Patent ID: 6875298
Filing Date: 2005-04-05
Classification: B29C,Y10T

Abstract:
1. A process for producing light weight plastic molded articles comprising the steps of: a) providing a mold having a movable mold half and a stationary mold half forming a mold cavity between said mold halves when said mold halves are brought together into a molding relationship; b) providing a nozzle having a tip with a tip passage in fluid communication with said mold cavity during filling of said mold cavity, said nozzle having a body with outer passages and an inner passage in fluid communication with said tip passage and a slide movable into said inner passage to provide fluid communication of said inner passage with said tip passage and out of said inner passage to provide fluid communication of said inner passage with said tip passage; c) providing under pressure i) plastic molding material to said outer passages and ii) a substance creating gas when activated to said inner passage; d) moving said slide into and out of said central passage while injecting said plastic molding material into said mold cavity to form in said mold cavity, at discrete positions, inserts of gas creating substances encapsulated within said plastic molding material; and, e) activating said gas creating substances after said molding material has filled said mold cavity so that said inserts can expand as a gas to produce internal gas filled cavities at said discrete positions within said molded article.