Optimized reaction injection molding
AssigneeAT&T Bell Laboratories
InventorLouis T. Manzione
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AssigneeAT&T Bell Laboratories
InventorLouis T. Manzione
Estimating the term…
Articles made by the reaction injection molding process obtain a reduced residence time in the mold, hence increasing the production rate, by choosing processing and material parameters according to the inventive method. This method makes use of material parameters and processing conditions, including temperature and cavity shape for determining the viscosity of prepolymer material as it solidifies in the cavity. This information is used to optimize fluid injection rates, temperature of the fluid or cavity wall, choice of reactive fluid, or shape of the cavity. Articles having more complex geometries than previously obtained can be produced when the cavity filling is mathematically simulated according to the present procedure, typically by means of a computer. This can ensure against blockage of critical passages in the cavity, polymer degradation, etc.
A method of making an article by steps comprising flowing at least one fluid into a cavity, and reacting said fluid so as to produce an at least partially polymerized material in said cavity, wherein said fluid comprises a thermosetting fluid, and the parameters of said reacting are chosen so that said fluid in said cavity does not exceed desired limits on at least one of the factors of (1) chemical conversion or (2) temperature, whereby said at least one of the factors is determined by steps comprising simulating said flowing of said fluid by steps comprising dividing said cavity into a plurality of cells, assigning a marker to each cell for carrying information comprising the temperature, chemical conversion, viscosity, and velocity of the fluid in the cell, performing computations to determine said information, moving the marker a distance determined by the computed velocity, and iterating said computations for said fluid during the simulating of said flowing until said cavity is filled with said fluid, and thereafter continuing to compute at least one of said factors, utilizing as an initial condition therefor the final value of said factor computed for the simulating of said flowing.
Dependencies are inferred from the claim text.