Abstract: A microcellular injection blow molding system and method, and microcellular blow molded articles produced thereby, are described. The system is equipped to extrude microcellular material that changes in thickness, material density, or both in the machine direction while maintaining a constant pressure drop rate during nucleation just prior to extrusion, providing the ability to produce consistent uniform microcellular material independent of material thickness. The systems and methods are particularly useful in production of strong, thin-walled, non-liquid-permeable, opaque containers that do not contain reinforcing agent, chromophore, or residue of chemical blowing agent or chemical blowing agent by-product.

Abstract: High-density polyethylene (HDPE) foams that are essentially free of residual chemical blowing agents and reaction-by-products of chemical blowing agent are provided. The HDPE foams can be either microcellular foams or conventional foams. The foams can be produced in extrusion, injection molding, and blow molding processes that utilize a physical blowing agent. Specific die designs useful for making high quality foams are described.

Abstract: The invention provides blow molding methods and systems for polymer processing. The methods involve blow molding a parison of polymeric material using a variable blow pressure. The pressure is varied to produce high quality blow molded articles which may be formed of solid polymer or polymeric foam including microcellular material. In particular, foam articles can be produced at relatively low densities and/or with good definition. The blow molding systems and methods may be used to produce a variety of different types of articles including bottles, containers, cases, automotive parts, toys and panels.

Abstract: Balloons and balloon catheters with a superior overall combination of distensibility, elastic stress response and strength. The improved properties of the balloons result from the method or process used to form the balloons, as well as the polymeric materials used in said balloon forming process. Additionally, the enhanced combination of properties of the balloons will not be adversely affected by the novel sterilization process contemplated by this invention.

Abstract: High-density polyethylene (HDPE) foams that are essentially free of residual chemical blowing agents and reaction-by-products of chemical blowing agent are provided. The HDPE foams can be either microcellular foams or conventional foams. She foams can be produced in extrusion, injection molding, and blow molding processes that utilize a physical blowing agent. Specific die designs useful for making high quality foams are described.

Abstract: Systems and techniques for forming microcellular polymeric material, via injection molding, blow molding, continuous extrusion, or the like, at very low blowing agent levels, are described. The invention involves, in one aspect, the discovery of a region of very low blowing agent level where, surprisingly, microcellular material can be formed. Articles with particularly good surface properties are provided.

Abstract: Semi-crystalline microcellular foams that include a midlevel amount of nucleating agent, and methods of their production, are provided. The microcellular foams can be produced in typical polymer processing techniques such as extrusion, injection molding and blow molding. The foams exhibit excellent mechanical properties and can be formed over a broad range of density into a number of different foam articles.

Abstract: Balloons and balloon catheters with a superior overall combination of distensibility, elastic stress response and strength. The improved properties of the balloons result from the method or process used to form the balloons, as well as the polymeric materials used in said balloon forming process. Additionally, the enhanced combination of properties of the balloons will not be adversely affected by the novel sterilization process contemplated by this invention.

Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.

Abstract: Balloons and balloon catheters with superior overall combination of distensibility, elastic stress response and strength. The improved properties of a balloons result from the method or process used to form the balloons, as well as the polymeric materials used in said balloon forming process. Additionally, the enhanced combination of properties of the balloons will not be adversely affected by the novel sterilization process contemplated by this invention.

Abstract: Semi-crystalline microcellular foams that include a midlevel amount of nucleating agent, and methods of their production, are provided. The microcellular foams can be produced in typical polymer processing techniques such as extrusion, injection molding and blow molding. The foams exhibit excellent mechanical properties and can be formed over a broad range of density into a number of different foam articles.

Abstract: Balloons and balloon catheters with a superior overall combination of distensibility, elastic stress response and strength. The improved properties of the balloons result from the method or process used to form the balloons, as well as the polymeric materials used in said balloon forming process. Additionally, the enhanced combination of properties of the balloons will not be adversely affected by the novel sterilization process contemplated by this invention. A process for forming a balloon involves providing a parison of a block copolymer, subjecting the parison to at least one axial stretch step and at least one radial expansion step, and heating the expanded parison to a temperature below the melting temperature of the block copolymer.