University of Washington

Corumat, Inc.

Paccar Inc.

Dart Container Corporation

Microgreen Polymers, Inc.

Grow Plastics LLC

Michael Waggoner

Vipin Kumar

Krishna V Nadella

Gregory Lowman Branch

Jake Tyler Ferderer

James David Castner

Brian Aher

Gregory J Tudryn

Zack Kondo

The present invention provides a continuous process for solid-state expansion of a biopolymer, e.g., polylactic acid, which can be used to manufacture reduced-density thermoplastic materials with improved physical and thermal properties. By incorporating multiple stages of heating into the process as a means to regulate heat flux, unprecedented control of microstructure and crystallinity can be achieved. Thermoplastic sheets with the distinct cellular characteristics imparted by the process disclosed herein were found to be thicker and stronger than materials prepared by conventional processes. Thermoforming sheets with such characteristics enabled the production of light-weight, thermally-stable, compostable products that resist warping, and are thus suitable for a range of industrial applications.

Multilayer microcellular compostable bioplastics and their method of manufacture

Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity.

Rapid solid-state foaming

The instant application discloses, among other things, ways to manufacture reduced density thermoplastics. A rapid foaming process which may create a polymer product by saturating thermoplastic sheet or preforms, heating, and then forming into final shape, is described. The polymer product may include an integral solid skin. This method may be utilized with any thermoplastic. The material handling, saturation methods, and end products are also described.

Reduced density thermoplastics

Disclosed, among other things, are ways to manufacture layered structures. In one embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. These processes may be used to generate products with layered structures.

Layered structures

A method for saturating a thermoplastic polymer material includes continuously moving the polymer material through a pressurized pressure vessel. To do this, the method includes sealing the pressure vessel with a series of dynamic seals that allows the polymer material to continuously move through the pressure vessel while maintaining the pressure inside the pressure vessel.

Solid state microcellular foaming method including continuous saturation of solid polymeric material

The invention disclosed herein relates to relates to foamed thermoplastic material objects and articles of manufacture having an internal layered cellular structure, as well as to methods of making the same. In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material sheet, wherein the multi-layer thermoplastic material sheet has first and second discrete outer layers sandwiching a plurality of discrete inner foamed layers, and wherein the two outer layers and plurality discrete inner foamed layers are integral with one another. The thermoplastic material may be a semi-crystalline polymer such as, for example, PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polylactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof. The two outer layers may be unfoamed skin layers having smooth outer surfaces, and the discrete inner foamed layers may be microcellular.

Multi-layered foamed polymeric objects and related methods

A method for making a flat polymer foam having a core layer of nano-sized open, interconnected cells that includes saturating a solid-state polymer with a supercritical fluid, allowing the gas to desorb for at least 35 minutes, and then heating the gas-saturated solid polymer for at least 3 minutes while constraining the foam in the thickness dimension. Any skin layer formed on the exterior may be removed via polishing, thus creating a foam with an open structure from side to side. The foam can be used as a battery separator.

Method to produce nanoporous polymeric membranes

A process for producing cellular thermoplastic articles. The process comprises the steps of treating a solid parison made from a thermoplastic material with a saturating gas at an elevated pressure for a period of time to provide a gas-saturated parison; heating the gas-saturated parison to prepare a cellular parison; placing the cellular parison in a mold; and blowing a molding gas into the cellular parison to expand the cellular parison into the shape of the mold to provide a shaped cellular article.

Methods for blow molding solid-state cellular thermoplastic articles

A flow diffuser for vehicles of the type having an engine and an exhaust pipe generally includes a body including a plurality of inner diffusion ports extending through the body, wherein the body may be attached to an exhaust pipe at or near the exit plane of the exhaust pipe, wherein the body is sized to have a cross-sectional area that is smaller than the cross-sectional area of the exit plane of the exhaust pipe to create a plurality of outer diffusion ports around at least a portion of the outer perimeter of the body when coupled to the exhaust pipe, and one or more extension flaps extending from at least a portion of the outer perimeter of the body.

Exhaust diffuser

The invention disclosed herein relates to relates to foamed thermoplastic material objects and articles of manufacture having an internal layered cellular structure, as well as to methods of making the same. In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material sheet, wherein the multi-layer thermoplastic material sheet has first and second discrete outer layers sandwiching a plurality of discrete inner foamed layers, and wherein the two outer layers and plurality discrete inner foamed layers are integral with one another. The thermoplastic material may be a semi-crystalline polymer such as, for example, PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene napthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polyactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof. The two outer layers may be unfoamed skin layers having smooth outer surfaces, and the discrete inner foamed layers may be microcellular.

A flow diffuser for vehicles of the type having an engine and an exhaust pipe generally includes a body having a first end configured for attachment to an exhaust pipe, and a diffusion portion including first and second diffusion sections, and a plurality of diversion wings disposed within the body.

Exhaust gas diffuser

The invention disclosed herein relates to relates to foamed thermoplastic material objects and articles of manufacture having an internal layered cellular structure, as well as to methods of making the same. In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material sheet, wherein the multi-layer thermoplastic material sheet has first and second discrete outer layers sandwiching a plurality of discrete inner foamed layers, and wherein the two outer layers and plurality discrete inner foamed layers are integral with one another. The thermoplastic material may be a semi-crystalline polymer such as, for example, PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene napthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polylactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof. The two outer layers may be unfoamed skin layers having smooth outer surfaces, and the discrete inner foamed layers may be microcellular.

Growing community of inventors

Seattle, WA, United States of America

Michael Waggoner