The present invention relates to a polymeric foam, and a process for making the polymeric foam comprising the steps of a) providing a monomeric solution consisting of a polymerizable, ethylenically unsaturated monomer containing one or more acid groups, water and one or more crosslinkers having more than one polymerizable group per molecule; b) introducing a blowing agent to the monomer solution; c) treating the monomer solution with an ultrasonic treatment; d) introducing one or more initiation agents to the monomer solution; and e) polymerizing the monomer solution.

Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity.

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.

Components for articles of footwear and athletic equipment are provided including a foam. A variety of foams and foam components and compositions for forming the foams are provided. In some aspects, the foams and components including the foams can have exceptionally high energy return while also having improved durability and softness. In particular, midsoles including the foams are provided for use in an article of footwear. Methods of making the compositions and foams are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding or injection molding followed by compression molding.

A method of manufacturing a flexible intrinsically antimicrobial absorbent porosic composite controlling for an effective pore size using removable pore-forming substances and physically incorporated, non-leaching antimicrobials. A flexible intrinsically antimicrobial absorbent porosic composite controlled for an effective pore size composited physically incorporated, high-surface area, non-leaching antimicrobials, optionally in which the physically incorporated non-leaching antimicrobial exposes nanopillars on its surface to enhance antimicrobial activity. A kit that enhances the effectiveness of the intrinsically antimicrobial absorbent porosic composite by storing the composite within an antimicrobial container.

Components for articles of footwear and athletic equipment are provided including a foam. A variety of foams and foam components are provided. The articles include a composition having a foam structure, wherein the composition includes an ionomeric polymer and a plurality of cations, wherein the ionomeric copolymer is crosslinked by the cations. The crosslinks are ionic, so in some aspects the composition is free or essentially free of any covalent crosslinks between the ionomers. In particular, midsoles including the foams are provided for use in an article of footwear. Methods of making the compositions and foams are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding or injection molding followed by compression molding.

A method for producing expanded thermoplastic polymeric (eTP) material and tuning the density of the eTP during the process of producing said eTP wherein the density of the eTP material can be decreased by increasing the partial pressure of the at least one gas which is soluble in the TP material and/or by increasing the total pressure during the charging step.

There is provided a foamed sheet having the excellent impact absorbability and the excellent resistance to repetitive impacts. The foamed sheet of the present invention has an average cell diameter of 10 to 200 μm, a resiliency of 6.0 N/cm.sup.2 or less when compressed to 50% of an original thickness thereof, and a thickness recovery rate defined by the following equation of 90% or more:

thickness recovery rate (%)=(thickness 0.5 seconds after compressed state is released)/(original thickness)×100 original thickness: a thickness of the foamed sheet before a load is applied, thickness 0.5 seconds after compressed state is released: a thickness of the foamed sheet after a compressed state in which a load of 100 g/cm.sup.2 is applied to the foamed sheet is kept for 120 seconds followed by release of the foamed sheet from the compression and an elapse of 0.5 seconds from the release.

Bead foams may be made of thermoplastic polyurethane and polyethylene(s), and moldings produced therefrom, may made of a composition with (a) 60 to 90 wt. % thermoplastic polyurethane and (b) 10 to 40 wt. % of polyethylene, relative to a total 100% by weight. The bead foams and moldings may be produced and/or used for shoe intermediate soles, shoe insoles, shoe combisoles, cushioning elements for shoes, bicycle saddles, bicycle tires, damping elements, cushioning, mattresses, underlays, grips, protective films, in components in the automobile-interior sector or automobile-exterior sector, balls and sports equipment, or as floor covering.

The present invention relates to bead foams made of thermoplastic polyurethane and styrene polymer with a modulus of elasticity below 2700 MPa, to moldings produced therefrom, to processes for the production of the bead foams and moldings, and also to the use of the moldings for shoe intermediate soles, shoe insoles, shoe combisoles, cushioning elements for shoes, bicycle saddles, bicycle tires, damping elements, cushioning, mattresses, underlays, grips, protective films, in components in the automobile-interior sector or automobile-exterior sector, balls and sports equipment, or as floorcovering.