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US 10,800,136 B2Granted
Layered structures
AssigneeCorumat, Inc.
InventorMichael Waggoner
Life of this patent
Estimating the term…
Abstract
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.
Claims35
An article, comprising:
- a non-laminated polymer sheet including at least 60% by weight of a polylactic acid polymer material, the non-laminated polymer sheet having a first outer region, a second outer region, and an inner region disposed between the first outer region and the second outer region,
- the first outer region and the second outer region including cells having a dimension of 50 micrometers or less, and
- the inner region including cells having a dimension of at least 51 micrometers,
- wherein the non-laminated polymer sheet withstands deformation when at least one of the first outer region and the second outer region are exposed to a temperature of at least 180° F., and
- wherein the cells in the first outer region, the second outer region, and the inner region are formed by heating the non-laminated polymer sheet after the non-laminated polymer sheet has been exposed to a gas at a pressure of greater than 500 PSI for a predetermined time period, the predetermined time period sufficient to at least partially saturate the non-laminated polymer sheet with the gas, and less than 15 minutes.
2 more elements
The article of 8, wherein the filler is talc.
An article, comprising:
- a non-laminated polymer sheet including at least 60% by weight of a polylactic acid polymer material, the non-laminated polymer sheet having a first outer region, a second outer region, and an inner region disposed between the first outer region and the second outer region,
- the first outer region and the second outer region including a first plurality of cells having a dimension of 50 micrometers or less, and
- the inner region including a second plurality of cells having a dimension of at least 51 micrometers,
- wherein the first plurality of cells and the second plurality of cells are formed by heating the non-laminated polymer sheet after the non-laminated polymer sheet has been exposed to a gas at a pressure of greater than 500 PSI for a predetermined time period sufficient to at least partially saturate the non-laminated polymer sheet with the gas, and less than 15 minutes.
1 more element
An article, comprising:
- a non-laminated polymer sheet including at least 60% by weight of a polylactic acid polymer material, the non-laminated polymer sheet having a first outer region, a second outer region, and an inner region disposed between the first outer region and the second outer region,
- the first outer region and the second outer region including a first plurality of cells having a dimension of 50 micrometers or less, and
- the inner region including a second plurality of cells having a dimension of at least 51 micrometers,
- wherein the cells in the first outer region, the second outer region, and the inner region are formed by heating the non-laminated polymer sheet after the non-laminated polymer sheet has been exposed to a gas at a pressure of greater than 500 PSI for a predetermined time period, the predetermined time period sufficient to at least partially saturate the non-laminated polymer sheet with the gas, and less than 15 minutes.
1 more element
An article, comprising:
- a non-laminated polymer sheet including at least 60% by weight of a polylactic acid polymer material, the non-laminated polymer sheet having a first outer region, a second outer region, and an inner region disposed between the first outer region and the second outer region,
- the first outer region and the second outer region including a first plurality of cells having a dimension of 50 micrometers or less, and
- the inner region including a second plurality of cells having a dimension of at least 51 micrometers,
- wherein the cells in the inner region are elongated, and
- wherein the cells in the first outer region, the second outer region, and the inner region are formed by heating the non-laminated polymer sheet after the non-laminated polymer sheet has been exposed to a gas at a pressure of greater than 500 PSI for a predetermined time period, the predetermined time period sufficient to at least partially saturate the non-laminated polymer sheet with the gas, and less than 15 minutes.
2 more elements
Dependencies are inferred from the claim text.