Abstract:
The invention disclosed herein relates to relates to foamed thermoplastic material objects and articles of manufacture having an internal layered cellular structure, as well as to methods of making the same. In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material sheet, wherein the multi-layer thermoplastic material sheet has first and second discrete outer layers sandwiching a plurality of discrete inner foamed layers, and wherein the two outer layers and plurality discrete inner foamed layers are integral with one another. The thermoplastic material may be a semi-crystalline polymer such as, for example, PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene napthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polyactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof. The two outer layers may be unfoamed skin layers having smooth outer surfaces, and the discrete inner foamed layers may be microcellular.
Abstract:
This invention provides packages and containers produced by a solid state method for the manufacture of foamed polymeric material. 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, thereby forming a partially gas-saturated article, separating it from the gas channeling means, then 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 and recycleable scrap solid state process foamed polymer.
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:
A composite material includes a core and a shell that covers the core. The core has a volume that includes a first material and a void wherein the first material occupies less than 50% of the core's volume and has a three-dimensional shape that includes a plurality of components each having the same shape and arranged to form a series of repeating components within the volume. The shell includes a second material joined to the first material. Each of the first and second materials includes a thickness having a middle region and a outer region, and at least one of the first and second materials, includes a microstructure.
Abstract:
Un procedimiento de fabricación de un objeto polimérico espumado multicapa a partir de una lámina de material termoplástico monolítico sólido, teniendo la lámina de material termoplástico un primer nivel de cristalinidad global, comprendiendo el procedimiento: absorber una cantidad eficaz de un gas plastificante en la lámina de material termoplástico para dar una lámina de material termoplástico plastificado de forma reversible, impregnándose la lámina de material termoplástico plastificado con el gas plastificante y que tiene un segundo nivel de cristalinidad global que es superior al primer nivel de cristalinidad global, y un gradiente de cristalinidad a lo largo del espesor de la lámina en el que el nivel de cristalinidad es más bajo en el medio de la lámina y más alto en o próximo a las superficies, desorber al menos parte del gas plastificante de la lámina de material termoplástico plastificado; el calentamiento de la lámina de material termoplástico plastificado para dar una lámina espumada de material termoplástico que tiene un tercer nivel de cristalinidad global que es superior o igual al segundo nivel de cristalinidad global y una pluralidad de capas internas discretas (2, 2', 3) intercaladas entre la primera y segunda capas externas discretas (1, 1'); y formar o termoformar la lámina espumada de material termoplástico para dar el objeto polimérico espumado multicapa, teniendo el objeto polimérico espumado multicapa un cuarto nivel de cristalinidad global que es superior o igual al tercer nivel de cristalinidad global.
Abstract:
A method for debossing a surface of a thermoplastic material to which an ink is selectively applied. The force generated by the ink as it cures and adheres forms a decorative relief in the thermoplastic material's surface producing an article having aesthetic and tactile appeal without having to use a die to deform the surface and without having to apply and cure the ink in a step separate from the deformation of the surface.
Abstract:
A thermoplastic material having a thickness includes a polymer having a microstructure that includes a plurality of closed cells disposed in an inner region of the material's thickness. Each of the plurality of closed cells contains a void and each of the cells has a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 500 micrometers long. The thermoplastic material also includes a substantially solid skin disposed in an outer region of the material's thickness. The skin includes a surface having a surface energy and a texture that increases the surface energy to more than 38 dynes per square centimeter.
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:
La invención aquí descrita se refiere a un proceso para producir un artículo de manufactura conformado a partir de una hoja o rollo de un material termoplástico, en donde el material termoplástico esencialmente consiste de un material termoplástico virgen, en mezcla con un material termoplástico previamente procesado, en donde el material virgen y el material termoplástico previamente procesado son de la misma composición química, y en donde el material termoplástico previamente procesado está en una cantidad en el intervalo desde aproximadamente 5% hasta aproximadamente 95% en peso. El proceso comprende al menos las siguientes etapas: (a) someter a presión la hoja o rollo del material termoplástico con un gas plastificante bajo una presión y un periodo de tiempo selectos, suficientes para dar un material termoplástico plastificado en forma reversible, el material termoplástico plastificado éste impregnado con el gas plastificante; (b) despresurizar el material termoplástico plastificado para de esta manera desorber algo del gas plastificante del material termoplástico plastificado, y (c) formar el material termoplástico plastificado en el artículo de manufactura conformado, en donde la etapa de formación, ocurre antes que la concentración del gas plastificante impregnado sea inferior a aproximadamente 0.5% en peso.