Abstract: An extruded thin sheet foam is disclosed prepared from a polyolefin resin in which the blowing agent comprises a blend of from about 1 to 25% by weight of carbon dioxide and the balance of C3 to C4 VOCs. Thin foam sheets produced with the blowing agent age about twice as fast as foams prepared with VOCs, are remarkably stable, and can be produced at high throughputs.

Abstract: The invention provides systems, methods, and articles useful in the production of foams, and, in particular microcellular foams. The systems include a restriction element that reduces the backflow of polymer melt in an extruder while polymeric material is injected into a mold or ejected from a die. The restriction element is positioned upstream of a blowing agent injection port to maintain the solution of polymer and blowing agent in the extruder above a minimum pressure throughout an injection or ejection cycle, and preferably above the critical pressure required for the maintenance of a single-phase solution of polymer and blowing agent. The systems can be used in injection molding, blow molding, or in any other processing techniques that include injection or ejection cycles. In some embodiments, the systems utilize reciprocating screws for injection or ejection.

Abstract: Extruded, substantially closed-polystyrene foams that exhibit improved fire resistance yet contain lower levels of brominated fire retardant are disclosed. Methods of preparing the foams, comprising extruding the polystyrene with a novel fire retardant formulation comprising a mixture of a) a phosphate compound, preferably TPP; b) less than about 2.5 percent HBCD based on 100 percent polystyrene; and optionally c) a flow promoter such as dimethyldiphenylbutane, the extrusion process using a blowing agent which is preferably selected from carbon dioxide, mixtures of two or more of carbon dioxide, water, alcohol, ether and hydrocarbons, or a mixture of hydrofluorocarbons, alcohols, and hydrocarbons, are also disclosed. Use of the phosphate compound in the fire retardant formulation allows a reduction in the amount of brominated compound required and a reduction in the foaming temperature, resulting in lower density foams.

Abstract: The present invention is directed to a process for producing a polypropylene foam by mixing a high melt strength polypropylene and a blowing agent to form a melt mixture, reducing the temperature of the melt mixture at the exit of the apparatus to an exit temperature that is no more than 30° C. above the melt temperature of the neat polypropylene while maintaining the melt mixture at a pressure sufficient to prevent foaming; passing the mixture through said exit shaping orifice and exposing the mixture to atmospheric pressure, whereby the blowing agent expands causing cell formation resulting in foam formation, and orienting said foam. The foam is useful as tape backings, thermal and acoustical insulation and as a diffuse reflector for use in optical applications such as computer displays.

Abstract: In a process for preparing expandable polymer beads based on a mixture made from A. a biodegradable aliphatic/aromatic copolyester and B. a biodegradable naturally occurring polymer, the mixture A+B is melted in an extruder, mixed with a volatile organic blowing agent, extruded and pelletized.

Abstract: An extruded styrene resin foam obtained by extrusion-foaming of a styrene resin and excellent in environmental compatibility and excellent in flame retardant property and thermal insulating property, characterized in that it contains, as a blowing agent, 100 to 10% by weight of at least one of saturated hydrocarbons having 3 to 5 carbons and 0 to 90% by weight of other blowing agent, based on the total amount of the blowing agent, and contains (A) a halogenated flame retardant and (B) at least one compound selected from the group consisting of phosphorus type flame retardants containing nitrogen atom in a molecule, tetrazole compounds, cyanuric acid and derivatives thereof, isocyanuric acid and derivatives thereof, metal borates, and boron oxides.

Abstract: It is an object of the present invention to provide a microporous polyolefin membrane, high in pin puncture strength, adequate in pore diameter and high in porosity, comprising (A) an ultra-high-molecular-weight polyolefin having a weight-average molecular weight of 5×105 or more, or (B) a composition containing an ultra-high-molecular-weight polyolefin having a weight-average molecular weight of 5×105 or more, and having a porosity of 30 to 95%, bubble point exceeding 980 KPa and pin puncture strength of 4,900 mN/25 &mgr;m or more. The membrane can be used as a filter or as a separator for a battery.

Abstract: New cross-linked polymeric foam compositions, and methods for making the same, are provided. The new compositions utilize novel cross-linked polyolefin copolymers and show improvements in strength, toughness, flexibility, heat resistance and heat-sealing temperature ranges as compared to conventional low density polyethylene compositions. The new compositions also show processing improvements over linear low density polyethylene. The novel polyolefins, which are essentially linear, comprise ethylene polymerized with at least one alpha-unsaturated C3 to C20 olefinic comonomer, and optionally at least one C3 to C20 polyene, and exhibit, in an uncross-linked sense, a resin density in the range of about 0.86 g/cm3 to about 0.96 g/cm3, a melt index in the range of about 0.5 dg/min to about 100 dg/min, a molecular weight distribution in the range of from about 1.5 to about 3.5, and a composition distribution breadth index greater than about 45 percent.

Abstract: A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid N-aliphatic alcohol amide of the general formula R—CON(R′)R″. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R′ typically is hydrogen. R′ can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R″ is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R′ is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA).

Abstract: A novel class of transparent polymeric foams comprising submicron cells and a process for their production is described. The polymers are preferably high glass transition materials and the process comprises saturating a consolidated polymer shape with an inert gas at a temperature above the glass transition temperature of the polymer and under a pressure of at least 9000 psi for a period adequate to dissolve the gas in the polymer shape and then controllably cooling the polymer shape to produce the submicron cell structure.

Abstract: A novel class of transparent polymeric foams from high Tg polymers comprising submicron cells and a process for their production is described. The polymers are preferably high glass transition materials and the process comprises saturating a consolidated polymer shape with an inert gas at a temperature above the glass transition temperature of the polymer and under a pressure of at least 9000 psi for a period adequate to dissolve the gas in the polymer shape and then controllably cooling the polymer shape to produce the submicron cell structure.

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: Structural members for doors and the like can be manufactured from plastic foamed composites containing wood flour by the steps of (1) dry mixing a blend of powders including PVC powder, wood flour, powdered thermal stabilizers, powdered fowning agent and a powdered gelatinization agent, (2) adding the mixed powder to a thermal stirring mixer to obtain a homogeneous dispersion of the several powders (3) transferring the homogeneous dispersion of powders to a cold stirring mixer and stirring at speeds sufficient to avoid agglomeration of the homogeneous dispersion of the several powders and (4) placing the non-agglomerated homogeneous dispersion of the several powders in a feeding hopper of an extrusion machine and extruding shapes for the desired components. The vacuum venting of the extrusion machine can be controlled to achieve components with more desirable surface features. Lubricants can be added to the homogeneous dispersions of the several powders to aid in the extrusion process.

Abstract: Foamed thermoplastic polyolefin elastomer is formed by heating a foamable thermoplastic polyolefin elastomer-containing polymeric composition containing each of a first water-releasing blowing agent which is at least one of metal hydroxide and water hydrate of a salt of a metal of Group 1 or Group 2 of the Periodic Table and a second blowing agent which is neither a metal hydroxide nor a water hydrate of a salt of a metal of Group 1 or Group 2 of the Periodic Table, to a temperature above the melting point of the polyolefin elastomer. The second blowing agent may be a chemical blowing agent and may release, water, a mixture of water and carbon dioxide or another gas, including carbon monoxide, carbon dioxide, and nitrogen.

Abstract: The present invention provides a speaker unit comprising a diaphragm of 0.5 to 10 mm thick aromatic polycarbonate with a density of 0.03 to 0.6 g/cm3, and a mechanism for driving the diaphragm. The aromatic polycarbonate used for the diaphragm is preferably derived from bisphenol with a viscosity average molecular weight of 25,000 to 70,000. The invention further provides a speaker system comprising such a speaker unit attached to a cabinet and a method for manufacturing the speaker diaphragm.

Abstract: The present invention is a process for producing a thermoplastic foam sheet comprising contacting a molten monovinylidene aromatic or olefinic polymer with a physical blowing agent to form a polymer/blowing agent mixture, and foaming the mixture into a region of lower pressure within a sheet extrusion line, wherein the extrudate is pulled and compressed to form a thermoplastic foam sheet having a uniform thickness.

Abstract: This invention provides an expanded open-cell foam polymer composition comprising at least one linear or modified linear polyolefin, at least 50% of the cells being open, and the cells having an average size of at least 1 millimeter. It is desirable that the composition have a sound absorption coefficient as determined by ASTM D 1050 at 1,000 Hz which is greater than 0.15. In preferred foams the composition has an airflow resistivity of less than about 800,000 Rayls/m.

Abstract: An object is to provide a synthetic thermoplastic resin extruded foams having excellent thermal insulating properties and a method for producing the same, in which environment friendly water is used as a blowing agent in the most effective way while reducing the amount of blowing agents that affect the environment, and it is feasible to improve the production ratio of small cells in foams made up of large cells and small cells. A synthetic thermoplastic resin extruded foams having a foam density of 15 to 50 kg/m3 and an excellent cell structure which has an average call size of 0.7 mm or smaller or which mainly comprises small cells having a cell size of 0.25 mm or smaller and large cells having a cell size of 0.3 to 1 mm; and a method for producing the foams are provided, wherein the foams contains 0.2 to 10 parts by weight of bentonite, and water is used as a blowing agent.

Abstract: A drawn film production method comprising steps of drawing a crystalline thermoplastic resin film in the TD direction is characterized in that the orientation coefficient of the c-axis of the crystal of the thermoplastic resin in the film to the MD direction of the film is 0.8 or higher.

Abstract: A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid Naliphatic alcohol amide of the general formula R—CON(R′)R″. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R′ typically is hydrogen. R′ can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R″ is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R′ is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA).

Abstract: The invention concerns nucleating agent systems for foamable polymer compositions, preferably fluoropolymer resins, having foam cell nucleation sites using titanium dioxide based nucleating agents, and foamable polymers comprising the nucleating agents. The nucleating agent systems comprise TiO2, certain inorganic salts, and, optionally, sulfonic acid salts and/or phosphonic acid salts. The invention also concerns foamable composition concentrates and foamed thermoplastic insulation material comprising fluoropolymer and the nucleating agent systems.

Abstract: Microcellular rigid foams with a matrix consisting of cross-linked duromers, especially of polytriazine resins, and with an apparent density of 20 to 95 percent of the density of the compact matrix material. The rigid foams are highly stable and highly temperature resistant and are suitable for use, e.g., as material for aircraft lining.

Abstract: The invention concerns nucleating agent systems for foamable polymer compositions, preferably fluoropolymer resins, having foam cell nucleation sites using titanium dioxide based nucleating agents, and foamable polymers comprising the nucleating agents. The nucleating agent systems comprise TiO2, certain inorganic salts, and, optionally, sulfonic acid salts and/or phosphonic acid salts. The invention also concerns foamable composition concentrates and foamed thermoplastic insulation material comprising fluoropolymer and the nucleating agent systems.

Abstract: A heat-resistant polymer foam is disclosed which has excellent heat resistance, a fine cellular structure, and a low apparent density. The heat-resistant polymer foam comprises a heat-resistant polymer having a glass transition point of 120° C. or higher, e.g., a polyimide or polyether imide, and has an average cell diameter of from 0.01 &mgr;m to less than 10 &mgr;m. This heat-resistant polymer foam can be produced by, for example, impregnating a heat-resistant polymer under pressure with an non-reactive gas such as carbon dioxide, which is in, e.g., a supercritical state, reducing the pressure, and then heating the polymer at a temperature exceeding 120° C. to foam the polymer.

Abstract: Particulate, expandable styrene polymers capable of being processed into hard foamed plastic materials of a small density and containing, therefore, at least one foaming agent comprise at least aluminum in a particulate form for improving their thermal insulation properties. The styrene polymer particles comprise, after their expansion, a fine cell structure and contain the aluminum particles incorporated in a homogeneous distribution as an infrared ray reflecting material. The main proportion of these aluminum particles has the shape of platelets having a size between 1 and 15 &mgr;m. Styrene polymer particles produced in this manner can be foamed into plastic materials of foamed polystyrene particles which have a density of 30 g/l in maximum and improved heat insulation characteristics.

Abstract: Molding, including injection molding, of crystalline or semicrystalline polymeric material is described. Microcellular polymeric material is preferred. The invention involves use of a viscosity-reducing additive in molding that results in relatively better crystallinity at relatively lower mold temperatures, and lower aging time.

Abstract: A foam includes a blend of low density polyethylene and polypropylene having a melt tension of greater than about 20 centinewtons at 200° C.

Abstract: The present invention provides thick extruded foam which is extruded polyolefin resin foam having open cells, used for cushion material and packaging material and the like, which exhibits uniform physical product properties, high expansion ratio, and uniform cell diameter.

Abstract: A continuous method for making foams having uniform and/or small cell sizes and articles made with these foams are described. The method allows for adjusting or controlling cell size and cell size distribution by controlling temperature and/or blowing agent concentration. The foams feature small and/or uniform cell sizes and may be comprised of amorphous thermoplastic polymers, pressure sensitive adhesive compositions, and immiscible thermoplastic polymer compositions. A method for coextruding the foams is also described.

Abstract: There is provided a process for producing a foamed rubber comprising a step of foaming a rubber composition, which composition comprises: (A) 100 parts by weight of an ethylene-&agr;-olefin copolymer rubber, (B) 10 to 100 parts by weight of mica, and (C) 2 to 10 parts by weight of a foaming agent.

Abstract: Methods are provided in this invention to produce wood-like boards of polyvinylchloride, which are suitable for applications, such as graphic art, construction, furniture, etc. In one of the two embodiments disclosed in this invention, the wood-like polyvinyl chloride boards have smooth surface quality, a density below 0.95 g/cm3, good dimensional stability and strong abrasive resistance. These are produced by hot mixing, cold mixing, extrusion, calibration for quenching and subsequent cutting, to produce solid skin, foamed core products. In the other embodiment, the wood-like polyvinyl chloride boards have embossed surface quality, a density below 1.0 g/cm3, good dimensional stability and surface hardness. These are produced by hot mixing, cold mixing, extrusion and subsequent slow cooling with a roller system to produce embossed products.

Abstract: The present invention is a process for producing a thermoplastic foam sheet comprising contacting a molten monovinylidene aromatic or olefinic polymer with a physical blowing agent to form a polymer/blowing agent mixture, and foaming the mixture into a region of lower pressure within a sheet extrusion line, wherein the extrudate is pulled and compressed to form a thermoplastic foam sheet having a uniform thickness.

Abstract: The melt of polyvinyl aromatic polymers comprising from 10 to 45 weight % of star branched polymer prepared using a combination of thermal and tetra functional peroxide initiation has an improved melt strength permitting better foam formation for extrusion foam blown with conventional blowing agents and inert gases including CO2.

Abstract: Flame-retardant foam slabs are based on styrene polymers wherein from 1 to 12% by weight of expanded graphite and also, if desired, from 1 to 12% by weight of a phosphorus compound are present as flame retardants.

Abstract: The present invention relates to a foam, a process for preparing the foam and an article containing the foam. The foam contains a coupled propylene polymer and has a density in of from 9.6 to 801 kg/m3 and has either a foamability factor of more than 1.8 to less than 2.8 and an open cell content less than 20 percent, or a foamability factor of at least 2.8 and less than 15 and an open cell content of less than 50 percent. The process includes heating a coupled propylene polymer having a melt flow rate from 0.2 to 20 g/10 min and a melt strength of at least 39 cN to a molten state to produce a molten polymer material and mixing said molten polymer material with a blowing agent under conditions to produce a foamed material having a density in the range of from 9.6 to 801 kg/m3.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. These compositions comprise aqueous emulsions of film forming polymers in combination with microfibers. The preferred film forming polymers and the microfibers include functional groups capable of forming bonds, particularly hydrogen bonds, between these components. In another aspect of the invention, the compositions include a high temperature foam stabilizer, such as a high molecular weight fatty alcohols, having melting points greater than about 110° F.

Abstract: Flexible open-celled microcellular foams based on thermoplastic polymers are useful for fluid-absorbent hygiene articles.

Abstract: A method of producing a foamed material comprises contacting a material with a fluid mixture comprising carbon dioxide and a surfactant, wherein the surfactant facilitates the dissolution of the carbon dioxide into the material and then foam the material in the fluid mixture.

Abstract: The present invention relates to a process comprising the following phases: the feeding and melting of polypropylene to obtain a molten polymer; addition to the molten polymer of possible additives; mixing of the molten polymer with the additives; introduction of the expanding agent CO2 into the molten polymer; extrusion of the molten polymer, expanding agent and possible additives to produce an expanded polypropylene, wherein the polypropylene fed and melted in the first phase consists of a polypropylene which contains a quantity ranging from 15 to 25% of high melt strength polypropylene and wherein the temperature is lowered to a value of about 160° C. immediately after introducing the CO2 gas into the molten polymer.

Abstract: The present invention provides a process for producing a foamed resin article, the process comprising: a step (the first step) of impregnating any one crystalline thermoplastic resin or resin composition containing, as an elementary ingredient, a crystalline thermoplastic resin selected from a certain group, under an elevated pressure which is not lower than the critical pressure of a substance with which the selected crystalline thermoplastic resin or resin composition is to be impregnated, with a fluid of the substance, and a step (the second step) of releasing the resin or resin composition impregnated with the substance from the foregoing pressurized condition in a period of less than 10 seconds.

Abstract: Stable foam caulk, sealant and insulation compositions are disclosed. The compositions comprise solid, waxy non-ionic lipophilic surfactants having low HLB values. These surfactants, upon foamed dispensing of the composition, provide stable support for bubbles formed from drying of a latex emulsion of a film forming polymer and a volatile liquid hydrocarbon propellant. In addition to use in caulking, sealant or insulation methods, the composition can be used to form artificial terrains and other hardenable structural surfaces as backgrounds or support means for hobbies, crafts, and the like.

Abstract: The invention concerns nucleating agent systems for foamable polymer compositions, preferably fluoropolymer resins, having foam cell nucleation sites using titanium dioxide based nucleating agents, and foamable polymers comprising the nucleating agents. The nucleating agent systems comprise TiO2, certain inorganic salts, and, optionally, sulphonic acid and/or phosphonic salts. The invention also concerns foamable composition concentrates and foamed thermoplastic insulation material comprising fluoropolymer agent systems.

Abstract: This invention describes grafted blend compositions, processes for their preparation and fabricated articles, especially foams therefrom. The blends exhibit enhanced melt strength, melt elongation greater than or equal to about 20 mm/s, increased upper service temperature, increased modulus, and increased hardness. The grafted blend compositions have little or no high shear viscosity increase over a corresponding polymer of the same chemical composition absent the coupling agent.

Abstract: A continuous method for making foams having uniform and/or small cell sizes and articles made with these foams are described. The method allows for adjusting or controlling cell size and cell size distribution by controlling temperature and/or blowing agent concentration. The foams feature small and/or uniform cell sizes and may be comprised of amorphous thermoplastic polymers, pressure sensitive adhesive compositions, and immiscible thermoplastic polymer compositions. A method for coextruding the foams is also described.

Abstract: The invention disclosed provides a method for inducing nucleation in a polymer by subjecting the polymer containing dissolved gas to an external stress generated, for example, by applying hydrostatic or mechanical pressure. The applied stress restricts the bubble growth so that the foamed materials have small cells and high cell density. Such microcellular foams can be produced over a wide low temperature range, i.e. from the temperature at which the polymer is conditioned with the blowing agent up to about the glass transition temperature of the polymer-blowing agent system. Stress induced nucleation can also be conducted at higher temperatures i.e. up to about the Tg of the neat polymer, leading to foams with larger cells. A variety of homogeneous and heterogeneous foams can be produced by this technique.

Abstract: A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid N-aliphatic alcohol amide of the general formula R—CON(R′)R″. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R′ typically is hydrogen. R′ can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R″ is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R′ is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA).

Abstract: The product made of crosslinked polyolefin foam of the invention is characterized by a compression of at most 7 N/cm2, measured according to the ASTM D 1667 standard with a degree of compression of 30% and a rate of compression of 10 mm/minute, for a density of at least 100 kg/m3, it being understood that this maximum compression may decrease for lower densities and increase for higher densities. The invention comprises, moreover, the application of this product as a seal.

Abstract: A method using a two part process line is proposed for manufacturing foams from polymers or polymer mixtures useful for making molded bodies. The process line is divided into at least one first part and one second part. The polymer or polymer mixture is melted in the first part and a gas at a pressure increased relative to the melt pressure is added with the influence of a shearing and/or kneading device on the melted polymer or polymer mixture enriched with gas. In the second part of the process line, foam is formed from the gas-enriched polymer or polymer mixture at a higher pressure than the pressure in the first part of the process line. Membranes can be made from the molded bodies made by the method described above.

Abstract: A closed-cell polymer foam having a density of less than 100 kg.m−3 is described. The cells in the foam contain a foam blowing agent comprising (a) a blend of two or more hydrofluorocarbons, (b) a blend comprising a carbon dioxide and one or more hydrofluorocarbons or (c) a blend comprising dimethyl ether and one or more hydrofluorocarbons, and the polymer is a blend comprising at least 50% by weight of an olefinic polymer(s) and up to 50% by weight of a polar polymer(s) having a lower molecular weight than the olefinic polymer which when in the heat plasticised state is able to dissolve the foam blowing agent. A process for preparing the foam is also described.

Abstract: A method of producing a substantially open-cell, expanded polystyrene sheet, comprising the steps of: forming a mixture comprising from 30 to 95% of polystyrene incorporating an aliphatic hydrocarbon with 4-6 carbon atoms, from 0 to 65% of polystyrene, and from 0.2 to 10% of a nucleating agent, mixing the mixture obtained and melting it by heating inside an extruder, bringing the mixture to a temperature of 130-150° C. in the final portion of the extruder, extruding the mixture in a lower-pressure atmosphere to produce an expanded sheet, which has a low density and a high capacity to absorb aqueous liquids, particularly if a surfactant is added to the starting mixture, and which, when coupled with two films of plastics material gives rise to a laminate suitable for the production, by thermoforming, of trays of foods which may release aqueous liquids.