer. The physical properties of the foam are controlled to provide enhanced vibration damping and sound deadening in the carpet assembly.

Abstract: The present invention relates to cellular plastic insulating tubes or cellular plastic insulating plates of a flexible plastic foam with a groove- and tongue-like closing system arranged along the longitudinal axis, in which the groove and tongue can be undercut. The tongue consists of a more rigid or stiffer material than the material forming the groove, or, if the tongue consists of the same material as the insulating cellular material, this is reinforced or stiffened.

Abstract: The platelike floor covering article comprises a number of base elements and a covering material forming the walking surface, which covering material is bonded to the base elements. Each base element is a latticework surrounded by a rim member and has first latticed bars which support together with the rim member the covering material on the floor and comprises second latticed members of reduced height and supporting freely the covering material. The individual base elements are provided with slots for receipt of a ring-shaped interconnecting member which interconnects adjacent base elements. The floor covering article is mounted with help of a .perp.-shaped guiding member which projects into the gaps prevailing between adjacent base elements. The rim element is provided with further slots such that thoroughfares under the covering material are present, through which electrical cables or similar products can be located and kept away from view.

Abstract: A stiffener insert is incorporated into a molded composite article such as an automobile dashboard by inserting the stiffener insert between a pre-formed plastisol skin forming opposed mold walls for receiving an intermediate polyurethane foam layer therebetween and partially compressing a porous, resilient layer such as an open celled reticulated foam layer on opposite sides of the stiffener insert to an extent sufficient to exert a spring-like holding force to self-center the insert between the mold walls and yet insufficient to cause readout of the partially compressed porous insert layer through the outer plastisol skin on the final molded article. The partially compressed, porous, resilient layer on the stiffener insert permits flow of polyurethane foam therethrough to fill the mold cavity and is impregnated with the polyurethane foam to securely bond the stiffener insert in the composite article.

Abstract: A foam sealing tape comprises a foam sealing tape layer and an interlayer strip rolled up together in a compressed form. At least one wide-side surface of the interlayer strip has elevations which press into the foam sealing tape layer.

Abstract: An evaporative cooler in which a cooler pad includes a high loft body of synthetic fibers coated with a hydrophilic foam. The open nature of the pad allows air to flow freely through the pad, while the foam coating the fibers serves to wick water contacting the pad throughout the pad thus optimizing the cooling efficiency of the pad.

Abstract: A container having at least one heat-sealed juncture is formed from foam polymer sheet material. The foam polymer sheet material includes an area of crushed and compressed cellular structure directly adjacent the heat-sealed portion. The width of the crushed and compressed area is at least as great as the thickness of uncompressed foam in the layer.

Abstract: A molded foam-backed carpet assembly is provided which is suitable for use in automobiles and which includes a carpet layer, a moldable thermoplastic polymer layer and one or more foam pads fusibly bonded to the thermoplastic polymer layer and extending over less than the entire surface of the thermoplastic polymer layer to provide desired cushioning and sound and thermal insulation only in preselected areas of the carpet where needed.

Abstract: The invention relates to a thermal camouflage material comprising a supporting layer (4), e.g. a woven material, on which a polyethylene film layer (1), metallized on one side, has been laminated with the aid of fusion adhesive (3). The exposed surface of the plastic film is embossed to make it matte. Polyethylene is highly transparent to infrared radiation and has low emissivity, self radiation. By means of the metal layer (2) there is also obtained radiation insulation so that the outer layer (1) is in a thermal equilibrium which is hardly affected, e.g. by a warm object which is covered with the material, and the outer layer has a low emission ability of about 0.4-0.95, depending on thickness and pigmentation. By applying further patchy layers (5) patchy images will be obtained in image-forming by infrared sensitive instruments in the wavelength ranges 3-5 .mu.m and 8-14 .mu.m. The camouflage material may also include a layer of plastic foam insulating material arranged inwardly of the supporting layer.

Abstract: Insulated composite aluminum profile, a method and a device for manufacturing thereof. The composite profile comprises two separate profile portions provided with grooves. Plastic strips engage the grooves in order to interconnect the profile portions and form an enclosed space for an insulating plastic foam. The profile portions are placed in a fixture, which determines the dimensions of the composite profile and the plastic foam is inserted in the space in order to expand and cure therein. Thence, the profile is removed from the fixture and eventually rolled as to the outer rims of the grooves, which are deformed and thereby fix the plastic strip.

Abstract: A cellular seal coating is provided for uses such as assembling composite packages, which cellular seal coating is formed by electrostatically depositing finely divided, electrostatically chargeable bonding agent particles onto a preassembly member. Such bonding agent particles include a chemical blowing or foaming agent or system which forms gas bubbles when heated or otherwise energized in order to alter the thickness and strength of the seal coating so that it may, for example, fill gaps along assembly locations of a package or other article.

Abstract: The packing elements are each formed with a hooked configuration so as to abut each other without interlocking with each other. The free ends of the two legs of each element project beyond the main body portions so as to impart a hooked effect to the elements. The elements can be poured from a hopper into a container.

Abstract: A tread for surface contact with various surfaces of a human body, as feet, chest, abdomen, etc., has a base with upwardly projecting tines. A surface tread is provided in contact with, and is softer than, the tines. The relative hardness of the tines and the surface tread are designated. When the surface tread is urged toward the tines by a body portion urged against the surface tread, the tines, because of the relative hardness of the tines and the surface tread, will depress the surface portion and form dents or depressions therein. These depressions will mechanically resist side movement of the contacting tine portion and thus mechanically interlink the surface portion and the tines and thus the tines bend at midportion and with relatively little movement of the tip portions of the tines which is restrained because of the mechanical engagement with the tines and the depressions.

Abstract: A foamed material, which is adapting under pressure to the shape of parts, particularly of parts of the human body, but which on pressure relief again returns to a vast extent and after a certain restoring time into the original shape, consists of the following constituents:(a) substantially saturated liquid hydrocarbons;(b) unsaturated liquid hydrocarbons, preferably polybutadiene;(c) a reactive agent, preferably polyisocyanate, with which the unsaturated liquid hydrocarbons are reacted;(d) a cross-linking agent, for example ethylene hexane diol;(e) hollow microspheres, the thin shell of which consists of vinylidene chloride copolymer and the interior of which contains a gas.

Abstract: Foil, (aluminum) is secured to a plastic backing member (Styrofoam), and depressions made in the front face of the foil, which extend into the backing member, and are held by those members. The depressions are made in a pattern to form a picture, and plastic materials are placed in the depressions, that are transparent, of different colors, and of convex shape, acting as lenses. The plastic material includes casting resin, thixotropic thickening material, a dye, and a catalyst. Another form includes a rigid backing member and a stencil secured there to, and foil over the stencil, and the depressions are made in the foil, following the pattern in the stencil. Another embodiment includes a shaping form having raised elements and foil thereover; both are placed in a mold, and plastic material in fluent form placed over the foil and enabled to expand, the plastic material then constituting the backing member.

Abstract: A process of making raised line imprinted display mounts utilizing a foam polymer sheet having a thin polymer laminate covering includes the step of selecting a foam polymer sheet having a thin polymer laminate covering. The laminate covering surface is foil stamped with a die under predetermined pressure at predetermined temperatures and for elected dwell time to produce a raised line imprinted lettering or designs on the surface resembling an embossed surface stamping.

Abstract: The invention relates to a resinous polymer sheet material having surface decorative effects of contrasting gloss and to the method of making the same. The material is made by applying to a base a printing composition layer forming a pattern with designated areas containing a photoinitiator and then applying to said printing composition layer a resinous polymer wear layer having therein an actinic radiation curable polymerizable and cross-linkable monomeric materials. The composite thus produced is exposed to actinic radiation so that the areas above where the photoinitiators were applied are cross-linked. The product is then heated to form the composition. The resulting product has a lower gloss in such areas as compared to the remainder of the surface of the sheet.

Abstract: A transfer sheet comprising a releasable substrate and a heat-foamable pattern, and preferably a further foaming inhibiting pattern formed thereon is prepared, and these patterns are transferred onto a foamable resin layer such as a polyvinyl chloride plastisol containing a blowing agent. The entire structure is heated, whereupon there is obtained a decorative article in which a resin layer, as a whole, has foamed, and at the same time, at the parts where the foamable resin pattern has been transferred, projecting convex parts are formed by the foaming of the heat-foamable pattern, while depressed concave parts are formed at parts onto which the foaming inhibiting pattern has been transferred.

Abstract: Self carrying platform of the sandwich type forming a closed goods accommodating space, preferably for refrigerator/freezer trailers, comprising a core (15) and surface layers (16) laminated thereto. The surface layers consist of metal plates and the core of a constructional cellular plastics on PVC-basis. At least one mounting plate (17) for a wheel shaft arrangement/demountable body framing is adhesively attached to the core.

Abstract: A cellular foam product having a composite foam supporting substrate and a method for making same. The composite substrate includes a load supporting structure to which a continuous barrier film is bonded. The barrier film seals openings in the structure through which gas pressure loss and foam leakage may occur during subsequent foam generating reaction processes. The substrate is formed by coating desired foam supporting surfaces of the supporting structure with an adhesive and vacuum forming a preheated thin flexible plastic film to the supporting structure to bond the film to the foam supporting surfaces.

Abstract: A planar element for the absorption of air-transmitted sound, includes a flexible layer of open-cell foam material including a surface having protuberances with peaks formed thereon, and a flat closed cover layer formed of synthetic foil material fastened to the peaks of the protuberances, and a method of manufacturing the same.

Abstract: A metal-reinforced synthetic wood material which is composted of a metal assembly used for reinforcement, and synthetic resin for covering the metal assembly. The metal assembly is, for example, formed of a high-carbon special steel, and the synthetic resin is, for example, foamed polyurethane. This synthetic wood material is manufactured by a method, which method includes the steps of placing the metal assembly in a mold of a molding machine, and injecting the resin material into the mold in a reaction injection molding. Thus, the synthetic wood material having high moisture resistance and sufficient strength can be obtained.

Abstract: The vehicle panel, such as a door panel with a pull handle, is formed from a skin with a cover portion (18) and a loop portion (12) connected by spaced sides (32). A reinforcement member (24) is disposed inside the loop portion (12) and supported by a support panel (22). Cellular material (30) is disposed along the cover portion (18) of the skin and through the channel of the spaced sides (32) into the loop portion (12). The spaced sides (32) of the skin and the cellular material (30) disposed therein are removed to define the loop portion (12) integral with the body portion (14). Cover plates (38) are secured to the reinforcement member (24) to cover the exposed areas of cellular material (30) where the spaced sides (32) of the skin and cellular material (30) have been removed.

Abstract: A decorative laminate having a differential texture and a differential gloss, and a method of manufacture therefor, are provided wherein the laminate has an embossed surface comprising raised segments which contain PVC resin particles adjoining recessed segments which do not contain PVC resin particles whereby the raised and recessed segments impart a relief pattern on the surface of the decorative laminate, and the raised segments have a rougher surface texture and a lower gloss than the recessed segments. The decorative article is useful as a floor covering.

Abstract: The invention concerns a cushioned body for use in the interior of automotive vehicles, such as an armrest. A generally flat cushioning body comprised of elastic foam plastic has a stiffening insert imbedded in it. The stiffening insert is in the form of a mat, like a fiberglass cloth. Two rows of integral projections project from one surface of the cushioned body, and the projections include foamed sections of the stiffening insert. The projections along opposite longitudinal edges of the body are bent outward, oppositely to each other for facilitating securement of the cushioning body. Stiffening stop projections are placed on the inwardly facing sides of the projections in one row. As appropriate, the cushioned body is bent, for covering over a bent vehicle body section, as in an armrest, or the like.