A method of forming a single piece, shaped, down feather thermally insulating article having different thermal insulating sections is described. A mold is formed with a cavity defining a non-uniformed prescribed shape and having sections of different shapes and depths. Down feather clusters or a mixture thereof is mixed with a binding material and is injected into the mold which is then heated with a suitable heat source to cause the binding material to soften and fuse the mixture together. After cooling the mold, there is formed a single piece, shaped, down feather article which is comprised of sections having different thermal insulating values for use in a product where parts of the product provide different thermal insulating properties.

A method of forming a single piece, shaped, down feather thermally insulating article having different thermal insulating sections is described. A mold is formed with a cavity defining a non-uniformed prescribed shape and having sections of different shapes and depths. Down feather clusters or a mixture thereof is mixed with a binding material and is injected into the mold which is then heated with a suitable heat source to cause the binding material to soften and fuse the mixture together. After cooling the mold, there is formed a single piece, shaped, down feather article which is comprised of sections having different thermal insulating values for use in a product where parts of the product provide different thermal insulating properties.

In a method for producing a three-dimensional mold and a three-dimensional shaped object by means of layer-by-layer material application, geometry data for the shaped object, a support part having a base surface for holding the three-dimensional shaped object, and a first and a second material that can be solidified are made available. In the solidified state, the second material includes at least one main component that can be cross-linked by means of treatment with energy, and a latent hardener that can be thermally activated, by means of which chemical cross-linking of the main component can be triggered by means of the effect of heat. To form a negative-shape layer, the first material is applied to the base surface and/or to a solidified material layer of the three-dimensional shaped object situated on this surface, in accordance with the geometry data, in such a manner that the negative-shape layer has at least one cavity that has a negative shape of a material layer of the shaped object to be produced. The negative-shape layer is solidified. To form a shaped-object layer, the cavity is filled with the second material, and afterward its main component is partially cross-linked by means of treatment with energy, and solidified. Regions of the solidified negative-shape layer and/or shaped-object layer that project beyond a plane arranged at a distance from the base surface are removed by means of material removal. The steps mentioned above are repeated at least once. The main component is further cross-linked by means of a heat treatment, and solidified in such a manner that the second material has a greater strength than the solidified first material and the second material after partial cross-linking. The negative-shape layers are removed from the shaped object.

A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler; providing a processing plasticizer; adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler; providing a processing plasticizer; adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

Provided is a resin composition having excellent electromagnetic wave shielding properties. A resin composition containing: a thermoplastic resin (A); graphite (B); and two or more kinds of carbon black (C), the two or more kinds of carbon black (C) including a first carbon black (C-1) having a BET specific surface area of 600 m.sup.2/g or more and a second carbon black (C-2) having a BET specific surface area of less than 600 m.sup.2/g.

Provided is a resin composition with which a resin molded article having excellent heat dissipation can be obtained. A resin composition containing: a thermoplastic resin; graphite; and a fibrous body, when the resin composition in a molten state is filled in a mold from a direction orthogonal to a thickness direction of a resulting resin molded article 1 and molded to obtain a resin molded article 1 of 100 mm in length?100 mm in width?2 mm in thickness, in a cross-section obtained by cutting the resin molded article 1 along a direction X parallel to a filling direction and a thickness direction Z, among regions 1A to 1E obtained by dividing the cross-section into five equal parts in the thickness direction Z, an average orientation angle (A) with respect to a plane direction of the graphite in at least one of the regions 1A and 1E on outermost layer sides being 15? or less, and an average orientation angle (B) with respect to the plane direction of the graphite in the central region 1C being 35? or more.

An algae-elastomer composite including an elastomer matrix; algae; and a mixing additive sufficient to achieve a desired property. The algae can be present in a milled condition having a particle size value of between about 10 and 120 microns. The algae is mixed with the elastomer matrix in a dry condition having a moisture content of below about 10%. A method of preparing the algae-based elastomer composite is provided that includes the steps of: premixing an elastomer matrix; adding an algae filler; adding a mixing additive that includes a plasticizer; forming an elastomer-algae blend by blending the algae and elastomer to a temperature sufficient to be further mixed, wherein the temperature is about 10 C. higher than the temperature sufficient for the elastomer alone; adding and mixing a curing or vulcanizing agent for the elastomer dispersing the elastomer-algae blend; and heating and curing the elastomer-algae blend into a final form.

An algae-elastomer composite including an elastomer matrix; algae; and a mixing additive sufficient to achieve a desired property. The algae can be present in a milled condition having a particle size value of between about 10 and 120 microns. The algae is mixed with the elastomer matrix in a dry condition having a moisture content of below about 10%. A method of preparing the algae-based elastomer composite is provided that includes the steps of: premixing an elastomer matrix; adding an algae filler; adding a mixing additive that includes a plasticizer; forming an elastomer-algae blend by blending the algae and elastomer to a temperature sufficient to be further mixed, wherein the temperature is about 10 C. higher than the temperature sufficient for the elastomer alone; adding and mixing a curing or vulcanizing agent for the elastomer dispersing the elastomer-algae blend; and heating and curing the elastomer-algae blend into a final form.

The present invention refers to a biocomposite that incorporates cereal bran as reinforcement material in a polymer matrix, using compatibilizing agents that favor the interaction of said materials. The present invention also refers to the method for producing said biocomposite under controlled operating conditions: Temperature, speed, particle size and moisture, which comprises the steps of heating the polymer matrix, adding a compatibilizing agent and a reinforcement material, cooling the mixture, drying, and granulating, to obtain a product with special physicochemical and mechanical characteristics, like those of conventional plastics.