A polymeric sheet, at least partially cross-linked and/or foamed, having a substantially open cell foam structure is described. A continuous method of manufacturing of an at least partially cross-linked, open cell foamed polymeric sheet is also described.

A method for forming a thermoplastic body having regions with varied material composition and/or porosity. Powder blends comprising a thermoplastic polymer, a sacrificial porogen and an inorganic reinforcement or filler are molded to form complementary parts with closely toleranced mating surfaces. The parts are formed discretely, assembled and compression molded to provide a unitary article that is free from discernible boundaries between the assembled parts. Each part in the assembly has differences in composition and/or porosity, and the assembly has accurate physical features throughout the sections of the formed article, without distortion and nonuniformities caused by variable compaction and densification rates in methods that involve compression molding powder blends in a single step.

The present disclosure provides a polymeric membrane. The polymeric membrane includes a first thermoplastic elastomer layer that comprises a styrenic thermoplastic. The thermoplastic elastomer layer has a foam structure. The polymeric membrane can further include an optional second thermoplastic elastomer layer in contact with the first polyolefin layer.

The present disclosure provides a polymeric membrane. The polymeric membrane includes a first thermoplastic elastomer layer. The thermoplastic elastomer is a styrenic thermoplastic. The polymeric membrane can further include an optional second thermoplastic elastomer layer in contact with the first polyolefin layer.

This provides an improved process for making a flexible, porous, dissolvable solid sheet article with improved pore structures.

Open cell foam compositions are provided including a thermoplastic polymeric matrix and at least one filler. In some embodiments of the foam compositions, the filler includes nepheline syenite. Methods of making the foam compositions are described, the methods including (a) obtaining a composite materials containing a first thermoplastic polymer having a filler component and a blowing agent distributed therein; (b) coextruding the composite material with a second thermoplastic polymer and a third thermoplastic polymer to form a three-layer composition, wherein the three-layer composition includes a middle layer comprising an open cell foam formed from the foam composition, and the middle layer is disposed between the first and the second outer layers formed from the second and the third thermoplastic polymers, respectively; and (c) separating the middle layer from each of the first and the second outer layer. The first thermoplastic polymer is different from the second and the third thermoplastic polymers.

A method of printing a cellular solid (120) by direct bubble writing comprises introducing an ink formulation (102) comprising a polymerizable monomer and a gas (104) into a nozzle (106), which includes a core flow channel (108) radially surrounded by an outer flow channel (110). The ink formulation is directed into the outer flow channel (110) and the gas is directed into the core channel (108). The ink formulation (102) and the gas (104) are ejected out of the nozzle (106) as a stream of bubbles (112), where each bubble includes a core (114) comprising the gas and a liquid shell (116) overlying the core that comprises the ink formulation. After ejection, the polymerizable monomer is polymerized to form a solid polymeric shell (118) from the liquid shell (116), and the bubbles are deposited on a substrate (122) moving relative to the nozzle (106). Thus, a polymeric cellular solid (120) having a predetermined geometry is printed.

A seat trim cover for an automotive seat is formed into a 3-dimensional shape by compression molding a laminated moldable foam in a 3-dimensional. The laminated moldable foam comprises at least a layer of cellular polyurethane foam compression moldable in a temperature range of about 220° F. to about 260° F. The 3-dimensional mold is heated to a temperature range of about 150° F. to about 320° F. The layer of cellular foam is adhered to a cover material layer and pre-cut into a pre-laminated blank prior to molding into the 3-dimensional shape. Optionally, seat heaters or other components can be integrated with the laminated foam prior to compression molding the seat trim cover.

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.

The mat of the present invention includes a main body integrally formed by a plastic material. The main body at least has a first surface and a second surface adjacent to the first face. The first face and the second face have different surface physical characteristics. The first surface and the second surface are shaped into a third surface and a fourth surface respectively. The third surface and the fourth surface have a substantially same surface physical characteristic. An angle between the third surface and the fourth surface outside the main body is a specific value.