Abstract: Disclosed herein are novel shut-off nozzles for injection molding systems for creating and injecting foaming polymers to form molded polymer products. In one embodiment, a shut-off nozzle includes a main body with a flow path, a connector body securable to the main body, a nozzle tip securable to the main body, and a shut-off mechanism. The nozzle tip includes an internal passage and a cooling mechanism for solidifying molten polymer in the nozzle tip at an end of an injection cycle of an injection molding process such that the solidified polymer in the nozzle tip is joined with a formed polymer part. When the main body and nozzle tip are secured together the flow path is colinear with the internal passage. The shut-off mechanism includes a passageway intersecting the flow path at an angle to the flow path and a pin positioned in the passageway.

Abstract: Disclosed herein is a product and methods of using that product for constructing walls and other structures. The product is a locking block that is designed for use in building walls and other structures quickly and inexpensively. The locking blocks are fabricated from polymers to form a robust physical structure that resists damage and provides for a relatively clean work space during assembly. The locking blocks include matching male and female features that reversibly secure the blocks together and are self-aligning to guide workmen on block placement during assembly. The design of the blocks eliminates the need to apply mortar or other adhesive methods to secure the blocks together, which greatly reduces labor costs as compared to typical construction products and methods. Because no mortar or other adhesive is used, the blocks can be efficiently and effectively disassembled and reused.

Abstract: Molded polymer foam articles are described as having a novel a foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article, including in the surface region extending 500 microns beneath the surface of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a thickness of more than 2 cm, a volume of more than 1000 cm3; or both a volume of more than 1000 cm3 and a thickness of more than 2 cm. Methods of making the molded polymer foam articles are also described.

Abstract: Disclosed herein are novel methods for forming a polymer part including providing an injection molding system with a shut-off nozzle, where the shut-off nozzle includes a main body, a nozzle tip body, a flow path through the main body and the nozzle tip body, a nozzle tip, and a shut-off mechanism. The nozzle tip includes an internal passage and a cooling mechanism. The shut-off mechanism includes a passageway intersecting the flow path at an angle and a pin positioned in the passageway. The method further includes the steps of initiating an injection molding cycle by injecting molten polymer through the shut-off nozzle into a cavity of a mold, actuating the shut-off mechanism to move the pin in the passageway into the intersection of the passageway and flow path, and initiating the cooling mechanism to solidify molten polymer in the nozzle tip to form a solid slug.

Abstract: Disclosed herein is a novel shut-off nozzle for use with an injection molding system for creating and injecting foaming polymers to form products and other components. The shut-off nozzle is designed to increase cell nucleation during the foaming process, increase the pressure drop rate as the polymer is injected into a mold, and stop drooling of the foamed polymer at the end of an injection cycle. The shut-off nozzle includes an angled shut-off needle, which significantly reduces the amount of waste in each injection cycle and a water-cooling circuit to rapidly cool and solidify the molten polymer remaining in the shut-off nozzle at the end of each injection cycle.

Abstract: Disclosed herein are methods and systems for determining mold designs, polymer formulations, and processing parameters for forming a thermoplastic foam with desired cellular structure and mechanical and physical properties. In one example, the system includes a plaque mold and a plurality of interchangeable mold cavities including one pair of mold cavities used to form a solid polymer sample and two or more pairs of mold cavities for forming thermoplastic foam samples. The mold cavities include a plurality of sensors to determine pressures and temperature at various locations within the mold cavities. Samples are compared and determinations are made based on the comparison and evaluation of data regarding mold designs, formulations, and/or processing parameters.

Abstract: Disclosed herein is a product and methods of using that product for constructing walls and other structures. The product is a locking block that is designed for use in building walls and other structures quickly and inexpensively. The locking blocks are fabricated from polymers to form a robust physical structure that resists damage and provides for a relatively clean work space during assembly. The locking blocks include matching male and female features that reversibly secure the blocks together and are self-aligning to guide workmen on block placement during assembly. The design of the blocks eliminates the need to apply mortar or other adhesive methods to secure the blocks together, which greatly reduces labor costs as compared to typical construction products and methods. Because no mortar or other adhesive is used, the blocks can be efficiently and effectively disassembled and reused.

Abstract: Molded polymer foam articles are described as having a novel foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a shape and volume wherein a sphere having a diameter between 2 cm and 1000 cm would fit within the article in at least one location without protruding from a surface of the article, and the article further has a total volume of more than 1000 cm3. Methods of making a stabilized molten polymer foam, and of making a molded polymer foam article using the stabilized molten polymer foam are also described.

Abstract: Molded polymer foam articles are described as having a novel a foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article, including in the surface region extending 500 microns beneath the surface of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a thickness of more than 2 cm, a volume of more than 1000 cm3; or both a volume of more than 1000 cm3 and a thickness of more than 2 cm. Methods of making the molded polymer foam articles are also described.

Abstract: Molded polymer foam articles are described as having a novel foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a shape and volume wherein a sphere having a diameter between 2 cm and 1000 cm would fit within the article in at least one location without protruding from a surface of the article, and the article further has a total volume of more than 1000 cm3. Methods of making a stabilized molten polymer foam, and of making a molded polymer foam article using the stabilized molten polymer foam are also described.

Abstract: Molded polymer foam articles are described as having a novel a foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article, including in the surface region extending 500 microns beneath the surface of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a thickness of more than 2 cm, a volume of more than 1000 cm3; or both a volume of more than 1000 cm3 and a thickness of more than 2 cm. Methods of making the molded polymer foam articles are also described.

Abstract: Molded polymer foam articles are described as having a novel a foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article, including in the surface region extending 500 microns beneath the surface of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a thickness of more than 2 cm, a volume of more than 1000 cm3; or both a volume of more than 1000 cm3 and a thickness of more than 2 cm. Methods of making the molded polymer foam articles are also described.

Abstract: Molded polymer foam articles are described as having a novel a foam structure. The polymer foam articles include a continuous polymer matrix defining a plurality of pneumatoceles therein which is present throughout the entirety of the article, including in the surface region extending 500 microns beneath the surface of the article. The surface region is further characterized as having compressed pneumatoceles. The novel foam structure is achieved even when molding polymer foam articles comprising a thickness of more than 2 cm, a volume of more than 1000 cm3; or both a volume of more than 1000 cm3 and a thickness of more than 2 cm. Methods of making the molded polymer foam articles are also described.