Described herein are physically crosslinked, closed cell continuous multilayer foam structures that includes a foam layer comprising polypropylene, polyethylene, or a combination of polypropylene and polyethylene and a polyamide cap layer. The multilayer foam structure can be obtained by coextruding a multilayer structure comprising at least one foam composition layer and at least one cap composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.

There is provided a skin foam-in-place foamed article comprising a pad (15) and a bag-like outer material (20) covering the pad (15). The outer material (20) has a top layer (21) and a liner layer (22) made of a foamed resin. The liner layer (22) has a closed cell structure. A pad-side skin layer (27a) having a density higher than that of a bulk layer (26) is provided on the liner layer (22), on a side of the pad (15). A corona treatment is applied to the pad-side skin layer (27a).

Articles (100, 200, 300) comprising first (101, 201, 301) and second layers (102, 202, 302) each having first and second opposed major surfaces and between the first and second layers a series of first walls (110, 210, 310) having aspect ratios between 1.5 and 5 providing a series of microchannels, and methods for making the same. Embodiment of coextruded articles described herein are useful, for example, in cushioning applications where high levels of compression are desired.

The present invention relates to molded foam having no hollow space caused in a plate-shaped portion. The molded foam comprises a tube body and a plate-shaped portion joined to the outer side of the tube body. The expansion ratio of the molded foam is lower than two, and a value of a thickness B/a thickness A as a relationship between the thickness A of the tube body at the periphery of a point joined to the plate-shaped portion and the thickness B of the plate-shaped portion is less than 2.82.

The present disclosure is directed to a physically crosslinked, closed cell continuous multilayer foam structure comprising at least one foam polypropylene/polyethylene layer with a TPU cap layer. The multilayer foam structure can be obtained by coextruding a multilayer structure comprising at least one foam composition layer with at least one cap composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.

Described herein are physically crosslinked, closed cell continuous multilayer foam structures that includes a foam layer comprising polypropylene, polyethylene, or a combination of polypropylene and polyethylene and a polyamide cap layer. The multilayer foam structure can be obtained by coextruding a multilayer structure comprising at least one foam composition layer and at least one cap composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.

The instant application discloses, among other things, ways to manufacture reduced density thermoplastics. A rapid foaming process which may create a polymer product by saturating thermoplastic sheet or preforms, heating, and then forming into final shape, is described. The polymer product may include an integral solid skin. This method may be utilized with any thermoplastic. The material handling, saturation methods, and end products are also described.

The process for forming closed cell expanded low density polyethylene foam includes the steps of: providing a mixture including low density polyethylene pellets and an effective amount of hydrocarbon scavenger additives or degassing agents, such as glycerides; adding a primary blowing agent comprising one of liquid propane, liquid butane, and combinations thereof, to the mixture and gasifying the blowing agent to expand the low density polyethylene; forming the expanded low density polyethylene into sheets, curing the expanded low density polyethylene until 80%, generally at least 99%, of the primary blowing agent is dissipated from cells within the expanded low density polyethylene forming evacuated closed cell low density polyethylene sheets.

The present invention relates to an expanded beads molded article containing a block copolymer of a polyethylene block and an ethylene-α-olefin copolymer block and having a density of 30 kg/m.sup.3 or more and less than 150 kg/m.sup.3 and a modulus of repulsion elasticity of 60% or more. The sole member of the present invention includes the expanded beads molded article of the present invention.

The invention relates to a molding composed of extruded foam, wherein at least one fiber (F) is present with a fiber region (FB2) within the molding and is surrounded by the extruded foam, while a fiber region (FB1) of the fiber (F) projects from a first side of the molding and a fiber region (FB3) of the fiber (F) projects from a second side of the molding, and the extruded foam is produced by an extrusion process comprising the following steps: I) providing a polymer melt in an extruder, II) introducing at least one blowing agent into the polymer melt provided in step I) to obtain a foamable polymer melt, III) extruding the foamable polymer melt obtained in step II) from the extruder through at least one die aperture into an area at lower pressure, with expansion of the foamable polymer melt to obtain an expanded foam, and IV) calibrating the expanded foam from step III) by conducting the expanded foam through a shaping tool to obtain the extruded foam.