Abstract: Articles comprising a skin layer comprising virgin polymer and a core layer comprising a recycled polymer, along with associated systems and methods, are generally provided.

Abstract: Methods and systems that include introducing blowing agent into a hopper of a polymeric foam system.

Abstract: Blow molding methods and related blow molded articles are described herein.

Abstract: Methods and systems that include introducing blowing agent into a hopper of a polymeric foam processing system.

Abstract: Methods and systems that include introducing blowing agent into a hopper of a polymeric foam system.

Abstract: Methods and systems that include introducing blowing agent into a hopper of a polymeric foam processing system.

Abstract: Blowing agent introduction polymeric foam processing methods and systems are described herein.

Abstract: Polymeric foam processing systems and methods.

Abstract: Polymeric foam processing systems and methods.

Abstract: Methods and systems that include introducing blowing agent into a hopper of a polymeric foam processing system.

Abstract: Injection molding methods used to form polymeric foam articles (e.g., microcellular foam articles) are described herein.

Abstract: Methods and systems that include introducing blowing agent into a hopper of a polymeric foam system.

Abstract: Methods and systems of introducing blowing agent in a polymeric foam process are described. The methods and systems may be used to discontinuously introduce blowing agent in polymeric foam processes (e.g., injection molding processes) that discontinuously plasticate polymeric material.

Abstract: The invention relates to systems and methods for creating a foamed part. An example method includes providing a polymer processing system, providing a mold having at least one expandable mold cavity in fluid communication with the polymer processing system, mixing polymeric material and blowing agent within the polymer processing system to produce a unfoamed mixture, injecting a volume of the mixture of polymeric material and blowing agent from the polymer processing system and into the expandable mold cavity, and expanding the mold cavity to expand the unfoamed mixture within the mold cavity and form the foamed part.

Abstract: Systems and methods of processing polymer foam materials are provided. The methods involve introducing blowing agent downstream of an extruder. For example, the blowing agent may be introduced into a static mixing device positioned between the extruder and a mold. The methods may be used in connection with injection molding systems to produce high quality injection molded polymer foam articles.

Abstract: The invention relates to systems and methods for creating a foamed part. An example method includes providing a polymer processing system, providing a mold having at least one expandable mold cavity in fluid communication with the polymer processing system, mixing polymeric material and blowing agent within the polymer processing system to produce a unfoamed mixture, injecting a volume of the mixture of polymeric material and blowing agent from the polymer processing system and into the expandable mold cavity, and expanding the mold cavity to expand the unfoamed mixture within the mold cavity and form the foamed part.

Abstract: Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.

Abstract: Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.

Abstract: Polymer molding processes, such as injection-molding processes, include use of a viscosity-reducing supercritical fluid additive resulting in less breakage of reinforcing fibers upon introduction into the mold.

Abstract: The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures.