A polymer composite contains tubular particles, which contain at least one resin with fibres embedded. The tubular particles have an average length in the range of 0.5 mm to 60 mm and an average wall thickness in the range of 0.0005 mm to 30 mm, whereas the fibers have an average diameter in the range of 0.0005 mm to 5.0 mm. A process can be used to prepare the polymer composite containing tubular particles. The polymer composite can be used as a cushioning material, which can be formed into a cushioning article such as a shoe sole, a furniture cushion, a bed mattress, an automotive seat cushion, a flooring substrate, an outdoor/walking surface, a mat, a pad, and the like.

Disclosed is a system 100 and method 700 for preparing pre-impregnated continuous fiber tapes and filaments. The system comprises an agitation unit 101, an impregnation unit 102 and a consolidation unit 104. The agitation unit 101 is configured to draw fibers from a material source and oscillate in a back and forth motion, perpendicular to a feed direction of the fibers, thereby forming agitated fibers. The impregnation unit 102 is configured to impinge a metered matrix material on the moving agitated fibers and pass over stationary lobed surfaces 304 in the impregnation unit 102, thereby forming an impregnated tape 306. The consolidation unit 104 comprises a consolidation die 503, which is heated in order to pass the impregnated tape 306 through the consolidation die 503 and convert into continuous fiber filaments by a multistage channel configured to gradually decrease the cross section of the impregnated tape 306.

A method of manufacturing a polymer coated cellulose nanocrystal composite material begins with an aqueous cellulose nanocrystal (CNC) suspension mixture. The aqueous CNC suspension mixture is dried to remove the liquid solvent from the aqueous CNC suspension mixture to form a dry CNC powder. Diethylenetriamine (DETA) is combined with melted Maleated-anhydride Polypropylene (MAPP) to form a DETA-functionalized MAPP (MA) mixture. The MA mixture is cooled and pelletized to form MA pellets. The MA pellets, the dry CNC powder, and a neat polypropylene (PP) are combined to form a CNC-PP mixture. The CNC-PP mixture is compounded by melting, subsequently cooled and pelletized to form CNC-PP pellets.

In order to solve problems of strength and volume of part, the invention provides an article reinforced by multi-dimensional fibers and a method for manufacturing the article. The article includes a core portion and a shell layer portion. The core portion is made of thermoplastic resin and the fibers in which a majority of and a minority of the fibers are respectively arranged in a major and a minor directions. The method includes: preparing a core portion made of thermoplastic resin and the fibers in which a majority of and a minority of the fibers are respectively arranged in a major and a minor directions, loading the core portion into a mold, and forming a shell layer portion in the mold to enclose the core portion. The article manufactured by the method of this invention can reduce the weight and increase the strength of the parts.

A process for producing a thermoplastic composite pipe, where the process includes: a) providing a tubular liner having a wall containing a thermoplastic polymer A in the region of the outer surface; b) providing a tape containing reinforcing fibres in a matrix containing a thermoplastic polymer B, where polymer A and polymer B are different; c) applying a film or a composite which is produced in d) and is composed of a film and a tape provided in step b) to the tubular liner, with melting of the outer surface of the liner and of the contact surface of the film either beforehand, simultaneously or thereafter, d) applying the tape provided in b) to the outer surface of the film, with melting of the outer surface of the film applied and of the contact surface of the tape either beforehand, simultaneously or thereafter,
where the surface of the film which is brought into contact with the liner contains a moulding compound containing polymer A to an extent of at least 30% by weight, and the opposite surface of the film contains a moulding compound containing polymer B to an extent of at least 30% by weight.

Molded polymer foam articles are described as having a novel foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a shape and volume wherein a sphere having a diameter between 2 cm and 1000 cm would fit within the article in at least one location without protruding from a surface of the article, and the article further has a total volume of more than 1000 cm.sup.3. Methods of making a stabilized molten polymer foam, and of making a molded polymer foam article using the stabilized molten polymer foam are also described.

Molded polymer foam articles are described as having a novel foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a shape and volume wherein a sphere having a diameter between 2 cm and 1000 cm would fit within the article in at least one location without protruding from a surface of the article, and the article further has a total volume of more than 1000 cm.sup.3. Methods of making a stabilized molten polymer foam, and of making a molded polymer foam article using the stabilized molten polymer foam are also described.

The present invention relates to thermoplastic olefin elastomer expanded beads, having an average aspect ratio of 1.10 or less and an average circularity of 0.985 or more. The thermoplastic olefin elastomer expanded beads preferably have a crystal structure such that a melting peak inherent in the thermoplastic olefin elastomer (inherent peak) and one or more melting peaks on a higher temperature side than the inherent peak (high temperature peaks) appear on a DSC curve obtained when heating the expanded beads from 23° C. to 200° C. at a heating rate of 10° C./min.

Disclosed are azeotropic or azeotrope-like compositions containing Z-1,1,1,4,4,4-hexafluoro-2-butene and methyl perfluoropropyl ether. Also disclosed is process of using the azeotropic or azeotrope-like composition as blowing agents for preparing a thermoplastic or thermoset foam. Also disclosed is a process of using the azeotropic or azeotrope-like composition as a refrigerant for producing cooling or heating. Also disclosed is a process of using such azeotropic or azeotrope-like compositions as solvents. Also disclosed is a process of using the azeotropic or azeotrope-like composition as propellants for producing an aerosol. Also disclosed is a process of using such azeotropic or azeotrope-like compositions as heat transfer media. Also disclosed is a process of extinguishing or suppressing a fire by using such azeotropic or azeotrope-like compositions. Also disclosed is a process of using such azeotropic or azeotrope-like compositions as dielectrics.

In general, in various embodiments, the present disclosure is directed systems and methods for producing a porous surface from a solid piece of polymer. In particular, the present disclosure is directed to systems that include a track assembly, mold assembly, press assembly, and methods for using the same for producing a porous surface from a solid piece of polymer. In some embodiments, the present systems and methods are directed to processing a polymer at a temperature below a melting point of the polymer to produce a solid piece of polymer with an integrated a porous surface.