Abstract:
A material comprises a first layer that includes a thermoplastic polymer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The material also includes a second layer including a thermoplastic polymer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The material also includes an interface layer formed by fusion bonding the first layer to the second layer, the interface layer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that is at least 100 micrometers long.
Abstract:
A container comprises a wall and a bottom. The wail includes a thermoplastic poiymer materiai, and forms a cylindrical shape. The thermoplastic poiymer materiai has a microslructure that includes a plurality of closed ceils, each cell containing a void and each cell having a maximum dimension extending across the void within the ceil that ranges between 1 micrometer and 200 micrometers Song. The bottom is joined to an end of the cylindrical shape to close the end such that the beverage and/or other items disposed inside the cylindrical shape don't escape through the end of the shape.
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:
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:
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:
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:
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 material comprises a first layer that includes a thermoplastic polymer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The material also includes a second layer including a thermoplastic polymer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The material also includes an interface layer formed by fusion bonding the first layer to the second layer, the interface layer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that is at least 100 micrometers long.
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:
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.