Abstract: A thermoplastic molding composition suitable for the preparation of foam is disclosed. The composition comprises a thermoplastic resinous component and a foaming agent which includes A) (i) 0.01 to 4.8% alumina hydrate (aluminum hydroxide) in combination with (ii) 0.01 to 4.8% of an acidic additive or B) 0.01 to 4.8% of the reaction product of said (i) and said (ii), the percentages being relative to the weight of the composition to be foamed. The invention is based on the finding that the foaming of the composition does not lead to any significant reduction in molecular weight of the resinous component or to troublesome discoloration of the foam, even during its re-extrusion.

Abstract: The present invention provides a foamable epoxy resin composition (A) 100 parts by weight of a liquid epoxy resin (B) 0.5-20 parts by weight of a latent curing agent, (C) 0.5-15 parts by weight of a foaming agent having a decomposition temperature of 100.degree.-220.degree. C., (D) 0.05-5 parts by weight of a surface active agent and (E) 10-200 parts by weight of a rubbery elastomer or a powdery halogen-free thermoplastic resin of 150 .mu.m or less in average particle diameter, which composition has a melt viscosity of 2.5.times.10.sup.3 -5.times.10.sup.4 dPa.multidot.s at the decomposition temperature of said foaming agent. The composition can provide a foamed material of rigidity and good heat resistance, having an expansion ratio of 5 times or more and a dense cell structure of 0.5 mm or less in average cell diameter.

Abstract: The present invention includes an improved blowing agent concentrate, comprising:(a) a vinyl aromatic polymer;(b) a preformed blend of a styrene/diene block copolymer and a hydrocarbon rubber extending oil; and(c) at least one blowing agent.The blowing agent concentrate is utilized to prepare foamable materials based on a variety of thermoplastic organic polymers. The foamable materials can in turn be molded into a variety of thermoplastic structures.

Abstract: Flame-retardant polyurethane foam products are produced by mixing and reacting an organic phosphorus containing compound which will react with a polyisocyanate compound and produce a gaseous compound and a polyisocyanate compound in the presence of a polyurethane catalyst. No other blowing agent is necessary.The flame-retardant polyurethane foam products may be used for thermal and sound-insulation, for cushioning, for molding useful objects and as a cavity filler.

Abstract: The invention relates to a breathable, plastic film, useful as a wall covering material. A low boiling additive, such as water, is added to a plastisol before extrusion. During extrusion and curing of the plastisol into a film or coating, the low boiling additive is volatilized and the resulting evolved gas perforates the forming film. In this manner a permeable plastic film, such as vinyl, is produced.

Abstract: Blowing agent compositions for use in the production of peroxide cross-linked polyethylene foams. The improved properties and a process for the production of such foams are described.

Abstract: A lightly crosslinked polymer foam and a process for its production, wherein the crosslinking occurs in the extruder, which comprises melt processing an olefinic polymer, with a volatile blowing agent, a free-radical generating peroxide as a crosslinking agent, and an antioxidant as a countervailing agent.

Abstract: A composition and foam insulation for copper tubing is described herein which is formulated to retard copper oxidation and eliminate or reduce stress corrosion in the copper tubing. The copper compatible, elastomeric foam insulation is made from a composition comprising 100 parts by weight of rubber, vinyl chloride polymer at about 15 to about 85 pphr, a plasticizer selected from the group consisting of an alkyl phosphate ester and an oxyalkyl phosphate ester at about 10 to about 100 pphr, a fire retardant in an amount of at least about 100 pphr, a stabilizer in an amount effective to prevent degradation of the rubber and vinyl chloride polymer, a preservative at from about 0.1 to about 10 pphr, and a lubricant at about 10 to about 85 pphr, wherein the composition and foamed product contains no more than about 5 parts of free phenol per million.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitor as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. the sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.

Abstract: Polymer compositions for molding in the presence of a foaming agent which comprise at least a polyolefin resin as a base resin and low polarity boron compound powder which is not decomposed at a foaming temperature, such as boron nitride powder as a nucleator. Polymer compositions of the invention are useful for formation of a foamed insulating layer on a conductive material by way of foam molding. By using said polymer composition, a foamed insulating layer excellent in insulation properties which has small dielectric loss factor, tan .delta., at high frequency and high extent of foaming of not less than 70% can be obtained.

Abstract: Processes using high temperature thermoplastic polymers in the in-situ fabrication in the formation of foamed composite sandwich or foam articles often result in weak unsound products which may be avoided by utilizing a high temperature thermoplastic in powder form (22), a blowing agent having a high decomposition temperature (24), and, if desired, reinforcers and/or fillers (28), admixing the thermoplastic, blowing agent and reinforcer and fillers (30), placing the admixture in a mold and, if forming a composite structure, in abutment with at least one skin (34), compacting the contents of the mold (37), and applying sufficient heat and/or pressure to the mold and its contents to melt the thermoplastic and generate gas within said mixture by decomposition of the blowing agent (38). Also, an activator may be included with the blowing agent which promotes the production of gas (26).

Abstract: A flame retardant composition and process which is particularly useful for rebonded foam products. The composition of the present invention includes a solid component of magnesium sulfate, boric acid, decabromodiphenylethylene oxide (DECA) and antimony trioxide and a liquid component of halogenated phosphorous. The present invention is based upon the discovery of the synergism between boric acid and DECA. The process, according to the present invention, includes the steps of forming a dispersion of the solid portion of the flame retardant composition along with a small amount of water based adhesive to a mass of foam chips. The treated chips are then dried to permit handling and storage. The dried foam chips subsequently are mixed with a conventional urethane prepolymer binder and the liquid halogenated phosphorous flame retardant compound. After mixing the foam mass is transferred to molds and steamed to allow the binder to cure.

Abstract: Flame retardant vinylaromatic thermoplastic resin compositions are provided comprising 100 parts vinylaromatic polymer, 0.1 to 2.0 parts of at least one brominated aliphatic compound, 0.5 to 3.0 parts of at least one other and different brominated organic compound having a higher volatilization temperature and greater heat stability than said brominated aliphatic compound and from 0.05 to 5 parts of at least one melt flow promoter.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 to 5.0 weight percent of the polymer, and sodium dihydrogen phosphate as an activator to react with the sodium borohydride and produce hydrogen gas. The sodium borohydride and the sodium dihydrogen phosphate are kept separated from direct contact with each other, such as by encapsulating the components, until gas production is desired when the polymer is heated.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that evolves minimal water and does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 weight percent of the polymer to be foamed, and a polyhydric alcohol such as six-carbon mannitol as an activator to react with the sodium borohydride and produce hydrogen gas. Boric acid can be included with the alcohol. The sodium borohydride is kept separated from the other reactive components such as by encapsulation until gas production is desired when the polymer is heated and molded.

Abstract: The present invention is a flame retarded thermoplastic resin composition comprising a thermoplastic resin, optional adjuvants for the resin, and a flame retardant; the flame retardant is an amine salt of a phosphorus acid in an effective amount.

Abstract: A foamable thermoplastic molding composition comprising:a) an aromatic polycarbonate, andb) 0.1 to 5% by weight of a hydrate of an inorganic salt, is disclosed. The salt is inert to the polycarbonate and is capable of releasing its water of hydration only at a temperature above 100.degree. C.The composition which may optionally further contain c) up to 10% by weight of a nucleating agent, and d) up to 30% by weight of glass fibers is characterized by its good pore structure.

Abstract: The water resistance of intumescent compositions is improved if the composition comprises at least one organotin derivative of a polyol. Organotin derivatives of polyols can be produced by reacting polyol with dialkyltin oxide or with dialkyltin dialkoxide.

Abstract: A method of making a foamed polymer article by injection molding, using a foaming agent that does not form byproducts which could pit or chalk the polymer surface. The foaming agent contains sodium borohydride in an amount from 0.01 to 5.0 weight percent of the polymer, and sodium dihydrogen phosphate as an activator to react with the sodium borohydride and produce hydrogen gas. The sodium borohydride and the sodium dihydrogen phosphate are kept separated from direct contact with each other, such as by encapsulating the components, until gas production is desired when the polymer is heated.

Abstract: A method of treating hazardous material or other substrate with an aqueous air foam, comprising the steps of (1) preparing an aqueous solution or dispersion comprising (a) water-soluble polyhydroxy polymer having a plurality of hydrogen-bondable 1,2- and/or 1,3-diol structures capable of complexation with the borate anion, B(OH).sub.4.sup.

Abstract: Processes using high temperature thermoplastic polymers in the in-situ fabrication in the formation of foamed composite sandwich or foam articles often result in weak unsound products which may be avoided by utilizing a high temperature thermoplastic in powder form (22), a blowing agent having a high decomposition temperature (24), and, if desired, reinforcers and/or fillers, (28), mixing the thermoplastic, blowing agent and reinforcer and fillers (30), placing the mixture in a mold and, if forming a composite structure, in abutment with at least one skin (34), and applying sufficient heat and/or pressure to the mold and its contents to melt the thermoplastic and generate gas within said mixture by decomposition of the blowing agent (38). Also, an activator may be included with the blowing agent which promotes the production of gas (26). The thermoplastic should be free from any material which will react with the blowing agent or the activator at temperatures below the melting point of the thermoplastic.

Abstract: This invention is a polymer containing a plurality of ketone groups in the polymer backbone and containing an amount of a non-volatile, ionizable metal salt sufficient to render it static dissipative. The polymer is substantially devoid of a fatty acid salt, a C.sub.6 -C.sub.30 carboxylic acid ester and a phosphate ester compound. The static dissipative polymer can be used neat or blended with other polymers for use in applications requiring static dissipative behavior.

Abstract: A flame retardant composition and process which is particularly useful for rebonded foam products. The composition of the present invention includes a solid component of magnesium sulfate, boric acid, decabromodiphenylethylene oxide (DECA) and antimony trioxide and a liquid component of halogenated phosphorous. The present invention is based upon the discovery of the synergism between boric acid and DECA. The process, according to the present invention, includes the steps of forming a dispersion of the solid portion of the flame retardant composition along with a small amount of water based adhesive to a mass of foam chips. The treated chips are then dried to permit handling and storage. The dried foam chips subsequently are mixed with a conventional urethane prepolymer binder and the liquid halogenated phosphorous flame retardant compound. After mixing the foam mass is transferred to molds and steamed to allow the binder to cure.

Abstract: Flame-retardant polyurethane foam is produced by mixing and reacting a polyol, a phosphorus acid and a compound containing two or more isocyanate radicals. The flame-retardant polyurethane foam may be used for cushioning, sound and thermal insulation, coating agent, molding agent, or as a cavity filler.

Abstract: Disclosed is an intumescent curable composition which contains as a resinous binder a flexible polyepoxide resin. The polyepoxide is cured with an appropriate curing agent adapted for the particular resin. An additive component is present which contains a mixture of materials which provide a source of(i) zinc,(ii) boron,(iii) phosphorus, and(iv) an expansion gas upon thermal decomposition. The composition is capable of forming a carbonaceous char upon exposure to heat or flame, with the proviso that the cured, unburned composition has sufficient flexibility that is passes at least 10 continuous cycles of a cold cycle test without cracking. The cold cycle test involves the following steps: the composition is applied at a thickness of 0.5 inch (12.7 millimeters) to a 10 inch (0.0254 meter) section of a 4W13 I-beam having two thermocouples attached to the surface, allowed to cure at ambient temperature for 16 hours, force cured for 5 days at about 60.degree. C. and subjected to the cold cycle test.

Abstract: A fire resistant resin for use as a binder in reinforced plastics and a resultant reinforced plastic includes the reaction product of (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.A method of making a fire resistant resin binder for reinforced plastics and the method of making such reinforced plastics including, (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.

Abstract: Flame retardant polyurethane foams are produced by mixing and reacting a polyol, a low molecular weight compound with 1 or more active hydrogen, an organic polyisocyanate and an acidic boron compound in the presence of an organo-metal urethane catalyst.The flame-retardant polyurethane foam may be used for thermal and sound insulation, for cushioning and for molding useful objects.

Abstract: A fire resistant resin for use as a binder in reinforced plastics and a resultant reinforced plastic includes the reaction product of (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.A method of making a fire resistant resin binder for reinforced plastics and the method of making such reinforced plastics including, (a) at least one resorcinol component selected from the group consisting of resorcinol and resorcinol formaldehyde novolak resin, and (b) a phenolic resole resin. The reaction may be achieved in the presence of an alkaline catalyst.

Abstract: Disclosed is an intumescent curable composition which contains as a resinous binder a flexible polyepoxide resin. The polyepoxide is cured with an appropriate curing agent adapted for the particular resin. An additive component is present which contains a mixture of materials which provide a source of(i) zinc,(ii) boron,(iii) phosphorus, and(iv) an expansion gas upon thermal decomposition. The composition is capable of forming a carbonaceous char upon exposure to heat or flame, with the proviso that the cured, unburned composition has sufficient flexibility that it passes at least 10 continuous cycles of a cold cycle test without cracking. The cold cycle test involves the following steps; the composition is applied at a thickness of 0.5 inch (12.7 millimeters) to a 10 inch (0.254 meter) section of a 4W13 I-beam having two thermocouples attached to the surface, allowed to cure at ambient temperature for 16 hours, force cured for 5 days at about 60.degree. C. an subjected to the cold cycle test.

Abstract: An expandable, powder coating composition is disclosed which comprises (a) a thermoplastic resin containing a copolymer of ethylene with vinyl acetate, (b) a cross-linking agent containing an organic peroxide, (c) a blowing agent, and (d) an organic plasticizer. Powder coating of a surface of a tube or box to be used in air conditioners with the coating composition can give a heat-insulating, foamed sheath or lining over the surface.

Abstract: An improvement in the method for the foaming of polyvinylchloride resins by the use of a blowing agent and an activator therefor which uses as the activator a mixture of at least one organotin mercapto acid ester and a diorganotin oxide complex with an ester of an oxygen-containing acid.

Abstract: Stable flame-retardant polyol-oxidated silicon-acidic boron emulsions are produced by mixing and reacting a liquid organic polyol, and oxidated silicon compound and an acidic boron compound. This flame-retardant emulsion is useful in the production of flame-retardant polyurethane, polyester and polyesteramide products.

Abstract: This invention relates to the use of a special class of sulfonic and phosphonic acids, and salts of the acids, to give improved nucleation for foam extrusion of thermoplastics using either dissolved gas or chemical blowing agents to produce foam.

Abstract: A method of treating hazardous material or other substrate with an aqueous air foam, comprising the steps of (1) preparing an aqueous solution or dispersion comprising (a) water-soluble polyhydroxy polymer having a plurality of hydrogen-bondable 1,2- and/or 1,3-diol structures capable of complexation with the borate anion, B(OH).sub.4.sup.

Abstract: An improved process for producing sulfur-cured polyphosphazene foams is disclosed. The process comprises foaming more than one storable, stable accelerator base composition comprising the sulfur curing agent, a phosphazene oil and a polyphosphazene. A masterbatch of the same or similar polyphosphazene is made by mixing together a hydrated filler, processing aids and phosphazene oil. The matchbatch and accelerator base composition are then blended and foamed and cured.

Abstract: This invention relates to the use of a special class of sulfonic and phosphonic acids, and salts of the acids, to give improved nucleation for foam extrusion of thermoplastics using either dissolved gas or chemical blowing agents to produce foam.

Abstract: A foamed article of a chlorinated vinyl chloride resin containing an inorganic material, which contains an inorganic fibrous material in an amount of not less than 0.003 g per 1 cm.sup.3 of the article or inorganic particles in an amount of not less than 0.06 g per 1 cm.sup.3 of the article and which has dimensional retention of not less than 70% when the article is heated at 200.degree. C.

Abstract: An improvement in the method for the foaming of polyvinylchloride resins by the use of a blowing agent and an activator therefor which uses as the activator a mixture of at least one organotin mercapto acid ester and a diorganotin oxide complex with an ester of an oxygen-containing acid.

Abstract: A fire-retardant coating material includes a fluid intumescent material and conductive particles of various sizes dispersed or suspended therein for particular applications. The fluid intumescent material includes a foaming agent, a blowing agent gas source, a carbonific or charring agent, a film-forming binder, a solvent and, in some cases, a pigment or filler. The conductive particles are formed of a substrate and a conductive coating.

Abstract: The invention is a composition useful for the preparation of POWADIR membranes of a bisphenol-based polycarbonate wherein at least 25 percent by weight of the bisphenol moieties are tetrahalogenated, wherein the halogen is Cl or Br, the composition comprising (i) a bisphenol-based polycarbonate wherein at least 25 percent by weight of the bisphenol moieties are tetrahalogenated, wherein the halogen is Cl or Br, (ii) a solvent for such polycarbonate, and (iii) a non-solvent for such polycarbonate. The composition is useful for extruding membranes wherein the membranes formed are POWADIR membranes with a discriminating region capable of separating oxygen from nitrogen.The composition of this invention allows the formation of membranes with excellent physical properties, good separation factors for oxygen and nitrogen, with excellent fluxes.

Abstract: A new rigid polyvinyl chloride foam is provided which has been improved with respect to the thickness of its non-foamed layer and the surface properties including its tensile strength and compressive strength. The foam can be produced preferably by mixing 3-10 parts per hundred of resin (per hundred resin) of dioctyl phthalate and 4-20 phr of an impact-resistance modifier such as a methyl methacrylate acid-butadiene-styrene copolymer with a composition of 100 phr of vinyl chloride resin, 5 phr of a processing aid, 2 phr of a heat stabilizer, 0.5 phr of a lubricant, 0.75 phr of a foaming agent and 0.75 phr of boric acid, and then extruding the resulting mixture from a single-screw extruder.

Abstract: A fireproof, compressible, intumescent, elastomeric material useful to seal expansion joints, curtain wall gaps and penetrations in floors and walls in order to prevent the passage of flame and smoke. A seal of the material retains strength before and after exposure to fire and provides superior resistance to the impact, erosion, and cooling effects of a hose stream used to combat a fire. The composition of this compressible, fireproof material consists of elastomers, vulcanizing agents, fillers, softening agents, and an intumescent. This fireproof material may be in cellular or noncellular form with various degrees of compressibility and softness. It can be produced in sheets, molded parts, and continuous length strips. It may be vulcanized or nonvulcanized.

Abstract: A new rigid polyvinyl chloride foam is provided which has been improved with respect to the thickness of its non-foamed layer and the surface properties including its tensile strength and compressive strength. The foam can be produced preferably by mixing (per hundred resin) dioctyl phthalate and 4-20 phr of an impact-resistance modifier such as a methyl methacrylate acid-butadiene-styrene copolymer with a composition 100 phr of vinyl chloride resin, 5 phr of processing aid, 2 phr of a heat stabilizer, 0.5 phr of a lubricant, 0.75 phr of a foaming agent and 0.75 phr of boric acid, and then extruding the resulting mixture from a single-screw extruder.

Abstract: This invention relates to the use of a special class of sulfonic and phosphonic acids, and salts of the acids, to give improved nucleation for foam extrusion of thermoplastics using either dissolved gas or chemical blowing agents to produce foam.

Abstract: The present invention provides for a bone growth material for filling in defects or hollow portions of bones to be ingrown by and coalesce with bone tissues wherein the bone growth material is comprised of expanded PTFE and calcium phosphate.

Abstract: A method is provided for reducing the density of silicone foam from a platinum catalyzed foamable two-package mixture of vinyl organosiloxane, organohydrogen siloxane, and hydroxylated material. The platinum catalyst used in the foamable mixture is in the form of a mixture of a platinum vinyl siloxane and a platinum triarylphosphine. A platinum catalyst mixture of platinum vinylsiloxane and triarylphosphine also has been found effective.

Abstract: A method is provided for reducing the density of silicone foam from a platinum catalyzed foamable two-package mixture of vinyl organosiloxane, organohydrogen siloxane, and hydroxylated material. The platinum catalyst used in the foamable mixture is in the form of a mixture of a platinum vinyl siloxane and a platinum triarylphosphine. A platinum catalyst mixture of platinum vinylsiloxane and triarylphosphine also has been found effective.

Abstract: Included is a process for the preparation of a ((neocarbyl)contrasting-halo-substituted)phosphorate comprising serially contacting (1) a phosphorus trihalide with a neocarbyl alcohol; (2) an oxirane; (3) a halogenating agent; and (4) an oxirane, under conditions sufficient to prepare the ((neocarbyl)contrasting-halo-substituted)-phosphorate. The phosphate can be very pure.Also included is a method for improving a production characteristic of flame-retardant polyurethanes. The characteristic may be selected from the group consisting of (1) processability; (2) scorch; (3) odor; (4) flame-retardant efficiency; and (5) combinations thereof. The method comprises incorporation into a polyurethane an amount effective to reduce combustibility of the foregoing phosphorate flame retardant under conditions sufficient to improve said characteristic. Also included is the flame-retardant polyurethane composition of said method.

Abstract: A flame-retardant polymer is created by forming a first resin typically by reacting resorcinol with furfural in a ratio of one mole of the former to less than a mole of the latter in the presence of an alkaline catalyst. A resole is then formed by reacting typically phenol with formaldehyde in a ratio of one mole of phenol to more than a mole of the aldehyde in the presence of an alkaline catalyst. The first resin and resole are mixed together with a powered oxyborate compound such as zinc borate and allowed to polymerize to form the polymer.

Abstract: A method of making a foam injection molded article is disclosed wherein corrosion of the mold element is significantly reduced or substantially eliminated. The method comprises dispersing effective amounts of a primary chemical blowing agent of sodium borohydride and an activation system of sodium bicarbonate/citric acid mix into a polymer resin to form a mixture. The mixture is then heated whereby the activation system releases water and the sodium borohydride reacts with the water to produce hydrogen gas. The mixture is subsequently injected into a mold to obtain expansion of the polymer resin to form the foam article. The invention also comprehends a corresponding chemical blowing agent composition.