Patent ID: 8852473
Filing Date: 2014-10-07
Classification: B29C

Abstract:
1. A process for the manufacture of a composite polymer foam comprising: A) saturating a polymer pellet or powder with an inert gas under conditions of elevated temperature of from about the glass transition temperature of the polymer to about 100° C. above the melting point of the polymer and elevated pressure; B) lowering the temperature and releasing the pressure to yield a polymer foam precursor; C) coating a plurality of pins or tubes with an adhesive; D) placing the polymer foam precursor into a mold containing said plurality of reinforcing pins or tubes in fixed positions within the mold, wherein said pins or tubes possess an angle of inclination between 0° and 90′; and E) heating the mold containing the polymer foam precursor and the pins or tubes to a temperature between about 30° C. below to about 150° C. above the melting point of the polymer under an inert gas at elevated pressure between just above ambient to about 500 psi, thereby forming an integrated composite foam.