Abstract: A process for expanding small diameter polystyrene beads is disclosed. The process comprises applying a steam pressure of about three to seven pounds per square inch at a temperature of about two hundred twenty degrees Fahrenheit to two hundred forty degrees Fahrenheit to a plurality of expandable polystyrene beads until each of the plurality of expandable polystyrene beads has expanded to a diameter of about 0.030 inches to 0.125 inches, wherein each of the plurality of expandable polystyrene beads has an unexpanded diameter of about 0.015 inches to about 0.028 inches.

Abstract: Provided is a hollow foamed blow-molded article having a high heat resistance, employing a thermoplastic resin composition containing a mixed resin of a polyphenylene ether resin and a polystyrene resin, as a base resin. The foamed blow-molded article, may be produced by extruding a foamable molten resin composition obtained by kneading the thermoplastic resin composition and a blowing agent to form a foamed parison, and blow molding the foamed parison. A glass transition temperature of the thermoplastic resin composition is 110° C. or higher. A melt viscosity of the thermoplastic resin composition at a temperature of the glass transition temperature+80° C. and at a shear rate of 100/sec is 3000 to 9500 Pa·s. The physical blowing agent is a blowing agent containing a hydrocarbon compound having 3-5 carbon atoms. A blending amount of the physical blowing agent is 0.4 to 1 mol per kg of the thermoplastic resin composition.

Abstract: An electronic percussion pad includes: a pad main body that is formed of a foaming elastomer; and a composite layer that includes an expandable fiber sheet laminated on a front surface of the pad main body. In the composite layer, fiber of the fiber sheet and a foaming elastomer of the pad main body are present, and the composite layer contains bubbles.

Abstract: A method for making a shapeable article from poly(lactic acid) includes treating solid poly(lactic acid) that results in the solid poly(lactic acid) having a crystallinity of at least 20% by weight based on the weight of the solid poly(lactic acid) and a gas concentration of 6% to 16% by weight based on the weight of the solid poly(lactic acid); and heating the solid poly(lactic acid) having said minimum crystallinity and gas concentration to produce a cellular poly(lactic acid) article that is shapeable. The shapeable cellular poly(lactic acid) article is advantageous in that the article can be further shaped by heat and/or pressure (or vacuum), such as via thermoforming, into a variety of useful products.

Abstract: The present invention relates to a porous manganese oxide-based lithium absorbent and a method for preparing the same. The method includes the steps of preparing a mixture by mixing a reactant for the synthesis of a lithium-manganese oxide precursor powder with an inorganic binder, molding the mixture, preparing a porous lithium-manganese oxide precursor molded body by heat-treating the molded mixture, and acid-treating the porous lithium-manganese oxide precursor molded body such that lithium ions of the porous lithium-manganese oxide precursor are exchanged with hydrogen ions, wherein pores are formed in the lithium-manganese oxide precursor molded body by gas generated in the heat treatment. The porous manganese oxide-based lithium adsorbent according to the present invention is easy to handle and has many more adsorption reaction sites compared to existing molded adsorbents, thus providing high lithium adsorption efficiency.

Abstract: In one embodiment, the method for making a polymer article comprises: orienting polymer chains in one direction more than any other direction to form an oriented article, contacting the oriented article with a foaming agent, and foaming the material to form the reflective polymer article comprising planar cell structures having a length “l” and a thickness “t”.

Abstract: The invention discloses a thermoplastic elastomer composite, a component of electronic cigarette and a method of preparing the component of electronic cigarette. The thermoplastic elastomer composite comprises 65-85 weight % of a main body material, 10-25 weight % of a microspheres foaming agent and 5-10 weight % of an agent. The component of electronic cigarette made of the thermoplastic elastomer composite, has high elasticity and a wide hardness adjusting range, can be adjusted according to users' requirements, and has good taste and feel. The component can be provided with decorative patterns that are similar to tobacco leaves in production, and can simulate appearance of a real cigar and visual effects of real tobacco of cigarettes. The component has high elasticity, and it is non-toxic and non-pollution. The method can be carried out in a simple manner, and can improve the production efficiency.

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 method comprising injection molding a plastic part from a polymer formulation comprising an injection moldable thermoplastic and an additive, wherein the additive has a decomposition temperature that establishes a maximum processing temperature for the polymer formulation. The additive will thermally decompose to generate gaseous products causing visible bubble formation in the surface of the plastic part in response to exposure to a processing temperature that exceeds the decomposition temperature of the additive. A suitable additive may be, for example, selected from oxalates, carbamic acids, carbonic acids, diazocarbonyl compounds, and combinations thereof.

Abstract: There are provided a forming device capable of drying at a high speed and of manufacturing a thermosetting resin foam plate more efficiently and stably without multilayering any unnecessary surface material, and a method of efficiently manufacturing a thermosetting resin foam plate therefor. A thermosetting resin foam plate is manufactured by: mixing a resin composition containing at least a thermosetting resin, a foaming agent and a curing agent in a mixer; continuously discharging the resin composition on a traveling air-permeable and flexible surface material, and at the same time covering the upper surface of the resin composition with an air-permeable and flexible surface material; and passing the covered resin composition through a forming device equipped with conveyors having apertures having an aperture area ratio of 15% or more and 80% or less to form and cure the resin composition.

Abstract: A mold, a molding machine, and a foamed molded body manufacturing method are provided that are capable of more reliably preventing ingress of foamed resin into a gas discharge hole using a gas-impermeable member and capable of adequately discharging gas inside the cavity to the cavity outside through the gas discharge hole during foam molding, and that are also capable of achieving good design characteristics in a foamed molded body. A gas discharge hole 5 is provided at a cavity 4 inner face of a mold 1 and discharges gas inside the cavity 4 to outside the cavity 4. A gas-permeable member 6 is disposed inside the cavity 4 of the mold 1 so as to cover the gas discharge hole 5, and a gas-impermeable member 8 is disposed on the gas discharge hole 5 side of the gas-permeable member 6 so as to face the gas discharge hole 5.

Abstract: A method of manufacturing foamed thermoplastic films and trash bags wherein a foaming agent is added to a base thermoplastic resin. The resultant foaming agent/base resin mixture is extruded to form a single-ply foamed thermoplastic film. The film may be formed into bag, such as a trash bag.

Abstract: Disclosed herein are methods and pressure vessels for solid-state microcellular processing of thermoplastic rolls and sheets. In one embodiment, the present invention is directed to a method for making a gas impregnated interleaved roll, which method comprises: providing a pressure vessel having an internal pressure chamber and a rotatable shaft horizontally positioned within the pressure chamber; placing an interleaved roll about the rotatable shaft and within the pressure chamber, wherein the interleaved roll is made from a thermoplastic material sheet interleaved together with a gas-channeling material sheet; pressurizing the pressure chamber to a selected pressure; rotating the rotatable shaft having the interleaved roll thereabouts (thereby rotating the interleaved roll) while under pressure for a selected period of time; and depressurizing the internal chamber to yield the gas impregnated interleaved roll.

Abstract: A conductive plastic article (31) is disclosed suited for a housing that offers improved shielding against electromagnetic interference or that offers improved electrostatic discharge properties. The plastic article is made by means of low pressure injection molding. The article (31) comprises at least 0.25 volume percent of electrically conductive additives (38). The article (31) comprises a cellular structure. The cellular structure is created by the use of a blowing or foaming agent. At least 0.25 weight percent of blowing or foaming agent is used in the production of the conductive plastic article (31).

Abstract: A pin or tube reinforced polymeric foam and a method of manufacture thereof. The reinforcing pins or tubes are incorporated into the polymeric foam during or after fabrication of the reinforced polymer foam and are preferably coated with an adhesive or binder layer prior to fabrication.

Abstract: A process for preparing hollow ceramic or metal microspheres, comprising the steps of: forming ceramic or metal slurry, comprising ceramic or metal powders, water and dispersant and having a certain solid phase content, into a stable foam slurry by using a foaming agent; introducing the stable foam slurry into a centrifugal atomization equipment to atomize it into hollow slurry droplets, while being sprayed into a molding chamber; drying rapidly to form hollow microsphere green body; collecting the hollow microsphere green body and sintering. The hollow microsphere prepared has a particle size of 0.001-1.5 mm and high quality and low cost. The process is adapted to produce various inorganic material powders into hollow microspheres. The present invention also provides a device for preparing hollow ceramic or metal microspheres and hollow microspheres.

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 system and method for sintering dental restorations. The system can include a monolithic sintering support comprising a surface, and at least one dental restoration positioned in direct contact with the surface of the monolithic sintering support. The method can include providing a monolithic sintering support comprising a surface, positioning a dental restoration in direct contact with the surface, and sintering the dental restoration while the dental restoration is in direct contact with the surface of the monolithic sintering support to form a sintered dental restoration.

Abstract: A method comprising injection molding a plastic part from a polymer formulation comprising an injection moldable thermoplastic and a fluorescent compound, wherein the fluorescent compound has a decomposition temperature that establishes a maximum processing temperature for the polymer formulation. The fluorescent compound will thermally decompose to generate gaseous products causing visible bubble formation in the surface of the plastic part in response to exposure to a processing temperature that exceeds the decomposition temperature of the fluorescent compound. If the plastic part was processed without exposure to a processing temperature that exceeds the decomposition temperature of the fluorescent compound, then any fluorescent compound within the plastic part will cause the plastic part to fluoresce in response to exposure to black light. A suitable fluorescent compound may be, for example, selected from oxalates, carbamic acids, carbonic acids, diazocarbonyl compounds, and combinations thereof.

Abstract: In one form, the invention is directed to a method for forming a porous implant suitable for a cavity from which tissue has been removed, including mixing soluble alginate and a radiopaque imaging agent with water; incorporating a gas or a pore forming agent into the alginate-water mixture; transferring the alginate-water mixture with the gas or the pore forming agent into a mold to form the mixture into a solid body of desired shape; removing the water from the body; and converting at least part of the soluble alginate to a less soluble alginate. In another form, the invention includes forming a mixture by mixing about 0.5 percent to about 4 percent by weight chitosan into an acidified aqueous solution containing 1 percent to 25 percent by weight acetic acid, along with about 0.5 percent to about 5 percent by weight of a powdered radiopaque imaging agent.

Abstract: A method of manufacturing a porous cementitious product, which method comprises: forming a cementitious premix; casting the premix in a desired configuration; generating gas bubbles within the premix; and curing the premix, wherein gas bubbles are generated and/or collapsed at specific locations within the premix in order to produce a porosity profile along a cross-section of the product such that the product comprises a relatively low density core region and higher density outer regions.

Abstract: Embodiments of the invention described herein thus provide a carvable pumpkin that is durable, can be reused, that has enhanced fire retardance, and that has a bright brilliant color that remains intact upon carving. These improvements help ensure that the pumpkins are safer, such that if they catch fire, they provide a flame barrier and burn out in about a minute or less. The improvements also help provide brightly colored pumpkins that do not have an external coating or layer of paint that can be easily scratched off. Finally, the improvements help provide pumpkins with a substantially uniform skin or otherwise controllable thickness, which can ease carving and provide an enhanced user experience.

Abstract: A foamed and stretched plastic container having a basic structure which includes a mouth portion and a body wall continuous to the mouth portion and is stretch-formed, the body wall forming a foamed region where foamed cells are distributed, and the mouth portion being an unfoamed region where no foamed cell is present, wherein the foamed cells present in the foamed region have a flat shape being stretched in the direction of stretch, and the foamed cells positioned in the central portion in the direction of thickness of the container wall have the largest lengths in the direction of maximum stretch.

Abstract: A method for producing expandable pellets can include introducing a vinyl aromatic polymer and an expandable agent to a pelletizer (L). The pelletizer (L) can have a die plate having a holes of large diameter. During the start-up of the production of the expandable pellets, pellets can be produced in the pelletizer (L). When the polymer flow rate is in the operating range of the pelletizer (S), the introduction of the vinyl aromatic polymer and the expandable agent can be switched from the pelletizer (L) to the pelletizer (S). The pelletizer (S) can be operated at conditions effective to produce the expandable pellets. The pelletizer (S) can have a die plate having holes of small diameter. The expandable pellets can be recovered from the pelletizer (S), and the pellets can be recovered from the pelletizer (L).

Abstract: Two partings are provided, a movable core edge face where core back is performed with a mold plate being configured of multiple plates is provided within the thickness of a component edge face, and a driving unit is provided to a pushing-cut shape and a nipping shape. With a molding process, after filling of a foaming resin, the sub parting moves in the core-back direction by predetermined amount, but a punching insert block, a nipping insert block, a slant core, and an outer slider do not move in the core-back direction, and maintain in a position before core back.

Abstract: A process for manufacturing a self-extinguishing cable including at least one transmissive element and at least one flame-retardant coating in a position radially external to the at least one transmissive element, wherein the at least one coating includes an expanded flame-retardant polymeric material having (a) at least one expandable polymer; (b) at least one expanding agent; (c) at least one flame-retardant inorganic filler, in an amount of 100 parts by weight of 250 parts by weight with respect to 100 parts by weight of the at least one expandable polymer. The process includes the following steps: (i) feeding the flame-retardant polymeric material to an extruding apparatus, therein melting and mixing it; (ii) passing the flame-retardant polymeric material obtained in step (i) through at least one static mixer; and (iii) depositing by extrusion the flame-retardant polymeric material obtained in step (ii) onto the at least one transmissive element conveyed to the extruding apparatus.

Abstract: An object of the present invention is to provide a molded body that is easy to produce and obtained by foaming a polycarbonate copolymer containing, as a raw material, isosorbide that is lightweight and excellent in mechanical properties and like. The present invention relates to a foam-molded body containing a polycarbonate copolymer having a structural unit derived from a dihydroxy compound represented by the following formula (1): and a structural unit derived from other dihydroxy compounds, and having a glass transition temperature (Tg) of less than 145° C.

Abstract: In order to obtain a flame-retardant polyolefin resin expanding molded product which has excellent in-mold moldability and excellent surface appearance and satisfies the FMVSS flammability even if carbon black is added, polyolefin resin particles containing, with respect to 100 parts by weight of polyolefin resin, (i) 0.03 part by weight to 5 parts by weight of phosphorous flame retardant having a phosphorous content of 7% by weight or more, a melting point of 120° C. or more, and a 5% by weight decomposition temperature within a range of 240° C. to 320° C. and (ii) 0.5 part by weight to 20 parts by weight of carbon black are expanded.

Abstract: The invention relates to a biologically degradable composite material and to a process for the preparation thereof. The biologically degradable composite material according to the invention is preferably a bone reconstruction material which can be used in the field of regenerative medicine, especially as a temporary bone defect filler for bone regeneration.

Abstract: One or more of hydrolysed wheat flour, soluble dietary fibre, prebiotic dietary fibre, polydextrose and soluble corn fibre are used as basic matrix-forming ingredients in an expanded food product. The matrix-forming ingredients are mixed together with water, plus a whey protein isolate or whey protein concentrate, to increase the protein content of the food. A dough is formed which is then formed into pieces which are temperature conditioned before being expanded under a vacuum caused by evaporation of moisture in the dough. All steps of the process of making the expanded food products, including any subsequent drying, is carried out at a temperature not exceeding 75° C., which advantageously allows mixing in of temperature sensitive ingredients, e.g. vitamins, pharmaceuticals, at the dough forming stage. The products have a honeycomb structure and there is no significant change in flavour or nutritional value of the ingredients caused by the process of manufacture.

Abstract: An apparatus for producing a porous body that forms an expandable slurry containing at least inorganic powder, a foaming agent, and a binder into a sheet, causes the expandable slurry sheet to be foamed and baked, and thereby produces the porous body, the apparatus includes: a mixer preparing the expandable slurry by containing inorganic powder, a foaming agent, and a binder; a die-coater that has a discharge opening which discharges the expandable slurry provided from the mixer to an external thereof so as to shape the expandable slurry into a sheet; and a carrier sheet arranged so as to face the discharge opening of the die-coater with a gap interposed therebetween, and feeding the expandable slurry discharged from the discharge opening, wherein a flow path of the expandable slurry from inside the mixer to the discharge opening of the die-coater is hermetically sealed from an outside.

Abstract: A foam form sheet material having a first large surface comprising substantially only closed cells and an opposite large surface and an interior comprising substantially only open cells. This material comprises a cross linked olefin thermoplastic polymer or copolymer. The foam is made by mixing the polymer with a blowing agent and a cross linking agent. The mixture is maintained in a two roll mill means for a time sufficient to initiate cross linking and to initiate foaming to form closed cells. The sheet material is then disposed in a second two roll mill means having a nip that is larger than the thickness of the foamed sheet material and maintained under elevated temperature and pressure sufficient to initiate further cross linking and foaming. The fully cross linked cell foam is then compressed to rupture the closed cells that are disposed in the interior to form open cells.

Abstract: A method of fabricating a foamed, injection-molded component is provided. The method includes the step of introducing a liquid, a nucleating agent and a polymer into an injection barrel of an injection molding machine. The liquid, the nucleating agent and the polymer are injected into a mold corresponding in shape to the component and the component is released from the mold.

Abstract: To provide an expansion injection molding process, which is freed from the occurrence of swirl marks on the surface of a molded article and by which foamed injection moldings having good appearance can be produced in a short molding cycle and at a low cost; and a mold for expansion injection molding. A movable mold 2 is moved toward a fixed mold 1, whereby a sealing member 6 set on at least one of a pair of facing surfaces of the mold 1 and mold 2 in the outside of a cavity is brought into contact with the other of the facing surfaces or a sealing member 6 set thereon to make the cavity 3 gas-sealed state. While keeping the gas-sealed state, the movable mold 2 is further moved toward the fixed mold 1 with the sealing member 6 compressed, whereby the volume of the cavity 3 is decreased to enhance the pressure in the cavity 3 to a level exceeding the atmospheric pressure. Then, a thermoplastic resin is injected into the cavity 3 of an enhanced pressure.

Abstract: A method for manufacturing foam core materials comprising locating into a mold a solid activatable material, the activatable material being amenable to plastic deformation and pliable enough to take on the general contours and shape of the mold prior to activation of the activatable material. The method may further include simultaneously activating and shaping the material into a foam core defined by the mold wherein the activatable material conforms to the shape of the mold due to the force of expansion of the activatable material during the activation.

Abstract: Embodiments of the present invention relate to a method of dispensing a porous material and to a method of making a porous material insert for various plant grow pots, plant bowls, and plant baskets, the porous material insert including a growth enhancing element integrated with and dispersed throughout the insert.

Abstract: A method of manufacturing a porous ceramic article is provided that includes injecting a gas into a precursor batch material. The gas is pressurized to a positive gauge pressure. Exemplary gasses that can be injected into the precursor batch material include at least one of nitrogen, helium, neon, argon, krypton, and xenon. Air can also be injected into the precursor batch material, including air in which at least a portion of CO2 and/or O2 naturally occurring in air has been removed.

Abstract: The thermochromic foam cleaning pad of the invention is an artificial sponge made from a foam material that changes firmness or rigidity based on the temperature thereof. The foam also includes thermochromic additives therein that change the color of the foam based on the temperature. This provides a visual indication of the temperature of the foam.

Abstract: In order to achieve the object of providing a mixture by means of which, in particular, sintered moldings can be obtained that are virtually free of surface stains produced by soot particles, a mixture is proposed which comprises at least one pressing aid and at least one additive, wherein the additive is selected from a group of substances which have releasable carbon dioxide.

Abstract: The present invention relates to a process for producing a molded silicone rubber sponge by filling a sponge-forming silicone rubber composition into a cavity of a mold, wherein after the aforementioned sponge-forming silicone rubber composition is cured, and before mold opening of the aforementioned mold, gas present in the aforementioned cavity is discharged. Thereby, a molded silicone rubber sponge without damage such as chips or the like can be effectively produced.

Abstract: A synthetic wicker yarn capable of simulating a rolled leaf style, while being adapted to facilitate weaving. The yarn has an extruded, elongated body fabricated from a blend of a plurality of foamed polymers. The body has a surface of a first color, an x-axis and y-axis along a cross-sectional portion of the elongated body, and a longitudinal z-axis along its length. The x-axis has a first effective diameter and the y-axis has a second effective diameter. The body includes at least two rounded, foamed polymer folds, which project transversely from the x-axis and run longitudinally along a portion of the body. These folds simulate the margins of a leaf wrapped into a roll. Between the folds is a substantially concave crease within the surface of the body, also oriented longitudinally. The effective diameters are configured to form a substantially elliptical cross section that is easy to weave.

Abstract: Process for the production of nanoporous foamed active substance-containing preparations, wherein the active substance is present embedded in a pharmaceutically acceptable polymer, wherein, in stage a) loading of a polymeric molding composition or a polymer melt with a propellant is effected at a pressure and at a temperature at which the propellant is in the supercritical state, in stage b) heating of the laden polymer molding compound or melt is carried out under pressure at a temperature which lies in the range from ?40 to +60° C., preferably ?20 to +55° C., and especially preferably 0 to +50° C. around the glass transition temperature of the unladen (prior to loading) polymeric molding compound and in stage c) a depressurization of the polymeric molding compound or melt laden in stage a) and heated under pressure in stage b) is effected out with a depressurization rate in the range from 15,000 to 200,000 MPa/sec.

Abstract: A single-sided, slip resistant, self-adhesive material is produced using a blown film process which produces a film having an interior layer capable of being treated or coated to accept a pressure sensitive adhesive, a middle layer of flexible polyolefin and an exterior polyolefin elastomer layer in combination with a blowing agent to produce a single-sided slip resistant material. A number of in-line rollers are provided after a pair of rollers, which form part of a machine direction orienter (MDO) that is used in line in the manufacturing process to heat, and then cool and condition (anneal and relieve any stresses and/or thickness inconsistencies) the film prior to the film being coated on one side with a pressure sensitive adhesive.

Abstract: A system for making carbon foam anodes including a digestion vessel in communication with a coal feedstock unit for producing a digested coal; a mold having an interior for accepting the digested coal to produce an ungraphitized carbon foam anode having a desired shape; a pressure unit in communication with the mold for producing an increased pressure within the interior of said mold; a heating element in communication with the mold to provide heat to the mold sufficient to convert the digested coal into the ungraphitized carbon foam anode; and a graphitization oven for graphitizing the ungraphitized carbon foam anode to produce the carbon foam anode. The present invention further includes methods for making carbon foam anodes.

Abstract: A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic materials applied to the plurality of glass fibers is disclosed herein. The process includes the step of enclosing the muffler preform in a chamber. The process also includes the step of surrounding the muffler preform with steam. The process also includes the step of causing steam to enter the muffler preform from multiple directions.

Abstract: A method for making heat-insulated paper containers and the products made by the same. The method includes steps of: (a) mixing and blending polyethylene terephthalate or polypropylene with an adhesive to form a polymer material; (b) heating and extruding the polymer material with an extruder machine to form a film and coating a surface of paper with the film; (c) cooling and laminating the paper with a laminating roller; (d) continuously coating another surface of the paper with a foam material; and then furling the paper after drying; and cutting the paper into a semi-product and then molding into a paper container; (e) heating the foam material with a heating device. The method can enhance the foam uniformity and the production rate, and decrease the defective rate.

Abstract: [Object] To provide an excellent foaming agent which does not have problems in handling and operation (example: risk of explosion or fire) and inhibition of cross-linking resulting from a foaming agent and problems, such as, mold pollution and environmental pollution, caused by a foaming agent residue, which has excellent uniform dispersibility in a subject of foaming, and which can be used as an alternative to the chemical decomposition type foaming agent. [Solution] A foaming agent formed from at least (A) a high molecular compound having a saturated water absorption of 10 to 1,000 g/g in ion-exchanged water (25° C.) and (B) water, wherein a storage modulus (G?) of the agent, determined on the basis of a viscoelasticity measurement at a temperature of 20° C., is 8.0×101 to 1.0×106 Pa at a frequency of 5 rad/s.

Abstract: Methods of forming polymeric foams are provided. The methods may involve co-extruding a foam layer along with one or more skin layers. In some embodiments, the skin layer(s) may be removed (e.g., in a peeling operation); while, in other embodiments, the skin layer(s) may form part of the final article. The methods are particularly well suited for producing polymeric foams from polymeric materials that are considered to be difficult to foam by those of skill in the art.

Abstract: A process for making closed-cell, alkenyl aromatic polymer foams using nano-particle nucleation agents to control the cell morphology of the resulting foam includes forming a polymer melt at a temperature above the polymer glass transition temperature (for crystal polymers) or the polymer melt point (for amorphous polymers); incorporating selected nano-particles into the polymer melt; incorporating blowing agents into the polymer melt at an elevated pressure; optionally incorporating other additives, such as flame retardants, into the polymer melt; and extruding the polymer melt under conditions sufficient to produce a foam product having a desired cell morphology, characterized by parameters such as reduced average cell size range and/or increased asymmetry of the cells.

Abstract: Thermoplastic particle foams which have cells having a mean cell size in the range from 20 to 500 ?m and in which the cell membranes have a nanocellular or fibrous structure having pore or fiber diameters below 1500 nm, and also processes for producing them.