Molding system and method

Abstract

The present application relates to molding systems and methods. A molding system and a method for operating the molding system are provided. The method includes flowing a molten polymeric material from an upstream device into an in-mold conditioning chamber in a fill position, at which the in-mold conditioning chamber is at least partially positioned within a mold cavity. The method also includes adjusting at least one of a temperature of the molten polymeric material in the in-mold conditioning chamber and a pressure applied to the molten polymeric material in the in-mold conditioning chamber to produce a first conditioned molten polymeric material, and releasing the conditioned molten polymeric material from the in-mold conditioning chamber into the mold cavity.

Description

[0001] This application is a divisional of application number 201980059612.9, filed on September 20, 2019, having the title “MOLDING SYSTEM AND METHOD”.

[0002] CROSS REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 734,927, filed on September 21, 2018, entitled “MOLDING SYSTEM AND METHOD”. The entire contents of the above-listed application are incorporated herein by reference for all purposes. TECHNICAL FIELD

[0004] The present specification generally relates to systems and methods for molding polymeric materials. BACKGROUND

[0005] Injection molding systems are used to inject a polymeric melt into a mold to form a polymeric product, good, part, or the like. Physical blowing agents such as supercritical fluids (SCFs) (e.g., nitrogen or carbon dioxide) have been used in certain injection molding processes. For example, some molding processes inject an SCF into a polymeric melt in an injection barrel to dissolve the SCF in the polymeric melt. In other molding methods, polymeric pellets are primed with an SCF prior to forming the polymeric melt in the injection barrel. Both of these methods result in a molten single-phase solution (SPS) of SCF dissolved in the polymer. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 A diagram of a molding system is shown.

[0007] Figures 2 to 4 A molding sequence for molding an article using the molding system shown in Figure 1

[0008] Figure 5 Another example of a molding system is shown.

[0009] Figure 6 A method for operating a molding system is shown.

[0010] Figure 7 A detailed method for operating a molding system is shown.

[0011] Figure 8 Another method for operating a molding system including two in-mold conditioning chambers is shown.

[0012] Figure 9 A graph depicting pressure curves, piston position, and control signals during a molding process is shown. ​DETAILED DESCRIPTION

[0013] Various types of molding techniques, such as microcellular foam injection molding, have been used to manufacture plastic products, goods, components, and the like. In microcellular foam injection molding, attempts have been made to reduce injection cycle times and product weight. However, in practice, previous injection molding systems have failed to achieve desired material properties of the molded polymer. Specifically, previous molding systems have suffered from inadequate temperature and pressure control during the molding process. For example, the polymer material can experience undesirable pressure and temperature variations in intermediate components positioned between the mold and the injection device, such as flow channels and other conduits designed to deliver the polymer material to the mold. These control deficiencies can cause a number of problems, including, but not limited to, undesirable nucleation and / or bubble growth in the polymer material. As a result of the undesirable nucleation and / or bubble growth, reductions in strength, stiffness, surface quality, and inconsistencies in polymer density can occur. Undesirable pressure and temperature variations in the polymer material can also limit the selection of source materials used in the molding process, thereby hindering product design options and, in particular, the properties of the molded product.

[0014] The molding systems and methods described herein overcome at least some of the aforementioned challenges. In one example, a method is provided that includes flowing a molten polymer material from an upstream device into an in-mold conditioning chamber in a fill position, where the in-mold conditioning chamber is at least partially positioned within a mold cavity. The method also includes adjusting at least one of a temperature of the molten polymer material in the in-mold conditioning chamber and a pressure applied to the molten polymer material in the in-mold conditioning chamber to produce a conditioned molten polymer material, and releasing the conditioned molten polymer material from the in-mold conditioning chamber into the mold cavity. As the temperature and / or pressure adjustments of the molten polymer material occur within the mold cavity, unintended and / or undesirable variations in the polymer material properties, such as shear heating, premature nucleation, and the like, can be avoided, losses in the system can be reduced, and precise selection of the physical and mechanical properties of the molded article can be achieved. Additionally, adjusting the temperature and / or pressure of the molten polymer material nested in a sealed volume of the mold cavity allows for a wider variety of source materials to be selected, if desired, enabling the molding process to be applied to a wide variety of molded articles and manufacturing fields.

[0015] In another example, a molding system is provided. In this example, the molding system includes an in-mold conditioning chamber configured to condition a temperature of a molten polymeric material and / or a pressure applied to the molten polymeric material to generate a conditioned molten polymeric material. The in-mold conditioning chamber is also configured to be disposed in a fill position and a withdrawn position. In the fill position, the in-mold conditioning chamber is in fluid communication with an upstream device and at least partially positioned within a mold cavity. Conversely, in the withdrawn position, the in-mold conditioning chamber is positioned outside of the mold cavity. As such, the chamber that conditions the temperature and / or pressure of the molten polymeric material is nested within the mold, thereby eliminating intermediate piping (e.g., runners) between the conditioning chamber and the mold. As a result, losses of the molten polymeric material, undesirable changes in material properties, etc. in the intermediate piping between the conditioning chamber and the mold can be avoided, thereby improving the adjustability of the molten polymeric material.

[0016] In yet another example, a method for operating a molding system is provided. In this example, the method includes actively conditioning a melt strength of a molten polymeric material in an in-mold conditioning chamber by applying a controlled pressure to the molten polymeric material and / or actively conditioning a temperature of the molten polymeric material to generate a conditioned molten polymeric material. The method also includes releasing the conditioned molten polymeric material from the in-mold conditioning chamber into a mold cavity. As a result, the material properties of a molded article can be selected with even greater granularity, further increasing the adaptability and adjustability of the molding method.

[0017] Figure 1 An illustration of an example of a molding system 100 is shown. Although Figure 1 The molding system 100 illustrated in FIG. 1 is depicted as an apparatus having various parts, components, etc. enclosed therein or coupled thereto, in other embodiments, various components in the molding system 100 can be at least partially housed in different housings that can be spaced apart from one another. Moreover, it should be appreciated that the form, profile, etc. of the molding system can vary in other embodiments.

[0018] The molding system 100 includes a device 102 that receives a polymeric material 104 from a storage chamber 106. In the illustrated example, the device 102 is an injection device configured to selectively inject a molten polymeric material into a downstream component, e.g., via a nozzle. As a result, the molding system can be an injection molding system. However, in other examples, the device can be an extrusion device configured to push a polymeric material through a restriction. It should be appreciated that components in the system can be referred to as upstream and downstream components. For example, the device 102 can be referred to as an upstream device when described with respect to a downstream mold cavity. Likewise, the mold cavity, runners, etc. can be referred to as downstream components with respect to the device 102.

[0019] The storage chamber 106 is in Figure 1The storage chamber 106 is shown as a hopper. However, many suitable forms of storage chambers have been contemplated, such as tubes, drums, pressurized vessels, etc. Additionally, in other examples, the system can include multiple storage chambers. Furthermore, the polymeric material 104 can be dried within the storage chamber 106 or prior to placing the material in the storage chamber. Also, the polymeric material 104 can be in the form of chips, pellets, powder, rods, etc.

[0020] The polymeric material 104 includes one or more thermoplastic polymers. The one or more thermoplastic polymers can include a thermoplastic elastomer (TPE). The one or more thermoplastic polymers can include an aliphatic polymer, an aromatic polymer, or a mixture of the two. In one example, the one or more thermoplastic polymers can include a homopolymer, a copolymer (including a terpolymer), or a mixture of the two. The copolymer can be, for example, a random copolymer, a block copolymer, an alternating copolymer, a periodic copolymer, or a graft copolymer. The one or more thermoplastic polymers can include an olefin homopolymer or an olefin copolymer or a mixture of an olefin homopolymer and an olefin copolymer. Examples of olefin polymers include polyethylene (PE) and polypropylene (PP). For example, the PE can be a PE homopolymer, such as a low-density PE or a high-density PE, a low-molecular-weight PE or a ultra-high-molecular-weight PE, a linear PE or a branched PE, etc. The PE can be an ethylene copolymer, such as an ethylene-vinyl acetate (EVA) copolymer, an ethylene-vinyl alcohol (EVOH) copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-unsaturated mono fatty acid copolymer, etc. In one example, the one or more thermoplastic polymers can include a polyacrylate, such as a polyacrylic acid, an ester of polyacrylic acid, a polyacrylonitrile, a polyacrylic acid acetate, a polyacrylic acid methyl ester, a polyacrylic acid ethyl ester, a polyacrylic acid butyl ester, a polymethyl methacrylate, a polyvinyl acetate, etc., including derivatives thereof, copolymers thereof, and any mixture thereof. The one or more thermoplastic polymers can include an ionomer polymer. The ionomer polymer can be, for example, a polycarboxylic acid or a derivative of a polycarboxylic acid. The ionomer polymer can be a sodium salt, a magnesium salt, a potassium salt, or a salt of another metal ion. The ionomer polymer can be a fatty acid-modified ionomer polymer. Examples of ionomer polymers include a poly(styrene sulfonic acid) and an ethylene-methacrylic acid copolymer. The one or more thermoplastic polymers can include a polycarbonate. The one or more thermoplastic polymers can include a fluoropolymer. The one or more thermoplastic polymers can include a polysiloxane. The one or more thermoplastic polymers can include a vinyl polymer, such as a polyvinyl chloride (PVC), a polyvinyl acetate, a polyvinyl alcohol, etc. The one or more thermoplastic polymers can include a polystyrene. The polystyrene can be a styrene copolymer, such as an acrylonitrile butadiene styrene (ABS), a styrene acrylonitrile (SAN), a styrene ethylene butylene styrene (SEBS), a styrene ethylene propylene styrene (SEPS), a styrene butadiene styrene (SBS), etc. The one or more thermoplastic polymers can include a polyamide (PA). The PA can be a PA 6, a PA 66, a PA 11, or a copolymer thereof. The polyester can be an aliphatic polyester homopolymer or an aliphatic polyester copolymer, such as a polyglycolic acid, a polylactic acid, a polycaprolactone, a polyhydroxybutyrate, etc. The polyester can be a semi-aromatic copolymer, such as a polyethylene terephthalate (PET) or a polybutylene terephthalate (PBT). The one or more thermoplastic polymers can include a polyether, such as a polyethylene glycol or a polypropylene glycol, including copolymers thereof.The one or more thermoplastic polymers can include polyurethanes, including aromatic polyurethanes derived from aromatic isocyanates, such as diphenylmethane diisocyanate (MDI) or toluene diisocyanate (TDI), or aliphatic polyurethanes derived from aliphatic isocyanates, such as hexamethylene diisocyanate (HDI) or isophorone diisocyanate (IPDI), or mixtures of both aromatic and aliphatic polyurethanes.

[0021] In addition to the one or more thermoplastic polymers, the polymeric material 104 can also include a chemical blowing agent that forms a gas when heated. For example, the chemical blowing agent can be an azo compound, such as adodicarbonamide, sodium bicarbonate, or isocyanate. Optionally, in addition to the one or more thermoplastic polymers, the polymeric material 104 can also include a crosslinking agent. The crosslinking agent can be a peroxide-based crosslinking agent, such as dicumyl peroxide. Optionally, in addition to the one or more thermoplastic polymers, the polymeric material 104 can also include one or more fillers, such as glass fibers, powdered glass, modified or natural silica, calcium carbonate, mica, paper, wood flour, modified or natural clays, modified or unmodified synthetic clays, talc, and the like.

[0022] In particular, in one example, the polymeric material 104 can include EVA and / or thermoplastic polyurethane (TPU), and the molding system 100 can produce molded footwear components (e.g., uppers, midsoles, and / or outsoles). However, the molding system 100 and methods described herein have profound applicability beyond the footwear industry, such as the automotive industry, the aerospace industry, the packaging industry, the sporting goods industry, and the like. Thus, the molding system can be designed to manufacture a wide variety of articles in any of the aforementioned industries. As described herein, the articles can be any goods, products, components, items, parts, and the like used in any of the aforementioned industries or other suitable industries, fields, and the like.

[0023] Figure 1 The apparatus 102 shown in FIG. 1 includes a barrel 108 and a drive apparatus 110 designed to regulate (e.g., rotate and / or advance and retract) a screw housed in the barrel. For example, the drive apparatus can include a motor (e.g., an electric motor) that rotates and / or axially moves a shaft coupled to the screw. The apparatus 102 is configured to provide molten polymeric material to a downstream component 113, such as an in-mold conditioning chamber and a mold.

[0024] The heating device 112 is also coupled to the barrel 108 and is designed to heat the polymeric material in the barrel 108 to form a molten polymeric material. Specifically, the heating device 112 is coupled to the outer surface 114 of the barrel 108 and circumferentially surrounds the barrel. However, alternative configurations of the heating device 112 have been contemplated, such as a heating device that partially surrounds the barrel and / or a heating device that is integrated into the barrel. The heating device 112 can include an electrically heated component, a hydraulically heated component, etc. Thus, the heating device 112 can include a heat exchanger, an electric resistance heater, a heat pump, etc., which can be controlled by the computing device 124 based on operating conditions (e.g., ambient temperature, barrel temperature, barrel pressure, etc.) as shown in FIG. 1. In other examples, the heating device 112 can be positioned at other suitable locations in the system, such as the storage chamber 106. Figure 1

[0025] The molding system 100 can also include a blowing agent delivery assembly 116 configured to flow a blowing agent, a pigment, etc. into the barrel 108. In one example, the blowing agent delivery assembly can be designed to inject a blowing agent into the barrel 108 through a port. However, other suitable types of blowing agent delivery assemblies have been contemplated. For example, the blowing agent delivery assembly 116 can be integrated into the storage chamber 106, can be positioned upstream of the storage chamber 106, or can not be included in the system. If the blowing agent delivery assembly 116 is integrated into the storage chamber 106 or is positioned upstream thereof, the storage chamber can include a solid polymeric material and a blowing agent. In one example, the blowing agent can be included in the polymeric material.

[0026] The blowing agent delivery assembly 116 includes a blowing agent storage device 118 that stores a blowing agent 120. In some examples, the blowing agent can include a physical blowing agent and / or a chemical blowing agent. Specifically, in some examples, the blowing agent can include nitrogen and / or carbon dioxide. However, other suitable blowing agents can be used, such as a hydrocarbon (e.g., pentane, isopentane, and / or cyclopentane), a hydrochlorofluorocarbon (HCFC), a mixture thereof, etc. Moreover, the blowing agent stored in the blowing agent storage device 118 can be stored as an SCF and / or flowed into the barrel 108. For example, supercritical nitrogen and / or supercritical carbon dioxide can be flowed into the barrel. However, in other examples, the blowing agent can be flowed into the barrel as a gas and / or a liquid, and the conditions in the barrel can cause the blowing agent to achieve a supercritical state. Moreover, in other examples, when the blowing agent includes two substances, such as nitrogen and carbon dioxide, the blowing agent delivery assembly can include one port that delivers the first substance (e.g., nitrogen) into the barrel and another port that delivers the second substance (e.g., carbon dioxide) into the barrel. However, in other cases, one port that delivers both substances can be used.

[0027] ​The blowing agent delivery assembly 116 also includes a blowing agent valve 122 coupled to the barrel 108. The blowing agent valve 122 is designed to regulate the amount of blowing agent that flows into the barrel 108. For example, the blowing agent valve 122 can open / close to allow blowing agent to flow into the barrel during certain operating conditions and prevent blowing agent from flowing into the barrel during other operating conditions. Also, the blowing agent valve 122 can have multiple different open positions, allowing the flow rate of blowing agent delivered to the barrel 108 to be adjusted. When blowing agent is delivered to the barrel 108, a molten SPS can be formed therein. Thus, in one example, the molten SPS can include a molten polymeric material and a blowing agent dissolved therein.

[0028] Figure 1 A computing device 124 included in the molding system 100 is shown. It should be appreciated that the computing device 124 can be a controller designed to regulate various aspects of the molding process. The computing device 124 includes a memory 126 and a processor 128. Instructions can be stored in the memory that are executable by the processor to perform the methods, control strategies, etc. described herein. The memory 126 can include volatile, nonvolatile, non-transitory, dynamic, static, read / write, read-only, random access, sequential access, location- addressable, file- addressable, and / or content-addressable devices. Additionally, the processor 128 can be a single-core or multi-core device, and the instructions executed thereon can be configured for sequential, parallel, and / or distributed processing. Although the computing device 124 is shown as being directly coupled to the external housing 130 of the system, in other cases the computing device 124 can be located remotely. Moreover, the computing device 124 can be electronically (e.g., wired and / or wirelessly) connected to the device 102 and / or other components in the system.

[0029] The computing device 124 can also include a display device 132. The display device 132 can be used to present visual representations of data held by the memory 126. The graphics presented on the display device 132 can take the form of, for example, a graphical user interface (GUI) or other suitable interface. The computing device 124 also includes an input device 134. In the illustrated example, the input device 134 is in the form of a keyboard. The input device can additionally or alternatively include a mouse, joystick, camera, microphone, touch screen, etc. Thus, in some examples, user input can be used to regulate different aspects of the molding process. Additionally or alternatively, automated instructions can trigger changes in the molding process. Moreover, in other embodiments, the display device and / or input device can be omitted from the computing device.

[0030] The computing device 124 can also include a condition indicator 133 that can indicate that the molding system 100 has reached one or more desired operating conditions (e.g., adjustment chamber pressure and / or temperature set points, mold temperature set points, mold counter pressure set points, combinations thereof, etc.). Thus, the condition indicator 133 can indicate to a system operator the desired conditions that have been achieved, such as a desired adjustment chamber pressure or temperature, as discussed in detail herein. In response to the triggering of the condition indicator, the system operator can command the system to take a desired action via the input device 134, such as commanding the in-mold adjustment chamber to release the adjusted molten polymeric material (e.g., adjusted molten SPS) held therein into the mold cavity. The condition indicator 133 can include audio, graphical, and / or haptic components for alerting the system operator. The graphical indicator can be a graphic presented on a display device and / or can include one or more lights for signaling the operator. In this way, certain aspects of the molding process can be manually controlled. However, in other examples, more automated control strategies can be utilized.

[0031] The sensors 136 can also provide signals to the computing device 124. These sensors can include temperature sensors, pressure sensors, and the like. These sensors can be attached to or integrated into the device 102 and / or downstream components, as discussed in detail herein with respect to Figures 2 to 4 More detail. For example, the device 102 can include temperature sensors, pressure sensors, and / or combined temperature-pressure sensors that send signals to the computing device 124. The sensors enable the temperature and pressure in selected sections of the system to be determined.

[0032] The computing device 124 also sends and receives signals from the device 102, the drive device 110, the heating device 112, and the blowing agent valve 122, as well as the cartridge valve 204, the gate valve 232, the flow channel temperature regulation device 222 (e.g., the pump 228 and the heat exchanger 230), the polymeric material adjustment assembly 246 (e.g., the temperature regulation mechanism 248 (e.g., the pump 264 and / or the heat exchanger 266) and the pressure regulation mechanism 250 (e.g., the piston actuator)), the chamber retraction device 268 (e.g., the actuator 272), and the mold actuation device 280 (e.g., the clamping device 284), which are shown in Figures 2 to 4 and discussed in more detail herein. The above-described devices, mechanisms, valves, assemblies, etc. can include actuators that facilitate adjustment of the devices, mechanisms, valves, assemblies, etc. For example, the blowing agent valve 122 can include a valve actuator that adjusts the degree to which the valve is open / closed. It will be appreciated that other devices, mechanisms, valves, assemblies, etc. can also include actuators that work in a similar manner to allow adjustment of the devices, mechanisms, valves, assemblies, etc.

[0033] Figures 2 to 4 A detailed view of the molding system 100 is shown. In particular,Figures 2 to 4 The sequential steps in the molding process are illustrated. Figure 1 The computing device 124, shown in Figures 2 to 4 the molding steps are illustrated. Thus, the computing device 124 can send and receive signals to / from various components in the molding system 100, as Figures 2 to 4 shown in

[0034] Turning specifically to Figure 2 , a cross-sectional view of the apparatus 102 is depicted. The apparatus 102 includes a barrel 108 that at least partially encloses a screw 200. The storage chamber 106 is again shown as coupled to the barrel 108 and providing polymer material thereto.

[0035] A drive apparatus 110 (e.g., a drive motor) is coupled to the screw 200. The drive apparatus 110 is designed to rotate the screw 200 and / or advance and retract the screw in the barrel 108. Rotation of the screw causes the polymer material to flow downstream through the barrel, and advancing the screw in the barrel toward the nozzle 202 increases the pressure applied to the molten polymer material in front of the screw. Thus, when the barrel valve 204 is open, the molten polymer material can flow out of the barrel. An axis 206 about which the screw rotates and advances / retracts is provided as a reference. In other examples, separate actuators can be used to rotate and advance / retract the screw.

[0036] As the polymer material moves through the barrel 108, the polymer material can be heated via a heating apparatus 112 coupled to the barrel 108. It will be appreciated that the heating apparatus 112 can increase the temperature of the barrel 108, and in turn, the temperature of the polymer material. Thus, a molten polymer material can be formed in the barrel after the polymer material is heated. As previously mentioned, the heating apparatus can be controlled by the computing device 124, shown in Figure 1 .

[0037] Figure 2 The blowing agent delivery assembly 116 is also shown in . As previously mentioned, the blowing agent delivery assembly 116 includes a blowing agent storage device 118 and a blowing agent valve 122. A blowing agent conduit 208 can extend between the blowing agent valve 122 and the blowing agent storage device 118. Another blowing agent conduit 210 can extend between the blowing agent valve 122 and the barrel 108. Specifically, in the illustrated example, the blowing agent conduit 210 opens into an interior section 212 of the barrel 108 in which the screw 200 is housed. However, many suitable blowing agent delivery assembly configurations have been contemplated. For example, the blowing agent valve 122 can be integrated into the barrel 108. As previously mentioned, when the blowing agent flows into the molten polymer material in the barrel, a molten SPS can be formed. Thus, the molten SPS can include molten polymer material in which the blowing agent is dissolved. However, in other examples, the SPS can be produced upstream of the barrel 108.

[0038] A section 214 of the barrel 108 downstream of the screw 200 accumulates molten polymeric material during operation of the apparatus 102. Specifically, in one example, the section 214 of the barrel can accumulate molten SPS. As previously mentioned, the section 214 of the barrel 108 can retain molten polymeric material. In the illustrated example, a pressure sensor 216 and a temperature sensor 218 are shown coupled to the barrel 108 downstream of the screw 200 and in electronic communication with the computing device 124 shown in FIG. 1. Figure 1 However, in other examples, additional or alternative suitable sensor locations have been contemplated, such as at an upstream location adjacent to the screw. Furthermore, in other examples, a single sensor can be used to measure temperature and pressure, or these sensors can be omitted from the system.

[0039] The barrel 108 includes the nozzle 202 and, in the illustrated example, includes a barrel valve 204. The barrel valve 204 can be configured to regulate the flow rate of molten polymeric material from the barrel 108 into a flow channel 220 coupled to the barrel 108. The barrel valve 204 can be opened and closed via control signals from the computing device 124 shown in FIG. 1 to regulate the flow of molten polymeric material from the barrel 108 to downstream components. For example, the barrel valve 204 can be opened when a pressure and / or temperature setpoint in the barrel is reached. However, in other examples, the barrel valve can be omitted from the molding system 100. Figure 1

[0040] When the barrel valve 204 is opened, the flow channel 220 can receive molten polymeric material from the barrel 108. A flow channel temperature regulation device 222 configured to regulate the temperature of the molten polymeric material flowing through the flow channel 220 is also included in the molding system 100. However, in other examples, the flow channel temperature regulation device 222 can be omitted from the system.

[0041] The flow channel temperature regulation device 222 includes a fluid circuit 224 (e.g., a coolant circuit) that passes through a flow channel housing 226 and a pump 228 that regulates the flow of fluid through the circuit. Thus, it should be appreciated that fluid can be circulated through the fluid circuit 224 during operation of the flow channel temperature regulation device 222. Additionally, the flow channel temperature regulation device 222 includes a heat exchanger 230 that adds heat to and / or removes heat from fluid flowing therethrough. Thus, if desired, the temperature of the molten polymeric material flowing through the flow channel can be increased and / or decreased. Additionally or alternatively, electric heating and / or cooling components and / or other suitable components can be used in the temperature regulation device.

[0042] ​The heat exchangers 230 and / or other heat exchangers described herein can include components such as coolant tubes, counterflow assemblies, fins, coils, and the like to enable heat to be transferred to or removed from the working fluid in the fluid circuit 224. Further, in one example, the heat exchanger configurations can vary between heat exchangers to achieve a desired amount of heating / cooling, while in other examples, the heat exchangers can have similar designs. The pumps 228 and / or other pumps described herein can include components that allow for a pumping action, such as a plunger, a pumping cavity, a seal, a vane, and the like. For example, the pumps can be positive displacement pumps, centrifugal pumps, and the like. In one example, the pump configurations can vary between pumps to achieve a desired fluid flow rate, while in other examples, the pumps can have similar designs.

[0043] A gate valve 232 can be included in the flow channel 220. Specifically, in the illustrated example, the gate valve 232 is positioned upstream of an outlet 235 of the flow channel 220. However, in other examples, the gate valve 232 can be omitted from the molding system 100 or can be positioned in other suitable locations. The gate valve 232 is designed to allow and prohibit the flow of molten polymeric material therethrough. Additionally, a sensor 233 can be coupled to the flow channel 220 downstream of the gate valve 232. However, in other examples, the sensor 233 can be positioned upstream of the gate valve 232. Additionally, the sensor 233 can include a temperature and / or pressure sensor. However, in other examples, a single sensor can be designed to sense both temperature and pressure, or these sensors can be omitted from the system, and the temperature and / or pressure can be inferred from other sensors and / or system configurations. The gate valve 232 can receive control signals from the computing device 124 shown in FIG. 1 to control its operation. For example, the computing device can instruct the gate valve to open when the downstream components are filled with molten polymeric material and to close after the filling operation. Figure 1

[0044] An in-mold conditioning chamber 234 is also included in the molding system 100. The in-mold conditioning chamber 234 includes a chamber housing 236 and an internal cavity 238. The in-mold conditioning chamber 234 is shown in a fill position in which a lip 240 of the chamber housing 236 is engaged (e.g., sealed) with an inner wall 242 of a mold cavity 244 of a mold 245. Thus, in the fill position, the in-mold conditioning chamber 234 and, specifically, the internal cavity 238 can be in fluid communication with the flow channel 220 and can be fluidly isolated from the remainder of the mold cavity 244. In this manner, molten polymeric material can be held within the in-mold conditioning chamber while undergoing pressure and / or temperature conditioning. Further, in the fill position, an outer surface 247 of the chamber housing 236 can be at least partially enclosed (e.g., completely enclosed) by the mold housing 279. Further, in the fill position, the chamber housing 236 can extend through an opening 249 in the mold housing 279. ​

[0045] The sensor 237 is shown coupled to the in-mold conditioning chamber 234 and can include a temperature sensor and a pressure sensor. However, in other examples, a single sensor can sense both the temperature and pressure in the conditioning chamber, or a sensor can not be included in the system. It will also be appreciated that in one example, the in-mold conditioning chamber 234 can have a circular cross-sectional profile. However, many cross-sectional profiles have been contemplated, such as an elliptical profile, a square profile, or a profile having different regions. For example, a baffle can extend through the interior of the in-mold conditioning chamber to divide the chamber into fluidly separated segments. However, a variety of conditioning chamber profiles have been contemplated.

[0046] The polymer material conditioning assembly 246 is coupled to the in-mold conditioning chamber 234. The polymer material conditioning assembly 246 is designed to adjust the temperature of the molten polymer material in the in-mold conditioning chamber 234 and / or the pressure applied to the molten polymer material in the in-mold conditioning chamber 234. For example, the temperature of the molten polymer material can be increased when the computing device determines that the molten polymer material is below a desired temperature, or the pressure applied to the molten polymer material can be increased when it is determined that the pressure applied to the molten polymer material is below a threshold. It will be appreciated that many control strategies have been contemplated. For example, a pressure and / or temperature adjustment can occur when the temperature of the molten polymer material and / or the pressure applied to the molten polymer material increases or decreases by a threshold amount. The temperature threshold can be 0.0001 °C, 0.001 °C, 0.5 °C, etc. The pressure threshold can be 0.0001 kPa, 0.001 kPa, 0.1 kPa, etc. It will be appreciated that the above-mentioned thresholds are provided as examples, and many thresholds can be used.

[0047] In the illustrated example, the polymer material conditioning assembly 246 includes a temperature adjustment mechanism 248 and a pressure adjustment mechanism 250. However, in other examples, the assembly can include only one of the temperature and pressure adjustment mechanisms.

[0048] The pressure adjustment mechanism 250 includes a piston 252 disposed in the interior cavity 238 of the in-mold conditioning chamber 234. In particular, the piston 252 can extend across the width of the chamber and can be moved in opposite directions along an axis 254 by a piston actuator 256 coupled to the piston via a valve stem 258. The piston actuator 256 can include a hydraulic device, an electronic device, etc. that moves the valve stem and piston in opposite axial directions. In this way, the volume of the interior cavity 238 can be changed to alter the pressure of the molten polymer material applied thereto. Figure 1 The computing device 124 shown in FIG. 2 can send command signals to the pressure adjustment mechanism 250, specifically the piston actuator 256, to extend and retract the piston 252. For example, the piston can be retracted to fill the conditioning chamber with molten polymer material and extended after the conditioning chamber is returned to the mold cavity in a subsequent molding cycle.

[0049] exist Figure 2 In the example shown, piston 252 extends into runner 220. In this way, piston 252 can also be used to change the pressure of the molten polymer material applied to runner 220. Therefore, the piston can retract to introduce molten polymer material into the in-mold adjustment chamber 234. However, in other cases, piston 252 may not be designed to extend beyond the inner wall 242 of mold cavity 244. In this example, gate valve 232 may be positioned in outlet 235 of runner 220.

[0050] Temperature regulation mechanism 248 includes a fluid circuit 260 (e.g., a coolant circuit) passing through the chamber shell 236 of the in-mold adjustment chamber 234. Additionally or alternatively, fluid circuit 260 may pass through a section of piston 252, thereby increasing the area of ​​the adjustment chamber that can be heated and / or cooled. Pump 264 that generates and / or regulates the flow of fluid (e.g., coolant) through fluid circuit 260 is also included in temperature regulation mechanism 248. To change fluid heating or cooling, the pump output can be changed to alter the flow rate of the fluid through the fluid circuit. Heat exchanger 266 that increases or decreases the temperature of the fluid flowing through it is also included in temperature regulation mechanism 248. Additionally or alternatively, electric heating and / or cooling devices (e.g., Peltier devices, resistance heaters, etc.) may be included in temperature regulation mechanism 248. In other instances, heating rods may be additionally or alternatively used to increase the temperature of the molten polymer material.

[0051] Figure 1 The computing device 124 shown can send command signals to the temperature regulating mechanism 248, and specifically the pump 264 and / or heat exchanger 266, to change the heat delivered to or removed from the molten polymer material in the in-mold conditioning chamber 234. For example, when the temperature of the molten polymer material is higher than a desired value, the pump output can be increased to increase the cooling of the molten polymer material. In this way, the computing device can command the molten polymer material conditioning assembly 246, and specifically the pressure regulating mechanism 250 and temperature regulating mechanism 248, to increase / decrease the temperature of the molten polymer material in the in-mold conditioning chamber 234 and / or the outlet 235 of the flow channel 220 and / or the pressure applied to the molten polymer material. The temperature and pressure regulating commands can be selected based on a setpoint that allows the molten polymer material to achieve the desired physical and mechanical properties. Therefore, the properties of the molded article can be modified based on the end-use goals of the molded article. In this way, the properties of the article can be selected to match the design goals if needed.

[0052] The position of the in-mold adjustment chamber 234 can be adjusted by the chamber retraction device 268. Specifically, the chamber retraction device 268 is designed to position the in-mold adjustment chamber 234 in the filling position. Figure 2 (as shown) and withdrawal location (Figure 4 As will be discussed in greater detail herein, the in-mold conditioning chamber 234 can be removed from the mold cavity. It will also be appreciated that the chamber retraction device 268 is configured to establish and break a seal between the in-mold conditioning chamber and the interior surface of the mold.

[0053] In the illustrated example, the chamber retraction device 268 includes a rod 270 coupled to the chamber housing 236 and an actuator 272 (e.g., a motor, a piston (e.g., a hydraulic piston, a pneumatic piston, etc.), etc.). However, other suitable chamber retraction device configurations have also been contemplated. The actuator 272 is designed to extend and retract the rod 270, and thus move the chamber housing 236 into and out of the mold cavity 244. Accordingly, the chamber housing 236 is movable in opposite directions to place the in-mold conditioning chamber 234 inside and outside of the mold cavity 244. In particular, the chamber retraction device 268, and specifically the actuator 272, can be commanded by the computing device 124 shown in Figure 1 In-mold conditioning chamber 234 can be filled with molten polymer material from the upstream components while it is in the mold, and subsequently released to cause the molten polymer material in the mold to foam.

[0054] With continued reference to Figure 2 The chamber retraction device 268 can also include a sealing mechanism 274 designed to seal the mold cavity 244 when the in-mold conditioning chamber 234 is removed from the mold cavity 244. The sealing mechanism 274 can receive control signals from the computing device 124 shown in Figure 1 The sealing mechanism 274 can include suitable mechanisms, e.g., seals, housings, shafts, pivots, pistons, combinations thereof, etc., to allow the sealing function to be achieved.

[0055] As Figure 2As illustrated, the mold 245 includes two segments (i.e., a first segment 276 and a second segment 278). These segments are included in a mold housing 279. The mold 245 can be clamped and unclamped via a mold actuation device 280. The mold actuation device 280 can include tie bars 282 attached to clamping devices 284 (e.g., clamping cylinders) and a mechanism, such as a motor, a piston (e.g., hydraulic and / or pneumatic), a gear, etc., to effectuate the clamping / unclamping action of the mold. As shown, the tie bars 282 are attached to the second segment 278 of the mold 245. Once the article has been formed and / or cooled in the mold, the tie bars 282 and clamping devices 284 enable the mold to open. Thus, the first segment 276 and the second segment 278 can be clamped and then unclamped such that these segments are spaced apart from one another. However, other suitable mold configurations have also been contemplated. The mold actuation device 280 can receive control signals from the computing device 124 shown in FIG. 1 to open and close the mold during the molding cycle. Figure 1 The computing device 124 shown in FIG. 1 can receive control signals from the mold actuation device 280 to open and close the mold during the molding cycle.

[0056] The molding system 100 can also include a gas counter pressure (GCP) assembly 286 configured to adjust (e.g., increase and / or decrease) the pressure in the mold 245 before, during, and / or after the flow of molten polymeric material into the mold cavity 244. The GCP assembly 286 includes a gas reservoir 287 that stores pressurized gas. In some examples, the gas can be air and / or nitrogen. The GCP assembly 286 also includes a counter pressure valve 288 commanded by the computing device 124. The counter pressure valve 288 regulates the amount of gas that flows into the mold cavity 244 via a line 289 that extends between the gas reservoir 287 and the mold cavity 244. The valve 288 can also be used to adjust the rate of release of pressurized gas from the mold cavity 244. However, in other examples, a separate valve can control the rate of release of pressurized gas from the mold cavity.

[0057] Figure 3 One stage in the molding process is shown, where the molten polymeric material flows into the in-mold conditioning chamber 234 when the chamber is in the fill position. As previously described, in the fill position, the lip 240 is in sealing engagement with the inner wall 242 of the mold cavity 244 of the mold 245. Thus, the interior cavity 238 of the in-mold conditioning chamber 234 is sealed off from the rest of the mold cavity 244. Further, it should be appreciated that in the fill position, the in-mold conditioning chamber 234 is in direct fluid communication with the flow channel 220. However, other conditioning chamber fill configurations have also been contemplated.

[0058] Additionally, in the illustrated molding stage, the piston 252 in the pressure regulating mechanism 250 is in a first position, where the piston 252 is in sealing engagement with the inner wall 242 of the mold cavity 244 of the mold 245. Thus, the interior cavity 238 of the in-mold conditioning chamber 234 is sealed off from the rest of the mold cavity 244. Further, it should be appreciated that in the illustrated molding stage, the in-mold conditioning chamber 234 is in direct fluid communication with the flow channel 220. However, other conditioning chamber configurations have also been contemplated. Figure 3 In the illustrated molding stage, the piston 252 in the pressure regulating mechanism 250 is in a first position, where the piston 252 is in sealing engagement with the inner wall 242 of the mold cavity 244 of the mold 245. Thus, the interior cavity 238 of the in-mold conditioning chamber 234 is sealed off from the rest of the mold cavity 244. Further, it should be appreciated that in the illustrated molding stage, the in-mold conditioning chamber 234 is in direct fluid communication with the flow channel 220. However, other conditioning chamber configurations have also been contemplated. Figure 1The piston actuator 256, commanded by the computing device 124, retracts into the in-mold adjustment chamber 234. Changing the volume of the in-mold adjustment chamber 234 by adjusting the piston allows molten polymer material to be introduced into the chamber at the desired pressure and flow rate. In this way, the properties of the molten polymer material can be precisely controlled to reduce the likelihood of undesirable (e.g., premature) nucleation in the molten polymer material.

[0059] Additionally, in device 102, screw 200 can advance within barrel 108 to cause molten polymer material to flow through flow channel 220 and into in-mold conditioning chamber 234. Screw movement can be initiated via drive device 110. Furthermore, it should be understood that barrel valve 204 can be opened to allow molten polymer material to flow from device 102 into flow channel 220 and subsequently into in-mold conditioning chamber 234. Gate valve 232 can also be opened as molten polymer material flows into in-mold conditioning chamber 234 and subsequently closed to achieve temperature and / or pressure regulation in the conditioning chamber.

[0060] Additionally, in one instance, the temperature regulating mechanism 248 may also be composed of... Figure 1 The computing device 124 shown controls the adjustment of the temperature of the molten polymer material contained in the in-mold conditioning chamber 234. For example, the temperature of the molten polymer material in the in-mold conditioning chamber 234 can be increased or decreased until the molten polymer material reaches a temperature setpoint or a desired temperature range. For example, the output of the pump 264 and / or the configuration of the heat exchanger 266 can be adjusted to heat or cool the molten polymer material in the conditioning chamber. Furthermore, in one instance, pressure and temperature regulation can be performed during overlapping durations, or in other instances, pressure and temperature regulation can be implemented during non-overlapping durations. Additionally, it should be understood that the gate valve 232 can be closed simultaneously with temperature and / or pressure regulation of the molten polymer material in the in-mold conditioning chamber 234.

[0061] The runner temperature control device 222 can also be adjusted to heat or cool the molten polymer material as it is introduced from the runner 220 into the mold conditioning chamber 234. For example, the temperature of the molten polymer material in the runner 220 can be increased or decreased to maintain the molten polymer material at or within a desired temperature range as it flows into the mold conditioning chamber 234.

[0062] Furthermore, in some cases, the in-mold conditioning chamber 234 may be filled with molten polymer material in a continuous phase. Thus, the in-mold conditioning chamber 234 may have layers with different conditioning and / or layers with different types of polymer materials.

[0063] In a first example, during a first phase, a polymer material adjusted via a first protocol (e.g., adjusting a first amount of temperature and / or pressure) can flow into the in-mold conditioning chamber 234. Continuing the first example, during a second phase, a polymer material adjusted via a second protocol (e.g., adjusting a second amount of temperature and / or pressure) can be introduced into the in-mold conditioning chamber 234. It should be appreciated that temperature adjustment mechanisms coupled to the flow channel 220 can be used to adjust the temperature of the polymer material. Moreover, as the polymer material flows into the in-mold conditioning chamber 234 during the first and second phases, the polymer material conditioning assembly 246 can be adjusted to achieve different levels of polymer conditioning. In this way, layers of polymer material having different degrees of conditioning can be formed in the in-mold conditioning chamber 234. It should be appreciated that in such an example, the polymer materials flowing into the conditioning chamber at different phases can be delivered from different upstream devices in some cases. However, in other cases, the polymer materials delivered to the in-mold conditioning chamber 234 can be provided by a single upstream device (e.g., device 102).

[0064] In a second example, during a first phase, a first polymer material can be introduced into the in-mold conditioning chamber 234, and during a second phase, a second polymer material can be introduced into the in-mold conditioning chamber. In such an example, the first polymer material can be different than the second polymer material. For example, the first polymer can have a different polymer, filler, and / or blowing agent than the second polymer material. In one use case example, the first polymer material can be EVA, and the second polymer material can be TPU. However, many suitable combinations of polymer materials have been contemplated. In this way, different types of polymer materials can be layered in the in-mold conditioning chamber to achieve more granular conditioning of the properties of the molded article.

[0065] In a third example, during a first phase, a first polymer material having a first conditioning protocol can be delivered to the in-mold conditioning chamber 234 during the first phase. Continuing the third example, during a second phase, a second polymer material having a second conditioning protocol can be introduced into the in-mold conditioning chamber 234. In such an example, the first polymer material can be different than the second polymer material. In this way, different polymer materials having different degrees of conditioning can be formed as layers in the in-mold conditioning chamber.

[0066] In any of the foregoing examples where different polymer material layers having different adjustments and / or material compositions are released into the mold cavity 244, polymer material layers exhibiting different properties can be achieved. For example, a first layer (e.g., lower layer) of polymer material in the mold can have a greater density than a second layer (e.g., upper layer). In such an example, the first layer of polymer material in the mold can experience less foaming than the second layer. Additionally, in some cases, one of the layers can be substantially unfoamed, while the other layer can be foamed. In yet another example, a first layer of polymer material in the mold can be at a higher temperature than a second layer, which can affect the melt strength of the polymer material in the layers. Thus, the first layer of polymer material in the mold can have a greater melt strength than the second layer, or vice versa.

[0067] Figure 4 Another stage in the molding process in the molding system 100 is shown after the polymer material has been released into the mold cavity 244 and the in-mold adjustment chamber 234 has been removed from the mold cavity and placed in the retracted position. In this manner, the molten polymer material can be quickly released into the mold and nucleation in the polymer material can unfold as designed without any unexpected changes in the polymer material. Thus, the physical and mechanical properties of the molded article are precisely controlled. Additionally, the gate valve 232 can be closed when the in-mold adjustment chamber is removed from the mold.

[0068] In particular, Figure 1 The computing device 124 in the in-mold adjustment chamber 234 can send a control signal to the chamber retraction device 268 and specifically to the actuator 272 to cause the rod 270 to retract and move the chamber housing 236 out of the mold cavity 244 of the mold 245 to a position outside of the cavity, and break the seal between the mold cavity 244 and the in-mold adjustment chamber 234. Thus, the chamber housing 236 can move through the opening in the mold housing 279 during removal of the in-mold adjustment chamber from the mold.

[0069] Figure 4 A seal mechanism 274 that seals the segment 400 of the mold housing 279 is also shown as the in-mold adjustment chamber 234 is retracted. In this manner, the likelihood of polymer material escaping from the mold is reduced.

[0070] Figure 5 Another example of a molding system 500 is shown. Figure 5 The molding system 500 shown in FIG. 5 can include components, devices, parts, assemblies, etc. that can have similar functionality, properties, profiles, etc. as the components, devices, parts, assemblies, etc. shown in the molding system 100 in FIG. 1. For example, the molding system 500 includes a mold 245 that can have similar functionality, properties, profiles, etc. as the mold 245 shown in the molding system 100 in FIG. 1. Figures 1 to 4 The molding system 500 shown in FIG. 5 can include components, devices, parts, assemblies, etc. that can have similar functionality, properties, profiles, etc. as the components, devices, parts, assemblies, etc. shown in the molding system 100 in FIG. 1. For example, the molding system 500 includes a mold 245 that can have similar functionality, properties, profiles, etc. as the mold 245 shown in the molding system 100 in FIG. 1. Figures 1 to 4The components shown in the molding system 100 include the device 502 (e.g., injection device, extrusion device, etc.), runner 504, mold 506, etc. Therefore, redundant descriptions are omitted. Furthermore, it should be understood that... Figure 5 The system components shown can be accessed via, for example... Figure 1 The computing device 124 shown is used for commands, control, etc. Therefore, the computing device can... Figure 5 The various components in the molding system 500 shown send and receive signals to perform the molding methods, processes, control schemes, etc., described herein.

[0071] The molding system 500 includes runners 504. Figure 5 In the example shown, the flow channel 504 includes a first branch 508 supplying molten polymer material to the first in-mold adjustment chamber 510 and a second branch 509 supplying molten polymer material to the second in-mold adjustment chamber 514. Similar to... Figures 2 to 4 Gate valve 512 of the gate valve 232 shown may be included in the first branch 508. However, in other instances, gate valve 512 may be omitted from the system. Additionally, gate valve 513 may be included in the second branch 509. The gate valve is designed to regulate the amount of molten polymer material flowing through the branch of flow channel 504.

[0072] Figure 5 The molding system 500 includes a first in-mold adjustment chamber 510 and a second in-mold adjustment chamber 514. As shown, both in-mold adjustment chambers are in the filled position, in which they are sealed and separated from the rest of the mold cavity 516.

[0073] A first polymer material adjustment assembly 518, including a temperature regulation mechanism 520 and a pressure regulation mechanism 522 having a piston 523, is shown as being coupled to a first in-mold adjustment chamber 510. Figure 5 The first chamber retraction device 524 is also shown. As described above, the first in-mold adjustment chamber 510, the first polymer material adjustment assembly 518, and / or the first chamber retraction device 524 may have the same... Figures 2 to 4 The in-mold adjustment chamber 234, polymer material adjustment assembly 246, and chamber retraction device 268 shown in the figure have similar features.

[0074] The second polymer material adjustment assembly 526 is also shown coupled to the second in-mold adjustment chamber 514. The second polymer material adjustment assembly 526 includes a temperature regulation mechanism 528 and a pressure regulation mechanism 530. The temperature regulation mechanism 528 may include a fluid circuit 532, a pump 534, and a heat exchanger 536. The pump 534 may drive fluid through the fluid circuit, and the heat exchanger may remove or add heat to the fluid flowing through the circuit. Additionally or alternatively, an electric heating / cooling device included in the temperature regulation mechanism may be used to heat and / or cool the second in-mold adjustment chamber 514.

[0075] The pressure regulating mechanism 530 includes a piston 538 coupled to a piston actuator 540 via a valve stem 542. Additionally, the piston 538 is movable in an opposite direction to change the pressure applied to the molten polymeric material in the second in-mold conditioning chamber 514.

[0076] The second chamber retraction device 544 is shown coupled to the second in-mold conditioning chamber 514. Similar to the first chamber retraction device 524, the second chamber retraction device 544 moves the second in-mold conditioning chamber 514 into and out of the mold cavity 516. Thus, the second chamber retraction device can include a rod, an actuator, etc., similar to the other retraction devices described herein. It should be appreciated, however, that the size and other features of the retraction devices can vary depending on the size and / or profile of the corresponding conditioning chamber, the position of the conditioning chamber, etc. Thus, the second chamber retraction device can be configured to seal, unseal, and / or remove the second in-mold conditioning chamber 514 from the mold cavity 516.

[0077] In one example, the temperature and pressure regulation in the first in-mold conditioning chamber 510 and the second in-mold conditioning chamber 514 can be performed independently. Thus, in one use case example, the temperature and / or pressure in the first in-mold conditioning chamber 510 can be increased while the temperature and / or pressure in the second in-mold conditioning chamber 514 can be decreased, or vice versa. In another use case example, the temperature and / or pressure in the first in-mold conditioning chamber 510 can be increased or decreased in tandem with an increase or decrease in the temperature and / or pressure in the second in-mold conditioning chamber 514. In this way, the properties of the target section of the molded article can be selected to achieve the desired physical and mechanical characteristics.

[0078] In the illustrated example, the first in-mold conditioning chamber 510 and the second in-mold conditioning chamber 514 can have similar internal volumes. In other examples, however, the first in-mold conditioning chamber 510 and the second in-mold conditioning chamber 514 can have different internal volumes. The internal volumes can be selected based on the desired amount of molten polymeric material that is expected to be released from each chamber during a molding cycle to achieve the design goals of the molded article. For example, the first in-mold conditioning chamber can have a larger internal volume than the second in-mold conditioning chamber, or vice versa.

[0079] In another example, the first temperature regulating mechanism 520 and the second temperature regulating mechanism 528 can utilize a common pump and heat exchanger. In this way, the fluid circuits in the first and second temperature regulating mechanisms can be in fluid communication. In this way, the heating / cooling system can share common components, thereby improving the efficiency of the system and reducing the profile of the system.

[0080] In yet another example, the first in-mold conditioning chamber 510 can receive molten polymeric material from a second device (e.g., an injection device) that is different from the device 502 (e.g., an injection device). The second device can produce molten SPS, for example, with a different polymeric material, filler, blowing agent (e.g., SCF), etc. than the first device. In this way, the molded article can have segments of different types of materials. Thus, the article can have a greater amount of material variation, allowing for selection of materials in targeted segments based on particular end-use goals. For example, in one use case, it can be desirable for a portion of a shoe sole to have greater flexibility, while another portion of the shoe sole has greater impact resistance. Thus, the polymeric material injected near the front of the shoe sole can be selected and / or conditioned to exhibit increased flexibility, while the polymeric material of the back of the shoe sole can be selected and / or conditioned to exhibit greater impact resistance. In this way, a greater amount of polymeric conditioning granularity can be achieved during the molding process. However, it should be appreciated that many variations of material properties and distribution of polymeric material in the molded article are possible for the molding systems described herein.

[0081] In other examples, the orientation of the in-mold conditioning chambers can not be equivalent. For example, in one example, the first in-mold conditioning chamber 510 can be oriented vertically, while the second in-mold conditioning chamber 514 can be oriented horizontally. Figure 5 In the illustrated example, the central axes of the pistons 538 and 523 in the first and second in-mold conditioning chambers 510 and 514, respectively, are parallel to one another. However, in other examples, the axes of the chambers can not be parallel, and the in-mold conditioning chambers 510 and 514 can be removed from different directions, sides, etc. of the mold. Thus, molten polymeric material can be introduced from both chambers into a target area of the mold to achieve a desired distribution of polymeric material in the mold. Further, in one example, the first in-mold conditioning chamber 510 and the second in-mold conditioning chamber 514 can transition from a fill position to a withdrawal position at a selected time. Specifically, in one example, the first in-mold conditioning chamber can release from the fill position at a different time than the second in-mold conditioning chamber releases from its fill position. For example, the conditioned molten polymeric material in the first in-mold conditioning chamber can be released before the conditioned molten polymeric material from the second in-mold conditioning chamber is released to allow the polymeric material in the first chamber to expand to a desired location in the mold without interference from the polymeric material released from the second conditioning chamber. However, in other examples, the polymeric material in each of the first and second in-mold conditioning chambers can be released at the same or overlapping times.

[0082] Additionally, in some examples, each of the first and / or second in-mold conditioning chambers 510 and 514 can be filled with a layer of polymeric material, respectively. In one example, each of the layers of polymeric material can have a different polymer, filler, and / or blowing agent. Additionally or alternatively, the layers of polymeric material in the first and / or second in-mold conditioning chambers can be conditioned by different amounts. For example, in the first or second in-mold conditioning chamber, a first layer of polymeric material can have a higher temperature than a second layer of polymeric material.

[0083] Additionally, in some examples, the polymeric material in these layers and / or in the different conditioning chambers can achieve different degrees of foaming when released into the mold. For example, the polymeric material in the first in-mold conditioning chamber 510 can not foam when released into the mold, while the polymeric material in the second in-mold conditioning chamber 514 can foam the desired amount. Additionally, the layer of polymeric material in the first and / or second in-mold conditioning chamber can achieve a greater degree of foaming than the layer of polymeric material in the first and / or second in-mold conditioning chamber. In this way, there can be a difference in the foaming of the polymer in the different layers in one or both conditioning chambers when the conditioning chambers are unsealed, and / or there can be a difference in the foaming between the separate conditioning chambers. Thus, the material properties of the molded article can be adjusted with even greater precision.

[0084] It should also be appreciated that the molding system 500 can include a mold actuation device for opening and closing the mold, which is similar to the mold actuation device 280 shown in Figure 2 FIG. 4. Additionally, the molding system 500 can also include a GCP assembly 550, which is similar to the GCP assembly 286 shown in Figure 2 FIG. 4.

[0085] Figure 6 A method 600 for operating a molding system is shown. The method 600, as well as other methods described herein, can be implemented by the molding systems, portions, devices, etc. described herein with respect to Figures 1 to 5 FIG. 1. However, in other examples, these methods can be implemented by other suitable molding systems, portions, devices, etc.

[0086] At 602, the method includes forming a molten polymeric material with a blowing agent. However, in other examples, the molten polymeric material can be formed without a blowing agent. Forming the molten polymeric material with a blowing agent can include steps 604-606 and / or steps 608-610. At 604, the method includes forming the molten polymeric material in a device (e.g., an injection device or an extrusion device). For example, a heater coupled to the device can be activated to heat the polymeric material in a barrel of the device to form the molten polymeric material.

[0087] At 606, the method includes flowing a blowing agent into the molten polymer material via the blowing agent delivery assembly as the molten polymer material travels through the apparatus to form a molten SPS. Thus, the molten SPS can include molten polymer material having the blowing agent dissolved therein. In one example, the blowing agent can be a physical blowing agent, such as carbon dioxide and / or nitrogen that can be in a supercritical state. However, in other examples, the blowing agent can be a chemical blowing agent. Further, in other examples, the blowing agent can not be flowed into the apparatus, and thus the apparatus can include molten polymer material having no blowing agent dissolved therein. In yet another example, the blowing agent can be dissolved in the molten polymer material upstream of the apparatus.

[0088] On the other hand, at 608, the method includes producing the polymer material with the blowing agent upstream of the apparatus. For example, the polymer material can be manufactured with the blowing agent, or the blowing agent can be introduced into the polymer material in a storage chamber or a component upstream of the storage chamber. Next, at 610, the method includes heating the polymer material with the blowing agent to form a molten polymer material in the apparatus. In this way, the blowing agent can be introduced into the polymer material upstream of the apparatus, and then the polymer material and blowing agent can be heated to form a molten polymer material with the blowing agent.

[0089] At 612, the method includes flowing the molten polymer material from the flow channel into the in-mold conditioning chamber. In one example, a piston in the in-mold conditioning chamber can retract to facilitate the flow of the molten polymer material into the in-mold conditioning chamber. Additionally, in one example, a gate valve can open or remain open, and a screw can advance in a barrel of the apparatus to allow the molten polymer material to flow into the in-mold conditioning chamber. Additionally or alternatively, a barrel valve can open to allow the molten polymer material to flow from the apparatus to the in-mold conditioning chamber. As previously described, in certain instances, the polymer material can flow into the conditioning chamber in a sequence to form layers.

[0090] Next, at 614, the method includes adjusting a temperature of the molten polymeric material in the in-mold conditioning chamber and / or a pressure applied to the molten polymeric material in the in-mold conditioning chamber by operating the polymeric material conditioning assembly coupled to the in-mold conditioning chamber to generate a conditioned molten polymeric material. The temperature and / or pressure adjustment of the molten polymeric material can be selected to alter physical and mechanical properties of the molded article. For example, step 614 can additionally or alternatively include adjusting a melt strength of the molten polymeric material (e.g., molten SPS) in the in-mold conditioning chamber. In one example, the melt strength of the molten polymeric material can be increased to improve the quality of the molded article. Melt strength can be defined as the resistance of the molten polymeric material to stretch. Thus, in one example, melt strength can be a measure of shear viscosity, extensional viscosity, and / or modulus. In one specific example, an adjustment in melt strength is considered to occur when one or more of the shear viscosity, extensional viscosity, and / or modulus of the molten polymeric material changes by a threshold amount (e.g., 0.5%, 1.0%, 1.5%, etc.).

[0091] At 616, the method can include increasing the pressure in the mold cavity via the GCP assembly. However, in other examples, the GCP can not be used during the molding process, and thus step 616 can be omitted. It should also be appreciated that the GCP can be released during and / or after the introduction of the conditioned polymeric material into the mold. The release rate of the GCP can be based on system conditions, such as the temperature of the polymeric material, the pressure applied to the polymeric material in the in-mold conditioning chamber, the polymeric composition, etc.

[0092] At 618, the method includes releasing the conditioned molten polymeric material into the mold cavity. The release of the conditioned molten polymeric material into the mold enables the article to form in the mold. In one example, the chamber retraction device can be actuated to move the in-mold conditioning chamber away from the inner wall of the mold cavity, thereby breaking the seal between the in-mold conditioning chamber and the inner wall of the mold cavity, thereby releasing the polymeric material into the mold cavity. Thus, the conditioned polymeric material can be rapidly released into the mold cavity, enabling the foaming in the polymeric material to develop as intended.

[0093] At 620, the method includes removing the in-mold conditioning chamber from the mold cavity. A chamber retraction device can be used to remove the in-mold conditioning chamber. For example, the chamber retraction device can move the chamber housing to the outside of the mold cavity. Additionally, after removing the in-mold conditioning chamber from the mold cavity, the mold cavity can be sealed via a sealing mechanism. In this way, the area where the conditioning chamber was removed from the mold can be sealed to reduce (e.g., prevent) the likelihood of polymer material escaping from the mold. Next, at 622, the method includes cooling the article in the mold, and at 624, the method includes removing the article from the mold. In some examples, the article can cool a predetermined amount (e.g., 5°C, 10°C, 20°C, etc.) before being released from the mold only after the desired amount of cooling has been achieved. Further, in some examples, the amount of cooling can be expressed as a percentage of the peak polymer temperature, a percentage of the ambient temperature, etc. For example, the article can be released from the mold when the temperature of the article has dropped by 10%, 20%, 30%, etc. of the peak polymer material temperature.

[0094] The method 600 enables a temperature and / or pressure regulated molten polymer material to be directly released into a mold cavity to reduce the likelihood of, and in some cases avoid, undesirable material property changes in the molten polymer material prior to introducing the molten polymer material into the mold. For example, when the molten polymer material is precisely controlled for temperature and pressure, and then released directly into the mold cavity from a conditioning chamber nested in the mold, undesirable nucleation can be avoided.

[0095] Figure 7 A more detailed method 700 for operating a molding system is shown. At 701, the method includes forming a molten polymer material with a blowing agent. Forming a molten polymer material with a blowing agent can include steps 702-708 and / or steps 710-712.

[0096] At 702, the method includes feeding a polymer material into a device (e.g., an injection device or an extrusion device). For example, pellets, chips, etc. can be fed from a storage chamber into a barrel of the device.

[0097] Next, at 704, the method includes heating the polymer material in the device to form a molten polymer material. In one example, step 704 can also include shearing the polymer material via a screw included in the device. The polymer material heating can be performed by activating a heating device coupled to the barrel. At 706, the method includes moving the molten polymer material through the device. For example, a screw enclosed in the barrel can be rotated and / or moved forward to advance the molten polymer material through the barrel.

[0098] Next, at 708, the method includes flowing a blowing agent into the molten polymeric material as it travels through the apparatus. Thus, it should be appreciated that the molten SPS can form in the barrel. In such examples, the blowing agent can be a physical blowing agent, which in some cases can be a SCF such as supercritical nitrogen and / or carbon dioxide. However, other suitable blowing agents have been contemplated. Moreover, in other examples, the barrel can include only the molten polymeric material.

[0099] On the other hand, at 710, the method includes generating the polymeric material with the blowing agent, and at 712, the method includes heating the polymeric material with the blowing agent to form the molten polymeric material. The polymeric material can be generated with the blowing agent in a process that manufactures the blowing agent or in a component upstream of the apparatus, such as a storage chamber. For example, the blowing agent delivery assembly can be coupled to the storage chamber and provide the polymeric material thereto.

[0100] At 714, the method includes flowing the molten polymeric material from the apparatus into the in-mold conditioning chamber. The flow of the molten polymeric material can be conducted by opening a barrel valve in the apparatus, opening a gate valve in the flow channel, and / or retracting a piston into the in-mold conditioning chamber. In particular, in one example, the piston can be in an extended position in which the piston is positioned in the flow channel, and the piston can be retracted into a position within the chamber to regulate the flow of the molten polymeric material therein.

[0101] At 716, the method includes determining whether the molten polymeric material is at a desired temperature or a desired temperature range in the in-mold conditioning chamber. The temperature determination can involve comparing a temperature and / or pressure signal from a sensor in the system to a predetermined temperature setpoint and / or range. For example, a temperature sensor coupled to the in-mold conditioning chamber can indicate that the molten polymeric material temperature is below the desired range. Thus, it can be determined that the molten polymeric material is not at the desired temperature. However, a variety of schemes can be utilized to determine whether the molten polymeric material is at the desired temperature or the desired temperature range.

[0102] If the molten polymeric material in the in-mold conditioning chamber is not at the desired temperature or the desired temperature range (NO at 716), the method proceeds to 718, where the method includes adjusting the temperature of the molten polymeric material in the in-mold conditioning chamber. The temperature of the molten polymeric material can be adjusted by operating a temperature adjustment mechanism in the polymeric material conditioning assembly. For example, the circulation of coolant in a coolant loop can be increased to decrease the temperature of the molten polymeric material, and / or a heater coupled to the in-mold conditioning chamber can be activated to increase the polymeric material temperature. In particular, in one example, the temperature of the molten polymeric material can be adjusted to reduce losses in the system and / or enable the molten polymeric material to achieve a desired property, as previously discussed.

[0103] On the other hand, if the molten polymeric material is at a desired temperature or within a desired temperature range (716 is "yes"), the method proceeds to 720. At 720, the method includes determining whether the pressure applied to the molten polymeric material in the in-mold conditioning chamber is at a desired level or within an acceptable range. The pressure determination can be made by comparing pressure and / or temperature signals from sensors in the system to predetermined pressure set points and / or ranges. For example, a pressure sensor coupled to the in-mold conditioning chamber can indicate that the pressure applied to the molten polymeric material is below a desired range, set point, etc. Accordingly, it can be determined that the pressure applied to the molten polymeric material is not at a desired level. However, numerous schemes for determining whether the pressure applied to the molten polymeric material is at a desired level have been contemplated.

[0104] If the pressure applied to the molten polymeric material is not at a desired level or within a desired range (720 is "no"), then the method moves to 722, where the method includes adjusting the pressure applied to the molten polymeric material in the in-mold conditioning chamber. Adjusting the pressure applied to the molten polymeric material can include adjusting the position of the piston in the in-mold conditioning chamber. Accordingly, the piston can be moved in a first direction to increase the pressure applied to the molten polymeric material and in a second direction opposite the first direction to decrease the pressure applied to the molten polymeric material.

[0105] On the other hand, if the pressure applied to the molten polymeric material is at a desired level or within a desired range (720 is "yes"), then the method proceeds to 724, where the method includes releasing the molten polymeric material from the in-mold conditioning chamber into the mold cavity. In this way, the temperature and / or pressure adjusted molten polymeric material can flow into the mold cavity. Releasing the molten polymeric material into the mold cavity can include actuating the chamber retraction device to break the seal between the in-mold conditioning chamber housing and the inner wall of the mold cavity.

[0106] At 726, the method includes removing the in-mold conditioning chamber from the mold cavity. This removal can be made by actuating the chamber retraction device to retract the in-mold conditioning chamber into an area outside of the mold cavity.

[0107] At 728, the method can include cooling or heating the mold, releasing counter pressure in the mold, and at 730, the method includes opening the mold. Opening the mold can include actuating a clamping device coupled to a first section of the mold to release the first section from a second section. However, various suitable techniques for opening the mold have been contemplated. At 732, the method includes removing the article from the mold. Additionally, the article can be removed from the mold when the article has reached a desired amount of cooling.

[0108] The method 700 enables precise regulation of the temperature of the molten polymeric material and / or the pressure applied to the molten polymeric material before and / or as the molten polymeric material is released into the mold, thereby allowing fine-tuning of various properties of the polymeric material (e.g., bubble size, bubble distribution, skin thickness, etc.). As a result, the molding process can be precisely controlled to mold articles having targeted properties.

[0109] Figure 8 A method 800 for operating a molding system is shown. In particular, the method 800 can be performed via a molding system having two in-mold conditioning chambers, such as the molding system shown in FIGS. 1-3. However, it should be appreciated that in other examples, the method 800 can be performed using other suitable molding systems. Figure 5

[0110] At 802, the method includes forming a molten polymeric material with a blowing agent. However, in other examples, the molten polymeric material can be formed without a blowing agent. Forming the molten polymeric material with a blowing agent can include steps 804-806 and / or steps 808-810. At 804, the method includes heating a polymeric material in a device (e.g., an injection device or an extrusion device) to form the molten polymeric material. For example, a heater coupled to the device can be activated to heat a polymeric material in a barrel of the device to form the molten polymeric material.

[0111] At 806, the method includes flowing the blowing agent into the molten polymeric material via a blowing agent delivery assembly as the molten polymeric material travels through the device to form the molten polymeric material. Thus, in one example, the molten SPS can be formed in a device that includes a molten polymeric material with a blowing agent dissolved therein. In one example, the blowing agent can be a physical blowing agent, such as carbon dioxide and / or nitrogen that can be in a supercritical state. However, in other examples, the blowing agent can be a chemical blowing agent. Further, in other examples, the blowing agent can not be flowed into the device, and thus the device can include a molten polymeric material without a blowing agent dissolved therein. In yet another example, the blowing agent can be dissolved in the molten polymeric material upstream of the device.

[0112] On the other hand, at 808, the method includes creating a polymeric material with a blowing agent upstream of the device. For example, the polymeric material can be manufactured with a blowing agent, or the blowing agent can be introduced into the polymeric material in a storage chamber or a component upstream of the storage chamber. Next, at 810, the method includes heating the polymeric material with the blowing agent to form the molten polymeric material in the device. In this way, the blowing agent can be introduced into the polymeric material upstream of the device, and then the polymeric material and blowing agent can be heated to form the molten polymeric material with the blowing agent.

[0113] ​Next, at 812, the method includes flowing the molten polymeric material from the apparatus into the first in-mold conditioning chamber, and at 814, the method includes flowing the molten polymeric material from the apparatus into the second in-mold conditioning chamber, respectively. In particular, the molten polymeric material can flow from the apparatus to a flow channel and then from a branch of the flow channel to the first and second in-mold conditioning chambers. However, in other examples, separate apparatuses (e.g., injection apparatuses) can provide different types of polymeric material to the first and second in-mold conditioning chambers. As previously mentioned, in certain instances, the polymeric material can flow into one or both of the conditioning chambers in sequence to form different layers.

[0114] At 816, the method includes adjusting the temperature of the molten polymeric material in the first in-mold conditioning chamber and / or the pressure applied to the molten polymeric material in the first in-mold conditioning chamber to generate a first conditioned molten polymeric material, and at 818, the method includes adjusting the temperature of the molten polymeric material in the second in-mold conditioning chamber and / or the pressure applied to the molten polymeric material in the second in-mold conditioning chamber to generate a second conditioned molten polymeric material. In one example, the level of temperature and / or pressure adjustment in the first in-mold conditioning chamber can be different than the level of temperature and / or pressure adjustment in the second in-mold conditioning chamber. In this way, the molten polymeric material in the first and second in-mold conditioning chambers can be independently controlled. For example, the molten polymeric material in the first and second in-mold conditioning chambers can be temperature and / or pressure adjusted, respectively, to achieve varying density gradients in the molded article. Thus, if desired, a molded article having variable properties can be obtained. For example, it can be desirable to provide a denser foam in the heel section of the sole of an article of footwear, while providing a less dense foam in other sections of the sole. In another use case scenario, a section, portion, etc. of the molded article can be designed to have improved insulating capabilities, and another section, portion, etc. of the molded article can be designed to have improved compliance. The use case scenarios are provided as examples to help understand the potential applications of the molding method, and numerous use case scenarios have been contemplated. Further, in other examples, the pressure and / or temperature adjustments in the first and second in-mold conditioning chambers can be made using similar set points.

[0115] At 820, the method includes increasing the pressure in the mold cavity via the GCP assembly. For example, a valve in the GCP assembly can open to introduce high pressure gas into the mold cavity. In this way, another layer of control can be utilized to release the conditioned molten polymeric material into the mold, enabling additional conditioning of the properties of the polymeric material.

[0116] At 822, the method includes releasing the first adjusted molten polymeric material from the first in-mold adjustment chamber into the mold cavity. For example, the chamber retraction device connected to the first in-mold adjustment chamber can be actuated to break the seal between the first in-mold adjustment chamber and the wall of the mold cavity to quickly release the first adjusted molten polymeric material into the rest of the mold.

[0117] At 824, the method includes removing the first in-mold adjustment chamber from the mold. The chamber retraction device can be actuated to move the first in-mold adjustment chamber to a position outside of the mold cavity.

[0118] At 826, the method includes releasing the second adjusted molten polymeric material from the second in-mold adjustment chamber into the mold cavity, and at 828, the method includes removing the second in-mold adjustment chamber from the mold. Again, the chamber retraction device can be actuated to release the second adjusted molten polymeric material into the mold and remove the second in-mold adjustment chamber from the mold cavity. It should be appreciated that, in one example, steps 824 and 828 can be implemented in overlapping time periods, or in other examples, steps 824 and 828 can be implemented in consecutive time. Conversely, in one example, steps 822 and 826 can be implemented in overlapping time periods, or in other examples, steps 822 and 826 can be implemented in consecutive time. Also, it should be appreciated that, after the two in-mold adjustment chambers release polymeric material into the mold cavity, the article can be formed in the mold.

[0119] Next, at 830, the method includes cooling the article in the mold, and at 832, the method includes removing the article from the mold. Again, the article can be removed from the mold when it has reached a desired amount of cooling.

[0120] If desired, the method 800 enables multiple in-mold adjustment chambers to release molten polymeric material into the mold cavity to allow for individual adjustment of material properties in regions of the article. In this way, regions of the article can have different physical and mechanical properties. Thus, a more granular level of mold adjustment can be achieved to mold an article having desired properties. For example, the article can be molded to have one section, layer, etc. with greater abrasion resistance and another section, layer, etc. with greater compliance. In another example, sections of the article can have different densities resulting from different degrees of foaming in the polymeric material. Thus, the article can have a varying density gradient that can allow the article to have a desired weight distribution, bending properties, etc.

[0121] Turning now to Figure 9 depicts pressure plots, piston position plots, and control signal plots during a molding process. The molding process can be conducted by the molding system described above with respect to Figures 1 to 5 or can be implemented by other suitable molding systems. Figure 9The examples of FIGS. 9A-9D are drawn substantially to scale, although each point is not labeled with a numerical value. In this way, the relative differences in timing can be estimated by the scale of the drawing. However, other relative timings can be used if desired. Additionally, in each of the graphs, time is represented on the horizontal axis. Additionally, Figure 9 The graphical control strategy illustrated in FIGS. 9A-9D is for an example use case, and many molding system control strategies have been contemplated.

[0122] Specifically, plot 902 illustrates a GCP plot, plot 904 illustrates a barrel pressure plot, and plot 906 indicates an in-mold adjustment chamber pressure.

[0123] A piston position plot for the piston in the pressure adjustment mechanism is indicated at 908. An upper limit value on the vertical axis can indicate a piston position in which the volume of the in-mold adjustment chamber is at or near its maximum volume, while a lower limit value on the vertical axis can indicate a piston position in which the volume of the in-mold adjustment chamber is at or near its minimum volume.

[0124] A control signal sent to the chamber retraction device is indicated at 910. An insert and an exit value are indicated on the vertical axis. The insert value corresponds to a control signal that commands the in-mold adjustment chamber to be placed in a fill position in which the chamber is sealed by the outer wall of the mold cavity. On the other hand, the exit value corresponds to a control signal that commands the in-mold adjustment chamber to move out of the mold cavity. Thus, the exit control signal can break the seal between the adjustment chamber and the wall of the mold cavity.

[0125] A control signal sent to the gate valve in the flow channel is indicated at 912. An open and a closed value are indicated on the vertical axis. The open value corresponds to a gate valve control signal that opens the gate valve to allow molten polymer material to flow from the flow channel to the in-mold adjustment chamber. On the other hand, the closed value corresponds to a gate valve control signal that closes the gate valve, thereby preventing molten polymer material from flowing from the flow channel to the downstream component. Although plot 912 only shows an open signal and a closed signal, it will be appreciated that the gate valve can have multiple open positions that allow for adjustment of the polymer material flow rate.

[0126] At tO, the in-mold adjustment chamber is in a fill position in the mold cavity. Additionally, at tO, the piston is moving from a lower position toward an upper position, and the gate valve is open. In this way, the in-mold adjustment chamber can be filled with molten polymer material (e.g., molten SPS). At tO, the mold is pressurized via the GCP assembly. It will also be appreciated that the mold is closed or maintained in a closed position at tO. Furthermore, in one example, a barrel valve can be opened to allow molten polymer material to flow from the device into the flow channel, and / or a screw can be advanced in the barrel of the device to assist in the flow of polymer material into the in-mold adjustment chamber. Additionally, the barrel pressure decreases, followed by an increase between tO and tl.

[0127] At tl, the gate valve is closed. Additionally, at tl, the piston can reach the upper position. However, it should be appreciated that the position of the piston can be selected based on the desired amount of pressure adjustment of the molten polymeric material enclosed in the adjustment chamber. Thus, at tl, the filling of the in-mold adjustment chamber is stopped.

[0128] Next, at t2, the in-mold adjustment chamber is commanded to withdraw from the mold cavity. In this manner, the seal between the in-mold adjustment chamber and the inner walls of the mold cavity is broken. In this manner, the molten polymeric material can be quickly released from the in-mold adjustment chamber into the mold cavity. Thus, as the polymeric material enters the mold cavity, foaming can occur in the polymeric material. Additionally, at t2, the GCP in the mold cavity increases. In this manner, the foaming of the polymeric material in the mold can be precisely controlled. However, in other examples, the GCP can be maintained at a desired level or released at t2. Additionally, at t2, the piston can be moved toward the lower position. However, in other examples, the piston can be moved toward the lower position at a different time.

[0129] Additionally, at t2, the in-mold adjustment chamber is lowered to a lower level. While curve 906 illustrates the pressure within the chamber to be equilibrated between tO and t2, it should be appreciated that the pressure applied to the molten polymeric material in the in-mold adjustment chamber can be adjusted at any time prior to t2 based on operating conditions in the system. Such pressure adjustment can be made via a pressure control mechanism in the polymeric material adjustment assembly. For example, the in-mold adjustment chamber pressure can be increased to reduce the likelihood of unwanted nucleation in the molten polymeric material. However, in other examples, the adjustment chamber pressure can be decreased. In this manner, the in-mold adjustment chamber pressure can have a different profile than the one illustrated. Moreover, it should be appreciated that temperature adjustment of the molten polymeric material can be made at any time prior to t2 to allow for temperature adjustment of the molten polymeric material in the in-mold adjustment chamber.

[0130] Additionally, at t2, the screw can retract into the barrel to decrease the barrel pressure. However, in other examples, the screw can not retract and / or the barrel pressure can not decrease.

[0131] Next, at t3, the GCP is released from the mold cavity. The GCP is released to enable the molten polymeric material to flow from the in-mold adjustment chamber into the mold cavity at a desired rate and achieve a desired amount of foaming. Next, at t4, the in-mold adjustment chamber can be placed in the filling position in anticipation of another molding cycle. Additionally, at t4, the mold can open, and once the mold is open, the foamed article can be removed from the mold.

[0132] It will be appreciated that the molding process can be repeated to generate multiple articles from the mold, if desired. In such instances, the time interval for molding one article is referred to as the cycle time. It will be appreciated that the cycle time can be reduced, if desired, due to temperature and pressure control of the molten polymeric material. For example, the molten polymeric material can be at a lower temperature when entering the mold compared to previous molding techniques, thereby reducing the cycle time. However, in other instances, the molten polymeric material can be at a higher temperature than previous molding processes.

[0133] The present disclosure is further described in the following paragraphs. In one aspect, a method for operating a molding system is provided. The method includes flowing a first molten polymeric material from an upstream device into a first in-mold conditioning chamber in a fill position, at which the first in-mold conditioning chamber is at least partially positioned within a mold cavity; adjusting at least one of a temperature of the first molten polymeric material in the first in-mold conditioning chamber and a pressure applied to the first molten polymeric material in the first in-mold conditioning chamber to produce a first conditioned molten polymeric material; and releasing the first conditioned molten polymeric material from the first in-mold conditioning chamber into the mold cavity. In one instance, the method can further include removing the first in-mold conditioning chamber from the mold cavity. Further, in one instance, the method can further include flowing a second molten polymeric material into a second in-mold conditioning chamber in a fill position, at which the second in-mold conditioning chamber is at least partially within the mold cavity; adjusting at least one of a temperature of the second molten polymeric material in the second in-mold conditioning chamber and a pressure applied to the second molten polymeric material in the second in-mold conditioning chamber to produce a second conditioned molten polymeric material; and releasing the second conditioned molten polymeric material from the second in-mold conditioning chamber into the mold cavity. Further, in one instance, the method can further include cooling the first conditioned molten polymeric material in the mold cavity to form a molded article. Additionally, in one instance, the method can further include removing the molded article from the mold cavity.

[0134] In another aspect, a molding system is provided that includes a first in-mold conditioning chamber configured to adjust a temperature and / or a pressure applied to a first molten polymeric material to generate a first conditioned molten polymeric material and configured to be disposed in a fill position and a withdrawn position, wherein in the fill position the first in-mold conditioning chamber is in fluid communication with an upstream device and is at least partially positioned within a mold cavity, and wherein in the withdrawn position the first in-mold conditioning chamber is positioned outside of the mold cavity.

[0135] In another aspect, a method for operating a molding system is provided. The method includes actively adjusting a melt strength of a molten polymeric material in an in-mold conditioning chamber by applying a controlled pressure to the molten polymeric material, and / or actively adjusting a temperature of the molten polymeric material to generate a conditioned molten polymeric material, and releasing the conditioned molten polymeric material from the in-mold conditioning chamber into a mold cavity. In one example, the method can further include adjusting at least one of a pressure applied to a first molten polymeric material and a temperature of the first molten polymeric material to generate a first conditioned molten polymeric material in a first in-mold conditioning chamber, and adjusting at least one of a pressure applied to a second molten polymeric material and a temperature of the second molten polymeric material to generate a second conditioned molten polymeric material in a second in-mold conditioning chamber. In one example, the method can further include cooling the conditioned molten polymeric material in the mold cavity to form a molded article. In one example, the method can further include removing the molded article from the mold cavity.

[0136] In another aspect, a method for operating a molding system is provided. The method includes releasing a first conditioned molten polymeric material from a first in-mold conditioning chamber positioned at least partially within a mold cavity into the mold cavity, and releasing a second conditioned molten polymeric material from a second in-mold conditioning chamber positioned at least partially within the mold cavity into the mold cavity, wherein the releasing of the first and second conditioned molten polymeric materials into the mold cavity creates an article within the mold cavity. The method can further include adjusting at least one of a pressure applied to a first molten polymeric material and a temperature of the first molten polymeric material to generate the first conditioned molten polymeric material in the first in-mold conditioning chamber, and adjusting at least one of a pressure applied to a second molten polymeric material and a temperature of the second molten polymeric material to generate the second conditioned molten polymeric material in the second in-mold conditioning chamber. In one example, the method can further include cooling the first conditioned molten polymeric material in the mold cavity to form a molded article, and removing the molded article from the mold cavity.

[0137] In any of the aspects or combination of aspects, releasing the first conditioned molten polymeric material into the mold cavity can include actuating a chamber retraction device coupled to the first in-mold conditioning chamber to break a seal between the first in-mold conditioning chamber and an inner wall of the mold cavity.

[0138] In any of the aspects or combination of aspects, the step of adjusting at least one of a temperature of the first molten polymeric material and a pressure applied to the first molten polymeric material can be implemented prior to releasing the first conditioned molten polymeric material into the mold cavity.

[0139] In any of the aspects or combination of aspects, the time at which the first adjusted molten polymeric material is released into the mold cavity from the first in-mold conditioning chamber can be different than the time at which the second adjusted molten polymeric material is released into the mold cavity from the second in-mold conditioning chamber.

[0140] In any of the aspects or combination of aspects, the volume of the first in-mold conditioning chamber can not equal the volume of the second in-mold conditioning chamber.

[0141] In any of the aspects or combination of aspects, the temperature and / or pressure applied to the first molten polymeric material can be different than the temperature and / or pressure applied to the second molten polymeric material.

[0142] In any of the aspects or combination of aspects, the first molten polymeric material can include a blowing agent dissolved in the first molten polymeric material.

[0143] In any of the aspects or combination of aspects, the blowing agent can be a physical blowing agent.

[0144] In any of the aspects or combination of aspects, the physical blowing agent can be a SCF.

[0145] In any of the aspects or combination of aspects, in the fill position, the first in-mold conditioning chamber is engaged with an inner wall of the mold cavity and is in direct fluid communication with an outlet of the upstream device, and wherein the upstream device is a flow channel.

[0146] In any of the aspects or combination of aspects, the blowing agent can be dissolved in the first molten polymeric material to produce a first molten SPS.

[0147] In any of the aspects or combination of aspects, the molding system can further include a second in-mold conditioning chamber configured to be disposed in a fill position and a withdrawn position, wherein in the fill position, the second in-mold conditioning chamber receives a second molten polymeric material from an upstream device and is at least partially positioned within the mold cavity.

[0148] In any of the aspects or combination of aspects, releasing the adjusted molten polymeric material into the mold cavity can include breaking a seal between an inner wall of the mold cavity and a lip of the in-mold conditioning chamber.

[0149] In any of the aspects or combination of aspects, actively adjusting the melt strength of the molten polymeric material can include increasing the melt strength of the molten polymeric material.

[0150] In any of the aspects or combination of aspects, the foaming agent can be dissolved in the molten polymeric material to form a molten SPS.

[0151] In any of the aspects or combination of aspects, the article can have a varying density gradient.

[0152] In any of the aspects or combination of aspects, the first adjusted molten polymeric material and the second adjusted molten polymeric material can be released into the mold cavity at different times.

[0153] In any of the aspects or combination of aspects, the temperature and / or pressure applied to the first molten polymeric material can be different than the temperature and / or pressure applied to the second molten polymeric material.

[0154] In any of the aspects or combination of aspects, the molding system can further include a polymeric material adjustment assembly coupled to the first in-mold adjustment chamber and configured to adjust the temperature of the molten polymeric material in the first in-mold adjustment chamber and / or the pressure applied to the molten polymeric material in the first in-mold adjustment chamber.

[0155] In any of the aspects or combination of aspects, the polymeric material adjustment assembly can include a movable piston configured to adjust the volume of the first in-mold adjustment chamber.

[0156] In any of the aspects or combination of aspects, the polymeric material adjustment assembly can include a coolant loop through a housing of the first in-mold adjustment chamber, a thermoelectric heater integrated within or coupled to the housing of the first in-mold adjustment chamber, and / or a thermoelectric cooler integrated within or coupled to the housing of the first in-mold adjustment chamber.

[0157] In any of the aspects or combination of aspects, the method can further include adjusting the pressure within the mold cavity via a gas counter pressure (GCP) assembly prior to and / or during the release of the first and second adjusted molten polymeric materials from the first and second in-mold adjustment chambers into the mold cavity.

[0158] In any of the aspects or combination of aspects, the method can further include adjusting the pressure within the mold cavity via a gas counter pressure (GCP) assembly prior to and / or during the release of the first adjusted molten polymeric material from the first in-mold adjustment chamber into the mold cavity.

[0159] It should be noted that the example control and estimation routines included herein can be used with a variety of system configurations. The control methods and routines disclosed herein can be stored as executable instructions in a non-transitory memory and can be executed by a molding system.

[0160] The particular routines described herein can represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and so on. As such, various acts, operations, and / or functions illustrated can be performed in the manner described, in parallel, or omitted in some instances. Likewise, the order of various acts, operations, and / or functions presented in the examples described herein is not essential for achieving the features and advantages of example embodiments described herein, but is provided to explain the functionality of the example embodiments. One or more of the acts, operations, and / or functions illustrated can be repeated, omitted, and / or combined in some instances. Additionally, the described acts, operations, and / or functions can be represented by code stored on a non-transitory memory of a computer readable storage medium that is programmed to implement the described acts, operations, and / or functions by executing the instructions in a molding system including various components. It should be understood that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. The subject matter of the application includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations disclosed herein, as well as other features, functions, and / or properties inherent in each variably described component.

[0161] The appended claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims can refer to "an" element or "a first" element or the equivalent thereof. Such claims should be understood to include one or more such elements, neither requiring nor excluding two or more elements. Other combinations and sub-combinations of disclosed features, functions, elements, and / or properties can be claimed through amendment of the present claims or presentation of additional claims in the application or corresponding application. Such amended claims, whether they expand the claims or narrow the claims, are to be considered within the scope of the subject matter of the application.

Claims

1. A method for operating a molding system, the method comprising: flowing a first molten polymeric material from an upstream device into a first in-mold conditioning chamber in a fill position, at which the first in-mold conditioning chamber is at least partially positioned within a mold cavity; adjusting at least one of a temperature of the first molten polymeric material in the first in-mold conditioning chamber and a pressure applied to the first molten polymeric material in the first in-mold conditioning chamber to produce a first conditioned molten polymeric material; releasing the first conditioned molten polymeric material from the first in-mold conditioning chamber into the mold cavity; and actuating a chamber retraction device coupled to the first in-mold conditioning chamber to break a seal between the first in-mold conditioning chamber and an inner wall of the mold cavity.

2. The method of claim 1, wherein the step of adjusting at least one of the temperature of the first molten polymeric material and the pressure applied to the first molten polymeric material is performed prior to releasing the first conditioned molten polymeric material into the mold cavity.

3. The method of claim 1, further comprising: flowing a second molten polymeric material into a second in-mold conditioning chamber in a fill position, at which the second in-mold conditioning chamber is at least partially within the mold cavity; adjusting at least one of a temperature of the second molten polymeric material in the second in-mold conditioning chamber and a pressure applied to the second molten polymeric material in the second in-mold conditioning chamber to produce a second conditioned molten polymeric material; and releasing the second conditioned molten polymeric material from the second in-mold conditioning chamber into the mold cavity.

4. The method of claim 3, wherein a time at which the first conditioned molten polymeric material is released from the first in-mold conditioning chamber into the mold cavity is different than a time at which the second conditioned molten polymeric material is released from the second in-mold conditioning chamber into the mold cavity.

5. The method of claim 3, wherein a volume of the first in-mold conditioning chamber is not equal to a volume of the second in-mold conditioning chamber.

6. The method of claim 3, wherein the temperature of the first molten polymeric material and / or the pressure applied to the first molten polymeric material is different than the temperature of the second molten polymeric material and / or the pressure applied to the second molten polymeric material.

7. The method of claim 1, wherein the first molten polymeric material comprises a molten single-phase solution (SPS) having a blowing agent dissolved therein.

8. The method of claim 7, wherein the blowing agent is a physical blowing agent or a chemical blowing agent.

9. The method of claim 1, further comprising adjusting a pressure within the mold cavity via a gas counter pressure (GCP) assembly prior to and / or during the release of the first conditioned molten polymeric material from the first in-mold conditioning chamber into the mold cavity. ​ ​

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