Abstract: A microlayer is provided having a pigment that may include carbon black particles ranging from about 25 nm to about 200 nm in diameter and/or titanium dioxide (Ti02) particles ranging from about 54 nm to about 390 nm in diameter. Such a microlayer may be used in a film that has a core layer adjacent to a substrate layer, which is itself adjacent to an outer layer. The core layer may one or more first multilayers having at least one of carbon black particles ranging from about 25 nm to about 200 nm in diameter and Ti02 particles ranging from about 54 nm to about 390 nm in diameter. Such a film is characterized by an opacity of at least about 90%. A multilayer core layer will result in a film having an Elmendorff tear strength of at least about 27.9 g.

Abstract: Some embodiments of the present invention provides a method of preparing a thermoformed article composed of polylactic acid that includes the steps of providing a foam sheet comprising polylactic acid having a D-lactic acid stereo-isomer content that is about 3 mole % or less, exposing the sheet to a temperature of at least about 190° C., and forming the heated sheet in a mold at a mold temperature that is at least about 50° C. and for a length of time to form a thermoformed article having a PLA crystalline content of at least about 10%. Surprisingly, it has been discovered that heat resistant thermoformed articles can be prepared in accordance with embodiments of the invention wherein the time required for forming the foam sheet into a molded article is less than about 10 seconds.

Abstract: The presently disclosed subject matter relates generally to method of producing thermoplastic foam from a blend of polyolefin and acrylated epoxidized fatty acid using a phsyical blowing agent. Specifically, the presently disclosed subject matter includes embodiments wherein the acrylated epoxidized fatty acid is added to the polyolefin resin in an amount of from about 0.1% to about 10%, based on the total weight of the resin. The presently disclosed subject matter also includes the foam produced by the disclosed method.

Abstract: The presently disclosed subject matter relates generally to method of producing thermoplastic foam from a blend of polyolefin and acrylated epoxidized fatty acid using a phsyical blowing agent. Specifically, the presently disclosed subject matter includes embodiments wherein the acrylated epoxidized fatty acid is added to the polyolefin resin in an amount of from about 0.1% to about 10%, based on the total weight of the resin. The presently disclosed subject matter also includes the foam produced by the disclosed method.

Abstract: A foam comprises (a) starch, (b) plasticizer, (c) compatibilizer, and (d) polyolefin selected from one or more of ethylene homopolymer, ethylene/alpha-olefin copolymer, ethylene/vinyl ester of aliphatic carboxylic acid copolymer, propylene homopolymer, and propylene copolymers. The ratio of A to B is at least 0.01, where A is the sum of the weights of components (a) and (b), and B is the sum of the weights of components (a) though (d). The foam may have a density of at most 10 pounds/cubic foot.

Abstract: Some embodiments of the present invention provides a method of preparing a thermoformed article composed of polylactic acid that includes the steps of providing a foam sheet comprising polylactic acid having a D-lactic acid stereo-isomer content that is about 3 mole % or less, exposing the sheet to a temperature of at least about 190° C., and forming the heated sheet in a mold at a mold temperature that is at least about 50° C. and for a length of time to form a thermoformed article having a PLA crystalline content of at least about 10%. Surprisingly, it has been discovered that heat resistant thermoformed articles can be prepared in accordance with embodiments of the invention wherein the time required for forming the foam sheet into a molded article is less than about 10 seconds.

Abstract: A foam precursor mixture of polylactic acid (PLA) resin having a D-lactic acid content that is about 3 mole % or less; nucleating agent; chain extender; and hydrocarbon blowing agent is provided. The foaming mixture is substantially free of a crosslinking agent. The foam premixture can be used to prepare PLA foams having improved heat resistance, lower densities, smaller cells, and higher cell counts. PLA foams in accordance with the invention may be useful for preparing thermoformed articles such as trays. PLA foamed articles may be prepared that exhibit heat resistance above a temperature of about 49° C. or more, and in particular, a heat resistance at 5 minutes of exposure in excess of about 74° C.

Abstract: The invention is directed to a floor underlayment material comprising a film sheet having an inner surface attached to a foam sheet and an outer surface including a plurality of recesses formed therein. The plurality of recesses define one or more fluid pathways through which a fluid may migrate across the outer surface of the film layer. The underlayment material may be used in a flooring system to help prevent or limit the accumulation of a fluid between the floor and the subfloor. In one embodiment, the underlayment material may be disposed between a subfloor and floor with the outer surface of the film layer being disposed adjacent to the underside of the floor. The one or more fluid pathways provide channels through which a fluid such as moisture vapor may escape from within a flooring system and thereby reduce the accumulation of moisture in the flooring system.

Abstract: The present invention provides a method for producing a UV induced crosslinked foam in which a melt stream comprising a thermoplastic polymer, a UV crosslinking agent and a photoinitiator is crosslinked by exposing the melt stream to a source of UV light source prior to extruding the melt through an extrusion die. Exposing the melt stream to UV light causes the photoinitiator to become excited and react with the crosslinking agent to generate a free radical. The thus generated free radical reacts with the thermoplastic polymer to induce crosslinking in the polymer. Crosslinking of the polymer can be done prior to extrusion so that the crosslinking process can be carried out without additional steps and/or without the aid of chemical crosslinking agents. The invention also provides an apparatus for producing a crosslinked foam in which the apparatus includes a UV chamber disposed between the extruder and the die through which UV light can be introduced into the melt stream.

Abstract: An expanded cellular ethylenic polymer product is provided from an irradiated, noncross-linked linear ethylenic polymer. Linear ethylenic polymers can be irradiated at ambient conditions sufficient to introduce branching in the polymer in the absence of detectable cross-linking as indicated by the absence of gels. The irradiated linear ethylenic polymer is compatible with highly branched low density polyethylene and, when mixed therewith, produces a resin having a single broad based melting temperature range as determined by direct scanning calorimetry, which indicates that the polymers in the mixture have similar crystallization behavior suitable for producing low density foams by extrusion foaming. The linear polymers can be obtained from recycled shrink wrap film. Low densities of from 0.7 to less than 4 pcf can be achieved. The foams typically have improved tear resistance as compared to previous products prepared from low density polyethylene, at comparable low densities.

Abstract: A foam formed from ethylene/vinyl acetate copolymer having a melt index of greater than 1 gram/10 minutes and a vinyl acetate content ranging from about 5 to about 25 weight percent.

Abstract: An extruded thin sheet foam is disclosed prepared from a polyolefin resin in which the blowing agent comprises a blend of from about 1 to 25% by weight of carbon dioxide and the balance of C3 to C4 VOCs. Thin foam sheets produced with the blowing agent age about twice as fast as foams prepared with VOCs, are remarkably stable, and can be produced at high throughputs.

Abstract: A foam and method for making such foam includes a blend of a low density polyethylene and a higher density ethylene polymer. The ethylene polymer has a density ranging from greater than 0.94 to about 0.97 grams/cubic centimeter and a melt flow index of greater than 10 g/10 minutes, and may include at least one member selected from ethylene/alpha-olefin copolymer, ethylene homopolymer, and blends thereof.

Abstract: Flexible sheet materials having a foam layer and a film layer of polymer materials, at least one of the layers being formed from a filled polymer resin composition containing filler material comprising 30% to 65% by weight of the composition. The filled resin composition includes an ethylene copolymer such as ethylene vinyl acetate and may include other polymers such as polyethylene. The film layer provides a vapor barrier function. The layer having the filler provides a sound transmission loss. A preferred embodiment of an underlayment has a filler resin film layer of 6 to 30 mils thickness and a polymer foam layer of 75 mils thickness, the underlayment providing a sound transmission loss of at least about 2.5 dB at 1000 Hz.

Abstract: A composite structure, which generally includes: a. a foam sheet comprising polyolefin; and b. a coating disposed on at least one surface of the polyolefin foam sheet, the coating comprising at least one member selected from ethylene/propylene rubber, homogeneous ethylene/alpha-olefin copolymer, ethylene/acrylic acid copolymer, ethylene/vinyl acetate copolymer, and blends of the foregoing.

Abstract: A foam, comprising a blend of (a) from 0.1 to 4.9 weight percent ethylene/styrene interpolymer; and (b) from 95.1 to 99.9 weight percent polyethylene homopolymer or copolymer.

Abstract: A composite structure, which generally includes: a. a foam sheet comprising polyolefin; and b. a coating disposed on at least one surface of the polyolefin foam sheet, the coating comprising at least one member selected from the group consisting of ethylene/propylene rubber, homogeneous ethylene/alpha-olefin copolymer, and ethylene/acrylic acid copolymer.

Abstract: The invention is a composite pad that is particularly useful in a horse trailer, exercise room, playroom, or the like. The pad has a moisture impermeable and scuff resistant outer skin layer, a cushioning layer, an impact absorbing layer, and a backing layer.

Abstract: An expanded cellular ethylenic polymer product is provided from an irradiated, noncross-linked linear ethylenic polymer. Linear ethylenic polymers can be irradiated at ambient conditions sufficient to introduce branching in the polymer in the absence of detectable cross-linking as indicated by the absence of gels. The irradiated linear ethylenic polymer is compatible with highly branched low density polyethylene and, when mixed therewith, produces a resin having a single broad based melting temperature range as determined by direct scanning calorimetry, which indicates that the polymers in the mixture have similar crystallization behavior suitable for producing low density foams by extrusion foaming. The linear polymers can be obtained from recycled shrink wrap film. Low densities of from 0.7 to less than 4 pcf can be achieved. The foams typically have improved tear resistance as compared to previous products prepared from low density polyethylene, at comparable low densities.

Abstract: The invention is a composite mat that is useful in horse trailers, assembly-line settings, specialty packaging, or the like. The mat has a force distributing upper layer and an impact absorbing layer disposed below the force distributing layer.