A method for impregnating a polymeric granulate with a physical blowing agent is disclosed. The polymeric granulate can be a typical material such as a polycarbonate that is used in foam injection moulding processes. The physical blowing agent can be carbon dioxide which impregnates that polymeric granulate at a temperature range of 40° to 120° C. and a pressure range of 15 to 55 bar. Preferably, the polymeric granulate is heated in a range of 50° to 90° with a range of 60° to 80° preferred. A pressure range of 25 to 45 bar is preferred with a range of 30 to 40 bar more preferred.

A method for impregnating a polymeric granulate with a physical blowing agent is disclosed. The polymeric granulate can be a typical material such as a polycarbonate that is used in foam injection moulding processes. The physical blowing agent can be carbon dioxide which impregnates that polymeric granulate at a temperature range of 40° to 120° C. and a pressure range of 15 to 55 bar. Preferably, the polymeric granulate is heated in a range of 50° to 90° with a range of 60° to 80° preferred. A pressure range of 25 to 45 bar is preferred with a range of 30 to 40 bar more preferred.

A method of forming an oral care implement, a method of forming a head plate for an oral care implement, and an oral care implement or head plate formed therefrom. The head plate may have micro-sized or fine features. The method may include providing an amount of a first solid material upstream of a first mold cavity; prior to the first solid material entering the first mold cavity, applying ultrasonic energy to the first solid material to melt the first solid material into a first molten material; flowing the first molten material into the first mold cavity; allowing the first molten material to harden within the first mold cavity to form a head plate comprising micro-sized features; forming a body from a second material, the body including a handle portion and a head portion; and coupling the head plate to the head portion of the body.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

A drink cup includes a body formed to include an interior fluid-storage region and a brim. The brim is coupled to the body to surround an opening into the interior fluid-storage region. The brim is formed by a brim-forming machine.

According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

A melting unit melts a solid material into a molten material. The melt unit includes a reservoir, a hopper, and a melt grid disposed between the hopper and the reservoir. The melt grid heats the solid material into the molten material such that the molten material flows from the hopper to the reservoir. The melt unit includes a plurality of guide members, where the molten material flows through plurality of flow channels defined by the melt grid and along the plurality of guide members as the molten material flows from the hopper to the reservoir.

Systems for thermal forming an object are provided. In some embodiments, a system for thermal forming an object using a mold includes one or more processors, and memory including instructions that, when executed by the one or more processors, cause the system to perform the following operations: receiving a mold identifier identifying the mold; determining mold process information for forming the object based on the mold identifier; inserting a material into a heating area, the material having a geometry selected based on the mold process information; heating the material using one or more independently controllable heat sources; and forming the object by disposing the heated material over or into at least a portion of the mold.