Apparatus and methods for optimizing injection molding parameters, formulations, and mold structure

A plaque mold assembly for forming foamed polymer components and investigating behavior of a polymer during the molding process, the plaque mold assembly comprising:

• a plurality of pairs of mold cavities, each pair of the plurality of pairs of mold cavities including a first mold cavity and a second mold cavity, wherein each pair of the plurality of pairs of mold cavities is arranged to form a foamed polymer component unique to the pair of mold cavities;
• an A-side of the plaque mold assembly including a first recess arranged to accommodate the removable placement of each of the first mold cavities of the plurality of pairs of mold cavities, wherein the arrangement of the first recess accommodates only one of the first mold cavities at a time;
• a B-side of the plaque mold assembly including a second recess arranged to accommodate the removable placement of each of the second mold cavities of the plurality of pairs of mold cavities, wherein the arrangement of the second recess accommodates only one of the second mold cavities at a time;
• a plurality of sensors positioned within each of the plurality of pairs of mold cavities;
• a venting system arranged to provide a path for gases not incorporated into the foamed polymer component during formation to exit the mold cavity;
• and
• a collection system to collect and store gases not incorporated into the foamed polymer component during formation, wherein the collection system includes:
• a collection cylinder;
• a hose connecting the venting system to the collection system;
• a movable piston to vary the volume of the collection cylinder so that the collection cylinder does not affect pressure in the pair of mold cavities;
• and
• a one way valve that allows gases to enter the collection cylinder and prevents gases from exiting the cylinder;
• wherein the plurality of sensors includes at least one sensor positioned in each of the plurality of mold cavities.