Extruding A Solid Polymer Containing Material To Form A Cellular Product Patents (Class 521/79)
  • Patent number: 6380272
    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 foaming 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.
    Type: Grant
    Filed: August 23, 2000
    Date of Patent: April 30, 2002
    Inventor: Kuei Yung Wang Chen
  • Publication number: 20020045040
    Abstract: A microporous soundproofing material constituted of an expanded material formed through the step of impregnating a thermoplastic elastomer with an inert gas at a high pressure and then decompressing the impregnated elastomer. The soundproofing material has a high characteristic impedance, is clean and lightweight, and has excellent flexibility. This microporous soundproofing material includes: a microporous soundproofing material which is constituted of an expanded material formed through the step of impregnating an unexpanded molding comprising a thermoplastic elastomer with an inert gas at a high pressure and then decompressing the impregnated molding; and a microporous soundproofing material which is constituted of an expanded material formed by impregnating a molten thermoplastic elastomer with an inert gas at a high pressure and then subjecting the impregnated elastomer to molding simultaneously with decompression.
    Type: Application
    Filed: December 29, 2000
    Publication date: April 18, 2002
    Inventors: Mitsuhiro Kanada, Yoshihiro Minamizaki, Takayuki Yamamoto, Yasuhiko Kawaguchi, Katsuhiko Tachibana, Tomohiro Taruno, Tomohide Banba, Hideyuki Kitai, Manabu Matsunaga, Nobuyuki Takahashi
  • Patent number: 6369120
    Abstract: An acoustical insulation foam having, either with or without elastification, an Asker C hardness of less than about 65, a density of about 5 to about 150 kg/m3, a cell size of about 0.05 to about 15 mm, an open cell content of 0 to about 100 volume percent, a thickness of about 1 to about 200 mm, and a width of about 100 to about 3000 mm; comprising; (A) one or more alkenyl aromatic polymers, (B) one or more substantially random interpolymers and (C) optionally, one or more nucleating agents and (D) optionally, one or more other additives; and (E) one or more blowing agents.
    Type: Grant
    Filed: October 12, 2000
    Date of Patent: April 9, 2002
    Assignee: The Dow Chemical Company
    Inventors: Bharat I. Chaudhary, Russell P. Barry, Chung P. Park, Martin Reimers
  • Patent number: 6355341
    Abstract: This invention pertains to a composition and a process for preparing a closed cell alkenyl aromatic polymer foam having enlarged cell size, comprising one or more alkenyl aromatic polymers, one or more substantially random interpolymers, one or more blowing agents having zero ozone depletion potential and optionally one or more co-blowing agents, and optionally, one or more nucleating agents and optionally, one or more other additives. This combination allows the manufacture of closed cell, low density alkenyl aromatic polymer foams of enlarged cell size, when blowing agents of relatively high nucleation potential are employed. When such blowing agents are used with alkenyl aromatic polymers in the absence of the substantially random interpolymers, small cell foams result.
    Type: Grant
    Filed: August 31, 1999
    Date of Patent: March 12, 2002
    Assignee: The Dow Chemical Company
    Inventors: Bharat I. Chaudhary, Russell P. Barry, Lawrence S. Hood, Chung P. Park
  • Patent number: 6350789
    Abstract: The present invention generally relates to methods for preparing extruded foam products and more particularly to a methods for producing such products with a blowing agent containing 134a and an alcohol.
    Type: Grant
    Filed: April 30, 2001
    Date of Patent: February 26, 2002
    Assignee: Owens Corning Fiberglas Technology, Inc.
    Inventors: Larry Michael Miller, Raymond Marshall Breindel, Mitchell Zane Weekley, Thomas Earl Cisar, Kerry Jerome Prince
  • Patent number: 6346556
    Abstract: A silicone rubber sponge composition, a silicone rubber sponge, and a process for production thereof. The silicone rubber sponge composition comprises (A) 100 parts by weight organopolysiloxane gum described by average structural unit RaSiO(4−a)/2, where R is a monovalent hydrocarbon group or haloalkyl and a is 1.8 to 2.3 and having a viscosity at 25° C. of 1,000,000 mPa·s or above, (B) 1 to 400 parts by weight inorganic filler, (C) 0.01 to 50 parts by weight hollow thermoplastic resin particles, (D) 0.01 to 10 parts by weight a water-in-oil emulsion with silicone oil an oil phase, and (E) a curing agent in an amount sufficient to cure the composition.
    Type: Grant
    Filed: April 5, 2001
    Date of Patent: February 12, 2002
    Assignee: Dow Corning Toray Silicone Company, Ltd.
    Inventors: Katsuya Baba, Manabu Suto, Akito Nakamura
  • Patent number: 6340713
    Abstract: Particulate expandable styrene polymers contain homogeneously distributed graphite particles and can be processed to give self-extinguishing foams having a density of ≦35 g/l.
    Type: Grant
    Filed: November 15, 1999
    Date of Patent: January 22, 2002
    Assignee: BASF Aktiengesellschaft
    Inventors: Guiscard Glück, Klaus Hahn, Knut Kaempfer, Dieter Naegele, Frank Braun
  • Publication number: 20020006975
    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 of less than 3 mm.
    Type: Application
    Filed: January 12, 2001
    Publication date: January 17, 2002
    Inventors: Gary C. Welsh, Michael M. Ballot, Roldolfo J. Salmang
  • Publication number: 20020006976
    Abstract: A process for making a macrocellular acoustic foam is disclosed in which a foamable gel made of a blowing agent and a polymeric resin composition is subjected to an extrusion process at a die pressure greater than the prefoaming critical die pressure but less than or equal to four times that of said prefoaming critical die pressure and macrocellular foams obtainable by that process are also disclosed which are made of:
    Type: Application
    Filed: February 13, 2001
    Publication date: January 17, 2002
    Inventors: Suresh Subramonian, Sandrine Burgun, Chung P. Park
  • Patent number: 6339109
    Abstract: A method of preparing cellular pellets from a prepolymer comprising a blowing agent, the method comprising the steps of: a) extruding the prepolymer through a die, the die maintained at conditions such that the blowing agent remains in the condensed phase in the prepolymer prior to emerging from the die, and b) upon emergence of the prepolymer through the die, substantially simultaneously cooling the prepolymer by contacting the prepolymer with a cooling agent and cutting the prepolymer; the conditions outside the die being maintained such that the blowing agent vaporizes in the prepolymer to form pores.
    Type: Grant
    Filed: August 10, 1999
    Date of Patent: January 15, 2002
    Assignee: General Electric Company
    Inventors: James Day, Harish Radhakrishna Acharya
  • Patent number: 6331576
    Abstract: A surface decorated foam skin of cross-linked rubbery soft olefin resin, comprising rubbery soft olefin resin, characterizing by having (1) an average cell diameter of 50 to 400 &mgr;m, (2) a crystallinity of 5 to 40% (3) a hysteresis loss of 35% or lower, and (4) an embossing percentage of 40% or higher.
    Type: Grant
    Filed: December 19, 2000
    Date of Patent: December 18, 2001
    Assignee: NHK Spring Co Ltd
    Inventors: Koichi Kusakawa, Shigeki Ichimura
  • Patent number: 6329439
    Abstract: A tapered stepped land having a choked funnel section which terminates in a lateral longitudinal section results in the formation of a foamed extrudate of a vulcanized blend of polyolefin and rubber which is a mass of closed cells having a specific gravity in the range from about 0.1 to 0.5 and the cells are sheathed in a dense non-porous, smoothly continuous skin which is formed integrally with the extrudate. The dense skin makes it possible to deposit a thin slip-coating of a low friction material longitudinally upon a chosen portion of the surface. An extruded weatherseal for the glass of an automobile's window has the slip-coating deposited as a thin film on a contacting strip of a surface which is in contact with the glass.
    Type: Grant
    Filed: December 27, 2000
    Date of Patent: December 11, 2001
    Assignee: Advanced Elastomer Systems, L.P.
    Inventors: Duane E. Peterson, Antonius Van Meesche
  • Patent number: 6326413
    Abstract: A process and apparatus for producing polyurethane foam, comprising bringing together under pressure one or more foam components and a gaseous CO2 auxiliary blowing agent and discharging the combination through a permeable discharge head in the form of plural individual wire meshes sintered together to form at least one composite element having a structure such as to require repeated division, divergence and convergence of flow paths and impingement of the individual flows with the sintered wire mesh and the flows through adjacent pores in three dimensions within its axial thickness, and at which the pressure is reduced for forming a froth, wherein the combination of the foam components and gaseous CO2 is arranged to be in a non-homogeneous state containing gas bubbles prior to passage through the discharge head.
    Type: Grant
    Filed: August 25, 2000
    Date of Patent: December 4, 2001
    Assignee: Beamech Group Limited
    Inventors: James B. Blackwell, Geoffrey Buckley, John J. Blackwell, Stephen W. Blackwell
  • Patent number: 6326411
    Abstract: The mixture comprising a polymer, an adsorbtion agent including an expansion agent and a nucleating agent is produced before being placed in an extruder. The result is a finished product of expanded cellular polymer comprising more than 90% by volume of closed cells.
    Type: Grant
    Filed: July 19, 1999
    Date of Patent: December 4, 2001
    Assignee: Nextrom Holding SA
    Inventors: Philippe Desarzens, Eric Affolter
  • Patent number: 6323269
    Abstract: A mineral containing thermoplastic granule for incorporation in a thermoplastic material to produce a thermoplastic end product, the granule comprising at least 50% by weight of an inorganic particulate material, at least 0.1% by weight of an additive comprising a blowing agent, and the balance comprising a thermoplastic binder.
    Type: Grant
    Filed: April 24, 1998
    Date of Patent: November 27, 2001
    Assignee: Imerys Pigments, Inc.
    Inventors: David A. Skelhorn, Allison R Calhoun
  • Patent number: 6323245
    Abstract: A blowing agent for expanding an extrudable, expandable polyolefin foam product, the blowing agent including a blend of isobutane and n-butane. The isobutane is present in the blend at a weight percentage ranging from 35 to 65 and the n-butane is present in the blend at a weight percentage ranging from 35 to 65.
    Type: Grant
    Filed: August 24, 2000
    Date of Patent: November 27, 2001
    Assignee: Sealed Air Corporation (US)
    Inventors: N. S. Ramesh, S. T. Lee, Lloyd George
  • Patent number: 6319961
    Abstract: The present invention provides an ethylene resin foamed product containing uniform cells and having excellent appearance, toughness and flexibility. The ethylene resin foamed product comprises an ethylene/&agr;-olefin copolymer having the following properties: the density is in the range of 0.880 to 0.940 g/cm3; the melt flow rate (MFR) at 190° C. under a load of 2.16 kg is in the range of 0.1 to 20 g/10 min; the decane-soluble component fraction (W) at room temperature and the density (d) satisfy the relation W<80×exp(−100(d−0.88))+0.1 in case of MFR≦10 g/10 min and the relation W<80×(MFR-9)0.26×exp(−100(d−0.88))+0.1 in case of MFR>10 g/10 min; and the temperature (TM) at the maximum peak position in the endothermic curve as measured by a differential scanning calorimeter and the density (d) satisfy the relation Tm<400×d−250.
    Type: Grant
    Filed: September 19, 2000
    Date of Patent: November 20, 2001
    Assignee: Mitsui Chemicals INC
    Inventor: Mamoru Takahashi
  • Patent number: 6315931
    Abstract: A method for producing a foamed granulate, wherein a thermoplastic synthetic material is placed in an extruder, the synthetic material is melted, a pressurized expanding agent is fed through one or several injection nozzles, the molten material enriched with the expanding medium is foamed as it exits through a perforated plate arranged at the outlet of the extruder and is granulated by a cutting device arranged behind the perforated plate. Also disclosed is a device for implementing the method and the foamed granulate.
    Type: Grant
    Filed: November 5, 1999
    Date of Patent: November 13, 2001
    Assignee: Gefinex Polymerschaeume GmbH
    Inventors: Juergen Bruning, Otto Deseke, Joachim Meyke
  • Patent number: 6315932
    Abstract: An extrusion foaming method for obtaining a styrene resin foam by introducing a blowing agent into the resin under pressure by which a foam having excellent heat insulating property and compressive strength can be produced with excellent stability using a blowing agent which is as environmentally safe as possible, characterized in that a foam is obtained by using a blowing agent comprising mainly less than 40% by weight and 5% by weight or more of an ether, and more than 60% by weight and not more than 95% by weight of a saturated hydrocarbon having 3 to 5 carbon atoms, based on the entire amount of the blowing agent, or as required, by using a blowing agent wherein a part of the saturated hydrocarbon in the foregoing blowing agent is replaced by a fluorinated hydrocarbon with concern for the environment, and preferably in that the ratio Z/X of cells constituting the foam wherein X is the average cell size in the direction of extrusion and Z is the average cell size in the direction of thickness is adjusted t
    Type: Grant
    Filed: August 23, 1999
    Date of Patent: November 13, 2001
    Assignee: Kaneka Corporation
    Inventors: Hiroshi Fujiwara, Hiroshi Kobayashi, Fuminobu Hirose
  • Patent number: 6316512
    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.
    Type: Grant
    Filed: April 24, 2000
    Date of Patent: November 13, 2001
    Assignee: Sentinel Products Corp.
    Inventors: John D. Bambara, Matthew L. Kozma, Robert F. Hurley
  • Publication number: 20010039299
    Abstract: An extruded, coalesced foam strand propylene polymer material that is either open-celled and useful for sound insulation applications or close celled and useful for thermal insulation applications.
    Type: Application
    Filed: March 9, 2001
    Publication date: November 8, 2001
    Inventors: Chung P. Park, Michel Brucker, Georges Eschenlauer, Michael E. Schaller, Jean-Francois Koenig
  • Publication number: 20010031794
    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.
    Type: Application
    Filed: April 6, 2001
    Publication date: October 18, 2001
    Inventors: Takayuki Yamamoto, Amane Mochizuki, Takami Hikita, Tomohiro Taruno, Tomohide Banba, Mitsuhiro Kanada
  • Publication number: 20010031796
    Abstract: A material for the production by extrusion or molding or calendering of light articles has a chemical formulation comprising at least a thermoplastic polymer. A predetermined amount of polymeric microspheres containing isopentane is added to said at least a thermoplastic polymer. A process for producing said material comprises a first step during which the thermoplastic polymer is mixed to further components (such as thermal stabilizers and/or costabilizers and/or additives) and a second step during which the mixture is granulated in order to obtain a granular compound. At the end of the first step, and advantageously immediately before the beginning of said second step, a predetermined amount of polymeric microspheres containing isopentane is added to the mixture. Said material is used for the production by injection molding or extrusion or calendering of light articles in the shoe industry, particularly of shoe soles.
    Type: Application
    Filed: May 21, 2001
    Publication date: October 18, 2001
    Inventors: Giorgio Peretti, Renzo Pasetto
  • Patent number: 6303666
    Abstract: A process is provided for the production of expanded olefinic thermoplastic elastomer product having good external appearance, flexibility and heat resistance. This process features using, as raw materials, a particular olefinic thermoplastic elastomer and carbon dioxide as a blowing agent.
    Type: Grant
    Filed: July 23, 1999
    Date of Patent: October 16, 2001
    Assignee: Mitsui Chemicals, Inc.
    Inventors: Kaoru Yorita, Eiichi Sugihara, Masahiro Takedachi, Haruo Inoue, Shigeo Nishikawa, Yoko Shimada, Michio Eriguchi, Takanori Sueda, Akira Uchiyama, Yuichi Ito
  • Patent number: 6300384
    Abstract: A silicone rubber sponge composition, a silicone rubber sponge, and a process for production thereof. The silicone rubber sponge composition, comprises (A) 100 parts by weight organopolysiloxane gum described by average structural unit RaSiO(4−a)/2, where R is a monovalent hydrocarbon group or haloalkyl and a is 1.8 to 2.3 and having a viscosity at 25° C. of 1,000,000 mPa·s or above, (B) 1 to 400 parts by weight inorganic filler, (C) 0.01 to 50 parts by weight hollow thermoplastic resin particles, (D) 0.1 to 10 parts by weight thermally decomposable blowing agent, and (E) a curing agent in an amount sufficient to cure the composition.
    Type: Grant
    Filed: April 4, 2001
    Date of Patent: October 9, 2001
    Assignee: Dow Corning Toray Silicone Company, Ltd.
    Inventors: Katsuya Baba, Hiroshi Honma, Akito Nakamura
  • Patent number: 6299808
    Abstract: The invention comprises a fully continuous process for shaping a high internal phase emulsion (HIPE) with a polymerizable continuous phase into dry foam, comprising 1) providing a high internal phase emulsion (HIPE) comprising (a) at least 70 percent by volume of an eternal phase comprising one or more polymerizable monomer; (b) a surfactant in an amount effective to produce a high internal phase emulsion; and (c) an internal phase; 20 depositing the emulsion onto a lower moving support substrate; 3) leveling the emulsion to a desired thickness above the support substrate; 4) polymerizing the monomers by running the emulsion and the lower moving support substrate through a heating zone for a time sufficient to polymerize at least 75% of the monomer in the HIPE by the end of the heating zone; and 5) drying the polymerized HIPE in a drying zone for a time sufficient to produce a foam having greater than 50% of the internal phase removed.
    Type: Grant
    Filed: June 5, 2000
    Date of Patent: October 9, 2001
    Assignee: The Dow Chemical Company
    Inventors: Steven W. Mork, Bruce A. Malone
  • Patent number: 6300383
    Abstract: A silicone rubber sponge composition, a silicone rubber sponge, and a process for making the silicone rubber sponge. The silicone rubber sponge composition comprises (A) 100 parts by weight organopolysiloxane gum described by average structural unit RaSiO(4−a)/2, where R is a monovalent hydrocarbon group or haloalkyl and a is 1.8 to 2.3 and having a viscosity of 1,000,000 mPa·s or above at 25° C., (B) 1 to 400 parts by weight inorganic filler, (C) 0.01 to 50 parts by weight hollow thermoplastic resin particles, (D) 0.1 to 10 parts by weight liquid compound with a boiling point above room temperature, and (E) a curing agent in an amount sufficient to cure the composition.
    Type: Grant
    Filed: March 29, 2001
    Date of Patent: October 9, 2001
    Assignee: Dow Corning Toray Silicone Company, Ltd.
    Inventors: Katsuya Baba, Hiroshi Honma, Akito Nakamura
  • Patent number: 6299809
    Abstract: Method and composition for making an expanded polyethylene material by forming a foamable melt of polyethylene, a nucleating agent, a material which retards migration of alkanes, and a blowing agent which comprises 10 to 100 mole percent ethane. In one disclosed embodiment, the melt is passed through an annular extrusion die to form an elongated tube of extruded material which is then expanded, slit lengthwise and laid flat to form a sheet of the expanded material.
    Type: Grant
    Filed: March 12, 1997
    Date of Patent: October 9, 2001
    Assignee: Free-Flow Packaging International, Inc.
    Inventors: William D. McIntyre, Roderick R. Alire, Ronald N. Clazie
  • Patent number: 6294115
    Abstract: Semi-crystalline microcellular foams that include a midlevel amount of nucleating agent, and methods of their production, are provided. The microcellular foams can be produced in typical polymer processing techniques such as extrusion, injection molding and blow molding. The foams exhibit excellent mechanical properties and can be formed over a broad range of density into a number of different foam articles.
    Type: Grant
    Filed: May 4, 2000
    Date of Patent: September 25, 2001
    Assignee: Trexel, Inc.
    Inventors: Kent Blizard, Kelvin T. Okamoto, Jere R. Anderson
  • Patent number: 6291539
    Abstract: A flexible, low density thermoplastic foam and a method for lowering the density and increasing the flexibility of a thermoplastic foam having a melting temperature and being either amorphous with a softening temperature or semicrystalline with a glass transition temperature.
    Type: Grant
    Filed: May 10, 2000
    Date of Patent: September 18, 2001
    Assignee: Armacell Enterprise GmbH
    Inventors: David W. Kreiser, Allan L. Dinkel, Juerg Patrik Weibel
  • Patent number: 6290884
    Abstract: The present invention provides a process for producing uncrosslinked polypropylene-based resin foam sheets which is characterized by using an extrusion foaming apparatus having a gear pump which is interposed between the extruder and the die and which is linked by means of adapters, wherein the pressure (Pg) at the inlet of the gear pump is within the range specified by the following formula (Formula 1) and the extruder is controlled so that the value of Pg is constant. Formula 1 Pc≦Pg(atm)≦Pc+90 Pc=(&khgr;−1)/H &khgr;: theoretical expansion ratio when the foaming agent added is 100% held H: coefficient of solubility of the foaming gas in the resin at the resin temperature in the gear pump inlet (cm3(STP)/cm3·atm) and the like.
    Type: Grant
    Filed: July 30, 1999
    Date of Patent: September 18, 2001
    Assignee: Sumitomo Chemical Company, Limited
    Inventors: Akinobu Sakamoto, Tatsuhiro Nagamatsu
  • Patent number: 6284077
    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.
    Type: Grant
    Filed: December 16, 1999
    Date of Patent: September 4, 2001
    Assignee: DAP Products Inc.
    Inventors: Patrick J. Lucas, Anthony J. Taylor
  • Patent number: 6284359
    Abstract: A biodegradable, water dispersible shaped core product useful in winding or rolling and storage of paper goods is provided by extruding starch which has a particle size of 800 to 1200 microns into an expanded, closed cell starch product.
    Type: Grant
    Filed: September 29, 1997
    Date of Patent: September 4, 2001
    Assignee: National Starch and Chemical Company Investment Holding Corporation
    Inventors: Richard R. Rose, Beth C. Tormey, Paul A. Altieri
  • Patent number: 6284810
    Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.
    Type: Grant
    Filed: February 26, 1999
    Date of Patent: September 4, 2001
    Assignee: Trexel, Inc.
    Inventors: Theodore A. Burnham, Sung W. Cha, Robert H. Walat, Roland Y. Kim, Jere R. Anderson, James F. Stevenson, Nam P. Suh, Matthew Pallaver
  • Publication number: 20010014702
    Abstract: Processes for producing alkenyl aromatic foams utilizing a cycloaliphatic gas as blowing agent, are described. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased thermal insulation properties.
    Type: Application
    Filed: February 1, 2001
    Publication date: August 16, 2001
    Applicant: Reedy International Corporation
    Inventors: Walter R. Harfmann, Michael E. Reedy
  • Patent number: 6274641
    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.
    Type: Grant
    Filed: October 4, 2000
    Date of Patent: August 14, 2001
    Assignee: Nova Chemical INC
    Inventor: Steven M. Krupinski
  • Patent number: 6274640
    Abstract: The present invention generally relates to methods for preparing extruded foam products and more particularly to a methods for producing such products with a blowing agent containing 134a and an alcohol.
    Type: Grant
    Filed: August 17, 2000
    Date of Patent: August 14, 2001
    Assignee: Owens Corning Fiberglas Technology, Inc.
    Inventors: Larry Michael Miller, Raymond Marshall Breindel, Mitchell Zane Weekley, Thomas Earl Cisar, Kerry Jerome Prince
  • Patent number: 6274639
    Abstract: An improved durable, low density, high build polyurethane coating is disclosed, as well as its method of manufacture. A slow reacting polyisocyanate is combined with a polyol so as to form a uniform mixture with an extremely long pot life. The low viscosity uniform mixture can then be sprayed onto a substrate using a conventional spray gun. A polyurethane catalyst is introduced after formation of the uniform mixture, preferably via a second spray nozzle so that catalyst is externally mixed into the polyisocyanate/polyol spray stream. This is a 100%, or near 100%, solids system so that there is very low volatile organic compound emissions.
    Type: Grant
    Filed: April 20, 2000
    Date of Patent: August 14, 2001
    Assignee: Lockheed Martin Corporation
    Inventors: James E. Foreman, Douglas R. Dowell, Bobby G. Isler
  • Publication number: 20010010849
    Abstract: A polymeric foam article is comprised mainly of homopolymeric polypropylene, or unimodal polypropylene. The polymeric article can be microcellular, and can be formed into a drinking straw.
    Type: Application
    Filed: March 26, 2001
    Publication date: August 2, 2001
    Inventors: Kent Blizard, Srinath Tupil, William Malavich
  • Patent number: 6268046
    Abstract: In one embodiment, the present invention relates to a process for preparing foam board or sheet including the steps of (A) forming a foamable mixture of (1) a major amount of a styrenic polymer having a high melt index, (2) a minor amount of a low melt index styrenic polymer, and (3) a blowing agent containing a major amount of carbon dioxide under a pressure sufficient to prevent prefoaming of the mixture, and (B) foaming the mixture into a region of reduced pressure to form a foam product.
    Type: Grant
    Filed: October 21, 1999
    Date of Patent: July 31, 2001
    Assignee: Owens Corning Fiberglas Technology, Inc.
    Inventors: Larry Michael Miller, Thomas Earl Cisar, Raymond Marshall Breindel, Mitchell Zane Weekley
  • Patent number: 6262138
    Abstract: There is provided a foamed article having a low density, large thickness, a high closed cell ratio and a small average cell diameter. A foamed extrusion article having a density of 50 to 10 kg/m3 and a closed cell ratio of at least 40% is obtained by mixing a mixed resin comprising (a) 50 to 95 parts by weight of a polypropylene resin having a melt tension at 230° C. of at least 0.05 N, (b) 50 to 5 parts by weight of a polystyrene resin, and (c) 0.5 to 15.0 parts by weight of a hydrogenated block copolymer of styrene, isoprene and styrene based on 100 parts by weight of the polypropylene resin (a) and the polystyrene resin (b) with a foaming agent in an extruder, and then releasing into a low-pressure zone.
    Type: Grant
    Filed: July 7, 2000
    Date of Patent: July 17, 2001
    Assignee: Kaneka Corporation
    Inventors: Osamu Miyama, Haruo Tomita
  • Patent number: 6258862
    Abstract: A composition including, by weight: from 40 to 80% of at least one uncrosslinked composition (A) including at least one polyolefin (PA); from 60 to 20% of at least one crosslinked composition (B) including at least one propylene polymer (PB) and at least one ethylene-vinyl acetate (EVA) copolymer. The composition B has preferably been obtained beforehand by processing a composition including from 10 to 49% of at least one propylene polymer (PB), from 90 to 51% by weight of at least one ethylene-vinyl acetate copolymer, and from 100 to 1500 ppm by weight of at least one crosslinking agent. This composition makes it possible especially to manufacture foam sheets which can be employed in the motor vehicle industry, which are thermoformable, HF weldable and recyclable.
    Type: Grant
    Filed: June 25, 1997
    Date of Patent: July 10, 2001
    Assignee: Solvay (Société Anonyme)
    Inventors: Pierre Matz, Edmond Mulkens
  • Patent number: 6258863
    Abstract: Process for producing alkenyl aromtic foams utilizing a cycloaliphatic gas as blowing agent, are described. Also disclosed are alkenyl aromatic foams produced by the process which exhibit increased thermal insulation properties.
    Type: Grant
    Filed: December 7, 1998
    Date of Patent: July 10, 2001
    Assignee: Reedy International Corporation
    Inventors: Walter R. Harfmann, Michael E. Reedy
  • Patent number: 6248799
    Abstract: A material for the production by extrusion or molding or calendering of light articles has a chemical formulation comprising at least a thermoplastic polymer. A predetermined amount of polymeric microspheres containing isopentane is added to said at least a thermoplastic polymer. A process for producing said material comprises a first step during which the thermoplastic polymer is mixed to further components (such as thermal stabilizers and/or costabilizers and/or additives) and a second step during which the mixture is granulated in order to obtain a granular compound. At the end of the first step, and advantageously immediately before the beginning of said second step, a predetermined amount of polymeric microspheres containing isopentane is added to the mixture. Said material is used for the production by injection molding or extrusion or calendering of light articles in the shoe industry, particularly of shoe soles.
    Type: Grant
    Filed: November 8, 2000
    Date of Patent: June 19, 2001
    Assignee: Interplastica S.R.L.
    Inventors: Giorgio Peretti, Renzo Pasetto
  • Patent number: 6245272
    Abstract: It is an object of the present invention to provide a microporous polyolefin membrane, high in elongation and porosity, low in shrinkage, and capable of improving battery characteristics, safety and productivity, when used for battery separators. The microporous polyolefin membrane of the present invention comprises (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 45 to 95%, elongation at break of 300% or more, bubble point exceeding 980 KPa and thermal shrinkage in the TD direction of 3% or less. The present invention also provides a method for producing the above microporous polyolefin membrane.
    Type: Grant
    Filed: December 1, 2000
    Date of Patent: June 12, 2001
    Assignee: Tonen Chemical Corporation
    Inventors: Kotaro Takita, Hidehiko Funaoka, Norimitsu Kaimai, Shigeaki Kobayashi, Koichi Kono
  • Patent number: 6245823
    Abstract: Method and composition for making an expanded polyethylene material by forming a foamable melt of polyethylene, a nucleating agent, a material which retards migration of alkanes, and a blowing agent which comprises 10 to 100 mole percent ethane. In one disclosed embodiment, the melt is passed through an annular extrusion die to form an elongated tube of extruded material which is then expanded, slit lengthwise and laid flat to form a sheet of the expanded material.
    Type: Grant
    Filed: October 20, 1995
    Date of Patent: June 12, 2001
    Assignee: Free-Flow Packaging International, Inc.
    Inventors: William D. McIntyre, Roderick R. Alire, Ronald N. Clazie
  • Patent number: 6245266
    Abstract: A method for making an oriented foam generally includes the steps of: a. blending molten polyethylene and a blowing agent to form a foamable mixture; b. producing a foam by extruding the mixture at a predetermined rate through a die and into a region of reduced pressure so that the blowing agent expands within the mixture; and c. orienting the foam by drawing the foam out of the die at a rate that is between 1 and 1.5 times greater than the predetermined rate at which the mixture is extruded.
    Type: Grant
    Filed: March 15, 1999
    Date of Patent: June 12, 2001
    Assignee: Sealed Air Corp. (US)
    Inventors: Natarajan S. Ramesh, Lloyd George
  • Patent number: 6242502
    Abstract: The invention relates to a process for preparing a foamed thermoplastic elastomeric article,comprising the following steps: heating a mixture comprising a thermoplastic elastomer selected from the group comprising styrene based thermoplastic elastomers and thermoplastic polyolefin elastomers, and an effective amount of a water releasing chemical compound, to a temperature at which the water releasing chemical compound releases water, which is above the melting point of the thermoplastic elastomer, and releasing the resulting heated mixture to atmospheric conditions. The invention also relates to a foamable polymeric composition as well as to a foamed thermoplastic elastomeric article.
    Type: Grant
    Filed: August 23, 1999
    Date of Patent: June 5, 2001
    Assignee: DSM N.V.
    Inventors: Ryszard Brzoskowski, Yundong Wang, Christopher La Tulippe, Robert Dion, Cai Hua
  • Patent number: 6241220
    Abstract: A process and apparatus for producing a polymeric foam, wherein foam components are brought together under pressure and are passed through a permeable discharge head where the pressure is reduced. The permeable discharge head comprises a diffuser element having a structure such as to require division, divergence and convergence of flow paths in three dimensions within its axial thickness, considered in the direction of flow therethrough. The diffuser element comprises plural individual woven wire meshes sintered together to form a composite element. The invention also provides the diffuser element.
    Type: Grant
    Filed: July 9, 1999
    Date of Patent: June 5, 2001
    Assignee: Beamech Group Limited
    Inventors: James Brian Blackwell, Geoffrey Buckley, John James Blackwell, Stephen William Blackwell
  • Patent number: 6235360
    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 for foods which may release aqueous liquids.
    Type: Grant
    Filed: October 21, 1999
    Date of Patent: May 22, 2001
    Assignee: Sirap-Gema S.p.A.
    Inventors: Federico Lanzani, Renato Mauri