Composite particles, compositions and foam compositions containing composite particles, articles, and methods of making and using same

A method of making a foam composition, the method comprising:

• a. compressing a mixture, the mixture comprising an uncrosslinked thermoplastic matrix material and a plurality of composite particles distributed in the uncrosslinked thermoplastic matrix material, wherein the mixture exhibits an elastic modulus of 0.5 megaPascals (MPa) or greater, and wherein the plurality of composite particles each comprises:
• i. a chemical blowing agent particle encapsulated within a shell comprising an uncrosslinked thermoplastic material, wherein the uncrosslinked thermoplastic material exhibits a complex viscosity of 3,700 Pa·s or greater at a decomposition temperature of the chemical blowing agent particle and wherein the uncrosslinked thermoplastic material has a glass transition temperature below the decomposition temperature of the chemical blowing agent;
• and
• b. heating the compressed mixture, thereby forming the foam composition.

A method of making a foam composition, the method comprising:

• a. casting a mixture in a mold, the mixture comprising an uncrosslinked thermoplastic matrix material and a plurality of composite particles distributed in the uncrosslinked thermoplastic matrix material, wherein the mixture exhibits an elastic modulus of 0.5 megaPascals (MPa) or greater, and wherein the plurality of composite particles each comprises:
• i. a chemical blowing agent particle encapsulated within a shell comprising an uncrosslinked thermoplastic material, wherein the uncrosslinked thermoplastic material exhibits a complex viscosity of 3,700 Pa·s or greater at a decomposition temperature of the chemical blowing agent particle and wherein the uncrosslinked thermoplastic material has a glass transition temperature below the decomposition temperature of the chemical blowing agent;
• and
• b. heating the cast mixture, thereby forming the foam composition.