Abstract:
A method of making a vehicle headrest restraint and connecting first and second molds to form a mold cavity. A first material is injected with a first density into the mold cavity. A second material is injected with a second density into the mold cavity. The first and second materials are cooled to develop an integrally formed headrest.
Abstract:
Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.
Abstract:
Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.
Abstract:
An apparatus and methods for mixing and injecting a foam core within an extruded shell preferably of plastic downstream from an extrusion die to produce a uniform building product. The preferred apparatus includes a mixing head injector for mixing a binary system foam. The mixing head injector incorporates pressurized gas injection for homogenization of the foam core. A preferred method employs the mixing head injector and a novel calibrator thereby allowing injection of a foam core within the shell as it passes through a calibrator to reliably produce a uniform building product. An alternative method employs a second extruder. Alternative methods employ a mounting fixture downstream of a first calibrator.
Abstract:
A method for injection molding a product having a non-cellular skin layer and a cellular core portion. The method involves successive or simultaneous injection of a non-foamable resin material and a foamable resin material through a sprue bushing having an injection channel connected to the mold cavity and a pair of fixed feed channels intersecting with the injection channel. The injection mold has a bore with a sprue bushing therein. The sprue bushing having an injection channel therein and intersecting with a pair of fixed feed channels. Injection units deliver the materials to the pair of fixed feed channels.
Abstract:
A multidensity polyurethane foam article suitable for use as a seat cushion includes a supportive layer of firm foam and a comfortable layer of softer foam. The multidensity article has a sag factor of about 3.0 to about 4.5, and the two foam layers are bonded together without employing adhesives. The multidensity foam article is prepared by placing a first formulation capable of yielding a firm foam into a mold and permitting said formulation to start creaming, rising and foaming; introducing a second liquid formulation capable of forming a soft foam into the mold after the first formulation has completed 10 to 80% of its potential rise so that the second formulation passes through the rising first formulation and the first formulation floats upon the second formulation; and then permitting the two formulations to cream, foam, rise and cure into a single multidensity article having a firm supportive foam layer and a soft foam layer, which layers are bonded and knitted together at their common boundary during the curing process.
Abstract:
Method and apparatus for the intermittent manufacture of multi-layer molded bodies of thermoplastic material with a foamed core and an unfoamed shell, wherein a strand of a nonfoaming plastic of ring-shaped cross-section enclosing a strand of plastic containing a foaming agent is injected into a mold.
Abstract:
A method of making a vehicle headrest restraint and connecting first and second molds to form a mold cavity. A first material is injected with a first density into the mold cavity. A second material is injected with a second density into the mold cavity. The first and second materials are allowed to develop an integrally formed headrest.
Abstract:
Mold for processing expandable or expanded plastic particles for producing a multi-component particle foam component, that includes a mold cavity delimited by mold walls, having at least one mold element, which in particular is slide-like or slide-shaped, wherein the at least one mold element is mounted so as to be movable between a first orientation and/or position and at least one further orientation and/or position in which it projects at least in portions into the mold cavity, and wherein the at least one mold element is designed with, or has, a flow channel structure having at least one flow channel which extends inside the mold element and through which a process fluid can flow.
Abstract:
Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.