An example starch-based material for forming a biodegradable component includes a mixture of a starch and an expansion additive. The starch has an amylose content of less than about 70% by weight. The expansion additive enhances the expansion and physical properties of the starch. A method of preparing a starch-based material is also disclosed and an alternate starch-based material for forming a biodegradable component is also disclosed.

An example starch-based material for forming a biodegradable component includes a mixture of a starch and an expansion additive. The starch has an amylose content of less than about 70% by weight. The expansion additive enhances the expansion and physical properties of the starch. A method of preparing a starch-based material is also disclosed and an alternate starch-based material for forming a biodegradable component is also disclosed.

Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the additive manufacturing methods comprise increasing the temperature of a plurality of foam particles with actinic radiation under conditions effective to fuse a portion of the plurality of foam particles comprising one or more thermoplastic elastomers. Increasing the temperature of the foam particles can be carried out for one or multiple iterations. The disclosed methods can be used to manufacturer articles with sub-regions that exhibit differing degrees of fusion between the foam particles, thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. 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.

Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the disclosed methods comprise selectively depositing a binding material on foam particles in a target area such that the binding material coats at least a portion of defining surfaces of the foam particles with the binding material. The binding material is then cured to affix foam particles in the target area to one another. In various aspects, the disclosed methods can be used to manufacturer articles with sub-regions that differential levels of affixing between the foam particles, and thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. 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.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

A light-blocking article is designed to be lightweight but effective to block most incident actinic radiation and can be designed into fabrics, curtains, and other materials. Such an article has an opacifying layer that is capable of blocking predetermined electromagnetic radiation. The article contains (a) porous particles comprising a continuous polymeric binder and pores within the continuous polymeric binder, the porous particles having a glass transition temperature of at least 25° C. and a mode particle size of at least 2 μm and up to and including 50 μm. The article also contains an opacifying colorant that absorbs the predetermined electromagnetic radiation (such as within 400 nm to 700 nm), in an amount of at least 0.001 weight % based on the total dry weight of the opacifying layer, and a matrix polymer in which the porous particles and opacifying colorant are dispersed.

A light-blocking article is designed to be lightweight but effective to block most incident actinic radiation and can be designed into fabrics, curtains, and other materials. Such an article has an opacifying layer that is capable of blocking predetermined electromagnetic radiation. The article contains (a) porous particles comprising a continuous polymeric binder and pores within the continuous polymeric binder, the porous particles having a glass transition temperature of at least 25° C. and a mode particle size of at least 2 μm and up to and including 50 μm. The article also contains an opacifying colorant that absorbs the predetermined electromagnetic radiation (such as within 400 nm to 700 nm), in an amount of at least 0.001 weight % based on the total dry weight of the opacifying layer, and a matrix polymer in which the porous particles and opacifying colorant are dispersed.

A process for producing foamed thermoplastic polyurethane particles comprises the steps of a) melting a thermoplastic polyurethane in a first extruder (E1), b) injecting a gaseous blowing agent in a second extruder (E2), c) impregnating the gaseous blowing agent homogeneously into the thermoplastic polyurethane melt in a third extruder (E3), d) extruding the impregnated thermoplastic polyurethane melt through a die plate and granulating the melt in an underwater granulation device under temperature and pressure conditions to form foamed thermoplastic polyurethane particles.

A process for producing foamed thermoplastic polyurethane particles comprises the steps of a) melting a thermoplastic polyurethane in a first extruder (E1), b) injecting a gaseous blowing agent in a second extruder (E2), c) impregnating the gaseous blowing agent homogeneously into the thermoplastic polyurethane melt in a third extruder (E3), d) extruding the impregnated thermoplastic polyurethane melt through a die plate and granulating the melt in an underwater granulation device under temperature and pressure conditions to form foamed thermoplastic polyurethane particles.