A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

This document discloses a process for injection moulded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection moulding the thermoplastic biopolymer or biopolymer blend into a suitable mould shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection moulding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A process for the production of expanded material based on sulfone polymers includes an extrusion step in an extruder of virgin sulfone polymer with the injection of at least one expanding agent and in the presence of at least one nucleating agent, and a recycling step of part of the expanded material, which provides a recycled product used as raw material fed to the extruder in combination with the virgin sulfone polymer.

The invention relates to a casting device for applying a foaming reaction mixture, to at least a partial width of a cover layer, wherein the casting device comprises: a supply connection for feeding in the reaction mixture; at least one exit slit extending in a transverse direction for the exiting of the reaction mixture; two slit plates arranged opposite one another, wherein a slit space extends between the slit plates in a vertical direction above the exit slit. A supply channel connected to the supply connection is formed between the slit plates, which closes off the slit space above the exit slit in the vertical direction The supply channel has a channel cross-section, the main dimension of which is larger that the width of the slit space. The reaction mixture can be introduced into the slit space to distribute the reaction mixture over the length of the supply channel.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

An expanded bead has a foamed layer made of a polypropylene-based resin and a specific shape including one or more defective portions. The polypropylene-based resin constituting the foamed layer contains a polypropylene-based resin (A) having a melting point of 135 C. to 150 C. and a flexural modulus of less than 1000 MPa, and a polypropylene-based resin (B) having a melting point of 145 C. to 160 C. and a flexural modulus of 1000 MPa or more. The mass ratio between the resin (A) and the resin (B) in the polypropylene-based resin is represented by resin (A):resin (B)=65:35 to 35:65.