Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

A (super)hydrophobic isocyanate based organic aerogel/xerogel/cryogel having a water contact angle of at least 90 comprising: a cross-linked porous network structure made of polyurethane and/or polyisocyanurate and/or polyurea, and hydrophobic compounds having before the gelling step at least one isocyanate-reactive group and no isocyanate groups
Characterized in that said hydrophobic compounds are covalently bonded within the porous network of the aerogel/xerogel/cryogel and wherein said bondings are created during the gelling step of the formation of the isocyanate based organic aerogel/xerogel/cryogel cross-linked porous network structure.

A (super)hydrophobic isocyanate based organic aerogel/xerogel/cryogel having a water contact angle of at least 90 comprising: a cross-linked porous network structure made of polyurethane and/or polyisocyanurate and/or polyurea, and hydrophobic compounds having before the gelling step at least one isocyanate-reactive group and no isocyanate groups
Characterized in that said hydrophobic compounds are covalently bonded within the porous network of the aerogel/xerogel/cryogel and wherein said bondings are created during the gelling step of the formation of the isocyanate based organic aerogel/xerogel/cryogel cross-linked porous network structure.

A foamed, opacifying element useful as a light-blocking article is prepared with a dry opacifying layer on a substrate. The dry opacifying layer is densified, followed by application of a functional composition formulation to form a functional composition upon drying and curing at a coverage of 0.5-15 g/m.sup.2. The functional composition comprises at least: (i) glass particles such as hollow glass particles at a coverage of 0.1-2.2 g/cm.sup.2, and can also include any or combination of a (iv) water-soluble or water-dispersible organic polymeric binder that may be crosslinked, thickeners, coating aids having an HLB of at least 5, (ii) lubricants, (iii) tinting materials, and (v) crosslinking agents. Among other properties, the presence of the glass particles provides additional heat absorption for the foamed, opacifying elements that can be formed into light-blocking materials.

A foamed, opacifying element is useful as a light-blocking article, and includes a substrate; an opacifying layer disposed on the substrate, and a functional composition disposed over the opacifying layer. The functional composition comprises a tinting material comprising one or more pigments, one or more dyes, or a combination thereof to provide a desired tint or colorant to the entire foamed, opacifying element.

Foamed, opacifying elements are prepared using a foamable aqueous composition containing porous particles and an opacifying colorant. This composition is aerated, disposed onto a substrate, and dried. The dry foamed composition is densified, and cured in either order. At some point after the drying feature, a functional composition is disposed onto either the dry foamed composition or the opacifying layer, and dried. This functional composition has either or both of: (i) inorganic or organic spacer particles having a mode particle size of 1 to 100 m, and which inorganic or organic spacer particles resist melt flow at a pressure of up to and including 100 psi (689.5 kPa) and a temperature of up to and including 220 C.; and (iii) a tinting material comprising a pigment, dye, or a combination thereof. The (i) inorganic or organic spacer particles and the (iii) tinting material are different materials.

A supported elastomeric foam (100) includes an elastomeric matrix (102) formed of an elastomer and including a reinforcement region (104) and a foamed region (106). The foamed region includes gas filled cells (108) in the elastomer, and the reinforcement region includes a porous layer (204) having an interconnected network of pores at least partially imbibed with the elastomer. The foam can include an adhesive at a surface of the foam. A compressible seal (802) including a compressible body, which can be elastomeric foam, can also include a pattern of discontinuous adhesive regions about which the compressible body can deform to form a sea. The supported elastomeric foam can form a gas tight seal in an interface when placed under minimal compression.

A supported elastomeric foam (100) includes an elastomeric matrix (102) formed of an elastomer and including a reinforcement region (104) and a foamed region (106). The foamed region includes gas filled cells (108) in the elastomer, and the reinforcement region includes a porous layer having an interconnected network of pores at least partially imbibed with the elastomer. The foam can include an adhesive at a surface of the foam. A compressible seal including a compressible body, which can be elastomeric foam, can also include a pattern of discontinuous adhesive regions about which the compressible body can deform to form a seal.

A supported elastomeric foam (100) includes an elastomeric matrix (102) formed of an elastomer and including a reinforcement region (104) and a foamed region (106). The foamed region includes gas filled cells (108) in the elastomer, and the reinforcement region includes a porous layer having an interconnected network of pores at least partially imbibed with the elastomer. The foam can include an adhesive at a surface of the foam. A compressible seal including a compressible body, which can be elastomeric foam, can also include a pattern of discontinuous adhesive regions about which the compressible body can deform to form a seal.

A low temperature process which comprises several steps to integrate polymeric foams with at least one polymeric body in order to obtain a final body with improved properties is provided; the process being performed at a low temperature in order to avoid deformations in the polymeric body which compromise the functionality and other properties of the final body. The process comprises the steps of selecting the materials involved to guarantee the adhesion between them, the processability, their use and/or recycling, among other properties; impregnating the polymeric material to be foamed with a gas; generating the foam; and integrating the foam with the at least one polymeric body.