US6884823B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Injection molding of polymeric material
Assignee: Trexel Inc
•
Filing: 1999-06-18
•
Granted: 2005-04-26
•
Expires: 2019-06-18
Abstract
Abstract Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.
Inventors
- 👤 David E. Pierick
- 👤 Jere R. Anderson
- 👤 Sung W. Cha
- 👤 Liqin Chen
- 👤 James F. Stevenson
- 👤 Dana E. Laing
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 17:17
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/34; B29C44/3469; B29C44/02; B29C44/04; B29C44/0461; B29C44/0492; B29C44/3442; B29C44/3446; B29C48/00; B29C48/022; B29C48/25; B29C48/269; B29C48/2694; B29C48/285; B29C48/29; B29C48/295; B29C48/36; B29C48/375; B29C48/388; B29C48/395; B29C48/45; B29C48/50; B29C48/74; B29C2948/00; B29C2948/92; B29C2948/92009; B29C2948/92019; B29C2948/92114; B29C2948/922; B29C2948/92209; B29C2948/92323; B29C2948/92361; B29C2948/9238; B29C2948/924; B29C2948/92409; B29C2948/92428; B29C2948/92447; B29C2948/92504; B29C2948/92609; B29C2948/92657; B29C48/001; B29C48/0011; B29C48/0012; B29C48/03; B29C48/15; B29K; B29K2105/00; B29K2105/0005; B29K2105/04; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953
Claims Analysis
Total Claims: 158
Claim 1
Independent Claim
53 words
An article comprising: a molded microcellular polymeric article formed by urging a flowable material into a molding chamber and allowing the microcellular article to form therein having a shape essentially identical to that of the molding chamber, including at least one portion having a cross-sectional dimension of no more than about 0.125 inch.
Claim 2
Dependent Claim
53 words
An article comprising: a molded microcellular polymeric article formed by urging a flowable material into a molding chamber and allowing the microcellular article to form therein having a shape essentially identical to that of the molding chamber, including at least one portion having a cross-sectional dimension of no more than about 0.125 inch.
Claim 3
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 5%.
Claim 4
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 10%.
Claim 5
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 15%.
Claim 6
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 20%.
Claim 7
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 25%.
Claim 8
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 30%.
Claim 9
Dependent Claim
34 words
An article as in claim 1 , the article having a surface, corresponding to an interior surface of a molding chamber, that is free of splay and swirl visible to the naked human eye.
Claim 10
Dependent Claim
16 words
An article as in claim 1 , having a void volume of at least about 50%.
Claim 11
Dependent Claim
41 words
An article as in claim 1 , including residual chemical blowing agent or reaction by-product of chemical blowing agent in an amount less than that inherently found in articles blown with about 0.1 percent by weight chemical blowing agent or more.
Claim 12
Dependent Claim
23 words
An article as in claim 1 , including at least one portion having a cross-sectional dimension of no more than about 0.100 inch.
Claim 13
Dependent Claim
23 words
An article as in claim 1 , including at least one portion having a cross-sectional dimension of no more than about 0.075 inch.
Claim 14
Dependent Claim
23 words
An article as in claim 1 , including at least one portion having a cross-sectional dimension of no more than about 0.050 inch.
Claim 15
Dependent Claim
23 words
An article as in claim 1 , including at least one portion having a cross-sectional dimension of no more than about 0.025 inch.
Claim 16
Dependent Claim
23 words
An article as in claim 1 , including at least one portion having a cross-sectional dimension of no more than about 0.010 inch.
Claim 17
Dependent Claim
18 words
An article as in claim 1 , having an average cell size of less than about 100 microns.
Claim 18
Dependent Claim
18 words
An article as in claim 1 , having an average cell size of less than about 30 microns.
Claim 19
Dependent Claim
16 words
An article as in claim 1 , having a maximum cell size of about 50 microns.
Claim 20
Dependent Claim
16 words
An article as in claim 1 , having a maximum cell size of about 5 microns.
Claim 21
Dependent Claim
14 words
An article as in claim 1 , wherein the microcellular material is essentially closed-cell.
Claim 22
Dependent Claim
76 words
An article comprising: a three-dimensional microcellular polymeric article formed by urging a flowable material into a molding chamber and allowing the microcellular article to form therein, the article having three intersecting, principal axes corresponding to the three dimensions, one of the dimensions associated with a first axis varying as a function of position along a second, perpendicular axis, the article including at least one portion having a cross-sectional dimension of no more than about 0.125 Inch.
Claim 23
Dependent Claim
76 words
An article comprising: a three-dimensional microcellular polymeric article formed by urging a flowable material into a molding chamber and allowing the microcellular article to form therein, the article having three intersecting, principal axes corresponding to the three dimensions, one of the dimensions associated with a first axis varying as a function of position along a second, perpendicular axis, the article including at least one portion having a cross-sectional dimension of no more than about 0.125 Inch.
Claim 24
Dependent Claim
12 words
An article as in claim 1 , wherein the article is injection-molded.
Claim 25
Dependent Claim
28 words
An article as in claim 1 , wherein the article is form ed by urging a thermoplastic polymer into a mold and allowing the article to form therein.
Claim 26
Dependent Claim
33 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of no more than-about 0.075 inch and a void volume of at least about 5%.
Claim 27
Dependent Claim
33 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of no more than-about 0.075 inch and a void volume of at least about 5%.
Claim 28
Dependent Claim
16 words
An article as in claim 24 , having a void volume of at least about 10%.
Claim 29
Dependent Claim
16 words
An article as in claim 24 , having a void volume of at least about 15%.
Claim 30
Dependent Claim
16 words
An article as in claim 24 , having a void volume of at least about 20%.
Claim 31
Dependent Claim
16 words
An article as in claim 24 , having a void volume of at least about 30%.
Claim 32
Dependent Claim
14 words
An article as in claim having a void volume of at least about 40%.
Claim 33
Dependent Claim
16 words
An article as in claim 24 , having a void volume of at least about 50%.
Claim 34
Dependent Claim
23 words
An article as in claim 24 , including at least one portion having a cross-sectional dimension of no more than about 0.050 inch.
Claim 35
Dependent Claim
23 words
An article as in claim 24 , including at least one portion having a cross-sectional dimension of no more than about 0.025 inch.
Claim 36
Dependent Claim
23 words
An article as in claim 24 , including at least one portion having a cross-sectional dimension of no more than about 0.010 inch.
Claim 37
Dependent Claim
20 words
An article as in claim 24 , wherein at least 25% of the area of the article comprises said portion.
Claim 38
Dependent Claim
20 words
An article as in claim 24 , wherein at least 50% of the area of the article comprises said portion.
Claim 39
Dependent Claim
18 words
An article as in claim 24 , wherein 100% of the area of the article comprises said portion.
Claim 40
Dependent Claim
36 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of between about 0.075 inch and about 0.125 inch and a void volume of at least about 10%.
Claim 41
Dependent Claim
36 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of between about 0.075 inch and about 0.125 inch and a void volume of at least about 10%.
Claim 42
Dependent Claim
16 words
An article as in claim 37 , having a void volume of at least about 20%.
Claim 43
Dependent Claim
16 words
An article as in claim 37 , having a void volume of at least about 30%.
Claim 44
Dependent Claim
16 words
An article as in claim 37 , having a void volume of at least about 40%.
Claim 45
Dependent Claim
16 words
An article as in claim 37 , having a void volume of at least about 50%.
Claim 46
Dependent Claim
20 words
An article as in claim 37 , wherein at least 25% of the area of the article comprises said portion.
Claim 47
Dependent Claim
20 words
An article as in claim 37 , wherein at least 50% of the area of the article comprises said portion.
Claim 48
Dependent Claim
18 words
An article as in claim 37 , wherein 100% of the area of the article comprises said portion.
Claim 49
Dependent Claim
36 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of between about 0.125 inch and about 0.150 inch and a void volume of at least about 15%.
Claim 50
Dependent Claim
36 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of between about 0.125 inch and about 0.150 inch and a void volume of at least about 15%.
Claim 51
Dependent Claim
16 words
An article as in claim 45 , having a void volume of at least about 20%.
Claim 52
Dependent Claim
16 words
An article as in claim 45 , having a void volume of at least about 30%.
Claim 53
Dependent Claim
16 words
An article as in claim 45 , having a void volume of at least about 40%.
Claim 54
Dependent Claim
16 words
An article as in claim 45 , having a void volume of at least about 50%.
Claim 55
Dependent Claim
20 words
An article as in claim 45 , wherein at least 25% of the area of the article comprises said portion.
Claim 56
Dependent Claim
20 words
An article as in claim 45 , wherein at least 50% of the area of the article comprises said portion.
Claim 57
Dependent Claim
18 words
An article as in claim 45 , wherein 100% of the area of the article comprises said portion.
Claim 58
Dependent Claim
36 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of between about 0.150 inch and about 0.350 inch and a void volume of at least about 20%.
Claim 59
Dependent Claim
36 words
An article comprising: a molded microcellular polymeric foam article including at least one portion having a cross-sectional dimension of between about 0.150 inch and about 0.350 inch and a void volume of at least about 20%.
Claim 60
Dependent Claim
16 words
An article as in claim 53 , having a void volume of at least about 30%.
Claim 61
Dependent Claim
16 words
An article as in claim 53 , having a void volume of at least about 40%.
Claim 62
Dependent Claim
16 words
An article as in claim 53 , having a void volume of at least about 50%.
Claim 63
Dependent Claim
16 words
An article as in claim 53 , having a void volume of at least about 60%.
Claim 64
Dependent Claim
16 words
An article as in claim 53 , having a void volume of at least about 70%.
Claim 65
Dependent Claim
20 words
An article as in claim 53 , wherein at least 25% of the area of the article comprises said portion.
Claim 66
Dependent Claim
20 words
An article as in claim 53 , wherein at least 50% of the area of the article comprises said portion.
Claim 67
Dependent Claim
18 words
An article as in claim 53 , wherein 100% of the area of the article comprises said portion.
Claim 68
Dependent Claim
28 words
An article as in claim 53 , wherein the article includes at least one portion having a cross-sectional dimension of between about 0.150 inch and about 0.200 inch.
Claim 69
Dependent Claim
46 words
An article comprising: a molded microcellular polymeric article including a plurality of cells wherein at least 70% of the total number of cells have a cell size of less man 150 microns and a portion having a cross-sectional dimension of no more than about 0.125 inch.
Claim 70
Dependent Claim
46 words
An article comprising: a molded microcellular polymeric article including a plurality of cells wherein at least 70% of the total number of cells have a cell size of less man 150 microns and a portion having a cross-sectional dimension of no more than about 0.125 inch.
Claim 71
Dependent Claim
26 words
An article as in claim 63 , wherein less than 20% of the total number of cells have a cell size of greater than 800 microns.
Claim 72
Dependent Claim
26 words
An article as in claim 63 , wherein less than 20% of the total number of cells have a cell size of greater than 500 microns.
Claim 73
Dependent Claim
26 words
An article as in claim 63 , wherein less than 20% of the total number of cells have a cell size of greater than 200 microns.
Claim 74
Dependent Claim
15 words
An article as in claim 63 , having a void volume of at least 10%.
Claim 75
Dependent Claim
15 words
An article as in claim 63 , having a void volume of at least 20%.
Claim 76
Dependent Claim
15 words
An article as in claim 63 , having a void volume of at least 30%.
Claim 77
Dependent Claim
15 words
An article as in claim 63 , having a void volume of at least 40%.
Claim 78
Dependent Claim
15 words
An article as in claim 63 , having a void volume of at least 50%.
Claim 79
Dependent Claim
26 words
An article as in claim 63 , wherein at least 80% of the total number of cells have a cell size of less than 150 microns.
Claim 80
Dependent Claim
25 words
An article as in claim 63 , wherein at 90% of the total number of cells have a cell size of less than 150 microns.
Claim 81
Dependent Claim
26 words
An article as in claim 63 , wherein at least 95% of the total number of cells have a cell size of less than 150 microns.
Claim 82
Dependent Claim
26 words
An article as in claim 63 , wherein at least 99% of the total number of cells have a cell size of less than 150 microns.
Claim 83
Dependent Claim
26 words
An article as in claim 63 , wherein at least 70% of the total number of cells have a cell size of less than 1100 microns.
Claim 84
Dependent Claim
26 words
An article as in claim 63 , wherein at least 80% of the total number of cells have a cell size of less than 100 microns.
Claim 85
Dependent Claim
26 words
An article as in claim 63 , wherein at least 90% of the total number of cells have a cell size of less than 100 microns.
Claim 86
Dependent Claim
26 words
An article as in claim 63 , wherein at least 95% of the total number of cells have a cell size of less than 100 microns.
Claim 87
Dependent Claim
26 words
An article as in claim 63 , wherein at least 99% of the total number of cells have a cell size of less than 100 microns.
Claim 88
Dependent Claim
69 words
An article comprising: a three dimensional microcellular polymeric foam article having three intersecting, principal axes corresponding to the three dimensions, one of the dimensions associated with a first axis varying as a function of position along a second, perpendicular axis, the article including at least one portion having a cross-sectional dimension of no more than about 0.125 inch, the article having a void volume of at least about 20%.
Claim 89
Dependent Claim
69 words
An article comprising: a three dimensional microcellular polymeric foam article having three intersecting, principal axes corresponding to the three dimensions, one of the dimensions associated with a first axis varying as a function of position along a second, perpendicular axis, the article including at least one portion having a cross-sectional dimension of no more than about 0.125 inch, the article having a void volume of at least about 20%.
Claim 90
Dependent Claim
22 words
An article as in claim 1 , having a cell density of greater than at least 10 6 cells per cubic centimeter.
Claim 91
Dependent Claim
17 words
An article as in claim 1 , having an average cell size of less than 50 micron.
Claim 92
Dependent Claim
16 words
An article as in claim 1 , having a length-to-thickness ratio of at least about 75:1.
Claim 93
Dependent Claim
16 words
An article as in claim 1 , having a length-to-thickness ratio of at least about 150:1.
Claim 94
Dependent Claim
24 words
An article as in claim 1 , wherein the article is essentially free of residual chemical blowing agent or reaction-by-products of chemical blowing agent.
Claim 95
Dependent Claim
28 words
An article as in claim 1 , having a section of less than 0.100 inch, the section having a strength-to-density ratio of at least about 280,000 psi/g/cubic centimeter.
Claim 96
Dependent Claim
17 words
An article as in claim 1 , wherein the article is a molded microcellular thermoplastic elastomeric article.
Claim 97
Dependent Claim
26 words
An article as in claim 1 , including an outer skin having a thickness of at least three times an average cell size of the article.
Claim 98
Dependent Claim
12 words
An article as in claim 1 , comprising two dissimilar polymeric materials.
Claim 99
Dependent Claim
22 words
An article as in claim 24 , having a cell density of greater than at least 10 6 cells per cubic centimeter.
Claim 100
Dependent Claim
17 words
An article as in claim 24 , having an average cell size of less than 50 micron.
Claim 101
Dependent Claim
17 words
An article as in claim 24 , having an average cell size of less than 100 micron.
Claim 102
Dependent Claim
16 words
An article as in claim 24 , having a length-to-thickness ratio of at least about 75:1.
Claim 103
Dependent Claim
16 words
An article as in claim 24 , having a length-to-thickness ratio of at least about 150:1.
Claim 104
Dependent Claim
24 words
An article as in claim 24 , wherein the article is essentially free of residual chemical blowing agent or reaction-by-products of chemical blowing agent.
Claim 105
Dependent Claim
20 words
An article as in claim 24 , wherein the polymeric foam article is a molded microcellular thermoplastic elastomeric foam article.
Claim 106
Dependent Claim
17 words
An article as in claim 24 , wherein the article is a molded microcellular thermoplastic foam article.
Claim 107
Dependent Claim
17 words
An article as in claim 24 , wherein the article is an injection-molded microcellular polymeric foam article.
Claim 108
Dependent Claim
26 words
An article as in claim 24 , including an outer skin having a thickness of at least three times an average cell size of the article.
Claim 109
Dependent Claim
12 words
An article as in claim 24 , comprising two dissimilar polymeric materials.
Claim 110
Dependent Claim
13 words
An article as in claim 24 , wherein the article is essentially closed-cell.
Claim 111
Dependent Claim
21 words
An article as in claim 37 having a cell density of greater than at least 10 6 cells per cubic centimeter.
Claim 112
Dependent Claim
17 words
An article as in claim 37 , having an average cell size of less than 50 micron.
Claim 113
Dependent Claim
17 words
An article as in claim 37 , having an average cell size of less than 100 micron.
Claim 114
Dependent Claim
16 words
An article as in claim 37 , having a length-to-thickness ratio of at least about 75:1.
Claim 115
Dependent Claim
16 words
An article as in claim 37 , having a length-to-thickness ratio of at least about 150:1.
Claim 116
Dependent Claim
24 words
An article as in claim 37 , wherein the article is essentially free of residual chemical blowing agent or reaction-by-products of chemical blowing agent.
Claim 117
Dependent Claim
20 words
An article as in claim 37 , wherein the polymeric foam article is a molded microcellular thermoplastic elastomeric foam article.
Claim 118
Dependent Claim
17 words
An article as in claim 37 , wherein the article is a molded microcellular thermoplastic foam article.
Claim 119
Dependent Claim
17 words
An article as in claim 37 , wherein the article is an injection-molded microcellular polymeric foam article.
Claim 120
Dependent Claim
26 words
An article as in claim 37 , including an outer skin having a thickness of at least three times an average cell size of the article.
Claim 121
Dependent Claim
12 words
An article as in claim 37 , comprising two dissimilar polymeric materials.
Claim 122
Dependent Claim
13 words
An article as in claim 37 , wherein the article is essentially closed-cell.
Claim 123
Dependent Claim
22 words
An article as in claim 45 , having a cell density of greater than at least 10 6 cells per cubic centimeter.
Claim 124
Dependent Claim
17 words
An article as in claim 45 , having an average cell size of less than 50 micron.
Claim 125
Dependent Claim
17 words
An article as in claim 45 , having an average cell size of less than 100 micron.
Claim 126
Dependent Claim
16 words
An article as in claim 45 , having a length-to-thickness ratio of at least about 75:1.
Claim 127
Dependent Claim
16 words
An article as in claim 45 , having a length-to-thickness ratio of at least about 130:1.
Claim 128
Dependent Claim
24 words
An article as in claim 45 , wherein the article is essentially free of residual chemical blowing agent or reaction-by-products of chemical blowing agent.
Claim 129
Dependent Claim
20 words
An article as in claim 45 , wherein the polymeric foam article is a molded microcellular thermoplastic elastomeric foam article.
Claim 130
Dependent Claim
17 words
An article as in claim 45 , wherein the article is a molded microcellular thermoplastic foam article.
Claim 131
Dependent Claim
17 words
An article as in claim 45 , wherein the article is an injection-molded microcellular polymeric foam article.
Claim 132
Dependent Claim
26 words
An article as in claim 45 , including an outer skin having a thickness of at least three times an average cell size of the article.
Claim 133
Dependent Claim
12 words
An article as in claim 45 , comprising two dissimilar polymeric materials.
Claim 134
Dependent Claim
13 words
An article as in claim 45 , wherein the article is essentially closed-cell.
Claim 135
Dependent Claim
22 words
An article as in claim 53 , having a cell density of greater than at least 10 6 cells per cubic centimeter.
Claim 136
Dependent Claim
17 words
An article as in claim 53 , having an average cell size of less than 50 micron.
Claim 137
Dependent Claim
17 words
An article as in claim 53 , having an average cell size of less than 100 micron.
Claim 138
Dependent Claim
16 words
An article as in claim 53 , having a length-to-thickness ratio of at least about 75:1.
Claim 139
Dependent Claim
16 words
An article as in claim 53 , having a length-to-thickness ratio of at least about 150:1.
Claim 140
Dependent Claim
24 words
An article as in claim 53 , wherein the article is essentially free of residual chemical blowing agent or reaction-by-products of chemical blowing agent.
Claim 141
Dependent Claim
20 words
An article as in claim 53 , wherein the polymeric foam article is a molded microcellular thermoplastic elastomeric foam article.
Claim 142
Dependent Claim
17 words
An article as in claim 53 , wherein the article is a molded microcellular thermoplastic foam article.
Claim 143
Dependent Claim
17 words
An article as in claim 53 , wherein the article is an injection-molded microcellular polymeric foam article.
Claim 144
Dependent Claim
26 words
An article as in claim 53 , including an outer skin having a thickness of at least three times an average cell size of the article.
Claim 145
Dependent Claim
12 words
An article as in claim 53 , comprising two dissimilar polymeric materials.
Claim 146
Dependent Claim
13 words
An article as in claim 53 , wherein the article is essentially closed-cell.
Claim 147
Dependent Claim
22 words
An article as in claim 63 , having a cell density of greater than at least 10 6 cells per cubic centimeter.
Claim 148
Dependent Claim
17 words
An article as in claim 63 , having an average cell size of less than 50 micron.
Claim 149
Dependent Claim
17 words
An article as in claim 63 , having an average cell size of less than 100 micron.
Claim 150
Dependent Claim
16 words
An article as in claim 63 , having a length-to-thickness ratio of at least about 75:1.
Claim 151
Dependent Claim
16 words
An article as in claim 63 , having a length-to-thickness ratio of at least about 150:1.
Claim 152
Dependent Claim
24 words
An article as in claim 63 , wherein the article is essentially free of residual chemical blowing agent or reaction-by-products of chemical blowing agent.
Claim 153
Dependent Claim
20 words
An article as in claim 63 , wherein the polymeric foam article is a molded microcellular thermoplastic elastomeric foam article.
Claim 154
Dependent Claim
17 words
An article as in claim 63 , wherein the article is a molded microcellular thermoplastic foam article.
Claim 155
Dependent Claim
17 words
An article as in claim 63 , wherein the article is an injection-molded microcellular polymeric foam article.
Claim 156
Dependent Claim
26 words
An article as in claim 63 , including an outer skin having a thickness of at least three times an average cell size of the article.
Claim 157
Dependent Claim
12 words
An article as in claim 63 , comprising two dissimilar polymeric materials.
Claim 158
Dependent Claim
13 words
An article as in claim 63 , wherein the article is essentially closed-cell.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2008-04-25 | 2008-10-25 | 2009-04-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2012-04-25 | 2012-10-25 | 2013-04-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2016-04-25 | 2016-10-25 | 2017-04-26 | $7700.00 | Window Closed / Lapsed |