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Uniformly dense polymeric foam body

United States Patent

July 15, 2003
View the Complete Patent at the US Patent & Trademark Office
Sandia National Laboratories - Visit the Intellectual Property Management and Licensing Website
A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm.sup.3 to about 0.5 g/cm.sup.3 is disclosed. The method utilizes a thermally expandable polymer microsphere material wherein some of the microspheres are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about C., and then cooling the mold to a temperature below C. the molded part achieves a bulk density which varies by less then about .+-.6% everywhere throughout the part volume.
Whinnery, Jr.; Leroy (Danville, CA)
Sandia Corporation (Livermore, CA)
10/ 210,534
July 31, 2002
STATEMENT OF GOVERNMENT INTEREST This invention was made with support under United States Government contract no. DE-AC04-94AL85000 awarded by the U.S. Department of Energy to Sandia Corporation. The Government has certain rights in the invention.