Abstract:
A solid state foaming process permits the use of up to 100 % recycled pre- and post-consumer polymer for the manufacture of foamed polymer material and thermoformed foamed polymer articles. The process enables the optional formation of integral unfoamed skins of controllable depth and crystallinity on foamed polymeric materails suitable for a wide variety of applications. Because this process does not alter the underlying chemistry of the material all scrap from the manufacturing process may be reused without additive to form new foamed polymeric materials and articles.
Abstract:
This invention provides packages and containers (201) produced by a solid state method for the manufacture of foam polymeric material (204). The packages are suitable for pre-cooking or sterilization, insulated transport, cooking vessel, reheating, and storage of food. The gas impregnated thermoforming (GIT) process includes interleaving an article of raw polymeric material with a gas channeling means; exposing the article to a non-reacting gas at elevated pressure to achieve a desired concentration of gas within the polymer (204), thereby forming a partially gas-saturated article (201), separating it from the gas channeling means, the decompressing, foaming and forming it at a temperature below the material's melt temperature; and finally trimming it to produce a finished foamed polymeric material (204) and recycleable scrap solid state process foamed polymer.
Abstract:
An apparatus (un-interleaver) for unwinding a roll of material interleaved with another material, and for separating the materials, includes a first platform, a second platform, a tension-sensor, an edge-sensor, and a controller. The controller monitors signals generated by the tension-sensor and the edge-sensor, and in response to the signals: a) causes the speed at which the second platform rotates to change to maintain a predetermined tension in the second material as the second material travels from the first platform toward the second platform, and b) causes the second platform to move relative to the first platform to align the edge of the second material traveling toward the roll of second material with the edge of the second material in the roll.
Abstract:
A method for joining two components includes positioning a thermoplastic polymer portion of a first component adjacent a thermoplastic polymer portion of a second component such that the first and second portions form an interface. At least one of the portions includes a microstructure having a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void. The method also includes exerting pressure on the thermoplastic polymer portions to form a bond at the interface that holds the portions together. The plurality of closed cells, and especially those adjacent the surface of the thermoplastic polymer portion that form the interface, help isolate thermally and/or chemically the surface from the remainder of the portion.
Abstract:
A solid state process utilizes gas impregnation to enhance thermoforming of thermoplastic material. If the gas is plasticizing, the article is thereby platicized for thermoforming. In some embodiments, the invention provides foaming the polymer prior to or during thermoforming by creating high levels of dissolved gas during gas exposure. Foaming may proceed spontaneously upon decompression from gas pressure, or foaming may be enhanced by heating the polymer sheet (112) near to or above the polymer~s glass transition temperature, thereby producing plasticized foamed polymer for thermoforming. When objects of unfoamed polymer are desired, foaming may be suppressed by thermoforming gas saturated articles under gas pressure. This process may be used to enhance the thermoforming performance of articles that have been previously foamed, including articles foamed by prior processes. In some embodiments, polymer is sufficiently platicized so that it may be foamed without heating. Platicization of the polymer is reversible.
Abstract:
A solution is proposed for forming a thermoplastic material (116) into a desired shape. A corresponding method comprises increasing the thermoplastic material's degree of crystallinity by infusing the thermoplastic material (116) with a gas for a period, wherein the thermoplastic material (116) includes a core (304) and a surface layer (306a, 306b) adjacent the core (304), and has a threshold degree of crystallinity above which bubbles will not nucleate when the gas-infused thermoplastic material is heated to its glass-transition-temperature, and wherein the increase in the material's degree of crystallinity includes the surface layer's degree of crystallinity being greater than the core's degree of crystallinity, and less than the thermoplastic material's threshold degree of crystallinity; allowing, for a period, gas infused into the thermoplastic material (116) to migrate out of the material (116); nucleating bubbles in the gas-infused thermoplastic material (116) by causing the gas-infused thermoplastic material (116) to reach a temperature that is at least the glass-transition-temperature of the gas-infused thermoplastic material (116); holding, for a period, the temperature that is at least the glass-transition-temperature of the gas-infused thermoplastic material (116) to allow the bubbles to grow in size; reducing the temperature of the gas-infused thermoplastic material (116) to stop the bubbles from growing in size; and thermoforming the thermoplastic material (116) into a shape.
Abstract:
A method for infusing gas into a thermoplastic material includes positioning a sheet of a thermoplastic material into a vertical or substantially vertical position; positioning a sheet of a gas-permeable material into a vertical or substantially vertical position; and winding together the positioned sheet of thermoplastic material sheet and the positioned sheet of gas-permeable material to form a roll of the thermoplastic material interleaved with the gas-permeable material, the interleaved roll having a longitudinal axis oriented in a vertical or substantially vertical position. The method also includes exposing the interleaved roll to an atmosphere of a gas pressurized to infuse the thermoplastic material with the gas, while the longitudinal axis of the interleaved roll is oriented in a vertical or substantially vertical position; and then unwinding the gas-infused interleaved roll, while the longitudinal axis of the interleaved roll remains in a vertical or substantially vertical position.
Abstract:
Methods for saturating a plurality of parisons simultaneously with a saturating gas are disclosed. The parisons may be saturated using a sealed elongated tube through which the parisons are transferred. Parisons may be stacked vertically or horizontally using modular trays, and then loaded into pressure vessels. Parisons may be saturated in individual pressure vessels which are re-pressurized at various intervals. The gas-saturated parisons can be re -heated and blow molded to provide cellular blow-molded articles.