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

Abstract: Condensation polymerization followed by a supercritical extraction step can be used to obtain highly cross-linked nanoporous polymers with high surface area, controlled pore sizes and rigid structural integrity. The invention polymers are useful for applications requiring separation membranes.

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

Abstract: The present invention is directed to an underlayment composition for an artificial playing surface comprised of a butadiene rubber, such as polybutadiene or styrene-butadiene that is commercially available as recycled polycord tires that have been granulized. An inorganic-base moisture-retaining agent such as vermiculite or perlite is also included in the composition in addition to a binder comprised of a mixture of isocyanate polyurethane and an inorganic acid. The present invention also provides a method of making the present composition. The method comprises the steps of mixing thoroughly granulized particles of butadiene rubber in a mixing container, mixing an inorganic-based moisture-retaining component with the butadiene rubber, mixing an acid having a pH .ltoreq.3 with the butadiene rubber and the inorganic-based moisture-retaining component, and mixing an isocyanate polyurethane with the butadiene rubber, the inorganic-based moisture-retaining component and the acid.

Abstract: Foam forming techniques capable of permitting foaming of biodegradable resin to be positively and uniformly accomplished to provide a biodegradable resin foam with satisfactory quality. The biodegradable resin foam is made of biodegradable resin consisting of a main biodegradable resin ingredient of 100.degree. C. or more in melting point and a low-melting biodegradable resin ingredient of 100.degree. C. or less in melting point. The biodegradable resin foam is produced by placing a starting material consisting of at least biodegradable resin and a substantial amount of moisture in a heated and pressurized environment, releasing the starting material from the environment to foam the biodegradable resin, and subjecting the foamed resin to forming by means of a forming mold. An apparatus for producing the foamed biodegradable resin foam includes a pressure adjusting chamber, an air-permeable forming mold, a pressure reducing tank and an injection machine.

Abstract: Disclosed is a compatibilized carbon black useful in melt processing of plastic material. The carbon black is coated with a compatibilizing agent which enhances the dispersibility of the carbon black in a melt of the plastic material. Further disclosed are processes for making plastic foam structures with the compatibilized carbon black.

Abstract: Disclosed is a low density, dimensionally-stable, extruded propylene polymer foam comprising primarily of an expanded propylene polymer material wherein the foam has a blowing agent comprising at least 15 percent by weight of one or more inorganic blowing agents. The propylene polymer material comprises at least about 15 weight percent of propylene monomeric units. The foam has a density of from about 10 to about 150 kilograms per cubic meter. The foam having an average cell wall thickness of less than about 35 micrometers.

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

Abstract: The use of prime starch to make a starch graft copolymer allows the resulting starch graft copolymer to be extruded with reduced torque and pressure as compared to a starch graft copolymer made from conventional dried starch.

Abstract: The present invention is directed to an underlayment composition for an artificial playing surface comprised of a butadiene rubber, such as polybutadiene or styrene-butadiene that is commercially available as recycled polycord tires that have been granulized. An inorganic-base moisture-retaining agent such as vermiculite or perlite is also included in the composition in addition to a binder comprised of a mixture of isocyanate polyurethane and an inorganic acid. The present invention also provides a method of making the present composition. The method comprises the steps of mixing thoroughly granulized particles of butadiene rubber in a mixing container, mixing an inorganic-based moisture-retaining component with the butadiene rubber, mixing an acid having a pH.ltoreq.3 with the butadiene rubber and the inorganic-based moisture-retaining component, and mixing an isocyanate polyurethane with the butadiene rubber, the inorganic-based moisture-retaining component and the acid.

Abstract: An electrorheological(ER) composite material with solid, elastomeric characteristics in the form of an elastomer matrix encompassing an ER fluid. This ER composite material changes certain of its physical properties in response to an imposed electric field (as do known ER fluids), but it has the advantage of maintaining a defined spatial volume without the need of sophisticated seals. It also provides desirable design features inherent in an elastic solid having the specific capability of being molded in conjunction with a containment surface to which it strongly adhesively bonds. Certain physical properties of these ER composite materials and their physical response to the application of an electric field may be varied by varying the properties and/or the proportions of the ER fluid component and the resin prepolymer component which are employed in formulating the composite.

Abstract: An expandable conductive-silicone rubber composition includes (A) an organopolysiloxane having at least two alkenyl groups, (B) conductive carbon black, (C) an organic peroxide of the formula: ##STR1## wherein R.sup.2 and R.sup.3 each are a monovalent C.sub.3 -C.sub.10 hydrocarbon group or a group of --SiR.sup.4.sub.3 wherein R.sup.4 is methyl, ethyl or phenyl, X is --(CH.sub.2).sub.n --, --CH.sub.2 --C(CH.sub.3).sub.2 --CH.sub.2 -- or --(C.sub.2 H.sub.4 O).sub.m --C.sub.2 H.sub.4 -- wherein n=2 to 8 and m=1 to 4, (D) an organohydrogenpolysiloxane, (E) a platinum catalyst, and (F) a blowing agent. It is fully stable during shelf storage, has a long pot life, and is rapidly expandable and curable through hot air vulcanization into conductive silicone rubber foam having high conductivity and improved fatigue endurance of sponge cells when the foam is used as a sponge roll.

Abstract: A low density foam having a density less than 15 pounds per cubic foot (240 kg/m.sup.3) is formed from an amorphous polyethylene terephthalate polymer. An expandable resin composition is also disclosed, comprising an amorphous polyethylene terephthalate polymer and a blowing agent mixture comprising a low permeability blowing agent and a high solubility blowing agent. Unexpanded and partially expanded foam particles, impregnated with the blowing agent mixture are disclosed. Numerous methods are disclosed for producing lightweight foams from amorphous polyethylene terephthalate polymers. One such method utilizes an Accumulating Extrusion Expansion System which avoids problems experienced with the prior art when attempting to extrusion expand polyesters.

Abstract: A lightweight, electroconductive foam comprising an effective amount of a conductive ionic salt, a polymer capable of complexing said conductive ionic salt and an effective amount of particulate conductive material such as carbon black or metal is disclosed. Additionally, a method of preparing a lightweight electroconductive foam having a surface resistivity less than about 10.sup.10 ohms per square by an extrusion process is disclosed. Foams of the present invention exhibit relatively high conductivities yet require only relatively low amounts of particulate conductive material.

Abstract: A process for producing thin microporous polymeric films for a variety of uses. The process utilizes a dense gas (liquified gas or supercritical fluid) selected to combine with a solvent-containing polymeric film so that the solvent is dissolved in the dense gas, the polymer is substantially insoluble in the dense gas, and two phases are formed. A microporous film is obtained by removal of a dense gas-solvent phase.

Abstract: An uncrosslinked, closed cell, low density ethylenic polymer foam having a density of less than 150 kg/m.sup.3 is prepared from, for example, uncrosslinked low density polyethylene using inorganic blowing agents, such as carbon dioxide, argon, or mixtures thereof. A process for preparing such uncrosslinked, closed cell, low density ethylenic polymer foam comprising extruding a ethylenic polymer of suitable melt tension using a 100 percent inorganic blowing agent, such as carbon dioxide, argon, or mixtures thereof, and the foams produced with this process are also disclosed.

Abstract: Disclosed is a compatibilized carbon black useful in melt processing of plastic material. The carbon black is coated with a compatibilizing agent which enhances the dispersibility of the carbon black in a melt of the plastic material. Further disclosed are processes for making plastic foam structures with the compatibilized carbon black.

Abstract: Disclosed is a foamable styrenic polymer gel containing an aqueous blowing agent capable of forming a closed-cell, unimodal foam structure. The gel composes in admixture the flowable melt of a polymer composition having greater than 50 percent by weight of a styrenic polymer and a blowing agent having about 1 percent or more by weight water based upon the total weight of the blowing agent. The styrenic polymer has a degree of water solubility sufficient to ensure formation of a unimodal foam structure instead of a bimodal foam structure. The unimodal cell size distribution provides desirable fabricability and machinability characteristics for the foam structure.

Abstract: Disclosed is a method of insulating a surface or enclosure by applying to the surface or enclosure a polymeric foam structure of a polymer material and carbon black. The carbon black is generally uniformly dispersed in the polymer matrix in the form of discrete particles substantially free of agglomeration. A preferred carbon black is thermal black. The carbon black provides a number of advantages over those previously employed commercially. Further disclosed is a process for making the foam structure. Further disclosed is an extruded, insulative foam structure of the type described above.

Abstract: A process for producing a high quality silicone foam by free foaming, in which a two-component addition crosslinking system is used, comprised of a component A which contains a silicone polymer having at least two double bonds per molecule, preferably vinyl groups, a complexed organo-platinum for example with butanol, fumed silica, and water, as well as further additives, if appropriate, and a component B which contains a silicone polymer having at least two double bonds per molecule, preferably vinyl groups, fumed silica, and polydimethyl hydrogen siloxane as SiH crosslinking agent. The two components A and B are mixed, and the reaction mixture is subsequently pressurized, preferably using compressed air or nitrogen, in a storage vessel over several hours so that the gas is present in the mixture in a dissolved form.

Abstract: An improved polystyrene foam having less corrugation is disclosed which uses carbon dioxide as the blowing agent and 1-30 weight percent endothermic agent, such as water, with the weight based on the total carbon dioxide blowing agent and endothermic agent weight. This combination of carbon dioxide and endothermic agent decreases the corrugation of the thermoplastic foam, while just slightly increasing density, when the process parameters, including throughput, are equivalent to using only carbon dioxide. The process an also allow an increased foaming temperature and greater process throughput of an equivalent density thermoplastic foam at approximately equivalent corrugation levels when compared to the use of only using only carbon dioxide.

Abstract: Disclosed is a flexibilized, insulative styrenic polymer foam structure comprising a foam of a polymeric composition of a styrenic polymer greater than 50 percent by weight styrenic monomeric units, the foam having relatively larger primary cells with an average cell size range of about 0.05 to about 1.2 millimeters and relatively smaller secondary cells ranging in cell size from about 5 percent to about 50 percent of the average cell size of the primary cells. The primary and secondary cells constitute at least about 90 percent of the total cell volume within the foam structure. Between 1 and 30 percent by number of the cells have microscopic "pinholes" between them. The presence of the pinholes enhances the flexure of the foam structure. Further disclosed is a method of insulating a surface comprising applying to the surface an insulating panel fashioned from the structure of claim 1.

Abstract: To arrive at an economical method of producing water-expanded polymer resin moldings, it is proposed that a monomer component and a cross-linker on an acrylate basis and/or a PMMA prepolymer be used as resin-forming components of a curable mixture.

Abstract: Organic resins with high surface areas and porosities, which are insoluble in organic solvents and contain few or no flexible groups in the resin structure, are disclosed. Also disclosed is a process for making such resins from polyfunctional aryl alkali metal compounds and a second polyfunctional monomer. Such resins are useful as absorbants.

Abstract: An electro-responsive elastomeric material comprising (A) an electrically insulating polymer having a specific modulus of elasticity and (B) a fine powder dispersed in the polymer which electrically polarizes under an electric field independent of water changes its viscoelasticity upon voltage application. The powder has a mean particle size of 0.5 to 500 .mu.m and is (1) a fine carbonaceous powder having a C/H atomic ratio of from 1.2 to 5, (2) composite particles having minute particulates of an insulating material dispersed in a matrix phase of a carbonaceous or carbide material, (3) composite particles having minute particulates of a carbonaceous or carbide material dispersed in a matrix phase of an insulating material, or (4) a fine composite powder of a stratum clay mineral having a two-dimensional stratum structure with a carbonaceous or carbide material incorporated between the strata.

Abstract: Low density styrene polymer foams having highly desirable physical properties are prepared employing as a blowing agent a mixture of carbon dioxide, lower alcohol and water. The cell size can be effectively controlled by controlling the amount of water in the blowing agent mixture, i.e., small cell or large cell foams can be prepared. A process for preparing such foams is also disclosed.

Abstract: A concrete fluid structure deteriorated to the condition of removal of substance of the concrete by sulfuric acids and like corrosive material in contact therewith is restored by a substratum of epoxy foam, polyurethane foam, or a combination thereof having a relatively thin layer of polyvinyl chloride or polyethylene bonded to the outward facing surface of the foam and bonding the layer to the structure. A method for forming the substratum in the location of the deteriorated structure is described.

Abstract: The improved adhesion is provided by incorporating into an adhesive and/or sealant plastic material an effective amount of cyclodextrin or a complex of cyclodextrin and blowing agent. Where the complex of cyclodextrin and blowing agent is employed, an expandable mixture is formed.

Abstract: To arrive at an economical method of producing water-expanded polymer resin moldings, it is proposed that a monomer component and a cross-linker on an acrylate basis and/or a PMMA prepolymer be used as resin-forming components of a curable mixture, with the weight ratio of the water component to the resin-forming component being at least 1:1.

Abstract: The present invention is a styrenic polymer foam blown with solely carbon dioxide and a process for making that styrenic polymer foam. Foam sheet made by this process is especially useful for thermoforming purposes.

Abstract: A foamable, curable composition or mass based on silicone is disclosed which comprises components which expand at higher temperatures and which do not burn or are difficult to burn. The mass is suitable for fire-proofing, since the burning temperature leads to an expansion of these components. The mass can be used to seal or cover objects which are in danger of burning or can be formed into a finished, molded object or body and used as such.

Abstract: Low density styrene polymer foams having highly desirable physical properties are prepared employing as a blowing agent a mixture of carbon dioxide, lower alcohol and water. The cell size can be effectively controlled by controlling the amount of water in the blowing agent mixture, i.e., small cell or large cell foams can be prepared. A process for preparing such foams is also disclosed.

Abstract: Disclosed is a a bimodal, insulative, styrenic polymer foam structure comprising a foam of a styrene polymer material of greater than 50 percent by weight of styrenic monomeric units, the foam having relatively larger primary cells with a cell size range of 0.05 to 1.2 millimeters and relatively smaller secondary cells ranging in cell size from about 5 percent to about 50 percent of the average cell size of the primary cells. The primary and secondary cells constitute at least about 90 percent of the total cell volume within the foam structure. The bimodal structure has an amount of carbon black sufficient to reduce the thermal conductivity of the structure below that of a corresponding bimodal structure without carbon black. Further disclosed is a process for making the foam structure.

Abstract: The present invention is directed to foams produced from poly(aryl ethers) and mixtures of poly(aryl ethers) with various non-poly(aryl ether) polymers. These foams are produced using aqueous blowing agents comprising water as the only blowing agent, or mixtures of water with another blowing agent material.

Abstract: A flexible foamed liquid crystal polymer film or sheet having uniformly small cells or bubbles. The foam cells are essentially spherical and have mean diameters less than or equal to approximately 250 microns. The cell size distribution is relatively small. The foamed sheet is made by extruding the polymer through a die under pressure at a temperature near or below the polymer's melting point; a gas or chemical blowing agent is extruded with the polymer to produce foaming as the polymer exits the die.

Abstract: Starch-based biodegradable packaging fillers are provided which have high volumes, low weights, and excellent compressibility and resiliency properties. The products of the invention are fabricated by extrusion of a starch substrate, most preferably normal wheat starch, in the presence of minor amounts of a polyalkylene glycol or derivative thereof and/or a particulate bubble-nucleating agent. Effective biodegradable packaging fillers can thus be fabricated without the use of expensive modified starch substrates; however, such substrates can also be employed if desired, and the additives of the invention improve these products as well. In preferred production procedures, the additives are mixed with the starch substrate, and the mixture is preconditioned and then extruded through a twin screw extruder.

Abstract: A water-vapor permeable, waterproof coated fabric having a fibrous base fabric, and a porous film coated on one side of the base fabric. The porous film comprises a synthetic polymer composed mainly of a polyurethane resin and inorganic fine particles having a mean particle diameter of not more than 0.1 .mu.m. In the porous film, microcells intercommunicate in the thicknesswise direction of the film to form a honeycomb skin core structure having a diameter of 1 to 20 .mu.m. The porous film has a multiplicity of micropores having a diameter of not more than 1 .mu.m. The coated fabric has waterproof and water-vapor permeability characteristics sufficient to meet such performance characteristics required in various applications, such as rainwears, military garments, and sportswears.

Abstract: A closed cell, rigid, polymer foam comprising the reaction product of a polyisocyanate and an isocyanatereactive compound in the presence of (a) a foaming agent, (b) at least about 2 percent by weight of carbon black, based on the weight of the polymer in the foam, and (c) a capped polyoxyalkylene compound which helps bring about a uniform dispersion of the carbon black throughout the foam so that the aged k-factor of the foam is below the aged k-factor of the corresponding unfilled foam.

Abstract: A lightweight, biodegradable packaging material and method for manufacturing the same. The product is made from an initial or starting material which is principally corn grit that is mixed with a binding agent and water extruded under heat and pressure and allowed to expand to form the packaging material.

Abstract: Starch-based biodegradable packaging fillers are provided which have high volumes, low weights, and excellent compressibility and resiliency properties. The products of the invention are fabricted by extrusion of a starch substrate, most preferably normal wheat starch, in the presence of minor amounts of a polyalkylene glycol or derivative thereof and/or a particulate bubble-nucleating agent. Effective biodegradable packaging fillers can thus be fabricated without the use of expensive modified starch substrates; however, such substrates can also be employed if desired, and the additives of the invention improve these products as well. In preferred production procedures, the additives are mixed with the starch substrate, and the mixture is preconditioned and then extruded through a twin screw extruder.

Abstract: Disclosed are a polymer gel in which a phase transition occurs due to a stimulus, a method of manufacturing such a polymer gel, and an actuator which employs such a polymer gel. The polymer gel which is formed by polymerizing monomers at a temperature equal to or less than a phase transition temperature of the resultant polymer gel and separating and/or classifying the polymer gel into fractions according to its size at a temperature equal to or greater than the phase transition temperature thereof. Alternatively, the polymer gel is separated and/or classified into fractions by adding a low molecular weight compound that can dissolve and swell the polymer gel to separate the polymer gel into fractions based upon a difference in dissolving rate or swelling rate. Alternatively separation and/or classification of the polymer gel is performed by a combination of the above-described two methods. In consequence, the resultant polymer gel has an average particle size ranging from 0.1 .mu.m to 100 .mu.

Abstract: Compositions and a process for manufacture are provided for synthetic polymer-propellant systems that form cohesive foamed structures from which aqueous solutions can be expressed, where the useful temperature range over which these structures form is broadened by using a propellant mixture consisting predominantly of a propellant that is a poor solvent for the polymer and has a vapor pressure in the range of 10-35 psig at 20 C in combination with a small amount of a propellant that is a good solvent for the polymer; and where these coherent foamed structures can be formed even with aqueous solutions containing 0 to about 30% alcohol, provided that insoluble fine-particle solids that do not pack and become difficult to redisperse are included in the composition.

Abstract: The present invention is directed to foams produced from poly(aryl ethers) and mixtures of poly(aryl ethers) with various non-poly(aryl ether) polymers. These foams are produced using aqueous blowing agents comprising water as the only blowing agent, or mixtures of water with another blowing agent material.

Abstract: In accordance with the present method for preparing an elastomeric silicone foam, an inert gas is injected under superatmospheric pressure during or after the merging of a silanol-containing organopolysiloxane that is liquid at room temperature an organohydrogenpolysiloxane that is liquid at room temperature, and hydrosilation catalyst, the merging step is followed by mechanical mixing in an enclosed chamber, at which time the mixture is ejected into the atmosphere. Completion of cure with simultaneous evolution of hydrogen occur under atmospheric pressure with the reactive ingredients and the inert gas all present in a homogeneously microdispersed/mixed state. The present method stabilizes the cells formed by the hydrogen and makes possible the development of a large quantity of cells of uniform size and uniform distribution, resulting in a high-expansion ratio foam.

Abstract: A supermicrocellular foamed material and a method for producing such material, the material to be foamed such as a polymerplastic material, having a supercritical fluid, such as carbon dioxide in its supercritical state, introduced into the material to form a foamed fluid/material system having a plurality of cells distributed substantially throughout the material. Cell densities lying in a range from about 10.sup.9 to about 10.sup.15 per cubic centimeter of the material can be achieved with the average cell sizes being at least less than 2.0 microns and preferably in a range from about 0.1 micron to about 1.0 micron.

Abstract: A microporous sheet comprising a polymeric matrix having a liquid insoluble, particulate, activated polysaccharide media dispersed therein; use of the sheet in affinity chromatography or ion-exchange chromatography or as a biochemical reactor or battery separator; processes for manufacturing the sheet; apparatus containing the microporous sheet as its active element; and methods for using such sheet.

Abstract: A biodegradable shaped product comprising an expanded modified flour product preferably having at least 40% by weight amylose content and containing about 2% or more by weight of an inorganic water soluble salt, said expanded product having a low density, closed cell structure with good resilience and compressibility.Another embodiment provides a biodegradable packaging material comprising an expanded, low density, closed cell modified flour product, the flour preferably having at least 40% by weight amylose content and containing about 2% or more by weight of an inorganic water soluble salt, and the expanded product having a bulk density of less than about 2.0 lb/ft.sup.3, a resiliency of at least about 50%, and a compressibility of from about 100 to 800 g/cm.sup.2.

Abstract: A foam absorber having electromagnetic energy attenuation characteristics comprising an open cell reticulated polyurethane foam impregnated with a conductive ink applied to a surface of the foam substrate. The conductive ink is applied as by spraying to a surface of the foam, coating such surface and gradiently loading the foam with the ink by penetration of the ink in gradually decreasing amount into the foam to a final depth therein. The conductive ink is comprised of an epoxy resin carrier and a combination of carbon and a metal such as silver, copper or nickel, preferably silver. The ink is applied as a curable mixture containing a solvent, to the foam substrate, the solvent is evaporated following coating and penetration of the ink into the foam, and the epoxy carrier of the ink in the foam substrate is cured.

Abstract: An improved method of using polymer compositions to produce foamed plastics, wherein a major, auxiliary source of blowing agent for the foam is the decomposition of dialkyl dicarbonates. The dialkyl dicarbonates can be decomposed over temperatures ranging from about 10.degree. C. to about 45.degree. C. when used in combination with particular tertiary amine decomposition catalysts. Enhanced production of carbon dioxide is obtained by the addition of water.

Abstract: A closed cell, rigid, polymer foam comprising the reaction product of a polyisocyanate and an isocyanate-reactive compound in the presence of (a) a foaming agent, (b) at least about 2 percent by weight of carbon black, based on the weight of the polymer in the foam, and (c) a capped polyoxyalkylene compound which helps bring about a uniform dispersion of the carbon black throughout the foam so that the aged k-factor of the foam is below the aged k-factor of the corresponding unfilled foam.