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 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.

Provided is a material having an excellent sound-absorbing performance which can be easily applied to the desired area at the operation site and which can effectively prevent sound leakage. The material includes an open-cell soft polyurethane foam prepared from a 2-part reactive urethane resin composition prepared from a polyisocyanate component and a polyol-containing component, wherein the polyol-containing component comprises a polyol component, catalysts, a foam stabilizer, an amine compound having primary or secondary amino groups, and carbon dioxide; wherein an average sound absorption coefficient of said polyurethane foam is 30% or more, measured in accordance with JIS A 1405-2:2007 for 63 hertz to 5000 hertz; and the length of liquid-dripping is within 300 mm.

An injection-molding method includes providing an extruding system configured to produce a mixture, a first discharging channel including a first outlet, a second discharging channel including a second outlet, and a molding device including a space and first and second feeding ports communicable with the space and respectively engageable with the first and second outlets; engaging the first outlet with the first feeding port; engaging the second outlet with the second feeding port; injecting the mixture through the first outlet and the first feeding port; and injecting the mixture through the second outlet and the second feeding port.

To provide a new foam molding method and injection molding machine capable of solving variation in a wall thickness and a foamed state, sensor corrosion, a complexity of sensor positioning, and the like. The above-described problem is solved by a foam molding method comprising a resin filling step of filling a mold (2), clamped by a predetermined mold clamping force (Pc), with a resin (R) at a predetermined molding injection pressure (Pi), a filling stopping step of stopping the filling of the resin (R) when, while monitoring a mold gap (Lm) of the mold (2) during the filling, a predetermined mold gap value set in advance is reached, a surface layer curing and filled resin cooling step of curing a surface layer of the resin (R) for a certain time and cooling the filled resin (R) for a certain time after the filling of the resin (R) is stopped, a volume controlling step of controlling a volume increase by reducing the mold clamping force after curing the surface layer of the resin (R) for a certain time, and a taking out step of taking out a foam-molded product by opening the mold (2) after the volume control is performed and after cooling the filled resin (R) for a certain time.

To provide a new foam molding method and injection molding machine capable of solving variation in a wall thickness and a foamed state, sensor corrosion, a complexity of sensor positioning, and the like. The above-described problem is solved by a foam molding method comprising a resin filling step of filling a mold (2), clamped by a predetermined mold clamping force (Pc), with a resin (R) at a predetermined molding injection pressure (Pi), a filling stopping step of stopping the filling of the resin (R) when, while monitoring a mold gap (Lm) of the mold (2) during the filling, a predetermined mold gap value set in advance is reached, a surface layer curing and filled resin cooling step of curing a surface layer of the resin (R) for a certain time and cooling the filled resin (R) for a certain time after the filling of the resin (R) is stopped, a volume controlling step of controlling a volume increase by reducing the mold clamping force after curing the surface layer of the resin (R) for a certain time, and a taking out step of taking out a foam-molded product by opening the mold (2) after the volume control is performed and after cooling the filled resin (R) for a certain time.

A seat pad manufacturing method is provided. The method includes disposing a sheet member inside a foaming mold for shaping a seat pad, then injecting a foaming resin material into the foaming mold and foaming a resin foamed body through mold clamping, and demolding the resin foamed body in a state in which the sheet member is buried in the resin foamed body. Both end parts of the sheet member in the right-left direction and both end parts of the sheet member in the extending direction are each temporarily fastened to the surface of the mold through a fastener. The foaming resin material is injected into a space between the mold surface and the sheet member. A central part of the sheet member deforms into a shape curved in a convex shape as the sheet member is pressed upward through expansion of the foaming resin material.

A method of forming an article by controlling the thickness of a portion of the plastic composition which comprises a layer of molten plastic composition between opposite first and second solid skins, so that the thickness is constant with a very low tolerance of +/−0.5%, preferably +/−0.2%, when the portion is subsequently exposed to a reduced pressure to cause expansion of the layer of molten plastic composition to form a core layer of expanded cellular foam between the first and second solid skins, and by controlling the stretch of the first solid skin to be within the range of 0.5 to 3%, the expansion of the plastic composition can be highly uniformly controlled in the expanded wall parts.

A method of forming an article by controlling the thickness of a portion of the plastic composition which comprises a layer of molten plastic composition between opposite first and second solid skins, so that the thickness is constant with a very low tolerance of +/−0.5%, preferably +/−0.2%, when the portion is subsequently exposed to a reduced pressure to cause expansion of the layer of molten plastic composition to form a core layer of expanded cellular foam between the first and second solid skins, and by controlling the stretch of the first solid skin to be within the range of 0.5 to 3%, the expansion of the plastic composition can be highly uniformly controlled in the expanded wall parts.

A foam molding apparatus and a foam molding method thereby are proposed. The foam molding apparatus includes a foaming agent supply unit configured to supply a foaming agent, a molten resin supply unit configured to supply molten resin, a fixed mixing unit configured to produce a foaming resin-critical solution by mixing a foaming agent supplied from the foaming agent supply unit and molten resin supplied from the molten resin supply unit through a rod-shaped body, and a molding unit configured to mold a foam molding product using the foaming resin-critical solution supplied from the fixed mixing unit. Accordingly, it is possible to produce a foaming resin-critical solution by uniformly mixing a large amount of high-viscosity gel-state molten resin and a high-pressure compressed and low-viscosity foaming agent, using high-strength multiple channels.