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US 2024/0286325 A1Published application
Injection moulding process for the preparation of a foamed article with improved surface quality
AssigneeSabic Global Technologies B.V.
InventorsAngel Yanev, Kar-Man Raymond Chu, Junhua Zhang, Dimphna Johanna Maria van Beek, Daniel Bande
Life of this patent
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Abstract
The present invention relates to an injection moulding process for the preparation of a foamed article with improved surface quality. The present invention further relates to a foamed article obtained or obtainable by the injection moulding process.
Claims14
An injection moulding process for preparing a foamed article in a mould comprising the following sequential steps:
- a) Closing the mould to form a mould cavity having a volume V1;
- b) Injecting a foamable polymer composition into the mould cavity to form a filled mold cavity in which at least 90% of the volume V1 is filled;
- c) Applying a pressure P to the foamable polymer composition in the filled mold cavity for a duration t, wherein t is in the range from 1.3 to 10.2 s;
- d) Increasing the volume of the filled mould cavity to a volume V2, e.g. by opening the filled mould cavity at least partially to allow expansion of the foamable polymer into a pre-foamed article;
- and
- e) Allowing the pre-foamed article to solidify to form the foamed article;
- and
- f) Ejecting the foamed article from the mould.
5 more elements
An injection moulding process for preparing a foamed article in a mould comprising the following sequential steps:
- a) Closing the mould to form a mould cavity having a volume V1;
- b) Injecting a foamable polymer composition into the mould cavity to form a filled mold cavity in which at least 90% of the volume V1 is filled, wherein step b) is not injected at an injection speed of 250 cm3/s and step b) does not have duration of 0.21 s;
- c) Applying a pressure P to the foamable polymer composition in the filled mold cavity for a duration t, wherein t is in the range from 1.3 to 10.2 s, wherein P is not 400 bar and/or t is not 5 S;
- d) Increasing the volume of the filled mould cavity to a volume V2 to allow expansion of the foamable polymer into a pre-foamed article, wherein the duration of step d) is at least or longer than 1 s and the mould cavity is not opened by 1 mm;
- e) Allowing the pre-foamed article to solidify to form the foamed article, wherein the duration of step e) is not 40 s;
- and
- f) Ejecting the foamed article from the mould.
4 more elements
An injection moulding process for preparing a foamed article in a mould comprising the following sequential steps:
- a) Closing the mould to form a mould cavity having a volume V1;
- b) Injecting a foamable polymer composition into the mould cavity to form a filled mold cavity in which at least 90% of the volume V1 is filled;
- c) Applying a pressure P to the foamable polymer composition in the filled mold cavity for a duration t, wherein t is in the range from 1.3 to 10.2 s;
- d) Increasing the volume of the filled mould cavity to a volume V2 to allow expansion of the foamable polymer into a pre-foamed article;
- e) Allowing the pre-foamed article to solidify to form the foamed article, wherein the duration of step e) is not 40 s;
- and
- f) Ejecting the foamed article from the mould,
- wherein the process is not a process comprising the following sequential steps:
- a1) Closing the mould to form a mould cavity having a volume V11;
- b1) Injecting a foamable polymer composition into the mould cavity to form a filled mold cavity in which at least 90% of the volume V11 is filled, wherein step b1) has a duration of 0.21 s and step b1) is injected with an injection speed of 250 cm3/s;
- c1) Applying a pressure P1 of 400 bar to the foamable polymer composition in the filled mold cavity for a duration t1 of 5 s;
- d1) Increasing the volume of the filled mould cavity to a volume V21, by opening the mould cavity by 1 mm to allow expansion of the foamable polymer into a pre-foamed article, wherein step d) has a duration of at most 1 s or less than 1 s;
- e1) Allowing the pre-foamed article to solidify to form the foamed article, wherein the duration of step e1) is 40 s;
- and
- f1) Ejecting the foamed article from the mould.
12 more elements
An injection moulding process for preparing a foamed article in a mould comprising the following sequential steps:
- a) Closing the mould to form a mould cavity having a volume V1;
- b) Injecting a foamable polymer composition into the mould cavity to form a filled mold cavity in which at least 90% of the volume V1 is filled;
- c) Applying a pressure P to the foamable polymer composition in the filled mold cavity for a duration t, wherein t is in the range from 5.1 to 10.2 s;
- d) Increasing the volume of the filled mould cavity to a volume V2 to allow expansion of the foamable polymer into a pre-foamed article;
- e) Allowing the pre-foamed article to solidify to form the foamed article;
- and
- f) Ejecting the foamed article from the mould.
4 more elements
Dependencies are inferred from the claim text.