1. A method for producing at least two sections of high density carbon foam within a single container, the method comprising the steps of:
dividing a coal bed into at least two coal bed sections in a container, wherein the coal bed comprises comminuted agglomerating bituminous coal;
simultaneously heating the at least two coal bed sections to a first elevated temperature, wherein the first elevated temperature is sufficient to convert said at least two coal bed sections into at least two substantially homogeneous, non-sintered, open cell carbon materials; and
continued heating of the at least two substantially homogeneous, non-sintered, open cell carbon materials at an elevated temperature for a time sufficient to essentially eliminate the plastic properties of the at least two substantially homogeneous, non-sintered, open cell carbon materials to provide at least two sections of high density carbon foam.
2. The method of claim 1, further comprising the step of heating said high density carbon foam to a second elevated temperature greater than about 700\xb0 C.
3. The method of claim 2, wherein said second elevated temperature is greater than about 950\xb0 C.
4. The method of claim 1, wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere.
5. The method of claim 2, wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere.
6. The method of claim 3, wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere.
7. The method of claim 1, further comprising the step of cooling said high density carbon foam to essentially ambient temperature under an essentially inert, non-oxidizing atmosphere.
8. The method of claim 2, further comprising the step of cooling said high density carbon foam to essentially ambient temperature under an essentially inert, non-oxidizing atmosphere.
9. The method of claim 3, further comprising the step of cooling said high density carbon foam from said to essentially ambient temperature under an essentially inert, non-oxidizing atmosphere.
10. The method of claim 1, further comprising the step of compacting at least one coal bed section.
11. The method of claim 1, further comprising the step of covering the container with a lid prior to heating said at least two coal bed sections.
12. The method of claim 1, further comprising the step of placing a bottom surface covering in said container prior to introduction of said comminuted agglomerating bituminous coal.
13. The method of claim 1, further comprising the step of covering a least a portion of one coal bed top surface with a coal bed covering.
14. The method of claim 13, further comprising the step of covering a least a portion of a coal bed covering with a rigid sheet material.
15. The method of claim 1, further comprising the step of covering a least a portion of at least one of a coal bed top surface with a rigid sheet material.
16. The method of claim 1, further comprising the step of compacting at least a portion of at least one coal bed section, wherein said compacting of at least a portion of at least one coal bed section is performed prior to introduction of the coal into the container.
17. The method of claim 1, wherein said atmosphere has a pressure between about 0 psig and 500 psig.
18. The method of claim 7, further comprising the step of heating said high density carbon foam to a second elevated temperature greater than about 700\xb0 C. after said cooling.
19. The method of claim 18, wherein said second elevated temperature is greater than about 950\xb0 C.
20. The method of claim 18, wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere.
21. The method of claim 19, wherein said heating is conducted under an essentially inert, non-oxidizing atmosphere.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A process for forming a film nonwoven laminate having cushioning cells comprising:
extruding a thermoplastic film-forming polymer composition; blowing the extruded thermoplastic polymer composition to form a blown film bubble; directing the bubble to a nip formed between a first roller and a second roller, wherein the first roller has an outer surface comprising a continuous pattern of land areas defining a plurality of discrete openings, apertures or holes, and wherein the first and second rollers partially collapse the bubble into a nascent film sheet comprising a first film layer, a second film layer, and a plurality of cushioning cells defined between the first film layer and the second film layer; providing a fibrous nonwoven web; and directing the fibrous nonwoven web between the second roller and the nascent film to form a laminate comprising the nascent film and the fibrous nonwoven web.
2. The process of claim 1 wherein the second roller comprises a smooth outer surface.
3. The process of claim 1 further comprising the step of applying a vacuum to the plurality of discrete openings, apertures or holes.
4. The process of claim 1 wherein gas is blown into the blown film bubble to support the bubble.
5. The process of claim 4 further comprising the step of entraining the gas into the cushioning cells.
6. The process of claim 4 further comprising the step of applying a vacuum to the plurality of discrete openings, apertures or holes.
7. The process of claim 6 wherein the plurality of discrete opening, apertures or holes are in fluid communication with a manifold from which the vacuum is drawn.
8. The process of claim 6 wherein the air in the film bubble has an absolute pressure greater than an absolute pressure in the plurality of discrete openings, apertures or holes.
9. The process of claim 8 wherein the absolute pressure in the film bubble is greater than the absolute pressure in the plurality of discrete openings, apertures or holes by between about 0.1 and about 5 psi.
10. The process of claim 1 wherein the cushioning cells are discrete cushioning cells having an internal gas volume of about 0.0001 to 1.0 cubic centimeters.
11. The process of claim 1 wherein the cushioning cells are discrete cushioning cells having an internal gas volume of about 0.001 to about 0.1 cubic centimeters.
12. The process of claim 1 wherein the first and second film layers are elastic.
13. The process of claim 1 further comprising the step of applying an adhesive to the fibrous nonwoven web prior to directing the fibrous nonwoven web between the second roller and the nascent film.
14. The process of claim 1 wherein the fibrous nonwoven web is provided in a necked condition.
15. The process of claim 1 wherein the nip is a heated nip.
16. A film nonwoven laminate having cushioning cells formed from the process of claim 1.
17. A cross machine direction elastic film nonwoven laminate having cushioning cells formed from the process of claim 1.
18. A personal care product comprising the laminate of claim 16.
19. A film nonwoven laminate comprising a first blown film layer, a second blown film layer, and a fibrous nonwoven web, wherein the first and second blown film layers define a plurality of cushioning cells therebetween.
20. A personal care product comprising the laminate of claim 19.
21. A process for forming a film having cushioning cells comprising:
extruding a thermoplastic film-forming polymer composition; blowing the extruded thermoplastic polymer composition to form a blown film bubble; directing the bubble to a nip formed between a first roller and a second roller, wherein the first roller has an outer surface comprising a continuous pattern of land areas defining a plurality of discrete openings, apertures or holes, and wherein the first and second rollers partially collapse the bubble into a nascent film sheet comprising a first film layer, a second film layer, and a plurality of cushioning cells defined between the first film layer and the second film layer.
22. A film having cushioning cells comprising a first nascent blown film layer, a second nascent blown film layer, and a plurality of cushioning cells defined between the first film layer and the second film layer.
23. A film nonwoven laminate having cushioning cells comprising a nascent film sheet comprising a first film layer, a second film layer, and a plurality of cushioning cells defined between the first film layer and the second film layer; and a fibrous nonwoven web bonded to the nascent film sheet.