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: Three-dimensional (3D) suction molding methods and related polymeric foam articles are described. The methods may be used in discontinuous plastication processes.

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 present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.

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 present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.

Abstract: The present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.

Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.

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.