A method of making a foamed article comprises (a) milling a block or sheet of thermoplastic polymer to form a precursor; (b) crosslinking the thermoplastic polymer; (c) heating the precursor to a first temperature to soften the thermoplastic polymer; (d) infusing the thermoplastic polymer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymer; and (e) while the thermoplastic polymer is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

Closed cell foam articles, such as sports balls, and related manufacturing methods are disclosed herein. The article includes a main body made of closed-cell elastomeric resin foam having a density ranging between about 0.050 sg and about 0.800 sg after curing. Some articles are assembled by inserting a cured core into a main body so that the core is secured in the main body via an interference fit, and the core has one or more portions extending to the exterior surface of the main body such that the an exposed surface of the one or more exposed portions of the core blend substantially with the exterior surface of the main body.

Closed cell foam articles, such as sports balls, and related manufacturing methods are disclosed herein. The article includes a main body made of closed-cell elastomeric resin foam having a density ranging between about 0.050 sg and about 0.800 sg after curing. Some articles are assembled by inserting a cured core into a main body so that the core is secured in the main body via an interference fit, and the core has one or more portions extending to the exterior surface of the main body such that the an exposed surface of the one or more exposed portions of the core blend substantially with the exterior surface of the main body.

A method of forming a component of a vehicle heating, ventilation, and air-conditioning system from polymeric material includes providing a molding system including at least one mold cavity defining the component. A base resin is introduced to the mold system via an inlet. A chemical foaming agent is blended with the base resin to form a composition. The composition is then further heated and blended under pressure, wherein the chemical foaming agent decomposes within the composition. The composition is introduced to the mold cavity, wherein a reduced minimized pressure of the mold cavity facilitates initiation of a nucleation of the composition, wherein the composition expands to fill the mold cavity.

The invention provides a porous stamp material for laser processing that is available for continuous extrusion molding. A material including at least 100 parts by weight of thermoplastic resin, 50-250 parts by weight of hydroxylated compound whose dehydration starting temperature is 100 to 500 C., and water-soluble pore-forming material that has 10-60 m average particle diameter is mixed to obtain a mixed material. The obtained mixed material is extruded to obtain an extrusion molded product. The obtained extrusion molded product is processed with an aqueous solvent to elute the water-soluble pore-forming material, thereby yielding a porous stamp material that has continuous pores having 10-60 m pore diameter. The obtained porous stamp material is laser-processed to manufacture a stamp.

An article of footwear has an upper and a sole structure. The upper includes a base layer and one or more tensile strands. The sole structure includes an auxetic element operable to expand in two orthogonal horizontal directions in response to a tension applied in one of the directions. Each tensile strand has at least one end secured in fixed position relative to a peripheral region of the sole structure.

Non-time dependent measured variables are used to effectively determine an optimal hold profile for an expanding crosslinking polymer part in a mold cavity. A system and/or approach may first inject molten expanding crosslinking polymer into a mold cavity, then measure at least one non-time dependent variable during an injection molding cycle. Next, the system and/or method commences a hold profile for the part, and upon completing the hold profile, the part is ejected from the mold cavity.

Non-time dependent measured variables are used to effectively determine an optimal hold profile for an expanding crosslinking polymer part in a mold cavity. A system and/or approach may first inject molten expanding crosslinking polymer into a mold cavity, then measure at least one non-time dependent variable during an injection molding cycle. Next, the system and/or method commences a hold profile for the part, and upon completing the hold profile, the part is ejected from the mold cavity, whereupon a cure profile is commenced.

A mold device includes a lower mold seat, a lower die core assembly mounted to the lower mold seat and including a lower die core unit defining a mold cavity, an upper mold seat, and an upper die core assembly mounted to the upper mold seat and including an upper die core unit covering the mold cavity. The lower die core unit includes an internal loop for a cooled gas to flow therethrough, and is made of a first porous material so as to allow the cooled gas to flow out of the lower die core unit. The upper die core unit includes an upper die core passage for the cooled gas to flow therethrough, and is made of a second porous material so as to allow the cooled gas to flow out of the upper die core unit.

The present disclosure relates to a method for preparing a foamed structure, comprising: providing a preform prepared from one or more of thermoplastic materials, in which the preform has corresponding shape of the foamed structure; subjecting the preform to a first treatment with a first supercritical fluid at a first temperature and a first pressure; optionally, subjecting the preform treated with the first supercritical fluid to a second treatment with a second supercritical fluid at a second temperature and a second pressure; and foaming the resulting preform into a structure having predetermined shape and size.