Abstract: Extruded propylene-based resin foam according to the present invention is formed by extrusion-foaming a propylene-based resin, and the extruded propylene-based resin foam has a closed cell content of less than 40% and an expansion ratio of 10 or more. Since the extruded propylene-based resin foam has an open-cell structure in which a cell-broken state is formed at a desired level and has a high expansion ratio, each cell in the foam has a sound absorption performance, such that the extruded foam is excellent in sound absorption performance.

Abstract: Prepare an extruded thermoplastic polymer foam having a thermoplastic polymer composition having defined therein multiple cells, the thermoplastic polymer foam containing at least one thermoplastic polymer, a brominated flame retardant, an epoxy containing organic compound and 180 weight parts or less of water extractable cations using a brominated flame retardant, an innocuous stabilizer and a blowing agent containing water.

Abstract: A production method comprising the step of charging prepolymer, a foaming agent and an active hydrogen-containing compound in specified amounts into a tank and foaming/mixing them for a specified time by a mixer, and the subsequent step of pouring the mixture liquid into a metal mold.

Abstract: This invention relates to foam insulating products, particularly extruded polystyrene foam, containing nano-graphite as a process additive for improving the physical properties of foam products.

Abstract: A synthetic polymer foam is produced which incorporates fine particles of expandable graphite which surprisingly impart excellent fire resistant properties to the foam, particularly to foam made with a non-halogenated hydrocarbon as the primary blowing agent. For best results, the foam is produced through mixing the constituent materials, including the expandable graphite using a screw extruder. The foam can also be produced by creating a graphite/polyol or graphite/isocyanate dispersion in an extruder then mixing the remaining components in a conventional batch mixing or high pressure spraying process. Alternatively, conventional mixing can be used for the entire process, but use of a screw extruder in whole or in part is preferred.

Abstract: Polymeric foam and polymeric foam products that contain a foamable polymer material, nanographite, and 1,1,2,2-tetrafluoroethane (HFC-134) are provided. Preferably, the foamable polymer material is an alkenyl aromatic polymer material. The foam is free of other conventional blowing agents typically utilized in preparing a foamed product. The nanographite is not chemically or surface modified and is preferably compounded in a polyethylene methyl acrylate copolymer (EMA), which is used both as a medium and a carrier for the nanographite. The nanographite may be compounded in the polymer in an amount up to 60% loading. In addition, the nanographite acts as a nucleating agent, R-value enhancer, infrared attenuating agent, lubricant, UV absorber, and process aid. The inventive foam composition produces extruded foams that have R-values that are equal to or better than conventional extruded foams produced with 1-chloro-1,1-difluoroethane (HCFC-142b).

Abstract: A method of forming a syntactic foam, said method including the steps of: providing a predetermined amount of constituent materials, said constituent materials including hollow microspheres, a solvent and a first binder; mixing the constituent materials; allowing the constituent materials to separate into at least a phase substantially including said hollow microspheres and a binder phase; transferring the hollow microsphere phase into a mould; and forming a syntactic foam in said mould.

Abstract: A polyolefin foam capable of absorbing high amounts of liquid comprises 30 to 94 wt % of a foamable polyolefin and 6 to 70 wt % of a particulate solid material.

Abstract: A process for making an extruded foamable composition is disclosed where the foamable composition includes a partially-crystalline melt processable perfluoropolymer and a foam nucleating package. The process makes a foamed product having uniform foam cell size at high speeds without loss of product quality.

Abstract: Expanded and extruded biodegradable polymer foams are obtained using biodegradable polymers and environmentally benign non-VOC methyl formate as a blowing agent. The blowing agent can be a blend further including at least one co-blowing agent, preferably an environmentally friendly species (e.g., non-VOC), which is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s), water or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The blowing agent blend can include any combination of methyl formate and one or more co-blowing agents. The polymer foam can include a biodegradable polymer or its blends with other biodegradable polymers or conventional (non-biodegradable) polymers. The methyl formate-based blowing agent blends produce stable foams for various applications, including containers, packaging systems, as well as for insulation and protective cushioning.

Abstract: The invention provides a process for the production of a 5 crosslinked polymer foam, which comprises the following steps: (I) blending a polymer with a blowing agent, (II) forming the blend into a sheet, (III) crosslinking the sheet, and (IV) foaming the sheet, wherein the blowing agent is blended in an amount of 3 to 25 based on the total weight of the polyolefin and the blowing agent, and is composed of (A) 3 to 50% of one or more inorganic carbonates and (B) 50 to 97 of one or more compounds selected from the group consisting of polycarboxylic acids, salts thereof, and derivatives thereof.

Abstract: Prepare an extruded thermoplastic polymer foam having less 1000 parts per million, based on total polymer weight, of cations from water soluble salts that exist or form into a solid or glassy state that is less malleable than the thermoplastic polymer as the foamable composition exits an extrusion die during foam manufacturing using a brominated flame retardant, an innocuous stabilizer and a blowing agent containing water.

Abstract: This invention relates to improvements in products and processes for cleaning up oil, chemical, or other hydrocarbon spills, and cleaning up the environment where such spills have occurred. In one aspect of the invention, there is provided an adsorbent polymeric composition which is oleophilic and capable of adsorption of other chemicals and hydrocarbons from both land and water, the adsorbent composition including polyethylene/vinyl acetate copolymer, catalyst, cross-linking agent, lubricant, blowing agent and a bulking agent. In a second aspect of the invention there is provided a method of manufacture of an adsorbent composition for use in retrieving and recycling oil, chemicals and hydrocarbons from land or water environments.

Abstract: Polymer extruded foams that contain cell size enlarging agents are provided. The inventive composition includes a foamable polymer material, at least one blowing agent, and at least one cell size enlarging agent. The blowing agent utilized in the inventive composition is preferably selected such that the composition has a zero ozone depletion and low global warming potential. Examples include any inorganic blowing agents and/or non-hydrogenated chlorofluorocarbons (non-HCFCs). The foamable polymer material is preferably polystyrene. The cell size enlarging agent may be chosen from ethylene vinyl acetate (EVA) and/or ethylene methyl acrylate (EMA). The cell size enlarging agent permits the formation of a foam with large cell sizes that are desirable to achieve a high insulation value and to optimize the physical properties of the foamed product. In addition, the cell size enlarging agent provides an increased cell size to the foamed product without detracting from the physical and thermal properties.

Abstract: A blowing agent blend for making thermoplastic polymer foams comprises methyl formate. The blowing agent blend can further comprise at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s), water or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The thermoplastic polymer foam can be an alkenyl aromatic polymer foam, e.g. a polystyrene foam. The blowing agent blend can comprise any combination of methyl formate and one or more co-blowing agents. The methyl formate-based blowing agent blends produce stable foams for various applications, including containers, packaging systems, as well as insulation boards and building materials. A process for the preparation of such foams is also provided.

Abstract: A blowing agent blend for making thermoplastic polymer foams comprises methyl formate. The blowing agent blend can further comprise at least one co-blowing agent. The co-blowing agent is either a physical co-blowing agent (e.g. an inorganic agent, a hydrocarbon, a halogenated hydrocarbon, a hydrocarbon with polar, functional group(s), water or any combination thereof), or a chemical co-blowing agent, or combinations thereof. The thermoplastic polymer foam can be an alkenyl aromatic polymer foam, e.g. a polystyrene foam. The blowing agent blend can comprise 100 mol % methyl formate, or it can comprise any combination of methyl formate and one or more co-blowing agents. The methyl formate-based blowing agent blends produce stable foams. A process for the preparation of such foams is also provided.

Abstract: Polymeric composite materials, particularly highly filled polyurethane composite materials are described herein. Such highly filled polyurethane composite materials may be formed by reaction and extrusion of one or more polyols, one or more di- or poly-isocyanates, and from about 45 to about 85 weight percent of inorganic filler such as fly ash. Certain polyols, including plant-based polyols can be used. Certain composite materials also contain chain extenders and/or crosslinkers. The polyurethane composite material may also contain fibers such as chopped or axial fibers which further provide good mechanical properties to the composite material. Shaped articles containing the polyurethane composite material have been found to have good mechanical properties, such that the shaped articles are suitable for building applications.

Abstract: The foam sheet of the present invention is biodegradable, can be recycled, has good processability, is lightweight, exhibits excellent appearance, has practically satisfactory heat resistance and is more acceptable to the environment. There is provided a crosslinked biodegradable resin continuous foam sheet comprising biodegradable resin, and has an expansion rate of about 1.5 to about 50 and a gel fraction of about 3% or more. There is further provided a method for producing the foam sheet comprising the steps of: (1) preparing a sheet from a resin composition comprising a biodegradable resin, a thermal decomposable blowing agent, and a crosslinking promoter; (2) irradiating the resulting sheet with an ionizing radiation to crosslink the resin composition; and (3) subjecting the crosslinked sheet to heat treatment to continuously prepare a crosslinked foam sheet.

Abstract: A process for an extruded resin foam, comprising extruding a foamable composition comprising a melted polystyrene resin and a physical blowing agent through a die to obtain a polystyrene resin foam having a thickness of at least 10 mm and a transverse cross-sectional area of at least 50 cm2, wherein said extrusion is performed so that the ratio Mz/Mn of a Z average molecular weight Mz of the polystyrene resin foam to a number average molecular weight Mn of the polystyrene resin foam, each measured by gel permeation chromatography, is 8.0 or more.

Abstract: A non-crosslinked polyolefin foam comprises a plastics component and a blowing agent. The plastics component comprises a first constituent and a second constituent. The first constituent is a Ziegler-Natta catalyzed linear low density polyolefin and the second constituent is a low density polyolefin in one embodiment. The Ziegler-Natta catalyzed linear low density polyolefin has a polydispersity of less than 10 and a melt flow index less than 10 g/10 minutes. The second constituent may be a polypropylene.

Abstract: The present invention provides a foam cushion, a method of making the foam cushion, and a method of using the foam cushion. The foam cushion is formed from: (a) at least one of rubber and a resin; (b) a blowing agent; (c) a polymeric adhesion modifier; (d) a decomposition accelerating agent, and (e) a cross-linking agent.

Abstract: A method for producing an alkenyl aromatic polymer foam structure that comprises melting at least one alkenyl aromatic polymer resin. An effective amount of blowing agent mixture is dissolved in the at least one alkenyl aromatic polymer. The blowing agent mixture comprises at least one VOC blowing agent and acetone. The majority by mole percent of the VOC blowing agent is selected from n-butane, iso-butane, propane and combinations thereof. An extrudate is formed comprising the at least one alkenyl aromatic polymer resin, the at least one VOC blowing agent, and acetone. The extrudate comprises less than about 2.7 wt. % of the at least one VOC blowing agent. The extrudate is transferred to an expansion zone and permitted to expand to produce the foam structure. The foam structure has an extruded density less than about 7 lbs/ft3 and a basis weight of less than about 20 grams per 100 in2.

Abstract: This invention relates to foam insulating products, particularly extruded polystyrene foam, containing asphalt as an infrared attuation and process additives for improving the insulating properties and for reducing the manufacturing cost of the foam products.

Abstract: U.S. Pat. No. 6,232,354 issued May 15, 2001 describes an environmentally friendly and commercially practicable process for the production of microcellular polymer foams from amorphous, semi-crystalline and crystalline polymers which involves consolidating the polymer, saturating the polymer with an inert gas at elevated temperature and under elevated pressure, and controllably cooling, i.e. quenching the saturated polymer under a variety of temperature and pressure conditions to produce either a closed or open celled microcellular foam or a high density microcellular foam. It has now been discovered that a process similar to that described in this patent can be used for the production of nanocomposite and molecular-composite foams that exhibit exceptional physical properties.

Abstract: A macrocellular foam is described having improved cell size and Fire-test-response Characteristics, among other features, which is obtained by selecting a particle size less than 1 micron for the flame retardant adjuvant. The inventors found that the amount of fire retardant adjuvant can be increased for a given foam cell size or the foam cell size can be increased for a given amount of fire retardant adjuvant, allowing the production of foams having exceptionally large, well-formed, cells that have excellent Fire-test-response Characteristics. The benefits are especially noteworthy in relation to thermoplastic foams and inorganic flame retardation adjuvants, due to the unexpected reduction in the nucleation effect of the adjuvant. The foams are useful for improving the acoustic performance of products that are required to meet certain Fire-test-response Characteristics.

Abstract: One aspect is a robot system comprising a flexible artificial skin operable to be mechanically flexed under the control of a computational system. The system comprises a first set of software instructions operable to receive and process input images to determine that at least one human likely is present. The system comprises a second set of software instructions operable to determine a response to a perceived human presence, whereby the computational system shall output signals corresponding to the response, such that, in at least some instances, the output signals cause the controlled flexing of the artificial skin.

Abstract: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.

Abstract: A process for forming an oil-sorbent composition of matter with bound combinations of styrene-butadiene-styrene (SBS) and ethylene propylene diene monomer (EPDM) utilizes a low-temperature extrusion process. The SBS, or both materials, may be in the form of multitudes of granules. In certain preferred embodiments, the combination is 10-30% by weight and the SBS is about 30% styrene and manufactured without talc. The composition of matter can be extruded into a solid, compliant body for use in a product for absorbing oil. The material can be extruded, in one preferred embodiment, into an extended cylinder body having an axial hole.

Abstract: In accordance with the present invention, there are provided thermosetting resin compositions with a reduced propensity to shrink in volume upon cure and methods of use therefor. The compositions of the present invention include compounds having aromatic, rigid-rod like spacer groups between the crosslinkable moieties. As such, these compounds impart a degree of liquid crystal-like character to the thermosetting resin composition which results in lower shrinkage upon cure. This effect follows from the well-known expansion that occurs when liquid crystal-like materials pass from a nematic liquid crystal-like state to an isotropic state. Further provided by the present invention are low shrinkage die attach pastes and methods of use therefor.

Abstract: Open-celled membranes from thermoplastic polymers are prepared from foamed polymer melts by extrusion through a die and particulary suitable for filtration.

Abstract: The present invention relates to a method for making an open celled microcellular foam comprising providing at least one foamable polymer and a crosslinking agent in an extruder, injecting at least one blowing agent into said at least one foamable polymer and said crosslinking agent in said extruder, blending said blowing agent injected into said at least one foamable polymer and said crosslinking agent in said extruder, feeding said blended blowing agent, at least one foamable polymer and said crosslinking agent in said extruder to a die, and depressurizing said blended blowing agent, said at least one foamable polymer and said crosslinking agent.

Abstract: The present invention is directed to a novel foamed polymer material for use as a dielectric in electric transmission lines. The foam dielectric of the present invention is obtained from extrusion of a polymer alloy and a supercritical fluid, especially carbon dioxide. Specifically, the foam polymer dielectric is made by: (1) feeding a polymer alloy into an extruder and heating the polymer alloy, (2) feeding a supercritical fluid into the extruder, (3) mixing the polymer alloy and the supercritical fluid, (4) exiting the polymer alloy and the supercritical fluid from the extruder, and (5) passing the polymer alloy and the supercritical fluid through a crosshead. The foam dielectric of the present invention may be used in coaxial transmission lines. In this embodiment, an inner conductor is surrounded by the foam dielectric, which is further surrounded by a second conductor. Stripline and microstripline transmission lines may also be manufactured using the disclosed foam dielectric.

Abstract: Thermoplastic polymer foams having sound deadening properties satisfactory for demanding applications are provided which have mechanical strength, which are economical to manufacture, and which are hydrolytically stable. Methods of preparing these foams are also provided. The foams are useful in sound management, cushion packaging, filtering, and fluid absorption and exhibit one or more of the following properties: 1) average cell size greater than about 2 mm; 2) substantially open-cell structure and 3) relatively large pores connecting the cells. In order that the foam be acoustically active, the foam should possess a substantially open-cell structure and a relatively low airflow resistivity. Foams with substantially open-cell structure and relatively low airflow resistivity are prepared by mechanically opening a foam having an average cell size greater than about 2 mm. In most cases, such mechanical opening creates relatively large pores connecting the cells.

Abstract: PTFE pellets with good bulk density, homogeneity, and flowability properties may be obtained by: (1) wetting a PTFE powder with a solvent, to obtain a wetted PTFE powder; (2) forming the wetted PTFE powder into agglomerated pellets of PTFE; and (3) drying the agglomerated pellets of PTFE pellets, in which the drying of the agglomerated pellets of PTFE is carried out in a fluidized bed drier. The PTFE pellets so obtained may be used to prepare molded articles of PTFE.

Abstract: This invention relates to foam insulating products, particularly extruded polystyrene foam, containing asphalt as an infrared attuation and process additives for improving the insulating properties and for reducing the manufacturing cost of the foam products.

Abstract: An object of the present invention is to provide a foamed polyolefin resin sheet which exhibits a high adhesive strength when laminated with a layer formed of a saponified ethylene-vinyl ester copolymer and which still exhibits a high adhesive strength even when laminated with a layer of a thermoplastic resin having relatively low polarity such as a polyolefin resin. This object is attained by a foamed polyolefin resin sheet including a foamed polyolefin resin layer and a non-foamed surface layer formed of a thermoplastic resin composition having an A1/A2 ratio falling within a range between 1×10?8 and 1×10?1, wherein A1 is a maximum absorbance of the infrared absorption spectrum of the thermoplastic resin composition within an infrared ray wave number region of from 1700 to 1750 cm?1 and A2 is a maximum absorbance of the infrared absorption spectrum of the thermoplastic resin composition within an infrared ray wave number region of from 1455 to 1465 cm?1.

Abstract: Open celled membranes from thermoplastic polymers are prepared from foamed polymer melts by extrusion through a die.

Abstract: Novel window and patio door frame members are formed by an extrusion process that provide these members with at least one channel and with an outer weather resistant surface and an internal imitation wood surface together with integrated sealing strips formed in the channels for the doors, these components being fully integrated. The process is carried out by extruding a foamed profile with a channel through a first die therein having reduced dimensions where a protective shell is desired, co-extruding a plastic with said foamed profile in a second die to form a protective shell where the reduced dimensions occur, passing the co-extrusion though a calibration die, and then heating the co-extrusion at selected location where weather stripping is desired and then passing the co-extrusion through a final die where plastic weather stripping is extruded therewith and then cooling the integrated member.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.

Abstract: A foam formed from ethylene/vinyl acetate copolymer having a melt index of greater than 1 gram/10 minutes and a vinyl acetate content ranging from about 5 to about 25 weight percent.

Abstract: A process for producing modified thermoplastic resin by subjecting a thermoplastic resin to a modifying reaction in a molten state, comprising performing the modifying reaction using carbon dioxide as the reaction medium, wherein carbon dioxide is used in a proportion of 2-200 parts by weight per 100 parts by weight of the thermoplastic resin, whereby the efficiency and the uniformity of the reaction can be increased to a high extent while attaining considerable decrease in the remaining amount of the unreacted components in the resulting modified thermoplastic resin without having recourse to the use of an organic reaction solvent, so that the production can be realized easily at a low cost in an efficient manner.

Abstract: The present invention relates to polyester urethanes comprising polypentadecalactone segments. These polyester urethanes do show good properties which may be adjusted in a controlled manner. In preferred embodiments the polyester urethanes display additionally polycaprolactone segments. Such polymer may show shape memory effects.

Abstract: An extruded styrene resin foam which is produced by using a blowing agent imposing a reduced load on the environment and has outstandingly excellent thermal insulating property and flame retardant property adapted for construction use.

Abstract: A method for making a one-component epoxy resin system comprises reacting (A) an epoxy resin and (B) an amine solidifying system present in insufficient quantities to cause gelation in the presence of a latent hardener (C) and an expanding agent (E), each of which remains unreacted under the reaction conditions for (A) and (B), to yield a product with a Kofler Heat Bank melting point of less than 55° C. and a melting point stability of at least six months at normal workshop temperatures.

Abstract: The present invention relates to a method for making an open celled microcellular foam comprising providing at least one foamable polymer and a crosslinking agent in an extruder, injecting at least one blowing agent into said at least one foamable polymer and said crosslinking agent in said extruder, blending said blowing agent injected into said at least one foamable polymer and said crosslinking agent in said extruder, feeding said blended blowing agent, at least one foamable polymer and said crosslinking agent in said extruder to a die, and depressurizing said blended blowing agent, said at least one foamable polymer and said crosslinking agent.

Abstract: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.

Abstract: A foamed thermoplastic resin sheet has a foaming ratio of not less than 2.5, and cells, existing in an interior part which extends inward from a depth of 20 percent a whole thickness of the sheet from the front and rear surfaces thereof respectively in a thickness direction thereof and from 15 percent a width of the sheet from both side edges respectively, satisfy the following expressions (1) and (2): 0.5≦D/C≦0.9  (1) 0.5≦E/C≦0.9  (2) where C represents a mean cell diameter in the thickness direction of the foamed thermoplastic resin sheet, D represents a mean cell diameter in an extrusion direction (MD) of the same, and E represents a mean cell diameter in the width direction (TD) of the same. The foamed thermoplastic resin sheet thus arranged has a high foaming ratio, and is formed thick.

Abstract: The invention relates to a method for the production of polyurethane block foam, wherein a polyurethane reactive mixture containing carbon dioxide is suddenly relieved from a pressure above the pressure breaking the equilibrium of the carbon dioxide to a normal pressure, wherein the liquid polyurethane reactive mixture is foamed by releasing dissolved carbon dioxide.

Abstract: Carbon dioxide in a supercritical state is caused to permeate into a resin composition formed by sufficiently kneading a thermoplastic copolymer having a polysiloxane structure at recurring units. Subsequently, the resin composition is degassed by cooling and/or pressure reduction. As a result of degassing, a resin foam body 1 having a fine and uniform micro-cellular foam structure is obtained. The resin foam body 1 has a cyclic structure in which a resin phase 2 and a pore phase 3 are continuous and intertwined. The resin foam body 1 shows an excellent reflectivity relative to rays of light and is highly nonflammable, while it is very strong and lightweight.

Abstract: There is disclosed a process for producing alkenyl aromatic foams utilizing a combination of atmospheric and organic gases as blowing agent, preferably using greater than 30% by weight of atmospheric gas, and preferably also using a predetermined about of a masterbatch mix comprising a styrenic polymer, a rubbery block copolymer, and a solid blowing agent. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased densities, increased thermoforming capabilities, increased post-expansion properties, and increased retainment of the atmospheric and organic gases.