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: It is an object of the present invention to provide a method for easily and economically producing an expansion-molded polypropylene-based resin article stably with a high porosity, that has continuous voids and that can be used as materials such as a sound absorbing material and a draining material. More specifically, the present invention relates to a method for producing an expansion-molded polypropylene-based resin article, in which a mold is filled with expanded polypropylene-based resin particles, and the expanded particles are heated and fused using water vapor, and then cooled, wherein expanded polypropylene-based resin particles are used in which a polypropylene-based resin having a melt index (MI) of not less than 0.1 g/10 minutes and not more than 9 g/10 minutes is used as a base resin, a cell size is not more than 150 ?m, two melting peaks are present on a DSC curve obtained by differential scanning calorimetry, and ?/(?+?) is not less than 0.35 and not more than 0.

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: After introducing gas into a cavity of a clamped die to boost a pressure therein, a resin material containing a foaming agent is injected. After forming a skin layer, at the same time as a start of a core-back operation for foaming the resin material or after the core-back operation, gas in the cavity is vacuum-suctioned to make a pressure in the cavity less than the atmospheric pressure. By cooling and solidifying, an injection foam molded article is obtained. Before complete solidification, gas between the resin material and an inner surface of the die is reliably discharged out of the cavity, so that surface recesses and generation of swirl marks due to gas accumulation can be prevented.

Abstract: A foam play article comprises: an elastic tube for forming an elastic rubber layer; a foam formed by foaming polyurethane materials (2) in the elastic tube (1); and a coating layer (7) coated on the elastic rubber layer. The article may be manufactured by a method which comprises: providing polyurethane foam materials; attaching a material injector (5) to an elastic tube (1); injecting a predetermined amount of the polyurethane foam materials to the elastic tube (1) through the material injector (5); placing the elastic tube (5) in a mold (6) to provide a foam therein; applying a coating layer onto an outer surface of the foam; and drying the coated foam. The-thus formed play article has superior surface gloss, improved waterproof, soft tactile sensation, and higher stability.

Abstract: Method for fabricating a structure in the form of a plate, and structure in the form of a plate, in particular formed from silicon, including at least one substrate, a superstrate and at least one intermediate layer interposed between the substrate and the superstrate, in which the intermediate layer comprises at least one base material having distributed therein atoms or molecules termed extrinsic atoms or molecules which differ from the atoms or molecules of the base material, and in which a heat treatment is applied to said plate so that, in the temperature range of said heat treatment, the intermediate layer is plastically deformable and the presence of the selected extrinsic atoms or molecules in the selected base material causes the irreversible formation of micro-bubbles or micro-cavities in the intermediate layer.

Abstract: A pre-expanded polypropylene resin particle can be produced in the following manner: a polypropylene resin particle produced by an under water cut method, water, a dispersing agent, and a foaming agent are charged in a pressure-resistant container, the resulting mixture is heated to a temperature equal to or higher than the softening temperature of the polypropylene resin particle to allow the polypropylene resin particle to be impregnated with the foaming agent under pressure, and the resulting product is released into the atmosphere having a pressure lower than the pressure of the inside of the pressure-resistant container. As the polypropylene resin composition, a composition is used which comprises 100 parts by weight of a polypropylene resin and 1 to 20 parts by weight of a polyethylene resin having a melt viscosity of 10 to 2000 mPa·s at 140° C.

Abstract: The method of the present invention is adapted to foam and crosslink a raw material including a rubber, a crosslinking agent and a foaming agent. The method includes the following steps: (1) a first crosslinking and foaming step, placing the raw material into a first mold, crosslinking and foaming the raw material to form a pre-molded body; (2) a second crosslinking and foaming step, withdrawing the pre-molded body from the first mold, placing the pre-molded body into a second mold after the pre-molded body being cooled down, crosslinking and foaming the pre-molded body to form a molded body; and (3) a third crosslinking and foaming step, withdrawing the molded body from the second mold, placing the molded body into a heating device after the molded body being cooled down, crosslinking and foaming the molded body to form a product.

Abstract: The method of manufacturing an article having a surface, a skin, and a core includes closing a first mold portion on a compressible seal. The seal is disposed between the first and second mold portions. The portions define a pressurizable mold cavity having a spaced apart injection port and a vent. The mold cavity is pressurized at a first pressure greater than atmospheric pressure. Molten plastic and blowing agent are injected form gas cells within the mixture. The gas cells have an internal pressure exceeding the first pressure. After waiting for a first period, the pressurizing gas is vented for a second period at a rate sufficient to rupture the gas cells which form a skin adjacent to the mold cavity wall. The skin defines a core cavity filled with the foamed mixture, which is solidified. The mold portions are separated releasing the article.

Abstract: Methods are disclosed for improving the storage performance of polymeric stents that reduce or eliminate the effects of long term aging on the properties of the stents. A polymeric stent or a polymeric tube from which a stent is made is heated to a temperature between ambient and the glass transition temperature of the polymer for a period of time. The heating causes densification or an increase in density of the polymer which stabilizes the properties of the polymer in later processing steps and storage. The stent can be made from a polymeric tube that is expanded at a temperature above the glass transition temperature and cooled to maintain an expanded diameter.

Abstract: Optionally reinforced, lightweight microcellular polyamide shaped articles, e.g., automotive body or interior parts, are produced by injection molding a polyamide matrix in the presence of a fluid in the supercritical state.

Abstract: A process for the production of an open-cell carbon foam from a metallic salt of a lignosulfonate is described. The process includes heating the metallic salt of a lignosulfonate from ambient temperature to a maximum temperature, greater than about 250° C., at a rate sufficiently slow as to provide for essentially uniform heating of the lignin derived material. Heating of the lignin derived material is performed in a non-oxidizing atmosphere having a pressure greater than about 100 psig. The resultant carbon foam can subsequently be optionally subjected to carbonization or graphitization temperatures as desired. The resultant carbon foam has a regular open-cell structure. Densities of the carbon foam products are commonly in the range of about 0.1 g/cm3 to 0.2 g/cm3. The carbon foams may also exhibit compressive strengths of up to about 200 psi. The carbon foam materials potentially have utility as lightweight thermal barriers and in many other of the applications associated with carbon foams.

Abstract: A glass run channel having an elongated shape, which is mounted on a window frame of a vehicle door, guides moving up and down of a windowpane and is made of a polymer material, the glass run channel including a run channel main body that forms the main part of the glass run channel, the run channel main body including, a base bottom portion, an interior side wall portion, an exterior side wall portion, an interior seal lip and an exterior seal lip, wherein the run channel main body has a foamed part made of a foamable polymer material that includes a thermoplastic elastomer material and thermal expansion capsules, and has foaming cells which are formed by expansion of the thermal expansion capsules, and wherein a water absorption rate of the foamed part of the run channel main body is adjusted to 5% or less.

Abstract: A method for the manufacture of a molding composition from a raw material melt which is charged with an additive includes the steps: charging a conveyor apparatus with a raw material which includes a liquid or gooey pasty composition or a granulate; converting the raw material into a raw material melt by heat supply to the raw material; charging the raw material melt with an additive; mixing of the raw material melt with the additive to produce a molding composition; and discharging the molding composition from the conveyor apparatus. The charging of the raw material melt with the additive takes place through a metering device which is arranged in a passage section of the conveyor apparatus and/or subsequent to the conveyor apparatus with the raw material melt flowing through and/or around the passage section. The metering device includes at least one metering element which is arranged in a recess of the passage section.

Abstract: A process for making a container comprises injection molding a polymer preform having a non-reactive gas entrapped within the walls thereof; cooling the preform to a temperature below the polymer softening temperature, the cooled preform having an initial material volume; reheating the cooled preform to a temperature greater than the polymer softening temperature; and blow molding the reheated preform, to prepare a container consisting essentially of a microcellular foamed polymer having a non-reactive gas contained within the foam cells, wherein the material volume of the container is greater than the initial material volume of the cooled preform measured at the same temperature.

Abstract: An earpiece of flexible foam construction which incorporates recycled pulverized polyurethane foam (RPPF). RPPF constituting 5% to 30% of the improved foam has been found to be useful. The novel and unique nature of RPPF allows for the replacement of a higher cost component with a lower cost component while maintaining or improving physical properties, such as sound attenuation, sound control, comfort and fit.

Abstract: A process for making foamed glasses and ceramics from sol-gels is disclosed. The method includes preparing a mixture of reactants capable of forming a sol-gel with addition of a catalyst to control the condensation stage followed by foaming using vigorous agitation in the presence of surfactants. The gelled bodies are aged, dried, and thermally stabilized to obtain a consolidated macroporous material. The resulting structure comprises a three-dimensional network of spherical open pores that are thoroughly interconnected. The process may involve sol-gel systems using a mixture of metal alkoxides, and may produce glasses in unary systems (SiO2), binary systems (70% mol SiO2-30% mol CaO), and ternary systems (60% mol SiO2, 36% mol CaO, 4% mol P2O5). The macro-porous material has pores in the 10-500 ?m range and has potential for use as matrix in tissue engineering, in bone repair, and in organ regeneration.

Abstract: The invention provides a polyurethane foam manufactured from a polyisocyanate and a polycarbonate polyol. Moreover, the invention provides a method of manufacturing the polyurethane foam manufactured from a polyisocyanate and a polycarbonate polyol, comprising mixing the polyisocyanate and polycarbonate polyol together and foaming same.

Abstract: Fire-resistant, medium density molded polyurethane foams which may be removed from a mold in substantially shorter times than previously possible are produced by the process of the present invention. These reduced de-mold times are achieved by including a solid flame retardant composition in the polyurethane foam forming composition. This solid flame retardant composition includes a melamine coated ammonium polyphosphate and zinc borate.

Abstract: A method of manufacturing a foam having a negative Poisson's ratio comprising the steps: placing a pad 12 of open cell polyurethane foam on a moulding surface 4; placing a flexible membrane 18 over the exposed surface of the foam to create a sealed chamber 20 between the moulding surface 4 and the flexible membrane 18 in which the foam pad 12 is disposed; applying an isostatic pressure difference between the inside and the outside of the chamber 20 thereby collapsing the foam pad 12 between the flexible membrane 18 and the moulding surface 4; heating the foam pad 12 to a predetermined temperature, and subsequently cooling the foam pad 12 while collapsed.

Abstract: An object of the invention is to provide a method for manufacturing a molded foam which is lightweight and excellent in strength. According to the invention, a method for manufacturing a molded foam from a foamed parison includes: an extruding step of extruding a resin blend containing a foaming agent and a thermoplastic resin to form a foamed parison; an attaching step of closely attaching facing portions of an inner wall surface of the foamed parison to each other to form a foamed parison laminated body; a mold clamping step of sealing and mold clamping the foamed parison laminated body by clamping the foamed parison laminated body by split mold blocks; and a sucking step of sucking air between the split mold blocks to reduce a pressure between the split mold blocks, after the attaching step and the mold clamping step.

Abstract: A method of compression molding a plastic article, such as a closure, includes providing a molten polymeric material, comprising a mixture of at least one molten polymer and a gas blended therein. The polymeric material is molded between cooperating male and female molds, with relative movement of the molds controlled to form a mold cavity with a predetermined volume. Formation in this manner acts to produce a molded closure with substantially reduced density, thus achieving desired material savings, while still providing a closure or like article exhibiting desired performance characteristics.

Abstract: A process for forming plastic articles is described which uses a machine (10) having a pair of hingedly-connected female moulds (12, 14), which can be heated and cooled and which can be clamped together. The process involves placing a plastic particulate material in each mould (12, 14) when they are in an open position and heating the moulds (12, 14) to form a plastic skin (58, 60) lining each mould (12, 14). An expandable filler material (62) is then placed in one mould and the two moulds clamped closed to form a completely closed cavity. The plastic skins in the two moulds bond together to form a continuous plastic shell (66) completely encasing the filler material (62).

Abstract: The present invention relates to a process for producing a molded silicone rubber sponge by filling a sponge-forming silicone rubber composition into a cavity of a mold, wherein after the aforementioned sponge-forming silicone rubber composition is cured, and before mold opening of the aforementioned mold, gas present in the aforementioned cavity is discharged. Thereby, a molded silicone rubber sponge without damage such as chips or the like can be effectively produced.

Abstract: Porous ceramic articles may be produced by using a gas as a pore former, where the gas is injected into a ceramic precursor batch material and mixed. Pressure is then applied to mixture such that the gas liquefies. The pressure is maintained during formation of a green body, maintaining the gas in a liquefied state. After formation of the green body, the pressure is removed whereby the gas returns to a gaseous state, creating pores in the green body. The green body may then be fired to produce a porous ceramic article.

Abstract: A method to produce a conductive transfer roller, and the transfer roller. The method to produce the conductive transfer roller includes adding and mixing a conductive substance, an ionic conductive agent, a vulcanizing agent, and a blowing agent and at least one of elastic materials selected from a group consisting of EPMD (ethylene propylene) rubber, NBR (acrylonitrile butadiene) rubber, ECO (epichlorohydrin ethylene oxide) rubber, and CR (chloroprene rubber), extruding the compound, blowing the extruded material by passing it through a continuous mobile foaming device, pressing the foam onto a shaft and applying a secondary curing, and grinding the foam to a desired thickness.

Abstract: A (meth)acrylic pressure-sensitive adhesive foam reduced in the amount of a foaming adjuvant compared with the conventional foam and having a high air bubble content, and a method for producing the same are provided. The foam includes a partial polymer having (a) one or more alkyl (meth)acrylate monomers having one reactive unsaturated group, the alkyl group having 12 or less carbon atoms, (b) a monomer for crosslinking, which is copolymerizable with the component (a), and (c) a copolymer of the component (a) and the component (b); a thermally conductive filler; and a foaming adjuvant containing surface modified nanoparticles having a particle diameter of 20 nm or less, wherein a crosslinked structure containing the component (c) is formed in the curable composition.

Abstract: Foamed thermoplastic polymeric mechanical planarization polishing pads (“MP pads”) made with supercritical fluids are presented. A supercritical fluid foaming agent is dissolved in a thermoplastic polymer. A rapid change in the solubility and volume of the supercritical fluid foaming agent in the thermoplastic polymer results in foaming of the thermoplastic polymer. Foamed thermoplastic polymeric MP pads are advantageously both significantly and uniformly porous.

Abstract: Two or more different materials such as food material are co-extruded through adjacent orifices of an extruder. The flows of the two materials are cut in a direction transverse to the flow to form segments of flow. These segments are interspersed so as to join upstream and downstream of each segment of first material to a segment of a second material. Generally two rows of joined segmented flows are extruded side by side. Preferably between the two rows is formed a boundary cell wall which usually is transformed to a harder material after extrusion. Cell walls of the harder material may surround, in two or three dimensions, cells of softer or foamed material. The apparatus and method to provide the food product having the cell-like structure is particularly useful for producing confectionery products formed of chocolate, marzipan or dough materials.

Abstract: An apparatus for injection molding products from a mass including at least natural mono or polymers, provided with at least one mold cavity (2) and a deaeration channel (10) at least partly surrounding the mold cavity (2), wherein, between the deaeration channel and the mold cavity an overflow (8) space is provided which, on the one side, is in communication with the deaeration channel and, on the other side, with the mold cavity (2).

Abstract: Process for continuous manufacture of an unlimited length latex foam block including at least two layers to form after successive cross cuts resting articles such as mattresses, cushions and parts of such articles. At least a first and second latex foam mixture with different characteristics among them are separately prepared and sent consecutively at a predetermined distance from each other on a laying surface in continuous progress. The second mixture is deposited on the already shaped first layer. The first and the second layers are gelatinized concurrently at the same place. The two layers are directly joined to each other along the contact surface by mechanical co-penetration of appendices of the one into micro-cavities of the other and by reciprocal tack of the two layers latex particles following breaking of the protective barrier between particles during gelatinizing.

Abstract: The present invention relates to an anti-termite styrofoam heat insulation material which is safe for use with humans and animals and method for making the same. The material contains the insecticide Thiamethoxam.

Abstract: A container comprises a micro cellular foamed polymer, and a non-reactive gas contained within the micro cellular foam cells, wherein the container has a silvery appearance. The process for making the container comprises injection molding a polymer preform having a non-reactive gas entrapped within the walls thereof, cooling the preform to a temperature below the polymer softening temperature, reheating the preform to a temperature above the polymer softening temperature, and blow molding the preform, to prepare a container comprising a micro cellular foamed polymer having a non-reactive gas contained within the micro cellular foam cells.

Abstract: A method for combining materials (such as impregnating materials with functional materials) uses a combination of supercritical fluid technology and polymer melt processing technology. The functional material is soluble in a near supercritical or supercritical fluid, which dissolves in the matrix/bulk material during melt processing. Controlling the processing conditions facilitates a change of state for the fluid, which results in the precipitation of the functional material in the bulk material. The impregnated bulk material may be shaped using conventional polymer based processing techniques such as extrusion and injection moulding.

Abstract: The invention relates to a solid powdery composition comprising unexpanded thermally expandable microspheres including a thermoplastic polymer shell encapsulating a propellant and from about 0.1 to about 50 wt % of at least one inhibitor selected from the group consisting of acids having a melting point below about 200° C. and precursors therefore. The invention further relates to preparation and use thereof, a composition comprising a polymeric resin, preparation thereof, a process for working a polymeric resin and a material obtainable thereby.

Abstract: The present invention describes a process and respective installation for continuous production of foamed polymeric sheets by extrusion, another object of the invention being the development and use of polypropylene-based formulations comprising linear polypropylenes and branched polypropylenes. The installation includes four stages: a first stage of extrusion foaming, in which a foaming agent, either of a chemical or physical nature, in the latter case introduced in supercritical conditions, is mixed with the polymeric mass melted previously in the first stages of the extruder, the material expanding exactly at the outlet of the lips of the planar extrusion head; a second stage of calibration and cooling of the foamed sheet, in which the expanded plastic material is cooled by contact in a system of vacuum calibrators and by contact with water in a cooling bath; a stage of collection of the foamed panel; and a final stage of cutting of the foamed sheet, defining the final dimensions thereof.

Abstract: A process for the preparation of expandable styrene polymers having a molecular weight Mw of greater than 170,000 g/mol, which comprises conveying a blowing agent-containing styrene polymer melt having a temperature of at least 120° C. through a die plate with holes whose diameter at the die exit is at most 1.5 mm, and subsequently granulating the extrudate, and expandable styrene polymers (EPS) having a molecular weight Mw of more than 170,000 g/mol with 0.05 to 1.5% by weight of internal water.

Abstract: The present invention provides a steam room of a foamed resin molding machine that is superior in terms of heat insulation property and durability, a foamed resin molding machine, and a method for molding a foamed resin. At least one of frames, back plates and center plates that together constitute steam rooms of a foamed resin molding machine are made of foamed aluminum. Alternatively, foamed aluminum plates are laminated onto the frames or the back plates are constituted into a sandwiched structure that incorporates interposed foamed aluminum plates, respectively. The foamed aluminum is advantageous in that its high heat insulation property prevents waste in thermal energy of steam, and other merits include reductions in cycle times.

Abstract: A method of injection molding produces a microcellular material. In this method, a polymer is melted and blended with a supercritical fluid to produce a single-phase polymer-gas solution. This solution is injected through a nozzle and into a mold. When injected through the nozzle, gas in the solution (from the supercritical fluid) emerges from the polymer, which then solidifies. In emerging from the solution, the gas causes the nucleation of cells that result in a microcellular structure. A foam material comprises a polymer having a microcellular structure formed by the nucleation of micro-cells. The micro-cells are formed by the dispersing of a supercritical fluid in a liquid solution of the polymer when the polymer is subjected to a pressure drop. A feminine hygiene device is fabricated from a foamed polymer.

Abstract: A method of producing a hydrophilic polyurethane foam structure containing a silver salt, chosen from the group of silver sulphate, silver citrate, silver acetate, silver carbonate, silver lactate and silver phosphate, or a mixture of these salts includes the steps of (a) providing a water phase containing a surfactant, and at least one silver salt, wherein the at least one silver salt is dispersed in the water phase; (b) providing a isocyanate-terminated polyether having functionality of more than (2); (c) mixing the water phase and the isocyanate-terminated polyether, immediately transferring the resulting mixture to a mould whereby a foam structure is obtained; and (d) drying the foam structure until it has a moisture content of at most 10% (wt). The hydrophilic polyurethane foam structure produced by the method and a wound dressing containing the foam structure are also described.

Abstract: An example molding method includes: feeding a molten foamable resin by injection in a cavity formed in a molding die; allowing the molten foamable resin to flow in the cavity; and foaming and solidifying the molten foamable resin to mold a resin foam product. The example molding method performs flow rate control by controlling a flow rate of the molten foamable resin at a welding portion to be equal to or higher than a flow rate of the molten foamable resin at an upstream portion adjacent to the welding portion.

Abstract: An apparatus (1) for continuously forming a continuous element (2) made of expanded plastic material comprises: a loading section (8) of a loose mass of granules made of expandable plastic material; a sintering section (16) of the continuous element (2) made of expanded plastic material extending downstream of the loading section (8); a stabilizing section (17) of the continuous element (2) made of expanded plastic material extending downstream of the sintering section (16); a forming runnel (18) extending along the sintering (16) and stabilizing (17) sections and defined between a pair of lateral walls (19, 20) and a pair of gas permeable conveyor belts (21, 22), respectively lower and upper, supported by respective supporting tracks (23, 24).

Abstract: An injection-foaming molding process for manufacturing a formed article by injecting a molten resin containing a foaming agent into a cavity of a mold being retained in an openable state and then expanding the cavity by opening the mold to allow the resin to foam includes: i) a step of discontinuing a cavity of a mold from a resin-reserving section located at front end of a screw immediately after the completion of injection of a molten resin containing an expandable resin into the mold cavity; and ii) a step of keeping the resin-reserving section under pressure at least equal to back pressure for charging during a period from the completion of injection to start of charging the molten resin containing the expandable resin for next shot, decreasing pressure in the resin-reserving section to back pressure for charging, and then starting the charging.

Abstract: The apparatus is provided for impregnating a melt of polymer with a fluid working medium, such as, an expanding agent or an additive. Impregnation is carried out for the purpose of manufacturing foamed shaped parts using an injection molding machine. The impregnating body includes at least one melt channel formed in a gas permeable segment and a channel system for fluid infeed. The gas permeable material, e.g. sintered metal, separates the fluid from the stream of melt in the melt channel(s). Each melt channel has open pores at its inner surface which enable the impregnation. The melt channels can contain static mixers in the stream of melt to promote the distribution of the diffused fluid in the flow of melt.

Abstract: The invention relates to a process and a device for the production of polyurethane clock foam, in which the reaction mixture, after flowing through a mixer, flows freely from an outflow opening and then flows through an accumulation chamber, in which a static pressure is built up, a gap and finally an expansion chamber.

Abstract: A carbon-containing modified polystyrene type resin particle of the present invention includes: a carbon-containing polypropylene type resin, and a polystyrene type resin in an amount of not less than 100 parts by weight but less than 400 parts by weight per 100 parts by weight of the carbon-containing polypropylene type resin, wherein the polystyrene type resin ratio at the central part of the particle is at least 1.2 times the polystyrene type resin ratio of the overall particle, the polystyrene type resin ratio being calculated by using the ratio (D698/D1376) of absorbances at 698 cm?1 and 1376 cm?1 which are obtained by infrared absorption spectra measured by ATR infrared spectroscopic analysis.

Abstract: This invention relates to fire-resistant, flexible, molded, medium density polyurethane foams. These foams typically have a density of from 10 to 30 pcf. The foams are the reaction product of a) at least one polyester polyol, b) at least one highly branched polyether polyol, c) at least one chain extender, d) a polymethylene poly(phenyl isocyanate), an isocyanate group containing prepolymer based on a polymethylene poly(phenyl isocyanate), or mixtures thereof, e) a solid flame retardant and f) water. This invention also relates to a process for preparing these polyurethane foams in open molds.

Abstract: A method of forming a composition of expanded polylactic acid (PLA) resin beads comprising impregnating PLA resin beads with CO2 and holding the impregnated beads at a temperature and pressure that prevents the beads from foaming while allowing the level of impregnated CO2 to reduce. The method may comprise pre-expanding the beads at a pre-expansion temperature. Promptly following pre-expansion or after a desired storage period, the method may comprise introducing the pre-expanded beads into a mould and further expanding and fusing the beads in the mould by application of a temperature greater than the temperature used for pre-expansion. Preferred moulded products include moulded blocks and shaped moulded products, especially blocks adapted to form packing material. Other preferred moulded products include convenience items such as containers including clamshell containers, pots, boxes, bowls, cups, plates and trays.

Abstract: The invention relates to a plant and a process for the production of foam in a continuous slabstock process in which the actual foam height profile is detected transversely to the feed direction and a correcting variable for the slabstock process based on deviation of the actual foam height profile from a desired foam height profile is determined.

Abstract: Disclosed herein are roll fed air heated flotation ovens and related thermoforming systems, assemblies, and machines that enable the corrugation-free expansion of a gas impregnated thermoplastic web passing through an oven chamber (without use of a pin-chain assembly), as well as to related methods. In an embodiment, a gas impregnated thermoplastic web is conveyed and expanded through an elongated air heated oven chamber, wherein the elongated oven chamber includes a plurality of downwardly directed heated air nozzles positioned at regular intervals along and within the upper portion of the oven chamber, and a plurality of upwardly directed heated air nozzles positioned at regular intervals along and within the lower portion of the oven chamber, but staggered apart from the downwardly directed heated air nozzles such that the gas impregnated thermoplastic material web undulates in an up and down wavelike fashion, thereby minimizing sagging, bagging, puckering, and/or buckling of the web.