Three-dimensional (3D) suction molding methods and related polymeric foam articles are described. The methods may be used in discontinuous plastication processes.

The method for manufacturing a foamed product uses a manufacturing apparatus having a plasticizing cylinder in which an introduction port for introducing a physical blowing agent into a starvation zone is formed, and an introduction speed adjustment container connected to the introduction port, wherein the manufacturing method comprises: turning a thermoplastic resin into a molten resin; introducing the physical blowing agent at a predetermined pressure into the starvation zone through the introduction speed adjustment container and maintaining the starvation zone at a predetermined pressure; setting the molten resin to a starved state; bringing the molten resin in the starved state and the pressurized fluid into contact with each other; and molding the molten resin into a foamed product. The maximum value of the inner diameter of the introduction speed adjustment container is larger than the inner diameter of the introduction port.

Injection molding methods used to form polymeric foam articles (e.g., microcellular foam articles) are described herein.

A foam molding method includes: moving a screw backward to take air into a heating barrel through a nozzle part in a state in which a shut-off nozzle is opened, the shut-off nozzle that opens or closes the nozzle part for injecting the molten resin and is disposed on a heating barrel; closing the shut-off nozzle and moving the screw forward, to diffuse the air taken into the heating barrel, in the molten resin in the heating barrel; feeding the molten resin forward while dispersing the air as the air bubbles in the molten resin by moving the screw backward while rotating it in a state in which the shut-off nozzle is closed; and opening the shut-off nozzle, to inject the molten resin containing the dispersed air bubbles into the cavity.

Methods and systems of introducing blowing agent in a polymeric foam process are described. The methods and systems may be used to discontinuously introduce blowing agent in polymeric foam processes (e.g., injection molding processes) that discontinuously plasticate polymeric material.

A supercritical fluid microcellular injection molding method includes the following steps. Preheating: the feed pipe is preheated to a hot melt temperature of polymer. Feeding: the polymer is poured into the hopper and enters the feed pipe. A metering screw is rotatably received in the feed pipe for forwardly pushing the hot molten polymer when being rotated. Injecting SCF: the SCF is injected into the feed pipe and mixed with the hot molten polymer into a homogeneous monophasic fluid. Quantitative discharge and depressurization: the monophasic fluid flows across a first gear pump and a second gear pump mounted on the front end of the feed pipe. Discharging and molding: the monophasic fluid actuated by the first gear pump and the second gear pump is injected and molded by the die head fixed to the discharge end of the second gear pump.

The disclosure is directed to a solid part, and a device and process of making the solid part. The process includes introducing a glass fiber filled polymeric material to a hopper of an injection molding machine, where the glass fibers have a pre-molding length, melting the glass fiber filled polymeric material to form a melt in a plasticizing unit, pressurizing the plasticizing unit of the injection molding machine with a blowing agent, dissolving the blowing agent into the melt, injecting the melt into a mold cavity up to 100% of volume, and forming the solid part.

A producing method for producing a foam-molded product by using a plasticizing cylinder having, from an upstream side in the following order: a plasticization zone, a flow rate adjusting zone and a starvation zone, the producing method includes: plasticizing and melting a thermoplastic resin into a molten resin in the plasticization zone; adjusting a flow rate of the molten resin in the flow rate adjusting zone; allowing the molten resin to be in a starved state in the starvation zone; introducing a pressurized fluid containing the physical foaming agent having a fixed pressure into the starvation zone so as to retain the starvation zone at the fixed pressure; bringing the molten resin in the starved state in contact with the pressurized fluid in the starvation zone in a state in which the starvation zone is retained at the fixed pressure; and molding the molten resin into the foam-molded product.

A monolithic injection molded plastic part including an interior core, a surface formed as a monolithic structure with the interior core, and a distribution of hollow cells formed within the interior core during an injection molding process from a blowing agent and methods for making the same are provided. Such methods include preparing a mixture of unmelted plastic resin, filler agent, and blowing agent, melting the mixture into a viscous combination using a standard injection molding machine, injecting a set amount of the viscous combination into a hollow cavity of an injection mold secured within the standard injection molding machine, and holding the set amount of the viscous combination in the hollow cavity at a low pressure for a hold time until the viscous combination sets into a monolithic structure at least partially filling the hollow cavity and the blowing agent forms a distribution of hollow cells throughout the monolithic structure.

A monolithic injection molded plastic part including an interior core, a surface formed as a monolithic structure with the interior core, and a distribution of hollow cells formed within the interior core during an injection molding process from a blowing agent and methods for making the same are provided. Such methods include preparing a mixture of unmelted plastic resin, filler agent, and blowing agent, melting the mixture into a viscous combination using a standard injection molding machine, injecting a set amount of the viscous combination into a hollow cavity of an injection mold secured within the standard injection molding machine, and holding the set amount of the viscous combination in the hollow cavity at a low pressure for a hold time until the viscous combination sets into a monolithic structure at least partially filling the hollow cavity and the blowing agent forms a distribution of hollow cells throughout the monolithic structure.