A technique for initiating the formation of pores in a polymeric material that contains a thermoplastic composition is provided. The thermoplastic composition contains microinclusion and nanoinclusion additives dispersed within a continuous phase that includes a matrix polymer. To initiate pore formation, the polymeric material is mechanically drawn (e.g., bending, stretching, twisting, etc.) to impart energy to the interface of the continuous phase and inclusion additives, which enables the inclusion additives to separate from the interface to create the porous network. The material is also drawn in a solid state in the sense that it is kept at a temperature below the melting temperature of the matrix polymer.

Fiber-reinforced organic polymer aerogels, articles of manufacture and uses thereof are described. The reinforced aerogels include a fiber-reinforced organic polymer matrix having an at least bimodal pore size distribution with a first mode of pores having an average pore size of less than or equal to 50 nanometers (nm) and a second mode of pores having an average pore size of greater than 50 nm and a thermal conductivity of less than or equal to 30 mW/m.Math.K at a temperature of 20 C.

An ester-based elastomer expanded molded article comprising a fusion of expanded particles that contain an ester-based elastomer as a base resin.

Disclosed, among other things, are ways to manufacture layered structures. In one 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. These processes may be used to generate products with layered structures.

A foam molded article includes a main agent resin, a filler of greater than or equal to 15% by mass and less than or equal to 80% by mass, and a foaming agent of greater than or equal to 0.01% by mass and less than or equal to 10% by mass, and a foaming ratio caused by the foaming agent is greater than or equal to 1.1 times.

Fiber-reinforced organic polymer aerogels, articles of manufacture and uses thereof are described. The reinforced aerogels include a fiber-reinforced organic polymer matrix having an at least bimodal pore size distribution with a first mode of pores having an average pore size of less than or equal to 50 nanometers (nm) and a second mode of pores having an average pore size of greater than 50 nm and a thermal conductivity of less than or equal to 30 mW/m.Math.K at a temperature of 20 C.

The scope of this invention is to disclose the method of foaming a superior impact mitigation material, namely semi-closed cell hybrid polyurea foam, using scalable manufacturing process that is geometry-independent and allows for greater control of the resulting foam properties. while the process discussed herein, can be easily used to make complex geometries (e.g., padding foam for helmets, outsoles for walking and running shoes, body armors or other protection applications.

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.

Organic polymer aerogels, articles of manufacture, and uses thereof are described. The aerogels include an organic polymer matrix and microstructures dispersed within the aerogels, which provides for superior thermal conductivity and mechanical properties.

A moisture barrier layer-foamed polymeric composite sheet underlayment article comprising a foamed polymeric sheet and a moisture barrier layer adhered thereto is disclosed. In one aspect, cork particles are present in the composite.