Trexel, Inc.

New Balance Athletics, Inc.

Levi A Kishbaugh

Samuel Edward Dix

Jingyi Xu

Juan C Cardona

Kevin J Levesque

Sean Brendon Murphy

Kelvin Tsugio Okamoto

David Edward Pierick

Patrick Y Choe

Theodore A Burnham

Liqin Chen

Albert H Guillemette

Joseph P Vadala, Jr

Samantha Whitney

Scott E Ludwig

David E Pierick

Kelvin T Okamoto

Methods and systems that include introducing blowing agent into a hopper of a polymeric foam processing system.

Blowing agents in polymer foam processing systems

Articles comprising a skin layer comprising virgin polymer and a core layer comprising a recycled polymer, along with associated systems and methods, are generally provided.

Co-injection molding of foam articles

Polymeric foam processing systems and methods.

Polymeric foam processing systems and methods

Methods and systems that include introducing blowing agent into a hopper of a polymeric foam system.

Blowing agent introduction into hopper of polymer foam processing

The invention relates to systems and methods for creating a foamed part. An example method includes providing a polymer processing system, providing a mold having at least one expandable mold cavity in fluid communication with the polymer processing system, mixing polymeric material and blowing agent within the polymer processing system to produce a unfoamed mixture, injecting a volume of the mixture of polymeric material and blowing agent from the polymer processing system and into the expandable mold cavity, and expanding the mold cavity to expand the unfoamed mixture within the mold cavity and form the foamed part.

Injection molding systems and methods for forming materials used in footwear and materials manufactured by said systems and methods

Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.

Method of processing polymers using a single screw

Polymer molding processes, such as injection-molding processes, include use of a viscosity-reducing supercritical fluid additive resulting in less breakage of reinforcing fibers upon introduction into the mold.

Fiber-filled molded articles

The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures. Reduced injection temperature and pressure may widen the processing window, increase flexibility in the selection of substrate materials, and can eliminate the need for a barrier layer that is sometimes used in conventional processes. The method may be used to produce a variety of in-mold decorated articles.

Growing community of inventors

Groveland, MA, United States of America

Levi A Kishbaugh