Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity.

A method for producing expanded thermoplastic polymeric (eTP) material and tuning the density of the eTP during the process of producing said eTP wherein the density of the eTP material can be decreased by increasing the partial pressure of the at least one gas which is soluble in the TP material and/or by increasing the total pressure during the charging step.

This disclosure describes processes for producing polymer foams, and compositions of matter relating to these processes. A process includes the steps of dispersing an organic nucleating agent in a dispersing medium to obtain an additive dispersion, contacting the additive dispersion with a mineral nucleating agent to obtain a hybrid nucleating agent containing the organic nucleating agent localized on at least a portion of a surface of the mineral nucleating agent, and contacting the hybrid nucleating agent with a polymer in the presence of a foaming agent to obtain a polymer foam. A foamed polymer of the present disclosure includes a cellular matrix containing a polymer material, and a mineral matrix of particles containing a hybrid nucleating agent dispersed in the cellular matrix, in which the hybrid nucleating agent contains an organic nucleating agent localized on at least a portion of a surface of an inorganic material.

The invention relates to an acoustic phase mask, the phase mask having a variation in the acoustic index n, characterized in that the phase mask comprises a body comprising: at least one matrix formed from a deformable solid material, having a shear modulus of less than 10 MPa, and pores formed in the matrix, the pores being mostly filled with gas, the deformable solid material extending between the pores, the body having a porosity φ less than or equal to 50%, and a controlled porosity φ gradient resulting in a variation of the acoustic index n spatially in the body.

Ultra-stable aqueous foam comprises hydrophobic silica particles residing within bubbles in an aqueous solution of a hydrophilic polymer, a protein, or aqueous dispersible colloidal particles. The combination of the hydrophobic and hydrophilic components stabilizes the foam interfaces to result in long term stability of the foam. The foams can be crosslinked to stable monolithic foams and used for structural foams, coatings, and thermal insulating for construction.

Foamed articles including a foamed thermoplastic elastomeric material, methods of making the articles, and methods for manufacturing articles of footwear, apparel, and athletic equipment incorporating the articles are provided. One exemplary method for making a foamed article comprises placing an article comprising a foamable fibrous element and carbon dioxide in a vessel, the foamable fibrous element comprising a plurality of filaments, fibers, and/or yarns, wherein each member of the plurality comprises a foamable material; maintaining the vessel at a first pressure and first temperature at which the carbon dioxide is a liquid and carbon dioxide is soluble in the foamable material; optionally exposing the infused article to a second temperature and second pressure; and subjecting the article to a third pressure and third temperature at which the infused carbon dioxide phase transitions to a gas, thereby expanding the foamable material into a foamed material and forming the foamed article.

A thermoplastic elastomer foam is made by incorporating a gaseous or supercritical blowing agent under pressure into a molten thermoplastic elastomer comprising polymeric crystalline domains, then releasing the pressure to foam the thermoplastic elastomer.

A method of curing a composite part, including placing an uncured composite part on a mandrel, placing a plurality of expandable pellets on the uncured composite part, expanding the plurality of expandable pellets, applying a positive pressure to the uncured composite part, and curing the uncured composite part.

A composition is used for producing novel types of foam in that they combine specifically good flame-retardant properties with a good elongation at break. These novel types of foam are produced from a blend of polyether sulphone (PES) and polyphenylene sulphone (PPSU).

A microcellular thermoplastic polyurethane foamed sheet with a high foaming ratio includes components of: TPU with 70100 parts by weight, and polydimethylsiloxane with 030 parts by weight. The present disclosure has the following advantages: because the supercritical fluid has a relatively high solubility in the polydimethylsiloxane while the polydimethylsiloxane has a relatively low interfacial tension, mixing a small amount of polydimethylsiloxane into the TPU significantly facilitates the diffusion speed of the supercritical fluid in the TPU and shortens the diffusion equilibrium time of the supercritical fluid in the TPU. In addition, a method of manufacturing a microcellular thermoplastic polyurethane foamed sheet with a high foaming ratio is further provided.