Abstract: Provided is a method of stabilizing an elastomeric property of an elastomeric material. The method includes placing the elastomeric material in a pressurizing chamber and applying a suitable hydrostatic pressure to the elastomeric material within the pressurizing chamber to at least partially compress the elastomeric material. Application of the hydrostatic pressure is maintained for a period of time suitable to at least partially stabilize a restorative force exhibited by the elastomeric material in response to subsequent exposures of the elastomeric material to a compressive force.

Abstract: A pneumatic tire with a double layer innerliner structure bonded to an inner face of the tire carcass for reducing noise generated by air vibrations inside of the tire's air chamber, and a method of making the tire. The double layer structure includes a first innerliner layer of non-foamed rubber adjacent the carcass and a second innerliner layer of foamed porous rubber forming an innermost surface of the tire. The foamed porous rubber is formed by curing a rubber composition having a nitrogen-releasing foaming agent dispersed therein that decomposes at the vulcanization temperature to release nitrogen gas. The second innerliner layer further has an open-celled structure with a plurality of open cavities that are formed by physically altering the innermost surface of the foamed innerliner layer.

Abstract: A plastic is converted from an initial condition with a higher density into a foamed condition with a lower density using a blowing agent, wherein the plastic is cross-linked prior to foaming by means of a first cross-linking agent and during the foaming by means of at least one second cross-linking agent.

Abstract: The present invention comprises a novel process for the preparation of carbon based structured materials with controlled topology, morphology and functionality. The nanostructured materials are prepared by controlled carbonization, or pyrolysis, of precursors comprising phase separated copolymers. The precursor materials are selected to phase separate and self organize in bulk, in solution, in the presence of phase selective solvents, at surfaces, interfaces or during fabrication, into articles, fibers or films exhibiting well-defined, self-organized morphology or precursors of well-defined, self-organized, bi- or tri-phasic morphology. Compositional control over the (co)polymers provides control over the structure of the phase separated precursor whose organization therein dictates the nanostructure of the material obtained after carbonization or pyrolysis, wherein each dimension of the formed structure can be predetermined.

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

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

Abstract: A method of purification of physiological liquids of organism has the step of passing a physiological liquid through a material which has a size, a shape, and a structure selected so as to remove toxic compounds from the physiological liquid and is composed of a partially chloromethylated porous highly crosslinked styrene or divinylbenzene copolymer which initially have surface exposed chloromethyl groups in which thereafter chlorine is replaced with an element which forms different surface exposed functional groups with a greater hydrophilicity and greater biocompatibility than that of the chloromethyl group.

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. An apparatus suitable for preparing such foams with an expanded cross-section.

Abstract: A battery separator is a polypropylene microporous membrane, made from a beta-nucleated precursor, and having an electrical resistance of less than 30 ohms-inches per mil, and a puncture strength of greater than 400 grams-force per mil. mil.

Abstract: This invention has for an object thereof the provision of a method for the production of a porous cross-linked polymer which can freely control the upper and lower surface behavior of the porous cross-linked polymer, the width and the thickness of the polymer and can perform continuously a process ranting from a step of supplying the emulsion through a step of polymerizing it. The object of this invention, in the production of a porous cross-linked polymer by polymerizing a water-in-oil type high internal phase emulsion, is accomplished by a method for the production of a porous cross-linked polymer characterized by performing continuously a process ranting from a step of supplying the emulsion through a step of polymerizing it while having the outer surface part of the emulsion retain an atmosphere or a state having a lower oxygen content than the ambient air.

Abstract: An ink wastage absorber is made from a flexible polyurethane foam having an air-permeability of 1.0 cc/cm2/sec or more, or is made from a flexible polyurethane foam produced by using a foamable raw material containing a polyol, an isocyanate, a catalyst, and a foaming agent, wherein the polyurethane foam is impregnated with a surface active agent. An ink supporter includes an ink permeation member provided at a portion corresponding to a printer head and an ink absorbing member being in contact with the ink permeation member.

Abstract: The invention relates to a sustained release composition and methods of forming and using said composition for the sustained release of biologically active agent. The sustained release compositions of the invention comprise a biocompatible polymer and a biologically active agent characterized by a porous center and a less porous outer layer wherein the center and outer layer consist of essentially the same materials. The sustained release compositions can be prepared by annealing at least a substantial portion of the exterior surface of a polymer/active agent matrix. The compositions which have been annealed exhibit a decrease in the release of agent over the first 24 hours following administration (i.e., reduced burst) and as a result can show an increase in the duration of sustained release thereby providing increased therapeutic benefits.

Abstract: The present invention relates to a porous or microporous film of a high molecular weight polyolefin excellent in strength and air-permeability and suitable for use in filtering materials, separators for aqueous electrolyte batteries, separator films for batteries, separator films for electrolytic capacitors, and air-permeable films; for moisture-permeable water-proof use such as paper diapers and house-wrapping films; and for other uses such as cloths, package and printing, as well as a process for producing same. The feature of the present invention resides in an aspect that the film is composed of fibrils comprising extended-chain crystals and lamellar crystals and/or fibrils comprising helicoidal crystals.This porous film of a high molecular weight polyolefin is produced by subjecting an air-impermeable film of a high molecular weight polyolefin to thermal treatment followed by, if necessary, a stretching treatment and/or a thermosetting treatment.

Abstract: Polyurethane foam pads for use in the topical care and treatment of the skin are disclosed. The polyurethane pads are formed from a polymerized combination of an aqueous mixture having at least one skin conditioning agent (such as Vitamin E or aloe) and a quantity of hydrophilic urethane prepolymer. The skin conditioning agents are incorporated directly into the cell structure of the polyurethane foam pad and are readily released when contacted with water.

Abstract: This invention is a partially or semi-cured foam used to form the pipe insulation. The semi-cured foam is very flexible and can be formed around a pipe for a long period of time after production. The semi-cured phenolic foam board of this invention is a closed cell foam. The semi-cured foam is further cured in the formed shape. Upon curing the foam retains the shape of the preform. The semi-cured product is very flexible, once fully cured, the insulation becomes rigid.

Abstract: An improved process for the preparation of a pitch foam with a microcellular structure and a uniform pore size comprises the steps of (a) pressing a quantity of a pitch to provide a pressed article, (b) placing the pressed article in a pressure vessel, (c) introducing an inert gas into the pressure vessel under an elevated pressure of about 200 to 500 psi, (d) heating the pressed article within the pressure vessel to about 10.degree. to 40.degree. C.

Abstract: In order to improve the sealing property and the resistance to pressure of a gasket coated with foam rubber layers, the foam rubber layers are formed on both surfaces of a metal plate from a rubber which is swollen by the medium to be sealed by the gasket, e.g. a rubber having an oil swelling property such as an NBR, is used. In this way the sealing property thereof is improved.

Abstract: This pertains to the general field of gels, foams, and aerogels, particularly, to low density open cell organic foams and low density open cell carbon foams, and methods for preparing them. These low density open cell organic foams are derived from organic gels which may be prepared from hydroxylated benzenes (such as phenol, catechol, resorcinol, hydroquinone, and phloroglucinol) and aldehydes (such as formaldehyde and furfural) using lower than conventional catalyst concentrations (e.g, an R/C value of greater than about 1000, yielding an initial room temperature pH typically lower than about 6.0). These organic foams are characterized by relatively large particle and pore sizes, high porosity, and high surface area. Low density open cell carbon foams derived from such organic foams are also shown, as are methods for preparing same. These carbon foams are also characterized by relatively large particle and pore sizes, high porosity, high surface area, and high electrical capacitance.

Abstract: A flexible, flame-bondable polyurethane-polyether block foam is prepared by a process in which at least one diol is added to the block foam.

Abstract: Process for preparing a flexible polyurethane foam by reacting a polyisocyanate and two different polyols under foam forming conditions so as to prepare a rigid foam and by crushing the rigid foam so obtained. Flexible foams are obtained which do not show a major glass transition temperature between -100.degree. C. and +25.degree. C.

Abstract: There is an evacuated insulation panel comprising a corestock of an open-cell alkenyl aromatic polymer foam and a deformable receptacle. The foam has an open cell content of about 70 percent or more. The foam is situated within the receptacle. The receptacle is hermetically sealed. The open-cells of the foam and the interior of the receptacle are evacuated to an absolute pressure of about 10 torr or less. The foam has indentations therein which extend in two dimensions across a surface of the foam. The receptacle substantially conforms to the shape of the foam, including the indentations within. The panel has one or more surfaces which are substantially non-wrinkled. Further disclosed is a method for making the panel.

Abstract: Disclosed is an evacuated and unevacuated microcellular foam containing an infrared attenuating agent (IAA). The evacuated foam has an average cell size of about 70 micrometers or less. The unevacuated foam has an average cell size of 1.0 micrometers or less. The IAA provide a greater proportional reduction in foam thermal conductivity in these foams than in foams of larger cell size. Further disclosed is a method of using the foams.

Abstract: Method and composition for selectively removing liquid hydrocarbon from floors and other hard surfaces comprising granular polyisocyanurate foam. The composition desirably includes a particulate material having a bulk density greater than the polyisocyanurate foam for increasing the overall bulk density of the composition and imparting slip resistance to the floor or hard surface. Suitable particulate material includes angular sand and comminuted cellular glass. The granular polyisocyanurate foam and particulate material can be supplied from scrap material to reduce cost and landfill waste.

Abstract: Method and composition for selectively removing liquid hydrocarbon from floors and other hard surfaces comprising granular polyisocyanurate foam. The composition desirably includes a particulate material having a bulk density greater than the polyisocyanurate foam for increasing the overall bulk density of the composition and imparting slip resistance to the floor or hard surface. Suitable particulate material includes angular sand and comminuted cellular glass. The granular polyisocyanurate foam and particulate material can be supplied from scrap material to reduce cost and landfill waste.

Abstract: Disclosed is a compressed, evacuated, open-cell polymer foam, the foam having an open cell content of about 70 percent or more prior to compression, the foam having a thickness of about 40 to about 90 percent of the initial thickness of the foam prior to compression, the foam having an absolute cell gas pressure of about 10 torr or less in its open cells, the foam having a density of about 16 to about 250 kilograms per cubic meter. Further disclosed is an evacuated insulation panel employing the foam.

Abstract: Post-treatment method of polyolefin resin pre-expanded particles comprising: introducing the polyolefin resin pre-expanded particles foamed by using an inflammable blowing agent into an extraction vessel filled with steam previously; feeding an additional steam into the extraction vessel; extracting the inflammable blowing agent gas from the polyolefin resin pre-expanded particles; discharging the resulting steam which contains the extracted inflammable blowing agent gas from the extraction vessel continuously or intermittently; and liquefying the steam to separate and recover the inflammable blowing agent gas. According to the post-treatment method of polyolefin resin pre-expanded particles, the inflammable blowing agent can be extracted from the pre-expanded particles in a short period of time and the extracted inflammable blowing agent can be re-used.

Abstract: A method of preparing near net shape, monolithic, porous SiC foams is disclosed. Organosilicon precursors are used to produce polymeric gels by thermally induced phase separation, wherein, a sufficiently concentrated solution of an organosilicon polymer is cooled below its solidification temperature to form a gel. Following solvent removal from the gel, the polymer foam is pretreated in an oxygen plasma in order to raise its glass transition temperature. The pretreated foam is then pyrolized in an inert atmosphere to form a SiC foam.

Abstract: Process for removing unwanted material from wanted material containing water by bringing an isocyanate-containing prepolymer into contact with the materials, allowing the prepolymer to react with the water to form a flexible foam and removing the foam obtained from the wanted material.

Abstract: A method for the preparation of a flexible, open-celled, urethane foam which comprises reacting at least one isocyanate and at least one polyol in the presence of at least one catalyst and an epoxidized soybean oil, wherein each polyol is a saturated polyether polyol. A further aspect of the present invention provides a pre-formation method for the preparation of a flexible, open-celled, urethane foam, the method comprising reacting at least one isocyanate and at least one polyol in the presence of at least one catalyst and about 7 phR to about 25 phR of an epoxidized soybean oil, wherein each polyol is a saturated polyester polydol. Flexible, open-celled urethane foams prepared in accordance with the methods set forth previously are also included in the present invention.

Abstract: A method for processing a low dielectric constant material includes dispersing an additive material in a porous low dielectric constant layer, fabricating a desired electronic structure, and then removing the additive material from the pores of the low dielectric constant layer. The removal of the additive material from the pores can be accomplished by sublimation, evaporation, and diffusion. Applications for the low dielectric constant layer include the use as an overlay layer for interconnecting a circuit chip supported by a substrate and the use as printed circuit board material.

Abstract: Methods for reducing the quantity of emissions emanating from a foam-forming composition during the preparation of a fully-cured foam comprising contacting emissions emanating from the foam-forming composition during preparation of the fully-cured foam with vegetable oil. A further aspect provides a method for reducing the quantity of emissions emanating from a fully-formed foam during hot processing of the foam comprising contacting emissions emanating from the foam during such hot processing with vegetable oil.

Abstract: Low thermal conductivity insulation for refrigerators and the like is produced by blowing a resinous foam in an inert (e.g., nitrogen) atmosphere with a mixture of carbon dioxide and a low thermal conductivity inert gas such as krypton or xenon. The foam is then sealed in a gas-impervious enclosure and carbon dioxide is removed therefrom, typically by inclusion in said enclosure of a solid material reacted therewith such as an alkaline reagent. The final partial pressure of the low thermal conductivity gas in the enclosure is in the range of about 20-200 torr, and the total pressure is up to 110% of said partial pressure.

Abstract: A microporous film with improved resistance to elevated temperatures from a first, thermoplastic polymer, the internal and external surfaces of the film being provided with a continuous coating layer of a second polymer having a higher softening temperature than the first polymer and process for coating a film of a first polymer with a layer of a second polymer.

Abstract: A microcellular carbon foam characterized by a density in the range of about 30 to 1000 mg/cm.sup.3, substantially uniform distribution of cell sizes of diameters less than 100 .mu.m with a majority of the cells being of a diameter of less than about 10 .mu.m, well interconnected strut morphology providing open porosity, and an expanded d(002) X-ray turbostatic spacing greater than 3.50 angstroms. The precursor for the carbon foam is prepared by the phase inversion of polyacrylonitrile in a solution consisting essentially of at least one alkali metal halide and a phase inversion solvent for the polyacrylonitrile.

Abstract: A method for treating the surface of a thin porous film material of tetrafluoroethylene resin is disclosed, which comprises heating said surface to a temperature higher than the thermal decomposition point of said resin so as to decompose and remove part of said surface. The resulting thin porous film material of tetrafluoroethylene resin has an adhesive surface while retaining the desired pore size, hardness, and degree of penetration of adhesive.

Abstract: A microcellular carbon foam characterized by a density in the range of about 30 to 1000 mg/cm.sup.3, substantially uniform distribution of cell sizes of diameters less than 100 .mu.m with a majority of the cells being of a diameter of less than about 10 .mu.m, well interconnected strut morphology providing open porosity, and an expanded d(002) X-ray turbostatic spacing greater than 3.50 angstroms. The precursor for the carbon foam is prepared by the phase inversion of polyacrylonitrile in a solution consisting essentially of at least one alkali metal halide and a phase inversion solvent for the polyacrylonitrile.

Abstract: Disclosed are absorbent foam materials suitable for use as or in the absorbent cores of absorbent articles, such as diapers which absorb and retain aqueous body fluids. Such foam materials comprise hydrophilic, flexible open-celled structures which are preferably prepared by polymerizing high internal phase (HIPE) water-in-oil emulsions. Such foam materials have a pore volume of from about 12 to 100 mL/g, and a capillary suction specific surface area of from about 0.5 to 5.0 m.sup.2 /g. These materials also exhibit a resistance to compression deflection such that a confining pressure of 5.1 kPa produces after 15 minutes a strain of from about 5% to 95% compression when the material is saturated at 37.degree. C. to its free absorbent capacity with synthetic urine.

Abstract: A method for treating the surface of a thin porous film material of tetrafluoroethylene resin is disclosed, which comprises heating said surface to a temperature higher than the thermal decomposition point of said resin so as to decompose and remove part of said surface. The resulting thin porous film material of tetrafluoroethylene resin has an adhesive surface while retaining the desired pore size, hardness, and degree of penetration of adhesive.

Abstract: Dimensionally stable, cured phenolic foams are described that have a thermal conductivity after 10-days below 0.0185 watts/m .degree.C., a density of 30 to 70 kg/cubic meter and a closed-cell content of at least 85%.

Abstract: This invention is a method to speed up and prevent inconsistent rates of reaction in the reduction of volume of polystyrene foam products by the application of a liquid and vapors of a terpine or isoprenoid compound where a heat activation within 90 days of the use provides maximum reactivity. In one embodiment the process is localized by the addition of heaters in the processing vessels or tanks to insure active agent form of d-limonene reduction agent.

Abstract: A method for treating the surface of a thin porous film material of tetrafluoroethylene resin is disclosed, which comprises heating said surface to a temperature higher than the thermal decomposition point of said resin so as to decompose and remove part of said surface. The resulting thin porous film material of tetrafluoroethylene resin has an adhesive surface while retaining the desired pore size, hardness, and degree of penetration of adhesive.

Abstract: A process for removing an oxidizable organic compound from an oxidizing gas stream which includes contacting the gas stream with a bed of carbonaceous adsorbent particles, wherein the adsorbent particles comprise porous pyrolyzed particles of a polysulfonated cross-linked synthetic copolymer, to adsorb the oxidizable organic compound on the adsorbent particles.

Abstract: A porous, crystallized, aromatic polycarbonate prepolymer is disclosed, which comprises recurring aromatic carbonate units and terminal hydroxyl and aryl carbonate groups, wherein these terminal groups are in a specific molar ratio and has specific number average molecular weight, surface area and crystallinity. The prepolymer can readily be converted by solid-state condensation polymerization to a porous, crystallized, aromatic polycarbonate having excellent properties. The porous, crystallized, aromatic polycarbonate of the present invention can readily be molded to obtain a shaped, porous, crystallized polycarbonate. The porous, crystallized, aromatic polycarbonate and the shaped, porous, crystallized polycarbonate of the present invention have excellent heat resistance and solvent resistance and exhibit advantageously low water absorption so that these are suited for use as a filter material, an adsorbent or the like.

Abstract: A method of felting porous polychloroprene latex foam to obtain desired properties. Such felting renders the finished foam suitable for controlled ink flow required for printing purposes. The felting is accomplished by reducing the volume of the porous polychloroprene latex foam and heating at a temperature of 400.degree. to 460.degree. F. for five to ten minutes.

Abstract: A microcellular carbon foam characterized by a density in the range of about 30 to 1000 mg/cm.sup.3, substantially uniform distribution of cell sizes of diameters less than 100 .mu.m with a majority of the cells being of a diameter of less than about 10 .mu.m, well interconnected strut morphology providing open porosity, and an expanded d(002) X-ray turbostatic spacing greater than 3.50 angstroms. The precursor for the carbon foam is prepared by the phase inversion of polyacrylonitrile in a solution consisting essentially of at least one alkali metal halide and a phase inversion solvent for the polyacrylonitrile.

Abstract: A porous, crystallized, aromatic polycarbonate prepolymer is disclosed, which comprises recurring aromatic carbonate units and terminal hydroxyl and aryl carbonate groups, wherein these terminal groups are in a specific molar ratio, and has specific number average molecular weight, surface area and crystallinity. The prepolymer can readily be converted by solid-state condensation polymerization to a porous, crystallized, aromatic polycarbonate having excellent properties. The porous, crystallized, aromatic polycarbonate of the present invention can readily be molded to obtain a shaped, porous, crystallized polycarbonate. The porous, crystallized, aromatic polycarbonate and the shaped, porous, crystallized polycarbonate of the present invention have excellent heat resistance and solvent resistance and exhibit advantageously low water absorption so that these are suited for use as a filter material, an adsorbent or the like.

Abstract: A method for drying foams, and in particular inorganic and organic aerogels, so that intricate internal pore/cell structure is maintained utilizing a select group of fluorocarbon solvents. Replacement of precursor diluents with a fluorocarbon solvent, followed by direct sublimation, is employed to dry the foam in place of critical point drying.

Abstract: A process for the dissolution of polyurethane foams is disclosed. A polyurethane foam may be dissolved, or removed from a substrate, by contacting the polyurethane foam with 1,2-dialkyl imidazole, alone or as a co-solvent.

Abstract: A process for rapidly cooling porous foam material to prevent oxidation or autoignition of said foam. The process includes a first cooling step wherein cooled ambient air is drawn through the foam block thereby cooling, dehumidifying and removing fumes from said block before being vented, a second cooling step wherein cooled ambient air is drawn through the block for further cooling thereof, with sublimates in the block being condensed and redeposited within the block, and a third cooling step wherein ambient air is drawn through the material so as to remove remaining fumes, heat and moisture therefrom. The process of the present invention advantageously utilizes a foam formulation which includes an increased percentage of water for providing adequate foaming of the material while minimizing or obviating the need for including toxic auxiliary blowing agents in the formulation.

Abstract: Polypropylene microporous films characterized by having a porosity of 30-35%, an average pore size of 200-800 Angstroms, a permeation coefficient for nitrogen of 1-5.times.10.sup.-3 ml/cm sec atm and a tensile strength of greater than 60 MPA in all directions within the film plane are prepared by the consecutive steps of biaxial stretching a non-porous starting film of high .beta.-crystal content and heat setting the stretched film.