Abstract: A propylene polymer composition of high melt tension, which is especially favorable for foam moldings of uniform thickness, and foam moldings thereof having a uniform thickness, are obtained by melt-kneading a polymer mixture of a specific ethylene polymer (A) and a specific olefin multi-stage polymer (B) to satisfy the following formula: Log(MS)>0.91−0.

Abstract: Disclosed is substantially spherical porous beads of an aromatic polyether ketone resin, which have an average particle diameter of 50 to 5,000 &mgr;m and a porosity of 40 to 99%. Also disclosed is a method for producing porous beads, which comprises: mixing, while heating, an aromatic polyether ketone resin with a sol vent capable of dissolving the resin to thereby obtain a resin solution; dispersing the resin solution in a liquid dispersion medium which is incapable of dissolving the resin and is non-miscible with the solvent, to thereby obtain a dispersion having the resin solution dispersed therein in the form of globules; cooling the dispersion while maintaining the dispersed form of the resin solution in the liquid dispersion medium, to thereby solidify the resin in the resin solution; and separating the solidified resin from a mixture of the solvent and the liquid dispersion medium, thereby obtaining substantially spherical porous beads of the aromatic polyether ketone resin.

Abstract: Foamed and expanded beads including a polyester-based resin containing at least 35 mole % of an aliphatic ester component. The foamed beads have a gel fraction of at least 5 % by weight and comprises at least one gel accelerating agent selected from fatty acids having 12-25 carbon atoms, metal salts of the fatty acids, esters of the fatty acids and amides of the fatty acids in an amount of 0.15-3 % by weight. A foam molding is obtained by heating the foamed and expanded beads in a mold.

Abstract: The invention relates to expanded polypropylene beads having a density of from 5 to 200 g/l and a bead diameter of from 1 to 10 mm which comprise from 0.002 to 20% by weight of graphite particles.

Abstract: The present invention relates to a method of removing water immiscible porogens from macroreticular copolymers comprising distilling said porogen in water soluble organic solvent.

Abstract: A process for forming certain aqueous polymeric dispersions including a first emulsion polymer having an average particle diameter of 150 to 3000 nanometers and a second emulsion polymer having an average particle diameter of 40 to 600 nanometers where at least the first emulsion polymer particles, when dry, contain at least one void is provided. Also provided are the aqueous polymeric dispersions made by the process and paper or paperboard coatings and paints including the aqueous polymeric dispersions.

Abstract: A process of producing expandable styrene resin particles, wherein in suspension polymerization of styrene monomers, the concentration of oxygen in a reaction vessel is kept low at least in a late stage of the polymerization, and the resulting styrene resin particles are impregnated with an expanding agent before or after completion of the polymerization. Preferably, at a polymerization rate of 60% or higher, the concentration of oxygen in the reaction vessel is kept at 7 vol % or lower. When additional styrene monomers are added during the polymerization, they are added and adsorbed to styrene resin particles in the course of polymerization while the concentration of oxygen is kept low. By this method, the particles whose internal portion has a low molecular weight and surface portion has a high molecular weight are obtained. A foamed article produced from the particles has high strength and a good appearance.

Abstract: The present invention is directed to thermo-expandable microspheres and to the expanded microballoons, microcellular foam or foamed composite material that results upon heating the microspheres. The thermo-expandable microsphere of the present invention is characterized by having a polymeric wall surrounding one or more pockets or particles of blowing agent or propellant within the microsphere. The polymeric wall may have reactive functional groups on its surface to give a fusible microsphere. When the microspheres are heated, they expand to form microballoons comprising polymeric shells surrounding one or more internal gaseous voids, and when the microspheres are expanded while in contact with each other, a microcellular foam may be formed. The foam consists of a plurality of microballoons fused together, optionally aided by functional groups present on the surface of the heated microspheres that act to crosslink the material.

Abstract: A method for producing manufactured articles made of composite material comprising the steps of: First completely filling a mold with granules of a pre-expanded polymer in granular form, selected from the group consisting of polystyrene, polypropylene, copolymer of polyphenylene oxide and polystyrene and mixtures thereof; subsequently injecting in the mold an isocyanate mixed with a compound possessing active hydrogen whereby they are filled in void spaces among the granules; and condensing said isocyanate with said compound possessing active hydrogen to yield a polyurethane foam which, by expanding, subsequently completely fills the spaces among the pre-expanded polymer granules.

Abstract: A method of forming, by polymerization in an aqueous dispersion at pressures in excess of one atmosphere, a plurality of porous particles having at least one polymeric phase and, additionally, having a pore filling phase containing a fugitive substance is disclosed. Replacement of the fugitive substance with a gas is further disclosed. Gas-filled porous particles and their aqueous dispersions are also disclosed.

Abstract: Pre-expanded particles of polyolefin resin having less fluctuation in expansion ratio, uniform particle size and low expansion ratio are provided without using any volatile foaming agent. The low expansion ratio means 2 to 10 times, preferably 3 to 8 times. Resin particles to be released are uniformly contacted with saturated vapor at the time of pre-expanding polyolefin resin particles by dispersing the resin particles into an aqueous dispersion medium in a closed vessel, heating the resin particles to temperature of at least the softening point of the polyolefin resin and releasing the particles from the closed vessel into an atmosphere of lower pressure than the inner pressure of the closed vessel.

Abstract: A method of producing a thermally expansive microcapsule that is excellent in heat resistance and solvent resistance, narrow in breadth of the distribution of particle size, and extremely low in secondary cohesion of the particles when heated, wherein a polymer obtained from the component comprising not less than 80 weight % of monomer of nitrile series, less than weight % of monomer of non-nitrile series, and 0.05-1 weight % of at least tetrafunctional cross-linking agent and/or of long side chain of cross-linking agent is used to micro-encapsulate a volatile expanding agent that comes into its gaseous state at a temperature equal to or less than a softening point of the polymer.

Abstract: The present invention is directed to thermo-expandable microspheres and to the expanded microballoons, microcellular foam or foamed composite material that results upon heating the microspheres. The thermo-expandable microsphere of the present invention is characterized by having a polymeric wall surrounding one or more pockets or particles of blowing agent or propellant within the microsphere. The polymeric wall may have reactive functional groups on its surface to give a fusible microsphere. When the microspheres are heated, they expand to form microballoons comprising polymeric shells surrounding one or more internal gaseous voids, and when the microspheres are expanded while in contact with each other, a microcellular foam may be formed. The foam consists of a plurality of microballoons fused together, optionally aided by functional groups present on the surface of the heated microspheres that act to crosslink the material.

Abstract: Foamable microspheres with a foaming agent enclosed in the shell of a polymer, wherein the average particle diameter of the microspheres is within a range of 3 to 100 &mgr;m, and the coefficient of variation of the particle diameter distribution thereof is at most 1.50%, and production process of foamable microspheres by a suspension polymerization process.

Abstract: Non-Newtonian fluids, such as partially polymerized monomers or solutions of polymer in monomer may be pressure atomized below the free surface of a continuous liquid phase to produce a dispersed phase. A uniform or customized droplet size distribution can be obtained by imposing a required pressure pulsation on a flowing monomer upstream the atomizer inlet. This initial particle size distribution can be maintained or modified during subsequent polymerization process in a low shear, controlled turbulence flow pattern, created without mechanical agitation within the continuous liquid, by continuously or periodically injecting an inert gas at selected locations within the reactor.

Abstract: Enhanced conversion rates are realized in a suspension polymerization process for styrene through the use of peroxide initiators having one hour half life temperatures from 101° to 111° C. are disclosed. Also disclosed are suitable initiator combinations which provide polymeric products with low residual monomer content at reduced process temperatures, polymerizable compositions containing such initiators and products produced by such processes and compositions.

Abstract: A packing material for solid phase extraction, which is a particle having an exclusion limit molecular weight of 1×103 to 1.5×104 in gel permeation chromatography using a standard polystyrene as the sample. A column for solid phase extraction and a cartridge for solid phase extraction, a method of using the packing material; and a process for treating a sample using the column or cartridge are also disclosed.

Abstract: A water-containing polyolefin resin composition containing a polyolefin resin and a hydrophilic polymer and having a water content of 1 to 50% by weight which is suitable for use in preparation of polyolefin resin pre-expanded particles, and pre-expanded particles of a polyolefin resin prepared by pre-expanding the water-containing polyolefin resin composition the particles having a an apparent expansion ratio of 5 to 60, a closed cell ratio of 80 to 100% and an average cell diameter of 50 to 500 &mgr;m.

Abstract: Polyolefin resin pre-expanded particles having two fusion peaks on DSC curve wherein the proportion of the heat of fusion Qh of the peak appearing on the high temperature side based on the total heat of fusion of the two peaks represented by the equation: [Qh/(Ql+Qh)]×100 falls within the range of 10 to 60% in which Ql is the heat of fusion of the peak appearing on the low temperature side, and the standard deviation of said proportion is not more than 1.2. The pre-expanded particles are prepared by releasing an aqueous dispersion of resin particles impregnated with a blowing agent from a vessel into an atmosphere of lower pressure than the inner pressure of the vessel to expand the particles, while stepwise or continuously raising the inner temperature or the inner pressure of the vessel at a specific rate, and can be molded with stable molding cycle to give cellular molded articles having stable dimensions.

Abstract: A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm3 to about 0.5 g/cm3 is disclosed. The method utilizes a thermally expandable polymer microsphere material wherein some of the microspheres are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130° C., and then cooling the mold to a temperature below 80° C. the molded part achieves a bulk density which varies by less then about ±6% everywhere throughout the part volume.

Abstract: In brief, a lighting fixture is provided. The lighting fixture has both a transmitted and reflected light component employing a polymeric material which has an appearance, in varying degrees, of white. The material has internal elements which can be varied to be either highly reflective or permit efficient diffuse transmission of incident light rays. The ratio of reflected to transmitted light and the degree of diffusion are tailored to the application, light source and desired appearance. The material is adapted for providing a selected diffuse transmission component of a total fixture output. The material provides a set diffuse transmission component of greater than 1% and less than 25% where the material is formed by pigmenting a transparent material with a white pigment.

Abstract: Expanded, substantially non-crosslinked polypropylene resin beads capable of producing a high rididity foamed molding at a relatively low temperature. The beads are produced by a process including a step of dispersing substantially non-crosslinked polypropylene resin particles in a dispersing medium containing an organic peroxide to obtain a dispersion, a step of heating the dispersion to decompose the organic peroxide and to modify the surface of the surface-modified polypropylene resin particles, and a step of expanding the non-crosslinked, surface-modified polypropylene resin particles using a blowing agent.

Abstract: Systems, apparatus combinations and methods for producing a coating powder are provided wherein a stream of a powder coating precursor including at least one resin and at least one additional powder coating ingredient is contacted with a process fluid effective to reduce the viscosity of the powder coating precursor to allow processing of the powder coating precursor at a lower temperature.

Abstract: A non-halogenated, fire retardant, expandable poly (arylene ether)/polystyrene blends is produced by the method comprising, in a first step, forming a fire retardant mixture comprising a non-halogenated fire retardant, poly(arylene ether) resin and polystyrene resin by intimately mixing in melt; and in a second step, forming the non-halogenated, fire retardant, expandable poly (arylene ether)/polystyrene blend by intimately mixing in melt the fire retardant mixture with a blowing agent.

Abstract: In brief, a lighting fixture is provided. The lighting fixture has both a transmitted and reflected light component employing a polymeric material which has an appearance, in varying degrees, of white. The material has internal elements which can be varied to be either highly reflective or permit efficient diffuse transmission of incident light rays. The ratio of reflected to transmitted light and the degree of diffusion are tailored to the application, light source and desired appearance. The material is adapted for providing a selected diffuse transmission component of a total fixture output. The material provides a set diffuse transmission component of greater than 1% and less than 25% where the material is formed by pigmenting a transparent material with a white pigment.

Abstract: The present invention provides a water-absorbent resin powder and its production process and use, wherein the water-absorbent resin powder has high liquid permeability and high water absorbency. The production process for a water-absorbent resin powder, according to the present invention, comprises the step of obtaining water-absorbent crosslinked polymer particles by an aqueous solution polymerization step, and grinding the resultant crosslinked polymer particles until the bulk density thereof increases to not lower than 0.72 (g/ml). The water-absorbent resin powder is characterized by being arbitrarily pulverized and having a bulk density of not lower than 0.74 (g/ml) and a water absorption capacity of not lower than 20 (g/g) for 0.9 weight % physiological saline under a load of 0.7 psi (4.83 kPa). In addition, the absorbent structure comprises the above water-absorbent resin powder and a fibrous material. The absorbent article comprises an absorbent layer including the above absorbent structure.

Abstract: A process for the preparation of styrene polymers containing water as the sole expanding agent by polymerization of styrene in aqueous suspension in the presence of an amphiphilic organic emulsifier which carries both hydrophilic and hydrophobic groups, or a polar group-containing, water-miscible polymer.

Abstract: The invention relates to a process for the production of styrene polymers containing water as expanding agent by suspension polymerization of styrene in the presence of an emulsifying auxiliary, the suspending agent being a mixture of water and an organic liquid which is water-miscible and which is virtually a non-solvent for polystyrene and has a boiling point below 100° C.

Abstract: A roller has an elastic layer formed by curing a silicone rubber material containing at least expanded resin microballons, wherein, when the roller is placed in a vacuum chamber in which atmospheric pressure is reduced to 0.001 MPa or less over 2 minutes, the roller has a gas permeability indicating the recovery characteristic where an increased amount of the thickness of the elastic layer after 10 minutes from the start of evacuation is two-thirds or less of the maximum increased amount of thickness of the elastic layer during a 10 minute period from the start of evacuation. The elastic layer is formed by curing a silicone rubber material containing the expanded resin microballoons and has air void portions formed by breaking the resin microballoons and passages connecting the air void portions therebetween.

Abstract: The present invention relates to a process for preparing post-crosslinked polymer bead with increased surface area and pore volume, and suitable pore size, allowing the separation of organic compounds by post-crosslinking gel-type copolymer bead whose crosslinking degree is low and initial surface area is small, or macroporous-type copolymer bead whose crosslinking degree is high and initial surface area is intermediate in the presence of a Friedel-Crafts catalyst, and polymer beads produced thereby. Though the surface area and pore volume of polymer beads may be varied depending on physical properties of copolymer beads and Friedel-Crafts reaction conditions, the present invention provides polymer beads with larger surface area than that of commercially available polymeric adsorbents produced by the conventional method employing a porogen only.

Abstract: The invention relates to thermally expandable microspheres comprising a thermoplastic polymer shell and a propellant entrapped therein, wherein said polymer shell is made of a homo- or co-polymer from ethylenically unsaturated monomers comprising more than 85 wt % of nitrile containing monomers and said propellant comprises at least 50 wt % of isooctane. The invention further relates to preparation and use of expandable microspheres, a composition comprising expandable microspheres and articles comprising foamed material containing expanded microspheres.

Abstract: A process for preparing pre-expanded particles of a thermoplastic resin without washing the prepared pre-expanded particles to remove a dispersing agent remaining thereon and without discharging waste water, which comprises charging particles of a thermoplastic resin and an aqueous dispersion medium containing a dispersing agent into a closed pressure vessel, heating the resulting aqueous dispersion to a temperature of not less than the softening point of the thermoplastic resin, thereby impregnating the particles with water to have a water content of 1 to 50% by weight, releasing the dispersion into a lower pressure atmosphere, thereby expanding the particles, recovering the dispersion medium containing the dispersing agent, and recycling it as a dispersion medium to the pressure vessel.

Abstract: The present invention is directed to thermo-expandable microspheres and to the expanded microballoons, microcellular foam or foamed composite material that results upon heating the microspheres. The thermo-expandable microsphere of the present invention is characterized by having a polymeric wall surrounding one or more pockets or particles of blowing agent or propellant within the microsphere. The polymeric wall may have reactive functional groups on its surface to give a fusible microsphere. When the microspheres are heated, they expand to form microballoons comprising polymeric shells surrounding one or more internal gaseous voids, and when the microspheres are expanded while in contact with each other, a microcellular foam may be formed. The foam consists of a plurality of microballoons fused together, optionally aided by functional groups present on the surface of the heated microspheres that act to crosslink the material.

Abstract: The present invention is directed to thermo-expandable microspheres and to the expanded microballoons, microcellular foam or foamed composite material that results upon heating the microspheres. The thermo-expandable microsphere of the present invention is characterized by having a polymeric wall surrounding one or more pockets or particles of blowing agent or propellant within the microsphere. The polymeric wall may have reactive functional groups on its surface to give a fusible microsphere. When the microspheres are heated, they expand to form microballoons comprising polymeric shells surrounding one or more internal gaseous voids, and when the microspheres are expanded while in contact with each other, a microcellular foam may be formed. The foam consists of a plurality of microballoons fused together, optionally aided by functional groups present on the surface of the heated microspheres that act to crosslink the material.

Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and methyl methacrylate. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: Copolymers are formed by suspension polymerization of monomers, including one or more styrenic monomers, and one or more acrylic monomers. The monomers can be polymerized in the presence of polymeric seeds. The polymerization can be carried out in the presence of one or more blowing agents, producing polymers that can be expanded. The methods are useful, for example, in forming expandable polymeric particles. The expandable polymer particles are useful in processes such as forming patterns for lost foam molding techniques.

Abstract: The invention relates to expandable olefin bead polymers which comprise a blowing agent with a boiling point of from −5 to 150° C., selected from the group consisting of alkanes, alkanols, ketones, ethers and esters. The particles are unfoamed and have a bulk density above 500 g/l, and can be foamed to a bulk density below 200 g/l after storage for one hour at room temperature in free contact with the atmosphere. They are prepared by impregnating polyolefin pellets in suspension in a pressure vessel with the blowing agent, cooling the batch below 100° C., reducing the pressure and isolating the particles.

Abstract: A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm3 to about 0.5 g/cm3 is disclosed. The method utilizes a thermally expandable polymer microballoon material wherein some of the microballoons are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130° C., and then cooling the mold to a temperature below 80° C. the molded part achieves a bulk density which varies by less then about ±6% everywhere throughout the part volume.

Abstract: In a process for preparing expanded or expandable polymer beads based on biodegradable saturated polyesters made from at least one diol and from at least one dicarboxylic acid, A. polymer pellets are dispersed in a liquid, B. a volatile blowing agent is injected into the dispersion and made to impregnate the pellets at an elevated temperature, C. the pressure on the dispersion is reduced at an elevated temperature, whereupon the pellets comprising blowing agent expand to give foam, and, respectively, D. the pellets are isolated from the liquid.

Abstract: The invention relates to expandable olefin bead polymers which comprise a blowing agent with a boiling point of from −5 to 150° C., selected from the group consisting of alkanes, alkanols, ketones, ethers and esters. The particles are unfoamed and have a bulk density above 500 g/l, and can be foamed to a bulk density below 200 g/l after storage for one hour at room temperature in free contact with the atmosphere. They are prepared by impregnating polyolefin pellets in suspension in a pressure vessel with the blowing agent, cooling the batch below 100° C., reducing the pressure and isolating the particles.

Abstract: A process for preparing expandable particulate styrene polymers wherein from 5 to 50% by weight of expanded graphite and also, if desired, from 2 to 20% by weight of a phosphorus compound, are present as flame retardants, by suspension polymerization of styrene in the presence of the flame retardants.

Abstract: An electrode for control of an electric field strength in a gaseous electrically insulating medium at the surface of the electrode and in the vicinity of the electrode, comprising an electrically conducting inner electrode (1′) and an electrically non-conducting layer (8) on at least parts of the surface of the inner electrode, wherein the thickness of the non-conducting layer is at least 5% of the mean diameter of the inner electrode and that the relative dielectric constant of the non-conducting layer is smaller than 3.

Abstract: A foam composition and method of making the same. The foam of the present invention comprises a mixture of glutarate ester plasticizer, adipate ester plasticizer, alcohol carboxylic acid ester, cell stabilizer, barium/zinc activator stabilizer, potassium/zinc activator stabilizer or zinc stabilizer, azodicarbonamide blowing agent, low-fogging vinyl dispersion resin, vinyl blending resin, and black acrylic pigment dispersion. The foam is made by the process of mixing the ingredients until a homogenous liquid mixture is present, de-airing the homogeneous liquid mixture, casting the liquid mixture on a non-fogging release-coated surface, expanding the cast liquid mixture by exposing it to an elevated temperature for a prescribed duration of time, and then either cooling the expanded mixture and winding it into rolls, or coating the stabilized composition with pressure sensitive adhesive, cooling it, and then winding it into rolls.

Abstract: The invention relates to expandable polystyrene beads which comprise graphite particles with an average particle size of more than 50 &mgr;m, and also to a process for their preparation by free-radical polymerization of styrene in aqueous suspension. The graphite particles, suspended in styrene, are added to the polymerization mixture at a conversion of from 10 to 100%.

Abstract: In brief, a lighting fixture is provided. The lighting fixture has both a transmitted and reflected light component employing a polymeric material which has an appearance, in varying degrees, of white. The material has internal elements which can be varied to be either highly reflective or permit efficient diffuse transmission of incident light rays. The ratio of reflected to transmitted light and the degree of diffusion are tailored to the application, light source and desired appearance. The material is adapted for providing a selected diffuse transmission component of a total fixture output. The material provides a set diffuse transmission component of greater than 1% and less than 25% where the material is formed by pigmenting a transparent material with a white pigment.

Abstract: A method for manufacturing polyolefin foam beads by a continuous process is disclosed by which the polyolefin foam beads can be produced with increased efficiency and productivity. The method comprises a step of impregnating foaming agent into polyolefin resin by mixing polyolefin resin particles, water and the foaming agent in a impregnation chamber under heat and pressure, followed by a step of storing the polyolefin resin containing the foaming agent in a storing chamber under heat and pressure. Thereafter, the resin particles are subjected to a foaming step by continuously or intermittently discharging the resin particles from the storing chamber to a low pressure expansion chamber by utilizing a discharging device, in the same time period when a next batch of polyolefin resin is added and mixed in the impregnation chamber after being supplied with the resin particles from a resin supply chamber.

Abstract: The invention relates to a process for preparing styrene polymers which comprise water as sole blowing agent, by polymerizing styrene in aqueous suspension in the presence of from 0.1 to 15% by weight of a solid substance insoluble in water and in styrene, for example carbon black or graphite.

Abstract: The invention relates to a process for the preparation of expandable able styrene polymers containing particles of graphite by polymerization merization of styrene in aqueous suspension in the presence of particles of graphite having a mass density of less than 1.8 g/cm3.

Abstract: The present invention provides a process for producing thermo-expansive microcapsules that disperse better than conventional products. In this process, thermo-expansive microcapsules are produced through suspension-polymerization in which a polymer is produced from polymerizing unsaturated ethylene monomers under the existence of one or more of metal compounds selected among zirconium compounds and titanium compounds and the resultant polymer microencapsulates a volatile blowing agent gasifying below the softening point of the polymer.

Abstract: Expandable styrene polymers containing graphite particles are prepared by polymerizing styrene in aqueous suspension in the presence of graphite particles and of two peroxides which decompose at different temperatures, by a process in which the peroxide decomposing at the lower temperature forms neither benzoyl nor benzyl radicals on decomposition.