A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A cavity includes a first cavity portion, and a second cavity portion that is formed between the first cavity portion and a runner and that corresponds to a baseboard. There is adopted a configuration in which a foamed admixture is supplied to the first cavity portion via the second cavity portion upon being supplied to the cavity via the runner. A collision portion with which the foamed admixture supplied to the cavity can collide before reaching the first cavity portion is formed at the second cavity portion.

A cavity includes a first cavity portion, and a second cavity portion that is formed between the first cavity portion and a runner and that corresponds to a baseboard. There is adopted a configuration in which a foamed admixture is supplied to the first cavity portion via the second cavity portion upon being supplied to the cavity via the runner. A collision portion with which the foamed admixture supplied to the cavity can collide before reaching the first cavity portion is formed at the second cavity portion.

A method for producing a composite molded component that includes an internal component, a primary molded portion covering the internal component, and a secondary molded portion covering the primary molded portion, wherein a rib portion that protrudes toward the secondary molded portion, the method including the steps of: (a) placing an intermediate component including the internal component and the primary molded portion in a mold; (b) pouring a resin for forming the secondary molded portion into the mold; (c) detecting a resin temperature of the resin in the mold; (d) determining, based on the resin temperature, a melting time during which the resin in the mold can be molten and fused to the rib portion of the primary molded portion; (e) determining, based on the melting time, whether a molten state of the rib portion is good or poor; and (f) releasing the composite molded component from the mold.

A method for producing a composite molded component that includes an internal component, a primary molded portion covering the internal component, and a secondary molded portion covering the primary molded portion, wherein a rib portion that protrudes toward the secondary molded portion, the method including the steps of: (a) placing an intermediate component including the internal component and the primary molded portion in a mold; (b) pouring a resin for forming the secondary molded portion into the mold; (c) detecting a resin temperature of the resin in the mold; (d) determining, based on the resin temperature, a melting time during which the resin in the mold can be molten and fused to the rib portion of the primary molded portion; (e) determining, based on the melting time, whether a molten state of the rib portion is good or poor; and (f) releasing the composite molded component from the mold.

An injection molding apparatus includes a mixing section having a hollow cylinder and a stirring member disposed in the cylinder, the mixing section generating a mixed material by using the stirring member to mix a first liquid and a second liquid that flow through the cylinder, the first liquid containing a thermoset material and the second liquid containing a polymerization initiator for initiating a polymerization reaction of the thermoset material, an injection section having a nozzle and being configured to inject the mixed material from the nozzle toward a cavity defined by a fixed molding die and a movable molding die, and a detection section configured to detect a state in the cylinder.

A control method of an injection molding machine that molds a molding product including a skin layer and a core layer in a mold unit by injecting a molding material to the mold unit from a nozzle, the control method including controlling, at a starting time of an injection process, a temperature of the molding material used to form the skin layer so as to be higher than a temperature of the molding material used to form the core layer.

A control method of an injection molding machine that molds a molding product including a skin layer and a core layer in a mold unit by injecting a molding material to the mold unit from a nozzle, the control method including controlling, at a starting time of an injection process, a temperature of the molding material used to form the skin layer so as to be higher than a temperature of the molding material used to form the core layer.

A shaped article comprising a polymer-based resin derived from cellulose, wherein the polymer-based resin has an HDT of at least 95° C., a bio-derived content of at least 20 wt %, a notched izod impact strength of greater than 80 J/m and at least one of the following properties chosen from: flexural modulus of greater than 1900 MPa; a spiral flow length or at least 3.0 cm; a flex creep deflection of less than 12 mm; a transmission of at least 70%; a ΔE value of less than 25; or an L* color of at least 85.

A shaped article comprising a polymer-based resin derived from cellulose, wherein the polymer-based resin has an HDT of at least 95° C., a bio-derived content of at least 20 wt %, a notched izod impact strength of greater than 80 J/m and at least one of the following properties chosen from: flexural modulus of greater than 1900 MPa; a spiral flow length or at least 3.0 cm; a flex creep deflection of less than 12 mm; a transmission of at least 70%; a ΔE value of less than 25; or an L* color of at least 85.