Update October 2015

A. Table of Contents

Contents

A. Table of Content ...... 1

B. Editorial ...... 2

C. News ...... 6

D. Patents and Journals ...... 11

a. New Foaming Technique: ...... 11

b. Blowing Agents: ...... 15

c. Foam products: ...... 15

d. Applications: ...... 17

e. Degradable and Sustainable Foam: ...... 21

f. Thermoset Foam; PU and Others: ...... 22

g. Microcellular and Expanded Particle: ...... 27

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Foam Update October 2015

B. Editorial

Foams 2015

Foams 2015 hosted by Society of Engineers (SPE) and co-hosted by Japan Society of Processing was presented at Kyoto University; tutorial Sep. 8-9, and Conference Sep. 10-11. It drew over 170 attendees from all over the world; a record in the foam conference since the nineties. 18 exhibitions including 10 gold sponsors were also quite impressive. Professor Oshima and his team did a wonderful job in organizing and administrative job! These 4 days event offers a tremendous communication platform for academia and industry, local and global experts, researchers and practitioners. There is no question foam itself is an international language. Moreover, enthusiasm and hospitality easily made barrier non-existing. 34 presentations and 20 posters offered tremendous insight in foam research and development, which became discussion points to encourage further thoughts.

The story of Microgreen’s microcellular PET sheet known as solid state foaming was reviewed in a positive note. Although it was shut down early part of this year, it indeed generated waves in the hot beverage coffee cup markets, especially in the airline industries as shown in Fig. 1. It was made with over 50% of recycled PET at about 50% weight reduction with good insulation through microcellular foaming. However, the competitive hot beverage market forced them to live with a low margin, which caused gross concerns on return on investment. The manufacturing capability was promising, yet breakthrough in processing was lacking. Overall, it was a good lesson for any company based on new business branched out from breakthrough technology.

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Foam Update October 2015

Fig. 1: Microgeen® Hot Beverage Cup for United Airlines

Mold bead foam was another popular subject in Foams 2015. Japan Styrene

Paper (JSP) Corp. and U. Bayreuth made interesting presentations. Bead foams show inherent benefits of low density in limited soaking time and foaming into irregular geometry. It has been a unique foamed product line for over three decades. JSP demonstrated high expansion bead foams; such as: 60X succinate (PBS) under the trade name of Green Block®as illustrated in Fig. 2. Moreover, (PLA) bead foam was developed through a special foaming process, through which crystallinity can increase as shown in Fig. 3 that its flex modulus is about 100% over PP bead foam at the same density. It increases its marketing exploitation. In evidence, the advantage of PLA crystallinity formation in the presence of CO2 can not only enhance its performance, but make very low density foam useful. These are critical business development factors to differentiate from the existing products.

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Foam Update October 2015

Fig. 2: Green Block®; PBS bead foam from JSP

Fig. 3: PLA bead foam crystallinity transformation process

Quite a few papers were devoted to nanocellular research works. Since nanocellular has a size close to molecular level, it offers a great platform to investigate nucleation. How gas molecules can get together to survive and, the, expand against the surrounding medium to form into a stable product. Fig. 4 shows a chart of cell size as a function of CO2 concentration. As more CO2 is dissolved in the polymer, cell size becomes smaller. It seems counterintuitive. As more CO2 is dissolved in the polymer, plasticization should increase to make less resistance toward cell growth. However, smaller cell was obtained, which simply suggests polymer free volume may be reduced and crystallinity increases to make nanocellular possible.

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Foam Update October 2015

Fig. 4: Cell size as afunction of CO2concentration for different ; (U. Washington, Guo et al)

Other interesting presentations include modified from Sekisui Plastics via reactive extrusion for more branching to get lowdensity polyamide foam. A nice work at Universiti Sains Malaysia was focused on moisture as a blowing agent in microwave foaming of natural rubber. It simply took advantage over high humidity and readily available rubber to make a useful product through foaming. Stretching sheet at transverse orientation shows perpendicular crystal growth, which could be a way to generate microporous film. It sounds like an interesting concept from Japan Advanced Institute of Science and Technology. Overall, Foams 2015 had a lot of great ideas. Careful follow up is very necessary to make some of them into pilot system for big scale quality analysis before commercialization. The good thing is that Poly-Foam at Shanghai, Dec. 2-3, 2015 will be another stage to evidence continued progress and new technology-business transition.

Editorial Office

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Foam Update October 2015

C. News

JUDGES OVERTURNS NYC’S EPS BAN Author(s) Putrich, G. S. Sources Plastics News Corporate/Assignee N/A Publication Date September 22, 2015 Abstract: New York State’s Supreme Court overturned New York City’s ban on expanded (EPS) in the usage of direct food contact, citing EPS is recyclable. The decision also delves into the more difficult question of whether recycling EPS is environmentally effective and economically feasible, concluding that NYC made an incorrect assessment based on extremely flawed data and inaccurate claims. NYC was not pleased with the decision and is reviewing options to keep the ban in effect. In April, Dart Container Corp. (DCC) and other companies filed a lawsuit to stop the ban. DCC offered recycling systems to upgrade NYC’s EPS recycling.

RECENT RESEARCH INTO THE UNITED STATES COLORED PU FOAMS INDUSTRY MARKET RESEARCH REPORT IN 2015 Author(s) Bhisey, R. Sources www.whatech.com Corporate/Assignee N/A Publication Date August 31, 2015 Abstract: The report provides a basic overview of the industry including definitions, classifications, applications and industry chain structure. The Colored PU Foams market analysis is provided for the United States markets including development trends, competitive landscape analysis, and key regions development status.

POLYMERIC FOAMS MARKET TO SEE ROBUST GROWTH Author(s) N/A Sources www.plastemart.com Corporate/Assignee N/A Publication Date September 11, 2015 Abstract: The U.S market for polymeric foam was nearly 7.9 bln lbs in 2014. This market is predicted to reach nearly 8.1 bln lbs in 2015 and nearly 9.3 bln lbs in 2020, with a compound annual growth rate (CAGR) of 2.8%.

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Foam Update October 2015

The segment reached nearly 4.4 bln lbs in 2015. This market is expected to grow to nearly 5.1 bln lbs in 2020, with a CAGR of 3%. The polystyrene market was nearly 2.3 bln lbs in 2015. This market is expected to grow to 2.4 bln lbs in 2020, with a CAGR of 2.4%.

2015 EUROPEAN FOAM THERMAL INSULATION PRODUCTS MARKET REPORT Author(s) N/A Sources www.prnewswire.com Corporate/Assignee N/A Publication Date September 10, 2015 Abstract: Produced from a mixture of polyols, isocyanates, process additives and blowing agents, polyurethane foams can provide very high performance insulating products, despite the change from CFC to CFC-free blowing agents.

NEW REPORT SHEDS LIGHT ON THE EUROPEAN AUTOMOTIVE FOAMS INDUSTRY 2015 Author(s) Modak, S. Sources www.whatech.com Corporate/Assignee N/A Publication Date September 7, 2015 Abstract: Europe Automotive Foams Industry 2015 Market Research Report is a new market research publication announced by Reportstack. This report is a professional and in-depth study on the current state of the Automotive Foams industry. Development policies and plans are discussed as well as manufacturing processes and Bill of Materials cost structures are also analyzed. This report also states import/export consumption, supply and demand Figures, cost, price, revenue and gross margins.

RESEARCH DELIVERS INSIGHT INTO THE FLEXIBLE COLORED PU FOAMS MARKET Author(s) N/A Sources www.whatech.com Corporate/Assignee N/A Publication Date September 7, 2015 Abstract: Foams play a significant role in commercial and industrial sector ranging from automotive to refrigeration. Based on the variants foams available in the market and increasing area of applications for flexible colored PU foams, the market is expected to

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Foam Update October 2015

experience growth in the near future.

GLOBAL METHYLENE DIPHENYL ISOCYANATE (MDI) MARKET 2015-2019 - REPORTLINKER REVIEW Author(s) N/A Sources www.marketwatch.com Corporate/Assignee N/A Publication Date September 23, 2015 Abstract: Technavio's report, Global MDI Market 2015-2019, has been prepared based on an in- depth market analysis with inputs from various industry experts. The report includes a comprehensive discussion on the market, an extensive coverage on various types of production techniques, applications, and demand-supply dynamics in various geographies. The report provides comments on both the existing market landscape and its growth prospects over the forecast period. The report further includes a discussion of the key vendors operating in this market.

TRENDING: BIOBASED MICROBEADS, FLEXIBLE FOAMS COULD OFFER RENEWABLE MATERIALS FOR HUNDREDS OF PRODUCTS Author(s) N/A Sources www.sustainablebrands.com Corporate/Assignee N/A Publication Date August 25, 2015 Abstract:

TerraVerdae BioWorks, an industrial biotechnology company developing advanced and environmentally sustainable biomaterials, announced Monday that it has successfully achieved key milestones for the commercial production for its line of

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Foam Update October 2015

Polyhydroxyalkanoate (PHA)-based biomaterials. These include 10,000-liter production runs of its line of biodegradable, natural microspheres for use in personal care and cosmetic products. TerraVerdae’s biobased beads are being primed as a direct replacement for the non-degradable microbeads that brands including L'Oréal, Unilever, Johnson & Johnson and P&G have taken steps to remove from their products after studies linked the beads to water pollution and ecosystem disruption in the Great Lakes.

POLYURETHANE TO LEAD GROWTH OF AEROSPACE FOAM MARKET AT OVER 7% TILL 2020 Author(s) N/A Sources Popular Plastics and Packaging 60, No.7, July 2015, p.73 ISSN: 0971-0078 Corporate/Assignee N/A Publication Date September 15, 2015 Abstract: A short report is presented on the global aerospace foam market, which is projected to grow at 5246.44 mln U.S. dollars by 2020. Polyurethane foams are identified as one of the largest markets, which are expected to grow. The North American market accounted for a share of more than 38.18 percent of the total market size in terms of volume in 2014.

TREXEL WILL EXPAND ITS OFFERING OF LIGHT-WEIGHTING AND QUALITY IMPROVEMENT PROCESS SOLUTIONS TO INCLUDE TECOCELL® CHEMICAL FOAMING AGENTS Author(s) N/A Sources www.thomasnet.com Corporate/Assignee N/A Publication Date September 9, 2015 Abstract: Trexel Inc. is widely known as the company that developed and commercialized the MuCell Process for the production of microcellular foamed parts in injection molding, and extrusion. This additive system, originally developed by Polyfil, represents the next generation in chemical foaming technologies. Having only one reaction point, unlike most foaming additive systems, TecoCell does not produce corrosive byproducts or require scavenger technology. Trexel has exclusive rights to commercialize TecoCell for all injection

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Foam Update October 2015

molding and automotive blow molding applications, while Polyfil will market their EcoCell line of CFA’s for extrusion opportunities.

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Foam Update October 2015

D. Patents and Journals

a. New Foaming Technique

GRAIN-BASED HOT CEREAL COMPOSITIONS HAVING REDUCED FOAMING Inventor(s) Duffy, D. K., McGurk Moen, M. E. Sources US Pat.: 9,131,715 Corporate/Assignee Ecolab USA Inc. (Saint Paul, MN) Publication Date September 15, 2015 Abstract: Grain-based hot cereal compositions having reduced foam capacity are disclosed. The compositions can include wheat farina, oat groats, rolled oats, and steel cut oats. The compositions comprise a stearyl antifoam agent that prevents boil over of the compositions during stove top or microwave cooking without adversely affecting the taste, texture, or appearance of the finished product.

PROCESS FOR THE PRODUCTION OF HIGH INTERNAL PHASE EMULSION FOAMS Inventor(s) Merrigan, S. R., Desmarais, T. A. Sources US Pat.App.: 20150246987 Corporate/Assignee N/A Publication Date September 3, 2015 Abstract: A method for polymerizing an open-cell foam including exposing an emulsion comprising a photoinitiator to an Ultraviolet light source, partially polymerizing the top surface of the emulsion, and moving the partially polymerized emulsion to a second polymerization stage.

POLYETHYLENE AEROGEL AND METHOD OF PRODUCTION Inventor(s) Attia, Y. A. Sources US Pat.App.: 20150247016 To Give Than To Receive - 11 -

Foam Update October 2015

Corporate/Assignee N/A Publication Date September 3, 2015 Abstract: A method for making polyethylene aerogels, including high molecular weight aerogels, commences by in a hydrocarbon solvent (e.g., toluene or benzene) in which polyethylene is insoluble at room temperature, adding polyethylene to the solvent heated to a temperature at which said polyethylene is soluble to form a reaction mixture. A free- radical catalyst is added to the reaction mixture and the reaction mixture is held until the desired gelation of the polyethylene has been achieved. The reaction mixture is cooled to about room temperature; and the hydrocarbon solvent is replaced with a gas (e.g., CO.sub.2 or air) to form the polyethylene aerogel. Optionally, the cooled reaction mixture can be contacted with an anti-solvent for polyethylene to replace the hydrocarbon solvent with the anti-solvent. Silica aerogel particles can be encapsulated in polyethylene aerogel by adding the particles to the polyethylene gelation reaction mixture.

METHOD TO PRODUCE MULTI-LAYER FOAM Inventor(s) Beyder ,E. Y., Kablov, E. N., Malyshenok, S. V., Petrova, G. N., Platonov, M. M., Rumyantseva, T. V., Sklyarevskaya, N. M. Sources RU 2561972 C1 Corporate/Assignee Aviation Materials Res Inst Publication Date September 10, 2015 Abstract: NOVELTY: Method to produce multi-layer foam plastic includes the following stages: preparation of at least two layers of composition capable of foaming, which contain a foaming agent, foaming of composition layers, connection of composition layers by means of welding, cooling of the produced multi-layer product. Besides, the initial composition is acrylimide polymer, besides, layers are connected simultaneously with foaming with the help of diffusion welding.

MECHANICAL PROPERTIES OF BOROSILICATE GLASS HOLLOW PARTICLE REINFORCED EPOXY MATRIX SYNTACTIC FOAMS Author(s) Zeltmann, S. E., Gupta, N., Chen, B., Ricci, W. Sources SAMPE 2015. Proceedings of a conference held in Baltimore, Maryland, USA, 18-21 May 2015 Editor(s): Beckwith S W; Maher M; Reyes G; Zimmerman P, SAMPE Covina, California, USA: SAMPE International Business Office, 2015, paper 94, pp.12 Corporate/Assignee New York University; Trelleborg AEM Publication Date N/A Abstract: Syntactic foams are a class of lightweight composites synthesised by dispersing hollow particles (microballoons) in a matrix material. These materials have found extensive use

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Foam Update October 2015

in underwater oil exploration equipment and submarine structures due to their outstanding compressive properties and tailorable buoyancy. In the majority of present applications and existing studies, these foams are fabricated using microballoons composed of soda-lime glass. However, sodium ions can leach out of the glass particle and cause disintegration of the particle wall when such foams are exposed to moisture for prolonged periods, as in the current applications. This reduces the structural integrity of the foam and permits water to fill the voids in the composite. In this work, syntactic foams are fabricated using borosilicate glass particles, which do not show degradation upon moisture exposure. The fabricated syntactic foams are tested for compressive properties at quasi-static and high strain rates. The compressive strength was observed to increase with increasing wall thickness of microballoons and decreasing particle volume fraction. The compressive strength increased by up to 90% at high strain rates compared to quasi-static, but no strain rate sensitivity was observed in the range of 750-1750/s. 27 Refs.

MICROWAVE PROCESSING OF SYNTACTIC FOAM FROM AN EXPANDABLE THERMOSET/ MIXTURE Author(s) Hong, Y., Fang, X., Yao, D. Sources Polymer Engineering and Science 55, No.8, 2015, p.1818-1828 Corporate/Assignee N/A Publication Date October 18, 2014 Abstract: In this work, a microwave expansion process to produce thermoset-matrix syntactic foam containing thermoplastic foam beads was designed and developed. Expandable polystyrene (EPS) microspheres and epoxy resin were chosen as a model material system. This process is featured with a capability to effectively expand EPS microspheres in syntactic foam with high EPS loading. The resin viscosity and specific microwave energy are found to be the two primary control parameters determining the process window. Mechanical characterization showed that the specific flexural strength and modulus of the syntactic foam are similar to those of the neat epoxy. By comparison, the flexural moduli over density squared or cubed of the foam are much higher, especially at high EPS loadings, than those of the neat resin. The foamed EPS microspheres can also effectively toughen the syntactic foam, preventing propagation of cracks. Furthermore, the microwave expansion process was found to be capable of molding syntactic foam parts of relatively sophisticated geometry with smooth surfaces.

INCORPORATION OF POSTCONSUMER POLYURETHANE FOAM INTO A POLYMER/CLAY AEROGEL MATRIX Author(s) Viggiano, R. P., Ball, E. E., Park, R. E., Haider, K. W., Schiraldi, D. A. Sources Journal of Applied Polymer Science 132, No.39, 2015, paper 42586, pp.8 Corporate/Assignee N/A

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Publication Date June 24, 2015 Abstract: The feasibility of incorporating ground recycled polyurethane (PU) foam into clay/polymer aerogels was demonstrated, and a range of compositions were prepared and characterized to determine the effect of variation in the formulations on density and mechanical properties of the resulting materials. This study followed a modified combinatorial approach. Initially, experiments were performed in water using either sodium exchanged montmorillonite or laponite clay, poly(vinyl alcohol) (PVOH) solution as the polymer binder, and the recycled PU foam. Freezing and freeze-drying the aqueous gels produced aerogels, which were characterized through density and mechanical testing, scanning electron microscopy, and thermal gravimetric analysis. The study was expanded by exploring alternative binder chemistries, including the use of an alginate polymer in place of the PVOH or adding a polyisocyanate as a crosslinking agent for PVOH. The effect of recycled PU foam content, clay type and level, and binder type and level on the mechanical properties of the aerogels were determined and will be discussed herein.

IN-SITU GROWN SILICA/WATER-BORNE EPOXY SHAPE MEMORY COMPOSITE FOAMS PREPARED WITHOUT BLOWING AGENT ADDITION Author(s) Dong, Y., Fu, Y., Ni, Q. Sources Journal of Applied Polymer Science 132, No.39, 2015, paper 42599, pp.11 Corporate/Assignee N/A Publication Date June 29, 2015 Abstract: Shape memory (SM) silica/epoxy composite foams were successfully synthesized via latex technology and prepared without blowing agent addition. Silica was synthesized via tetraethoxysilane (TEOS) hydrolysis. Silica/epoxy foams were obtained from the TEOS solution and water-borne epoxy mixtures after freeze-drying and foaming in the presence of residual moisture as the blowing agent under a vacuum at 110°C. The morphologies of the resulting foams were evaluated using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Compression and thermo-mechanical cycle tests were performed to measure the mechanical and SM properties of the foams. Experimental results indicated that the

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Foam Update October 2015

micrographs and mechanical properties of the foams were closely related to freeze-drying time. The final composite foams exhibited high shape recovery and fixity ratios and could maintain both properties at more than 90% even after five thermo-mechanical cycles. The properties obtained in the epoxy foams may offer new opportunities for their use in future structural applications.

b. Blowing Agents

MICROWAVE FOAMING OF NATURAL RUBBER: EXPLOITING MOISTURE A S BLOWING AGENT Author(s) Tan, Y., Ariff, Z. M. Sources Foams 2015; Sep. 10-11, 2015 at Kyoto University Corporate/Assignee N/A Publication Date N/A Abstract: An attempt of vulcanizing and foaming at the same time with natural rubber using conventional microwavce oven has been investigated. Initial results seemed quite promising. At 1.25% moisture, 0.1 relative density rubber foam was obtained. Large cell was present within the foam.

c. Foam Products

COMPOSITIONS COMPRISING ANTI-FOAMS Inventor(s) Panandiker, R. K., Kluesener, B. W. Sources US Pat.: 9,133,421 Corporate/Assignee The Procter & Gamble Company (Cincinnati, OH) Publication Date September 15, 2015 Abstract: The present application relates to compositions comprising anti-foams and methods of making and using such compositions. Such compositions encompass consumer products, cleaning and/or treatment compositions, fabric care composition and liquid laundry detergents that provide the desired suds profile via the addition of an antifoamer, yet are stable.

POLYMER-GRAPHITE NANOCOMPOSITES Inventor(s) Gortz, H., Minkwitz, R., Mulhaupt, R., Wissert, R., Steurer, P. Sources US Pat.: 9,120,909 Corporate/Assignee Styrolution Europe GmbH (DE) Publication Date September 1, 2015

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Foam Update October 2015

Abstract: Process for producing a polymer-graphite nanocomposite, which comprises the steps a) oxidation of graphite to graphite oxide, b) conversion of the graphite oxide into an aqueous dispersion, c) mixing of the aqueous dispersion comprising graphite oxide or, if appropriate, reduced graphite oxide which is obtained from b) with an aqueous polymer dispersion comprising at least one polymer and d) separating off the polymer-graphite mixture from the aqueous phase, wherein the graphite oxide which has been oxidized in step a) is reduced to graphite between step b) and c) or between step c) and d).

CELL SIZE ENLARGING AGENT FOR STYRENIC FOAM Inventor(s) Giza, K. M., Barger, M. A., Fox, R. T., Guerra, S. M., Walther, B. W. Sources US Pat.App.: 20150267020 Corporate/Assignee Dow Global Technologies Llc Publication Date September 24, 2015 Abstract: A styrenic polymer foam contains a polymer composition in the form of a continuous matrix defining multiple cells therein, the polymer composition contains a first polymer and second polymer, the first polymer being a maleic anhydride-grafted high density polyethylene and the second polymer being a styrenic polymer resin that is free of grafted maleic anhydride. The first polymer contains on average 0.05 or more weight-parts of grafted maleic anhydride based on total weight of the first polymer and the concentration of first polymer in the polymer composition is sufficient to provide at least six weight- parts of grafted maleic an hydride per million weight parts of the polymer composition.

FOAMED STRETCH- FORMED POLYOLEFIN RESIN BODY Inventor(s) Akuzawa, N., Ichikawa, K., Koiso, N., Iino, H. Sources US Pat.App.: 20150267019 Corporate/Assignee Toyo Seikan Group Holdings, Ltd. Publication Date September 24, 2015 Abstract: A foamed stretch-formed body which has a polyolefin resin single-layer structure that is physically foamed into an expansion ratio of 1.01 to 2.0 times, wherein the surface roughness Ra (JIS-B-0601-1994) is not more than 10 .mu.m in the region where the cells are distributed therein. Despite of its polyolefin resin single-layer structure, the foamed stretch-formed body effectively suppresses the deterioration in the appearance or in the light-shielding capability caused by foaming.

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Foam Update October 2015

AN ULTRA-THIN RESIN FOAM SHEET AND ITS MANUFACTURING METHOD AND USE Inventor(s) Wei, C., Chen, R. Sources CN 104610631 Corporate/Assignee Hubei Xiang source of new material Technology Co., Ltd. Publication Date May 13, 2015 Abstract: The present invention discloses a thin resin foam sheet and its manufacturing process and use its raw materials selection LLDPE, LDPE, MDPE and HDPE at least one as a base resin, the choice of an olefin-based thermoplastic elastomer or rubber as the resin modifier; raw materials further comprises a foaming agent and an antioxidant; its structure is a porous structure, having a thickness of 0.04-0.3mm, an apparent density of 0.1-0.5g / cm3; viewed from the thickness direction, consisting of at least two bubbles composition, and were round or irregular oval structure. The present invention is found to have an irregular oval cell structure and have a specific thickness and apparent density, ultra-thin resin foam than conventional foam sheet thinner, lighter, and more flexible and lighter than the film material volume, more suitable for thin, lightweight electronic devices seal the cushioning material or adhesive tape substrates.

d. Applications

COMPOSITE FOR PACKAGING A MEDICAL DEVICE AND METHOD OF FORMING THE SAME Inventor(s) Knowlton, D., Shaw Jr., D. J. Sources US Pat.: 9144464 Corporate/Assignee UFP Technologies, Inc. Publication Date September 29, 2015 Abstract: A composite for packaging a medical device has a first layer including an aromatic polyether polyurethane and a second layer. The first layer forms a base that has a plurality of walls extending therefrom to define a cavity for receiving the medical device. The second layer is disposed on the first layer opposite the cavity. The composite is formed from a method that includes the step of disposing the first layer on the

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Foam Update October 2015

second layer. The composite may also be included with a container to form a packaging system.

PACKAGING MATERIAL AND ITEM OF PACKAGING Inventor(s) Bergner, D. Sources US Pat.App.: 20150266643 Corporate/Assignee Coveris Rigid (Zell) Deutschland GMBH Publication Date September 24, 2015 Abstract: Packaging material for producing deep-drawn plastics material packagings, particularly of multipack packagings, wherein the material is constructed to be breakable, and packaging produced therefrom.

METHODS OF PRODUCING FOAMS AND NANOCOMPOSITES OF PHTHALONITRILE BASED RESINS, AND FOAMS AND NANOCOMPOSITES PRODUCED THEREOF Inventor(s) Hu, X., Liu, M. Sources US Pat.App.: 20150267022 Corporate/Assignee N/A Publication Date September 24, 2015 Abstract: Methods of producing a polymeric foam comprising or consisting of a polymer formed from phthalonitrile having general formula (I), (II), or (III), ##STR00001## are provided. Polymeric foams and nanocomposites of phthalonitrile based resins, and uses of the polymeric foams are also provided.

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Foam Update October 2015

COMPOSITION AND METHOD Inventor(s) Gibis, K. L., Van Loyen, D., Housmekerides, C. E. Sources US Pat.App.: 20150252301 Corporate/Assignee N/A Publication Date September 10, 2015 Abstract: A low-foaming composition for cleaning a ware-washing machine comprises water, an alkoxylate, an acid (preferably citric acid), and preferably a phase separation promoter (for example a polyethylene glycol or an ionic salt). The composition is in two separate layers under ambient conditions.

BUFFERING DEVICE AND PACKING DEVICE Inventor(s) Hu, Q., Chen, S., Hsiao, Y. Sources US Pat.App.: 20150246764 Corporate/Assignee N/A Publication Date September 3, 2015 Abstract: A packing device including a buffering device is disclosed. The buffering device includes a bottom buffering member and a top buffering member arranged with a plurality of installing slots. The top buffering member includes a first surface having a plurality of first slots corresponding to the installing slots and a second surface having a plurality of second slots corresponding to a plurality of installing slot sets. In view of the above, by arranging the first slot for clasping the liquid crystal module and the second slot for clasping the LCD TV, the buffering device and the packing device can be adopted to pack the liquid crystal module and the LCD TV. Not only the packing cost is reduced, but also mass production is facilitated due to simple structure.

PROCESS FOR MANUFACTURING A HEAT INSULATION CONTAINER Inventor(s) Chang, S., Su, H. Sources US Pat.App.: 20150246499 Corporate/Assignee N/A Publication Date September 3, 2015 Abstract:

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Foam Update October 2015

A process for manufacturing a heat insulation container mainly includes preparing a coating material by mixing a binder and a thermo-expandable powder, coating such coating material on a surface of a container and then heating the container to foam the coated material after the container is shaped. The foamed coating material is therefore provides the container with heat insulation property. The thermo-expandable powder consists of a plurality of thermo-expandable microcapsules, each of which consists of a thermoplastic polymer shell and a solvent wrapped by the thermoplastic polymer shell. To obtain a smooth surface, the soften point of the binder is required to be lower than the boiling point of the solvent.

METHOD AND DEVICE FOR PRODUCING A POLYMER MELT CONTAINING ADDITIVES AND BLOWING AGENTS Inventor(s) Metzger, J., Lechner, F., Schönfeld, S. Sources EP 2868686 Corporate/Assignee Coperion GmbH Publication Date May 6, 2015 Abstract: In a method and an apparatus for producing an additive and propellant-containing polymer melt (P AT), a first polymer melt (P 1) and a second polymer melt (P 2) is provided. By means of a screw machine (8) is at least one additive (A) to the first polymer melt (P 1) to a additive-containing polymer melt (P A) are mixed. Further, by means of a mixing device (41) at least one blowing agent (T) to the second polymer melt (P 2) to a propellant-containing polymer melt (P T) mixed. The propellant-containing polymer melt (P T) is the additive-containing polymer melt (P A) is supplied, which is located in the screw extruder (8). The propellant-containing polymer melt (P T) and the additive- containing polymer melt (P A) are mixed by the extruder (8) to the additive and propellant-containing polymer melt (P AT).

ONE KIND OF SAFE PACKAGING MATERIAL EPS

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Foam Update October 2015

Inventor(s) Yao, H., Cai, L. Sources CN 104670697 Corporate/Assignee Plastics Co., Ltd. Publication Date June 3, 2015 Abstract: One kind of EPS packaging material security, the use of seven co-extruded blown film technology to produce a structure of PE / TIE / PA / PVDC / EVOH / TIE / PE safety of EPS packaging materials, interlayer mass ratio of PA: TIE: PA: PVDC: EVOH: TIE: PE = 2: 1: 1.5: 1: 1.5: 1: 2. Production of the present invention EPS of safety packaging materials, gas permeability of less than 70cm3 / (m2.24h.1atm), not only to meet the EPS particles of dust, moisture-proof packaging requirements, but also to achieve the purpose of the barrier pentane vapor permeation , played the role of the security package.

e. Degradable and Sustainable Foam

PROCESS FOR PREPARING FOAMED POLYMER Inventor(s) Alberts, A. H., Rothenberg, G. Sources US Pat.: 9,127,120 Corporate/Assignee Universiteit Van Amsterdam (Amsterdam, NL) Publication Date September 8, 2015 Abstract: The invention pertains to a process for producing a glycerol tri-carboxylic acid polyester foam which comprises the steps of combining glycerol and a tri-carboxylic acid in the liquid phase to provide a reaction mixture, and keeping the reaction mixture at a temperature of between 80.degree. C. and 130.degree. C. from the start of the reaction until a conversion of at least 90% is obtained. The foamed polyester of the present invention is "green", biodegradable, and non-toxic, and can be cleanly combusted. It finds application in, int. al., packaging materials, insulation materials, and materials with a short life cycle.

POLYLACTIC ACID FOAMED MOLDED BODY AND METHOD FOR MANUFACTURING SAME Inventor(s) Jeon, B. J., Lee, E. K., Choi, C. J., Kim, M. H., Kim, J. M., Ji, S. W. Sources WO 2015111895 Corporate/Assignee Lg Hausys, Ltd. Publication Date July 30, 2015 Abstract: Provided is a polylactic acid foamed molded body having a thermal deformation temperature of 80 to 110°C.

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Foam Update October 2015

ONE KIND OF BIODEGRADABLE FOAMED PLASTIC Inventor(s) Song, X. Sources CN 104725758 Corporate/Assignee Qingdao new impetus culture media Ltd. Publication Date June 24, 2015 Abstract: The present invention discloses a biodegradable foamed plastic, characterized in that the components according to parts by weight of the composition of raw materials as follows: MAPP 40-50, 20-30 parts of ethylene-acrylic acid copolymers, thermoplastic polymer was 15-20 parts of chlorinated polyethylene 4-6 parts, flax stalk powder 20-30 parts, 30-40 parts of polyvinyl alcohol, polyethylene wax 3-5 parts, aluminum zirconium coupling agent 1-1.5 parts of antioxidant 1010 0.6-0.8 parts 0.5-0.7 parts of a photosensitizer, 3-5 parts of talc. Fusion hemp stalk powder with a thermoplastic polymer and other components, as well as enhance the role of the use of fillers such as talc, collaborative improve composite mechanics and heat resistance; a wide range of sources of raw materials, low prices, increase the added value of agricultural products; exert biological degradation and photodegradation dual role, to be readily biodegradable copolymer by photodegradation processing, and for polyvinyl alcohol, by biodegradation.

BIOENERGY RESIN COMPOSITION AND PREPARATION METHOD AND MOLDING Inventor(s) Fu, Q., Yan, L., Sun, X., Yu, X., Liu, X., Ge, L. Sources CN 104650605 Corporate/Assignee Huayu Automotive Components Co., Ltd. Publication Date May 27, 2015 Abstract: The present invention discloses a bioenergy resin particles, its preparation method and molded body, which is made from corn stalks 80-120 parts, parts 8-12 corn cob, soybean meal and other parts crushed 30-50 by double stick kneading, crushing extrusion, cooling stereotypes, cutting the resulting raw material nontoxic, readily available, pro environment, energy excellent decomposition time can be adjusted easily reused. Bioenergy resin particles of the present invention, have excellent workability, and can easily prepare a resin processed products, bio-energy film, multifunctional film, garbage bags, foam films, sheets.

f. Thermoset Foam; PU and Others

PROCESS FOR PRODUCING FLEXIBLE POLYURETHANE FOAM USING NATURAL OIL POLYOLS Inventor(s) Budeniuc, J. J., Tobias, J. D., Keller, R. J. Sources US Pat.: 9145466

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Foam Update October 2015

Corporate/Assignee Air Products and Chemicals, Inc. Publication Date September 29, 2015 Abstract: A composition and process useful to make flexible polyurethane foams and in particular flexible molded polyurethane foams is disclosed. The usage of dipolar aprotic liquids such as DMSO, DMI, sulfolane, N-methyl-acetoacetamide, N,N-dimethylacetoacetamide as well as glycols containing hydroxyl numbers OH#≦1100 as cell opening aides for 2- cyanoacetamide or other similar molecules containing active methylene or methine groups to make a polyurethane foam is also disclosed. The advantage of using cell opener aids results in a) no foam shrinkage; b) lower use levels of cell opener; c) foam performance reproducibility d) optimum physical properties. In addition, combining the acid blocked amine catalyst together with the cell opener and the cell opener aid results in a less corrosive mixture as well as provides a method that does not require mechanical crushing for cell opening.

Clay-isocyanate nanodispersions and polyurethane nanocomposite produced therewith Inventor(s) Harikrishnan, G., Macosko, C. W., Lindsay, C. I., Singh, S. N. Sources US Pat.: 9,133,319 Corporate/Assignee Huntsman International LLC Publication Date September 15, 2015 Abstract: Nanodispersions of inorganic clays in isocyanate may be created via pre-exfoliation, delamination, or both of the clay and subsequent mixing with isocyanate. In an embodiment, such an isocyanate nanodispersion is reacted with an isocyanate- reactive material or substrate to form a polyurethane nanocomposite.

POLYURETHANE FOAM ARTICLE Inventor(s) Sargent, E. A., Dow, D. R., Dunham, G. A., Earl, D. E., Lenzendorf, J. P. Sources US Pat.: 9,133,296 Corporate/Assignee 3M Innovative Properties Company (St. Paul, MN) Publication Date September 15, 2015 Abstract: Herein are disclosed an apparatus and method for reaction injection molding of polyurethane foam. In the method, a recirculation loop containing polyols along To Give Than To Receive - 23 -

Foam Update October 2015

with an effective amount of water, and a recirculation loop containing isocyanates, are each partially evacuated.

SYSTEM AND METHOD FOR PRODUCING AN IN-SITU PUR FOAM Inventor(s) Simancas, K., Von Benten, R., Hahnle, H., Hahn, K., Nestle, N., Ulanova, T., Assmann, J. Sources US Pat.App.: 20150252164 Corporate/Assignee N/A Publication Date September 10, 2015 Abstract: A system for producing an in-situ foam, which comprises the components from 50 to 98% by weight of one or more inorganic fillers A), from 1 to 48% by weight of one or more water-soluble, cationic polymers B), from 0.5 to 48% by weight of one or more surfactants C), from 0.01 to 5% by weight of one or more crosslinkers D) which are capable of reacting with the polymers B), from 0 to 20% by weight of one or more additives E), where the percentages by weight of the components A) to E) are based on the nonaqueous fraction and the sum of A) to E) is 100% by weight, process for producing an in-situ foam using the components of the system and foaming by means of a gas or a gas mixture and use for thermal insulation and filling of hollow spaces and hollow bodies.

PREPARING A POLYURETHANE FOAM COMPRISING METAL NANOPARTICLES, COMPRISES MIXING THE AQUEOUS SUSPENSION OF METAL NANOPARTICLES AT ROOM TEMPERATURE WITH A POLYOL PREMIX, AND ADDING METHYLENEDIPHENYL-4,4'-DIISOCYANATE TO THE MIXTURE Inventor(s) Banach, M., Pulit, J. Sources PL 406212 A1 Corporate/Assignee Politechnika Krakowska Publication Date June 8, 2015 Abstract:

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Foam Update October 2015

NOVELTY: Preparing a polyurethane foam comprising metal nanoparticles, comprises either: mixing the aqueous suspension of metal nanoparticles at room temperature with a polyol premix, and adding methylenediphenyl-4,4'-diisocyanate to the mixture; or mixing the suspension of metal nanoparticles in the polyethylene glycol at room temperature with a polyol premix, and adding water and methylenediphenyl-4,4'-diisocyanate to the mixture.

NATURAL VEGETABLE OIL-BASED FOAM AND PREPARATION PLANT LOAD Inventor(s) Ye, Y., Chen, J. Sources CN 104650309 Corporate/Assignee Fujian Generous Sponge Technology Co., Ltd. Publication Date May 27, 2015 Abstract: The present invention discloses a natural vegetable oil-based foam plant load and preparation, made from a combination of materials and isocyanate; combination of materials, comprising by weight: 100 Composite polyols, crosslinking agent or chain extender 0-8, the composite catalyst 0-3, a foam stabilizer of 0.5 to 4, 0.2 to 10 blowing agent, 0 to 50, the number of isocyanate ester of 0.3 to 0.75) ratio. The present invention is applied polyurethane technology to planting areas in order to have a unique absorption and retention characteristics and biodegradable characteristics, it can be applied to water retention desert, sand and so on.

POLYURETHANE SPONGE FACILITATING HIGHLY DISPERSED TIO2 NANOPARTICLES ON REDUCED GRAPHENE OXIDE SHEETS FOR ENHANCED PHOTOELECTRO-OXIDATION OF ETHANOL Author(s) Jing, L., Tan, H., Amal, R., Ng, Y., Sun, K. Sources Journal of Materials Chemistry A 3, No.30, 2015, p.15675-15682 Corporate/Assignee N/A Publication Date July 3, 2015 Abstract: Three-dimensional (3D) porous polyurethane sponge serves as the sacrificial scaffold for the hydrothermally-synthesized anatase TiO2-reduced graphene oxide (RGO) composites. The internal channel of the 3D polyurethane structure provides larger exposed TiO2 seeding and crystal growth area on the pre-adsorbed graphene oxide during the synthesis. The uniform pore size within the polyurethane also prevents severe aggregation of TiO2 nanoparticles. As a result, TiO2 nanoparticles

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Foam Update October 2015

are finely dispersed on the RGO sheets. In addition to the general advantages of introducing graphitic carbon to TiO2 (i.e. hydrophobic carbon for preferential organic adsorption and excellent electron transport of RGO), the presence of polyurethane sponge during the synthesis offers larger contact area between TiO2 and RGO which is facilitated by the excellent dispersion of TiO2. Besides, formation of Ti–O–C species is found at the interface and it extends the light absorption of the composite into visible light region. Combining the localized organic adsorption adjacent to TiO2, efficient charge transfer from large contact area of TiO2–RGO and the extended light response of the composite, this material demonstrates enhanced photoelectrochemical oxidation of ethanol.

A BASELINE MODEL FOR THE SIMULATION OF POLYURETHANE FOAMS VIA THE POPULATION BALANCE EQUATION Author(s) Karimi, M., Marchisio, D. L. Sources Macromolecular Theory and Simulations 24, No.4, 2015, p.291-300 Corporate/Assignee N/A Publication Date May 19, 2015 Abstract: In this work, a novel approach, based on the population balance equation (PBE), is presented and applied for the first time to the simulation of expanding polyurethane foams. The solution of the PBE allows to determine the evolution of the bubble size distribution (BSD) of the foam, which in turn defines the mechanical and thermal properties. The approach includes a kinetic model for the polymerization and blowing reactions, accounts for the presence of a physical blowing and for the total energy balance. Model predictions are compared with experiments from the literature for 12 different chemical recipes, highlighting acceptable agreement.

PHENOLIC FOAMS TOUGHENED WITH CROSSLINKED POLY (N-BUTYL ACRYLATE)/SILICA CORE-SHELL NANOCOMPOSITE PARTICLES Author(s) Yuan, J., Zhang, Y., Wang, Z. Sources Journal of Applied Polymer Science 132, No.40, 2015, paper 42590, pp.8 Corporate/Assignee N/A Publication Date July 7, 2015 Abstract: A new type of crosslinked poly (n-butyl acrylate) (PBA)/silica core-shell nanocomposite

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Foam Update October 2015

particles was adopted as toughening agent to improve the mechanical properties of phenolic foams. The effects of the nanocomposite particles on the structures and properties of lightweight phenolic foams were investigated. SEM result showed that the addition of a small quantity of the nanocomposite particles can significantly enhance the structural homogeneity of phenolic foams. Thermalgravimetric analysis result suggested that the incorporation of the nanocomposite particles did not affect the thermal stability of the toughened phenolic foams. The flexural strength, compressive strength, and elastic modulus of the phenolic foams increased distinctively after the addition of the nanocomposite particles, the maximum values of which increased by 36.0%, 42.9%, and 32.3%, respectively. In this study, the optimum dosage of the nanocomposite particles is 0.03 phr in the modified phenolic foams. Moreover, the influence on the flammability of phenolic foams by toughening can almost be neglected.

g. Microcellular and Expanded Particle

NANOCELLULAR THERMOPLASTIC FOAM AND PROCESS FOR MAKING THE SAME Inventor(s) Zhu, L., Costeux, S., Patanka, K. A., Moore, J. D. Sources US Pat.: 9145477 Corporate/Assignee Dow Global Technologies LLC Publication Date September 29, 2015 Abstract: Prepare a thermoplastic polymer foam having a porosity of 70% or more and at least one of: (i) an average cell size of 200 nanometers or less; and (ii) a nucleation density of at least 1×1015 effective nucleation sites per cubic centimeter of foamable polymer composition not including blowing agent using a foamable polymer composition containing a thermoplastic polymer selected from styrenic polymer and (meth)acrylic polymers, a blowing agent comprising at least 20 mole- percent carbon dioxide based on moles of blowing agent and an additive having a Total Hansen Solubility Parameter that differs from that of carbon dioxide by less than 2 and

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Foam Update October 2015

that is present at a concentration of 0.01 to 1.5 weight parts per hundred weight parts thermoplastic polymer.

CONTINUOUS PROCESS FOR EXTRUDING NANOPOROUS FOAM Inventor(s) Costeux, S., Lantz, D. R., Beaudon, D. A., Barger, M. A. Sources US Pat.: 9145478 Corporate/Assignee Dow Global Technologies LLC Publication Date September 29, 2015 Abstract: Prepare a polymeric nanofoam using a continuous extrusion process by providing a polymer melt of a polymer composition in an extruder, introducing carbon dioxide to a concentration above the solubility in the polymer melt, cooling the polymer melt without increasing the pressure to achieve conditions where all of the carbon dioxide is soluble in the polymer composition and then extruding the polymer composition and carbon dioxide mixture through an extrusion die so as to experience a pressure drop of at least five MegaPascals at a rate of at least ten MegaPascals per second and allowing the polymer composition to expand into a polymeric nanofoam.

EFFECTS OF PROCESSING PARAMETERS AND THERMAL HISTORY ON MICROCELLULAR FOAMING BEHAVIORS OF PEEK USING SUPERCRITICAL CO2 Author(s) Yang, Q., Zhang, G., Ma, Z., Li, J., Fan, X. Sources Journal of Applied Polymer Science 132, No.39, 2015, paper 42576, pp.11 Corporate/Assignee N/A Publication Date July 1, 2015 Abstract: In this study, we mainly investigate the solid-state foaming of (PEEK) with different crystallinities using supercritical CO2 as a physical blowing agent. The gaseous mass-transfer and thermophysical behaviors were studied. By altering the parameters of the foaming process, microcellular foams with different cell morphologies were prepared. The effect of crystallization on the cell morphology was also investigated in detail. The results indicate that the crystallization restricts gas diffusion in the material, and the thermophysical behaviors of the saturated PEEK sample with low crystallinity presents two cold crystallization peaks. The cell density decreases and the cell size increases as the saturation pressure increases. The cell density of the microcellular foams prepared under 20 MPa is 1.23 × 1010 cells/cm3, which is almost 10 times compares to

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Foam Update October 2015

that under 8 MPa. The cell size increases as the foaming time extends or the foaming temperature increases. It is interesting that the cell morphology with a bimodal cell-size distribution is generated when the samples are foamed at temperatures higher than 320°C for a sufficient time. Additionally, nanocellular foams can be obtained from a highly crystallized PEEK after the decrystallization process.

MICROCELLULAR FOAMING OF POLY(PHENYLENE SULFIDE)/POLY(ETHER SULFONES) BLENDS USING SUPERCRITICAL CARBON DIOXIDE Author(s) Ma, Z., Zhang, G., Shi, X., Yang, Q., Li, J., Liu, Y., Fan, X. Sources Journal of Applied Polymer Science 132, No.40, 2015, paper 42634, pp.14 Corporate/Assignee N/A Publication Date July 8, 2015 Abstract: Microcellular foaming of poly(phenylene sulfide)/poly(ether sulfones) (PPS/PES) blends presents a promising approach to produce high-performance cellular materials with tailored microstructures and enhanced properties. This study investigated the effects of multiphase blend composition and process conditions on the foaming behaviors and final cellular morphology, as well as the dynamic mechanical properties of the solid and microcellular foamed PPS/PES blends. The microcellular materials were prepared via a batch-foam processing, using the environment-friendly supercritical CO2 (scCO2) as a blowing agent. The saturation and desorption behaviors of CO2 in PPS/PES blends for various blend ratios (10 : 0, 8 : 2, 6 : 4, 5 : 5, 4 : 6, 2 : 8, and 0 : 10) were also elaborately discussed. The experimental results indicated that the foaming behaviors of PPS/PES blends are closely related to the blend morphology, crystallinity, and the mass-transfer rate of the CO2 in each polymer To Give Than To Receive - 29 -

Foam Update October 2015

phase. The mechanisms for the foaming behaviors of PPS/PES blends have been illustrated by establishing theoretical models.

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