Abstract: A foamable composition comprises in admixture (a) a high molecular weight thermoplastic resin in particulate form and an effective amount of (b) a foaming agent therefor comprising a pumpable liquid dispersion comprising (i) a solid blowing agent, (ii) a liquid carrier, and, optionally, (iii) a thickener. The liquid dispersion can be pumped directly into the hopper of a foam molding machine eliminating the need to pre-mix pelletized concentrates of the solid blowing agent.

Abstract: Substantially benzene-free copolymers of maleic anhydride and alkyl vinyl ethers having benzene present in an amount of less than about 1 ppm and an alkyl-substituted aromatic hydrocarbon present in an amount of about 2.0 wt. % or less, and a process for rendering a copolymer reaction product of maleic anhydride and an alkyl vinyl ether prepared in benzene solution substantially benzene-free, is described herein.

Abstract: Phenolic foams having a cell structure that is resistant to rupture under pressure and a slow deterioration of thermal insulation value are claimed. These foams can be cured to achieve dimensional stability without substantial adverse affect on their structure.

Abstract: This invention relates to the manufacture of closed cell phenolic foams from low viscosity phenol-formaldehyde resole resin. This method of manufacture provides a foam which exhibits many of the advantageous characteristics of phenolic foams manufactured from high viscosity resole resin, including good thermal retention. There is provided a method of making a phenolic foam comprising the steps of mixing(a) a phenol-formaldehyde resole resin having a water content of approximately 7.5% and a viscosity of approximately 2,800 cps at 40.degree. C.;(b) a high molecular weight gel forming ethylene oxide-propylene oxide block copolymer surfactant, such as Pluronic F-127 (trade mark);(c) a catalyst;(d) a blowing agent;and curing the resulting foam.

Abstract: Porous shaped articles made from a molded composite of ultra high molecular weight polyethylene and polyethylene wax are disclosed. These articles are produced by free-sintering a non intensively mixed blend of UHMW-PE particles and particles of a polyethylene wax. The process involves mixing the UHMW-PE and wax both in powdered form until a heterogeneous mixture is formed, but under conditions which do not lead to any substantial fracturing of the UHMW-PE particles or melting of either component. The heterogeneous mix is then transferred to a press mold to form a shape and pressure is applied sufficient only to maintain the enclosed volume of the shape. The mold is heated to a temperature above the melting point of the UHMW-PE for a period of time to allow the particles to soften, expand, and contact one another at their surfaces. The mixture is then quickly cooled.

Abstract: Thermosetting fluoropolymer foams are made by mixing fluid form thermosetting fluoropolymer components having a substantial fluorine content, placing the mixture in a pressure tight chamber, filling the chamber with a gas, at relatively low pressure, that is unreactive with the fluoropolymer components, allowing the mixture to gel, removing the gelled fluoropolymer from the chamber and thereafter heating the fluoropolymer at a relatively low temperature to simultaneously cure and foam the fluoropolymer. The resulting fluoropolymer product is closed celled with the cells storing the gas employed for foaming. The fluoropolymer resins employed may be any thermosetting fluoropolymer including fluoroepoxies, fluoropolyurethanes and fluoroacrylates.

Abstract: Closed-celled foams of high compressive strength are obtained by extruding a mixture of a styrene polymer and from 8 to 16% by weight of a blowing agent mixture containing from 2 to 20% by weight of ethyl chloride, from 2 to 20% by weight of carbon dioxide, from 20 to 80% by weight of dichlorodifluoromethane and from 10 to 60% by weight of monochlorodifluoromethane.

Abstract: Viscous liquids containing polymeric materials which will interact with one another upon contact and generate gas for foam expansion are intimately and homogeneously mixed in a very short period of time by passing them successively and continuously through first and second rotary dynamic shearing mixers, the first mixer being considerably smaller than the second mixer, and the mixture experiencing a brief period of respite from shearing between the two mixers. The mixture experiences a much higher degree of shear in the first mixer, where the heat necessary for promoting the reaction is provided through the shearing action but without creating localized hot-spots. The process is particularly well suited for the preparation of foamed polydiorganosiloxanes, on a continuous, commercial scale.

Abstract: The invention relates to a coagulable composition, to a process for the preparation of a coagulated material by impregnating a textile cloth in an impregnating bath containing the coagulable composition followed by coagulation in a coagulating bath and to the resulting coagulated material.The process of the invention is characterized in that the coagulation is carried out from the water phase, and the impregnating bath contains a chemical or physical foaming agent, wherein foaming occurs simultaneously with the coagulation or immediately thereafter.It is surprisingly found that according to the present invention a high quality coagulated material is obtained, having properties comparable with the coagulated material obtained according to conventional solvent based processes.

Abstract: A combination of materials is disclosed which imparts superior fire retardant properties to organic polymers and the gaseous by-products of those polymers. The combination is made up of an organo phosphate plasticizer, aluminum hydroxide or alumina hydrate, antimony trioxide, a borate, a brominated hydrocarbon and a chlorinated paraffin.

Abstract: A hard polyvinyl chloride resin composition is provided, which contains as essential components thereof the following components (a)-(e):(a) a polyvinyl chloride base resin produced by suspension polymerization and/or bulk polymerization;(b) a super high molecular acrylic resin base processing aid;(c) a stabilizer containing one or more Group-II and/or Group-IV metals;(d) a surfactant; and(e) a heat-decomposable organic foaming agent. The above composition is formed by extrusion into a hard polyvinyl chloride resin open-cell foam.

Abstract: A liquid, solvent-free or low-solvent hardenable polyurethane-modified bitumen composition is described, which is based on a bitumen modified with a polyurethane prepolymer. The compatibility between bitumen and polyurethane prepolymer is achieved by a plasticizer system comprising a primary and a secondary plasticizer. The inventive composition is particularly suitable as an adhesive, sealant, foam material or coating compound.

Abstract: Polyphenylene ether compositions rendered flame retardant with bromine-containing compounds can be foam molded into shaped articles free of streaking and without the generation of odors if the foaming agent comprises citric acid and sodium bicarbonate.

Abstract: An expandable composition for non-crosslinked foam comprising:(a) 80 to 99% by weight of a 1-butene homopolymer,(b) 20 to 1% by weight of an ethylene polymer, and(c) a blowing agent,the percentages being based on the total weight of the 1-butene homopolymer and the ethylene polymer.

Abstract: A combination of materials is disclosed which imparts superior fire retardant properties to organic polymers and the gaseous by-products of those polymers. The combination is made up of an organo phosphate plasticizer, aluminum hydroxide or alumina hydrate, antimony trioxide, a borate, a brominated hydrocarbon and a chlorinated paraffin.

Abstract: Various flame retardant agents have been added as a coating to seed beads of vinyl aromatic polymers. The resulting products have high resistance to burning and permit the use of lower concentrations of the retardant.

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: An expandable fluorine-contained polymer composition comprising (A) a fluorine-contained polymer in which the ratio (tan .delta.) of dynamic loss modulus to dynamic storage modulus at a temperature 30.degree. C. higher than the melting point of the polymer ranges from 0.3 to 0.9, and (B) a blowing agent, and a foam obtained from said composition.

Abstract: A plastic foam is made by mixing a plastic material or its origin material with a blowing agent which does not react with the material, said agent having a maximum vapor pressure of 10 Pa at the highest permissible application temperature of the plastic foam and having a minimum vapor pressure of 600 Pa at a pressure at which said material is in plastic condition. A formed body of the mixture is then exposed to a pressure low enough to evaporate the blowing agent and form bubbles in the mixture, whereupon the body is cooled at low pressure to solidify the plastic material and substantially condense said agent, thereby providing said body with closed cells having a reduced internal pressure.

Abstract: Polyphenylene ether compositions rendered flame retardant with bromine-containing compounds can be foam molded into shaped articles free of streaking and without the generation of odors if the foaming agent comprises citric acid and sodium bicarbonate.

Abstract: A fiber having 1/2-50% substantially gas-filled and essentially all closed cells having a diameter of 0.2-25 microns and a length to diameter ratio of greater than 500 is disclosed. The fiber is made by mixing a fluorocarbon blowing agent into molten polymer, shearing the polymer at a high shear rate, extruding the polymer in a spinneret capillary at a low jet velocity and a low capillary entrance pressure and drawing down the polymer at a total extension greater than 1000.

Abstract: This invention relates to a process for producing phenolformaldehyde foams, also known as phenolic foams, of improved properties. The inventive feature resides in using a controlled combination of the various components in the curing reaction mixture and in controlling the temperature within the mass of the curing mixture. The process is applicable to production of block or laminated foams. Phenolic foams find increasing use in building applications where their thermal insulation and fire resistant properties are of value.

Abstract: A mixture of CFC-113 and CFC-123 and/or CFC-123a where CFC-123 or CFC-123a is a significant portion of the total composition has been found to result in improved blowing agent performance in phenol-formaldehyde foams compared to CFC-113.The use of CFC-123 (or CFC-123a, or both), in combination with CFC-113 improves resole resin solubility and mixed ingredient solution stability, prior to foaming. In addition, because of the lower molecular weight of CFC-123 (or CFC-123a) compared to CFC-113 better blowing agent efficiency will be realized per unit weight. Also, the lower boiling points of CFC-123 and CFC-123a as compared to CFC-113 results in a more ready conversion of dissolved blowing agent to released gaseous blowing agent by the exothermic phenolic resin polymerization. And because of the lower molecular weight and lower boiling point factors, a lower density foam is realized.

Abstract: An expandable alkenyl aromatic polymer composition and methods of preparation are provided. The composition is admixed with a volatile blowing agent and an expansion aid which includes a polyphenylene ether. The composition may be extruded and then expanded by exposure to steam or hot air or may be impregnated with blowing agent and then expanded.

Abstract: A mixture of CFC-113 and CFC-123 and/or CFC-123a where CFC-123 or CFC-123a is a significant portion of the total composition has been found to result in improved blowing agent performance in phenol-formaldehyde foams compared to CFC-113.The use of CFC-123 (or CFC-123a, or both), in combination with CFC-113 improves resole resin solubility and mixed ingredient solution stability, prior to foaming. In addition, because of the lower molecular weight of CFC-123 (or CFC-123a) compared to CFC-113 better blowing agent efficiency will be realized per unit weight. Also, the lower boiling points of CFC-123 and CFC-123a as compared to CFC-113 results in a more ready conversion of dissolved blowing agent to released gaseous blowing agent by the exothermic phenolic resin polymerization. And because of the lower molecular weight and lower boiling point factors, a lower density foam is realized.

Abstract: An improved process for in situ production of a reticulated, open-cell polyurethane foam which comprises reacting a polyester/polyether polyol mixture with an aromatic polyisocyanate having a ratio of isocyanate moieties to aromatic moieties of about 2:1 in the presence of a catalyst and a blowing agent,the improvement comprises:said polyol mixture being(a) 80 to 95 parts by weight of polyester polyol and(b) 20 to 5 parts by weight of polyoxypropylene polyether polyol or a mixed poly(oxyethylene/oxypropylene polyether polyol, each having at least one polymer of ethylenically unsaturated monomers dispersed therein and a stabilizing surfactant for polyether polyurethane foam,and said process produces a polyurethane foam which has excellent strength properties and an exceeding low resistance to air flow.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: An expandable polyolefin composition and a method of preparation are provided. Isobutane or mixtures of isobutane with other physical blowing agents are utilized to expand polyolefin compositions which have been modified by the addition of a stability control agent. The composition has a high degree of dimensional stability and exhibits minimal shrinkage during curing and/or aging.

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: An expandable alkenyl aromatic polymer composition and methods of preparation are provided. The composition is admixed with a volatile blowing agent and an expansion aid which includes a polyphenylene ether. The composition may be extruded and then expanded by exposure to steam or hot air or may be impregnated with blowing agent and then expanded.

Abstract: An improved process for in situ production of a reticulated, open-cell polyurethane foam which comprises reacting a polyester/polyether polyol mixture with an aromatic polyisocyanate having a ratio of isocyanate moieties to aromatic moieties of about 2:1 in the presence of a catalyst and a blowing agent,the improvement comprises:said polyol mixture being(a) 80 to 95 parts by weight of polyester polyol and(b) 20 to 5 parts by weight of polyoxypropylene polyether polyol or a mixed poly(oxyethylene/oxypropylene polyether polyol, each having at least one polymer of ethylenically unsaturated monomers dispersed therein and a stabilizing surfactant for polyether polyurethane foam,and said process produces a polyurethane foam which has excellent strength properties and an exceeding low resistance to air flow.

Abstract: Ethylenic polymer/styrenic polymer blend foams are prepared from blends of (1) an ethylenic polymer resin having a density of from 0.915 to 0.930 g/cm.sup.3 and a melt index of from 0.2 to 2.6 grams/10 minutes and (2) a styrenic polymer resin having a melt flow rate of from 1.4 to 18 grams/10 minutes. Foams having an excellent overall combination of properties are obtained (1) when the density, D, of such foams is in the range of from 10 to 40 kg/m.sup.3 and the 25 percent compressive strength, F, in kg/cm.sup.2 is from 0.013D.sup.1.15 to 0.024D.sup.1.15 and (2) when the ratio, R, of the melt flow rate of the styrenic polymer employed divided by the melt index of the ethylenic polymer employed is from 7 to 90 and the content, Y, of the styrenic polymer in said blend, in parts by weight based upon 100 parts by weight of the ethylenic polymer resin, satisfies the following requirement:10.ltoreq.Y.ltoreq.3.94.7+1.18R-294.1 log (D).

Abstract: An expandable polyolefin composition and a method of preparation are provided. Isobutane or mixtures of isobutane with other physical blowing agents are utilized to expand polyolefin compositions which have been modified by the addition of a stability control agent. The composition has a high degree of dimensional stability and exhibits minimal shrinkage during curing and/or aging.

Abstract: Styrene polymer foam is prepared using a mixed blowing agent of carbon dioxide plus ethyl chloride and optionally a fluorocarbon to provide a foam having primary cells and secondary cells formed in the struts and walls.

Abstract: An expandable polyetherimide composition comprising (A) polyetherimide and (B) a blowing agent containing in the said agent at least 10% by weight of a volatile organic foaming component having a solubility parameter [.delta..sub.c ] satisfying the following equation.delta..sub.p -1.14.ltoreq..delta..sub.c .ltoreq..delta..sub.p +1.14,wherein .delta..sub.p is the solubility parameter of the polyetherimide, a dielectric constant of not less than 15, and a boiling point at normal pressure of not higher than 80.degree. C.; and a foam material obtained therefrom.

Abstract: This invention relates to a method of producing silicone elastomeric foam of low density. The method mixes polydiorganosiloxanes having hydroxyl endblocking or vinyl endblocking or mixtures of both along with water to react with silicon hydride in the presence of platinum catalyst to release hydrogen gas to create a froth which cures to a foam. The combination of ingredients allows the manufacture of silicone foam having different combinations of properties than those obtained from previous methods. Embodiments of the invention also make use of specific profoamers and specific alcohols to further modify the properties of the foams produced. The method of this invention yields a low cost, low density, silicone elastomeric foam having physical properties which enable it to be used in cushioning and sealing applications.

Abstract: This invention relates to a method of producing silicone elastomeric foam of low density. The method mixes polydiorganosiloxanes having hydroxyl endblocking or vinyl endblocking or mixtures of both along with water to react with silicon hydride in the presence of platinum catalyst to release hydrogen gas to create a froth which cures to a foam. The combination of ingredients allows the manufacture of silicone foam having different combinations of properties than those obtained from previous methods. Embodiments of the invention also make use of specific profoamers and specific alcohols to further modify the properties of the foams produced. The method of this invention yields a low cost, low density, silicone elastomeric foam having physical properties which enable it to be used in cushioning and sealing applications.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A polyphenylene oxide/polystyrene polymer blend foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming said foam comprising combining the polymer blend with a blowing agent member selected from the group consisting of methylene chloride, chloroform, 1,1,2-trichloroethane and mixtures thereof in molten form under pressure and extruding the same into a lower pressure region to form the foam.

Abstract: A composition useful in producing an open-cell, elastomeric silicone foam combines a silicone oil-in-water emulsion, which forms an elastomer upon removal of the water, with an aerosol propellant. When the composition is discharged to atmospheric pressure, a froth is formed. Removing water from the froth yields an open-cell foam. The froth is stabilized by surfactants, thickeners, or froth stabilizers selected from fibers or lauryl alcohol.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbided with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: Polyorganosiloxane foams exhibiting a desirable combination of low density, an average cell size below 4 mm. and an average cell concentration greater than 4 per linear centimeter are obtained by dispensing oxygen curable mercaptoorganosiloxane compositions containing a cobaltocene catalyst, a dispersed liquid or gaseous blowing agent and, as a foam stabilizer, a resinous organosiloxane copolymer comprising trimethylsiloxy units, SiO.sub.4/2 units and specified fluorine-containing organosiloxane units. The polymer portion of the composition includes at least one polyorganosiloxane containing at least 20 mole percent of dimethylsiloxane units and an average of more than 2 mercaptoalkyl or mercaptoalkylene groups per molecule.

Abstract: Plasticized polyphosphazene compositions exhibiting excellent flame resistance and low smoke output are disclosed. The plasticizers are resinous alkylated naphthalenes condensed with formaldehyde which are characterized by methylene bridges between naphthalenic rings with softening points ranging from 28.degree. F. to 158.degree. F.

Abstract: A composition useful in producing an open-cell, elastomeric silicone foam combines a silicone oil-in-water emulsion, which forms an elastomer upon removal of the water, with an aerosol propellant. When the composition is discharged to atmospheric pressure, a froth is formed. Removing water from the froth yields an open-cell foam. The froth is stabilized by surfactants, thickeners, or froth stabilizers selected from fibers or lauryl alcohol.

Abstract: Polyorganosiloxane foams are prepared by the volatilization of a blowing agent within a polyorganosiloxane composition that is curable by a hydrosilation reaction and includes as a foam stabilizer a resinous polyorganosiloxane comprising trimethylsiloxy units, SiO.sub.4/2 units and a specified class of fluorine-containing siloxane units.