Patents Assigned to Trexel, Inc.
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Patent number: 7615170Abstract: Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.Type: GrantFiled: December 30, 2004Date of Patent: November 10, 2009Assignee: Trexel, Inc.Inventors: Jingyi Xu, Juan C. Cardona, Levi A. Kishbaugh
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Publication number: 20080226892Abstract: Polymer molding processes, such as injection-molding processes, include use of a viscosity-reducing supercritical fluid additive resulting in less breakage of reinforcing fibers upon introduction into the mold.Type: ApplicationFiled: March 20, 2008Publication date: September 18, 2008Applicant: Trexel, Inc.Inventors: Levi A. Kishbaugh, Kevin J. Levesque, Albert H. Guillemette, Liqin Chen, Jingyi Xu, Kelvin T. Okamoto
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Publication number: 20080187741Abstract: The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures.Type: ApplicationFiled: April 11, 2008Publication date: August 7, 2008Applicant: Trexel, Inc.Inventors: Joseph P. Vadala, Levi A. Kishbaugh, Kevin J. Levesque, David E. Pierick
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Patent number: 7364677Abstract: The invention provides in-mold decorated articles and methods to form the articles. The in-mold decorated articles include a polymeric portion having a substrate material adhered to a surface of the polymeric portion. The substrate material may be, for example, a film or a fabric. In some embodiments, the polymeric portion may be a foam and, particularly, a microcellular polymeric material. The articles are formed by injecting a mixture of blowing agent and polymeric material into a mold cavity in which the substrate material is disposed, so that the substrate material is forced against a wall of the mold cavity. The blowing agent, which in certain preferred cases is a supercritical fluid, decreases the viscosity of the polymeric material and, therefore, enables reductions in injection pressures and temperatures.Type: GrantFiled: May 18, 2004Date of Patent: April 29, 2008Assignee: Trexel, Inc.Inventors: Joseph P. Vadala, Jr., Levi A. Kishbaugh, Kevin J. Levesque, David E. Pierick
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Patent number: 7364788Abstract: Polymer molding processes, such as injection-molding processes, include use of a viscosity-reducing supercritical fluid additive resulting in less breakage of reinforcing fibers upon introduction into the mold.Type: GrantFiled: December 23, 2003Date of Patent: April 29, 2008Assignee: Trexel, Inc.Inventors: Levi A. Kishbaugh, Kevin J. Levesque, Albert H. Guillemette, Liqin Chen, Jingyi Xu, Kelvin T. Okamoto
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Patent number: 7361294Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.Type: GrantFiled: February 2, 2005Date of Patent: April 22, 2008Assignee: Trexel, Inc.Inventors: David E. Pierick, Jere R. Anderson, Sung Woon Cha, Liqin Chen, James F. Stevenson, Dana E. Laing
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Publication number: 20080050576Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.Type: ApplicationFiled: August 20, 2007Publication date: February 28, 2008Applicant: Trexel, Inc.Inventors: David Pierick, Jere Anderson, Sung Cha, Liqin Chen, James Stevenson, Dana Laing
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Patent number: 7318713Abstract: Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.Type: GrantFiled: July 18, 2002Date of Patent: January 15, 2008Assignee: Trexel, Inc.Inventors: Jingyi Xu, Juan C. Cardona, Levi A. Kishbaugh
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Patent number: 7267534Abstract: The invention provides systems, methods, and articles useful in the production of foams, and, in particular microcellular foams. The systems include a restriction element that reduces the backflow of polymer melt in an extruder while polymeric material is injected into a mold or ejected from a die. The restriction element is positioned upstream of a blowing agent injection port to maintain the solution of polymer and blowing agent in the extruder above a minimum pressure throughout an injection or ejection cycle, and preferably above the critical pressure required for the maintenance of a single-phase solution of polymer and blowing agent. The systems can be used in injection molding, blow molding, or in any other processing techniques that include injection or ejection cycles. In some embodiments, the systems utilize reciprocating screws for injection or ejection.Type: GrantFiled: June 16, 2003Date of Patent: September 11, 2007Assignee: Trexel, Inc.Inventor: Jingyi Xu
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Publication number: 20070141188Abstract: The present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.Type: ApplicationFiled: October 6, 2006Publication date: June 21, 2007Applicant: Trexel, Inc.Inventor: Roland Kim
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Patent number: 7172333Abstract: An injection molding screw for metal injection molding includes a first end, a second end, a longitudinal body with a first stage and a second stage extending axially along a length of the screw between the ends, a pressure retention device, and optionally, a screw tip. The pressure retention element minimizes loss of pressure in the second stage portion.Type: GrantFiled: June 13, 2003Date of Patent: February 6, 2007Assignees: Southco, Inc., Trexel, Inc.Inventors: Glenn Anderson, Jingyi Xu
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Patent number: 7144532Abstract: The present invention provides blowing agent introduction systems and methods for introducing blowing agent into polymeric foam processing systems. The methods may involve introducing one or more doses of blowing agent into polymeric material in an extruder during a plastication period of a molding cycle. Prior to introduction, a dose is confined in an accumulator which, for example, has a volume defined between an inlet valve and an outlet valve. A control system may receive inputs related to system parameters (e.g., pressure of polymeric material in extruder, axial position of screw in barrel, whether screw is rotating, and the like) and based on the inputs coordinates operation of the valves to confine and introduce the blowing agent dose(s). The introduction systems may be used in discontinuous plasticating processes, such as injection molding and blow molding, and can be particularly useful in processes that use precise quantities of blowing agent.Type: GrantFiled: October 28, 2002Date of Patent: December 5, 2006Assignee: Trexel, Inc.Inventor: Roland Y. Kim
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Publication number: 20060035988Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.Type: ApplicationFiled: February 2, 2005Publication date: February 16, 2006Applicant: Trexel, Inc.Inventors: David Pierick, Jere Anderson, Sung Cha, Liqin Chen, James Stevenson, Dana Laing
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Publication number: 20050256215Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.Type: ApplicationFiled: April 25, 2005Publication date: November 17, 2005Applicant: Trexel, Inc.Inventors: Theodore Burnham, Sung Cha, Robert Walat, Roland Kim, Jere Anderson, James Stevenson, Nam Suh, Matthew Pallaver
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Patent number: 6926507Abstract: The invention provides a blowing agent delivery system for introducing a blowing agent into a polymeric foam processing system. The delivery system is designed to discontinuously introduce blowing agent from a continuous source into polymeric material within an extruder. The system, thus, may improve control over blowing agent delivery in discontinuous polymer processing systems such as injection molding or blow molding. In some embodiments, the blowing agent delivery system selectively directs blowing agent flow from the source to the extruder barrel, or through a bypassing passageway. In this manner, blowing agent may be continuously supplied by the source but discontinuously injected into the extruder barrel. During use, the delivery system may cause blowing agent to flow through the bypassing passageway, for example, when the screw stops plasticating polymeric material.Type: GrantFiled: February 13, 2001Date of Patent: August 9, 2005Assignee: Trexel, Inc.Inventors: Juan C. Cardona, Kevin J. Levesque, Theodore A. Burnham, Alan F. Matthieu, Roland Y. Kim
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Publication number: 20050163881Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.Type: ApplicationFiled: February 2, 2005Publication date: July 28, 2005Applicant: Trexel, Inc.Inventors: David Pierick, Jere Anderson, Sung Cha, Liqin Chen, James Stevenson, Dana Laing
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Publication number: 20050143479Abstract: Injection molding and blow molding systems that include screws having low L:D ratios are provided. The systems are capable of producing microcellular polymeric materials. In some cases, the systems may be formed by retrofitting conventional polymer processing systems. Retrofitting may involve changing (e.g., machining or replacing) existing components of the conventional system, as well as, adding new components to the system. For example, retrofitting generally involves replacing the conventional polymer processing screw with a new screw designed to satisfy conditions needed for processing microcellular materials. In other cases, the systems may be newly manufactured. The retrofitted or newly manufactured systems of the invention are considerably less expensive than newly manufactured microcellular processing systems having higher L:D ratios.Type: ApplicationFiled: December 30, 2004Publication date: June 30, 2005Applicant: Trexel, Inc.Inventors: Jingyi Xu, Juan Cardona, Levi Kishbaugh
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Patent number: 6884823Abstract: Injection molding systems and methods useful for making microcellular foamed materials are provided as well as microcellular articles. Pressure drop rate and shear rate are important features in some embodiments, and the invention provides systems for controlling these parameters in an injection molding system. Another aspect involves an injection molding system including a nucleator that is upstream of a pressurized mold. Another aspect involves an extrusion system with the reciprocating screw for forming a single phase solution of non-nucleated blowing agent and polymeric material. Another aspect involves very thin walled microcellular material and very thin walled polymeric material. Another aspect provides a method for producing high weight reductions in very thin-walled parts with surfaces that have no noticeable differences from non-foamed parts.Type: GrantFiled: June 18, 1999Date of Patent: April 26, 2005Assignee: Trexel, Inc.Inventors: David E. Pierick, Jere R. Anderson, Sung W. Cha, Liqin Chen, James F. Stevenson, Dana E. Laing
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Patent number: 6884377Abstract: Continuous polymeric extrusion nucleation systems and methods useful for making polymeric microcellular foamed materials, including crystalline and semi-crystalline polymeric microcellular materials, are provided. Pressure drop rate is an important feature in some embodiments, and the invention provides systems for controlling these and other parameters. One aspect involves a multiple-pathway nucleator that is separated from a shaping die by a residence chamber. Another aspect involves a die for making advantageously thick articles, including a multiple-pathway nucleation section. Microcellular material can be continuously extruded onto wire, resulting in a very thin, essentially closed-cell microcellular insulating coating secured to a wire. Other very thin microcellular products can be fabricated as well.Type: GrantFiled: July 27, 2000Date of Patent: April 26, 2005Assignee: Trexel, Inc.Inventors: Theodore A. Burnham, Sung W. Cha, Robert H. Walat, Roland Y. Kim, Jere R. Anderson, James F. Stevenson, Nam P. Suh, Matthew Pallaver
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Publication number: 20050042434Abstract: Polymer molding processes, such as injection-molding processes, include use of a viscosity-reducing supercritical fluid additive resulting in less breakage of reinforcing fibers upon introduction into the mold.Type: ApplicationFiled: December 23, 2003Publication date: February 24, 2005Applicant: Trexel, Inc.Inventors: Levi Kishbaugh, Kevin Levesque, Albert Guillemette, Liqin Chen, Jingyi Xu, Kelvin Okamoto