A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Process for producing a pressure-sensitive adhesive comprising expanded microballoons, wherein the constituents for forming the adhesive are mixed in a first mixing assembly, the mixed adhesive is transferred into a second mixing assembly into which, at the same time, unexpanded microballoons are fed, the microballoons are expanded in the second mixing assembly or on exit from the second mixing assembly, the adhesive mixture with the expanded microballoons is shaped to a layer in a shaping assembly in which expanded microballoons which have broken through the surface are pressed into the layer surface and the layer of adhesive mixture together with the expanded microballoons are optionally applied to a weblike backing material.

Process for producing a pressure-sensitive adhesive comprising expanded microballoons, wherein the constituents for forming the adhesive are mixed in a first mixing assembly, the mixed adhesive is transferred into a second mixing assembly into which, at the same time, unexpanded microballoons are fed, the microballoons are expanded in the second mixing assembly or on exit from the second mixing assembly, the adhesive mixture with the expanded microballoons is shaped to a layer in a shaping assembly in which expanded microballoons which have broken through the surface are pressed into the layer surface and the layer of adhesive mixture together with the expanded microballoons are optionally applied to a weblike backing material.

A composite elastic material comprises a bulk polymer material having fractions from 0.005 to 0.1 mm with fraction homogeneity of 10 to 100% which is presented by a granular fine dispersed bulk polymer material, a binding substance in the form of an agent with OH-groups in an amount of 10 to 50% by weight of the bulk polymer material, a crosslinking agent in an amount of 0.5 to 10% by weight of the agent with OH-groups, and a plasticizing agent in an amount of 0.02 to 2% by weight of the agent with OH-groups. To obtain the composite material, a binding substance is obtained by crosslinking the agent with OH-groups, plasticizing and distributing it over the volume of the bulk material, and fixing the binding substance on the surface of the bulk material.

A composite elastic material comprises a bulk polymer material having fractions from 0.005 to 0.1 mm with fraction homogeneity of 10 to 100% which is presented by a granular fine dispersed bulk polymer material, a binding substance in the form of an agent with OH-groups in an amount of 10 to 50% by weight of the bulk polymer material, a crosslinking agent in an amount of 0.5 to 10% by weight of the agent with OH-groups, and a plasticizing agent in an amount of 0.02 to 2% by weight of the agent with OH-groups. To obtain the composite material, a binding substance is obtained by crosslinking the agent with OH-groups, plasticizing and distributing it over the volume of the bulk material, and fixing the binding substance on the surface of the bulk material.

A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

A thermal insulating additive, product formed therefrom, and method of making the same, wherein the thermal insulating additive comprises a plurality of hollow polymeric particles having an average particle size up to about 0.3 micrometers. The hollow polymeric particles exhibit a mechanical strength in a compression test up to about 420 psi and a thermal conductivity that is less than 0.150 W/m-k. The hollow polymeric particles are individually formed as an alkaline swellable core that is at least partially encapsulated with two or more shell layers; the alkaline swellable core prior to swelling exhibits an average particle size that is less than about 50 nanometers.

A method for assembling two tubes (1, 2) made from thermoplastic materials, that involves welding by heating two applied rotational contact surfaces of two parts of two tubes (1, 2), respectively, arranged end to end or overlapping coaxially (XX). The method involves induction heating of at least one conductive welding element (4), arranged at the interface (3) between the two contact surfaces, by generating a magnetic field at said conductive welding element or elements, such that the melting of the thermoplastic materials constituting said contact surfaces produces a continuous and sealed weld at said interface on at least one closed loop along the entire perimeter of said interface.

An improved shock absorbing, light-weight, thermally insulative orthotic pad designed for use in a pad and boot assembly for hoofed livestock. The pad is comprised of a mixture of small particles incorporated and encased in elastomeric materials. The particles have a lower density than the elastomeric materials and possess better thermally insulative properties. The pad is preferably elliptically shaped when viewed from the top or bottom, may be wedge-shaped when viewed from the side, and may include a triangular projection designed to contact a horse's frog and/or a front projection designed to cushion an animal's toe. The pad may also have side clips and toe bumper.