The present disclosure relates to a process and article produced by injection molding. More particularly, a process and article produced by injection molding, that provides a part with one or more locations of a reduced density where such part competes in mechanical property characteristics with parts, such as vehicular components, otherwise produced from metallic materials.

A method for filling a mold cavity of a mold for producing a particle foam molding using particle foam material includes providing particle foam material, to be processed in a mold cavity of a mold for producing a particle foam molding, via at least one filling container device, wherein there is a first pressure level in the filling container device. The method also includes providing a mold cavity which is to be filled with a particle foam material that is to be processed for producing the or a particle foam molding, wherein there is a second pressure level in the mold cavity, and filling the mold cavity with particle foam material from the filling container device, wherein during the filling of the mold cavity a difference between the first pressure level and the second pressure level is purposefully varied by at least one measure for varying the difference between the first pressure level and the second pressure level.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

On a foam plastics molding machine, a molding unit, defined by a mold and an interface frame equipped with a number or quantity of plastic molding material and operating fluid inlets, is loaded into a raised window in a fixed frame of the machine by positioning the molding unit in a fixed position on a trolley; positioning the trolley astride a fixed platform; raising the platform so that vertical ribs on the interface frame slidably engage corresponding vertical guides forming part of the machine and on a level with the window; connecting the guides to the ribs; and moving the guides towards the window.

A containment jig (A) is disclosed of a holding apparatus for household appliance cabinets in a foaming system and its related locking mechanism, which includes holding walls (1, 2, 4), provided with a base edge and a free edge, apt to withhold a pressure force, basements (B1, B2), mutually approachable between a spaced relative position and a close relative position, which the base edges of said holding walls (1, 2, 4) are attached to locking means to constrain said free edges of said holding walls (1, 2, 4) to an opposite one of said basements (B1, B2) when they are in said close relative position, said locking means including, on one hand, one or more locking prongs (5, 6) and, on the other hand, corresponding matching seats, at least one of said locking prongs and said matching seats being mounted adjustable in position by a control.

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.

An injection molding method includes providing a molding device including a first mold, a second mold over the first mold and a first mold cavity defined by the first mold and the second mold; injecting a first material into the first mold cavity; forming a first layer from the first material; replacing the second mold by a third mold; injecting a second material into a second mold cavity defined by the first mold and the third mold; and forming a second layer from the second material disposed over the first layer, wherein the first material is different from the second material.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.