Abstract: A low density polymer composition including a polymer component capable of being cured, a low density filler in an amount sufficient to reduce the density of the polymer and a thixotrope present in a sufficient amount to impart a sufficient viscosity and to inhibit separation of the filler from the polymer until after the polymer is cured. The resulting lightweight, filled polymer composition is a strong electrical insulator, has low shrinkage, a low coefficient of thermal expansion, low cured density and a soft filler that does not harden the polymer. Methods of preparing and using the low density polymer compositions are also disclosed.

Abstract: The present invention aims to improve soundproof and heat insulating properties of a foamed plastic by reducing internal cells pressure inside foamed resins. A base polymer such as a polyester-based polyol and a volatile foaming agent having an conjugate unsaturated group (i.e., conjugate double carbon bonds and/or triple carbon bonds) such as chloroprene (bp. 51.degree. C.) and calcium stearate were blended and then mixed with a hardening agent such as hexamethylene diisocyanate. The volatile foaming agent existing in open cells of the foamed plastic sealed in the Al laminated film and between the film and the foamed plastic, i.e., gap, possesses an unsaturated group, such as isoprene. Thus polymerization may occur by irradiating with electron rays, and the inside of the foams and the gap region may be reduced in pressure while the bag of the laminated film retains its shape.

Abstract: An insulating foam composition, comprising a polyisocyanate component and a resin component that includes a polyepoxide, an aromatic polyester polyol, and a melamine resin. The foam will remain stable at temperatures up to 400.degree. F., continuously, and up to 450.degree. F., intermittently, and can be applied by spraying, pouring, or frothing directly onto surface of high temperature industrial apparatus.

Abstract: A polymer polyol is produced by a process comprising free radical polymerizing an addition polymerizable di-(substituted phenyl)monomer (e.g., methacrylic ester of diglycidylether of tetrabromobisphenol A) component in the presence of a polyol, wherein the monomer has at least one aromatic halogen and at least one aromatic ethylenically unsaturated substituent. The polymer polyol can also be made by copolymerizing said monomer with an additional ethylenically unsaturated monomer component such as styrene and acrylonitrile. Said polymer polyols are reacted with a polyisocyanate compound forming a flame retardant polyurethane foam.

Abstract: This invention relates to a reinforced closed-section structural-member structure making use of a heat-foamable filling reinforcement. The structure has been formed by connecting plural closed-section structural members (11-15) together. These closed-section structural members (11-15) are internally filled with a heat-foamed filling reinforcement (1) which comprises an epoxy resin material, a synthetic rubber material and a thermoplastic resin material as components.

Abstract: The present invention provides a method of reinforcing thin rigid plates. The method comprises applying, preferably by spray application, a curable composition onto one side of the rigid plate followed by curing the composition while only in contact with the rigid plate. The curable composition comprises: (i) a thermosetting resinous composition and (ii) expandable microspheres. The composition may optionally contain a particulate reinforcing material selected from the group consisting of milled glass fibers, milled carbon fibers, and mixtures thereof.

Abstract: A composition includes a polymethacrylimide polymer which is polymerized in the presence of an epoxy resin and a flame-inhibiting agent. Further, a process is described for making flame-resistant polymethacrylimide, which includes mixing an epoxy resin and a flame-inhibiting agent with a methacrylic acid and methacrylonitrile, and polymerizing. A polymethacrylimide foam so prepared has an LOI value of at least 25 and retains the good mechanical properties that are associated with polymethacrylimide foams.

Abstract: A low-density, porous material is prepared by mixing together microballoons and an oligomeric precursor to a polyesterimide polymer. The oligomeric precursor has an initial viscosity sufficiently low that it can flow and wet the microballoons when first heated to a polymerization processing temperature, and thereafter polymerize. Fibers may be controllably incorporated into the material during processing to impart specific properties, and air may be controllably incorporated into the material during processing to further decrease its density.

Abstract: A low-density, porous material is prepared by mixing together microballoons and an oligomeric precursor to a polyetherimide polymer. The oligomeric precursor has an initial viscosity sufficiently low that it can flow and wet the microballoons when first heated to a polymerization processing temperature, and thereafter polymerize. Fibers may be controllably incorporated into the material during processing to impart specific properties, and air may be controllably incorporated into the material during processing to further decrease its density.

Abstract: A rubber composition for sponge rubber which contains following components (A).about.(E) and satisfies the following requirements that the ratio by weight of (A)/(B) is 30/70.about.99/1 and the amount of component (C) is 50.about.400 parts by weight per 100 parts by weight of the total amount of components (A) and (B):(A): Epoxy group-containing acryl elastomer.(B): Ethylene copolymer which contains a carboxyl group(s) or a carboxylic anhydride group(s).(C): Hydroxyl compound of II or III group of typical metal element in periodic table.(D): Vulcanizer.(E): Foaming agent.The sponge rubber compositions of the invention can be used for sponge for insulator in the field of electricity, architecture, automobile and the like, because sponge rubber compositions of the invention have the characteristics of good heat resistance, good oil stability, high-foaming property, and good shape-retention.

Abstract: This invention is directed to a fire-resistant, essentially halogen-free epoxy composition that emits low amounts of smoke and toxic gas while burning. The one-part composition is particularly useful in aerospace applications for bonding, sealing and/or insulating metal, plastic and composite parts.

Abstract: The present invention provides a foamable epoxy resin composition (A) 100 parts by weight of a liquid epoxy resin (B) 0.5-20 parts by weight of a latent curing agent, (C) 0.5-15 parts by weight of a foaming agent having a decomposition temperature of 100.degree.-220.degree. C., (D) 0.05-5 parts by weight of a surface active agent and (E) 10-200 parts by weight of a rubbery elastomer or a powdery halogen-free thermoplastic resin of 150 .mu.m or less in average particle diameter, which composition has a melt viscosity of 2.5.times.10.sup.3 -5.times.10.sup.4 dPa.multidot.s at the decomposition temperature of said foaming agent. The composition can provide a foamed material of rigidity and good heat resistance, having an expansion ratio of 5 times or more and a dense cell structure of 0.5 mm or less in average cell diameter.

Abstract: A thin, tacky, non-pourable film of incompatible in situ-expandable thermoplastic particles and thermosettable matrix resin that contains an essentially uniform density and thickness across the breadth of the film. The in situ-expandable mass is not pourable yet can be easily dispensed in a uniform manner within a mold and thereafter expanded to the dimensions of the mold. Composites and reinforced compositions, as well as methods of molding, are disclosed.

Abstract: Improved hydrophilic materials, such as foams and films, are provided. These material find use in a wide variety of fluid absorbent products, especially those relating to the absorption of bodily fluids. The soft, absorbent, and resilient foams of this invention exhibit greater wet and dry mechanical strength when compared with those known in the art, as well as improved fluid wicking capacity and lower density. These improved properties are believed attributable to the incorporation into the foams of at least one polyfunctional aliphatic amine.The provided hydrophilic materials comprise the polymeric reaction product of a mixture which comprises at least one epoxy resin, at least one amine-terminated poly(alkylene oxide), and at least one polyfunctional aliphatic amine. Methods for preparing foams and other hydrophilic materials are also provided.

Abstract: A composite material having a substrate and an expanded, cured layer of an epoxy resin composition which is provided over a surface of the substrate and in which a major portion of the cells are present in a location adjacent to the interface between the substrate and the expanded layer and substantially no cells are present on the top surface portion of the expanded layer. The epoxy resin composition includes an acid anhydride curing agent and an alkali metal carbonate blowing agent. The composition is coated over the substrate and the coating is heated to sure and expand the composition while maintaining the top surface of the coating below the expansion temperature.

Abstract: A foam absorber having electromagnetic energy attenuation characteristics comprising an open cell reticulated polyurethane foam impregnated with a conductive ink applied to a surface of the foam substrate. The conductive ink is applied as by spraying to a surface of the foam, coating such surface and gradiently loading the foam with the ink by penetration of the ink in gradually decreasing amount into the foam to a final depth therein. The conductive ink is comprised of an epoxy resin carrier and a combination of carbon and a metal such as silver, copper or nickel, preferably silver. The ink is applied as a curable mixture containing a solvent, to the foam substrate, the solvent is evaporated following coating and penetration of the ink into the foam, and the epoxy carrier of the ink in the foam substrate is cured.

Abstract: A normally liquid epoxy resin obtainable by reaction of a bisphenol based oligocarbonate having terminal phenolic hydroxyl groups with an epihalohydrin, followed by dehydrohalogenation. The epoxy resin is capable of forming a tough cured product having improved flexural strength and flexural modulus. A process for the production of an epoxy resin foam in which a polyepoxy compound is crosslinked and simultaneously foamed by the aid of carbonate oligomers having terminal phenolic hydroxyl groups. The product is highly flexible against compression, bending and warp.

Abstract: A method for producing expandable thermoplastic microspheres by polymerisation in a reaction vessel of an ethylenically unsaturated monomer or a mixture of monomers in an aqueous suspension in the presence of a condensed propellant. In the method, the monomer or monomer mixture is suspended in the aqueous medium in the presence of a powder stabilizer which consists of a salt or hydroxide of any of the metals Ca, Mg, Ba, Fe, Zn, Ni or Mn. The powder stabilizer is insoluble in the aqueous medium at the pH the aqueous medium has at the polymerisation. The aqueous medium has at the polymerization. The aqueous medium may also contain a co-stabilizer. The method further comprises the step of washing off the powder stabilizer from the microspheres after the polymerization by lowering the pH of the aqueous medium by the addition of acid. Alternatively, amphoteric hydroxides can also be dissolved by a pH increase.

Abstract: A foam absorber having electromagnetic energy attenuation characteristics comprising an open cell reticulated polyurethane foam impregnated with a conductive ink applied to a surface of the foam substrate. The conductive ink is applied as by spraying to a surface of the foam, coating such surface and gradiently loading the foam with the ink by penetration of the ink in gradually decreasing amount into the foam to a final depth therein. The conductive ink is comprised of an epoxy resin carrier and a combination of carbon and a metal such as silver, copper or nickel, preferably silver. The ink is applied as a curable mixture containing a solvent, to the foam substrate, the solvent is evaporated following coating and penetration of the ink into the foam, and the epoxy carrier of the ink in the foam substrate is cured.

Abstract: A method of treating hazardous material or other substrate with an aqueous air foam, comprising the steps of (1) preparing an aqueous solution or dispersion comprising (a) water-soluble polyhydroxy polymer having a plurality of hydrogen-bondable 1,2- and/or 1,3-diol structures capable of complexation with the borate anion, B(OH).sub.4.sup.

Abstract: Compositions are disclosed which are suitable for the preparation of thermoplastic syntactic foam intermediate and final products. These compositions comprise a slurry or putty containing thermoplastic particles, microballoons, and a non-solvent, optionally in the presence of suitable thickeners, binders, and surfactants. In a preferred embodiment, the composition contains particles of an engineering thermoplastic having a mean particle size less then about 100 .mu.m, microballoons, water as the non-solvent, and a thickener/binder which is a lightly crosslinked polyacrylic acid.

Abstract: An improved lightweight, ablative coating that may be spray applied and cured without the development of appreciable shrinkage cracks. The ablative mixture consists essentially of phenolic microballoons, hollow glass spheres, glass fibers, ground cork, a flexibilized resin binder, and an activated colloidal clay.

Abstract: A water-base endothermic fire protective material comprising a heat curable thermosetting resin, inorganic fibers, an endothermic inorganic filler, and thermoplastic binder resin is disclosed. The material can vary in viscosity from a putty that is moldable or trowelable into place to a thin paste that can be sprayed to form a flexible and stable fire stop seal or coating. The material with essentially no shrinkage retains strength and adhesion qualities before and after exposure to fire and retains superior resistance to the impact, erosion, and cooling effects of a hose stream used to combat a fire.

Abstract: A method of treating hazardous material or other substrate with an aqueous air foam, comprising the steps of (1) preparing an aqueous solution or dispersion comprising (a) water-soluble polyhydroxy polymer having a plurality of hydrogen-bondable 1,2- and/or 1,3-diol structures capable of complexation with the borate anion, B(OH).sub.4.sup.

Abstract: A two-part system for reinforcing a hollow structural member and its method of use are provided. Part A of the two-part system is formed by adding a filler and unexpanded, thermally-expandable microspheres to a liquid thermosetting resin, such as an epoxy resin, in a quantity sufficient to produce a dough-like mass which can be readily kneaded. Part B is formed by adding a filler and a colorant, such as carbon black, to a liquid curing agent, again forming a dough-like mass. The curing agent is compatible with the thermosetting resin to promote cross-linking of the thermosetting resin upon contact with the curing agent.A hollow structural member is cleared of debris of the like and may be preheated to enhance the rate at which the thermosetting resin cross-links. The two parts are blended together until a reactive third dough of substantially uniform mixture is formed.

Abstract: A highly temperature resistant foam useful for insulating is disclosed. The foam is particularly useful for insulating stem pipes, hot water heaters and refinery and chemical processing plant pipes. The foam insulation utilizes a cross-linking agent comprised of melamine, which may be dissolved in an alcoholic base. The foam may also include an aromatic polyester polyol, a chlorinated polyester polyol, a nonyl phenol ethoxylate, a silicone based surfactant, and isocyanurate catalyst, a density controlling agent and polymeric isocyanate.The foam will stand consistent temperatures as high as 400.degree. F. It is suitable for spray or poured applications and may be frothed during application.

Abstract: This invention relates to a curable latex composition, films and foams produced therefrom and method for preparing said curable latex composition. The composition comprises a carboxylated latex, an epoxy resin emulsion containing an organo-soluble or organo-miscible catalyst and a water-soluble catalytic curing agent. The carboxylated latex comprises a copolymer of from 0 to 75 percent by weight of a vinyl aromatic monomer, from 0 to 85 percent by weight of a diene monomer and from 0.5 to 25 percent by weight of an ethylentically unsaturated carboxylic acid monomer, all weight percentages based on the total weight of the copolymer. The latex is produced by emulsion polymerization of one or more monomers in an aqueous environment. The various components of the curable latex composition may be maintained separately until shortly before use because of their ambient temperature curing properties. In some instances two or more components which do not react with each other can be premixed.

Abstract: Cured foams with a high degree of closed cellular structure, good stability under prolonged heat exposure and good compressive strength can be produced from a hot-foamable, thermosetting epoxy resin mixture containing (a) an epoxy resin or a mixture of epoxy resins with an average epoxide content of 4.4 to 5.0 equivalents/kg and an average epoxide functionality of more than 2.0, (b) a novolak with a hydroxyl equivalent weight of 90 to 120, 0.8 to 0.95 hydroxyl equivalents of component (b) being present in the epoxy resin mixture per 1 epoxide equivalent of component (a), (c) 1.0 to 1% by weight, based on the amount of components (a) and (b), of a curing accelerator, (d) 0.5 to 10% by weight, based on the amount of components (a) and (b), of a blowing agent which splits off nitrogen above 100.degree. C. with decomposition, (e) 0.3 to 1% by weight, based on the total amount of the epoxy resin mixture, of an emulsifier, and if appropriate (f) foam modifiers.

Abstract: An organic bulk polymer is disclosed having microscopically dispersed therein a liquid crystalline polymer in an amount sufficient to measurably improve the properties of the organic polymer relative to a like bulk polymer in the absence of the liquid crystalline polymer.

Abstract: A method of producing a porous material having open pores comprises the steps of preparing an emulsion slurry by vigorously agitating a mixture comprising a main ingredient, a polyamide hardener, a filler and water, casting said emulsion slurry in a water-impermeable mold, hardening said slurry while it contains the water. The main ingredient is a bisphenol-type epoxy resin added with one or more reactive diluents each having one or more epoxy rings per molecule and added in an amount of 18 to 50 wt %, based on 100 wt % of said bisphenol-type epoxy resin. A large size molded product having a high wet bending strength and a complicated contour can be produced.

Abstract: A method of adsorbing a substance such as an optically active substance, comprising contacting a solution of the substance in a solvent with an adsorbent consisting of a cross-linked polymer comprisingan optically active, synthetic poly(amino acid) represented by the general formula (I): ##STR1## wherein R stands for an organic group, R' stands for hydrogen or an alkyl group and n is an integer of at least 5, which may be protected at a terminal amino group anda carrier polymer supporting said synthetic poly(amino acid) thereon, said carrier polymer having affinity for said solvent. A method for producing the cross-linked polymer is also described.The adsorbent is especially useful for optical resolution of racemic mixtures.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermoplastic polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermosetting polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: A solution or colloidal dispersion of a polymer of an ethylenically unsaturated steroid derivative in an active hydrogen-containing compound is claimed. The polymer provides improved physical properties to a polyurethane made by reacting the solution or dispersion with an polyisocyanate.

Abstract: Polyurethanes are prepared from a polyol which itselve contains liquid crystalline moieties or which contains dispersed or dissolved liquid crystalline polymers. The use of this polyol is found to provide improved properties to polyurethanes, especially flexible polyurethane foams, which exhibit improved load bearing.

Abstract: This invention relates to a plastics material with a resin binder having a combination of fusible fillers and high temperature fillers. The fusible fillers begin melting at relatively low temperatures and retain a spreaded liquidous form over a large temperature range. The high temperature fillers resist melting at high temperatures and form an insulative layer over the resin binder of the plastics cellular material.

Abstract: A composition for use in a chloride ion electrode is provided herein. This composition is made up of a mixture of an epoxy resin, a vinyl chloride resin, one or more solvents, a quaternary ammonium salt and hardening agents for setting said epoxy resin; wherein said epoxy resin and the vinyl chloride resin is used at a ratio of 8:1 to 1:2 by weight. The present invention also relates to a response membrane produced from said composition and a method for producing the response membrane by setting or hardening the aforementioned composition. When the response membrane is used in the chloride ion selective electrode, it is capable of measuring a sample containing blood or protein and by use of the response membrane, it is possible to selectively determine chloride ions in a sample with a high degree of accuracy.

Abstract: Fiber-reinforced syntactic foam composites having a low specific gravity and a low coefficient of thermal expansion suitable for forming lightweight structures for spacecraft applications are prepared from a mixture of a heat curable thermosetting resin, hollow microspheres having a diameter of about 5 to 200 micrometers and fibers having a length less than or equal to 250 micrometers.

Abstract: The invention relates to a plastics cellular material comprising the reaction product of an unsaturated polyester resin containing a polymerizable unsaturated monomer and an epoxy-based vinyl ester in the presence of surfactants.

Abstract: Epoxy compounds are added to polycarbonate resin to reduce or eliminate the necessity of drying the resin prior to a foaming process.

Abstract: An expandable blend of a linear olefinic polymer and a crosslinkable polymer for production of lightly crosslinked foamed polymers and a process for the preparation thereof is provided. The presence of a crosslinkable polymer component in the blend increases the melt strength of the linear olefinic component so that conventional melt processing techniques may be utilized to produce foamed polymers. Both open and closed cell foams may be produced.

Abstract: Miscible blends of poly-2-oxazolines and thermoplastic polymers are disclosed herein. These blends exhibit a single glass transition point indicative of a miscible blend. The blends of this invention are useful as membranes, particularly separation membranes for mixtures of organic compounds or organic compounds and water and a perevaporation process.

Abstract: Fiber-reinforced syntactic foam composites having a low specific gravity and a coefficient of thermal expansion of about 9.0.times.10.sup.-6 in/in/.degree.F. (16.2.times.10.sup.-6 cm/cm/.degree.C.) or less are prepared from a mixture of: a heat curable thermosetting resin comprising an uncured polyglycidyl aromatic amine, a polycarboxylic acid anhydride curing agent, and a chosen curing accelerator; hollow microspheres having a diameter of about 5 to 200 micrometers; and fibers having a length less than or equal to 250 micrometers. These composites are useful for forming lightweight structures for space applications.

Abstract: Epoxy compounds are added to polycarbonate resin to reduce or eliminate the necessity of drying the resin prior to a foaming process.

Abstract: An absorbent, flexible, resilient, cellular polymer is provided which comprises the reaction product of at least one epoxy resin and amine terminated poly(alkylene oxide).

Abstract: The present invention relates to a flame-retardant polyolefin foam comprising a polyolefinic thermoplastic resin consisting mainly of a homopolymer of .alpha.-olefin or copolymer of .alpha.-olefins having 2 to 10 carbon atoms; 2 to 10 percent by weight as bromine content, based on the weight of the foam, of a bisphenol A-based brominated epoxy resin or a crosslinked product thereof; and 0 to 25 percent by weight, based on the weight of the foam, of an inorganic filler. The foam of the present invention has superior flame retardancy and thermoformability in addition to the superior heat insulating property and shock absorbing property of the polyolefin foam, and because of these superior characteristics it is useful as an automotive interior material, etc.

Abstract: A polyester polyurethane foam formulation useful in medical pads to support bedridden patients is described. The foam is formed by reaction of a polyester polyol, isocyanate and blowing agent combination of water and halogenated hydrocarbon auxiliary blowing agent. A halogenated flame retardant, e.g., an organophosphorus compound, is present. A liquid char forming and dripping ember retardant additive is also present.

Abstract: A polymer composition comprising an ethylene-vinyl acetate-carbon monoxide copolymer and a nitrogen-containing or an alicyclic epoxy compound, and a foamable polymer composition comprising an ethylene-vinyl acetate-carbon monoxide copolymer, a heat-decomposable organic blowing agent having a decomposition temperature of at least 90.degree. C., and a nitrogen-containing or an alicyclic epoxy compound.

Abstract: An absorbent cellular polymeric material is provided which exhibits enhanced water retentivity and may also exhibit enhanced compressibility. Such a material is provided by foaming the reaction product of a poly(aminoether) and an epoxy resin and quaternizing the resulting reaction product with, for example, an acid. The foam is particularly usable in products for absorbing body fluids.

Abstract: This invention relates to a plastics cellular material and to a process for production of a plastics cellular material. The plastics cellular material has a resin binder and is characterized by the inclusion of products of the reaction of polyester resins and epoxy-based vinyl esters in the presence of surfactants. The process includes taking a first mixture of an unsaturated fast curing polyester resin, epoxy-based vinyl esters, copolymerizeable monomers, a finely dispersed gas releasing salt, hardening accelerators, finely dispersed surfactants, and fillers. The process also includes taking a second mixture is mixed that includes an acidic solution, for reaction with the gas releasing salt as a blowing agent, and organic catalysts. The two mixtures are combined to form a third mixture that will foam in a controllable manner and cure to produce a foam material.