Injection molding of crosslinking polymers

Abstract

Non-time dependent measured variables are used to effectively determine an optimal hold profile for an expanding crosslinking polymer part in a mold cavity. A system and/or approach may first inject molten expanding crosslinking polymer into a mold cavity, then measure at least one non-time dependent variable during an injection molding cycle. Next, the system and/or method commences a hold profile for the part, and upon completing the hold profile, the part is ejected from the mold cavity, whereupon a cure profile is commenced.

What is claimed is: 
     
         1 . An expanding crosslinking polymer injection molding system comprising:
 an injection molding machine comprising an injection unit and a mold forming a mold cavity, the injection unit adapted to receive and inject a molten expanding crosslinking plastic material into the mold cavity to form a molded part;   a controller adapted to control operation of the injection molding machine; and   one or more sensors coupled to the injection molding machine and the controller;   wherein at least one of the one or more sensors is adapted to measure at least one non-time dependent variable during the injection mold cycle, wherein the controller is adapted to commence a hold profile for the expanding crosslinking polymer part and is further adapted to cause the molded part to be ejected from the mold cavity upon completing the hold profile and commence a cure profile for the molded part.   
     
     
         2 . The system of  claim 1 , wherein the controller commences the hold profile by commencing the hold profile when the measured at least one non-time dependent variable reaches a first threshold value, restricting additional molten expanding crosslinking polymer from being injected into the mold cavity, and terminating the hold profile when the measured at least one non-time dependent variables reaches a second threshold value. 
     
     
         3 . The system of  claim 2 , wherein the first threshold value is indicative of the mold cavity being substantially full of molten expanding cross linking polymer. 
     
     
         4 . The system of  claim 2 , wherein the second threshold value is indicative of the part being structurally sound. 
     
     
         5 . The system of  claim 2 , wherein the measured at least one non-time dependent variable comprises a cavity pressure value. 
     
     
         6 . The system of  claim 1 , wherein the hold profile commences at a substantially constant pressure. 
     
     
         7 . The system of  claim 1 , wherein commencing the cure profile comprises:
 measuring a different non-time dependent variable; and   upon the measured different non-time dependent variables reaching a third threshold value, terminating the hold profile.   
     
     
         8 . The system of  claim 7 , wherein the third threshold value is indicative of the part being structurally sound. 
     
     
         9 . The system of  claim 7 , wherein the measured different non-time dependent variable comprises a pressure value. 
     
     
         10 . The system of  claim 1 , wherein commencing the cure profile comprises allowing the part to cool for a predetermined amount of time.