Abstract: The present invention relates to an improved composite panel that is suitable for architectural and display applications and an advantageous method for making the composite panel. The composite panel comprises a foamed plastic core and two metallic skin layers bonded to the plastic core. The composite panel exhibits an effective bond strength sufficient to prevent peeling of the skin layers under normal use conditions, at least one visually flat surface substantially free of surface defects, and a stiffness to weight ratio of at least about 500 lbf-in/lbm/ft2.

Abstract: An at least two layer, unsupported, continuous microporous membrane is disclosed. The at least two layer, unsupported, continuous microporous membrane may include at least two different membrane pore size layers or the pore sizes may have about the same pore size. Apparatus and processes for fabricating at least a two layer unsupported, continuous, microporous membrane are also disclosed.

Abstract: A silicon carbide composite which is a flat composite comprising a porous preform of silicon carbide and a metal containing aluminum as the main component, infiltrated into the porous preform, said composite having a warpage of at most 250 &mgr;m per 10 cm of the principal plane length of the composite.

Abstract: Polymeric films including a layer of propylene resin having microvoids therein, the microvoids having been formed by stretching a web containing the beta-form of polypropylene, have shown low static cling when being unwound from rolls in labelling operations and also during destacking of pre-formed labels. The invention provides labels formed from such films.

Abstract: An elastic breathable film is disclosed. The film is formed from a thermoplastic elastomer that contains a filler. Once the film is formed, the film is stretched causing the formation of micropores. The thermoplastic elastomer then undergoes phase separation between hard segment blocks and soft segment blocks which restores elasticity to the film. In one embodiment, the thermoplastic elastomer is a thermoplastic polyurethane elastomer.

Abstract: A wall or panel has a thin concrete layer with a cross-sectional contour having protrusions and indentations forming other objects, such as stone work, brick or wood. A reinforcement layer may be affixed to the concrete layer to provide tensile strength and impact resistance to the concrete layer. A foam layer is affixed to the reinforcement layer to further reinforce the concrete layer, and so that the wall or panel is light weight. A second concrete layer or a rigid backing layer may be disposed opposite the concrete layer so that the foam is disposed therebetween. A method for forming the wall or panel includes spraying the concrete onto a mold surface which has indentations and protrusions for forming the other objects. The reinforcement layer is sprayed onto the cured concrete layer. The mold is closed and foam is introduced into the mold.

Abstract: A method of performing a lower temperature bonding technique to bond together two mating pieces of glass includes applying a sodium silicate aqueous solution between the two pieces.

Abstract: In accordance with the present invention, compositions and methods are provided in which a layered low dielectric constant nanoporous material is produced that comprises a first layer juxtaposing a substrate; a second nanoporous layer juxtaposing the first layer; and an additional layer juxtaposing the second layer. The layered dielectrics of the present invention are formed using nanoporous materials by a) depositing a first layer on a substrate; b) depositing a second layer that is nanoporous and that juxtaposes the first layer; c) treating the second layered material to produce nanoporosity; and d) depositing at least one additional layer that partially juxtaposes the second layer. A layer of wires or other electronic components can also be situated between the substrate layer and the first layer.

Abstract: A tri-laminate body panel stiffener includes two polymer layers with or without a backing. One of the layers is a compliant foam layer mounted against a substrate while the other layer is a rigid foam layer mounted against the compliant foam layer. In another aspect of the invention the laminate comprises a backing member having an expandable foam mounted thereto with two or more opposing edges of the laminate being of non-straight construction such as being wavy or saw tooth. A pattern of holes may be formed through the foam and backing layers.

Abstract: An absorbent and cut-resistant sheet having a cut-resistant material with a plurality of openings, and an absorbent material attached to the cut-resistant material. Preferably, the apertured cut-resistant material is in the form of sheet having a thickness of between about 0.005 inches and about 0.020 inches, and has an open area of less than about 50 percent. It is also preferred that the cut-resistant sheet have fold lines formed on a non-cutting surface, so as to make the material easily foldable and/or tearable. In addition, a stainable absorbent cover layer can be attached to a cutting surface of the cut-resistant sheet to provide an indication of where cutting has occurred, and to give the material a desirable appearance. A liquid impervious backing layer is also preferably attached to the absorbent material to resist the escape of fluid from the absorbent material. It is preferred that the cut-resistant sheet comprises a polymeric material.

Abstract: Novel gas-permeable membranes which are particularly useful in the packaging of fresh cut fruit and vegetables, and other respiring biological materials. The membranes have an O2 permeability of at least 775,000 ml/m2.atm.24 hrs, a P10 ratio of at least 1.3, and a ratio of CO2 permeability to O2 permeability (R) of at least 1.5, and are made by forming thin polymeric coatings on microporous polymeric films. Preferred coating polymers are side chain crystalline polymers. Preferred microporous films contain inorganic fillers, particularly such films based on ultrahigh molecular weight polyetheylene or polypropylene. FIG. 1 illustrates how O2 permeability an R ratio vary for different coating polymers and microporous films.

Abstract: The present invention is a process for making a nanochannel glass (NCG) replica, having the steps of: coating a face of an etched NCG with a replica material (with or without an intervening buffer layer), where the etched NCG face has a plurality of channels arranged in a desired pattern, to form a replica coating on the NCG conforming to the pattern; and removing the replica coating from the etched NCG. The present invention is also the replica made by this process.

Abstract: Biaxially oriented polymeric films having a core layer of a voided propylene homopolymer with a density of not more than 0.70 g/cm3, and at least one substantially non-voided layer on each surface of the core layer, the ratio of the combined thicknesses of the non-voided layers on the respective surfaces of the core layer being from 2:1 to 1:1. Films in accordance with the present invention have low curl, particularly after having been printed.

Abstract: An absorbent and cut-resistant sheet having a cut-resistant material with a plurality of openings, and an absorbent material attached to the cut-resistant material. Preferably, the apertured cut-resistant material is in the form of sheet having a thickness of between about 0.005 inches and about 0.020 inches, and has an open area of less than about 50 percent. It is also preferred that the cut-resistant sheet have fold lines formed on a non-cutting surface, so as to make the material easily foldable and/or tearable. In addition, a stainable absorbent cover layer can be attached to a cutting surface of the cut-resistant sheet to provide an indication of where cutting has occurred, and to give the material a desirable appearance. A liquid impervious backing layer is also preferably attached to the absorbent material to resist the escape of fluid from the absorbent material. It is preferred that the cut-resistant sheet comprises a polymeric material.

Abstract: An absorbent and cut-resistant sheet having a cut-resistant material with a plurality of openings, and an absorbent material attached to the cut-resistant material. Preferably, the apertured cut-resistant material is in the form of sheet having a thickness of between about 0.005 inches and about 0.020 inches, and has an open area of less than about 50 percent. It is also preferred that the cut-resistant sheet have fold lines formed on a non-cutting surface, so as to make the material easily foldable and/or tearable. In addition, a stainable absorbent cover layer can be attached to a cutting surface of the cut-resistant sheet to provide an indication of where cutting has occurred, and to give the material a desirable appearance. A liquid impervious backing layer is also preferably attached to the absorbent material to resist the escape of fluid from the absorbent material. It is preferred that the cut-resistant sheet comprises a polymeric material.

Abstract: A photographic element comprising a laminated base wherein said base comprises a voided polyester sheet having laminated thereto a biaxially oriented polyolefin sheet on the bottom of said polyester sheet and a biaxially oriented polyolefin sheet laminated to the top of said polyester sheet.

Abstract: An aluminum-thermoplastic composite surface structure. A sheet of aluminum is formed to a single-sided mold by heating the sheet and applying a ramp of gas pressure. A thermoplastic resin is heated and microballons are added to the resin to lower the viscosity of the resin, which is applied through a nozzle in a hexagonal pattern on the formed aluminum sheet. Upon cooling, the composite resin forms a honeycomb pattern. The hexagonal pattern transitions to a columnar pattern and a backing layer of aluminum sheet is gas pressure formed to the resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that bonds to the applied resin.

Abstract: This invention provides air impermeable liquid-water resistant water-vapor-permeable composites that are highly oleophobic and some of which have enhanced water-vapor-permeable properties. In its broadest aspect, the composites comprise: a layer of a microporous polymer that is water-vapor permeable and which is oleophobic, and which is liquid water-resistant. This layer is in contact with an air-impermeable, liquid water resistant, polymer layer that is permeable to water-vapor molecules. The oleophobic microporous polymer layer confers enhanced oleophobicity. In another aspect, a third layer of a microporous, water vapor permeable polymer can also be present on the other side of the air-impermeable polymer layer.

Abstract: A thermoplastic resin coated aluminum alloy sheet has excellent processing adhesion and high adhesion after retort processing such that laminated thermoplastic resin layers do not peel off even when the alloy sheet is subjected to severe processing such as stretching after deep drawing and furthermore, ironing. A production method and a production apparatus for the alloy sheet are also described. A treatment by an alkaline solution and a treatment by an acidic solution are sequentially applied to bring the surface of an aluminum alloy sheet into a specific surface state and then electrolytic chromic acid treatment is carried out by a known method so as to laminate a thermoplastic resin to an aluminum alloy sheet having a two-layered film which comprises metallic chromium as the lower layer and a chromium hydrate as the upper layer and has a specific surface condition.

Abstract: This invention provides air impermeable liquid-water resistant water vapor-permeable composites with enhanced water-vapor-permeable properties comprising: (a) a layer of a microporous polymer that is water-vapor permeable and which is liquid water-resistant in contact with (b) an air-impermeable, liquid water resistant, polymer layer that is permeable to water-vapor molecules, and (c) a third layer of a microporous, water vapor permeable, hydrophilic polymer present on the side of the air impermeable polymer layer opposite the microporous polymer (a).

Abstract: Articles including material laminated to a surface of a microcellular substrate are disclosed, as well as methods of making these articles. Microcellular polymeric material in sheet form can be extruded and continuously fed from the extruded to a lamination system, or microcellular sheet can be produced and stored, and then fed into a lamination system.

Abstract: A layered structure that includes a product mixture of numerous particles, a foamable substance, such as including a liquid binder, and a reacted dry binder is provided. The particles preferably are comprised of cellulosic, fibrous materials. The dry binder reacts with the liquid binder to create a strong bond among separated particles. The particles are separated during transport, together with the dry binder, before the dry binder is reacted with the foamed liquid binder. Upon contact with the liquid binder, the dry binder reacts to cause desired adhesion among the separated particles. The reacted dry binder is disposed relatively inwardly of the product mixture, while the liquid binder is located outwardly thereof, with at least some of the liquid binder, after curing, being disposed on outer portions of the product mixture. The layered structure also includes one or more outer members or panels that are laminated or otherwise joined to the outer surface portions of the product mixture.

Abstract: A surface covering containing at least one layer containing wear-resistant particles, such as aluminum oxide, is disclosed. Preferably, the wear-resistant particles are present in the outermost layer of the surface covering which is exposed to the environment. A method to improve wear and/or stain resistance to a surface covering is also disclosed and includes adding an effective amount of wear-resistant particles to a top coat layer or outermost layer of a surface covering optionally, with the use of a suspension aid. Also, layers of surface coverings having differences in gloss levels is also disclosed. Methods of making the surface covering are also disclosed.

Abstract: The invention relates to an photographic element comprising a transparent polymer sheet, at least one layer of biaxially oriented polyolefin sheet and at least one image layer wherein said polymer sheet has a stiffness in any direction of between 20 and 100 millinewtons, and said biaxially oriented polyolefin sheet has a spectral transmission of at least 40% and a reflection density less than 60%.

Abstract: The invention relates to an imaging element comprising a transparent polymer sheet, at least one layer of biaxially oriented polyolefin sheet and at least one image layer wherein said polymer sheet has a stiffness of between 20 and 100 millinewtons, and said biaxially oriented polyolefin sheet has a spectral transmission of at least 40% and a reflection density less than 60%.

Abstract: An opaque, oriented polymeric film structure comprises: (a) a core layer containing a thermoplastic polymeric matrix material which has a first surface and a second surface, the core layer having a plurality of voids, substantially all or all of the voids being free from a void-initiating particle and at least some of the voids being interconnected with an adjacent void in the polymeric matrix material, the number of voids not containing a void-initiating particle being sufficient to impart a significant degree of opacity to the film structure; and (b) at least one outer or skin layer containing a thermoplastic polymeric material and an effective amount of a nucleating agent to suppress cavitation in said at least one outer or skin layer. The film structure has a smooth surface and can be tailored to provide a controlled permeability, and is particularly suitable for food packaging.

Abstract: A support device for a computer mouse (mouse pad) comprises, extending over the lower foil made of foam material, at least one thin, colored liquid layer which is enclosed between two foils welded together along the edge in a liquid-tight manner and is visible through the transparent foil or foils. The liquid occupies the available cavity only incompletely and it spreads out in puddle-like patterns to define void spaces which change continuously due to the actuation of the mouse, thereby providing the mouse pad with an optically interesting appearance.

Abstract: Microporous articles formed by thermally induced phase separation from a diluent in combination with a thermoplastic polymer and a flame retardant providing novel flame retardant articles. Such articles are useful in clothing, wall or roofing barriers, optical films in electronic devices (such as light reflective and dispersive films), printing substrates and electrical insulation.

Abstract: In accordance with the present invention, a low dielectric constant structural layer is produced having increased mechanical strength and having a plurality of voids that comprises a substrate layer; a low dielectric structural layer juxtaposing the substrate layer; and an infiltrating layer comprising an infiltrating material having a volatile component and a reinforcing component juxtaposing the structural layer and coating at least some of the plurality of voids. Also, methods are provided in which the mechanical strength of a structural layer having a plurality of voids is increased by a) depositing the structural layer on a substrate layer; b) providing an infiltrating material having a volatile component and a reinforcing component; c) introducing the infiltrating material into at least some of the plurality of voids; and d) treating the infiltrating material such that the structural strength is increased by a substantial amount.