Abstract: A process for producing a flexible foam includes introducing a masterbatch material into an extruder, the masterbatch material consisting essentially of one or more thermoplastic polymers that are recycled, recyclable, biodegradable, and/or compostable, mixing an inert gas with the masterbatch material, extruding the masterbatch material through the extruder to form a polymer melt, passing the polymer melt through a die to form an extrudate, and allowing the extrudate to expand into a foam.

Abstract: A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

Abstract: This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories, The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized postconsumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.

Abstract: A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

Abstract: This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories. The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized post-consumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.

Abstract: This document discloses antistatic shoe insoles that include a flexible foam layer and antistatic filaments of textile material interspersed throughout the foam layer and extending passed or exposed at the surface of the shoe insole and methods of making such an antistatic shoe insole. The antistatic filaments are needle punched through the foam layer. The antistatic filaments may be any suitable antistatic material blended with any felt fiber such as wool fiber, cotton fiber, polyester fiber, or the like.

Abstract: This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories. The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized post-consumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.

Abstract: This document discloses antistatic shoe insoles that include a flexible foam layer and antistatic filaments of textile material interspersed throughout the foam layer and extending passed or exposed at the surface of the shoe insole and methods of making such an antistatic shoe insole. The antistatic filaments are needle punched through the foam layer. The antistatic filaments may be any suitable antistatic material blended with any felt fiber such as wool fiber, cotton fiber, polyester fiber, or the like.

Abstract: This document discloses algae-derived flexible foams, whether open-cell or closed-cell, with inherent antimicrobial and flame resistant properties, wherein a process of manufacturing includes the steps of: harvesting algae-biomass; sufficiently drying the algae biomass; blending the dried algae biomass with a carrier resin and various foaming ingredients; adding an algal-derived antimicrobial compound selected from various natural sulfated polysaccharides present in brown algae, red algae, and/or certain seaweeds (marine microalgae); and adding a sufficient quantity of dried algae biomass to the formulation to adequately create a fire resistant flexible foam material.

Abstract: This document presents algae-derived antimicrobial fiber substrates, and a method of making the same. The fiber may be a synthetic fiber, but can also be formed as a cellulosic (e.g., cotton). In various implementations, an algae-derived antimicrobial fiber substrate can be made to have identical properties and characteristics of nylon-6 of nylon 6-6 polymer or the like, and yet contain antimicrobial, anti-viral, and/or flame retardant algal derived substances. Any of various species of red algae, brown algae, blue-green algae, and brown seaweed (marine microalgae and/or macroalgae) are known to contain a high level of sulfated polysaccharides with inherent antimicrobial, antiviral, and flame-retardant properties, and can be used as described herein. Additionally disclosed are algae-derived flexible foams, whether open-cell or closed-cell, with inherent antimicrobial, antiviral, and flame resistant properties.

Abstract: A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.