A method of forming panels. The method comprises mixing a composition comprising curable resin, microspheres and at least one additive in the presence of a catalyst. The method further comprises transferring the composition to a cuboid shaped mold and allowing the composition to cure in the cuboid shaped mold to form a cuboid shaped body of syntactic foam material. The method further comprises demolding the cuboid shaped body of syntactic foam material and cutting panels from the cuboid shaped body of syntactic foam material. The method further comprises drying the panels.

A semicrystalline poly ketone powder useful for additive manufacturing may be made by dissolving a polyketone having differential scanning calorimetry (DSC) monomodal melt peak, at a temperature above 50? C. to below the melt temperature of the polyketone, precipitating the dissolved polyketone by cooling, addition of a nonsolvent or combination thereof. The method may be used to form polyketones having a DSC melt peak with an enthalpy greater than the starting polyketone.

A process for the manufacture of a solid thermoset foam includes the following successive stages: (a) making available an expandable and thermosetting composition containing a sugar and an acid catalyst chosen from strong acids, phosphoric acid and acidic inorganic salts, (b) introducing the expandable and thermosetting composition into a mold or applying the expandable composition to a support as a film with a thickness at least equal to 1 mm, and (c) heating the expandable and thermosetting composition to a temperature at least equal to 140 C., so as to form a block of solid thermoset foam.

Self-immolative polymers and compositions comprising such polymers are described. The polymers are copolymers of phthalaldehyde and one or more additional aldehydes and can degrade/decompose upon exposure to a desired stimulus, like light, heat, sound, or chemical trigger. The copolymers can be linear or cyclic, and can be crosslinked or uncrosslinked. Polymer compositions, including multilayered and multiregioned compositions, containing the copolymers are disclosed. These compositions can contain agents such as crosslinking agents, crosslinking catalysts, photocatalysts, theremocatalyts, sensitizers, chemical amplifiers, freezing point depressing agent, photo-response delaying agents, and the like. Methods of making and using the copolymers are also described.

The present invention is a phenolic resin foam board having a thickness of 40 mm or more to 300 mm or less, when the phenolic resin foam board is sliced into n pieces (n5) at approximately equal intervals of 8 mm or more to 10 mm or less, a density of an n-th specimen is d.sub.n, an average density of n pieces of specimens is d.sub.ave, a lowest density among the densities of n pieces of specimens is d.sub.min, 0(d.sub.aved.sub.min)/d.sub.ave0.12 is established, and when values for D.sub.i=(d.sub.i+d.sub.(i+1))/2 are calculated, D.sub.i values are plotted and points corresponding to the D.sub.i values are connected, resulting in a density distribution curve, no straight line parallel to the horizontal axis intersects the density distribution curve at four points.

A semicrystalline poly ketone powder useful for additive manufacturing may be made by dissolving a polyketone having differential scanning calorimetry (DSC) monomodal melt peak, at a temperature above 50 C. to below the melt temperature of the polyketone, precipitating the dissolved polyketone by cooling, addition of a nonsolvent or combination thereof. The method may be used to form polyketones having a DSC melt peak with an enthalpy greater than the starting polyketone.

A fiber-reinforced resin prepreg and a molded article obtained by molding a molding material including the fiber-reinforced resin prepreg are described. The fiber-reinforced resin prepreg contains a carbon fiber bundle and a matrix resin composition. The ipa value of the carbon fiber bundle measured by an electrochemical measurement method is 0.14 A/cm.sup.2 or more. The impact strength of a film obtained by solidifying the matrix resin composition under particular molding conditions is 12.0 kJ/m or more.

A cleaning implement for cleaning a target surface is provided that includes an erodible foam adapted to contact a surface to be cleaned and a rheological solid composition comprising a crystallizing agent and an aqueous phase.

In one instance a semicrystalline polyketone powder useful for additive manufacturing is comprised of a bimodal melt peak determined by an initial differential scanning calorimetry (DSC) scan at 20 C./min and a D.sub.90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 150 micrometers equivalent spherical diameter. In another instance, A composition is comprised of a semicrystalline polyketone powder having a melt peak and a recrystallization peak, wherein the melt peak and recrystallization peak fail to overlap.

The following is provided as a member for a composite material that has excellent durability, impact resistance, and productivity. A member for a composite material containing a resin component that contains polyaryletherketone as a main component. The resin component has a molecular weight distribution of 2 or more and less than 4 and a mass average molecular weight of 63000 or more. The composite material contains a resin and reinforcing fibers having a number average fiber length of 5 mm or more.