Abstract:
The present invention relates to a microcellular foam of a thermoplastic resin and a method for preparing the same, and more particularly to a microcellular foam comprising a skin layer having a porosity of below 5% and a core layer having a porosity of at least 5%, wherein the thickness of the skin layer accounts for 5 to 50% of the entire foam, and a method for preparing the same. The microcellular foam of the present invention is advantageous in that it has a thicker skin layer and smaller and uniform micropores in the core layer, compared with conventional microcellular foams, while having mechanical properties comparable to those of conventional non-foamed sheets.
Abstract:
An extrudable mixture is provided for producing a highly porous substrate using an extrusion process. More particularly, the present invention enables fibers, such as organic, inorganic, glass, ceramic or metal fibers, to be mixed into a mass that when extruded and cured, forms a highly porous substrate. Depending on the particular mixture, the present invention enables substrate porosities of about 60 % to about 90 %, and enables process advantages at other porosities, as well. The extrudable mixture may use a wide variety of fibers and additives, and is adaptable to a wide variety of operating environments and applications. Fibers, which have an aspect ratio greater than 1, are selected according to substrate requirements, and are mixed with binders, pore-formers, extrusion aids, and fluid to form a homogeneous extrudable mass. The homogeneous mass is extruded into a green substrate. The more volatile material is preferentially removed from the green substrate, which allows the fibers to interconnect and contact. As the curing process continues, fiber to fiber bonds are formed to produce a structure having a substantially open pore network. The resulting porous substrate is useful in many applications, for example, as a substrate for a filter or catalyst host, or catalytic converter.
Abstract:
The invention mainly concerns polymer beads designed to be expanded to make a foundry model having a mean diameter less than 0.35 mm. The invention is in particular applicable to the manufacture of metal parts, for example in the automotive field, by an expendable model method wherein an expanded polymer model is used made from such beads.
Abstract:
A process for preparing a gas permeable flexible graphite sheet is presented. The process includes providing graphite flakes; admixing the graphite flakes with a sacrificial additive to form a graphite mixture; compressing the graphite mixture into a sheet having sacrificial additive dispersed therethrough; and treating the sheet to at least partially remove the sacrificial additive to form a permeable flexible graphite sheet.
Abstract:
The inventive method consists in supplying molten polymer and expanding agent flows to a mixing area, in dispersing said expanding agent in a polymer melt by a rapid dividing mixing in a first static mixer, in holding and intensively dividingly mixing the thus obtained mixture in a second static mixer, in cooling the mixture, during mixing, in a third static mixer to an intermediate temperature, in cooling said mixture to a granulation temperature, in extruding polymer threads and subsequently quenching and granulating them. During processing, a weight ratio between the polymer melt flow G p and the expanding agent flow G BA ranges from 13.0 to 19.0, a temperature in the first static mixer for rapid dividing mixing is calculated according to formula (I), in the second and third static mixed according to formulas (II) and (III), respectively, wherein G BA max. is the quantity of a maximum possible expanding agent flow, G Bct. is the quantity of the used expanding agent flow at the ratio between the melt flow index and a weight average molecular mass (M w ) ranges within of (0.8-12.0)x 10 -5 . The inventive method makes it possible to produce polysteren in the form of expanding granules, within a wide range of molecular masses, and a shock-resistant polysterene.
Abstract:
An improved automated method and apparatus are provided for forming composite structures, by calendering two or more elements of a pre-impregnated composite material into a band of uncured composite material, and then forming the uncured band of composite material into one or more formed, uncured composite structures.
Abstract:
A method for the manufacture of a biocompatible porous prosthesis comprising the steps of applying a solution to a porous support structure for a prosthesis, said solution comprising a biocompatible block copolymer including one or more elastomeric blocks and one or more thermoplastic blocks, and a first solvent capable of dissolving said copolymer; and applying a second solvent capable of dissolving said first solvent but incapable of dissolving said copolymer to the surfaces of said prosthesis and thereby causing said copolymer to precipitate onto said support structure.
Abstract:
Processes for fabricating a customized, three-dimensional, bioerodable, polymeric prosthetic implant are provided. In a highly preferred embodiment, the prosthetic implant has a porous network. The method employs a sterolithography instrument, a solution comprising chains of one or more photocurable, bioerodable polymers and a photoinitiator, and a three-dimensional CAD image. In a highly preferred embodiment, the solution comprises poly (propylene) fumarate (PPF) and a solvent for controlling the viscosity of the solution. During the fabrication process, the solution is placed in a container in the stereolithography instrument. The container also holds a movable build platen for supporting each of the covalently bonded layers of the polymeric prosthetic implant that are formed when successive layers of the solution are exposed to UV light energy. The UV light energy is imparted to selected portions of each layer of the solution to produce a pattern of cross-linked and non-cross-linked polymeric regions corresponding to a cross-sectional image of the three-dimensional CAD image.
Abstract:
Disclosed are methods of manufacturing electronic devices, particularly integrated circuits. Such methods include the use of low dielectric constant material prepared by using a removable porogen material.