Gregory N Branch

US Patent:

7501175, Mar 10, 2009

Filed:

May 14, 2004

Appl. No.:

10/557755

Inventors:

Gregory L. Branch - Stanwood WA, US
Wiley D. Gunter - Erie PA, US

Assignee:

MicroGREEN Polymers, Inc. - Arlington WA

International Classification:

B32B 7/02

US Classification:

428218, 428212, 428217, 428 357, 428220, 428 365

Abstract:

This invention provides packages and containers produced by a solid state method for the manufacture of foamed polymeric material. The packages are suitable for pre-cooking or sterilization, insulated transport, cooking vessel, reheating, and storage of food. The gas impregnated thermoforming (GIT) process includes interleaving an article of raw polymeric material with a gas channeling means; exposing the article to a non-reacting gas at elevated pressure to achieve a desired concentration of gas within the polymer, thereby forming a partially gas-saturated article, separating it from the gas channeling means, then decompressing, foaming and forming it at a temperature below the material's melt temperature; and finally trimming it to produce a finished foamed polymeric material and recyclable scrap solid state process foamed polymer.

US Patent:

7585439, Sep 8, 2009

Filed:

May 14, 2004

Appl. No.:

10/557758

Inventors:

Gregory L. Branch - Stanwood WA, US
Trevor Wardle - Ashland KY, US

Assignee:

Micro Green Polymers, Inc. - Arlington WA

International Classification:

B29C 44/20
B29C 44/56
B29C 51/02

US Classification:

264 50, 264 51, 264102, 264345, 264234, 264235, 264321

Abstract:

A solid state foaming process permits the use of up to 100% recycled pre- and post-consumer polymer for the manufacture of foamed polymer material and thermoformed foamed polymer articles. The process enables the optional formation of integral unfoamed skins of controllable depth and crystallinity on foamed polymeric materials suitable for a wide variety of applications. Because this process does not alter the underlying chemistry of the material all scrap from the manufacturing process may be reused without additive to form new foamed polymeric materials and articles.

US Patent:

8377548, Feb 19, 2013

Filed:

Oct 5, 2010

Appl. No.:

12/898106

Inventors:

Krishna Nadella - Seattle WA, US
Gregory Branch - Camano Island WA, US
Vipin Kumar - Seattle WA, US
Michael A. Waggoner - Seattle WA, US

Assignee:

MicroGREEN Polymers Inc. - Arlington WA
University of Washington - Seattle WA

International Classification:

B32B 3/26
B32B 5/14

US Classification:

4283166, 4283105, 4283144, 4283148, 4283159, 4283188

Abstract:

The invention disclosed herein relates to relates to foamed thermoplastic material objects and articles of manufacture having an internal layered cellular structure, as well as to methods of making the same. In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material sheet, wherein the multi-layer thermoplastic material sheet has first and second discrete outer layers sandwiching a plurality of discrete inner foamed layers, and wherein the two outer layers and plurality discrete inner foamed layers are integral with one another. The thermoplastic material may be a semi-crystalline polymer such as, for example, PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene napthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polyactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof. The two outer layers may be unfoamed skin layers having smooth outer surfaces, and the discrete inner foamed layers may be microcellular.

US Patent:

8568125, Oct 29, 2013

Filed:

Apr 14, 2009

Appl. No.:

12/423790

Inventors:

Gregory Branch - Stanwood WA, US

Assignee:

MicroGREEN Polymers Inc. - Arlington WA

International Classification:

B29C 44/46
B29C 65/10

US Classification:

425216, 425215, 264 51, 156381, 156497, 156500

Abstract:

Disclosed herein are roll fed air heated flotation ovens and related thermoforming systems, assemblies, and machines that enable the corrugation-free expansion of a gas impregnated thermoplastic web passing through an oven chamber (without use of a pin-chain assembly), as well as to related methods. In an embodiment, a gas impregnated thermoplastic web is conveyed and expanded through an elongated air heated oven chamber, wherein the elongated oven chamber includes a plurality of downwardly directed heated air nozzles positioned at regular intervals along and within the upper portion of the oven chamber, and a plurality of upwardly directed heated air nozzles positioned at regular intervals along and within the lower portion of the oven chamber, but staggered apart from the downwardly directed heated air nozzles such that the gas impregnated thermoplastic material web undulates in an up and down wavelike fashion, thereby minimizing sagging, bagging, puckering, and/or buckling of the web.

US Patent:

20050203198, Sep 15, 2005

Filed:

Apr 13, 2005

Appl. No.:

11/106190

Inventors:

Gregory Branch - Stanwood WA, US
Trevor Wardle - Ashland KY, US

Assignee:

MICROGREEN POLYMERS, INC. - Stanwood WA

International Classification:

C08K003/00
C08J009/00

US Classification:

521091000

Abstract:

A solid state process utilizes gas impregnation to enhance thermoforming of thermoplastic material. If the gas is plasticizing, the article is thereby plasticized for thermoforming. In some embodiments, the invention provides foaming the polymer prior to or during thermoforming by creating high levels of dissolved gas during gas exposure. Foaming may proceed spontaneously upon decompression from gas pressure, or foaming may be enhanced by heating the polymer sheet near to or above the polymer's glass transition temperature, thereby producing plasticized foamed polymer for thermoforming. When objects of unfoamed polymer are desired, foaming may be suppressed by thermoforming gas saturated articles under gas pressure. This process may be used to enhance the thermoforming performance of articles that have been previously foamed, including articles foamed by prior art processes. In some embodiments, polymer is sufficiently plasticized so that it may be thermoformed without heating. Plasticization of the polymer is reversible.

US Patent:

20100163450, Jul 1, 2010

Filed:

Mar 9, 2010

Appl. No.:

12/720166

Inventors:

Gregory L. Branch - Camano Island WA, US

Assignee:

MICROGREEN POLYMERS, INC. - Arlington WA

International Classification:

B65D 85/00
B29C 44/02

US Classification:

2065246, 264 50

Abstract:

The present invention is directed to a deep draw microcellularly foamed polymeric container comprising a polymeric sidewall integrally connected to a polymeric base along a bottom edge. The polymeric sidewall and base are contiguous with each other and define a shape of an open top container. The polymeric sidewall and base have a contiguous inner microcellular foam structure (having average cell diameters ranging from about 5 to about 100 microns) surrounded by a smooth outer skin layer integrally connected therewith. The polymeric sidewall defines a container height and a top opening, wherein the top opening defines a top opening width, and wherein the polymeric base defines a container base width, and wherein the area defined by the top opening is greater than the area defined by the polymeric base, and wherein the ratio of the container height (h) to the top opening width (w) is greater than about 1:1 (h:w).

US Patent:

20120267814, Oct 25, 2012

Filed:

Jul 9, 2012

Appl. No.:

13/544763

Inventors:

Gregory Branch - Seattle WA, US
Krishna Nedella - Seattle WA, US

Assignee:

MicroGREEN Polymers Inc. - Arlington WA

International Classification:

B29C 44/34

US Classification:

264 50

Abstract:

Disclosed herein are roll fed air heated flotation ovens and related thermoforming systems, assemblies, and machines that enable the corrugation-free expansion of a gas impregnated thermoplastic web passing through an oven chamber (without use of a pin-chain assembly), as well as to related methods. In an embodiment, a gas impregnated thermoplastic web is conveyed and expanded through an elongated air heated oven chamber, wherein the elongated oven chamber includes a plurality of downwardly directed heated air nozzles positioned at regular intervals along and within the upper portion of the oven chamber, and a plurality of upwardly directed heated air nozzles positioned at regular intervals along and within the lower portion of the oven chamber, but staggered apart from the downwardly directed heated air nozzles such that the gas impregnated thermoplastic material web undulates in an up and down wavelike fashion, thereby minimizing sagging, bagging, puckering, and/or buckling of the web.

US Patent:

20130032287, Feb 7, 2013

Filed:

Aug 4, 2011

Appl. No.:

13/198418

Inventors:

Thomas J. Hagman - Seattle WA, US
Gregory Lowman Branch - Camano Island WA, US
James P. Dwyer - Seattle WA, US
Brian Edward Hood - Seattle WA, US
Erik Lund - Issaquah WA, US
Wade Matthew Morris - Auburn WA, US
Jonathan Richard Schwedhelm - Seattle WA, US
Thomas C. Stone - Seattle WA, US

Assignee:

THE BOEING COMPANY - Chicago IL

International Classification:

B32B 38/10
B32B 37/00

US Classification:

156267, 156299, 156324, 156353, 156511, 156530, 156538

Abstract:

Composite tape is laminated onto a substrate using a gantry to move a tape laminating head along the length of the substrate. The laminating head is mounted for movement along a beam on the gantry that extends across the width of the substrate. The direction of lamination may be altered by changing the angular orientation of the beam.