A method for manufacturing a stator for an electric machine, having the following steps: inserting a cast body with a nozzle from a first side of the stator into the stator, inserting a cast counterbody from a second opposing side of the stator into the stator, casting the stator with thermoplastic, thermosetting plastic, or resin by means of the nozzle, curing the thermoplastic, thermosetting plastic, or resin, wherein following the curing a cast-on piece of the thermoplastic, thermosetting plastic, or resin is sheared off using a rotational movement of the cast body or cast counterbody.

A method enabling the selection, modification and/or creation of polymer materials which can provide improved response to the application of local shear and/or extensional deformation inside the polymer melt in manufacturing technologies including injection molding, injection stretch blow molding, direct injection, extrusion blow molding, sheet extrusion, thermoforming, etc., is provided. A method for manufacturing a polymer article includes injecting or extruding molten polypropylene, polyethylene or polyester based polymer for converting it into semi-final shape while applying shear and/or extensional deformation on the polymer melt. Applying shear and/or extensional deformation on the polymer melt includes selectively modifying the flow path of the molten semi-crystallizable polymer as a function of local pressure profile over at least part of the flow path. Local pressure profile is a function of optimized response of the polymer melt to the applied local shear and/or extensional deformation over at least the part of the flow path.

A method of the selection, modification of existing, and/or creation of polyester based polymer materials, which provide improved response to the application of local shear and/or extensional deformation inside the polyester based polymer melt in injection stretch blow molding, is disclosed. A method for manufacturing a polymer article is also provided including injecting a molten polyester based polymer in a preform mold for converting it in a preform while applying shear and/or extensional deformation on the polyester based polymer melt. Applying shear and/or extensional deformation on the polyester based polymer melt includes modifying the flow path of the molten polymer as a function of local pressure profile over at least part of the flow path. The local pressure profile is determined as a function of optimized response of the polyester based polymer melt to the applied local shear and/or extensional deformation over at least said part of the flow path.

A polymer injection molding system in one embodiment includes a manifold comprising internal flow conduits configured for conveying polymer in a fluidic state. The manifold may be part of a hot or cold runner type molding unit. An injection nozzle fluidly coupled to the flow conduits interfaces with a mold cavity and is configured to inject polymer therein to form a molded article. The nozzle has a tubular valve body defining a central axial passage which receives a movable elongated valve pin. The valve pin is linearly movable to change the nozzle between open and closed positions for discharging or stopping polymer flow therefrom. The valve pin is further rotatable about its axis to induce shear on the polymer. This maintains the polymer in its flowable fluidic state between molding cycles to prevent polymer cold slug formation within the nozzle which can disrupt the flow resulting in incompletely formed articles.

A polymer injection molding system in one embodiment includes a manifold comprising internal flow conduits configured for conveying polymer in a fluidic state. The manifold may be part of a hot or cold runner type molding unit. An injection nozzle fluidly coupled to the flow conduits interfaces with a mold cavity and is configured to inject polymer therein to form a molded article. The nozzle has a tubular valve body defining a central axial passage which receives a movable elongated valve pin. The valve pin is linearly movable to change the nozzle between open and closed positions for discharging or stopping polymer flow therefrom. The valve pin is further rotatable about its axis to induce shear on the polymer. This maintains the polymer in its flowable fluidic state between molding cycles to prevent polymer cold slug formation within the nozzle which can disrupt the flow resulting in incompletely formed articles.

A method enabling the selection, modification and/or creation of polymer materials which can provide improved response to the application of local shear and/or extensional deformation inside the polymer melt in manufacturing technologies including injection molding, injection stretch blow molding, direct injection, extrusion blow molding, sheet extrusion, thermoforming, etc., is provided. A method for manufacturing a polymer article includes injecting or extruding molten polypropylene, polyethylene or polyester based polymer for converting it into semi-final shape while applying shear and/or extensional deformation on the polymer melt. Applying shear and/or extensional deformation on the polymer melt includes selectively modifying the flow path of the molten semi-crystallizable polymer as a function of local pressure profile over at least part of the flow path. Local pressure profile is a function of optimized response of the polymer melt to the applied local shear and/or extensional deformation over at least the part of the flow path.

A method enabling the selection, modification and/or creation of polymer materials which can provide improved response to the application of local shear and/or extensional deformation inside the polymer melt in manufacturing technologies including injection molding, injection stretch blow molding, direct injection, extrusion blow molding, sheet extrusion, thermoforming, etc., is provided. A method for manufacturing a polymer article includes injecting or extruding molten polypropylene, polyethylene or polyester based polymer for converting it into semi-final shape while applying shear and/or extensional deformation on the polymer melt. Applying shear and/or extensional deformation on the polymer melt includes selectively modifying the flow path of the molten semi-crystallizable polymer as a function of local pressure profile over at least part of the flow path. Local pressure profile is a function of optimized response of the polymer melt to the applied local shear and/or extensional deformation over at least the part of the flow path.

The present disclosure provides a method of measuring a true shear viscosity profile of a molding material in a capillary and a molding system performing the same. The method includes the operations of: determining a setpoint temperature of the molding material before injecting into the capillary; obtaining an initial shear viscosity profile at the setpoint temperature with respect to a shear rate of the molding material; fitting an initial temperature profile with respect to the shear rate according to the initial shear viscosity based on Cross William-Landel-Ferry model; fitting a first shear viscosity profile and a first temperature profile with respect to the shear rate according to the initial temperature profile based on the Cross-WLF model; and setting the first shear viscosity profile as the true shear viscosity profile when a difference between the first temperature profile and the initial temperature profile is not greater than a threshold.

The present disclosure provides a method of measuring a true shear viscosity profile of a molding material in a capillary and a molding system performing the same. The method includes the operations of: determining a setpoint temperature of the molding material before injecting into the capillary; obtaining an initial shear viscosity profile at the setpoint temperature with respect to a shear rate of the molding material; fitting an initial temperature profile with respect to the shear rate according to the initial shear viscosity based on Cross William-Landel-Ferry model; fitting a first shear viscosity profile and a first temperature profile with respect to the shear rate according to the initial temperature profile based on the Cross-WLF model; and setting the first shear viscosity profile as the true shear viscosity profile when a difference between the first temperature profile and the initial temperature profile is not greater than a threshold.

The present disclosure provides a molding system for preparing an injection-molded plastic article. The molding system includes a molding machine; a mold disposed on the molding machine and having a mold cavity for being filled with a molding resin including a plurality of polymer chains; a processing module configured to generate an anisotropic viscosity distribution of the molding resin in the mold cavity based on a molding condition for the molding machine; wherein the anisotropic viscosity distribution of the molding resin is generated based in part on consideration of an integral effect of a volume fraction and an aspect ratio of the plurality of fibers; and a controller coupled to the processing module and configured to control the molding machine with the molding condition using the generated anisotropic viscosity distribution of the molding resin to perform an actual molding process for preparing the injection-molded plastic article.