Abstract: A process of producing a thermoplastic polyester series resin foamed material is disclosed, which comprises heating and further foaming a thermoplastic polyester resin foamed material having a crystallinity of not higher than 30% by bringing into contact with water or steam of at least 60.degree. C. and then heating the foamed material by bringing into contact with a heating medium other than water of at least 100.degree. C. to further foaming the foamed material. A process of producing a thermoplastic polyester series resin foamed material is also disclosed, which comprises heating and further foaming a thermoplastic polyester series resin foamed material having a crystallinity of not higher than 30% by bringing into contact with water to steam of at least 60.degree. C., heating and further foaming the foamed material by bringing into contact with a heating medium other than water of at least 100.degree. C., and molding the foamed material by a mold.

Abstract: An improved process for rapidly cooling hot freshly polymerized foam is provided by passage of a fluid coolant stream having a water vapor content which initially is in the range from slightly below to above the dew point. In preferred embodiments the cooling fluid stream is recirculated, and auxiliary blowing agents and gaseous reaction products are removed and recovered.

Abstract: A method of felting partially cured open cell polychloroprene latex foam to obtain desired foam member properties with intricate geometric shapes. Such felting renders the finished foam suitable for controlled ink flow required for printing purposes. The foam is open cell latex polychloroprene, cured in a steam autoclave, washed and dried while in the partially cured state. Thereafter, the partially cured foam can be stored and formed into intricate shape and fully cured when required.

Abstract: A porous polytetrafluoroethylene resin material which comprises sintered or irradiated fluororesin powder inside the porous spaces of a continuously porous polytetrafluoroethylene resin base material.

Abstract: A semi-flexible or flexible phenolic foam composition having a substantially open cellular structure. It comprises the reaction product of a mixture of a phenol-aldehyde resin, a surfactant, a blowing agent; optionally a wetting agent and a catalyst. Also within the scope of the present invention is a method for producing a semi-flexible or flexible phenolic foam composition having a substantially opened cellular structure. This method comprises mixing a phenol-aldehyde resin with a surfactant, a blowing agent and optionally a cell opening and wetting agent; curing the mixture by reacting it with an acid catalyst; compressing the cured or semi-cured product below its original thickness and releasing the pressure, thereby obtaining the desired semi-flexible or flexible phenolic foam composition. The semi-flexible or flexible foam thus obtained possesses excellent insulation and flame retardant properties.

Abstract: A method of improving the flame resistance of foams, such as open cell polyimide foams, through the introduction of finely divided non-metallic inorganic particles which are gel forming and insoluble in water and polar organic liquids into the foam cells. A stable liquid suspension or gel, preferably aqueous is prepared using these particles. An opacifier such as finely divided titanium dioxide or tin oxide may also be added. An open cell foam product is placed in the gel until the cells fill with the gel. Excess gel is removed and the foam is dried, leaving the particles trapped in the cells. If desired, the foam may be post treated, such as by compression at the stabilizing temperature, resulting in a densified foam which further mechanically traps the particles and further improves the flame resistance.

Abstract: Foam particles of propylene polymers which have shrunk from 40 to 95% of their original volume and have a bulk density of from 10 to 30 g/1 can be expanded if they are treated with air or nitrogen under superatmospheric pressure, subsequently decompressed. If desired post-foamed by heating and, after aging, re-treated with air or nitrogen under superatmospheric pressure, subsequently decompressed and aged under atmospheric pressure until the pressure in the cells has dissipated.

Abstract: Composite foams are provided comprising a first rigid, microcellular, open-celled organic polymer foam having a density of from about 0.015 g/cm.sup.3 to about 0.20 g/cm.sup.3 and a pore size of from about 1 micron to about 30 microns, said first foam containing a second polymer having a density of from about 0.015 g/cm.sup.3 to about 0.20 g/cm.sup.3 or a second polymer foam having a density of from about 0.015 g/cm.sup.3 to about 0.20 g/cm.sup.3 and a pore size of from about 0.01 microns to about 1.0 micron within the open cells of said first foam.

Abstract: The thermal shrinkage and pyrolysis rate of plastic foam moldings are successfully controlled by coating the expandable plastic beads used in the preparation of the moldings with varying amounts of substantially water-insoluble inorganic siliceous materials. The plastic foam moldings are useful as patterns in an evaporative casting process, wherein the molding is vaporized and replaced by molten metal.

Abstract: Polyurethane foams having a specified glass transition temperature are densified for transportation or other purposes by heating the foam to a temperature above its T.sub.g, compressing the heated foam, and then cooling the compressed foam to a temperature below its T.sub.g. The cooled foam remains in a densified state until re-heated to a temperature above its T.sub.g, whereupon it re-expands to assume its original dimensions.

Abstract: A method of improving the flame resistance of foams, such as open cell polyimide foams, through the introduction of finely divided non-metallic inorganic particles which are gel forming and insoluble in water and polar organic liquids into the foam cells. A stable liquid suspension or gel, preferably aqueous is prepared using these particles. An opacifier such as finely divided titanium dioxide or tin oxide may also be added. An open cell foam product is placed in the gel until the cells fill with the gel. Excess gel is removed and the foam is dried, leaving the particles trapped in the cells. If desired, the foam may be post treated, such as by compression at the stabilizing temperature, resulting in a densified foam which further mechanically traps the particles and further improves the flame resistance.

Abstract: A method of improving the flame resistance of foams, such as open cell polyimide foams, through the introduction of finely divided metal oxide particles into the foam cells. A stable water suspension or gel is prepared using particles of metal oxides, such as aluminum oxide and silicon dioxide. An opacifier such as titanium dioxide may also be added. An open cell foam product is placed in the gel until the cells fill with the gel. Excess gel is removed and the foam is dried, leaving the metal oxide particles trapped in the cells. If desired, the foam may be post treated, such as by compression at the stabilizing temperature, resulting in a densified foam which further mechanically traps the particles.

Abstract: By compressing and heat curing a non-resilient, non-flexible recurable material formed by subjecting cured polyimide foam to the action of pressurized steam, a wide variety of useful articles may be produced. These include tough, flame-resistant plastic films, sheets, panels, boards, and shapes in general; composites (both reinforced and unreinforced); and laminates and other articles in which separate shapes or parts are bonded together by a new type of tough, flame-resistant adhesive. Additionally, heretofore worthless products such as the kerf cut away from buns of polyimide foam during the foam manufacturing process can be converted and vastly upgraded into any of such an array of new articles of manufacture such as those just mentioned.

Abstract: A flame-retardant polymeric foam which comprises a carbonaceous irreversibly heat set, cellular polymer derived from a stabilized polyacrylonitrile based foam.

Abstract: The polycondensation of resorcinol with formaldehyde under alkaline conditions results in the formation of surface functionalized polymer "Clusters". The covalent crosslinking of these "clusters" produces gels which when processed under supercritical conditions, produce low density, organic aerogels (density.ltoreq.100 mg/cc; cell size .ltoreq.0.1 microns). The aerogels are transparent, dark red in color and consist of interconnected colloidal-like particles with diameters of about 100.circle.. These aerogels may be further carbonized to form low density carbon foams with cell size of about 0.1 micron.TABLE I ______________________________________ Theo- [Form- retical Actual Formu- % alde- [Resor- density Density lation Solids hyde] cinol] Na.sub.2 CO.sub.3 (g/cc) (g/cc) ______________________________________ A 5.0% 0.29M 0.58M 0.0029M 0.050 0.079 B 5.0% 0.29M 0.58M 0.0019M 0.050 0.073 C 5.0% 0.29M 0.58M 0.0015M 0.050 0.070 D 4.0% 0.24M 0.47M 0.0012M 0.040 0.054 E 3.5% 0.21M 0.41M 0.0010M 0.035 0.044 F 2.

Abstract: A carbonized composite foam having a density less than about 50 mg/cm.sup.3 and individual cell sizes no greater than about 1 .mu.m in diameter is described, and the process of making it.

Abstract: A method of improving the flame resistance of foams, such as open cell polyimide foams, through the introduction of finely divided metal oxide particles into the foam cells. A stable water suspension or gel is prepared using particles of metal oxides, such as aluminum oxide and silicon dioxide. An opacifier such as titanium dioxide may also be added. An open cell foam product is placed in the gel until the cells fill with the gel. Excess gel is removed and the foam is dried, leaving the metal oxide particles trapped in the cells. If desired, the foam may be post treated, such as by compression at the stabilizing temperature, resulting in a densified foam which further mechanically traps the particles.

Abstract: Composite foams are provided comprising a first rigid, microcellular, open-celled organic polymer foam having a density of from about 0.015 g/cm.sup.3 to about 0.20 g/cm.sup.3 and a pore size of from about 1 micron to about 30 microns, said first foam containing a second polymer having a density of from about 0.015 g/cm.sup.3 to about 0.20 g/cm.sup.3 or a second polymer foam having a density of from about 0.015 g/cm.sup.3 to about 0.20 g/cm.sup.3 and a pore size of from about 0.01 microns to about 1.0 micron within the open cells of said first foam.

Abstract: A method of improving the flame resistance of foams, such as open cell polyimide foams, through the introduction of finely divided non-metallic inorganic particles which are gel forming and insoluble in water and polar organic liquids into the foam cells. A stable liquid suspension or gel, preferably aqueous is prepared using these particles. An opacifier such as finely divided titanium dioxide or tin oxide may also be added. An open cell foam product is placed in the gel until the cells fill with the gel. Excess gel is removed and the foam is dried, leaving the particles trapped in the cells. If desired, the foam may be post treated, such as by compression at the stabilizing temperature, resulting in a densified foam which further mechanically traps the particles and further improves the flame resistance.

Abstract: Cured polyimide foam is exposed to an atmosphere of steam at elevated temperature and pressure for a period of time sufficient to convert the foam into a non-flexible, non-resilient recurable cellular material. Preferably the process is conducted such that the cellular material is recurable to a flexible resilient foam having tensile strength properties similar to the tensile strength properties of the original cured polyimide foam subjected to the process. Before recuring, the non-flexible, non-resilient recurable cellular material may be shaped or contoured, and then recured. For example, by impressing shaped articles into the recurable material followed by recuring, shipping/storage containers for the articles are readily produced.

Abstract: Cured polyimide foam is exposed to an atmosphere of steam at elevated temperature and pressure for a period of time sufficient to convert the foam into a non-flexible, non-resilient recurable cellular material. Preferably the process is conducted such that the cellular material is recurable to a flexible resilient foam having tensile strength properties similar to the tensile strength properties of the original cured polyimide foam subjected to the process. Before recuring, the non-flexible, non-resilient recurable cellular material may be shaped or contoured, and then recured. For example, by impressing shaped articles into the recurable material followed by recuring, shipping/storage containers for the articles are readily produced.

Abstract: A hydrophilic porous membrane of polyvinylidene fluoride excelling in perviousness to water and other various properties and enjoying high commercial value, having uniform hydropilicity imparted to the surface of pores therein, which porous membrane is characterized by the fact that the reflection spectrum thereof in the visible zone is substantially unchanged from that which existed before the treatment for impartation of hydrophilicity. A method for the production of the hydrophilic porous membrane, characterized by chemically treating the porous membrane in a strong alkali solution containing an oxidizing agent.

Abstract: A process for post-treating pre-expanded polyolefin resin particles which comprises charging in a vessel pre-expanded polyolefin resin particles which are pre-expanded by using an inflammable blowing agent, supplying an inert gas into the vessel, and then discharging the inert gas with the inflammable blowing agent gas extracted from the pre-expanded polyolefin resin particles, from the vessel. According to the process of the invention, the inflammable blowing agent can be extracted efficiently, safely and in a short time from the pre-expanded polyolefin resin particles which are pre-expanded by using the inflammable blowing agent. Consequently, the spontaneous cambustion of the particles can be completely avoided even if sparks are generated on the surface of the pre-expanded particles, therefore, it becomes easy to handle the pre-expanded polyolefin resin particles because the particles can be dried and transported by a pneumatic conveyer.

Abstract: A method of improving the flame resistance of foams, such as open cell polyimide foams, through the introduction of finely divided metal oxide particles into the foam cells. A stable water suspension or gel is prepared using particles of metal oxides, such as aluminum oxide and silicon dioxide. An opacifier such as titanium dioxide may also be added. An open cell foam product is placed in the gel until the cells fill with the gel. Excess gel is removed and the foam is dried, leaving the metal oxide particles trapped in the cells. If desired, the foam may be post treated, such as by compression at the stabilizing temperature, resulting in a densified foam which further mechanically traps the particles.

Abstract: Disclosed is new type of implantable material for replacement of cartilaginous or fibrous tissue. The material has controlled porosity and is biocompatible. A method for making this material is also disclosed.

Abstract: Disclosed is new type of implantable material for replacement of cartilaginous or fibrous tissue. The material has controlled porosity and is biocompatible. A method for making this material is also disclosed.

Abstract: By compressing and heat curing a non-resilient, non-flexible recurable material formed by subjecting cured polyimide foam to the action of pressurized steam, a wide variety of useful articles may be produced. These include tough, flame-resistant plastic films, sheets, panels, boards, and shapes in general; composites (both reinforced and unreinforced); and laminates and other articles in which separate shapes or parts are bonded together by a new type of tough, flame-resistant adhesive. Additionally, heretofore worthless waste products such as the kerf cut away from buns of polyimide foam during the foam manufacturing process can be converted and vastly upgraded into any of such an array of new articles of manufacture such as those just mentioned.

Abstract: Cured polyimide foam is exposed to an atmosphere of steam at elevated temperature and pressure for a period of time sufficient to convert the foam into a non-flexible, non-resilient recurable cellular material. Preferably the process is conducted such that the cellular material is recurable to a flexible resilient foam having tensile strength properties similar to the tensile strength properties of the original cured polyimide foam subjected to the process. Before recuring, the non-flexible, non-resilient recurable cellular material may be shaped or contoured, and then recured. For example, by impressing shaped articles into the recurable material followed by recuring, shipping/storage containers for the articles are readily produced.

Abstract: The present invention discloses a hydrophilized porous membrane with a crosslinked hydrophilic polymer, which is composed principally of diacetone acrylamide, held physically on at least a part of the pore walls of a starting porous polyolefin membrane, as well as its production process. This hydrophilized porous polyolefin membrane has long-lasting hydrophilicity and good mechanical strength. Its components are dissolved out only minimally in application.

Abstract: By compressing and heat curing a non-resilient, non-flexible recurable material formed by subjecting cured polyimide foam to the action of pressurized steam, a wide variety of useful articles may be produced. These include tough, flame-resistant plastic films, sheets, panels, boards, and shapes in general; composites (both reinforced and unreinforced); and laminates and other articles in which separate shapes or parts are bonded together by a new type of tough, flame-resistant adhesive. Additionally, heretofore worthless waste products such as the kerf cut away from buns of polyimide foam during the foam manufacturing process can be converted and vastly upgraded into any of such an array of new articles of manufacture such as those just mentioned.

Abstract: Low density rigid foamed polyphosphazene articles having excellent physical and flammability properties are made by masticating a mixture of high molecular weight linear polyphosphazene, a curing agent (e.g., sulfur), an accelerator, a blowing agent and optionally fillers, processing aids and the like to form a substantially homogeneous blend and then stopping the masticating, heating to pre-cure and then heating to activate the blowing agent and complete the cure thereby forming a flexible foamed polyphosphazene composite, forming the flexible foamed polyphosphazene composition into a shaped composition, and thereafter heating the flexible foamed shaped polyphosphazene composition at a temperature and for a length of time which causes the flexible foamed polyphosphazene composition to become a rigid foamed polyphosphazene composition of the same shape as the flexible foamed polyphosphazene composition.

Abstract: Carbonaceous adsorbent particles having multimodal pore size, including micropores and macropores, with improved adsorptive and separative properties, are prepared by partial pyrolysis of polysulfonated macroporous precursor resins, said resins being in turn derived from macroporous poly(vinylaromatic) resins. The particles may be further treated by activating with reactive gases or by functionalization.

Abstract: A low density, open-celled microcellular carbon foam is disclosed which is prepared by dissolving a carbonizable polymer or copolymer in a solvent, pouring the solution into a mold, cooling the solution, removing the solvent, and then carbonizing the polymer or copolymer in a high temperature oven to produce the foam. If desired, an additive can be introduced in order to produce a doped carbon foam, and the foams can be made isotropic by selection of a suitable solvent. The low density, microcellular foams produced by this process are particularly useful in the fabrication of inertial confinement fusion targets, but can also be used as catalysts, absorbents, and electrodes.

Abstract: An electrically conductive composite material is disclosed which comprises a conductive open-celled, low density, microcellular carbon foam filled with a non-conductive polymer or resin. The composite material is prepared in a two-step process consisting of first preparing the microcellular carbon foam from a carbonizable polymer or copolymer using a phase separation process, then filling the carbon foam with the desired non-conductive polymer or resin. The electrically conductive composites of the present invention has a uniform and consistant pattern of filler distribution, and as a result is superior over prior art materials when used in battery components, electrodes, and the like.

Abstract: An electrically conductive polymer composite comprising a porous body of polymer A containing interconnected cavities, and polymer B containing an electrically conductive filler and filling the cavities of the porous body. This polymer composite can be made by filling the cavities of the porous body with a liquid monomer, monomer mixture or prepolymer and then polymerizing or cross-linking it to yield polymer B in solid form. The polymer composite has excellent mechanical properties and high electrical conductivity and, therefore, is suitable for use as an electrically conductive material, electromagnetic wave shielding material, heating element and antistatic material.

Abstract: The invention relates to polyamide pellets for use in the production of high molecular weight polytetramethyleneadipamide articles. The polyamide pellets have sizes of between 1 mm and 20 mm and porosity of between 0.1 and 20 vol %. Prepolymer polyamide pellets have a crushing strength of at least 0.5, and after-condensed pellets have crushing strength of at least 15 kg.

Abstract: A frozen open-celled material is prepared by saturating the material with a solution of 30 to 60 grams of salt to one liter of water. Preferably from 40 to 50 grams of salt to one liter of water. The saturated material, preferably open-celled polyurethane foam, is then frozen. Deterioration of the foam which occurs when plain water is used is essentially eliminated.

Abstract: A synthetic substrate for use in the rooting of cuttings and the raising of seedlings, comprising an expanded, semi-rigid, substantially hetero-cellular plastics material having a plurality of regions of relatively low density for receiving cuttings or seedlings to be propagated. The regions of low density are separated by regions of relatively high density which exhibit higher capillarity than the lower density regions.One way of forming the aforegoing substrate is to subject predetermined regions of a block of foamed polyurethane or other suitable, relatively low density plastics material to heat and pressure whereby to selectively compress and permanently deform the low density foamed material to produce the regions of relatively high density.The synthetic substrate of the invention may also be in the form of capillary matting for use in supplying water and/or nutrients to plants.

Abstract: A method of making structural panels having a controlled density polyimide core, generally with at least one face sheet. An open cell polyimide foam panel is impregnated with a liquid polyimide precursor, compressed to squeeze out all but a desired quantity of the polyimide precursor and dried. One or two face sheets are impregnated with the same liquid polyimide precursor and placed on one or both faces of the foam panel, with pre-drying of the face sheet if desired. This assembly is placed in a mold and subjected to slight compression. The assembly is heated to a moderate temperature for a suitable time to take on the mold configuration. Then the assembly is heated to the curing temperature of the polyimide precursor for a period sufficient to cause curing. The resulting structural panel has a selected density, which determines strength and rigidity, weight and other physical characteristics, controlled by the amount of precursor allowed to remain after the impregnation foam compression step.

Abstract: Improved reexpandable shrunken foam bodies of styrene-acrylonitrile type resin possessing an ability to reexpand to the original volume of the highly foamed state when left standing at room temperature under atmospheric pressure and a method for the manufacture of such reexpandable shrunken foam bodies.The aforementioned shrunken foam bodies are obtained by causing a styrene-acrylonitrile type resin to contain a prescribed large amount of a specific foaming agent exhibiting a slow gas permeation speed to the base resin and possessing the boiling point exceeding a fixed lower limit, heating the resin with steam thereby setting it to foam highly, and releasing the foamed resin into the atmosphere to be cooled and shrunk therein.The aforementioned shrunken foam bodies are convenient for the purpose of transportation and storage. They are useful as fillers intended to absorb shocks and insulate heat.

Abstract: A method for forming a molded thermoplastic foam structure comprising partially filling a mold with solvent imbibed particles of a thermoplastic resin, pressurizing said mold under conditions such as to prevent vaporization of said blowing agent during subsequent polymer melting, heating said polymer to a flowable state, releasing the mold pressure to permit foaming of the melt and expansion of the foamed polymer within the mold.

Abstract: New dynamic air freshener unit comprises a porous synthetic polymer support impregnated with a fragrance. The synthetic polymer support is one produced by:(a) bonding together small particles of solid polymer;(b) coagulating polymer solutions in a non-solvent for the polymer; or(c) expanding a thermoplastic or thermosetting plastic by means of a blowing agent; to form a porous body.The unit is especially useful in vacuum cleaners.

Abstract: A high temperature filter material, comprising a non-woven glass fiber matrix including mica particles, polymer micro-bits and a uniformly distributed binder system, is made by a wet laid procedure, as used in paper-making. A composition comprising the mica particles and polymer micro-bits, used in making the filter material, and a method of preparing the composition are also disclosed.

Abstract: A high temperature filter material, comprising a non-woven glass fiber matrix including mica particles, polymer micro-bits and a uniformly distributed binder system, is made by a wet laid procedure, as used in paper-making. A composition comprising the mica particles and polymer micro-bits, used in making the filter material, and a method of preparing the composition are also disclosed.

Abstract: A steam expandable alkenyl aromatic polymer composition and methods of preparation are provided. The composition is mixed with a volatile blowing agent containing, as a primary blowing agent, dichlorodifluoromethane and as a secondary blowing agent, a halogenated hydrocarbon, a hydrocarbon, or an aliphatic alcohol containing from 1 to 4 carbon atoms, the secondary blowing agent having a normal atmospherpic boiling point of from about 0.degree. to about 100.degree. C. The composition may be expanded by steam immediately after extrusion foaming or may be expanded after aging of the composition which has been impregnated with volatile blowing agent.

Abstract: A hydrophilized membrane of a porous hydrophobic material having micropores each defined by a surface at least part of which is coated with a hydrophilizing agent which is solid at about 20.degree. C. and substantially insoluble in water. The hydrophilizing agent is preferably selected from monofatty acid esters of propylene glycol. Also disclosed are processes for hydrophilizing such porous hydrophobic membranes.

Abstract: An open cell foam structure that has a negative Poisson's ratio. Structure can be created by triaxially compressing a conventional open-cell foam material and heating the compressed structure beyond the softening point to produce a permanent deformation in the structure of the material. The structure thus produced has cells whose ribs protrude into the cell resulting in unique properties for materials of this type.

Abstract: A hydrophilized membrane of a porous hydrophobic material having micropores each defined by a surface at least part of which is coated with a hydrophilizing agent which is solid at about 20.degree. C. and substantially insoluble in water. The hydrophilizing agent is preferably selected from monofatty acid esters of propylene glycol. Also disclosed are processes for hydrophilizing such porous hydrophobic membranes.

Abstract: A steam expandable alkenyl aromatic polymer composition and methods of preparation are provided. The composition is mixed with a volatile blowing agent containing, as a primary blowing agent, dichlorodifluoromethane and as a secondary blowing agent, a halogenated hydrocarbon, a hydrocarbon, or an aliphatic alcohol containing from 1 to 4 carbon atoms, the secondary blowing agent having a normal atmospherpic boiling point of from about 0.degree. to about 100.degree. C. The composition may be expanded by steam immediately after extrusion foaming or may be expanded after aging of the composition which has been impregnated with volatile blowing agent.

Abstract: A polyethylene microporous membrane having a thickness of at most 10 .mu.m, a breaking strength of at least 200 kg/cm.sup.2 and a porosity of at least 30% is produced by heating and dissolving polyethylene having a weight average molecular weight of at least 5.times.10.sup.5 in a solvent, forming a gel sheet from the resulting solution, subjecting the gel sheet to a solvent removal treatment to adjust the amount of the solvent in the gel sheet to 10 to 80% by weight, heating and stretching the sheet and then removing the residual solvent therefrom.