The present invention relates to a novel method for manufacturing rigid epoxy foams. Furthermore the present invention relates to materials, especially novel two-component epoxy systems that are used to conduct this method.

This novel process is characterized in that an epoxy resin is mixed with a blowing agent, especially an encapsulated blowing agent, and afterwards with an ionic liquid. Surprisingly the reaction, including foaming, starts at room temperature after a short time like after only 2 to 3 minutes.

In summary, the present invention comprises a two-component foam-in-place structural material and a process for producing a rigid epoxy foam.

A cured elastomer comprising: an elastomer at 100 parts per hundred rubber (phr); and an expandable thermoplastic microsphere at about 0.1 to about 10 phr. Such a cured elastomer can be used, optionally with additives, in an air barrier article that is selected from the group consisting of a tire innerliner, a pneumatic tire, a tire curing bladder, an air sleeves, a diaphragm, and a hose. With microspheres the compounded cured elastomer shows a reduction in specific gravity and a reduction in permeability. Both of these properties are highly desirable in tire design and performance.

Methods for manufacturing articles, including articles of footwear, apparel, and sporting equipment are provided. The methods comprise decorating a plurality of foam particles. The decorating can comprise applying a coating on the foam particles, or embossing or debossing the foam particles, or both. The decorating can comprise applying a coating on the foam particles by printing, painting, dyeing, applying a film, or any combination thereof. The plurality of foam particles are affixed utilizing aspects of additive manufacturing methods. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

A method of manufacturing a fluid control device includes extruding a polymer melt into a chamber defined by an outer surface of a support structure and a disintegrable metallic tubular member disposed at the support structure, the polymer melt comprising a high heat polymer and a foaming agent, the high heat polymer having a heat deflection temperature of about 100° C. to about 300° C. measured at 1.82 MPa in accordance with ASTM D648-18; sealing the chamber; and foaming the high heat polymer to produce a porous filtration medium in a compacted shape.

A method for producing a foamed body includes: forming a foamed layer precursor including applying a coating liquid onto a base to form a liquid film and applying an ink onto the liquid film by an inkjet method, where the coating liquid contains a foaming agent and an active energy ray curable material having a radical-polymerizable functional group, the active energy ray curable material contains a multifunctional active energy ray curable material having two or more radical-polymerizable functional groups, and the ink contains a foaming accelerator having a radical-polymerizable functional group; and foaming a desired position of the foamed layer precursor by heating to form a foamed layer. A functional group equivalent of the radical-polymerizable functional group in the foaming accelerator is greater than a functional group equivalent of the radical-polymerizable functional group in the active energy ray curable material.

Heat-expandable microspheres having a thermoplastic resin shell and a thermally-vaporizable blowing agent encapsulated therein. The thermoplastic resin is a copolymer produced from a polymerizable component containing 15 to 90 wt % of acrylonitrile, 3 to 50 wt % of an acrylate ester monomer (A) represented by formula (1) shown below, and 3 to 70 wt % of a methacrylate ester monomer (B) represented by formula (2) shown below. The weight ratio of the acrylate ester monomer (A) represented by formula (1) to the methacrylate ester monomer (B) represented by formula (2) in the polymerizable component (A:B) ranges from 10:90 to 90:10:

H.sub.2C═CH—COOR.sup.1  (1)

H.sub.2C═C(CH.sub.3)—COOR.sup.2  (2).

Also disclosed are hollow particles manufactured by expanding the heat-expandable microspheres; a composition containing a base compound and the heat-expandable microspheres or the hollow particles; and a formed product manufactured by molding or applying the composition.

A hot press cushioning material includes: a fiber material comprised of a multiplicity of randomly oriented fibers (1); rubber (2) present in voids between the fibers (1) of the fiber material; and independent pores (3) dispersedly present in the rubber (2).

A shock-absorbing sheet comprises a foamed resin layer having a thickness of 200 μm or less, a void ratio (P.sub.0.1) of a plane directional cross section at a thickness of 0.1 T, a void ratio (P.sub.0.5) of a plane directional cross section at a thickness of 0.5 T, and a void ratio (P.sub.0.9) of a plane directional cross section at a thickness of 0.9 T from one surface of the foamed resin layer each ranging from 10 to 70 area %; and the standard deviation (Pσ) for an average void ratio found from the void ratio (P.sub.0.1), the void ratio (P.sub.0.5) and the void ratio (P.sub.0.9) ranging from 1.0 to 20.

A molding thermal expansion structure includes a thermoplastic material and a thermal expansion material, wherein the thermoplastic material is 50 wt % to 90 wt % based on a weight of the molding thermal expansion structure; the thermal expansion material is 50 wt % to 10 wt % based on a weight of the molding thermal expansion structure; wherein, the thermal expansion material is expanded from a foaming original material through a pre-foaming process; the thermoplastic material and the thermal expansion material are mixed to form a mixed material; the mixed material is thermally expanded to form a thermal expansion structure in a molding apparatus. The molding thermal expansion structure provided in the present invention could satisfy various needs of light-weighted products. A molding method of the thermal expansion structure is also provided herein.

The invention relates to low density fluoropolymer foam, and preferably polyvinylidene fluoride (PVDF) foam, such as that made with KYNAR PVDF resins, and articles made of the foam. The foam is produced by adding microspheres containing blowing agents to the polymer and processing it through an extruder. The microspheres consist of a hard shell containing a physical blowing agent. The shell softens at elevated temperatures and allows the expansion of the blowing agent, and microsphere to create larger voids within the polymer matrix. By proper control of the polymer composition, viscosity, processing temperature, blowing agent selection, loading ratio, and finishing conditions, useful articles such as foamed PVDF pipe, tube, profiles, film, wire jacketing and other articles can be produced. The microspheres may be added to the fluoropolymer matrix by several means, including as part of a masterbatch with a compatible polymer carrier.