Abstract: An apparatus (un-interleaver) for unwinding a roll of material interleaved with another material, and for separating the materials, includes a first platform, a second platform, a tension-sensor, an edge-sensor, and a controller. The controller monitors signals generated by the tension sensor and the edge sensor, and in response to the signals: a) causes the speed at which the second platform rotates to change to maintain a predetermined tension in the second material as the second material travels from the first platform toward the second platform, and b) causes the second platform to move relative to the first platform to align the edge of the second material traveling toward the roll of second material with the edge of the second material in the roll.

Abstract: A method for generating a microstructure that includes microcellular bubbles, in a material that includes molecules of a thermoplastic polymer, comprises: determining a size-index for the material that represents an average size of the thermoplastic polymer molecules included in the material, and in response to the determined size-index, setting a parameter of a process to generate a microstructure in the material that includes microcellular bubbles. The process to generate a microstructure in the material includes: 1) infusing into the material, during a first period, a gas that does not react with the material, 2) making the gas-infused material thermodynamically unstable.

Abstract: An apparatus (un-interleaver) for unwinding a roll of material interleaved with another material, and for separating the materials, includes a first platform, a second platform, a tension-sensor, an edge-sensor, and a controller. The controller monitors signals generated by the tension sensor and the edge sensor, and in response to the signals: a) causes the speed at which the second platform rotates to change to maintain a predetermined tension in the second material as the second material travels from the first platform toward the second platform, and b) causes the second platform to move relative to the first platform to align the edge of the second material traveling toward the roll of second material with the edge of the second material in the roll.

Abstract: An apparatus (un-interleaver) for unwinding a roll of material interleaved with another material, and for separating the materials, includes a first platform, a second platform, a tension-sensor, an edge-sensor, and a controller. The controller monitors signals generated by the tension-sensor and the edge-sensor, and in response to the signals: a) causes the speed at which the second platform rotates to change to maintain a predetermined tension in the second material as the second material travels from the first platform toward the second platform, and b) causes the second platform to move relative to the first platform to align the edge of the second material traveling toward the roll of second material with the edge of the second material in the roll.

Abstract: A method for generating a microstructure that includes microcellular bubbles, in a material that includes molecules of a thermoplastic polymer, comprises: determining a size-index for the material that represents an average size of the thermoplastic polymer molecules included in the material, and in response to the determined size-index, setting a parameter of a process to generate a microstructure in the material that includes microcellular bubbles. The process to generate a microstructure in the material includes: 1) infusing into the material, during a first period, a gas that does not react with the material, 2) making the gas-infused material thermodynamically unstable.

Abstract: An apparatus (un-interleaver) for unwinding a roll of material interleaved with another material, and for separating the materials, includes a first platform, a second platform, a tension-sensor, an edge-sensor, and a controller. The controller monitors signals generated by the tension-sensor and the edge-sensor, and in response to the signals: a) causes the speed at which the second platform rotates to change to maintain a predetermined tension in the second material as the second material travels from the first platform toward the second platform, and b) causes the second platform to move relative to the first platform to align the edge of the second material traveling toward the roll of second material with the edge of the second material in the roll.

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: 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: 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: 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 process for producing cellular thermoplastic articles. The process comprises the steps of treating a solid parison made from a thermoplastic material with a saturating gas at an elevated pressure for a period of time to provide a gas-saturated parison; heating the gas-saturated parison to prepare a cellular parison; placing the cellular parison in a mold; and blowing a molding gas into the cellular parison to expand the cellular parison into the shape of the mold to provide a shaped cellular article.

Abstract: A material comprises a first layer that includes a thermoplastic polymer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The material also includes a second layer including a thermoplastic polymer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The material also includes an interface layer formed by fusion bonding the first layer to the second layer, the interface layer having a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that is at least 100 micrometers long.

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: 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 container comprises a wall and a bottom. The wall includes a thermoplastic polymer material, and forms a cylindrical shape. The thermoplastic polymer material has a microstructure that includes a plurality of closed cells, each cell containing a void and each cell having a maximum dimension extending across the void within the cell that ranges between 1 micrometer and 200 micrometers long. The bottom is joined to an end of the cylindrical shape to close the end such that the beverage and/or other items disposed inside the cylindrical shape don't escape through the end of the shape.

Abstract: Methods for reducing the density of thermoplastic materials and the articles made therefrom having similar or improved mechanical properties to the solid or noncellular material. Also disclosed are improvements to foaming methods and the cellular structures of the foams made therefrom, and methods for altering the impact strength of solid or noncellular thermoplastic materials and the shaping of the materials into useful articles.

Abstract: Methods for reducing the density of thermoplastic materials and the articles made therefrom having similar or improved mechanical properties to the solid or noncellular material. Also disclosed are improvements to foaming methods and the cellular structures of the foams made therefrom, and methods for altering the impact strength of solid or noncellular thermoplastic materials and the shaping of the materials into useful articles.

Abstract: Methods for reducing the density of thermoplastic materials and the articles made therefrom having similar or improved mechanical properties to the solid or noncellular material. Also disclosed are improvements to foaming methods and the cellular structures of the foams made therefrom, and methods for altering the impact strength of solid or noncellular thermoplastic materials and the shaping of the materials into useful articles.

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: A process for producing cellular thermoplastic articles. The process comprises the steps of treating a solid parison made from a thermoplastic material with a saturating gas at an elevated pressure for a period of time to provide a gas-saturated parison; heating the gas-saturated parison to prepare a cellular parison; placing the cellular parison in a mold; and blowing a molding gas into the cellular parison to expand the cellular parison into the shape of the mold to provide a shaped cellular article.