A wall panel includes a first and second planar skins and a core disposed therebetween. A first and second lateral edge extends between the skins. The second lateral edge comprises a female receiver. The first lateral edge comprises a male extension extending therefrom. The female receiver is formed in the core and has a depth equal to or greater than a length of the male extension. The male extension is formed from the core comprises a first parallel surface extending parallel to and offset from the first planar skin and a second parallel surface extending parallel to and offset from the second planar skin. A first tapered portion comprises a first tapered surface extending at an angle relative to a longitudinal axis from the first parallel surface to a rounded end, and a second tapered surface extending at the angle from the second parallel surface to the rounded end.

A wall panel includes a first and second planar skins and a core disposed therebetween. A first and second lateral edge extends between the skins. The second lateral edge comprises a female receiver. The first lateral edge comprises a male extension extending therefrom. The female receiver is formed in the core and has a depth equal to or greater than a length of the male extension. The male extension is formed from the core comprises a first parallel surface extending parallel to and offset from the first planar skin and a second parallel surface extending parallel to and offset from the second planar skin. A first tapered portion comprises a first tapered surface extending at an angle relative to a longitudinal axis from the first parallel surface to a rounded end, and a second tapered surface extending at the angle from the second parallel surface to the rounded end.

A wall panel includes a first and second planar skins and a core disposed therebetween. A first and second lateral edge extends between the skins. The second lateral edge comprises a female receiver. The first lateral edge comprises a male extension extending therefrom. The female receiver is formed in the core and has a depth equal to or greater than a length of the male extension. The male extension is formed from the core comprises a first parallel surface extending parallel to and offset from the first planar skin and a second parallel surface extending parallel to and offset from the second planar skin. A first tapered portion comprises a first tapered surface extending at an angle relative to a longitudinal axis from the first parallel surface to a rounded end, and a second tapered surface extending at the angle from the second parallel surface to the rounded end.

Methods of forming polymeric foams are provided. The methods may involve co-extruding a foam layer along with one or more skin layers. In some embodiments, the skin layer(s) may be removed (e.g., in a peeling operation); while, in other embodiments, the skin layer(s) may form part of the final article. The methods are particularly well suited for producing polymeric foams from polymeric materials that are considered to be difficult to foam by those of skill in the art.

A method produces porous materials by expansion of polymer gels. The porous materials can be a micro- or nano-porous polymer materials.

A method produces porous materials by expansion of polymer gels. The porous materials can be a micro- or nano-porous polymer materials.

The present invention provides a continuous process for solid-state expansion of a biopolymer, e.g., polylactic acid, which can be used to manufacture reduced-density thermoplastic materials with improved physical and thermal properties. By incorporating multiple stages of heating into the process as a means to regulate heat flux, unprecedented control of microstructure and crystallinity can be achieved. Thermoplastic sheets with the distinct cellular characteristics imparted by the process disclosed herein were found to be thicker and stronger than materials prepared by conventional processes. Thermoforming sheets with such characteristics enabled the production of light-weight, thermally-stable, compostable products that resist warping, and are thus suitable for a range of industrial applications.

There is provided herein thermoset porous polymer composites a methods for producing such composites. The method comprises: preparing a mixture comprising a resin, optionally a curing agent, and dry ice; optionally casting the mixture; curing the mixture to obtain the porous composite; and optionally controlling at least one of a reaction rate and an expansion rate of the mixture during the curing.

There is provided herein thermoset porous polymer composites a methods for producing such composites. The method comprises: preparing a mixture comprising a resin, optionally a curing agent, and dry ice; optionally casting the mixture; curing the mixture to obtain the porous composite; and optionally controlling at least one of a reaction rate and an expansion rate of the mixture during the curing.

The invention relates to a process for production of expanded thermoplastic elastomer, said process comprising the steps of: (e) adding monomers and/or oligomers used for producing the thermoplastic elastomer with or without further starting materials into a first stage of a polymer-processing machine, (f) mixing the monomers and/or oligomers and also the optionally added further starting materials and reacting the monomers and/or oligomers to give a polymer melt in the first stage of the polymer-processing machine, (g) passing the polymer melt into a second stage of a polymer-processing machine and adding a physical blowing agent with or without further starting materials to obtain a polymer melt comprising a blowing agent, (h) molding the polymer melt comprising a blowing agent into an expanded thermoplastic elastomer.