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:
The present invention is directed to a deep draw microcellularly foamed polymeric container comprising a polymeric sidewall integrally connected to a polymeric base along a bottom edge. The polymeric sidewall and base are contiguous with each other and define a shape of an open top container. The polymeric sidewall and base have a contiguous inner microcellular foam structure (having average cell diameters ranging from about 5 to about 100 microns) surrounded by a smooth outer skin layer integrally connected therewith. The polymeric sidewall defines a container height and a top opening, wherein the top opening defines a top opening width, and wherein the polymeric base defines a container base width, and wherein the area defined by the top opening is greater than the area defined by the polymeric base, and wherein the ratio of the container height (h) to the top opening width (w) is greater than about 1:1 (h:w).
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:
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.
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:
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 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 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.