Of About The Same Composition As, And Adjacent To, The Void-containing Component Patents (Class 428/318.6)
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Patent number: 6921571Abstract: The present invention intends to provide a thermoplastic resin foam molding comprising a substrate having a foam layer and a projection formed in one piece together with the substrate wherein the projection hardly separates from the substrate and they are firmly jointed together. The invention provides a thermoplastic resin foam molding comprising a substrate and a projection formed in one piece together with the substrate wherein the substrate has a foam layer and a skin layer containing no voids wherein the ratio (R/L) of the curvature R of a joint between the projection and the substrate to the thickness L of the skin layer is from 3 to 50.Type: GrantFiled: January 28, 2002Date of Patent: July 26, 2005Assignee: Sumitomo Chemical Company, LimitedInventor: Satoru Funakoshi
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Patent number: 6878437Abstract: A thermoplastic multi-layer composite structure is disclosed and in a first embodiment as a co-extruded acrylic polypropylene outer skin and high melt strength polypropylene substrate which is attracted to a first surface of a polypropylene foam core. An inner polypropylene skin is attached to a second surface of the foamed core, which can either be constructed from an expanded polypropylene or an extruded polypropylene and is attached to the outer and inner skin through the use of an adhesive. Where an extruded polypropylene foam core is provided, the skins can be attached to the foam core by adhesives or through a welding or bonding process in lieu of adhesives. Additionally, the extruded foam core can vary in density to provide a composite foam core. An all acrylic composite multi-layered structure is also provided.Type: GrantFiled: May 20, 1999Date of Patent: April 12, 2005Assignee: Brunswick CorporationInventor: Stephen Crane
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Patent number: 6872432Abstract: A hollow, reinforced, molded automotive hard top is made using a sheet of thermoplastic material with nanoparticles dispersed therein. The particles comprise less than 15% of total volume of the plastic sheet, at least 50% of the particles have a thickness less than about 20 layers, and at least 99% of the particles have a thickness of less than about 30 layers. The sheet is preheated and molded in an assembly having mold surfaces corresponding to the hard top configuration. Vacuum is applied to one side of the assembly and pressurized gas is applied to the opposite side of the assembly to force the sheet into conformity with the mold surfaces. After cooling, the conformed sheet is transferred to another mold assembly, where a reinforced plastic melt having a blowing agent is applied. Together, the solidified melt and the conformed plastic sheet form the hard top.Type: GrantFiled: August 16, 2002Date of Patent: March 29, 2005Assignee: Magna International of America, Inc.Inventor: Phillip S. Wilson
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Patent number: 6866923Abstract: A rigid closed cell polyisocyanate-based foams is created by reacting at least one organic polyisocyanate with compounds having at least two active hydrogen atoms in the presence of an n-pentane blowing agent. When the foam is formed into a laminated board with facers, the foam formulation includes a sufficient amount of a common blend of cleaning solvent chemicals to cause a noticeable improvement in facer adhesion. The chemicals used to improve facer adhesion are a standard blend of industrial cleaning solvents called “Di-Basic Esters” or DBE. The actual chemical compounds in one mode of this mixture are the methyl esters of about 59% glutaric acid, about 20% succinic acid, and about 21% adipic acid. The minimum rate of addition of the Di-Basic Esters”[DBE] thought to be effective may be less than about 0.5 parts per hundred parts of polyol (pphpp). The currently preferred embodiments use add-on rates within the range of about 0.5 to about 5.Type: GrantFiled: November 15, 2001Date of Patent: March 15, 2005Assignee: Atlas Roofing CorporationInventors: James D. Thornsberry, Gregory Islas, Robert H. Blanpied
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Patent number: 6861133Abstract: A composite molding is formed by welding and joining a foam to a substrate made of a synthetic resin, the foam including a hard skin layer and a foamed layer formed by foaming a foamable synthetic resin in an unhardened state within the skin layer as the pressure of a cavity is decreased, wherein the skin layer includes a cover covering the foamed layer and a collar projecting outward from the edge of the cover on the substrate side while being directly welded and joined to the surface of the substrate. Therefore, the edge of the skin layer on the substrate side can be adequately hardened, thereby enabling adequate formation of the foamed layer and adequate welding between the foam and the substrate.Type: GrantFiled: October 18, 2001Date of Patent: March 1, 2005Assignee: Moriroku Kabushiki KaishaInventors: Takashi Koike, Kouji Akasaka
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Patent number: 6858302Abstract: A composite structure is formed by depositing a one or more coatings on an open-cell foam skeleton to form a higher-density composite foam. In accordance with one aspect of the invention, the composite foam can be a carbon/carbon composite formed by a rapid densification process. The composite structure is suitable for use, for example, as a friction material employed in clutch and brake devices.Type: GrantFiled: September 30, 2003Date of Patent: February 22, 2005Assignee: Messier-Bugatti, Inc.Inventor: Raymond C. Loszewski
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Patent number: 6855952Abstract: A semiconductor device wherein a resin containing as a cross-linking component a compound having a plurality of styrene group and represented by chemical formula [1] is used as an insulating material: where R is a hydrocarbon structure which may have a substituent group or groups, R1 is hydrogen, methyl, or ethyl, m is and integer of 1 to 4, and n is an integer of not less than 2. With this, a semiconductor device and a semiconductor package which show excellent transmission characteristics and less power consumption are provided.Type: GrantFiled: March 28, 2003Date of Patent: February 15, 2005Assignee: Hitachi, Ltd.Inventors: Akira Nagai, Satoru Amou, Shinji Yamada, Takao Ishikawa, Hiroshi Nakano
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Patent number: 6843954Abstract: The present invention provides processes and an apparatus for injection-molding an article with a fluid channel formed therein. The process includes providing at least first and second resin streams within a mold cavity, causing the flow fronts (16) of the resin streams to meet at a longitudinal point in the mold cavity to form a first layer of solidified resin on a peripheral surface of the mold, the first layer having a knit line (20) at the longitudinal point where the resin streams meet; and introducing a fluid into the molten resin in the mold to form a fluid channel (50) and a second layer (32) of solidified resin, the second layer between the fluid channel and the first layer of solidified resin, wherein the second layer is devoid of a knit line at the longitudinal point in the mold cavity where the first and second flow fronts meet.Type: GrantFiled: February 23, 2001Date of Patent: January 18, 2005Assignee: Conix CorporationInventor: Marshall Ray Porter
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Publication number: 20040265568Abstract: A thermoplastic multi-layer composite structure is disclosed and consist in a first embodiment of a co-extruded acrylic polypropylene outer skin and high melt strength polypropylene Substrate which is attached to a first surface of a polypropylene foam core. An inner polypropylene skin can be provided and is attached to a second surface of the foam core. The foam core can either be constructed from an expanded polypropylene or an extruded polypropylene. Where an expanded polypropylene foam core is provided, the foam core is attached to the outer and inner skin through the use of a polypropylene adhesive. Where the extruded polypropylene foam core is provided, the skins can be attached to the foam core through a welding or bonding process in lieu of adhesives. The polypropylene adhesives can also be utilized for attaching the skins to the extruded foam core. Additionally, the extruded foam core can vary in density to provide a composite foam core.Type: ApplicationFiled: February 17, 2004Publication date: December 30, 2004Applicant: Brunswick CorporationInventor: Stephen Crane
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Patent number: 6830805Abstract: There is disclosed a method for manufacturing products through the use of waste materials of various kind, such as heterogeneous plastic materials, wood, minerals, etc., derived from recycling processes, differentiated waste collection systems, solid urban wastes, industrial processing scraps or by-products, and the like, such products being adapted to be used in a wide range of most varied applications, particularly though not exclusively for manufacturing structural parts and decorative finishes for office furniture as well as furniture for cinematography theaters, communities, concert halls and the like.Type: GrantFiled: June 10, 2002Date of Patent: December 14, 2004Assignee: Elma Chemicals SrlInventor: Mario Bertoglio
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Publication number: 20040247856Abstract: In order to facilitate the recycling of plastic composite materials and moldings produced thereof, the invention relates to a single-sort, mono-material composite material, comprising a core of thermoplastic foam and at least one reinforcing layer made of a composite consisting of fibers or strips of the same thermoplastic material as the foam. The invention further relates to a method for producing said single-sort composite material, during which the foam made of thermoplastic material is applied onto a pre-formed reinforcing layer and is welded there to each other and to the reinforcing layer by adding heat, a composite consisting of at least two layers of fabrics, knitted fabrics or non-wovens of fibers or strips made of the same thermoplastic material as the foam being used as reinforcing layer.Type: ApplicationFiled: March 8, 2004Publication date: December 9, 2004Inventors: Gerd Sikorski, Jurgen Bruning, Maik Ziegler, Kai Wacker
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Patent number: 6824864Abstract: The present invention relates to bioriented polyethylene films having high water vapor transmission rates (WVTR) and methods for preparing the same. The film comprises a base layer and skin layers. The base layer comprises highly cavitated polyethylene, such as medium density polyethylene (MDPE) or high density polyethylene (HDPE). The cavitating agent in the base layer may be calcium carbonate. At least one skin layer comprises (i) a copolymer of ethylene and at least one other monomer and (ii) a hydrocarbon resin, such as a cyclopentadiene resin. This copolymer (i) may be an ethylene-propylene copolymer or an ethylene-propylene-butene-1 terpolymer. The film may have unidirectional tear properties in the machine direction. This film is particularly useful for packaging food products, such as pieces of candy.Type: GrantFiled: October 23, 2001Date of Patent: November 30, 2004Assignee: ExxonMobil Oil CorporationInventor: Michael John Bader
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Patent number: 6821418Abstract: A process is provided for modifying a porous polystyrene monolith to render its internal pore surfaces grafted with alkyl groups, preferably of at least four carbon atoms, which includes the step of alkylating the monolith with a uniform liquid solution containing a Friedel-Crafts catalyst and an alkyl halide. A surface-modified monolith produced thereby is an efficient separation medium in reversed-phase liquid chromatography for both small and large biomolecules.Type: GrantFiled: January 29, 2003Date of Patent: November 23, 2004Assignee: Advion BioSciences, Inc.Inventor: Xian Huang
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Patent number: 6815028Abstract: A method for manufacturing a grip material consisting of a layer of polyurethane and a layer of EVA. A nylon cloth material is used as a temporary support for coagulating the polyurethane by a wet coagulation process. The coagulated polyurethane is then separated from the nylon cloth material and subsequently joined with a strip of EVA material to yield a grip material with the tackiness and superior shock cushioning characteristics of a polyurethane/felt grip combined with the water resistant and lightness characteristics of a polyurethane/EVA grip.Type: GrantFiled: May 27, 2003Date of Patent: November 9, 2004Inventor: Ben Huang
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Patent number: 6815051Abstract: A foam layer can be formed at a temperature at which the surface quality of a surface layer is not deteriorated, and a molding technique that is excellent in adhesiveness of a foam layer and a surface layer or/and a base member is developed. For the purpose of obtaining a resin molding composite, the present invention is characterized by a polyolefin resin molding composite comprising a surface layer and a foam layer, or a surface layer, a foam layer, and a base member, wherein the foam layer comprises a foam layer produced by fusion bonding thermoplastic expanded resin particles one another by molding, where the thermoplastic expanded resin particles comprises a core that is made of a crystalline thermoplastic resin and is in an expanded state and a polyethylene resin coat covering the core, and the surface layer comprises a thermoplastic synthetic resin having a melting point of 5° C. or more higher than a melting point of polyethylene resin constituting the coat of the particles.Type: GrantFiled: April 20, 2001Date of Patent: November 9, 2004Assignee: JSP CorporationInventors: Masaaki Yokoyama, Masahiro Tanaka
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Patent number: 6803083Abstract: The invention presents a composite profile for use in the production of windows, doors, facade elements or the like, having inner and outer metallic profiles spaced at a specific distance from each other by a plastic profile. The invention further proposes that the plastic profile contain a surface of a solid, non-porous first plastics material, in a core region, a fine-pored cellular structure of a second plastics material. Additionally, the plastic profile may either be a solid, multilayer profile or a hollow profile. Such plastics profiles are particularly adapted to absorb tensile, bending and/or pressure loads.Type: GrantFiled: June 21, 2002Date of Patent: October 12, 2004Assignee: Ensinger Kunststofftechnologie GbRInventor: Wilfried Ensinger
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Patent number: 6794025Abstract: The inventive method for producing packaging materials consisting of a polyolefin foam layer (B) coated with a coating film (A) on at least one side, which packaging material is formable into self supporting packaging items, such as trays, by thermoforming or folding, comprises a coextrusion step or an extrusion lamination step in which step the bonding between the polyolefin foam layer (B) and the coating is achieved. With the extrusion lamination step, the method is as follows: In a first method step, a single-layer or multi-layer coating film (A) is produced by extrusion or coextrusion, in a second method step a polyolefin foam sheet (B) is produced by expansion and extrusion and in the third method step the polyolefin foam sheet (B) is coated with the coating film (A) by extrusion lamination, wherein a polyolefin bonding layer (30) is extruded between the foam sheet (B) and the coating film (A) and pressure is applied to the combination.Type: GrantFiled: January 4, 2000Date of Patent: September 21, 2004Assignee: Convenience Food Systems, B.V.Inventors: Jacques Laurent, Michel Pittet
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Patent number: 6783844Abstract: Provided is a polypropylene resin foam-molded article which has a rib having a relatively small thickness and which has an improved strength at a boundary part between a main body part and the rib part without increasing a thickness of the rib part. The polypropylene resin foam-molded article is obtained by molding a material for a foam-molded article using a polypropylene resin, wherein the molded article comprises a main body part and a rib part provided vertically to the main body part; the rib part has a thickness (Tr) of 3 mm or less, or a thickness ratio (Tr/Tb) of a thickness of the rib part (Tr) to a thickness of the main body part (Tb) is 0.8 or less; the main body part and the rib part each comprise a non-foamed surface layer and an intermediate layer having a foamed structure; and the intermediate layer in the main body part is connected to the intermediate layer in the rib part.Type: GrantFiled: July 17, 2002Date of Patent: August 31, 2004Assignees: Chisso Corporation, Chisso Petrochemical CorporationInventors: Youichi Kugimiya, Kouichi Honda
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Patent number: 6777068Abstract: A door weather strip having an extruded member and a molded corner for connecting ends of the extruded member. The extruded member is composed of a foamed thermoplastic olefin elastomer which has an average cell diameter of 30 to 70 &mgr;m and an expansion ratio of 150 to 250%.Type: GrantFiled: January 26, 2001Date of Patent: August 17, 2004Assignee: Toyoda Gosei Co, Ltd.Inventors: Mitsunobu Teramoto, Masanori Aritake, Hitoshi Omori
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Patent number: 6767623Abstract: The invention relates to a sandwich panel comprising A. a core layer of polypropylene particle foam, B. cover layers of fiber-reinforced polypropylene and also optionally C. decorative layers, wherein the core layer includes from 1 to 30% by weight of recyclate particles of components A, B and optionally C.Type: GrantFiled: November 17, 2000Date of Patent: July 27, 2004Assignee: BASF AktiengesellschaftInventors: Christof Möck, Hermann Tatzel
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Publication number: 20040101674Abstract: Composite sheet material comprises a core (12) formed from cellular material having a respective skin of continuous sheet material on each side thereof. Both the core and the skins are formed of thermoplastic materials and the skins are attached to the core by a thermoplastic adhesive having a fusion temperature less than that of both the core and the skins.Type: ApplicationFiled: October 31, 2003Publication date: May 27, 2004Inventor: Leslie Ross
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Publication number: 20040101670Abstract: Corrosion- and chip-resistant coatings for high tensile steel components, such as automotive coil springs, are formed from a coating powder composition of “toughened” epoxy resin. In a single coat embodiment, the entire coating is loaded with at least 75 phr zinc powder. In a dual coat embodiment, an inner coat is loaded with at least 75 phr zinc and an outer, zinc-free coating is reinforced by the addition of fibers and/or by a foaming agent which renders it porous.Type: ApplicationFiled: November 21, 2003Publication date: May 27, 2004Inventors: Tina L. Grubb, Catherine A. Kleckner, William E. Wertz, Michael C. Siminski, Andrew T. Daly, Jeno Muthiah
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Patent number: 6740381Abstract: A fiber reinforced core is formed from plastics foam material having elongated porous and fibrous webs and/or rovings extending through the foam material. The rovings may extend angularly through the webs, and strips of the foam material may be helically wound with layers of crossing rovings to form the webs. Porous and fibrous skins for the core may be formed by the wound rovings and by parallel continuous rovings, and the foam strips may be formed with internal grooves adjacent the webs and connected by a feeder channel for infusing a hardenable adhesive resin into the grooves and outwardly through the webs to the skins with differential pressure on the resin.Type: GrantFiled: December 27, 2000Date of Patent: May 25, 2004Assignee: Webcore Technologies, Inc.Inventors: Stephen W. Day, Daniel M. Hutcheson, G. Scott Campbell
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Publication number: 20040096646Abstract: The invention relates to a lightweight wheel housing part of plastic for reduction of the transmission of rolling noises, spray water noises and stone impact noises into the vehicle interior and for protection from corrosion, the plastic being foamed or expanded plastic. Furthermore, the invention relates to the use of thermoplastic plastic, duroplastic plastic, elastomer or mixtures thereof for the production of lightweight wheel housing parts.Type: ApplicationFiled: December 23, 2003Publication date: May 20, 2004Inventors: Uwe Behrendt, Dirk Trapp
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Publication number: 20040096647Abstract: Recyclable vehicle interior trim panels, and methods of producing same, are provided. A vehicle interior trim panel may include a top layer of recyclable polymeric material and a backing layer bonded to the top layer in face-to-face relationship. The top layer includes a blend of various recyclable polymeric materials including an interpolymer component, a polypropylene copolymer component, a polypropylene component, a limestone component, and barium sulfate component, and has a thickness of between about 1.6 mm and about 2.0 mm. The top layer may include first and second layers of recyclable polymeric material adhered together in face-to-face relationship. The first layer includes a first interpolymer component, a second interpolymer component, a polypropylene copolymer component, a polypropylene component, a polyethylene polymer component, and a silicone component. The second layer includes an interpolymer component, a polypropylene copolymer component, a polypropylene component, and a limestone component.Type: ApplicationFiled: August 22, 2003Publication date: May 20, 2004Inventors: Girma Gebreselassie, Matt Starling, Surendra Khambete, Graham Tompson
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Patent number: 6736939Abstract: In a shoe press belt, in which the nip zone is narrower than the shoe width, the shearing force which normally acts on the belt at the outer boundary of the nip zone is made either weak or non-existent by forming the outer portions of the belt of less hardness than the inner, or central, portion of the belt, so that the less hard portions can be positioned directly opposite the outer boundaries of the nip zone. Alternatively, the outer portions of the belt can be made thinner than the central portion of the belt and the thinner portions positioned directly opposite to the nip zone boundaries. The shearing force applied to the belt at the nip ends of the roll is reduced or eliminated, cracking resulting from the shear force is reduced or avoided, and a belt having improved durability results.Type: GrantFiled: July 29, 2002Date of Patent: May 18, 2004Assignee: Ichikawa Co., Ltd.Inventor: Kazumasa Watanabe
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Patent number: 6733877Abstract: In order to create a full grain napa cowhide which exhibits the characteristics with respect to grain pipeyness and water vapor permeability that are required by the automotive and upholstery industries, a finish is applied to the grain side of the full grain leather. The finish includes a pigmented layer with a thickness of between 0.015 mm and 0.04 mm and is formed of a stabilized polyurethane and/or polyacrylate dispersion. The dispersion contains microspheres with a diameter of less than 45 &mgr;m, which form primarily closed cells, and at least 10% open cells by volume. The top side of the layer is provided with a napa embossing. A second layer, placed on the first layer, is formed from a cross-linked polyurethane-based varnish application containing a dulling agent. The leather undergoes a milling treatment.Type: GrantFiled: October 4, 2002Date of Patent: May 11, 2004Inventor: Philipp Schaefer
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Patent number: 6720066Abstract: The present invention is directed to a process for obtaining a substrate provided with a coating having photocatalytic properties, wherein the coating includes crystallized particles of an oxide of a metal A having photocatalytic properties. The crystallized particles are incorporated into the coating using a mineral binder comprising at least one oxide of a metal B also having photocatalytic properties in the crystallized state. The coating optionally includes at least oxide of a metal M devoid of photocatalytic properties and/or at least one silicon compound of the silicon oxide SiO2 type. The coating is deposited from liquid-phase dispersions containing the crystallized particles of the oxide of metal A and at least one precursor compound for the oxide of metal B of the binder and optionally a precursor compound for the oxide of metal M and for the Si compound, in a relative proportion A/(B+M+Si) by weight of the metals and Si ranging between 60/40 and 40/60.Type: GrantFiled: September 5, 2002Date of Patent: April 13, 2004Assignees: Saint-Gobain Glass France, Rhodia ChimieInventors: Xavier Talpaert, Michel Simonet, Corinne Lehaut, Thierry Chopin, Frédéric Magnin-Feysot
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Patent number: 6713139Abstract: The present invention provides a hollow foamed polyolefin-based resin container comprising an inner layer and an outer layer, at least one of the inner and outer layers being formed of a foamed polyolefin-based resin sheet, wherein at least a side wall part of the container has a hollow portion between the inner and outer layer and a process for produciong the same, and the like. The hollow foamed polyolefin-based resin container can be used as containers for retorted food products and other containers.Type: GrantFiled: September 27, 2002Date of Patent: March 30, 2004Assignee: Sumitomo Chemical Company, LimitedInventors: Nobuhiro Usui, Takeo Kitayama
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Patent number: 6706384Abstract: A technique and device for rehabilitating or repairing waste water system components or the like, comprising a spray-applied, multi-layer liner which seals the components and imparts structural integrity. The liner comprises a primer layer, a first moisture barrier layer, a foam layer and a second moisture barrier layer. The first and second moisture barrier layers are preferably made of the same material and form a skin on both sides of the internal foam layer. The combination of the foam layer and the two moisture barrier layers imparts structural strength and rigidity to the cured liner.Type: GrantFiled: March 22, 2000Date of Patent: March 16, 2004Inventor: James M. Hume
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Publication number: 20040013846Abstract: Provided is a polypropylene resin foam-molded article which has a rib having a relatively small thickness and which has an improved strength at a boundary part between a main body part and the rib part without increasing a thickness of the rib part. The polypropylene resin foam-molded article is obtained by molding a material for a foam-molded article using a polypropylene resin, wherein the molded article comprises a main body part and a rib part provided vertically to the main body part; the rib part has a thickness (Tr) of 3 mm or less, or a thickness ratio (Tr/Tb) of a thickness of the rib part (Tr) to a thickness of the main body part (Tb) is 0.8 or less; the main body part and the rib part each comprise a non-foamed surface layer and an intermediate layer having a foamed structure; and the intermediate layer in the main body part is connected to the intermediate layer in the rib part.Type: ApplicationFiled: July 17, 2002Publication date: January 22, 2004Applicants: Chisso Corporation, Chisso petrochemical CorporationInventors: Youichi Kugimiya, Kouichi Honda
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Patent number: 6677032Abstract: Corrosion- and chip-resistant coatings for high tensile steel components, such as automotive coil springs, are formed from a coating powder composition of “toughened” epoxy resin. In a single coat embodiment, the entire coating is loaded with at least 75 phr zinc powder. In a dual coat embodiment, an inner coat is loaded with at least 75 phr zinc and an outer, zinc-free coating is reinforced by the addition of fibers and/or by a foaming agent which renders it porous.Type: GrantFiled: November 1, 2000Date of Patent: January 13, 2004Assignee: Rohm and Haas CompanyInventors: Tina L. Grubb, Catherine A. Kleckner, William E. Wertz, Michael C. Siminski, Andrew T. Daly, Jeno Muthiah
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Patent number: 6673412Abstract: A composite material having a film operatively associated with a polyolefin foam layer and at least one metallic layer operatively associated with at least one of the foam layer and the film.Type: GrantFiled: March 19, 2001Date of Patent: January 6, 2004Assignee: Sealed Air CorporationInventors: Natarajan S. Ramesh, Nelson Malwitz
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Patent number: 6670029Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion.Type: GrantFiled: September 7, 2001Date of Patent: December 30, 2003Assignee: ADC Composites, LLCInventors: Edward J. Norton, Zenon O. Smotrycz
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Patent number: 6655730Abstract: The problem to be solved is to provide an automobile interior headliner member which is improved in the film forming property of a complex plastic material used as a base material of the automobile interior headliner member, and has high rigidity and excellent heat resistance, size stability and working efficiency upon attachment; and the base material. An automobile interior headliner molding or forming member which is obtained by kneading mica having a particle size of 10 to 100 &mgr;m with a polypropylene resin having a melt flow rate at 230° C. of 3 to 40 g/10 min to obtain the corresponding resin having a mica content of 15 to 40 wt. %, molding or forming the resin into a mica-containing polypropylene sheet of 100 to 300 &mgr;m thick and then stacking this sheet over each of both sides of an expanded polypropylene sheet of 2 to 6 mm thick obtained at an expansion ratio of 5 to 50 times; and an automobile interior headliner member molded or formed from the molding or forming member.Type: GrantFiled: April 10, 2001Date of Patent: December 2, 2003Assignee: Oji Paper Co., Ltd.Inventors: Shigeru Yamagata, Ryoetsu Sakurabashi, Hisanori Yagi, Mitsutoshi Ogata, Akihiko Kojima
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Publication number: 20030211309Abstract: Polypropylene films and methods for making the films having white opaque characteristics are disclosed. The films typically incorporate polymer blending to improve microcavitation, increased opacity, increased optical density and lower light transmission for a white opaque film with CaCO3 loading at and above 40% by weight. A combination of polypropylene resins of specified density, crystallinity and ratio relationships have been identified with TiO2.Type: ApplicationFiled: May 8, 2002Publication date: November 13, 2003Applicant: Vifan USA, Inc.Inventors: Vittoriano DiLuzio, Paul Alder, Michael T. Heffelfinger
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Publication number: 20030211310Abstract: The present invention is directed to a process for producing a polypropylene foam by mixing a high melt strength polypropylene and a blowing agent to form a melt mixture, reducing the temperature of the melt mixture at the exit of the apparatus to an exit temperature that is no more than 30° C. above the melt temperature of the neat polypropylene while maintaining the melt mixture at a pressure sufficient to prevent foaming; passing the mixture through said exit shaping orifice and exposing the mixture to atmospheric pressure, whereby the blowing agent expands causing cell formation resulting in foam formation, and orienting said foam. The foam is useful as tape backings, thermal and acoustical insulation and as a diffuse reflector for use in optical applications such as computer displays.Type: ApplicationFiled: November 7, 2002Publication date: November 13, 2003Inventors: Christopher K. Haas, Mark D. Gehlsen, Sara B. Mortenson, Joan M. Strobel
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Publication number: 20030211311Abstract: A vehicle bumper (20) integrates rigid and flexible components into a single co-injection molded structure. In a preferred embodiment, a flexible fascia (58) is provided with integrated rigid fastener brackets (62, 66, 70, 71), energy absorption structure and head lamp brackets and housings (62). A method for manufacturing such a bumper provides for the injection of two different plastic materials during the same molding process. The flexible plastic material first injected into the mold. Then, the rigid plastic material is injected at gates located where the rigid material is desired. In one embodiment, the rigid material is completely contained within the flexible material. The rigid material may be either a higher stiffness plastic or a fiber reinforced plastic.Type: ApplicationFiled: December 10, 2002Publication date: November 13, 2003Inventors: Marshall Ray Porter, Norman E Guschewski, Michael B Smith, Keith Korte, Todd C Parker, Russell R York
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Publication number: 20030203163Abstract: A molded product is made comprising a low-density product having a porous volume including cells and an essentially non-porous layer adjacent an external surface of the product. Essentially none of the cells are exposed at the external surface. The external surface is sufficiently tough, smooth, strong and durable to be suitable as a substrate for silk-screen printing.Type: ApplicationFiled: April 17, 2003Publication date: October 30, 2003Inventors: James S. W. Lee, Kwong-Wai Chow
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Patent number: 6627291Abstract: The present invention provides new patterned porous substrates and a new method for forming the new patterned porous substrates containing one or more selected patterns which is applicable to all porous structures regardless of their polymeric content, their method of manufacture or their UV absorbing characteristics.Type: GrantFiled: September 13, 2000Date of Patent: September 30, 2003Assignee: Millipore CorporationInventors: Phillip Clark, Wilson Moya
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Patent number: 6623847Abstract: A method for making a resilient cushion includes providing a particulate polymer, discrete pieces of foam and a plasticizer. The polymer, foam pieces and plasticizer are mixed and disposed in a mold. The mold is heated to cause melting of the polymer without melting of the foam. After coating of the melted polymer, a heterogeneous resilient cushion is formed with gelated polymer surrounding the discrete foam pieces.Type: GrantFiled: September 24, 1999Date of Patent: September 23, 2003Inventor: Paul M. Yates
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Patent number: 6617015Abstract: A motor vehicle has a first body part with a seal support flange thereon that supports a unitary seal construction having a flexible bulb seal portion engageable with second vehicle body part including a hood or other vehicle body part for sealing against leakage between the first and second vehicle body parts and an integrally formed base portion and wherein the flexible bulb seal is hollow and is formed of a soft low density thermoplastic foam and the integrally formed base portion is integrally extruded with the flexible bulb seal and is formed solely from polymeric material having spaced walls defining a recess for fitting the unitary seal construction in place on the support flange.Type: GrantFiled: June 19, 2001Date of Patent: September 9, 2003Assignee: Hahn Elastomer CorporationInventor: Kenneth W. Rood
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Patent number: 6617016Abstract: A low stress relaxation elastomeric material comprises a block copolymer having an elasotmeric soft block portion and thermoplastic hard block portions, at least one vinylarene resin and mineral oil. The elasotmeric material may be used in a film comprising an elastomeric layer and at least one substantially less elastomeric skin layer. The skin layer comprises a thermoplastic polymer such as polyolefins. The film exhibits desired elastic and stress relaxation properties at body temperature. The film is useful in forming a macroscopically-expanded, three-dimensional elastomeric web.Type: GrantFiled: February 20, 2002Date of Patent: September 9, 2003Assignee: The Procter & Gamble CompanyInventors: John Jianbin Zhang, John Joseph Curro, Michele Ann Mansfield
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Patent number: 6607803Abstract: A laminate composition of a thin film of low density polyethylene adhered to a sheet of low density polyethylene foam by means of a very thin layer of low density polyethylene. The polyethylene foam has a low density which is preferably between about 1.9 pcf and about 2.2 pcf. The bottom polyethylene film serves as a vapor barrier. One side of the polyethylene film extends beyond one edge of the polyethylene foam sheet. The laminate composition is installed in a free floating manner on the concrete subflooring, with the polyethylene film or the polyethylene foam sheet contacting the surface of the concrete subflooring. The laminate composition is usually in long strips, so when it is installed one edge of one strip overlies the extended portion of the polyethylene film of an adjacent strip. Tape having adhesive on both sides can be positioned between the overlay region to adhere together the overlaid portions to prevent movement thereof during installation of the laminate wood finish flooring.Type: GrantFiled: September 24, 1999Date of Patent: August 19, 2003Assignee: Pactiv CorporationInventor: Stephen M. Foster
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Publication number: 20030148692Abstract: A laminated sheet which contains a cross-linking foam material, and radiates far infrared so that it has heat-insulating and heat-retentive properties. The laminated sheet (1) has a three-layered structure including polyethylene foam (2) having a sheet shape that is one example of a cross-linking foam material in which a substance that radiates far infrared rays is mixed, non-woven fabric (3) having a sheet shape formed on a lower face thereof and a polyester film (4) formed on an upper face thereof. Since the laminated sheet of the present invention is allowed to radiate far infrared rays, it can greatly shorten the snow-melting time, etc., because of its heat reflection effects in comparison with a sheet made of a single material of non-woven fabric, and it also makes it possible to greatly improve heat-insulating and heat-retentive effects, and also to provide medical effects.Type: ApplicationFiled: January 10, 2003Publication date: August 7, 2003Inventor: Seishi Chikamori
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Patent number: 6599615Abstract: The present invention is a floor mat made from a rubber composite, the composite having a foam rubber core positioned between dense rubber layers. Protrusions or cleats, which are produced during the vulcanization process, extend outwardly from the lower surface of the mat. The present mat offers mat users desirable anti-fatigue characteristics that are achieved by (a) a combination of dense rubber and foam rubber layers and (b) the spaced positioning of a plurality of cleats over one surface of the mat. Such a mat is anticipated to be useful in service environments, such as hair styling salons, retail outlets, or restaurant kitchens, for example.Type: GrantFiled: November 15, 2001Date of Patent: July 29, 2003Assignee: Milliken & CompanyInventors: William O. Burke, III, Amy B. Streeton
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Publication number: 20030138621Abstract: Composite elements compriseType: ApplicationFiled: December 8, 1999Publication date: July 24, 2003Inventors: HEINRICH BOLLMANN, KLAUS GIESEN, RUEDIGER KRECH, ERHARD REICH
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Publication number: 20030129377Abstract: A molded article having a curved surface is formed from a heat curable reactive thermoset polymer resin powder containing an integrally formed insert bonded therein. The integrally formed insert may be threaded for subsequent attachment of the molded article to a frame or structure. The insert is partially surrounded by a boss with supporting features to ensure that the insert is orthogonally supported.Type: ApplicationFiled: November 26, 2002Publication date: July 10, 2003Inventor: Stewart M. Holmes
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Patent number: 6589646Abstract: A composite layered sheet or composite layered film made from thermoplastics or thermoplastic mixtures comprises at least one substrate layer A) and at least one functional layer B) which comprises one or more blowing agents or nucleating agents, where the functional layer B) is thinner than the substrate layer A). A process for producing the sheet or film and a process for producing thermally insulating moldings are described.Type: GrantFiled: May 5, 2000Date of Patent: July 8, 2003Assignee: BASF AktiengesellschaftInventor: Herbert Morgenstern
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Patent number: RE38745Abstract: A laminate composition of a thin film of low density polyethylene adhered to a sheet of low density polyethylene foam by means of a very thin layer of low density polyethylene. The polyethylene foam has a low density which is preferably between about 1.9 pcf and about 2.2 pcf. The bottom polyethylene film serves as a vapor barrier. One side of the polyethylene film extends beyond one edge of the polyethylene foam sheet. The laminate composition is installed in a free floating manner on the concrete subflooring, with the polyethylene film or the polyethylene foam sheet contacting the surface of the concrete subflooring. The laminate composition is usually in long strips, so when it is installed one edge of one strip overlies the extended portion of the polyethylene film of an adjacent strip. Then the laminate wood finish flooring, in plank form, is installed on top of the laminate composition in a free floating manner. The laminate wood planks fit together in a tongue-in-groove manner and are glued together.Type: GrantFiled: September 14, 2001Date of Patent: June 21, 2005Assignee: Pactiv CorporationInventor: Stephen M. Foster