Method of fabricating an injection molded component

• US 8,691,126 B2
• Filed: 01/18/2011
• Issued: 04/08/2014
• Est. Priority Date: 01/18/2011
• Status: Active Grant

• Current Assignee: Wisconsin Alumni Research Foundation (University of Wisconsin System)
• Original Assignee: Wisconsin Alumni Research Foundation (University of Wisconsin System)
• Inventors: Turng, Lih-Sheng, Peng, Jun
• Primary Examiner(s): HEITBRINK, JILL LYNNE
• Application Number:
  US13/008,401
• Publication Number:
  US 20120181729A1
• Time in Patent Office: 1,176 Days
• Field of Search: 264/328.17, 264/41, 264/51, 264/53
• US Class Current: 264/41
• CPC Class Codes: B29C 2045/1702 dissolving or absorbing a fluid in the plastic material
• CPC Class Codes: B29C 44/3469 Cell or pore nucleation
• CPC Class Codes: B29C 44/42 using pressure difference, e.g. by injection or by vacuum
• CPC Class Codes: B29C 45/17 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29K 2105/041 Microporous

Abstract

A method of fabricating a foamed, injection-molded component is provided. The method includes the step of introducing a liquid, a nucleating agent and a polymer into an injection barrel of an injection molding machine. The liquid, the nucleating agent and the polymer are injected into a mold corresponding in shape to the component and the component is released from the mold.

Claims

1. A method of fabricating an injection-molded component, comprising the steps of:

dispersing a nucleating agent in a liquid, the liquid including water;

introducing a polymer directly into an injection barrel of an injection molding machine;

introducing the liquid and nucleating agent directly into the injection barrel of the injection molding machine, at least a portion of the liquid and the nucleating agent being isolated from the polymer prior to introduction into the injection barrel;

plasticizing the polymer in the injection barrel;

mixing the liquid and nucleating agent into the plasticized polymer;

injecting the mixed liquid, nucleating agent and polymer into a mold corresponding in shape to the component; and

releasing the component from the mold.

2. The method of claim 1 wherein the nucleating agent is a salt.

3. The method of claim 1 wherein the nucleating agent is dissolved in the liquid prior to introduction into the injection barrel.

4. The method of claim 1 comprising the additional step of introducing an additive into the injection barrel, the additive altering a physical characteristic of the formed component.

5. A method of fabricating an injection-molded component, comprising the steps of:

dispersing a nucleating agent in a liquid, the liquid including water;

introducing the liquid directly into an injection barrel of an injection molding machine;

introducing a polymer into the injection barrel of the injection molding machine, the polymer being isolated from at least a portion of the liquid prior to introduction into the injection barrel;

plasticizing the polymer in the injection barrel;

mixing the liquid into the plasticized polymer;

injecting the mixed liquid and polymer into a mold corresponding in shape to the component; and

releasing the component from the mold.

6. The method of claim 5 wherein the nucleating agent is a salt.

7. The method of claim 5 wherein the nucleating agent is sodium chloride.

8. The method of claim 5 comprising the additional step of introducing an additive into the injection barrel, the additive altering a physical characteristic of the formed component.

9. The method of claim 5 wherein the step of dispersing the nucleating agent in the liquid includes the step of dissolving the nucleating agent in the liquid.