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US 8,574,473 B2Granted
Foamed resin injection molding method
AssigneeFord Global Technologies, LLC
InventorsHaoliang Michael Sun, Ellen Cheng-chi Lee, Junko Pauken
Life of this patent
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Abstract
An injection molding apparatus and method are provided. The method includes a molded cavity coupled to a resin injection apparatus which injects molten resin under pressure with a gas such that the resin foams within the mold cavity. An electrical heater is in contact with a first cavity surface, and a cooling medium cools the mold. The resin may include metallic flakes.
Claims11
A method for injection molding a part comprising the steps of:
- providing a mold cavity including a first mold portion comprising a first cavity surface and a second mold portion comprising a second cavity surface, wherein the first and second cavity surfaces define the mold cavity;
- providing metallic flakes in a molten resin;
- injecting a gas into the molten resin in a molten state containing the metallic flakes, such that the gas disturbs the metallic flakes in the resin and randomizes orientation of metallic flakes;
- heating the second mold portion with an electric heater to a temperature greater than 100° C., wherein the electric heater heats different zones of the second cavity surface to different temperatures;
- injecting the molten state resin and gas at an elevated pressure into the cavity;
- cooling the mold cavity to form a solid part;
- and
- ejecting the solid part from the mold cavity, wherein the gas creates micron-sized voids within the solid part and an outer surface of the solid part is substantially free of defects.
5 more elements
A method for injection molding a part comprising the steps of:
- providing a mold cavity having a first mold portion comprising a first cavity surface, and a second mold portion comprising a second cavity surface, wherein the first and second cavity surfaces define the mold cavity;
- providing a molten resin having metallic flakes;
- injecting a gas into the molten resin containing the metallic flakes, wherein the gas coming out of solution disturbs the metallic flakes in the resin and randomizes the orientation of the metallic flakes;
- heating the second mold to a temperature above 100° C., wherein the electric heater heats different zones of the second cavity surface to different temperatures;
- cooling the mold cavity to form a solid part;
- and
- ejecting a solid part from the mold cavity, wherein the gas creates micron-sized voids within the solid part and an outer surface of the solid part is substantially free of defects.
4 more elements
Dependencies are inferred from the claim text.