Abstract: The present invention is directed to foams produced from poly(aryl ethers) and mixtures of poly(aryl ethers) with various non-poly(aryl ether) polymers. These foams are produced using aqueous blowing agents comprising water as the only blowing agent, or mixtures of water with another blowing agent material.

Abstract: A porous, crystallized, aromatic polycarbonate prepolymer is disclosed, which comprises recurring aromatic carbonate units and terminal hydroxyl and aryl carbonate groups, wherein these terminal groups are in a specific molar ratio and has specific number average molecular weight, surface area and crystallinity. The prepolymer can readily be converted by solid-state condensation polymerization to a porous, crystallized, aromatic polycarbonate having excellent properties. The porous, crystallized, aromatic polycarbonate of the present invention can readily be molded to obtain a shaped, porous, crystallized polycarbonate. The porous, crystallized, aromatic polycarbonate and the shaped, porous, crystallized polycarbonate of the present invention have excellent heat resistance and solvent resistance and exhibit advantageously low water absorption so that these are suited for use as a filter material, an adsorbent or the like.

Abstract: Disclosed is a bimodal, insulative, styrenic polymer foam structure comprising a foam of a styrene polymer material of greater than 50 percent by weight of styrenic monomeric units, the foam having relatively larger primary cells with a cell size range of 0.05 to 1.2 millimeters and relatively smaller secondary cells ranging in cell size from about 5 percent to about 50 percent of the average cell size of the primary cells. The primary and secondary cells constitute at least about 90 percent of the total cell volume within the foam structure. The bimodal structure has an amount of carbon black sufficient to reduce the thermal conductivity of the structure below that of a corresponding bimodal structure without carbon black. Further disclosed is a process for making the foam structure.

Abstract: A porous, crystallized, aromatic polycarbonate prepolymer is disclosed, which comprises recurring aromatic carbonate units and terminal hydroxyl and aryl carbonate groups, wherein these terminal groups are in a specific molar ratio, and has specific number average molecular weight, surface area and crystallinity. The prepolymer can readily be converted by solid-state condensation polymerization to a porous, crystallized, aromatic polycarbonate having excellent properties. The porous, crystallized, aromatic polycarbonate of the present invention can readily be molded to obtain a shaped, porous, crystallized polycarbonate. The porous, crystallized, aromatic polycarbonate and the shaped, porous, crystallized polycarbonate of the present invention have excellent heat resistance and solvent resistance and exhibit advantageously low water absorption so that these are suited for use as a filter material, an adsorbent or the like.

Abstract: A polyurethane resin, rigid polyurethane foam and composite thereof prepared by using a polyol comprising a phenol resin base polyol mixed with an aminophenol base polyol or a polyphenylpolyxylylenepolyamine base polyol or a polymethylenepolyphenylpolyamine base polyol.

Abstract: The odor of blends of polyphenylene ether resin, alone, or in combination with a polystyrene resin or a high impact polystyrene is improved by including a carboxylic acid, and acid anhydride or mixture thereof in the compositions.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitor as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. the sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.

Abstract: The present invention is directed to foams produced from poly(aryl ethers) and mixtures of poly(aryl ethers) with various non-poly(aryl ether) polymers. These foams are produced using aqueous blowing agents comprising water as the only blowing agent, or mixtures of water with another blowing agent material.

Abstract: A hollow fiber of amorphous, hydroxy-ethylated poly-(2,6-dimethyl-p-oxyphenylene) (PPO-OH) with a glass transition temperature (Tg) of from 180.degree. to 200.degree. C. is disclosed, which is formed by a high-density, microporous layer on a macroporous backing, and having an outer diameter comprised within the range of from 450 to 550 .mu.m and an inner diameter comprised within the range of from 250 to 400 .mu.m.The process for preparing the hollow fibre and the use of said fibre in the processes of separation of gas mixtures are disclosed as well.

Abstract: A process for forming polymer powders by dissolving one or more polymers in a suitable solvent, followed by atomizing the solution into a droplet atmosphere of a non-solvent to precipitate polymer particles. The particles are separated from the non-solvent, washed and dried to produce a powder with a rounded particle morphology, high internal porosity and surface area, and high apparent density.Polymer powders with these properties can be pressed to dense shaped articles suitable for sintering in automated presses because the powders have good low and compressibility characteristics. The process if particularly useful when applied to soluble polymers that are not readily shaped by melt processing means.

Abstract: A flame-retardant spray-foamable phenolic urethane composition comprising a polyisocyanate component, a polyol component, an urethane-forming catalyst, a blowing agent and a foam stabilizer, wherein the polyol component comprises:(1) a modified benzylic ether phenol resin obtained by adding from 20 to 100 parts by weight of a polyhydric alcohol or its alkyleneoxide adduct to 100 parts by weight of a benzylic ether phenolic resin, followed by heating under reduced pressure, and(2) other polyol, in such amounts as to satisfy the following equation:(x+y)/z=0.2-1.5wherein x is the amount by weight of the polyhydric alcohol or its alkyleneoxide adduct, y is the amount by weight of said other polyol, and z is the amount by weight of the benzylic ether phenol resin.

Abstract: A process for the production of polycarbonate foam moldings is disclosed. Accordingly, a composition is prepared comprising mixing a thermoplastic polycarbonate resin and 0.01 to 1 mole-% of a transesterification catalyst anda) 0.1 to 5 mole-% of an aromatic polycarboxylic acid, optionally along with about 0.1 to 5 mole-% of at least one member selected from the group consisting of aliphatic hydroxy carboxylic acids and aliphatic polyalcohols, orb) 0.1 to 5 mole-% of H.sub.2 O, optionally along with at about 0.1 to 5 mole-% of at least one member selected from the group consisting of aliphatic hydroxycarboxylic acids and an aliphatic alcohols, orc) the additives of said a) and b), ord) 0.1 to 5 mole-% of at least one member selected from the group consisting of diarylcarbonates and oligocarbonates,said percent based in every case on moles aromatic carbonate structural units ##STR1## in which --O--R--O is a diphenolate residue.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 to 5.0 weight percent of the polymer, and sodium dihydrogen phosphate as an activator to react with the sodium borohydride and produce hydrogen gas. The sodium borohydride and the sodium dihydrogen phosphate are kept separated from direct contact with each other, such as by encapsulating the components, until gas production is desired when the polymer is heated.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitol as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. The sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.

Abstract: A foamable thermoplastic molding composition comprising:a) an aromatic polycarbonate, andb) 0.1 to 5% by weight of a hydrate of an inorganic salt, is disclosed. The salt is inert to the polycarbonate and is capable of releasing its water of hydration only at a temperature above 100.degree. C.The composition which may optionally further contain c) up to 10% by weight of a nucleating agent, and d) up to 30% by weight of glass fibers is characterized by its good pore structure.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 to 5.0 weight percent of the polymer, and sodium dihydrogen phosphate as an activator to react with the sodium borohydride and produce hydrogen gas. The sodium borohydride and the sodium dihydrogen phosphate are kept separated from direct contact with each other, such as by encapsulating the components, until gas production is desired when the polymer is heated.

Abstract: The invention relates to the use of polyarylene sulphides (PAS), preferably polyphenylene sulphide (PPS) for the preparation of a structural foam, a process for the production of this foam, and mouldings obtainable by this process.

Abstract: The invention relates to the use of polyarylene sulphides (PAS), preferably polyphenylene sulphide (PPS) for the preparation of a structrual foam, a process for the production of this foam, and moldings obtainable by this process.

Abstract: A process for the preparation of expandable granules based on polyaryl ether sulfones and/or polyether imides, containing from 5 to 20% by weight of a physical blowing agent, the blowing agent and the polymers being mixed in an extruder and subsequently extruded directly into a medium at less than 40.degree. C., and a process for the production of foams from expandable granules based on polyaryl ether sulfones and/or polyether imides, containing from 5 to 20% by weight of a physical blowing agent, the granules being press molded at from 120.degree. to 250.degree. C. and at a pressure of from 5 to 30 bar to form a sheet, and the sheet being subsequently foamed by reducing the pressure, are described.

Abstract: Expandable thermoplastic resin microparticle compositions comprising low intrinsic viscosity polyphenylene ethers and a method for producing foam therefrom are disclosed.

Abstract: Useful as catalysts for the reaction of a polyisocyanate or a partially blocked polyisocyanate with a hydroxyl-containing compound are hydroxyl-containing organotins such as, for example, compounds of formulas I-III ##STR1## where R is a C.sub.1 -C.sub.8 alkyl or an aryl group;R.sup.1 is a C.sub.2 -C.sub.22 divalent hydrocarbyl group which may contain a hydroxyl substituent;X is a linking group which may be --O--, --S-- or --O.sub.2 C--;Y is a hydroxyl-containing C.sub.3 -C.sub.5 alkylene group;Y' is a C.sub.1 -C.sub.9 divalent hydrocarbyl group;Z is divalent organic linking group; andn is 0 or 1.Suitable hydroxyl-containing organotin compounds would also include polymeric organotin compounds prepared by the reaction of a diorganotin oxide or diorganotin dichloride with HSCH.sub.2 CH(OH)CH.sub.2 XH, preferably in a 1:0.5-1 molar ratio, where X is --S-- or --O--.

Abstract: The disclosed invention is directed to polycyanoarylether membranes. These membranes are formed by reacting an aromatic diol with a dihalobenzonitrile or dinitrobenzonitrile in the presence of a base and a polar, aprotic solvent. These membranes can be provided as either homopolymers or copolymers.

Abstract: Expandable thermoplastic resin microparticle compositions comprising low intrinsic viscosity polyphenylene ethers and a method for producing foam therefrom are disclosed.

Abstract: A modified poly(2,6-dimethyl-p-oxyphenylene) with a glass transition temperature in the range of 180.degree.-220.degree. C. is described in which on the average between 10 and 60% of the macromolecules carry:a) an ##STR1## unit; or b) an ##STR2## unit. Said modified poly(2,6-dimethyl-p-oxyphenylene) is useful as a material in the preparation of flat membranes, in particular asymmetric membrane, for gas separation.

Abstract: The odor of blends of polyphenylene ether resin, alone, or in combination with a polystyrene resin or a high impact polystyrene is improved by including a carboxylic acid, an acid anhydride or mixture thereof in the compositions.

Abstract: A process for producing expandable thermoplastic resin beads which comprises suspending in an aqueous medium interpolymer beads comprising a polyphenylene ether resin and a polymerized vinyl aromatic monomer such as styrene, polymerizing the vinyl aromatic monomer in the presence of a polymerization catalyst to interpolymerize the vinyl aromatic monomer with the polyphenylene ether and, optionally, adding a cross-linking agent, to form interpolymerized thermoplastic resin beads, and introducing a blowing agent under pressure into the thermoplastic resin beads. The resulting resin beads have excellent foamability and molding fusability, and a foamed shaped article having superior thermal stability can be prepared from these beads.

Abstract: Hydrazone compounds having two organic moieties joined by a hydrazone group, such as phenylacetone t-butyl hydrazone, are useful blowing agents for foaming polymers, such as bisphenol A/phosgene polycarbonate at temperatures above about 280.degree. C., and particularly at about 300.degree. C. to about 310.degree. C. Polycarbonate polymers formed using the hydrazones as foaming agents show a high impact strength.

Abstract: An odor free polyphenylene ether is made from polymerization grade phenolic monomer which has been crystallized from a solvent. An amine free catalyst is used to polymerize the monomer. The polyphenylene ether is useful as a packaging material for food which is to be stored at a low temperature and/or cooked in the package at a high temperature.

Abstract: Foamed thermoplastic blends of Nylon 6,I/T and polycarbonate resin are provided which exhibit good chemical resistance. The foamed blends are useful for making foamed articles such as chemically resistant foamed sheet.

Abstract: A microporous polyetheretherketone (PEEK) membrane in the form of films and hollow fibers formed without sulfonating the PEEK polymer. Solid fibers and articles are also claimed. A method of making membranes, fibers and articles from solutions of PEEK in non-sulfonating acid solvents in claimed. Solvents include methane sulfonic acid and trifluoromethane sulfonic acid. Sulfuric acid may be used as a diluent in non-sulfonating amounts. PEEK membranes are used as supports for composite ultrafiltration and reverse osmosis membranes. A method of making membranes, fibers, and articles is also described.

Abstract: A process for producing expandable thermoplastic resin beads which comprises suspending in an aqueous medium interpolymer beads comprising a polyphenylene ether resin and a polymerized vinyl aromatic monomer such as styrene, polymerizing the vinyl aromatic monomer in the presence of a polymerization catalyst to interpolymerize the vinyl aromatic monomer with the polyphenylene ether and, optionally, adding a cross-linking agent, to form interpolymerized thermoplastic resin beads, and introducing a blowing agent under pressure into the thermoplastic resin beads. The resulting resin beads have excellent foamability and molding fusability, and a foamed shaped article having superior thermal stability can be prepared from these beads.

Abstract: The invention is a composition useful for the preparation of POWADIR membranes of a bisphenol-based polycarbonate wherein at least 25 percent by weight of the bisphenol moieties are tetrahalogenated, wherein the halogen is Cl or Br, the composition comprising (i) a bisphenol-based polycarbonate wherein at least 25 percent by weight of the bisphenol moieties are tetrahalogenated, wherein the halogen is Cl or Br, (ii) a solvent for such polycarbonate, and (iii) a non-solvent for such polycarbonate. The composition is useful for extruding membranes wherein the membranes formed are POWADIR membranes with a discriminating region capable of separating oxygen from nitrogen.The composition of this invention allows the formation of membranes with excellent physical properties, good separation factors for oxygen and nitrogen, with excellent fluxes.

Abstract: High boiling point polar organic solvent are useful solvents for poly(etheretherketone)-type polymers (PEEK). Solutions of PEEK may be used to form PEEK articles such as film, microporous sheet membrane, fiber and microporous hollow fibers. The microporous PEEK is useful as an ultrafiltration membrane and as a substrate for the formation of reverse osmosis membranes. A method of making PEEK articles including microporous sheet membranes is disclosed. A method of making PEEK fibers including microporous hollow membrane fibers is disclosed.

Abstract: Thermoplastic polyimide foams are provided which essentially consist of recurring units represented by the formula (I): ##STR1## wherein X is a bond, divalent hydrocarbon radical having from 1 to 10 carbon atoms etc. and R is an aliphatic radical having 2 or more carbon atoms, cycloaliphatic radical etc.The foams have an apparent density of from 0.02 to 0.2 g/cc, average cell diameter of 0.1 to 1 mm and a closed cell content of 50% or more.

Abstract: A process for producing cellular foamed articles from high temperature engineering polymers wherein polymeric blowing agents are utilized to expand the polymers. The process comprises mixing a first polymer capable of being foamed with a second polymer comprising at least one poly(alkylene carbonate) to provide a polymer blend; heating the polymer blend to a temperature sufficient to melt the polymer to be foamed and to decompose the second polymer to form gas inclusions within the first polymer; expanding the melted first polymer containing the gas inclusions to form a foamed article; and cooling the foamed article to a temperature below the melting or softening point of the foamed article. Polymers which may be foamed according to the process include those polymers which can tolerate processing temperatures in excess of 260.degree. C.

Abstract: A foamable composition comprises in admixture (a) a high molecular weight thermoplastic resin in particulate form and an effective amount of (b) a foaming agent therefor comprising a pumpable liquid dispersion comprising (i) a solid blowing agent, (ii) a liquid carrier, and, optionally, (iii) a thickener. The liquid dispersion can be pumped directly into the hopper of a foam molding machine eliminating the need to pre-mix pelletized concentrates of the solid blowing agent.

Abstract: In a process for the production of cellular products comprising thermoplastic or rubber materials the blowing agents employed have the formula: ##STR1## wherein A represents NHX, NRR' or ORX represents H or a lower alkyl group,R represents a lower alkyl group, andR' represents a lower alkyl group.The novel blowing agents provide high gas yields and have high decomposition temperatures while forming only inert nitrogen gas. They are particularly suitable for the production of cellular products from high temperature thermoplastic materials such as polycarbonates.

Abstract: This disclosure relates to a method for producing polyethylene open-cell foam materials, comprising a process step of pressurized heating at a temperature of 110.degree. to 135.degree. C. of a base compound consisting of polyethylene or a copolymer of polyethylene which has been compounded with an azodicarbonamide foaming agent and a bridging agent, in order to obtain a primary intermediate product with a cubical expansion coefficient of 1.0 to 2.0 times; a process step of heating the primary intermediate product under normal atmospheric pressure at a temperature of 150.degree..about.190.degree. C.

Abstract: Compositions useful in decomposition molding procedures such as destructive foam casting or ceramic or metallic powder sintering are provided by blends of polymers having greater than 50 weight percent propylene carbonate units and polymers having greater than 50 weight percent methyl methacrylate units. Such blends exhibit an unexpectedly even decomposition profile over the range of temperatures at which their constituent polymers each decompose relatively rapidly. The controlled decomposition rate reduces problems in destructive foam casting and ceramic or metallic powder molding caused by sudden release of gases by the foam pattern or the polymer binder. Preferred blends contain 35 to 65 weight percent poly(methyl methacrylate) and 65 to 35 weight percent poly(propylene carbonate), and very even decomposition behavior is exhibited by blends of 35 to 45 weight percent poly(methyl methacrylate) and 65 to 55 weight percent poly(propylene carbonate).

Abstract: Low density rigid foamed polyphosphazene articles having excellent physical and flammability properties are made by masticating a mixture of high molecular weight linear polyphosphazene, a curing agent (e.g., sulfur), an accelerator, a blowing agent and optionally fillers, processing aids and the like to form a substantially homogeneous blend and then stopping the masticating, heating to pre-cure and then heating to activate the blowing agent and complete the cure thereby forming a flexible foamed polyphosphazene composite, forming the flexible foamed polyphosphazene composition into a shaped composition, and thereafter heating the flexible foamed shaped polyphosphazene composition at a temperature and for a length of time which causes the flexible foamed polyphosphazene composition to become a rigid foamed polyphosphazene composition of the same shape as the flexible foamed polyphosphazene composition.

Abstract: This invention provides a method for the preparation of an article from a blend of at least two molecularly compatible polymers by treating the blend with a solvent which is a solvent for one of the polymers and a non-solvent for the other. The solvent can be removed while the article is restrained from undergoing substantial shrinkage, in which case a microporous article is obtained. Alternatively, the solvent can be removed while the article is permitted to shrink. In this case high shrinkage force (also referred to as recovery force) results which can be utilized to apply the article to a substrate. The final and intermediate articles are novel. In a preferred embodiment, the invention provides a microporous article having an average pore size of about 0.005 microns to about 1 micron.

Abstract: A low density extruded structural foam of closed cell structure having good compressive strength comprising a engineered thermoplastic resin, alone, or containing a flame retarding agent and/or nucleating agent, optionally combined with a vinyl aromatic resin, and a blowing agent is produced by feeding said resin, or composition, into a primary extruder wherein mixing, adding a blowing agent which is essentially insoluble in the resin at room temperature but soluble in the melt and further mixing, then optionally passing the mixture to a second, cooling extruder, passing said extruded mixture through a die, then expanding and foaming said composition into a foam article.

Abstract: A Chemical Blowing Agent (CBA) concentrate was developed comprising a modifying agent and a chemical blowing agent. The CBA is characterized in that its decomposition products contain a primary amine. The modifying agent is a blend of a maleic anhydride copolymer and a butadiene based rubber. It was surprisingly found that resin degradation which often accompanies foam moldings using a CBA of the present type and is expressed in terms of a reduction in the molecular weight of the resin, is much reduced upon the incorporation of the modifying agent and chemical blowing agent of the invention. The concentrate may optionally further comprise a polymeric resin component.

Abstract: A Chemical Blowing Agent (CBA) concentrate was developed comprising a modifying agent and a chemical blowing agent. The CBA is characterized in that its decomposition products contain a primary amine. The modifying agent is a blend of a maleic anhydride copolymer and a butadiene based rubber. It was surprisingly found that resin degradation which often accompanies foam moldings using a CBA of the present type and is expressed in terms of a reduction in the molecular weight of the resin, is much reduced upon the incorporation of the modifying agent and chemical blowing agent of the invention. The concentrate may optionally further comprise a polymeric resin component.

Abstract: The labor costs associated with manufacturing wooden articles often represent a substantial portion of the total cost of producing the wooden article. This invention discloses a polymeric composition which can be easily molded into articles which have physical properties which are very similar to those of wood. By utilizing the polymeric composition and techniques of this invention, it is possible to manufacture a wide variety of wood-like articles by molding at reduced costs. This invention specifically reveals a polymeric composition which can be molded into articles having wood-like physical properties which is comprised of (1) from about 80 to about 99 weight percent polyethylene terephthalate, (2) from about 1 to about 20 weight percent of a polycarbonate, and (3) from about 0.3 to about 2 weight percent of 5-phenyltetrazole. These polymeric compositions can be prepared utilizing scrap polyethylene terephthalate, such as recycled polyethylene terephthalate beverage bottles.

Abstract: Disclosed herein are microporous polybenzimidazole articles prepared by the addition of a leachable additive to a polybenzimidazole polymer solution or dope and the subsequent leaching of the additive from the polybenzimidazole article. The microporous polybenzimidazole article may be formed into filaments or films. The micropores of the microporous polybenzimidazole article may be filled with an absorbent resin which will act to absorb chemicals or other harmful products. The microporous polybenzimidazole article with absorbent material may be formed into clothing which is highly resistant to both chemicals and heat.

Abstract: The present invention relates to a process for molding a foamed article comprising mixing a polyphenylene sulfide resin with about 0.1 to 10% of an oligomeric sulfone carbonate as a foaming agent and with 0.1 to 2% of a basic catalyst at a temperature of about 150.degree. to 180.degree. C. and then heating the resulting mixture at a temperature of 280.degree.-350.degree. C. to affect a reaction mixture and introducing the reaction mixture into a suitable mold for producing a foamed article.

Abstract: Polyphenylene ether compositions rendered flame retardant with bromine-containing compounds can be foam molded into shaped articles free of streaking and without the generation of odors if the foaming agent comprises citric acid and sodium bicarbonate.

Abstract: Polymer polyols with high polymer or solids content made by the reaction of alkanolamines with polyisocyanates in a dispersing media of polymer polyols created from vinyl monomers in a conventional manner. The equivalents of alkanolamine to equivalents of polyisocyanate ranges from about 1/1 to 5/1 to give novel polymer polyols with solid contents from about 25% to up to 50%. Polyurethane foams made employing the novel polymer polyols of the present invention have higher load bearing properties, and provide a good balance between the load bearing properties and the open cell content of the foam to provide a stable foam, as compared with those employing only conventional polymer polyols.

Abstract: The labor costs associated with manufacturing wooden articles often represent a substantial portion of the total cost of producing the wooden article. This invention discloses a polymeric composition which can be easily molded into articles which have physical properties which are very similar to those of wood. By utilizing the polymeric composition and techniques of this invention, it is possible to manufacture a wide variety of wood-like articles by molding at reduced costs. This invention specifically reveals a polymeric composition which can be molded into articles having wood-like physical properties which is comprised of (1) from about 80 to about 99 weight percent polyethylene terephthalate, (2) from about 1 to about 20 weight percent of a polycarbonate, and (3) from about 0.3 to about 2 weight percent of 5-phenyltetrazole. These polymeric compositions can be prepared utilizing scrap polyethylene terephthalate, such as recycled polyethylene terephthalate beverage bottles.