Abstract: A polyester polymer containing micro glass fibers having an aspect ratio of greater than 1000, preferably from about 2000 to about 5000. Those micro glass fibers having these aspect ratios, preferably with mean fiber diameters of 1 microns or less, act as excellent nucleating agents to promote crystallization of the polymer melt during its cooling phase, improve the rheological behavior of the melt, reduce the crystalline half time during cooling phases, and are acceptable in polyester molded or thermoformed products which come into contact with food or beverage.

Abstract: Disclosed is an extruded, open-cell microcellular alkenyl aromatic polymer foam useful in insulating applications. The foam has an open cell content of about 70 percent or more. The foam has an average cell size of about 70 micrometers or less. The foam is particularly useful in evacuated or vacuum insulation panels. Further disclosed is a process for making the open-cell foam. Further disclosed is a fabricated foam article.

Abstract: In a process for producing polyolefin foam particles, partially foamed particles are produced in a first stage by extrusion of a polyolefin containing solid blowing agents, and these are then further foamed in the second stage using steam.

Abstract: A continuous process for making moldable foam beads comprising a non-crosslinked or crosslinked thermoplastic polymer foam are produced by mixing a composition comprising a non-crosslinkable or crosslinkable thermoplastic polymer or a thermoplastic polymer with a crosslinking agent, additives to achieve specific properties, a blowing agent, extruding the admixture under pressure, crosslinking, when applicable, the admixture under pressure, modulating the admixtures temperature to achieve the desired foaming properties, and then expanding the admixture in a zone of lower pressure to form a foam bead that can be molded.

Abstract: The density of rigid foamed articles made by the thermal decomposition of a blowing agent in a vinyl chloride polymer is reduced by the use of an organotin mercaptoalkylcarboxylate, alone, or in combination with an organotin halide or carboxylate which activate the blowing agent. Sulfides made from said organotin mercaptoalkylcarboxylate are also superior activators of the blowing agent.

Abstract: A method of producing an extruded plastics foam of enhanced physical strength includes intimately mixing a blowing agent incorporation CO.sub.2, the major portion of which is a natural gas, in a plastics resin melt to form a homogenous resin mix, and extruding the resin mix through an exit die into a region of lower pressure. At the point of extrusion out of the exit die, the temperature of the resin mix is adjusted so that it is below the critical temperature.

Abstract: A stability control agent composition for foamable polyolefin compositions comprising at least one compound that is a partial ester of fatty acid with polyol, and at least one compound selected from the group consisting of higher alkyl amines, fatty acid amides and/or complete esters of higher fatty acids.

Abstract: Apparatus and method for the production of hopper feedable thermoplastic pellets having zones or compartments which contain physically separated reactants which react only after being melt-mixed, as in a screw type extruder, reciproscrew injection machine, or similar device which heat forms pellets into a larger mass. This new class of thermoplastic molding materials relies mainly on the relatively slow reaction kinetics of contained large molecule molding materials to provide a time interval after melt-mixing of zoned pelletized reactants in an extruder barrel or injection molding machine. During this time period, the thermoplastic molding material is easily filled into injection molds. As the reaction progresses, the material becomes more viscous and such flow is difficult or impossible. The involved reactions may continue after demolding at room temperature during a post molding cure, or appliance service generated heat may cause post molding cure.

Abstract: Prefoamed polyolefin beads, produced by extrusion followed by granulation, have a crystal structure with a double peak.

Abstract: Disclosed is a normally solid, high molecular weight, gel-free, amorphous to predominantly crystalline, propylene polymer characterized by high melt strength due to strain hardening which is believed to be caused by free-end long chain branches of the molecular chains forming the polymer.Also disclosed is a process for making the polymer by high energy radiation of a normally solid, high molecular weight, linear, propylene polymer in a reduced active oxygen environment, maintaining the irradiated material in such environment for a specific period of time, and then deactivating free radicals in the material.Further disclosed is the use of the strain hardening polymer in extensional flow operations such as, for example, extrusion coating, film production, and thermoforming.

Abstract: A styrene resin composition is disclosed which constitutes 45 to 92% by weight of a styrene resin (A), 5 to 45% by weight of an olefin resin other than an ethylene-unsaturated carboxylic acid ester copolymer(B), and 3 to 25% by weight of an ethylene-unsaturated carboxylic acid ester copolymer (C). The styrene resin composition of the present invention may be used to make a variety of shaped articles which exhibit excellent mechanical properties, such as an impact strength, elongation at break and resistance against chemicals such as Freon and oil.

Abstract: Fluoropolymer having unstable end groups is used to form foamed fluoropolymer structures without added blowing agent.

Abstract: A method of manufacturing a thermoplastic polyester foam sheet comprises forming a roll by overlapping a thermoplastic polyester sheet and a separator on each other and rolling them, impregnating an inert gas into the thermoplastic polyester sheet while the roll is kept in a pressurized inert gas atmosphere, and foaming the thermoplastic polyester sheet by heating it under atmospheric pressure.

Abstract: A thermosetting foam, preferably polyisocyanurate or polyurethane foam, is prepared in an extruder which permits the incorporation of high levels of filler particles. The method includes introducing polyol, isocyanate and filler particles to an extruder screw for mixing. In conjunction with extruding, a catalyst is added. The catalyst may be added either in a last extruder barrel or with the extruder head. Foam with filler particle content in excess of 12% made be readily made. Filler particles, such as aluminum trihydrate, perlite, carbon black, diatomaceous earth, polyiso powders, ammonium phosphate, fly ash, barium sulfate, calcium silicate, and calcium carbonate, may be used. The process described is preferably used for making foam boards or bunstock.

Abstract: Foamed gaskets comprising at least one homogeneously branched ethylene polymer and at least one blowing agent are disclosed. The gaskets are particularly useful for sealing food and liquid containers and do not contribute to taste and/or odor of the packaged product, which is especially useful in food-stuff applications.

Abstract: A flexible closed cell polymeric foam contains expandable graphite as fire retardant. The foam is prepared by mixing a polymer, a curing agent, at least one blowing agent and an expandable graphite at a temperature of at least 100.degree. C. but below a temperature causing activation of the blowing agent to foam a foamable mixture and thereafter heating the foamable mixture to activate the blowing agent and cause foaming. The method of preparation may additionally include a curing step in which the foamable mixture is heated under pressure to activate simultaneously each of a curing agent, which is preferably a free radical curing agent, and a foaming agent. The foams are capable of meeting the U.S. Federal Aviation Authority Standards, especially the oil burner test of FAR 25 Appendix F, part II.

Abstract: Low density, heat stabilized, flame retardant styrenic polymer foam compositions, include a halogen-based flame retardant such as hexabromocyclododecane and zeolite A heat stabilizer.

Abstract: A foamed polyarylene sulfide according to the invention has a density which is reduced by at least 50% compared with the theoretical density of nonfoamed material, and is expediently produced by subjecting a polyarylene sulfoxide as such or a mixture of one or more polyarylene sulfides with a polyarylene sulfoxide to heat treatment. The temperature of the heat treatment is in the range from 250.degree. to 400.degree. C.

Abstract: A foam cell nucleating agent that is a combination of sulfonic or phosphonic acid or salt thereof and inorganic salt containing a polyatomic anion yields improved foaming of thermoplastic resins such as polyolefins and melt-fabricable fluoropolymers.

Abstract: The density of rigid foamed articles made by the thermal decomposition of a blowing agent in a vinyl chloride polymer is reduced by the use of an organotin halide in combination with a mercaptocarboxylic acid ester or a sulfide of such ester or a mixture of the ester and the sulfide to activate the blowing agent.

Abstract: The present invention relates to a composition for use as a blowing agent in injection molding processes. More specifically, the present invention is a blowing agent composition comprising a molecular sieve and a foaming agent, wherein the foaming agent is carded by the molecular sieve and evolves to form foamed plastic products. In addition, the present invention is a method for preparing a blowing agent composition and a foamable blowing agent-resin mixture. Furthermore, the present invention is a foamed plastic resin containing a molecular sieve. Additionally, the present invention provides a composition and method for foaming moisture-sensitive polymers comprising the addition of molecular sieves and a poly-hydroxy ester. The present invention also advances a method of encapsulating a blowing agent on a polymer substrate and a corresponding encapsulated blowing agent composition.

Abstract: Disclosed is a closed-cell polymer foam comprising a quantity of titanium dioxidce particulates sufficient to reduce the thermal conductivity of the foam to less than that of a corresponding foam without the titanium dioxide particulates. The titanium dioxide particulates have a wetting aggent applied to a substantial portion of their surfaces. Further disclosed are processes for making the foams.

Abstract: A scented plastic material such as a mesh net or scented bathing implement and method for producing same is taught. Briefly stated, a scented additive is simultaneously extruded with a plastic raw material in order to form an intermediate or raw stock. The intermediate or raw stock thereby has a particular scent or fragrance associated therewith and is embedded therein. The intermediate product is thereafter formed into a suitable end product.

Abstract: In order to produce a substantially biologically degradable polymer foam, a thermoplastic or disaggregated starch or a polymer mixture of thermoplastic or disaggregated starch with at least one biologically degradable hydrophobic polymer is used. In addition, the material is mixed with a biologically degradable fibrous or capsular material capable of binding water by capillary action, said material being at least partially treated or saturated with water before being mixed with the polymer. The polymer/material mixture thus obtained is processed under controlled pressure and temperature so that the water bound by capillarity in the material is released and causes the polymer to foam.

Abstract: A receptacle (10), such as an attache case or brief case, has a cover panel (22), back panel (24), front panel (26), top panel (30), bottom panel (32) opposing tabs (34) and opposing side panels (36). The case is made from a unitary sheet of expanded polyethylene. The expanded polyethylene sheet material is produced by encapsulating a thermoplastic blowing agent (azodicarbonamide) within an ethylene vinyl acetate carrier resin to form a pelletized compound which is combined with high-density polyethylene resin and extruded. The melt temperature of the pelletized blowing agent is lower than that of the polyethylene resin, and controls the expansion of the polyethylene resin.

Abstract: This invention relates to a process for preparing foamable branched polyester compositions having increased melt viscosity and melt strength, and a reduced level of unreacted monomeric branching agent. The process involves melt blending (A) a composition containing a polyolefin and branching agent, (B) a nucleating agent either in powder form or (B') in the form of a composition containing a polyolefin and nucleating agent, and a polyester.

Abstract: Disclosed is an extruded, open-cell alkenyl aromatic polymer foam useful in insulating applications. The foam has an open cell content of about 30 to about 80 percent. The foam further has in minor dimension and cross-section of greater than 0.25 inches. The foam has a high heat distortion temperature, and is particularly useful in roofing applications. Further disclosed is a process for making the open-cell foam.

Abstract: A molded closure for a liquid container comprising a thermoplastic elastomer and a blowing agent. The molded closure is particularly suitable for use as a synthetic wine cork in a wine bottle. The molded closure does not permit passage of oxygen into the container, does not absorb oxygen from the contents of the container, can be removed from the container using a corkscrew without significant expansion, crumbling or disintegration, does not significantly taint a liquid in the container, permits the container to be placed horizontally immediately after insertion of the molded closure, and can permanently retain printed matter on its surface.

Abstract: Disclosed is a foam structure of desirable mechanical strength made with a low molecular weight alkenyl aromatic polymer material and an inorganic blowing agent. The polymer material has an alkenyl aromatic polymer of a weight average molecular weight of 100,000 to 165,000. The foam structure can be made in processes with reduced pressure drop.

Abstract: The present invention provides a method for the semi-continuous production of microcellular foam articles. In a preferred embodiment, a roll of polymer sheet is provided with a gas channelling means interleaved between the layers of polymer. The roll is exposed to a non-reacting gas at elevated pressure for a period of time sufficient to achieve a desired concentration of gas within the polymer. The saturated polymer sheet is then separated from the gas channelling means and bubble nucleation and growth is initiated by heating the polymer sheet. After foaming, bubble nucleation and growth is quenched by cooling the foamed polymer sheet.

Abstract: Low density PET foam is extruded by heating PET resin above the crystalline melt point to melt the resin, combining Heptane as the blowing agent with the PET resin to create a mixture, cooling the mixture to a temperature of less than 538.degree. K., and extruding the foam through a die. The Heptane is about 0.5-5% by weight of the mixture, and preferably about 1-3%.

Abstract: Disclosed is an evacuated and unevacuated microcellular foam containing an infrared attenuating agent (IAA). The evacuated foam has an average cell size of about 70 micrometers or less. The unevacuated foam has an average cell size of 1.0 micrometers or less. The IAA provide a greater proportional reduction in foam thermal conductivity in these foams than in foams of larger cell size. Further disclosed is a method of using the foams.

Abstract: A hydrophilic polymer alloy which has a permanent hydrophilic nature, a sufficient mechanical strength and a high safety and which is suitable for the formation of hydrophilic porous membranes manufacturable by an industrially advantageous process can be prepared by blending an amorphous hydrophilic copolymer (X) containing 10 mole % or more of an ethylene unit, 10 to 60 mole % of a vinyl alcohol unit and 1 mole % or more of a vinyl acetate unit with a polyolefin (Y). Furthermore, this polymer alloy is also suitable for the formation of hydrophilic (porous) fibers having a sufficient mechanical strength and antistatic function.

Abstract: Disclosed is an extruded, open-cell microcellular alkenyl aromatic polymer foam useful in insulating applications. The foam has an open cell content of about 70 percent or more. The foam has an average cell size of about 70 micrometers or less. The foam is particularly useful in evacuated or vacuum insulation panels. Further disclosed is a process for making the open-cell foam.

Abstract: The present invention provides a process for producing thermoplastic foam, including:(a) melting a thermoplastic polymer to produce a polymer melt;(b) introducing a carbon dioxide blowing agent into the polymer melt;(c) adding to the polymer melt one or more additives selected from the group consisting of(1) polysiloxane, and(2) mineral oil; and(d) extruding and foaming the melted polymer melt, blowing agent, and one or more additives to produce thermoplastic foam.The resultant thermoplastic foam can be thermoformed into various foamed articles, such as foam packaging trays. The quality of foams made from a carbon dioxide blowing agent, and particularly 100% carbon dioxide, has been found to be substantially improved by adding one or more of the foregoing additives, i.e., polysiloxane, mineral oil and, optionally, polyolefin to the polymer melt during the extrusion and foaming process.

Abstract: An expandable thermoplastic composition is disclosed for extrusion foaming wherein the composition comprises a polyethylene resin and a blowing agent comprising ethane present in an amount of at least about 40 percent or more by weight based upon the total weight of the blowing agent and a different alkane selected from the group consisting of C.sub.1, C.sub.2, C.sub.3, C.sub.4, C.sub.5, and C.sub.6 alkanes and mixtures thereof, wherein the minimum percentage of ethane increases above 40 percent as the arithmetic mean carbon number of the different alkane increases from 3 to 5. A process for extrusion foaming of the composition is also disclosed.

Abstract: The present invention provides a polyethylenic foaming composition comprising (a) 100 parts by weight of an ethylenic copolymer having glycidyl groups consisting of 20 to 99.9% by weight of ethylene units, 0.1 to 30% by weight of a unit of a glycidyl ester of an unsaturated carboxylic acid or an unsaturated glycidyl ether, and 0 to 50% by weight of ethylenically unsaturated ester units other than a glycidyl ester, (b) 0.1 to 30 parts by weight of a carboxylic acid having 2 or more carboxyl groups and a molecular weight of 1500 or less, and (c) 0.1 to 20 parts by weight of a foaming agent of a thermal decomposition type. The present invention also provides a polyethylenic foam molded from said foaming composition.

Abstract: A branched random aliphatic-aromatic copolyesters suitable for foaming has increased melt viscosity and melt strength during extrusion and comprises repeating units of:[-{(O--R.sup.1 --O).sub.a --(CO--R.sup.2 --CO).sub.b }-{(O--R.sup.3 --O).sub.c --(CO--Ar--CO).sub.d }-](BA).sub.x.The mole percent of the acid components and diol components are each based on 100 mole percent. The aliphatic acid residue, --CO--R.sup.2 --CO--, is present in an amount b ranging from 30 to 95 percent and the aromatic acid residue, --CO--Ar--CO--, is present in an amount d ranging from 5 to 70 percent. The diol residues, --O--R.sup.1 --O-- and --O--R.sup.3 --O--, are present in an amount a of 0 to 100 mol percent and in an amount c of 100 to 0 mol percent, respectively. The branching agent, BA, is present in an amount x of 0.01 to 10 weight percent based on the total weight of acid residues, diol residues and branching agent. A foamed article of the branched random aliphatic-aromatic copolyesters is disclosed.

Abstract: A process for producing an automotive molded roof material is provided which comprises sheeting a foamable sheet forming composition comprising a specified propylene resin, a glass fiber, a radical initiator, a crosslinking auxiliary and a foaming agent in specific proportions into a foamable sheet, lining one side of the foamable sheet with a backing sheet so as to integrate these and irradiating the foamable sheet with ionizing radiation to thereby crosslink the propylene resin, followed by heating the foamable sheet so as to cause the foamable sheet to foam, placing a cover sheet on the other side of the foamed sheet before the sheet cools to solidify and press molding the cover sheet on the foamed sheet to cover. There is also provided an automotive molded roof material produced by the above process. An automotive molded roof material is obtained which can be recycled, is lightweight and has high rigidity.

Abstract: A process and apparatus are described for extruding a soft, low density elastomeric thermoplastic foam. A single screw extruder having a very large screw length to diameter ratio is provided to thoroughly mix the thermoplastic elastomer with a blowing agent. A thin, substantially taperless die is also provided to form extruded profiles. By using such a process and apparatus, a variety of complex-shaped extruded profiles may be easily produced.

Abstract: Disclosed is an extruded, linear, bimodal monovinyl aromatic polymer foam having a weight average molecular weight of from about 100,000 to about 200,000, greater than 5 percent by weight of its polymer chains having a weight average molecular weight of 500,000 to 1,000,000, and less than 5 percent by weight of its polymer chains having a weight average molecular weight of greater than 1,000,000. Use of the polymer enables process pressure drop to be significantly reduced and allows the formation of a foam of lower density and larger cross-section. Further disclosed is a process for making the extruded foam.

Abstract: A flexible closed cell polymeric foam contains expandable graphite as fire retardant. The foam is prepared by mixing a polymer, a curing agent, at least one blowing agent and an expandable graphite at a temperature of at least 100.degree. C. but below a temperature causing activation of the blowing agent to foam a foamable mixture and thereafter heating the foamable mixture to activate the blowing agent and cause foaming. The method of preparation may additionally include a curing step in which the foamable mixture is heated under pressure to activate simultaneously each of a curing agent, which is preferably a free radical curing agent, and a foaming agent. The foams are capable of meeting the US Federal Aviation Authority Standards, especially the oil burner test of FAR 25 Appendix F, part II.

Abstract: A plastic foam material composed of a blended resin composition which includes at least two thermoplastic resins and a silane-modified based resin. The blended resin composition consists essentially of 100 parts by weight of at least two thermoplastic resins, from about 1 to about 50 parts by weight of a silane-modified, cross-linked, thermoplastic resin; from about 0.001 to about 2.5 parts by weight of a cross-linking catalyst for use in a silane compound and from about 1 to about 20 parts by weight of a foaming agent. According to one embodiment of the present invention, the thermoplastic resins include at least two substantially incompatible and substantially uncross-linked thermoplastic resins, while in another embodiment the two thermoplastic resins need not be substantially incompatible. The blended resin composition may further include reinforcers such as glass fibers and filler. The thermodecomposition foaming agent decomposes at sufficiently high temperatures to yield a plastic foam material.

Abstract: A process for preparing an expandable resin composition comprising the following steps:(a) admixing, at a temperature in the range of about 120 to about 130 degrees C., the following components:(i) 100 parts by weight of a high pressure, low density homopolymer of ethylene;(ii) about 30 to about 200 parts by weight of a high density polyethylene having a melting point higher than the above mixing temperature;(iii) about 2 to about 50 parts by weight of polypropylene having a DSC melting point of not less than about 140 degrees C.; and(iv) about 0.1 to about 2 parts by weight of a silane coupling agent; and(b) admixing, at a temperature in the range of about 120 to about 130 degrees C., 100 parts by weight of the mixture produced in step (a) with 0.5 to 3 parts by weight of one or more chemical blowing agents having a decomposition temperature higher than the above mixing temperature.

Abstract: Low density, heat stabilized, flame retardant styrenic polymer foam compositions include a halogen-based flame retardant such as hexabromocyclododecane and zeolite A heat stabilizer.

Abstract: The present invention relates to relatively inexpensive multi-purpose expandable vibration damping material compositions particularly useful in constrained layer applications. The composition essentially includes an elastomeric polymer, plasticizer, thermoplastic polymer, foaming agent, adhesion promoters and filler. In addition to the aforementioned, under certain embodiments, the expandable vibration damping material compositions may also employ rheological modifiers such as cross-linking agents and epoxy curing agents.

Abstract: Disclosed is an expanded foamed bead of a rubber-modified styrene polymer, comprising a plurality of closed cells defined by cell walls which constitute a matrix for the bead, wherein each of the cell walls comprises two surfaces separated by a distance equal to the thickness of the cell wall.

Abstract: Disclosed is an extruded propylene polymer resin foam comprising a propylene polymer resin exhibiting a biaxial extensional viscosity of at least 3.0.times.10.sup.6 poise at a biaxial extensional strain of 0.2, and a biaxial strain hardening rate .alpha. of at least 0.25, the biaxial strain hardening rate .alpha. being defined by the following formula:.alpha.=0.77.times.(log .eta..sub.2 -log .eta..sub.1)wherein .eta..sub.1 represents the biaxial extensional viscosity at a biaxial extensional strain of 0.01, and .eta..sub.2 represents the biaxial extensional viscosity at a biaxial extensional strain of 0.2,said foam containing a vast plurality of cells, and having a thickness of at least 20 mm, a density of from 0.005 to 0.03 g/cm.sup.3, an average cell diameter of from 0.4 to 2.0 mm, and a closed cell ratio of at least 80%.

Abstract: A molded structure 1 produced by extrusion, such as an expanded plastic foam, a sheet, a profile or the like, contains at least 10% by volume of open cells 2, 4 which have a polyhedron-like shape and are adjacent to one another. A higher temperature during the extrusion in comparison with the extrusion of thermoplastic molded structures having a closed-cell structure results in deformation-free opening of the cells. Webs 3 of cell walls 5, 6 remain intact in shape whether they have orifices 7 or no passages, so that the mechanical strength of the cell skeleton or of the space matrix is retained.

Abstract: A process for foaming polyurethane reactive hot melt adhesive comprising the steps of:a) melting a reactive polyurethane adhesive containing 0.05 to 0.5% by weight of a 2,2'dimorpholinodiethyl ether or di(2,6-dimethylmorpholinodiethyl)ether catalyst in a heated reservoirb) pumping the adhesive from the heated into a heated reservoir recirculating foaming device;c) foaming the adhesive by injecting therein an effective amount of an anhydrous gas;d) discharging a portion of the foamed adhesive through an orifice onto a substrate to be bonded; ande) recirculating the remaining foamed adhesive back to the foaming device for discharge at a later time.