# US 8,877,331 B2 · Multi-layered foamed polymeric objects having segmented and varying physical properties and related methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,877,331 B2 - Document ID: US8877331B2 - Status: Granted - Kind: B2 - Application number: 12/566,520 - Filed: 2009-09-24 - Published: 2010-03-11 - Granted: 2014-11-04 - Earliest claimed: 2007-01-17 - Assignees: MicroGREEN Polymers, Inc.; University of Washington - Applicants: Krishna Nadella; Xiaoxi Wang - Inventors: Krishna Nadella; Xiaoxi Wang - Web page: https://patentgrep.com/patent/US8877331B2 ## CPC - B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} - B32B 1/00: Layered products having a non-planar shape - B32B 1/08: Tubular products - B32B 5/142: {Variation across the area of the layer} - B32B 5/145: {Variation across the thickness of the layer} - B32B 5/20: foamed in situ - B32B 5/22: characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)} - B32B 5/32: {at least two} layers being foamed {and next to each other} - B32B 7/02: Physical, chemical or physicochemical properties - B32B 7/025: Electric or magnetic properties - B32B 7/027: Thermal properties - B32B 27/065: {of foam} - B32B 27/281: {comprising polyimides} - B32B 27/285: {comprising polyethers} - B32B 27/288: {comprising polyketones} - B32B 27/308: {comprising acrylic (co)polymers} - B32B 27/36: comprising polyesters - B32B 27/365: {comprising polycarbonates} - B32B 2266/0214: Materials belonging to B32B27/00 - B32B 2266/0242: Acrylic resin - B32B 2266/0264: Polyester - B32B 2266/08: Closed cell foam - B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers - B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material - B32B 2307/20: having particular electrical or magnetic properties, e.g. piezoelectric - B32B 2307/30: having particular thermal properties - B32B 2307/50: having particular mechanical properties - B32B 2307/546: Flexural strength; Flexion stiffness - B32B 2307/702: Amorphous - B32B 2307/704: Crystalline - B32B 2307/72: Density - B32B 2457/00: Electrical equipment - B32B 2553/00: Packaging equipment or accessories not otherwise provided for - Y10T 428/1376: Foam or porous material containing - Y10T 428/1393: Multilayer [continuous layer] - Y10T 428/2495: Thickness [relative or absolute] - Y10T 428/249961: With gradual property change within a component - Y10T 428/249976: Voids specified as closed - Y10T 428/249977: Specified thickness of void-containing component [absolute or relative], numerical cell dimension or density - Y10T 428/249978: Voids specified as micro - Y10T 428/249979: Specified thickness of void-containing component [absolute or relative] or numerical cell dimension - Y10T 428/249981: Plural void-containing components - Y10T 428/249989: Integrally formed skin - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The invention relates to foamed thermoplastic material articles of manufacture having an internal layered cellular structure (with segmented and varying physical properties across one or more dimensions). In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture having a plurality of discrete physical properties segmented across one or more dimensions, comprising: a non-laminated multi-layer polymeric object having at least one discrete outer layer positioned adjacent to a plurality of discrete inner foamed layers, wherein the at least one discrete outer layer and the plurality of discrete inner foamed layers are integral with one another, and wherein the at least one discrete outer layer has an outer layer physical property and each of the plurality of discrete inner foamed layers has a respective inner foamed layer physical property, wherein the outer layer physical property and the inner foamed layer physical property are different from each other. ## Claims ### Claim 1 A multi-layer foamed polymeric article of manufacture having a plurality of different thermal and electrical properties segmented across one or more dimensions, comprising: a non-laminated multi-layer thermoplastic material object having at least one discrete outer unfoamed skin layer positioned adjacent to a plurality of discrete inner foamed layers, wherein the thermoplastic material object has a crystallinity gradient such that: the crystallinity of the plurality of discrete inner foamed layers is less than the crystallinity of the at least one discrete outer unfoamed skin layer, and the crystallinity of the inner foamed layer closest to the discrete outer unfoamed skin layer is more than the crystallinity of an inner-foamed layer disposed further away from the discrete outer unfoamed skin layer, wherein the at least one discrete outer unfoamed skin layer and the plurality of discrete inner foamed layers are integral with one another, wherein the plurality of discrete inner foamed layers each have a thickness that is greater than the thickness of the discrete outer unfoamed skin layer, and wherein the at least one discrete outer unfoamed skin layer has an outer skin layer physical property and each of the plurality of discrete inner foamed layers has a respective inner foamed layer physical property, wherein the outer skin layer physical property and the inner foamed layer physical property are different from each other. ### Claim 2 (depends on 1) The multi-layer foamed polymeric article of manufacture according to claim 1 wherein the thermoplastic material object is a semi-crystalline polymer, an amorphous polymer, or a combination thereof. ### Claim 3 (depends on 2) The multi-layer foamed polymeric article of manufacture according to claim 2 wherein the thermoplastic material is a polymer selected from the group consisting of PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene napthalate), PBT (polybutylene terphthalate), PLA (polyactide), PEI (polyetherimide), PEKK (polyetherketoneketone), polycarbonate, and blends thereof. ### Claim 4 (depends on 3) The multi-layer foamed polymeric article of manufacture according to claim 3 wherein each of the plurality of discrete inner foamed layers is microcellular. ### Claim 5 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the multi-layer thermoplastic material object is in the form of a multi-layer polymeric sheet, a multi-layer polymeric sphere, or a multi-layer polymeric cylinder. ### Claim 6 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the multi-layer thermoplastic material object is a multi-layer polymeric sheet, wherein the plurality of discrete physical properties vary in a step-wise manner across the thickness of the sheet. ### Claim 7 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the multi-layer thermoplastic material object is a multi-layer polymeric sheet, wherein the plurality of discrete physical properties vary in a step-wise manner across the surface of the sheet. ### Claim 8 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the outer skin layer physical property has a first dielectric constant and the inner foamed layer physical property has a second dielectric constant, wherein the first dielectric constant is greater than the second dielectric constant. ### Claim 9 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the outer skin layer physical property has a first heat capacity and the inner foamed layer physical property has a second heat capacity, wherein the first heat capacity is greater than the second heat capacity. ### Claim 10 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the at least one discrete outer unfoamed skin layer has a smooth outer surface. ### Claim 11 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the plurality of discrete inner foamed layers include two substantially identical second inner foamed layers, each positioned immediately adjacent to a respective one of two outer skin layers. ### Claim 12 (depends on 11) The multi-layer foamed polymeric article of manufacture according to claim 11 wherein the second inner foamed layers each include a first plurality of closed cells, wherein the first plurality of closed cells have an average cell diameter ranging from about 5 to 10 microns. ### Claim 13 (depends on 11) The multi-layer foamed polymeric article of manufacture according to claim 11 wherein the plurality of discrete inner foamed layers include a third inner foamed layer positioned immediately adjacent to and interposed between the second inner foamed layers. ### Claim 14 (depends on 11) The multi-layer foamed polymeric article of manufacture according to claim 11 wherein the plurality of discrete inner foamed layers include two substantially identical third inner foamed layers, each positioned immediately adjacent to a respective one of the second inner foamed layers. ### Claim 15 (depends on 14) The multi-layer foamed polymeric article of manufacture according to claim 14 wherein the third inner foamed layers each include a second plurality of closed cells, wherein the second plurality of closed cells have an average cell diameter ranging from about 30 to about 50 microns. ### Claim 16 (depends on 15) The multi-layer foamed polymeric article of manufacture according to claim 15 wherein the plurality of discrete inner foamed layers include a central fourth inner foamed layer positioned immediately adjacent to and interposed between the third inner foamed layers. ### Claim 17 (depends on 16) The multi-layer foamed polymeric article of manufacture according to claim 16 wherein the fourth inner foamed layer includes a third plurality of closed cells, wherein the third plurality of closed cells have an average cell diameter ranging from about 20 to about 40 microns. ### Claim 18 (depends on 4) The multi-layer foamed polymeric article of manufacture according to claim 4 wherein the density and stiffness of the multi-layer thermoplastic material sheet are graded across the sheet such that the outermost layers of the plurality of discrete inner foamed layers have the greatest density and stiffness of the plurality of discrete inner foamed layers. ### Claim 19 A multi-layer polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material object having at least one discrete outer unfoamed skin layer positioned adjacent to a plurality of discrete inner foamed layers, wherein the thermoplastic material object has a crystallinity gradient such that: the crystallinity of the plurality of discrete inner foamed layers is less than the crystallinity of the at least one discrete outer unfoamed skin layer, and the crystallinity of the inner foamed layer closest to the discrete outer unfoamed skin layer is more than the crystallinity of an inner foamed layer disposed further away from the discrete outer unfoamed skin layer, wherein the at least one outer unfoamed skin layer and the plurality of inner foamed layers are integral with one another, wherein each of the plurality of inner foamed layers has a thickness greater than the thickness of the outer unfoamed skin layer, wherein each of the plurality of inner foamed layers is populated with microcellular bubbles of about the same shape, with each layer having an average bubble size that is different than any adjacent layer, and wherein the at least one discrete outer unfoamed skin layer has a dielectric constant and each of the plurality of discrete inner foamed layers has a respective dielectric constant, wherein the dielectric constant of each of the outer and inner layers is different than the dielectric constant of each of the other outer and inner layers. ### Claim 20 (depends on 19) The multi-layer polymeric article of manufacture of claim 19 wherein the plurality of inner foamed layers include a first layer immediately adjacent to the at least one outer skin layer and a second layer immediately adjacent to the first layer. ### Claim 21 (depends on 20) The multi-layer polymeric article of manufacture of claim 20 wherein the plurality of inner foamed layers include a third layer immediately adjacent to the second layer. ### Claim 22 (depends on 21) The multi-layer polymeric article of manufacture of claim 21 wherein the first layer is populated with microcellular bubbles of about 1 to about 20 microns in average size. ### Claim 23 (depends on 22) The multi-layer polymeric article of manufacture of claim 22 wherein the second layer is populated with microcellular bubbles of about 15 microns to about 200 microns in average size. ### Claim 24 (depends on 23) The multi-layer polymeric article of manufacture of claim 23 wherein the second layer is populated with microcellular bubbles of about 50 microns to about 200 microns in average size. ### Claim 25 (depends on 24) The multi-layer polymeric article of manufacture of claim 24 wherein the thermoplastic material is a semi-crystalline polymer or an amorphous polymer. ### Claim 26 A multi-layer polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material object having: at least one first outer unfoamed skin layer having a first dielectric constant, at least one second discrete inner foamed layer having a second dielectric constant, at least one third discrete inner foamed layer having a third dielectric constant, wherein the at least one second discrete inner foamed layer is closer to the at least one first outer unfoamed skin layer than the at least one third discrete inner foamed layer, wherein the thermoplastic material object has a crystallinity gradient such that: the crystallinity of the at least one second discrete inner-foamed layer is less than the crystallinity of the at least one first outer unfoamed skin layer, and the crystallinity of the at least one third discrete inner-foamed layer is less than the crystallinity of the at least one second discrete inner-foamed layer, wherein the at least one first outer unfoamed skin layer and the second and third inner foamed layers are integral with one another, wherein the second and third inner foamed layers each has a thickness greater than the thickness of the first outer unfoamed skin layer, wherein the first dielectric constant is greater than the second dielectric constant, and wherein the second dielectric constant is greater than the third dielectric constant. ### Claim 27 (depends on 26) The multi-layer polymeric article of manufacture of claim 26 wherein the thermoplastic material is a semi-crystalline polymer or an amorphous polymer.