An injection molding method includes providing a molding device including a first mold, a second mold over the first mold and a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity; forming a first layer from the first material; replacing the second mold by a third mold; injecting a second material into a second mold cavity defined by the first mold and the third mold; and forming a second layer from the second material disposed over the first layer, wherein the first material is different from the second material.

The invention relates to a method of making a thin construction element (10) in sandwich lightweight construction having a high-quality surface (26). Including the steps of deep drawing a substrate film, placing the deep-drawn film into a cavity of a die, introducing partially expanded particles onto the substrate, heating to completely expanded the particle foam, curing the expanded particle foam, and opening the die to remove the molded article.

A container may include a sidewall. A container may include a base with a first portion and a second portion. The second portion may include a plurality of lobes with a thickness greater than a thickness of the first portion. The plurality of lobes may be formed by impregnating plastic with a foaming agent that may cause the plastic to foam during manufacturing.

A method of manufacturing a foam body having an anisotropic cell structure, the method including the steps of: expanding a polymer at an elevated temperature to form an initial foam body; and cooling the initial foam body under a negative pressure. There is also provided a method of manufacturing a foam body having an anisotropic cell structure, the method including the steps of: (a) in a first expansion step, expanding a foamable polymer composition substantially isotropically to form an initial foam body having an isotropic cell structure; and (b) in a second expansion step, expanding the initial foam body anisotropically in a selected direction under a negative pressure which applies an expanding force in the selected direction to provide a final foam body having an anisotropic cell structure. Apparatus for the methods are also disclosed.

Expanded rubber articles (11) and processes for making such, comprising: partially curing an expandable rubber formulation (2) by heating it in a first mould cavity (1) to form a moulded blank (3); releasing the moulded blank (3) from the first mould cavity (1) and allowing the moulded blank (5) to expand to form an expanded moulded blank (4); and further curing and expanding the expanded moulded blank (4) by heating it to form the expanded rubber article (11) comprising an expanded rubber part (6), wherein the expanded moulded blank (4) is heated in a second mould cavity (5). Optionally, the expanded moulded blank (4) is contacted with a further rubber formulation (7) and a substrate comprising a base material (9) and an elastomer bonding layer (8) in the second mould cavity (5) to form an expanded rubber article additionally comprising a solid rubber part (10) and a substrate (8, 9).

A moulded polymer article having a monolithic wall part composed of a polymer, the monolithic wall part having a core layer of expanded cellular foam, composed of the polymer, disposed between, and integral with, first and second solid skins, composed of the polymer, wherein the core layer is multilaminar and includes a first layer of the expanded cellular foam adjacent to the first solid skin, a second layer of the expanded cellular foam adjacent to the second solid skin, and an intermediate layer of the expanded cellular foam which is between, and adjacent to, the first and second layers, wherein the first and second layers have a first cellular microstructure of closed cells and the intermediate layer has a second cellular microstructure of cells which have an average aspect ratio between a maximum cell dimension and a minimum cell dimension which is greater than 2:1 and less than 5:1 and wherein in the second cellular microstructure the maximum cell dimension of the cells is oriented in a direction extending between the first and second solid skins.

A method of producing a container product comprises providing a mold including a first part and a second part. The mold is closed to define a cavity having a first area and a second area. A molten plastic composition including a polymer and a physical blowing agent is filled into the cavity. Then, the molten plastic composition in the cavity is cooled, such that the molten plastic composition in the first area is completely cooled and solidifies or a central portion of the first area has micro uncooled molten plastic composition. The second area has the plastic composition in the molten state. The first part of the mold is moved in the axial direction. The molten plastic composition in the second area forms a beehive foam after foaming and expansion. Then, the foamed container product in the mold is cooled to take shape and then removed after opening the mold.

The present disclosure provides a process. In an embodiment, the process includes providing a foamable composition. The foamable composition includes an ethylene-based elastomer, a blowing agent, and a peroxide. The process includes heating the foamable composition to form a pliable formulation. The pliable formulation has (i) a viscosity (0.1 rad/s at 180 C.) from greater than 70,000 Pa.Math.s to 2,000,000 Pa.Math.s, (ii) a tan delta (0.1 rad/s at 180 C.) from 0.2 to less than 2, (iii) a strain hardening index greater than 2.5 to 6, and (iv) an extensional viscosity (1 s.sup.1 at 180 C.) from greater than 400,000 Pa-s to 7,000,000 Pa-s. The process includes introducing the pliable formulation into a mold having an expandable mold cavity and unidirectionally expanding the expandable mold to form a crosslinked foam article. The process includes cooling, in the expanded mold, the crosslinked foam article; and removing the crosslinked foam article from the expandable mold.

A composite material, comprising a first component and a second component, the first component forming a three-dimensional mesh-type structure and the second component forming a matrix at least regionally filling the interstices between the first component, wherein the second component at least partially comprises an expanded material.

The present disclosure relates to a process and article produced by injection molding. More particularly, a process and article produced by injection molding, that provides a part with one or more locations of a reduced density where such part competes in mechanical property characteristics with parts, such as vehicular components, otherwise produced from metallic materials, and which part offers thermal insulation, flame resistance and EMI shielding.