# US 12,759,205 B2 · Apparatus and methods for optimizing injection molding parameters, formulations, and mold structure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,205 B2 - Document ID: US12759205B2 - Status: Granted - Kind: B2 - Application number: 18/417,762 - Filed: 2024-01-19 - Published: 2024-07-25 - Granted: 2026-10-13 - Earliest claimed: 2023-01-19 - Assignees: Moxietec, LLC - Applicants: Moxietec, LLC - Inventors: Abolfazl Mohebbi; Donald Jordan; Andrew Tempalski - Web page: https://patentgrep.com/patent/US12759205B2 ## CPC - B29C 45/34: having venting means - B29C 45/77: of velocity or pressure of moulding material - B29C 45/78: of temperature - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract Disclosed herein are methods and systems for determining mold designs, polymer formulations, and processing parameters for forming a thermoplastic foam with desired cellular structure and mechanical and physical properties. In one example, the system includes a plaque mold and a plurality of interchangeable mold cavities including one pair of mold cavities used to form a solid polymer sample and two or more pairs of mold cavities for forming thermoplastic foam samples. The mold cavities include a plurality of sensors to determine pressures and temperature at various locations within the mold cavities. Samples are compared and determinations are made based on the comparison and evaluation of data regarding mold designs, formulations, and/or processing parameters. Optionally, the methods and system disclosed herein can use a venting system and collection system to collect any outcoming gases to determine the solubility of specific polymer-gas combinations to further determine mold designs, formulations, and/or processing parameters. ## Claims ### Claim 1 A plaque mold assembly for forming foamed polymer components, 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 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 collection cylinder. ### Claim 2 (depends on 1) The plaque mold assembly of claim 1, wherein the plurality of pairs of mold cavities includes: a first pair of mold cavities arranged to form at least one solid polymer component; a second pair of mold cavities arranged to form at least one 3.2 mm thermoplastic foam component; a third pair of mold cavities arranged to form at least one 7.0 mm thermoplastic foam component; a fourth pair of mold cavities arranged to form at least one 14.0 mm thermoplastic foam component; and a fifth pair of mold cavities arranged to form at least one 25.4 mm thermoplastic foam component. ### Claim 3 (depends on 2) The plaque mold assembly of claim 2, wherein properties of the solid polymer component formed with the first pair of mold cavities can be compared with properties of the one or more thermoplastic foam components formed with the second, third, fourth, and/or fifth pair of mold cavities to analyze variables. ### Claim 4 (depends on 3) The plaque mold assembly of claim 3, wherein the variables include mold design, polymer formulation, and processing parameters. ### Claim 5 (depends on 3) The plaque mold assembly of claim 3, wherein the variables include mechanical properties including tensile strength, impact resistance, and bend strength. ### Claim 6 (depends on 1) The plaque mold assembly of claim 1, further comprising: a first water circulation system; and a second water circulation system independent of the first water circulation system. ### Claim 7 (depends on 6) The plaque mold assembly of claim 6, wherein the first and second water circulation systems can be independently controlled such that the formed polymer component comprises varying mechanical properties across different sections of the polymer component. ### Claim 8 (depends on 1) The plaque mold assembly of claim 1, wherein the volume of gases collected in the collection system during the formation process can be used to determine the gas solubility of the foamed polymer component. ### Claim 9 (depends on 1) The plaque mold assembly of claim 1, wherein the collection system includes: a second collection cylinder; a second movable piston to vary the volume of the second collection cylinder; and a second one way valve that allows gases to enter the second collection cylinder and prevents gases from exiting the second collection cylinder. ### Claim 10 (depends on 1) The plaque mold system of claim 1, wherein each collection cylinder includes a pressure sensor to measure the internal pressure of the collection cylinder. ### Claim 11 (depends on 1) The plaque mold system of claim 1, wherein each collection cylinder includes a temperature sensor to measure the temperature of gases in the collection cylinder. ### Claim 12 (depends on 1) The plaque mold assembly of claim 1, the plurality of pairs of mold cavities each including at least one sensor, wherein the at least one sensor is arranged to measure the environmental parameters at periodic intervals during the forming of the foamed polymer component. ### Claim 13 (depends on 1) The plaque mold assembly of claim 1, the plurality of pairs of mold cavities each including at least one sensor, wherein the at least one sensor is a plurality of sensors distributed throughout the pair of mold cavities-mold. ### Claim 14 (depends on 13) The plaque mold assembly of claim 13, wherein at least one of the plurality of sensors is arranged to measure pressure or temperature. ### Claim 15 (depends on 1) The plaque mold assembly of claim 1, wherein the volume of gases collected in the collection cylinder is quantified and used to determine the volume of gases incorporated into the foamed polymer component. ### Claim 16 (depends on 1) The plaque mold assembly of claim 1, wherein the collection system further comprises: tubing connected at one end to the hose and connected on the opposite end to the collection cylinder; and a valve positioned at the connection of the hose and tubing arranged to be selectively opened to allow gases to flow from the hose to the tubing and selectively closed to prevent gases from following from the hose to the tubing. ### Claim 17 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. ### Claim 18 (depends on 17) The plaque mold assembly of claim 17, wherein the sensor positioned in a first of the plurality of pairs of mold cavities measures temperature throughout the molding process, records the temperature measurements, and the temperature measurements are used to plot a chart of temperature versus time during the molding process. ### Claim 19 (depends on 17) The plaque mold assembly of claim 17, wherein the sensor positioned in a first of the plurality of pairs of mold cavities measures pressure throughout the molding process, records the pressure measurements, and the pressure measurements are used to plot a chart of temperature versus time during the molding process. ### Claim 20 (depends on 17) The plaque mold assembly of claim 17, wherein measurements captured by the sensor positioned in a first of the plurality of pairs of mold cavities are used to evaluate flow behavior of the polymer used to form the one or more foamed polymer component, process parameters used to form the one or more foamed polymer components, or mold design features of the mold cavity used to form the one or more foamed polymer components.