A method of manufacturing a multi-hardness and multi-elasticity foam mattress in which a plurality of foam blocks are formed integrally with each other by use of a continuous foaming process the method comprising the steps of: arranging a plurality of nozzles above one end of a molding plate; installing a separation wall between two adjacent ones of the respective nozzles arranged at the molding plate; laminating a release paper on the top of the molding plate; spraying foaming solutions from the nozzles, respectively, wherein the release paper moves in a direction toward the other end of the molding plate corresponding to a moving speed of the foaming solution; and molding a foam body having a plurality of zones where a plurality of unit foam blocks have multi-hardnesses and multi-elasticities.

A complex structure material includes a foam made of thermosetting resin and coverings made of thermoplastic resin. The foam includes a matrix and pores. At least some of the pores communicate with each other. The foam has a continuous porous structure formed by the matrix and the pores. The coverings cover inner walls of the pores in the foam.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.

An ink formulation for additive manufacturing of low density syntactic foams is described. The ink formulation can include a thermoset resin, a curing agent suitable for use with the thermoset resin, a plurality of hollow spheres, such as glass microballoons, one or more solvents, and one or more non-hollow, viscosity modifying filler. Also described are a method of preparing the ink formulation, a method of preparing three-dimensional objects comprising low density syntactic foams, and the three-dimensional objects prepared thereby.

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

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.

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

Microporous breathable films include a polyolefin and an inorganic filler dispersed in the polyolefin. Methods for forming polymeric films and articles of manufacture prepared therefrom are described.

The invention relates to a thermally insulated conduit pipe, comprising at least one medium pipe, at least one thermal insulation arranged around the medium pipe, and at least one outer jacket arranged around the thermal insulation, wherein the outer jacket possibly comprises a barrier made of plastic, and wherein the thermal insulation comprises a foam, the cell gas of which contains at least 10 vol % HFOs. Such conduit pipe has good insulating behavior, good environmental balance, and is easily producible.

A system including an injector, a press, and a robotic conveyance is used to form a physically foamed article of footwear component from a single-phase solution of a polymeric composition and a supercritical fluid. The parameters and features of the system are configured for the formation of the footwear component in an automated manner with enhanced throughput by the system.