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MOLD PROCESS FOR MAKING NANOFOAM

United States Patent Application

20170120486
A1
View the Complete Application at the US Patent & Trademark Office
Prepare nanofoam by: (a) providing a mold (10) with a mold cavity (12) defined by mold walls defining a sealable port (32); (b) providing a foamable polymer mixture containing a polymer and a blowing agent at a pressure at least 690 kilopascals above the saturation pressure for the polymer and blowing agent; (c) introducing the foamable polymer mixture into the mold cavity (12) while maintaining a temperature and pressure at least 690 kilopascals above the saturation pressure and controlling the pressure in the mold cavity (12) by expanding a wall of the mold; and (d) releasing pressure around the foamable mixture by moving a mold wall (20) at a rate of at least 45 centimeters per second, causing the foamable polymer mixture to expand into nanofoam having a porosity of at least 60 percent, a volume of at least 100 cubic centimeters and at least two orthogonal dimensions of four centimeter or more.
Costeux, Stephane (Midland, MI), Beaudoin, Daniel A. (Midland, MI), Kim, Hyunwoo (Midland, MI), Foether, Devin A. (Vassar, MI)
15/ 121,604
May 20, 2015
[0001] This invention was made with U.S. Government support under contract DE-EE0003916 awarded by the Department of Energy. The U.S. Government has certain rights in this invention.