Polyurethane foams and methods of manufacturing are described herein. The foam can include (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols; and (b) a filler. The amount of filler in the foam can be from 50 to 90% by weight, based on the total weight of the foam. The filler can include a plurality of fibers and/or a particulate filler. The polyurethane foams described herein are made without adding a surfactant to the reaction mixture. The density of the polyurethane foam can be at least 5 lb/ft.sup.3.

The presently disclosed subject matter is directed to a method of making a foam, specifically, the development of isocyanate-free foams using at least one unsaturated polyester. The at least one unsaturated polyester is a reaction product of at least one unsaturated cyclic anhydride, dicyclopentadiene, and at least one polyol. The disclosed formulation further comprises at least one reactive diluent and at least one initiator. The disclosed formulations are cured by a free radical mechanism.

Disclosed are porous elements that include sintered polymeric particles. The polymeric particles can be formed of a thermoplastic composition that includes a polyarylene sulfide. The polymeric particles sintered to form the porous elements have a very narrow size distribution. The porous elements can maintain their functionality and morphology even when utilized in high temperature applications.

The present disclosure relates to TPV compositions suitable for foaming, as well as foamed TPV compositions, methods of making the foregoing, and applications of various foamed TPV compositions. The TPV compositions comprise an at least partially vulcanized rubber component dispersed within a thermoplastic component comprising a thermoplastic resin and a propylene-based elastomer, oil, and optionally one or more additives. According to some aspects, the TPV composition may be made in part by preloading some portion of process oil prior to addition of the curative. TPV compositions provided herein are particularly suitable for foaming with thermo-expandable microsphere foaming agents.

A recycled PET foam material and a manufacturing method thereof are characterized in that a recycled material can be used. The manufacturing method includes the following steps: uniformly mixing PET resin, chain extender, antioxidant, flame retardant and heat stabilizer, and then mixing with a twin-screw extruder to obtain a foam PET resin. The PET foaming material obtained is a material having the advantages of light weight, large rigidity, high specific strength, good electrical insulation, good sound insulation and the like, low raw material cost, simple manufacturing process and environmental protection.

The present invention relates to a method of making a foamed cellulosic fiber-thermoplastic composite article. The method includes the steps of providing a copolymer composition, combining the copolymer composition and cellulosic fibers, applying heat, mixing energy and pressure to form a foamable mixture, and forming the foamable article in a molding or extruding operation. The method is characterized in that at least 10% of the cellulosic fibers have been thermally modified prior to being combined with the copolymer composition.

Disclosed are such co-polymers of vinylidene substituted aromatic monomers and unsaturated compounds containing nucleophilic groups chain extended by a copolymer of one or more vinylidene aromatic monomers and one or more unsaturated compounds having pendant electrophilic groups which copolymerize with the one or more vinylidene aromatic monomers. Disclosed are compositions comprising vinylidene substituted aromatic monomers and unsaturated compounds containing nucleophilic groups and a copolymer of one or more vinylidene aromatic monomers and one or more unsaturated compounds having pendant electrophilic groups, which may optionally, contain salts of alkaline earth metals, alkali metals, transition metals, post transition metals or metalloids. Disclosed are methods of preparing such chain-extended and/or branched copolymers.

A thermally expandable composition includes at least one polymer P cross-linkable by peroxide, and at least one acrylate, and at least one peroxide, azodicarbonamide and a zinc compound. The thermally expandable composition leads to low odor formation and low ammonia emission during and after the foaming process. The thermally expandable composition further shows excellent properties in terms of expansion stability.

A foaming resin composition of the present invention contains an aromatic vinyl-based resin and zinc oxide, wherein the size ratio (B/A), in which peak A is a 370 nm to 390 nm region and peak B is a 450 nm to 600 nm region, of zinc oxide is approximately 0.01 to approximately 1 when photoluminescence is measured, and the BET surface area thereof is approximately 1 m.sup.2/g to approximately 10 m.sup.2/g.

A method of manufacturing a thermally insulating product comprises: (a) forming a mixture comprising solvent and gel network former and optionally foaming agent; (b) dispersing a thermally insulating filler in the mixture; and (c) drying the mixture to form the thermally insulating product.