System and methods for a foaming process

Patent metadata

Field	Value
Publication number	US-2025144854-A1
Application number	US-202519015354-A
Country	US
Kind code	A1
Filing date	Jan 9, 2025
Priority date	Nov 21, 2018
Publication date	May 8, 2025
Grant date	—

Abstract

A foaming process and a method for operation of the foaming process are provided. The method includes flowing a molten polymeric material into a mold from an upstream device, receiving the molten polymeric material in a cavity of the mold, and maintaining a repeatable, uniform pressure profile as the molten polymeric material is delivered into the mold.

First claim

What is claimed is:

1 . A method for a foaming process, comprising:
flowing a molten polymeric material into a mold from an upstream device; receiving the molten polymeric material in a cavity of the mold; and maintaining a repeatable, uniform pressure profile after the molten polymeric material is delivered into the mold.

2 . The method of claim 1 , wherein maintaining the pressure profile includes adjusting the flowing of the molten polymeric material in response to a measured pressure in a nozzle of the upstream device while the molten polymeric material is injected into the mold and maintaining positive pressure on the molten polymeric material in the mold after injection of a predetermined amount of the molten polymeric material into the mold is completed.

3 . The method of claim 2 , further comprising removing the positive pressure on the molten polymeric material in the mold after a duration of time elapses.

4 . The method of claim 1 , wherein flowing the molten polymeric material into the mold comprises injecting a material comprising a plurality of pellets of different compositions and/or sizes.

5 . The method of claim 1 , wherein flowing the molten polymeric material into the mold includes forming a molten single phase solution (SPS) from a blowing agent and the molten polymeric material, the blowing agent dissolved in the molten polymeric material.

6 . The method of claim 1 , wherein maintaining the pressure profile of a nozzle of the upstream device is achieved by adjusting a rate that the molten polymeric material is injected into the cavity by the upstream device, the pressure profile including a fixed pressure, and adapting a screw of the upstream device to be automatically adjusted, the screw controlling an injection rate of the molten polymeric material into the cavity.

7 . The method of claim 1 , wherein maintaining the pressure profile in a nozzle of the upstream device is further achieved by adjusting a temperature of the molten polymeric material.

8 . The method of claim 1 , further comprising thermally curing the molten polymeric material over a consistent, reproducible period of time after the molten polymeric material is released from the mold and expands.

9 . The method of claim 1 , further comprising continuously monitoring, by a controller, the pressure profile using signals received from a pressure sensor and dynamically adjusting a flow rate of the molten polymeric material through a nozzle using a closed-pressure sensing loop in response to real-time data.

10 . The method of claim 9 , further comprising implementing, by the controller, a condition indicator that dynamically adjusts the flow rate of the molten polymeric material, based on real-time feedback from the pressure sensor and the closed-pressure sensing loop.

11 . The method of claim 1 , wherein the upstream device comprises a heating device, a temperature sensor, a screw, a barrel coupled to a nozzle, a pressure sensor, a closed-pressure sensing loop, and a controller connected to the heating device, the temperature sensor, the pressure sensor, and the closed-pressure sensing loop.

12 . The method of claim 11 , further comprising:
continuously monitoring, by the controller, both a temperature and a pressure of the molten polymeric material in the barrel using signals received from the temperature sensor and the pressure sensor; dynamically adjusting, by the controller, the temperature and pressure of the molten polymeric material using a condition indicator and the closed-pressure sensing loop to ensure consistent flow of the molten polymeric material into the mold; and determining, by the controller, that the molten polymeric material has reached a desired temperature and pressure, and synchronizing injection of the molten polymeric material into the mold.

Assignees

• Nike Inc

Inventors

• Hannemann Shayne
• Mcconnell Kimberly N
• Meyer Justin A
• Pollard Rick A

Classifications

• B29K2075/00

  Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• B29C44/42

  using pressure difference, e.g. by injection or by vacuum · CPC title

• B29C44/60 Primary

  Measuring, controlling or regulating · CPC title

• B29K2105/04

  cellular or porous · CPC title