Method of injection molding with pressurized-fluid assist and variable-volume reservoir

Claim 1

A method for controlling fluid delivery pressure in a process for making a hollow-shaped article from molten resin having a softening point in a fluid injection molding system including a fluid source having a fluid storage chamber with a variable working volume, a mold having an injection aperture and a mold cavity with interior surfaces and an injection nozzle comprising the steps of: storing a desired quantity of pressurized fluid in a desired working volume of the storage chamber at a predetermined initial fluid pressure; injecting an amount of molten resin sufficient for preparation of said hollow-shaped article from said injection nozzle at a resin injection pressure through said injection aperture and along a resin flow path; communicating the pressurized fluid from the variable working volume into said resin flow path to begin formation of a fluid cavity in the resin whereby the pressurized fluid penetrates the resin and to urge the material toward the interior surfaces of the mold cavity; continuing to communicate the pressurized fluid to continue formation of the fluid cavity and to distribute the molten resin over the interior surfaces of said mold cavity at a fluid pressure substantially reduced from the initial fluid pressure; enlarging the working volume of the storage chamber during the step of continuing to communicate upon formation of said fluid cavity and in response to the substantially reduced fluid pressure which occurs on formation of the fluid cavity to further continue formation of the fluid cavity while preventing blowing of the fluid completely through the molten resin; cooling the article to a temperature beneath the softening point of the resin; relieving the fluid pressure within the formed hollow-shaped article; and opening the mold to remove the formed hollow-shaped article.

Claim 2

A method for controlling fluid delivery pressure in a process for making a hollow-shaped article from molten resin having a softening point in a fluid injection molding system including a fluid source having a fluid storage chamber with a variable working volume, a mold having an injection aperture and a mold cavity with interior surfaces and an injection nozzle comprising the steps of: storing a desired quantity of pressurized fluid in a desired working volume of the storage chamber at a predetermined initial fluid pressure; injecting an amount of molten resin sufficient for preparation of said hollow-shaped article from said injection nozzle at a resin injection pressure through said injection aperture and along a resin flow path; communicating the pressurized fluid from the variable working volume into said resin flow path to begin formation of a fluid cavity in the resin whereby the pressurized fluid penetrates the resin and to urge the material toward the interior surfaces of the mold cavity; continuing to communicate the pressurized fluid to continue formation of the fluid cavity and to distribute the molten resin over the interior surfaces of said mold cavity at a fluid pressure substantially reduced from the initial fluid pressure; enlarging the working volume of the storage chamber during the step of continuing to communicate upon formation of said fluid cavity and in response to the substantially reduced fluid pressure which occurs on formation of the fluid cavity to further continue formation of the fluid cavity while preventing blowing of the fluid completely through the molten resin; cooling the article to a temperature beneath the softening point of the resin; relieving the fluid pressure within the formed hollow-shaped article; and opening the mold to remove the formed hollow-shaped article.