Abstract: Disposable lid comprises a thermoformed sheet in the shape of a lid for a hot beverage container. The sheet comprises a polymer composite of a polyolefin and at least one mineral filler. The sheet has a thickness less than about 0.035 inches and a heat deflection temperature at least comparable to that of high impact polystyrene.

Abstract: A multilayer polymer composite structure that includes a first layer including a polymer and at least one mineral filler and a second layer including a polymer. A third layer is positioned between the first layer and the second layer, wherein the third layer includes a mixture of material from at least the first and second layers. Preferably, the third layer is formed by recycling and mixing excess material from the multilayer polymer structure. The second layer can further include a colorant. The multilayer polymer structure can also include a fourth and/or fifth layer comprising a high clarity polymer and/or a high gloss polymer that provides a glossy surface or a sealant polymer that provides surface capable of being sealed. In a preferred embodiment, the multilayer polymer structure is thermoformed into a multilayer polymer article such as a container. Preferably, the container is a drinking cup.

Abstract: The present invention provides for a polymer composite foam with a treated filler and methods for making the same. The polymer composite foam includes a polymer capable of being formed into a polymeric foam and a treated filler, wherein the polymer defines a plurality of cells dispersed therethrough and the treated filler is dispersed throughout the polymer. The filler is treated by techniques which exfoliate, delaminate or intercalate the filler particles into individual micro and/or nano size particulates and platelets. Ideally, the treated filler has a median particle size ranging from about 0.1 nm-10 ?m. The treated filler enhances the rigidity, barrier properties, heat deflection temperature, nucleation characteristics, fire retardant characteristics and impact properties of the foam. The products fabricated from the polymer composite foam include containers, cups, sleeves, bags, plates, bowls, protective packaging, boards, sheets, void fillers, storageware, dinnerware and cookware.

Abstract: According to one embodiment, a container comprises a base. The base has a bottom wall and a continuous base wall which encompasses the bottom wall and extends upwardly therefrom. The base is made from a mixture of a polyolefin and a filler. The mixture is from about 30 to about 75 wt. % filler and from about 25 to about 70 wt. % polyolefin. A high aspect ratio filler and a low aspect ratio filler are included in the filler, with the high aspect ratio filler having an aspect ratio of at least 5:1 and the low aspect ratio filler having an aspect ratio of less than about 3:1. The filler comprises at least 50 wt. % of low aspect ratio filler.

Abstract: According to one embodiment, a container comprises a base. The base has a bottom wall and a continuous base wall which encompasses the bottom wall and extends upwardly therefrom. The base is made from a mixture of a polyolefin and a filler. The mixture is from about 30 to about 75 wt. % filler and from about 25 to about 70 wt. % polyolefin. A high aspect ratio filler and a low aspect ratio filler are included in the filler, with the high aspect ratio filler having an aspect ratio of at least 5:1 and the low aspect ratio filler having an aspect ratio of less than about 3:1. The filler comprises at least 50 wt. % of low aspect ratio filler.

Abstract: A continuous chain of connected absorbent pouches comprises a first panel, a second panel, and a super-absorbent material. Each of the absorbent pouches is adapted to absorb liquids. The first panel and the second panel are attached to each other along their respective general peripheries so as to form a space therebetween. The space comprises super-absorbent material. At least one of the first and second panels has at least one hole formed therein. The hole is of sufficient size to be permeable to liquid. Each of the pouches is adapted to absorb at least about 20 times its own weight of a 0.9 wt. % saline solution in an unloaded condition.

Abstract: A continuous chain of connected absorbent pouches comprises a first panel, a second panel, and a super-absorbent material. Each of the absorbent pouches is adapted to absorb liquids. The first panel and the second panel are attached to each other along their respective general peripheries so as to form a space therebetween. The space comprises super-absorbent material. At least one of the first and second panels has at least one hole formed therein. The hole is of sufficient size to be permeable to liquid. Each of the pouches is adapted to absorb at least about 20 times its own weight of a 0.9 wt. % saline solution in an unloaded condition.

Abstract: A process for preparing an injection-molded cutlery The process includes providing a mixture of a filler and a polymer The mixture comprises from about 30 to about 70 wt. % filler and from about 30 to about 70 wt.

Abstract: According to one embodiment, a container comprises a base The base has a bottom wall and a continuous base wall which encompasses the bottom wall and extends upwardly therefrom. The base is made from a mixture of a polyolefin and a filler. The mixture is from about 30 to about 75 wt. % filler and from about 25 to about 70 wt. % polyolefin. A high aspect ratio filler and a low aspect ratio filler are included in the filler, with the high aspect ratio filler having an aspect ratio of at least 5:1 and the low aspect ratio filler having an aspect ratio of less than about 3:1. The filler comprises at least 50 wt. % of low aspect ratio filler.

Abstract: According to one embodiment, a container comprises a base. The base has a bottom wall and a continuous base wall which encompasses the bottom wall and extends upwardly therefrom. The base is made from a mixture of a polyolefin and a filler. The mixture is from about 30 to about 75 wt. % filler and from about 25 to about 70 wt. % polyolefin. A high aspect ratio filler and a low aspect ratio filler are included in the filler, with the high aspect ratio filler having an aspect ratio of at least 5:1 and the low aspect ratio filler having an aspect ratio of less than about 3:1. The filler comprises at least 50 wt. % of low aspect ratio filler.

Abstract: A continuous chain of connected absorbent pouches comprises a first panel, a second panel, and a super-absorbent material. Each of the absorbent pouches is adapted to absorb liquids. The first panel and the second panel are attached to each other along their respective general peripheries so as to form a space therebetween. The space comprises super-absorbent material. At least one of the first and second panels has at least one hole formed therein. The hole is of sufficient size to be permeable to liquid. Each of the pouches is adapted to absorb at least about 20 times its own weight of a 0.9 wt. % saline solution in an unloaded condition.

Abstract: A process for preparing an injection-molded cutlery. The process includes providing a mixture of a filler and a polymer. The mixture comprises from about 30 to about 70 wt. % filler and from about 30 to about 70 wt. % polymer. The mixture is heated to its melting temperature and then injected into a mold. The mixture is cooled so as to form the cutlery. The cutlery is ejected from the mold.

Abstract: A blowing agent for foaming polystyrene consisting essentially of at least one low permeability compound (preferably a volatile organic compound (VOC)), at least one low volatility compound (preferably a non-VOC) and, optionally, at least one high volatility compound (preferably a non-VOC). In one embodiment, the low permeability volatile organic compound is selected from the group consisting of isopentane and isobutane, the low volatility non-volatile organic compound is acetone and the high volatility non-volatile organic compound is carbon dioxide. The blowing agent of the present invention may be used to foam a polystyrene foam structure. The blowing agent is directed to achieving low fugitive VOC emissions.

Abstract: A blowing agent for foaming polystyrene consisting essentially of at least one low permeability volatile organic compound, at least one low volatility non-volatile organic compound and, optionally, at least one high volatility non-volatile organic compound. In one embodiment, the low permeability volatile organic compound is selected from the group consisting of isopentane and isobutane, the low volatility non-volatile organic compound is acetone and the high volatility non-volatile organic compound is carbon dioxide. The blowing agent of the present invention may be used to foam a polystyrene foam structure. The blowing agent is directed to achieving low fugitive volatile organic compounds (VOC) emissions.

Abstract: A polystyrene resin in foam form having a basis weight of less than about 20 g/100 in.sup.2 and a density of about 6 lbs./ft.sup.3 or less, the foam precursor of which is either a polystyrene having a melt index of about 8 or more or a polystyrene in combination with a minor proportion of any other material which will result in a melt index of about 8 or more. A method of forming such a polystyrene resin foam structure includes combining the resin in molten form under pressure with the blowing agent of at least approximately 100% carbon dioxide and extruding the mixture through a die into an atmosphere of reduced pressure to form the foam structure.

Abstract: A polystyrene resin in foam form having a basis weight of less than about 20 g/100 in.sup.2 and a density of about 6 lbs./ft.sup.3 or less, the foam precursor of which is either a polystyrene having a melt index of about 8 or more or a polystyrene in combination with a minor proportion of any other material which will result in a melt index of about 8 or more. A method of forming such a polystyrene resin foam structure includes combining the resin in molten form under pressure with the blowing agent of at least approximately 100% carbon dioxide and extruding the mixture through a die into an atmosphere of reduced pressure to form the foam structure.

Abstract: A thermoforming oven for the convection heating of a continuous web of a thermoplastic foam or film material which is being advanced through the oven towards a thermoformer. Moreover, there is disclosed to a method for the improved and more uniform convective heating of a thermoplastic foam or film material which is advanced through a thermoforming oven. A countercurrent flow of a gaseous heating medium is regulated and directed so as to impart the greatest degree of uniformity of temperature thereto during heating and blow-up to the thermoplastic material being advanced in an intermittent manner through the convective oven.

Abstract: A method for forming a molded thermoplastic foam structure comprising partially filling a mold with solvent imbibed particles of a thermoplastic resin, pressurizing said mold under conditions such as to prevent vaporization of said blowing agent during subsequent polymer melting, heating said polymer to a flowable state, releasing the mold pressure to permit foaming of the melt and expansion of the foamed polymer within the mold.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.

Abstract: A foam structure having a density of less than about 20 lbs/ft.sup.3. The method of forming the same comprising forming a homogeneous melt blend under pressure of a polymer member selected from the group consisting of polyetherimide resin particles, polycarbonate resin particles, a polymer blend of polyphenylene oxide and polystyrene in particle form imbibed with a blowing agent, followed by extrusion of the same into a lower pressure atmosphere. A composition comprising said particles imbibed with methylene chloride, chloroform, 1,1,2-trichloroethane or mixtures thereof. A method of thermoforming said foam in sheet form.