Abstract: The present invention provides a continuous process for solid-state expansion of a biopolymer, e.g., polylactic acid, which can be used to manufacture reduced-density thermoplastic materials with improved physical and thermal properties. By incorporating multiple stages of heating into the process as a means to regulate heat flux, unprecedented control of microstructure and crystallinity can be achieved. Thermoplastic sheets with the distinct cellular characteristics imparted by the process disclosed herein were found to be thicker and stronger than materials prepared by conventional processes. Thermoforming sheets with such characteristics enabled the production of light-weight, thermally-stable, compostable products that resist warping, and are thus suitable for a range of industrial applications.

Abstract: Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example.

Abstract: A seating assembly includes a seat and an upright coupled with the seat. A pliable backrest is coupled with the upright and includes a support face and a coupling face. The pliable backrest includes a pliable material extending between the support and coupling faces. The support face is a first exterior face of the pliable back rest and the coupling face is a second exterior face of the pliable back rest. The coupling face is spaced away from the upright with a deformation gap. Another seating assembly includes a joint assembly along the upright member. The joint assembly includes a pivot configured to promote rotation of a first upright portion of the upright relative to a second upright portion. The joint assembly includes opposed stop interfaces configured to control rotation of the first upright portion relative to the second upright portion.

Abstract: The instant application discloses, among other things, ways to manufacture reduced density thermoplastics. A rapid foaming process which may create a polymer product by saturating thermoplastic sheet or preforms, heating, and then forming into final shape, is described. The polymer product may include an integral solid skin. This method may be utilized with any thermoplastic. The material handling, saturation methods, and end products are also described.

Abstract: A seating assembly includes a seat and an upright coupled with the seat. A pliable backrest is coupled with the upright and includes a support face and a coupling face. The pliable backrest includes a pliable material extending between the support and coupling faces. The support face is a first exterior face of the pliable back rest and the coupling face is a second exterior face of the pliable back rest. The coupling face is spaced away from the upright with a deformation gap. Another seating assembly includes a joint assembly along the upright member. The joint assembly includes a pivot configured to promote rotation of a first upright portion of the upright relative to a second upright portion. The joint assembly includes opposed stop interfaces configured to control rotation of the first upright portion relative to the second upright portion.

Abstract: A seating assembly includes a seat and an upright coupled with the seat. A pliable backrest is coupled with the upright and includes a support face and a coupling face. The pliable backrest includes a pliable material extending between the support and coupling faces. The support face is a first exterior face of the pliable back rest and the coupling face is a second exterior face of the pliable back rest. The coupling face is spaced away from the upright with a deformation gap. Another seating assembly includes a joint assembly along the upright member. The joint assembly includes a pivot configured to promote rotation of a first upright portion of the upright relative to a second upright portion. The joint assembly includes opposed stop interfaces configured to control rotation of the first upright portion relative to the second upright portion.

Abstract: A seating assembly includes a seat and an upright coupled with the seat. A pliable backrest is coupled with the upright and includes a support face and a coupling face. The pliable backrest includes a pliable material extending between the support and coupling faces. The support face is a first exterior face of the pliable back rest and the coupling face is a second exterior face of the pliable back rest. The coupling face is spaced away from the upright with a deformation gap. Another seating assembly includes a joint assembly along the upright member. The joint assembly includes a pivot configured to promote rotation of a first upright portion of the upright relative to a second upright portion. The joint assembly includes opposed stop interfaces configured to control rotation of the first upright portion relative to the second upright portion.

Abstract: Disclosed, among other things, are ways to manufacture layered structures. In one embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. These processes may be used to generate products with layered structures.

Abstract: The instant application discloses, among other things, ways to manufacture reduced density thermoplastics. A rapid foaming process which may create a polymer product by saturating thermoplastic sheet or preforms, heating, and then forming into final shape, is described. The polymer product may include an integral solid skin. This method may be utilized with any thermoplastic. The material handling, saturation methods, and end products are also described.

Abstract: A method for saturating a thermoplastic polymer material includes continuously moving the polymer material through a pressurized pressure vessel. To do this, the method includes sealing the pressure vessel with a series of dynamic seals that allows the polymer material to continuously move through the pressure vessel while maintaining the pressure inside the pressure vessel.

Abstract: Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example.

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 naphthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polylactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof.

Abstract: Disclosed, among other things, are ways to manufacture layered structures. In one embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. These processes may be used to generate products with layered structures.

Abstract: Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example.

Abstract: A method for making a flat polymer foam having a core layer of nano-sized open, interconnected cells that includes saturating a solid-state polymer with a supercritical fluid, allowing the gas to desorb for at least 35 minutes, and then heating the gas-saturated solid polymer for at least 3 minutes while constraining the foam in the thickness dimension. Any skin layer formed on the exterior may be removed via polishing, thus creating a foam with an open structure from side to side. The foam can be used as a battery separator.

Abstract: A composite material includes a core and a shell that covers the core. The core has a volume that includes a first material and a void wherein the first material occupies less than 50% of the core's volume and has a three-dimensional shape that includes a plurality of components each having the same shape and arranged to form a series of repeating components within the volume. The shell includes a second material joined to the first material. Each of the first and second materials includes a thickness having a middle region and a outer region, and at least one of the first and second materials, includes a microstructure.

Abstract: A putting alignment tool includes a pair of spaced, telescoping arms each having an upper end and a lower end. The upper ends are joined with a horizontal bubble level having a divot-repair fork hingedly attached thereto. Magnetically attached to the divot-repair fork is a ball marker. The lower ends of the arms are joined with a weighted ball that maintains the tool in a vertical orientation when the tool is suspended. Accordingly, a golfer extends the arms to a desired length and suspends the tool by grasping the upper end. The bubble level allows the golfer to verify that the weighted arms are indeed vertical. Then, the ball and cup are framed between the two arms to determine the optimum putting path.

Abstract: The instant application discloses, among other things, ways to manufacture reduced density thermoplastics. A rapid foaming process which may create a polymer product by saturating thermoplastic sheet or preforms, heating, and then forming into final shape, is described. The polymer product may include an integral solid skin. This method may be utilized with any thermoplastic. The material handling, saturation methods, and end products are also described.