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: 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: The present invention relates to apparatuses and methods for making interleaved cylindrical rolls from a polymer roll and a porous roll. The interleaved rolls disclosed herein are useful for subsequent high pressure gas impregnation and solid-state foam processing. In one embodiment, an interleaving apparatus comprises: a first rotatable platform for unwinding a first cylindrical roll of a first sheet material, the first rotatable platform being rotatable about a first central axis; a second rotatable platform for unwinding a second cylindrical roll of a second sheet material, the second rotatable platform being rotatable about a second central axis; and a third rotatable platform for winding, while the first and second materials are unwinding, the first sheet material together with the second sheet material to yield the interleaved cylindrical roll, the third rotatable platform being rotatable about a third axis and proximate to the first and second rotatable platforms.

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: Disclosed herein are roll fed air heated flotation ovens and related thermoforming systems, assemblies, and machines that enable the corrugation-free expansion of a gas impregnated thermoplastic web passing through an oven chamber (without use of a pin-chain assembly), as well as to related methods. In an embodiment, a gas impregnated thermoplastic web is conveyed and expanded through an elongated air heated oven chamber, wherein the elongated oven chamber includes a plurality of downwardly directed heated air nozzles positioned at regular intervals along and within the upper portion of the oven chamber, and a plurality of upwardly directed heated air nozzles positioned at regular intervals along and within the lower portion of the oven chamber, but staggered apart from the downwardly directed heated air nozzles such that the gas impregnated thermoplastic material web undulates in an up and down wavelike fashion, thereby minimizing sagging, bagging, puckering, and/or buckling of the web.

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: 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.

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: Disclosed herein are roll fed air heated flotation ovens and related thermoforming systems, assemblies, and machines that enable the corrugation-free expansion of a gas impregnated thermoplastic web passing through an oven chamber (without use of a pin-chain assembly), as well as to related methods. In an embodiment, a gas impregnated thermoplastic web is conveyed and expanded through an elongated air heated oven chamber, wherein the elongated oven chamber includes a plurality of downwardly directed heated air nozzles positioned at regular intervals along and within the upper portion of the oven chamber, and a plurality of upwardly directed heated air nozzles positioned at regular intervals along and within the lower portion of the oven chamber, but staggered apart from the downwardly directed heated air nozzles such that the gas impregnated thermoplastic material web undulates in an up and down wavelike fashion, thereby minimizing sagging, bagging, puckering, and/or buckling of the web.

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: 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 (polylactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof.

Abstract: The present invention relates to apparatuses and methods for making interleaved cylindrical rolls from a polymer roll and a porous roll. The interleaved rolls disclosed herein are useful for subsequent high pressure gas impregnation and solid-state foam processing. In one embodiment, an interleaving apparatus comprises: a first rotatable platform for unwinding a first cylindrical roll of a first sheet material, the first rotatable platform being rotatable about a first central axis; a second rotatable platform for unwinding a second cylindrical roll of a second sheet material, the second rotatable platform being rotatable about a second central axis; and a third rotatable platform for winding, while the first and second materials are unwinding, the first sheet material together with the second sheet material to yield the interleaved cylindrical roll, the third rotatable platform being rotatable about a third axis and proximate to the first and second rotatable platforms.

Abstract: Disclosed herein are methods for making expanded foamed polymeric panels from solid monolithic semi-crystalline thermoplastic material sheets having a first thickness, density, and volume. In one embodiment, the method comprises: absorbing an effective amount of a plasticizing gas into the semi-crystalline thermoplastic material sheet to yield a reversibly plasticized semi-crystalline thermoplastic material sheet that is differentially impregnated with the plasticizing gas to define a non-uniform gas concentration gradient across the initial first thickness; and heating the plasticized semi-crystalline thermoplastic sheet to yield the foamed polymeric panel, wherein the foamed polymeric panel comprises (1) a second thickness that is at least about three and half times greater than the first initial thickness, and (2) a non-uniform second density level that is less than the first density level.

Abstract: This invention provides packages and containers produced by a solid state method for the manufacture of foamed polymeric material. The packages are suitable for pre-cooking or sterilization, insulated transport, cooking vessel, reheating, and storage of food. The gas impregnated thermoforming (GIT) process includes interleaving an article of raw polymeric material with a gas channeling means; exposing the article to a non-reacting gas at elevated pressure to achieve a desired concentration of gas within the polymer, thereby forming a partially gas-saturated article, separating it from the gas channeling means, then decompressing, foaming and forming it at a temperature below the material's melt temperature; and finally trimming it to produce a finished foamed polymeric material and recyclable scrap solid state process foamed polymer.