A process of microcellular foam molding an article includes using a modifier to modify properties of amorphous PLA, pouring the modified amorphous PLA into a high pressure vessel, dissolving an SCF in the high pressure vessel to impregnate the modified amorphous PLA in the high pressure vessel which is configured to allow the SCF to effuse through, forming foamed pellets, conveying the foamed pellets to a mold in a second vessel filled with water or oil, heating the second vessel, and cooling the second vessel until a foamed article is finished in the mold.

The present invention provides a continuous process for solid-state expansion of a biopolymer, e.g., polylactic acid, which can be used to manufacture reduced-density thermoplastic materials with improved physical and thermal properties. By incorporating multiple stages of heating into the process as a means to regulate heat flux, unprecedented control of microstructure and crystallinity can be achieved. Thermoplastic sheets with the distinct cellular characteristics imparted by the process disclosed herein were found to be thicker and stronger than materials prepared by conventional processes. Thermoforming sheets with such characteristics enabled the production of light-weight, thermally-stable, compostable products that resist warping, and are thus suitable for a range of industrial applications.

An ultrasound-detectable polymeric device that offers superior visibility of the body of the device and decreased ultrasound angle dependence through the use of microcavities and methods of manufacturing thereof is disclosed. These microcavities enable superior ultrasound visualization due to diffuse reflection of sound waves when compared to solid polymeric objects, ensuring that a strong signal is received at the source of the ultrasound transducer and providing strong image contrast throughout the entire cross-section of the implant that is also robust to variable angles of insonation.

A composite structure includes a foam core formed from a first polymer and between about 0.5 wt. % and about 2.5 wt. % graphene. The foam core has an average pore size between about 25 m and about 75 m, and a cell density between about 410.sup.6 cells/mm.sup.2 and about 610.sup.6 cells/mm.sup.2. Also, an overmolded skin formed from a second polymer and between about 0.25 wt. % and about 5.0 wt. % graphene is disposed on the foam core. A method of manufacturing a composite structure includes injection molding a foam core from a first polymer containing between about 0.25 wt. % and about 5.0 wt. % graphene, and injection molding an overmolded skin from a second polymer containing graphene between about 0.25 wt. % and about 5.0 wt. % graphene.

A polyolefin microporous membrane has excellent self-discharge characteristics when the polyolefin microporous membrane is incorporated as a separator in a battery. The polyolefin microporous membrane has a membrane thickness change rate of 0% or more and 15% or less with respect to 100% of the membrane thickness of said polyolefin microporous membrane that has not heated nor compressed, wherein said membrane thickness change rate is obtained when said polyolefin microporous membrane is compressed under heat at a temperature of 80 C. at a pressure of 1 MPa for 60 minutes.

A technique for initiating the formation of pores in a polymeric material that contains a thermoplastic composition is provided. The thermoplastic composition contains microinclusion and nanoinclusion additives dispersed within a continuous phase that includes a matrix polymer. To initiate pore formation, the polymeric material is mechanically drawn (e.g., bending, stretching, twisting, etc.) to impart energy to the interface of the continuous phase and inclusion additives, which enables the inclusion additives to separate from the interface to create the porous network. The material is also drawn in a solid state in the sense that it is kept at a temperature below the melting temperature of the matrix polymer.

A thermoplastic micro-porous polyurethane elastomer material with a micro particle size and a method for preparing the same are provided. The material comprises, by weight, 1-97% of support frame polymer material, 1-97% of pressure-resistant low-resilience polymer material, 0.01-0.5% of nucleating agent, and 0.1-10% of foaming agent. The method comprises the following steps: (1) is feeding polymer materials and the nucleating agent from the front end of a double-screw extruder, feeding the foaming agent from the middle, hot-melting and fully mixing all the raw materials, then further homogenizing hot melt in a static mixer, and afterwards, controlling the pressure of the hot melt and quantitatively delivering the hot melt by a melt pump. (2) is pelletizing the hot melt entering an underwater pelletizing chamber from the melt pump via a die, separating particles carried out by process water, and screening and drying the particles to obtain a target product.

A solid state foamed microcellular foam sheet for use in forming a container is provided. The solid state foamed microcellular foam sheet includes a central foamed section defining a foam layer within the microcellular foam sheet having a first population of cells within which are interspersed a second population of cells.

A system for a vehicle comprises a body component of the vehicle that is formed of a microcellular foam and optionally having one or more decorative layers applied thereto and a radar device arranged behind the body component and configured to transmit/receive radar waves therethrough. A method of manufacturing a body component of a vehicle comprises obtaining a molten resin, introducing a gas or a chemical foaming agent into the molten resin to form a microcellular foam, injecting molding the microcellular foam by injecting the microcellular foam into a mold to form the body component, removing the body component from the mold, optionally applying one or more decorative layers to the body component, and arranging the body component in front of a radar device of the vehicle.

A shoe component includes a foam member including a thermoplastic material and a mixed material mixed to each other, wherein the weight percentage of the thermoplastic material is 90 wt % to 99 wt %, and the weight percentage of the mixed material is 10 wt % to 1 wt %. A manufacturing method of the shoe component is also disclosed herein.