Patent ID: 9630350
Date: 2017-04-25
CPC Classifications: B29C,Y10T

Claim:
1. A method for manufacturing a foam molded part without the use of release agents, the method-comprising: introducing a mold insert comprising an injection molded polyolefin into a molded part mold, wherein the molded part mold comprises an upper mold half and a lower mold half, wherein the upper mold half and lower mold half form a cavity having a shape when placed adjacent to each other, wherein the molded part mold is adapted to impress the shape of the cavity onto a material introduced into the cavity, wherein the mold insert comprises (a) an upper part, (b) a matching lower part, wherein the mold insert upper part and the mold insert matching lower part provide a reduced volume cavity shape, wherein the upper part and matching lower part are adapted to be disposed on matching surfaces of the upper mold half and lower mold half, respectively so that, when disposed on the matching surfaces of the upper mold half and lower mold half, the reduced volume cavity shape is formed by the mold insert, wherein the mold insert impresses the reduced volume cavity shape onto the injection molded polyolefin, wherein each of the upper part and lower matching part is comprised of the injection molded polyolefin having a thickness of between about 0.8 mm to about 8.0 mm, (c) a temperature conducting element disposed in each of the upper part and the matching lower part and (d) a fastening element associated with each of the upper part and matching lower part, wherein the fastening element provides a detachable connection for the upper part and the matching lower part to the upper mold half and lower mold half, respectively; disposing the upper mold half and lower mold half adjacent to each other so that the upper part and lower matching part are disposed adjacent to each other; injecting a hardenable and moldable material, without a release agent applied to either the upper part or lower matching part, into the reduced volume cavity, so that the reduced volume cavity impresses the shape of the reduced volume cavity onto the hardenable and moldable material; removing the mold insert with the hardenable and moldable material in the mold insert from the molded part mold; allowing the hardenable and moldable material to harden outside of the molded part mold; and removing the hardened material from the mold insert.