Foam Molding for Protective Package Structures

Composite foam injection molding with internal reinforcement structures. The process involves 3D printing reinforcing structures, attaching them to mold parts, forming a hollow space, injecting foamed resin, removing the molds, and optionally vacuuming and exhausting the mold cavities. The 3D printed reinforcement provides internal structure to the molded foam. The foaming process surrounds the reinforcement with foam. This provides a composite foam part with internal reinforcement.

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A method for making moulded fiber products like food packaging with improved properties by foam forming followed by hot pressing. The method involves creating a multi-layered foam structure from fiber, water, air, and foaming agents in a mold. Dewatering removes excess water, then hot pressing compresses and consolidates the foam into the final product. Using foaming agents like surfactants and polymers allows forming thick, uniform, and smooth fiber structures. This improves barrier properties and reduces roughness compared to water forming. Internal sizing agents can also be added to the foam to further enhance barrier performance.

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Method for manufacturing a laminate with a foam core and skin layers that provides the lightness and rigidity of injection foam molded products along with cushioning, tactile sensation, and appearance. The laminate is made by molding a thin skin layer, expanding a foam core between the skin layers, compressing the foam, and releasing it to form a laminate with foam layers sandwiched by solid skin layers. The key steps involve forming a cavity, injecting foam composition, expanding the foam, compressing it, and releasing to shape the laminate.

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A device and method for making recyclable adaptive express packaging that provides customized, protective packaging for irregularly shaped goods that can be easily shipped and reused. The packaging has an inner isolation layer, a middle quick-setting foam layer, and an outer mold layer. The isolation layer separates the goods from the foam, the mold shapes the foam, and supports the goods. The packaging is made by inserting goods into the isolation bag, injecting foam into the mold around the goods, and letting it set. The foam molds around the goods to provide customized protection. After shipping, the foam can be recycled and reused for future packages. The molded foam provides better compression and fall resistance than traditional packing methods.

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Manufacturing method for composite foam molded articles with complex shapes containing different foam materials. The method involves suspending a first foam molded body in the mold using vacuum adsorption, then closing the mold and filling it with second foam particles. The first foam body remains suspended during molding. This allows precise placement of the first foam body without vacuum suction during molding. The first and second foams integrate into a composite part with customizable properties.

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Method of forming molded fiber products with multiple layers that is faster and more versatile than existing methods. The key features are using foam as the forming material, variable mold spacing, and side channels to feed the foam between the molds. This allows multiple layers to be formed in one cycle instead of separate forming and pressing steps. The foam is made from fibers, water, air, and foaming chemicals. The foam properties can be adjusted. The product layers can be combined and pressed further to form the final product.

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A manufacturing process for packaging containers made of foamed polyethylene that provides a more efficient and automated method for shaping the containers with spherical shapes. The process involves using heated molds, ovens, and hot melt adhesive to shape the foam and protective layer materials into the containers. This allows creating complex shapes like spheres without cutting or sewing. The process also enables recycling scraps and reduces labor compared to traditional shaping methods.

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Manufacturing foam-molded parts with exposed embedded features using a molding process that allows easy control of the exposed dimensions. The process involves placing the buried part in the mold cavity, foaming the material around it, and injecting gas into the clearance space between the buried part and mold walls. The gas injection time is adjusted based on the buried part height to prevent foaming in that area. This allows the foam to grow around the buried part but not fill the clearance, exposing it in the finished foam part.

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Making lightweight, strong, and thermally insulating foamed polymer articles like cups by using a combination of physical and chemical blowing agents. The physical blowing agent expands the foam initially, separating the skins, and the chemical blowing agent continues expanding the foam as the physical gas dissipates. This allows thinner initial injection molded walls to be foamed to thicker expanded walls. The combination allows lower chemical blowing agent concentration and higher expansion factor compared to just chemical blowing agent.

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Molded articles with a foam member encapsulating a core, and a manufacturing method for them. The molded article has a foam member made of polymeric material surrounding the entire core, including its surfaces and sides. This provides complete enclosure and insulation of the core. The manufacturing method involves molding the foam around the core by injecting material into a mold with a support member for the core, then foaming it in place. The support member can be shrunk or removed after injection.

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Preparing a lightweight, high-strength musical instrument case with improved protection and aesthetics compared to existing options. The case body is made by a molding process involving foaming a thin plate material between matched concave and convex molds. The process involves steps like creating outer and inner mold shapes, then compressing a thin plate material between them to form the case body with foam sandwiched in between. This provides a lightweight, customizable, and visually appealing case body with good strength and protection for musical instruments.

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Green packaging material made from stacked foam sheets that provides cushioning and shock absorption without the environmental issues of traditional foam plastics. The green packaging material is formed by stacking foam sheets made using a molding process. The foam sheets are created by dispersing fiber in water-based foam and depositing it onto a net part. The foam sheets are then stacked to create the green packaging material. The molding process reduces water and energy consumption compared to traditional wet or dry forming methods. The green packaging material has thicknesses of 10-100mm and withstands pressures of 0.5-5 bar.

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Injection molding method for producing lightweight, insulated and rigid foam molded plastic products with dense surface layers and foam interiors using conventional injection molding machines and thin-walled molds away from the gate. The method involves: 1) enlarging the mold cavity volume gradually and uniformly before filling with resin to prevent foaming, 2) compressing the cavity after filling to pack the resin tightly and eliminate air pockets, and 3) maintaining consistent pressure during filling to prevent foaming. This allows creating foam-free or low-foaming dense surface layers while fully filling thin-walled mold sections away from the gate.

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Packaging container with improved adhesion between the molded body and cover film. The container has a foam molded body made from polyethylene terephthalate (PET) foam with an average cell size of 100-500 μm. This dense foam has low surface roughness, allowing better adhesion between the foam and the cover film. The adhesion force between the molded body and cover film is 500-1500 gf. The low roughness foam and optimized adhesion provide improved airtightness and sealing properties. The PET foam also has good heat insulation and is environmentally friendly.

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A method to manufacture two-color foam molded products with improved strength and adhesion between the primary and secondary foam molded parts. The method involves continuously molding the primary and secondary parts using a core back technique with molten resin containing supercritical fluid. In the core back step, expanding the mold volume before solidification allows the foam to expand, improving adhesion between layers and between the primary and secondary parts. This prevents peeling. The steps include filling the mold with foam resin, expanding the mold volume before solidification, then filling the mold with the second foam resin and expanding again.

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Container member and cap with reduced weight and improved appearance by foaming during molding. The container and cap are made by injecting a molten resin containing a supercritical fluid into a mold, foaming it, then injecting a second molten resin to form a dense layer on the foam. The foam layer with voids derived from the supercritical fluid is hidden beneath the dense layer. This prevents sink marks and foaming marks on the foam surface. The dense layer provides a smooth outer surface while the foam interior reduces weight. The foam and dense layers can be made from similar resins for easy recycling.

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Efficiently manufacturing foam-molded products like car seat cushions with reinforced layers that won't fall off or delaminate. The method involves adhering reinforcing fibers to the mold cavity surface, covering them with a material, compressing the fibers between the cover and cavity, then molding the foam. This improves fiber attachment and uniformity compared to directly molding the foam with fibers.

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Composite molded container that combines the water leakage resistance of a paper-based laminate with the heat resistance of a thermoplastic resin. The container has an upper part made of a paper-based laminate with a foam layer, and a lower part made of thermoplastic resin. The laminate and resin are integrated at the join. The laminate foams to provide insulation, while the resin provides strength and heat resistance. This allows containers with both water leakage and heat resistance properties. The laminate is formed by coating paper with foamed polyethylene, then heat welding the ends. The resin part is injection molded.

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Method for manufacturing and molding thermal insulation foam packaging boxes that improves efficiency and yield by using a specialized molding machine. The machine has a fixed frame, movable plate, and stripper. The mold has a through hole, injection device, and slots. The movable plate inserts into the mold, foam is injected, then the plate lowers to demold the box. A pressure block expands to clamp the foam. The stripper removes demolded boxes. This allows rapid automated demolding compared to manual demolding.

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Low-density, high-foaming ratio polymer foam material and a preparation method using core receding microcellular injection molding. The method involves modifying the polymer with fillers to change its viscoelasticity and allow dense, fine cells. High-pressure full injection fills the mold completely without pre-foaming. Holding pressure prevents foaming during cooling. This allows low-density, high-expansion foam with uniform bubbles compared to traditional short injection molding.

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