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US 2026/0115979 A1Published application
Foam material with thermal insulation, flame resistance and emi shielding
OwnerDavid Mark Pascoe, Benedetto Reginellainventors
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Abstract
The present disclosure relates to a process and article produced by injection molding. More particularly, a process and article produced by injection molding, that provides a part with one or more locations of a reduced density where such part competes in mechanical property characteristics with parts, such as vehicular components, otherwise produced from metallic materials, and which part offers thermal insulation, flame resistance and EMI shielding.
Claims27
A method of forming an injection molded part comprising:
- providing an injection mold comprising a first mold half and a second mold half that provides a molding cavity between the first mold half and the second mold half, wherein the molding cavity includes one or more locations having an initial spacing of at least 2.0 mm;
- injecting a polymer composition including a flame retardant into the molding cavity, the polymer composition including a foaming agent;
- increasing said molding cavity initial spacing at said one or more locations by at least 2.0 mm;
- and
- forming the injection molded part in the molding cavity from the polymer composition wherein the injection molded part includes a cellular structure.
2 more elements
A method of forming an injection molded part comprising:
- providing an injection mold comprising a first mold half and a second mold half that provides a molding cavity between the first mold half and the second mold half, wherein the molding cavity includes one or more locations with an initial spacing;
- providing one or a plurality of movable mold inserts wherein said inserts are capable of selectively retracting to increase said initial mold cavity spacing;
- injecting a polymer composition including a flame retardant into the molding cavity, the polymer composition including a foaming agent;
- selectively retracting at least one of said mold inserts to increase said initial mold cavity spacing at a first location in said mold and maintaining the initial mold spacing at a second location in said mold.
1 more element
A method of forming an injection molded part comprising:
- providing an injection mold comprising a first mold half and a second mold half including a first side having a location for injection of a polymer composition and a second side away from said first side;
- said mold providing a molding cavity between the first mold half and the second mold half, wherein the molding cavity includes one or more locations having an initial spacing of at least 2.0 mm;
- positioning a metal sheet or metal mesh in said mold;
- injecting a polymer composition including a flame retardant into the molding cavity, the polymer composition including a foaming agent;
- increasing said molding cavity initial spacing at said one or more locations by at least 2.0 mm;
- and
- forming the injection molded part in the molding cavity from the polymer composition wherein the injection molded part includes a cellular structure and a corresponding first side proximate to said location for injection of resin and second side away from said location for injection of plastic resin;
- and
- wherein a majority portion of said metal sheet or metal mesh is located more towards a second side of the part away from the location for injection of said polymer composition than said first side of said part.
6 more elements
A method of forming an injection molded part comprising:
- providing an injection mold comprising a first mold half and a second mold half including a first side having a location for injection of a polymer composition and a second side away from said first side;
- said mold providing a molding cavity between the first mold half and the second mold half, wherein the molding cavity includes one or more locations having an initial spacing of at least 2.0 mm;
- positioning a composite polymeric sheet in said mold configured to provide EMI shielding;
- injecting a polymer composition including a flame retardant into the molding cavity, the polymer composition including a foaming agent;
- increasing said molding cavity initial spacing at said one or more locations by at least 2.0 mm;
- and
- forming the injection molded part in the molding cavity from the polymer composition wherein the injection molded part includes a cellular structure and a corresponding first side proximate to said location for injection of resin and second side away from said location for injection of plastic resin;
- and
- wherein a majority portion of said composite polymeric sheet providing EMI shielding is located more towards a second side of the part away from the location for injection of said polymer composition than said first side of said part.
6 more elements
Dependencies are inferred from the claim text.