Articles and methods of making the same

Abstract

This invention discloses an article comprising a foamed component including a polymeric material; and a core embedded therein, the core including a first surface, a second surface, and a sidewall, the foamed component covering at least a portion of the first surface and the entire sidewall and the entire second surface. A method of manufacturing an article includes providing a molding apparatus including a first mold and a second mold, the first mold including a support member projecting from an inner wall. The method further includes disposing a core on the support member; disposing the second mold above the first mold to form a mold cavity, wherein the core is disposed in the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed component, wherein at least a portion of the first foamed component is in contact with the core.

Description

[0001] Cross-referencing related applications

[0002] This application claims Chinese Patent Application No. 202111001038.7, filed August 30, 2021; U.S. Patent Application No. 17 / 831,428, filed June 2, 2022; Taiwan Patent Application No. 110130996, filed August 23, 2021; and Taiwan Patent Application No. 110141372, filed November 5, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to an object and a method for manufacturing the same, and more particularly to an object comprising a foamed component and a core and a method for manufacturing the same. Background Technology

[0004] Objects containing foamed components and cores offer numerous advantages, such as high strength, low weight, impact resistance, and thermal insulation. These objects can be manufactured by bonding the foamed component and core together or interlocking them, thus exposing at least the entire surface of the core. Therefore, improvements are still needed in the structure of objects comprising foamed components and cores, and in their manufacturing methods. Summary of the Invention

[0005] One object of the present invention is to provide an object and a method for manufacturing the same.

[0006] According to a specific embodiment of the present invention, an object is disclosed. The object includes: a foamed component containing a polymeric material, and a core embedded in the foamed component. The core includes a first surface, a second surface opposite to the first surface, and a sidewall located between the first surface and the second surface. The foamed component covers at least a portion of the first surface and covers the entire sidewall and the entire second surface.

[0007] According to a specific embodiment of the present invention, a method for manufacturing an article is disclosed. The method includes: providing a molding apparatus, wherein the molding apparatus includes a first mold and a second mold corresponding to the first mold, the first mold including an inner wall and a support member protruding from the inner wall; disposing a core on the support member; and disposing the second mold above the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member. At least a portion of the first foamed member is in contact with the core. Attached Figure Description

[0008] The present invention can be best understood from the following embodiments when read in conjunction with the accompanying drawings. It should be noted that, according to standard industry practice, the various features are not drawn to scale. In fact, for clarity, the dimensions of the various features may be arbitrarily enlarged or reduced.

[0009] Figure 1 The diagram illustrates an exemplary object according to a specific embodiment of the present invention.

[0010] Figure 2 and Figure 2A The diagram illustrates a portion of an exemplary object according to a specific embodiment of the present invention.

[0011] Figures 3 to 6 For along Figure 1 A schematic cross-sectional view of the middle line II-II', illustrating an exemplary object according to a specific embodiment of the invention.

[0012] Figure 7 The following is a flowchart illustrating a method for manufacturing an object according to a specific embodiment of the present invention.

[0013] Figure 8 , Figure 13 , Figure 14 , Figures 17 to 21 The diagram shows a schematic cross-sectional view illustrating an exemplary operation of a method for manufacturing an object according to a specific embodiment of the present invention.

[0014] Figures 9 to 12 This is a schematic top view of a portion of an injection molding system used in a method for manufacturing an article according to a specific embodiment of the present invention.

[0015] Figure 15 and Figure 16 This is a schematic diagram of a portion of an injection molding system 100 according to a specific embodiment of the present invention.

[0016] Figure 22 The diagram illustrates an exemplary object according to a specific embodiment of the present invention.

[0017] Figures 23 to 26 The diagram shows a schematic cross-sectional view illustrating an exemplary operation of a method for manufacturing an object according to a specific embodiment of the present invention.

[0018] Figure 27 and Figure 28 The diagram illustrates an exemplary object according to a specific embodiment of the present invention.

[0019] Figure 29 According to a specific embodiment of the present invention Figure 1 A schematic diagram of a part of an injection molding system.

[0020] Figure 30According to a specific embodiment of the present invention Figure 29 An enlarged view of a portion of the injection molding system circled in dashed circles.

[0021] Figure 31 A graph illustrating the relationship between foaming dosage and shortest distance in a mixture according to a specific embodiment of the present invention is provided.

[0022] Figure 32 A graph illustrating the behavior of the ratio of foaming agent to polymer material with respect to the ratio of shortest distance to mixing rotor diameter according to a specific embodiment of the present invention is provided. Detailed Implementation

[0023] The following description provides numerous different specific embodiments or examples for implementing various features of the provided patented subject matter. Specific examples of components and configurations are described below to simplify the invention. Of course, these are merely examples and not limiting. For example, the following description of forming a first feature on or over a second feature may include specific embodiments in which the first and second features are formed in direct contact, and may also include specific embodiments in which an additional feature may be formed between the first and second features such that the first and second features are not in direct contact. Furthermore, reference numerals and / or letters may be repeated in various examples. This repetition is for simplicity and clarity and does not in itself imply a relationship between the various specific embodiments and / or configurations discussed.

[0024] In addition, this document may use spatial terms such as under, below, above, and above to describe the relationship between a component or feature and other elements(s) or features(s) as illustrated in the figures. Besides the orientations depicted in the figures, such spatial terms also cover different orientations of the device during use or operation. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial terms used herein may thus be interpreted.

[0025] While the numerical ranges and parameters describing the broad scope of this invention are approximate, the numerical values ​​disclosed in the specific examples are listed as precisely as possible. However, any numerical value inherently contains some error due to the standard deviation necessarily found in the corresponding test measurement. Furthermore, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, from the perspective of one skilled in the art, the term "about" means within an acceptable standard error of the average. Except in operational / working examples, or unless explicitly stated otherwise, all numerical ranges, quantities, values, and percentages described herein, such as material quantities, durations, temperatures, operating conditions, quantity ratios, etc., should be understood to be modified in all cases by the terms "generally," "approximately," or "about." Therefore, unless indicated to the contrary, the numerical parameters described in this invention and the claims following this document are approximate values ​​that may vary as needed. At a minimum, each numerical parameter should be interpreted according to the number of significant figures listed and by applying common rounding techniques. In this document, a range may be expressed as from one endpoint to the other or between two endpoints. Unless otherwise stated, all ranges disclosed herein include endpoints.

[0026] Figure 1 A schematic diagram illustrating an object according to a specific embodiment of the present invention. Figure 2 and Figure 2A A schematic diagram illustrating an object core according to a specific embodiment of the present invention is provided. The object core may have, for example, the following features: Figures 3 to 5 The various configurations shown by any of them. Figures 3 to 5 For along Figure 1 The diagram shows a schematic cross-sectional view along line II-II', illustrating various configurations of an object according to a specific embodiment of the invention. Please refer to [reference needed]. Figure 1 and Figure 2 The object 20 includes a foamed component 22 containing a polymeric material and a core 21 embedded in the foamed component 22. The core 21 improves the strength of the object 20. The core 21 and the foamed component 22 may correspond to each other in shape, and may be circular, elliptical, rectangular, square, or other desired shapes in top view, but are not limited thereto. In some embodiments, the object 20 is part of a footwear or a semi-finished product of a footwear. In some embodiments, the object 20 is the outsole of a footwear. In some embodiments, the object 20 is the midsole of a footwear. In some embodiments, the thickness of the object 20 is equal to or greater than 20 mm. In some embodiments, the thickness of the object 20 is equal to or greater than 25 mm.

[0027] In some embodiments, the foamed component 22 comprises a polymeric material, such as ethylene vinyl acetate (EVA), styrene-ethylene-butene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the foamed component 22 comprises a recyclable material. In some embodiments, the periphery thickness of the foamed component 22 is equal to or greater than 20 mm. In some embodiments, the periphery thickness of the foamed component 22 is equal to or greater than 25 mm. In some embodiments, the foamed component 22 further comprises a foaming agent. In some embodiments, the foaming agent may be any type of chemical or physical foaming agent known to those skilled in the art. In some embodiments, the foaming agent is a supercritical fluid. Supercritical fluids may include inert gases, such as carbon dioxide or nitrogen in a supercritical state. In some embodiments, the foamed component 22 is made of a molding material comprising a polymeric material and a foaming agent. In some embodiments, the article 20 has no adhesive.

[0028] In some embodiments, the core 21 includes a first surface 211, a second surface 212 opposite to the first surface 211, and a sidewall 213 located between the first surface 211 and the second surface 212. In some embodiments, the foaming member 22 covers at least a portion of the first surface 211 and the entire sidewall 213 and the entire second surface 212. In some embodiments, the foaming member 22 contacts at least a portion of the first surface 211 and the entire sidewall 213 and the entire second surface 212. In some embodiments, a portion of the first surface 211 is exposed through the foaming member 22. In some embodiments, a mark 374 is disposed at and recessed within the foaming member 22. In some embodiments, a portion of the first surface 211 is exposed through the mark 374. In some embodiments, viewed from above, the mark 374 overlaps with the core 21.

[0029] In some embodiments, the object 20 is not marked 374, and the core 21 is surrounded by the foaming member 22. In some embodiments, the foaming member 22 contacts the entire first surface 211, the entire sidewall 213, and the entire second surface 212.

[0030] In some embodiments, core 21 comprises a polymer material, such as ethylene vinyl acetate (EVA), styrene-ethylene-butene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, core 21 is a non-foamed component. In some embodiments, core 21 comprises recyclable material. Additionally, in some embodiments, core 21 is a foamed component. In some embodiments, the foamed component 305 comprises a polymer material and a blowing agent. In some embodiments, the stiffness of the non-foamed component is greater than the stiffness of the foamed component. In some embodiments, core 21 and foamed component 22 comprise the same material.

[0031] To enhance the bonding strength between the core 21 and the foamed component 22, in some embodiments, the surface area of ​​the core 21 is increased by forming a pattern on the first surface 211 and / or the second surface 212, and at least a portion of the foamed component 22 is conformal to the pattern. In some embodiments, the properties of the core 21 are influenced by the pattern. The pattern can be distributed on the core 21 and is not limited to a specific type, as long as the properties of the core 21 meet the actual requirements. In some embodiments, at least one of the first surface 211, the second surface 212, and the sidewall 213 is a rough surface. In some embodiments, the core 21 has a Young's modulus in the range of 230 to 430 kg / mm².

[0032] In some specific embodiments, please refer to the following: Figure 2A The core 21 includes two or more workpieces. In some embodiments, the core 21 includes a first layer 217 and a second layer 218 disposed on the first layer 217. Alternatively, in some embodiments, the first layer 217 is disposed on the second layer 218. In some embodiments, the first layer 217 is attached to the second layer 218. In some embodiments, the first layer 217 is a non-foamed component, and the second layer 218 is a foamed component. In some embodiments, the first layer 217 and the second layer 218 comprise the same or different materials. In some embodiments, the first layer 217 is directly bonded to the second layer 218. In some embodiments, an adhesive is applied between the first layer 217 and the second layer 218 to bond the first layer 217 and the second layer 218 together.

[0033] In some specific embodiments, please refer to the following: Figure 2 and Figure 3The pattern is a through-hole 214 extending between the first surface 211 and the second surface 212. In some embodiments, a portion of the foaming member 22 is disposed within the through-hole 214. In some embodiments, a plurality of through-holes 214 extend between the first surface 211 and the second surface 212. In some embodiments, the through-holes 214 are configured to penetrate the core 21. In some embodiments, the density, size, and shape of the through-holes 214 are not limited, as long as the characteristics of the core 21 meet the actual requirements.

[0034] In some specific embodiments, please refer to the following: Figure 2 and Figure 4 The pattern is a recess 215 recessed into the core 21 and disposed on the first surface 211. In some embodiments, a portion of the foaming member 22 is disposed in the recess 215. In some embodiments, a plurality of recesses 215 are disposed on the first surface 211, the second surface 212, and / or the sidewall 213 of the core 21. In some embodiments, the density, size, and depth of the recesses 215 are not limited, as long as the characteristics of the core 21 meet the actual needs.

[0035] In some specific embodiments, please refer to the following: Figure 2 and Figure 5 The pattern consists of protrusions 216 projecting from the first surface 211. In some embodiments, the foaming member 22 surrounds the protrusions 216. In some embodiments, a plurality of protrusions 216 are disposed on the first surface 211, the second surface 212, and / or the sidewalls 213 of the core 21. In some embodiments, the density, size, and height of the protrusions 216 are not limited, as long as the characteristics of the core 21 meet the actual requirements.

[0036] Figure 6 This is a schematic cross-sectional view of an object according to some specific embodiments of the present invention. Please refer to [reference needed] for some specific embodiments. Figure 6 A component 23 is disposed above the core 21 and the foam member 22. In some embodiments, the component 23 is attached to and disposed above the foam member 22. In some embodiments, a portion of the foam member 22 is disposed between the component 23 and the core 21, such that the core 21 does not contact the component 23. In some embodiments, the component 23 is adjacent to the core 21. In some embodiments, a first surface 211 of the core 21 faces the component 23. In some embodiments, the component 23 is any other suitable component of an insole, upper, or footwear.

[0037] Figure 7The present invention is a flowchart of an object manufacturing method 700 according to some specific embodiments thereof. Method 700 includes several steps: step (701), providing a molding apparatus, wherein the molding apparatus includes a first mold and a second mold corresponding to the first mold, the first mold including an inner wall and a support member protruding from the inner wall; step (702), disposing a core on the support member; step (703), disposing the second mold above the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; step (704), injecting a first material into the mold cavity; and step (705), foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member is in contact with the core.

[0038] To illustrate the concept and method 700 of the present invention, various specific embodiments are provided below. However, the present invention is not intended to be limited to any particular specific embodiment. Furthermore, the components, conditions, or parameters illustrated in different specific embodiments may be combined or modified to form different combinations of specific embodiments, as long as the components, parameters, or conditions used do not conflict. For ease of explanation, reference numerals having similar or identical functions and characteristics are repeated in different specific embodiments and drawings. Various operations of the injection molding method and the articles formed therefrom may have, as Figure 8 , Figure 13 , Figure 14 and 17 to Figure 21 Various configurations shown by either one. Figure 22 This is a schematic cross-sectional view of an article 20 manufactured by method 700 according to some specific embodiments of the present invention.

[0039] In some specific embodiments, Figure 8 The image illustrates an injection molding system 100 of a method 700 according to some specific embodiments of the present invention, specifically step 701. In some embodiments, the method 700 for manufacturing an article 20 includes step 701, which includes providing a molding apparatus 30, wherein the molding apparatus 30 includes a first mold 33 and a second mold 32 corresponding to the first mold 33. In some embodiments, the first mold 33 is a lower mold, and the second mold 32 is an upper mold. In some embodiments, the molding apparatus 30 includes a mold base 34 adjacent to the first mold 33 and the second mold 32. In some embodiments, the mold base 34 is attached to the first mold 33. In some embodiments, such as... Figure 8 The forming device 30 is shown to be provided or received. In some specific embodiments, the forming device 30 is configured to form the article 20.

[0040] In some embodiments, the first mold 33 and the second mold 32 are separated from each other during step 701. In some embodiments, the first mold 33 and the second mold 32 are complementary and separable. In some embodiments, the first mold 33 and the second mold 32 are complementary to each other to define a mold cavity (not shown).

[0041] In some embodiments, a first mold 33 defines a lower mold cavity 331, and a second mold 32 defines an upper mold cavity 321. In some embodiments, the first mold 33 includes an inner wall 332 and a support member 37 projecting from the inner wall 332. In some embodiments, the inner wall 332 of the first mold 33 is curved.

[0042] In some embodiments, at least one feed port 35 is provided at the molding device 30. In some embodiments, the feed port 35 is disposed at the first mold 33 or the second mold 32. In some embodiments, the feed port 35 may communicate with the upper mold cavity 321 or the lower mold cavity 331. For clarity and simplicity, Figure 8 Only one feed port 35 is shown within a mold, but this example is for illustration only and is not intended to limit these specific embodiments. Those skilled in the art will readily understand that a mold may include one or more feed ports 35 communicating with the upper mold cavity 321 or the lower mold cavity 331.

[0043] The feed port 35 is configured to receive molding material (not shown) into the upper mold cavity 321 and / or the lower mold cavity 331. In some embodiments, several feed ports 35 are arranged at the molding apparatus 30. The molding material can be conveyed into the molding apparatus 30 through the feed ports 35. In some embodiments, the molding material is injected into the upper mold cavity 321 and the lower mold cavity 331, and then foamed components 22 are formed in the upper mold cavity 321 and the lower mold cavity 331 after a period of time. In some embodiments, the feed port 35 is arranged at the first mold 33. In some embodiments, the feed port 35 may be arranged on the side wall of the first mold 33 or at any other suitable location, as long as the feed port 35 communicates with the lower mold cavity 331. In some embodiments, the first feed port 35 may be arranged at the second mold 32 to enter and exit the upper mold cavity 321, instead of being arranged at the first mold 33.

[0044] In some embodiments, a feed opening 351 is connected to a feed port 35. In some embodiments, the feed opening 351 is configured to convey molding material from the feed port to the molding apparatus 30. In some embodiments, the feed opening 351 is located on the inner wall 332 of the first mold 33 for conveying molding material from the feed port 35 to the lower mold cavity 331. In some embodiments, the feed opening 351 is located on the inner sidewall 333 of the first mold 33. In some embodiments, the feed opening 351 is located on the inner bottom wall 334 of the first mold 33. In some embodiments, the feed opening 351 is located on the inner wall 322 of the second mold 32. In some embodiments, the feed opening 351 is configured to be adjacent to and separate from the support member 37. In some embodiments, the feed port 35 communicates with a plurality of feed openings 351. In some embodiments, a plurality of feed openings 351 are respectively connected to the feed port 35. In some embodiments, the feed opening 351 may have different widths or diameters. The locations of the feed opening 351 are not particularly limited, and it may be configured in different regions of the inner wall 332 of the first mold 33 and the inner wall 322 of the second mold 32. In some embodiments, the end of the feed inlet 35 connected to the upper mold cavity 321 and / or the lower mold cavity 331 has a plurality of guide channels 352, wherein each guide channel 352 connects to a corresponding feed opening 351 and feed inlet 35.

[0045] In some embodiments, the mold base 34 includes openings 341. Each of these openings 341 extends through the mold base 34. The mold base 34 can be secured to the first mold 33 or the second mold 32 by screws, clamps, fasteners, etc. In some embodiments, the mold base 34 is made of the same material as the first mold 33. In some embodiments, the height H1 of the mold base 34 is greater than or equal to the height H2 of the first mold 33 or the second mold 32.

[0046] In some embodiments, the molding apparatus 30 further includes one or more pressure regulating systems 36. In some embodiments, a mating point 367 may connect to a lower mold cavity 331 or an upper mold cavity 321. In some embodiments, a plurality of mating points 367 may connect to an upper mold cavity 321 or a lower mold cavity 331. In some embodiments, the mating points 367 are configured to allow fluid or gas to enter or exit the molding apparatus 30. The position, shape, and number of the mating points 367 are not particularly limited and can be adjusted as needed. In some embodiments, each of these mating points 367 is an orifice.

[0047] The pressure regulation system 36 may include a first gas conduit 361, a second gas conduit 362, a gas source 363, a first valve 364, a second valve 365, and a pressure sensing unit 366. In some embodiments, one end of the first gas conduit 361 is connected to a connection point 367, and the other end of the first gas conduit 361 is connected to the gas source 363. In some embodiments, the gas source 363 is configured to supply a fluid or gas, wherein a suitable fluid or gas can be supplied as needed; for example, the fluid or gas may be air, an inert gas, etc., but the invention is not limited thereto. In some embodiments, one end of the first gas conduit 361 is coupled to the connection point 367.

[0048] In some embodiments, the junction 367 is configured to supply or discharge gas. A first valve 364 is located at a first gas conduit 361 and configured to control whether gas from a gas source 363 enters the lower mold cavity 331 and / or the upper mold cavity 321 through the first gas conduit 361 and the junction 367. In some embodiments, when the first valve 364 is open and the second valve 365 is closed, fluid or gas is supplied to the lower mold cavity 331 and / or the upper mold cavity 321; when the first valve 364 is closed and the second valve 365 is open, at least a portion of the fluid or gas in the lower mold cavity 331 and / or the upper mold cavity 321 is discharged.

[0049] In some embodiments, a second gas conduit 362 is coupled to a junction point 367. A second valve 365 is disposed at the second gas conduit 362 and configured to control whether gas from the lower mold cavity 331 or the upper mold cavity 321 is discharged through the second gas conduit 362 via the junction point 367. In some embodiments, the second gas conduit 362 is coupled to the junction point 367.

[0050] In some embodiments, one end of the second gas conduit 362 is connected to a space with a pressure lower than that in the lower mold cavity 331 or the upper mold cavity 321; for example, the external environment or a negative pressure space; however, the invention is not limited thereto. In some embodiments, the first valve 364 and the second valve 365 are not opened simultaneously.

[0051] The pressure sensing unit 366 is configured to sense the pressure within the lower mold cavity 331 or the upper mold cavity 321. The pressure sensing unit 366 is not limited to any particular type, as long as it can sense pressure and provide pressure information after sensing the pressure within the lower mold cavity 331 or the upper mold cavity 321. The pressure regulating system 36 adjusts the conditions for gas to leave / enter the lower mold cavity 331 or the upper mold cavity 321 based on the pressure information, thereby regulating the pressure within the lower mold cavity 331 or the upper mold cavity 321, so that the resulting composite material has a desired predetermined shape and properties.

[0052] In some embodiments, the pressure sensing unit 366 is disposed within the lower mold cavity, the upper mold cavity 321, the first gas conduit 361, or the second gas conduit 362. In some embodiments, the pressure sensing unit 366 is disposed within the lower mold cavity 331 and the upper mold cavity 321, and is located away from the feed opening 351. In some embodiments, the pressure regulating system 36 has a plurality of pressure sensing units 366. The number and location of the plurality of pressure sensing units 366 are not particularly limited; for example, they may be disposed on the inner walls 322 of the first mold 33 and the inner walls 332 of the second mold 32 and spaced apart from each other, and / or at any location in the first gas conduit 361, and / or at any location in the second gas conduit 362; however, the invention is not limited thereto.

[0053] In some embodiments, the support member 37 supports the core 21 and prevents the core 21 from contacting the inner wall 332 of the first mold 33. The core 21 may be disposed on the support member 37, and the molding material subsequently filled into the molding apparatus 30 may contact the first surface 211, the second surface 212, and the sidewall 213 of the core 21. In some embodiments, the surface area of ​​the top surface of the support member 37 is smaller than the surface area of ​​the first surface 211 of the core 21. In some embodiments, the support member 37 and the feed opening 351 are disposed at the inner wall 332 of the first mold 33. The support member 37, the feed opening 351, and the engagement point 367 are separate from each other.

[0054] In some embodiments, the support member 37 includes a plurality of support units 371, 372, 373 projecting from the inner wall 332. The support units 371, 372, 373 are spaced apart from each other. The position and number of the support units 371, 372, 373 are not particularly limited and can be adjusted as needed, for example, disposed in different regions of the inner wall 332 of the first mold 33. In some embodiments, the support units 371, 372, 373 are disposed at and project from the inner bottom wall 334 of the first mold 33. In some embodiments, at least two of the support units 371, 372, 373 are disposed on opposite sides of the inner wall 332 of the first mold 33. In some embodiments, the number of engagement points 367 is greater than the number of support units 371, 372, 373. The height of each of these support units 371, 372, 373 may be the same or different, as long as the core 21 can be disposed on the support units 371, 372, 373. In some specific embodiments, each of these support units 371, 372, and 373 has the same height.

[0055] In some embodiments, as seen in cross-sectional views, each of the support units 371, 372, and 373 is configured adjacent to a corresponding feed opening 351. In some embodiments, as seen in cross-sectional views, each of the support units 371, 372, and 373 is configured adjacent to a corresponding engagement point 367. In some embodiments, one of the support units 371, 372, and 373 is disposed between the corresponding feed opening 351 and the corresponding engagement point 367. In some embodiments, one of the support units 371, 372, and 373 is configured adjacent to the corresponding feed opening 351 and the corresponding engagement point 367. In some embodiments, one of the feed openings 351 is disposed between the corresponding engagement point 367 and the corresponding support unit 371.

[0056] In some embodiments, to maintain the temperature difference between the discharge channel 50 and the molding apparatus 30, the injection molding system 100 further includes an insulator 70 disposed between the discharge channel 50 and the molding apparatus 30. In some embodiments, the insulator 70 is disposed between the discharge channel 50 and the mold base 34. In some embodiments, the insulator 70 is disposed at the mold base 34. In some embodiments, the insulator 70 is positioned between the outlet 51 and the feed inlet 35.

[0057] The discharge channel 50 may extend into the insulator 70, thereby being partially surrounded by the insulator 70. In some embodiments, the insulator 70 includes an opening 71 configured to receive the discharge channel 50. The opening 71 of the insulator 70 is aligned with an opening 341 of the mold base 35 and a feed port 35. The opening 71 extends through the insulator 70. The insulator 70 may be secured to the mold base 34, for example, by screws. The insulator 70 may comprise a non-thermally conductive material, such as glass fiber. The insulator 70 may be entirely constructed of a non-metallic material. In some embodiments, the melting point of the insulator 70 is substantially higher than the temperature of the mixture flowing through the discharge channel 50. In some embodiments, the melting point of the insulator 70 is substantially greater than 180°C.

[0058] Figures 9 to 12 This is a schematic top view of a portion of the injection molding system 100 in step 701 of method 700 according to some specific embodiments of the present invention. Each of these portions may be the same in size and shape as each other, and the top view may be circular, elliptical, rectangular, square, curved, strip-shaped, or other desired shape, but is not limited thereto. In some specific embodiments, please refer to... Figure 9The support units 371, 372, and 373 have similar shapes. In some embodiments, each of these support units 371, 372, and 373 is strip-shaped when viewed from top view. Furthermore, the distance D1 between support units 371 and 372, and the distance D2 between support units 372 and 373, may be the same or different. In some embodiments, distance D1 is equal to distance D2. In some embodiments, distance D1 is not equal to distance D2. The lengths L1 of support unit 371, L2 of support unit 372, and L3 of support unit 373 may be the same or different. The lengths of L1, L2, and L3 are not limited, as long as the core 21 can be configured on the support member 37.

[0059] In some specific embodiments, please refer to the following: Figure 10 The support units 371, 372, and 373 have different shapes. In some embodiments, support unit 372 is disposed between support units 371 and 373. The shape of support unit 371 is similar to that of support unit 373, while the shape of support unit 372 is different from that of support unit 371. In some embodiments, support units 371, 372, and 373 are arranged in a row. For further details on some embodiments, please refer to [reference needed]. Figure 11 The support units 371, 372, and 373 are configured in an arc shape. For some specific embodiments, please refer to [the relevant documentation]. Figure 12 At least one of these support units 371, 372, and 373 is curved. In some embodiments, at least one of these feed openings 351 and one of these engagement points 367 are disposed between support units 371 and support units 373.

[0060] In some embodiments, method 700 further includes providing an extrusion system 10 configured to produce a molding material (not shown), and providing a discharge channel 50 communicatively connected to the extrusion system 10 and including a remote outlet 51 disposed at the extrusion system 10 and configured to discharge the molding material. In some embodiments, the inlet 35 of the molding device 30 may engage with the outlet 51.

[0061] In some specific embodiments, the extrusion system 10 and the discharge channel 50 are configured adjacent to the feed port 35 of the forming device 30. The forming device 30 is configured to receive forming material from the outlet 51 of the discharge channel 50.

[0062] In some embodiments, the method 700 for manufacturing the object includes step 702, which includes supporting the core 21 on the support member 37. For some specific embodiments, please refer to [reference needed]. Figure 13The core 21 is disposed on support units 371, 372, and 373. In some embodiments, the core 21 is disposed at the lower mold cavity 331. In some embodiments, the first surface 211 of the core 21 contacts the support unit 37. In some embodiments, the support unit 37 is disposed between the core 21 and the inner wall 332 of the first mold 33. Due to the support unit 37, the core 21 disposed within the molding apparatus 30 may not cover the feed opening 351 and the engagement point 367.

[0063] In some specific embodiments, please refer to the following again. Figure 2A and Figure 13 Step 702 includes disposing a first layer 217 of the core 21 over the support member 37, and disposing a second layer 218 of the core 21 over the first layer 217. In some embodiments, method 700 includes disposing the first layer 217 and the second layer 218 layer by layer in the molding apparatus 30. In some embodiments, the second layer 218 is attached to the first layer 217. In some embodiments, method 700 includes bonding the first layer 217 to the second layer 218, and simultaneously disposing the first layer 217 and the second layer 218 in the molding apparatus 30.

[0064] In some specific embodiments, the method 700 for manufacturing an object includes step 703, which involves placing a second mold 32 above a first mold 33 to form a mold cavity 31 defined by the first mold 33 and the second mold 32, wherein the core 21 is disposed within the mold cavity 31. For further details in some specific embodiments, please refer to... Figure 14 The molding device 30 is in a closed state. In some embodiments, when the molding device 30 is in the closed configuration, a mold cavity 31 is formed. In some embodiments, when the molding device 30 is closed, the first mold 33 and the second mold 32 are tightly engaged.

[0065] In some specific embodiments, method 700 includes engaging outlet 51 with inlet 35 of molding apparatus 30.

[0066] In some specific embodiments, please refer to the following again. Figure 8 and Figure 13At the beginning of steps 701 and 702, the extrusion system 10 and the discharge channel 50 are moved away from the molding apparatus 30. In some embodiments, the discharge channel 50 moves to a first position adjacent to the molding apparatus 30 before the outlet 51 engages with the inlet 35 of the molding apparatus 30. In some embodiments, the discharge channel 50 has already moved to the first position adjacent to the molding apparatus 30. At the first position, the discharge channel 50 is aligned with the opening 341 of the mold base 34 of the molding apparatus 30. In some embodiments, the distance between the outlet 51 and the mold base 34 is greater than 0. In some embodiments, at the first position, the discharge channel 50 is aligned with the opening 71 of the insulator 70 and the opening 341 of the mold base 341.

[0067] In some specific embodiments, please refer to the following: Figure 14 After the discharge channel 50 is aligned with the opening 341, the discharge channel 50 moves toward the molding device 30 and is received by the opening 341 of the mold base 34, and then the outlet 51 connects with the inlet 35. In some embodiments, the discharge channel 50 moves toward the molding device 30 and is received by the opening 341 of the mold base 34. In some embodiments, the discharge channel 50 moves toward the molding device 30 and is received by the opening 71 of the insulator 70 and the opening 341 of the mold base 34.

[0068] After the outlet 51 and the inlet 35 are connected, the outlet 51 and the inlet 35 form a flow path for the molding material, so that the discharge channel 50 can communicate with the mold cavity 31 through the inlet 35. The outlet 51 must be tightly connected to the inlet 35 to prevent the molding material from leaking out of the molding device 30.

[0069] In some embodiments, method 700 includes securing the discharge channel 50 to the molding apparatus 30. In some embodiments, the support device 40 applies force to prevent the extrusion system 10 from separating from the molding apparatus 30.

[0070] In some embodiments, when the extrusion system 10 injects molding material into the molding device 30, the molding device 30 can generate a reaction force opposite to the injection direction, and this reaction force can be transmitted to the discharge channel 50 and the extrusion system 10, such that the discharge channel 50 tends to separate from the molding device 30. In some embodiments, the support device 40 provides support against the reaction force opposite to the injection direction.

[0071] In some embodiments, the discharge channel 50 is secured to the forming device 30 by engaging a first component 41 of the support device 40 relative to a second component 42 of the support device 40, wherein the first component 41 protrudes from the extrusion system 10 and the second component 42 is disposed on the forming device 30. In some embodiments, the support device 40 provides force after engagement to prevent the discharge channel 50 from separating from the forming device 30.

[0072] Figure 15 This is a schematic diagram of a portion of an injection molding system 100 according to a specific embodiment of the present invention. In some specific embodiments, please refer to... Figure 15 The support device 40 includes a first component 41 and a second component 42 configured to engage with each other, wherein the first component 41 protrudes from the extrusion system 10 or the discharge channel 50, and the second component 42 is disposed on the forming device 30, but the invention is not limited thereto. In some embodiments, the first component 41 and the second component 42 may clamp each other; for example, the second component 42 is configured to receive the first component 41.

[0073] In some embodiments, the support device 40 is configured adjacent to the mold cavity 31 of the forming device 30. In some embodiments, the first component 41 is disposed on the discharge channel 50, and the second component 42 is disposed on the forming device 30. In some embodiments, the second component 42 is disposed on the mold base 34 of the forming device 30. In some embodiments, the first component 41 is part of the extrusion system 10 or the discharge channel 50, while the second component 42 is part of the forming device 30. In some embodiments, the first component 41 is part of the extrusion system 10 and is disposed near the discharge channel 50, and the second component 42 is disposed on or facing the mold base 34 of the forming device 30. In some embodiments, the first component 41 and the second component 42 can engage with each other to tightly engage the discharge channel 20 with the mold base 34 of the forming device 30.

[0074] In some specific embodiments, to prevent the extrusion system 10 and the molding device 30 from separating during injection, the engaged first component 41 is forcefully resisted against the second component 42. This force is equal to or greater than a critical value. This critical value can be adjusted based on the pressure within the mold cavity 31 and the diameter of the outlet 51, or based on other factors.

[0075] The position and number of the first component 41 can be adjusted as needed without particular limitation. The position and number of the second component 42 can also be adjusted as needed without particular limitation. In some embodiments, the position and number of the second component 42 correspond to the position and number of the first component 41. In some embodiments, the first component 41 can be placed at any suitable location on the discharge channel 50, and the second component 42 can be configured at any suitable location on the molding device 30. In some embodiments, the second component 42 is configured adjacent to the upper mold 32.

[0076] Figure 16 This is a schematic diagram of a portion of an injection molding system 100 according to a specific embodiment of the present invention. In some specific embodiments, please refer to... Figure 16 The support device 40 can be in one of two states: a locked state and an unlocked state. In the unlocked state, the first component 41 enters the corresponding second component 42, but is not yet locked by the second component 42. In other words, when the support device 40 is in the unlocked state, the first component 41 can still be pulled out of the second component 42. In the locked state, the first component 41 enters and is locked by the corresponding second component 42, so that the first component 41 cannot be withdrawn from the second component 42. Figure 16 The support device 40 is shown in the locked state. The support device 40 can be operated and controlled manually or automatically. The support device 40 can switch between the two states manually or automatically.

[0077] In some embodiments, the first component 41 is rotatably fixed to the extrusion system 10. In some embodiments, the first component 41 includes an elongated portion 411 and an arm portion 412. The elongated portion 411 and the arm portion 412 are rotatable in the direction indicated by arrow A. The elongated portion 411 is fixed to the extrusion system 10 and extends toward the upper die 32 in a first direction Z. The arm portion 412 is coupled to the elongated portion 411 and extends in a second direction X substantially perpendicular to the first direction Z, or in a third direction Y substantially perpendicular to the first direction Z. In some embodiments, the first component 41 has an inverted T-shape. After the first component 41 enters the second component 42, the support device 40 changes from an unlocked state to a locked state by rotating the arm portion 412 of the first component 41. In some embodiments, the first component 41 and the second component 42 are locked by rotating the arm portion 412 of the first component 41 by approximately 90 degrees. Figure 16 For example, after rotating the arm portion 412 by approximately 90 degrees, the arm portion 412 locks with the second component 42. Thus, the support device 40 is locked, and the discharge channel 20 is tightly engaged with the molding device 30, so that the mixture can begin to be injected from the extrusion system 10 and the discharge channel 50 into the molding device 30.

[0078] In some specific embodiments, please refer to the following: Figures 14 to 16 The discharge channel 50 is secured to the forming apparatus 30 by locking the support device 40, such as by rotating the first component 41 of the support device 40 relative to the second component 42 of the support unit 40, while simultaneously engaging the outlet 51 with the inlet 35. In some embodiments, when the outlet 51 engages with the inlet 35, the first component 41 enters the second component 42 and then locks with the second component 42. In some embodiments, the discharge channel 50 is secured to the forming apparatus 30 by rotating the elongated portion 411 and the arm portion 412 of the first component 41 of the support device 40, the elongated portion 411 being secured to the extrusion system 10 and extending in a first direction Z toward the forming apparatus 30, and the arm portion 412 being coupled to the elongated portion 411 and extending in a second direction X different from the first direction Z.

[0079] In some specific embodiments, please refer to the following: Figure 17 Method 700 further includes injecting gas G into the mold cavity 31 via a pressure regulating system 36 connected to the mold cavity 31 until a first predetermined pressure is sensed in the mold cavity 31 before the molding material is injected into the mold cavity 31. In some embodiments, gas G is injected into the mold cavity 31 via a first gas conduit 361. In some embodiments, gas G may be any suitable gas, for example, air, depending on the need; however, the invention is not limited thereto. In some embodiments, the pressure within the mold cavity 31 of the molding apparatus 30 is adjusted to the first predetermined pressure after the outlet 51 and the inlet 35 are engaged. Injection begins after the molding apparatus 30 has reached the first predetermined pressure.

[0080] In some embodiments, the pressure sensing unit 366 senses that the pressure in the mold cavity 31 is atmospheric pressure. In some embodiments, the first valve 364 is open, so gas G is injected into the mold cavity 31 through the first gas conduit 361. In some embodiments, when the feed port 35 is closed, gas G is injected into the mold cavity 31 through the pressure regulating system 36. In some embodiments, gas G is injected into the mold cavity 31 through the feed port 35.

[0081] In some embodiments, during the injection of gas G into the mold cavity 31, the pressure within the mold cavity 31 is continuously sensed. In some embodiments, the pressure sensing unit 366 continuously senses the pressure within the mold cavity 31 and injects gas G into the mold cavity 31 until a first predetermined pressure is sensed in the mold cavity 31; then, the first valve 364 and the second valve 365 of the pressure regulating system 36 are closed, and the injection of gas G into the mold cavity 31 ceases. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure.

[0082] In some specific embodiments, prior to step 704, the mold cavity 31 has a first predetermined pressure, and both the first valve 364 and the second valve 365 of the pressure regulating system 36 are closed.

[0083] In some embodiments, method 700 includes step 704, which includes injecting a first material M1 into mold cavity 31. In some embodiments, the molding material produced by extrusion system 10 is the first material M1. The first material M1 includes a polymer and a foaming agent. For further details, please refer to [link to relevant documentation]. Figure 18 The first material M1 is injected into the mold cavity 31 through the outlet 51 and the inlet 35. In some embodiments, step 704 includes injecting the first material M1 from the discharge channel 50 into the mold cavity 31 through the outlet 51 and the inlet 35. In some embodiments, the discharge channel 50 is at least partially surrounded by the molding device 30 during the injection of the first material M1.

[0084] In some embodiments, at least a portion of the first material M1 is disposed between the inner wall 332 of the first mold 33 and the core 21. In some embodiments, at least a portion of the first material M1 is disposed between the support units 371, 372, and 373. In some embodiments, at least a portion of the first material M1 is disposed in the recess 215 or through hole 214 of the core 21. In some embodiments, at least a portion of the first material M1 surrounds the protrusion 216 of the core 21.

[0085] In some embodiments, during step 704, during the injection of the first material M1 into the mold cavity 31 of the molding apparatus 30, the pressure in the mold cavity 31 changes rapidly, and the pressure sensing unit 366 continuously senses the pressure in the mold cavity 31. In some embodiments, the first material M1 is injected into the mold cavity 31 of the molding apparatus 30 from the feed port 35, and a first predetermined pressure is applied to the first material M1. In some embodiments, the first material M1 and gas G are disposed in the mold cavity 31, and the first material M1 will expand and foam in the mold cavity 31.

[0086] In some embodiments, the first material M1 is injected into the mold cavity 31 of the molding apparatus 30 through the feed port 35, thereby increasing the pressure within the mold cavity 31. In some embodiments, the pressure within the mold cavity 31 of the molding apparatus 30 rises above a first predetermined pressure. In some embodiments, the pressure within the mold cavity 31 of the molding apparatus 30 rises from the first predetermined pressure to a second predetermined pressure.

[0087] In some embodiments, after the first material M1 is injected into the mold cavity 31 having a first predetermined pressure, the pressure inside the mold cavity 31 increases. Therefore, setting a second predetermined pressure ensures that the mold cavity 31 remains within a suitable pressure range. In some embodiments, when the mold cavity 31 reaches the second predetermined pressure, the injection of the first material M1 into the mold cavity 31 is stopped.

[0088] In some embodiments, the process of injecting the first material M1 into the mold cavity 31 having a first predetermined pressure lasts for less than 1 second. In some embodiments, because the mold cavity 31 has a first predetermined pressure, the filling time of the first material M1 can be less than 0.5 seconds. During or upon completion of the injection, the pressure sensing unit 366 instantly senses the pressure within the mold cavity 31 and provides pressure information, thereby enabling the pressure regulating system 36 to adjust the pressure within the mold cavity 31 according to the pressure information, thus maintaining the pressure within the mold cavity 31 within a predetermined pressure range.

[0089] In some embodiments, the temperature of the discharge channel 50 is higher than the temperature of the molding apparatus 30 during the injection process. In some embodiments, an insulator 70 is used to maintain the temperature difference.

[0090] In some specific embodiments, please refer to the following: Figure 19 In step 705, method 700 includes foaming a first material M1 to form a first foamed member 221. At least a portion of the first foamed member 221 contacts the core 21. In some embodiments, at least a portion of the foamed member 221 contacts at least a portion of a first surface 211 and the entire sidewall 213 and the entire second surface 212 of the core 21. In some embodiments, the first surface 211 includes a first portion and a second portion, the first portion contacting the first foamed member 221 and the second portion contacting the support member 37.

[0091] In some embodiments, at least a portion of the first foaming member 221 is disposed between the inner wall 332 of the first mold 33 and the core 21. In some embodiments, at least a portion of the first material M1 is disposed between the support units 371, 372, and 373. In some embodiments, at least a portion of the first foaming member 221 is disposed in a recess 215 or a through-hole 214 of the core 21. In some embodiments, at least a portion of the first foaming member 221 surrounds a protrusion 216 of the core 21. In some embodiments, an object 20-1 is formed after the first foaming member 221 is formed. In some embodiments, the object 20-1 includes the core 21 and the first foaming member 221.

[0092] In some embodiments, method 700 further includes retracting the support member 37 into the first mold 33 or removing the support member 37 from the mold cavity 31 during or after the injection of the first material M1. In some embodiments, at least one of the support units 371, 372, and 373 is retracted or removed after the first foaming member 221 has foamed. In some embodiments, a mark 374 is formed on the first foaming member 221 after the support member 37 is retracted or removed. In some embodiments, the mark 374 is formed at a position corresponding to the position of the support member 37. In some embodiments, marks 374, 375, and 376 are formed at positions corresponding to the positions of the support units 371, 372, and 373, respectively, after the support units 371, 372, and 373 are retracted or removed. In some embodiments, the object 20-1 includes marks 374, 375, and 376. In some embodiments, the object 20-1 does not have marks 374, 375, and 376. The first foaming component 221 of the object 20-1 surrounds the core 21. In some embodiments, the object 20-1 may be further removed from the molding apparatus 30.

[0093] In some embodiments, a second portion of the first surface 211 of the core 21 is exposed through a mark 374, and a feed opening 351 is disposed near the mark 374. In some embodiments, each of these feed openings 351 is disposed near a corresponding one of the marks 374, 375, and 376.

[0094] In some embodiments, method 700 further includes venting gas G from mold cavity 31 to reduce the pressure in mold cavity 31 to a third predetermined pressure. In some embodiments, a portion of gas G is vented from mold cavity 31 after gas G is injected into mold cavity 31. In some embodiments, during step 705, gas G is vented from mold cavity 31 via pressure regulating system 36 for less than 1 second, while first material M1 foams in mold cavity 31. Due to the venting of gas G, the first material M1 in mold cavity 31 may have a lower density after the foaming process. In some embodiments, gas G is vented from mold cavity 31 via junction 367. In some embodiments, gas G is vented from mold cavity 31 during or after the foaming process of first material M1 in mold cavity 31. In some embodiments, the pressure in mold cavity 31 is reduced from a second predetermined pressure.

[0095] In some embodiments, when the pressure sensing unit 366 senses that the pressure in the mold cavity 31 is greater than a second predetermined pressure, a portion of the gas G in the mold cavity 31 is discharged until the pressure in the mold cavity 31 is within the predetermined pressure range. In some embodiments, the predetermined pressure range is between a first predetermined pressure and a second predetermined pressure. In some embodiments, the second valve 365 opens, and a portion of the gas in the mold cavity 31 is discharged through the second gas conduit 362.

[0096] In some specific embodiments, please refer to the following: Figure 20 Method 700 further includes injecting a second material M2 into the mold cavity 31 after removing or retracting the support member 37. In some embodiments, the ratio of polymeric material to foaming agent in the first material M1 is substantially equal to the ratio of polymeric material to foaming agent in the second material M2. In some embodiments, the composition of the first material M1 is similar to that of the second material M2. In some embodiments, the core 21 is surrounded by the first material M1 and the second material M2.

[0097] In some embodiments, the molding material produced by the extrusion system 10 is a second material M2. In some embodiments, the second material M2 is injected into the mold cavity 31 through the outlet 51 and the feed port 35. In some embodiments, the second material M2 is injected into the mold cavity 31 from the discharge channel 50 through the outlet 51 and the feed port 35. In some embodiments, the discharge channel 50 is at least partially surrounded by the molding device 30 during the injection of the second material M2.

[0098] In some embodiments, the second material M2 is positioned corresponding to the position of the support member 37. In some embodiments, the second material M2 is disposed in a mark 374. In some embodiments, the second material M2 is disposed in marks 374, 375, and 376 after marks 374, 375, and 376 are formed at various positions corresponding to the support units 371, 372, and 373, respectively. In some embodiments, at least a portion of the second material M2 is a first surface 211 in contact with the core 21. In some embodiments, the first foaming member 221 surrounds the second material M2. In some embodiments, at least a portion of the second material M2 is in contact with the first foaming member 221.

[0099] In some embodiments, method 700 further includes foaming a second material M2 to form a second foamed member 222. In some embodiments, the core 21 is surrounded by a first foamed member 221 and a second foamed member 222. In some embodiments, at least a portion of the second foamed member 222 is a first surface 211 in contact with the core 21. In some embodiments, the first foamed member 221 surrounds the second foamed member 222. In some embodiments, at least a portion of the second foamed member 222 is in contact with the first foamed member 221. In some embodiments, the article 20-2 is formed after the first foamed member 221 and the second foamed member 222 are formed. In some embodiments, the article includes the core 21, the first foamed member 221, and the second foamed member 222.

[0100] In some specific embodiments, after the second foamed component 222 is formed, the second mold 32 separates from the first mold 33, and the discharge channel 50 disengages from and is extracted from the molding device 30, such as... Figure 21 As shown. Outlet 51 exits from inlet 35. The forming device 30 exits from the closed configuration ( Figures 17 to 20 Change to a decoupled configuration () Figure 21 ).

[0101] In some specific embodiments, please refer to the following: Figure 22 After object 20-2 is formed, it is then removed from the first mold 33. In some specific embodiments, object 20-2 is picked up manually by a person or automatically by a robot, robotic arm, gripper, etc.

[0102] In some specific embodiments, method 700 further includes positioning component 23 within opening 322 of second mold 32 before injecting first material M1. Figures 23 to 26 The following is a schematic cross-sectional view of an injection molding system 200 illustrating steps 701 to 705 of method 700 according to some specific embodiments of the present invention. Figure 27 and Figure 28 This is a schematic cross-sectional view of an article 20-3 manufactured by method 700 according to some specific embodiments of the present invention.

[0103] In some specific embodiments, please refer to the following: Figure 23 The second mold 32 is in another configuration including an opening 322. In some embodiments, the second mold 32 includes an opening 322 configured relative to the first mold 33. See also [reference needed] for some embodiments. Figure 24 A component 23 may be received and configured therein by an opening 322. In some specific embodiments, the mold cavity 31 is defined by a first mold 33, a second mold 32, and component 23, such as Figure 25As shown. In some specific embodiments, the mold cavity 31 between the first material M1 injection assembly 23 and the inner wall 332 of the first mold 33 is as follows: Figure 26 As shown, similar to Figure 18 The operation is shown. During the formation of the first foamed component 221, component 23 is in contact with the first material M1. Thus, as... Figure 26 The manufactured item 20-3 is shown. In some embodiments, item 20-3 is a product or semi-product including component 23 and a first foaming member 221, at least a portion of the first foaming member 221 being disposed between the core 21 and component 23. In some embodiments, component 23 is any other suitable component of an insole, upper, or footwear.

[0104] In some specific embodiments, please refer to the following: Figure 27 The object 20-3 further includes a mark 374. In some embodiments, the object 20-3 further includes a plurality of marks 374, 375, and 376. For some specific embodiments, please refer to [reference needed]. Figure 28 Article 20-3 further includes a second foamed component 222 formed of a second material M2.

[0105] In some specific embodiments, method 700 includes injecting a first material M1 and a second material M2 from the extrusion system 10 into the discharge channel 50. Figure 29 This is a schematic diagram of an extrusion system according to the present invention in some specific embodiments. The extrusion system 10 includes a melting unit 120 and a mixing unit 130. In some specific embodiments, the extrusion system 10 includes a melting unit 120, a mixing unit 130, a foaming agent supply unit 140, an injection unit 150, a first flow control element 161, a second flow control element 162, and a monitoring module 180.

[0106] In some specific embodiments, please refer to the following: Figure 29 The melting unit 120 is configured to convey polymer material. In some embodiments, the melting unit 120 includes a pressure chamber 121, a first feed channel 122, a first discharge channel 123, and a pushing member 124. In some embodiments, the melting unit 120 further includes a feed hopper 125.

[0107] In some embodiments, a first feed channel 122 and a first discharge channel 123 are respectively disposed at both ends of the pressure chamber 121. In some embodiments, the first feed channel 122 communicates with the internal space 1211 of the pressure chamber 121, and the first discharge channel 123 communicates with the external space of the pressure chamber 121, wherein the first feed channel 122 is configured to convey polymer material to the internal space 1211 of the pressure chamber 121. In some embodiments, a feed hopper 125 is configured to convey polymer material to the internal space 1211 of the pressure chamber 121 through the first feed channel 122.

[0108] A pusher member 124 is configured to convey polymer material from a first feed channel 122 to a first discharge channel 123. In some embodiments, the pusher member 124 is disposed within the internal space 1211 of a pressure chamber 121. In some embodiments, the pusher member 124 is disposed within the internal space 1211 of the pressure chamber 121 between the first feed channel 122 and the first discharge channel 123, and is used to push the polymer material toward the first discharge channel 123. In some embodiments, the pusher member 124 is rotatable relative to the pressure chamber 121. In some embodiments, the polymer material is conveyed from the first feed channel 122 to the first discharge channel 123 by rotation of the pusher member 124. In some embodiments, the pusher member 124 cannot move in a direction parallel to the longitudinal axis of the pressure chamber 121.

[0109] In some embodiments, the length of the pushing member 124 extends along the length of the pressure chamber 121, and the ratio of the shortest distance D5 between the inner wall 1212 of the pressure chamber 121 and the pushing member 124 to the diameter D6 of the pushing member 124 is in the range of about 1:1500 to about 1:4500, and the polymer material can be uniformly melted by the melting unit 120. In some embodiments, the shortest distance D5 between the inner wall 1212 of the pressure chamber 121 and the pushing member 124 is approximately equal to or less than 0.3 mm. In some embodiments, the shortest distance D5 between the inner wall 1212 of the pressure chamber 121 and the pushing member 124 is between 0.01 and 0.05 mm.

[0110] The mixing unit 130 is configured to receive the polymer material from the melting unit 120 and to mix the polymer material with a foaming agent to form a mixture of the polymer material and the foaming agent. The mixing unit 130 includes a hollow mixing chamber 131, a second feed channel 132, a second discharge channel 133, and a mixing rotor 134.

[0111] A second feed channel 132 and a second discharge channel 133 are respectively disposed at both ends of the mixing chamber 131. In some embodiments, the second feed channel 132 is configured to convey polymer material. In some embodiments, the second discharge channel 133 is configured to convey and discharge the mixture.

[0112] The mixing rotor 134 is configured to mix the polymer material with a blowing agent to form a mixture within the mixing chamber 131. In some embodiments, the mixing rotor 134 is disposed within the mixing chamber 131. In some embodiments, the mixing rotor 134 is disposed within the mixing chamber 131 between the second feed channel 132 and the second discharge channel 133 to agitate the mixture within the mixing chamber. The mixing rotor 134 is rotatable to mix the polymer material with the blowing agent and to convey the mixture of polymer material and blowing agent from the second feed channel 132 to the second discharge channel 133. In some embodiments, the mixing rotor 134 cannot move in a direction parallel to the longitudinal axis of the mixing chamber 131.

[0113] In some embodiments, the length of the mixing rotor 134 extends along the length of the hollow mixing cartridge 131, and the ratio of the distance D3 between the inner wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is in the range of about 1:1500 to about 1:4500, and the mixture can be uniformly prepared by the extrusion system 10. In some embodiments, the mixture can be divided into multiple parts, and the ratio of foaming agent to polymer material in each part of the mixture prepared by the extrusion system 10 is substantially constant. In some embodiments, the ratio of polymer material to foaming agent in the first part of the mixture is substantially equal to the ratio of polymer material to foaming agent in the second part of the mixture. In some embodiments, the shortest distance D3 between the inner wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is approximately equal to or less than 0.3 mm. In some embodiments, the shortest distance D3 between the inner wall 1311 of the hollow mixing cartridge 131 and the mixing rotor 134 is between 0.01 and 0.09 mm.

[0114] Figure 30 This is an enlarged view of a portion of the extrusion system according to the present invention in some specific embodiments. To ensure uniform mixing of the molten polymer material and the foaming agent in the mixing chamber 131, please refer to [reference needed] in some specific embodiments. Figure 29 and Figure 30The mixing rotor 134 further includes a cylindrical column 1341 rotatably disposed within the mixing chamber 131, and a recess 1342 annularly disposed around the periphery of the column 1341. Therefore, when the column 1341 rotates, the polymer material and foaming agent are agitated by the recess 1342, thereby achieving the desired mixing effect. In some specific embodiments, the shortest distance D3 is the shortest distance between the recess 1342 and the inner wall 1311 of the hollow mixing chamber 131.

[0115] In some embodiments, when the shortest distance D3 is the shortest distance between the recess 1342 and the inner wall 1311 of the hollow mixing box 131, the shortest distance D3 is between 0.01 and 0.09 mm. In some embodiments, the diameter D4 of the mixing rotor 134 is between 45 and 75 mm. Table 1 lists the corresponding ratios of the shortest distance D3, diameter D4, and the shortest distance D3 between the recess 1342 and the inner wall 1311 of the hollow mixing box 131 to the diameter D4 of the mixing rotor 134.

[0116] Table 1

[0117]

[0118] In some specific embodiments, when the shortest distance D3 is substantially less than 0.01 mm, the predetermined amount of foaming agent in the mixture is substantially greater than 0.8 / cm. 3 ,like Figure 31 As shown. In some specific embodiments, if the foaming agent in the predetermined amount of mixture is significantly greater than 0.8 / cm³. 3 Then, the bubble density in the pre-measured mixture after foaming is significantly greater than 180,000 / cm³. 3 .

[0119] In some specific embodiments, the uniformity of the foaming agent and polymer material is optimized when the ratio of the shortest distance D3 to the distance D4 is between 1:1500 and 1:4500. In other words, the mixing of the foaming agent and polymer material by the mixing rotor 134 is average and uniform. In some specific embodiments, when the ratio of the shortest distance D3 to the distance D4 is between 1:1500 and 1:4500, such as Figure 32As shown, in a predetermined amount of mixture, the ratio of foaming agent to polymer material is between 4:1 and 3:1. In some specific embodiments, the ratio of foaming agent to polymer material in a predetermined amount of mixture is approximately 1:1. In some specific embodiments, if the ratio of foaming agent to polymer material in a predetermined amount of mixture is between 4:1 and 3:1, then after foaming, the ratio of bubbles to polymer material in the predetermined amount of mixture is also between 4:1 and 3:1. In some specific embodiments, after foaming, the ratio of bubbles to polymer material in a predetermined amount of mixture is approximately 4:1.

[0120] In some specific embodiments, please refer to the following again. Figure 29 The melting unit 120 includes a hollow pressure chamber 121 configured to contain polymer material and having a first pressure, and the mixing unit 130 includes a hollow mixing chamber 131 having a second pressure. In some embodiments, the first pressure is greater than the second pressure to prevent backflow. In some embodiments, the polymer material is drawn from the melting unit 120 to the mixing unit 130 by the difference between the first and second pressures.

[0121] The blowing agent supply unit 140 is connected to the mixing unit 130 and configured to deliver blowing agent into the mixing unit 130. In some embodiments, the blowing agent supply unit 140 is located between the first flow control element 161 and the second flow control element 162. In some embodiments, the blowing agent supply unit 140 is configured to be close to the first flow control element 161 and away from the second flow control element 162.

[0122] In some embodiments, a foaming agent source (not shown) is connected to the foaming agent supply unit 140 and configured to supply any type of foaming agent known to those skilled in the art. In some embodiments, the foaming agent is in a supercritical fluid state after being introduced into the mixing unit 130 by the foaming agent supply unit 140.

[0123] In some embodiments, a first flow control component 161 is disposed at a first interface 171 connecting the melting unit 120 to the mixing unit 130. The first interface 171 is configured to introduce polymer material from the melting unit 120 into the mixing unit 130. The first interface 171 is located between the melting unit 120 and the mixing unit 130. In some embodiments, the first interface 171 is configured to introduce polymer material from the pressure chamber 121 of the melting unit 120 into the mixing chamber 131 of the mixing unit 130. In some embodiments, the polymer material is conveyed and / or drawn from the melting unit 120 through the first interface 171 into the mixing unit 130 using the pressure difference between a first pressure and a second pressure.

[0124] In some specific embodiments, a first flow control component 161 is disposed between the melting unit 120 and the mixing unit 130, and is configured to control the flow of the polymer material from the melting unit 120 to the mixing unit 130. The first flow control component 161 may be a valve, a movable cap, etc.

[0125] In some specific embodiments, the first flow control element 161 is configured to switch between an open configuration and a closed configuration. The open configuration of the first flow control element 161 allows polymer material to flow from the melting unit 120 into the mixing unit 130, and the closed configuration of the first flow control element 161 prevents polymer material from flowing from the mixing unit 130 back into the melting unit 120.

[0126] In some embodiments, the first flow control component 161 is configured to maintain a pressure difference between the melting unit 120 and the mixing unit 130. In some embodiments, the first flow control component 161 is configured to maintain the pressure difference between the melting unit 120 and the mixing unit 130 by switching between an open configuration and a closed configuration, such that polymer material cannot flow from the mixing chamber 131 of the mixing unit 130 back to the pressurization chamber 121 of the melting unit 120. In some embodiments, the first flow control component 161 is configured to adjust a first pressure and / or a second pressure to maintain a pressure difference between the first pressure and the second pressure. In some embodiments, when the first pressure is similar to the second pressure, the first flow control component 161 is in a closed configuration.

[0127] In some embodiments, the injection unit 150 is configured to receive and discharge the mixture from the second discharge channel 133 of the mixing unit 130. In some embodiments, the injection unit 150 is configured to inject the mixture, and the discharge channel 50 is in communication with the injection unit 150.

[0128] In some specific embodiments, the injection unit 150 includes a hollow metering cartridge 151 configured to contain a mixture. The metering cartridge 151 has a hollow internal space 1511, wherein the internal space 1511 communicates with the second discharge channel 133 and is configured to contain the mixture. The injection unit 150 further includes a connecting channel 152 communicating with the internal space 1511 of the metering cartridge 151; and a discharge member 153 slidably disposed in the internal space 1511 of the metering cartridge 151 and configured to discharge the mixture from the metering cartridge 151 through an outlet 154.

[0129] In some embodiments, the mixture flows from the injection unit 150 into the discharge channel 50. In some embodiments, the mixture is a first material M1 and / or a second material M2.

[0130] One aspect of the present invention relates to an article. The article includes: a foamed member comprising a polymeric material; and a core embedded therein; wherein the core includes a first surface, a second surface opposite the first surface, and a sidewall located between the first surface and the second surface, the foamed member covering at least a portion of the first surface and covering the entire sidewall and the entire second surface.

[0131] In some embodiments, the core includes a through-hole extending between a first surface and a second surface. In some embodiments, a recess is recessed into the core and disposed at the first surface, the second surface, or a sidewall. In some embodiments, the core includes a protrusion projecting from the first surface, the second surface, or a sidewall, and the protrusion is surrounded by a foaming member. In some embodiments, the article further includes an assembly disposed on the core and the foaming member, with a portion of the foaming member disposed between the assembly and the core. In some embodiments, the core is surrounded by the foaming member.

[0132] One aspect of the present invention relates to a method of manufacturing an article. The method includes: providing a molding apparatus, wherein the molding apparatus includes a first mold and a second mold corresponding to the first mold, the first mold including an inner wall and a support member protruding from the inner wall; disposing a core on the support member; disposing the second mold above the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; injecting a first material into the mold cavity; and foaming the first material to form a first foamed member, wherein at least a portion of the first foamed member is in contact with the core.

[0133] In some embodiments, the method further includes retracting the support member into the first mold or removing the support member from the mold cavity during or after the injection of the first material. In some embodiments, the method further includes injecting a second material into the mold cavity after removing or retracting the support member. In some embodiments, the ratio of polymeric material to foaming agent in the first material is substantially equal to the ratio of polymeric material to foaming agent in the second material. In some embodiments, the method further includes forming a mark on the first foaming member at a location corresponding to the support member. In some embodiments, the method further includes injecting a gas into the mold cavity before injecting the first material to increase the pressure in the mold cavity to a first predetermined pressure. In some embodiments, the method further includes venting a gas from the mold cavity to reduce the pressure in the mold cavity to a second predetermined pressure. In some embodiments, at least a portion of the first material is disposed in a recess or a through-hole of the core.

[0134] In some embodiments, at least a portion of the first material is disposed between the inner wall and the core. In some embodiments, the support member includes a plurality of support units projecting from the inner wall, and at least a portion of the first material is disposed between these support units. In some embodiments, the core includes a first surface in contact with the support member, a second surface opposite the first surface, and a sidewall located between the first surface and the second surface, the first foaming member contacting at least a portion of the first surface and covering the entire sidewall and the entire second surface. In some embodiments, the method further includes disposing a component in an opening of the second mold before injecting the first material. In some embodiments, after injecting the first material, at least a portion of the first material is disposed between the component and the core. In some specific embodiments, the method further includes: providing an extrusion system configured to produce the first material and having a melting unit and a mixing unit; and providing a discharge channel communicating with the extrusion system and including an outlet disposed remotely in the extrusion system and configured to discharge the molded material, wherein a feed port of the molding device is correspondingly engaged with the outlet.

[0135] The foregoing overview of features of several specific embodiments enables those skilled in the art to better understand the various aspects of the invention. Those skilled in the art will understand that the invention can be readily used as the basis for designing or modifying other operations and structures to achieve the same purpose and / or the same advantages of the specific embodiments cited herein. Those skilled in the art will also understand that such equivalent constructions do not depart from the spirit and scope of the invention, and that various changes, substitutions, and modifications can be made without departing from the spirit and scope of the invention.

[0136] Furthermore, the scope of this invention is not limited to the specific embodiments of the procedures, machines, manufactures, compositions of matter, components, methods, and steps described herein. From the disclosure of this invention, those skilled in the art will readily understand that, based on this invention, existing or future-developed procedures, machines, manufactures, compositions of matter, components, methods, or steps can be used to perform the same functions or obtain substantially the same results as the corresponding embodiments described herein. Therefore, it is intended that the scope of the following claims include such procedures, machines, manufactures, compositions of matter, components, methods, and steps.

[0137] Symbol explanation:

[0138] 10. Extrusion System

[0139] 20, 20-1, 20-2, 20-3 objects

[0140] 21 cores

[0141] 22 Foamed components

[0142] 23 components

[0143] 30 Molding device

[0144] 32 Second mold

[0145] 33 First mold

[0146] 34 Mold base

[0147] 35 Feed Inlet

[0148] 36 Pressure Regulation System

[0149] 37 Supporting components

[0150] 40 Support device

[0151] 41 First Component

[0152] 42 Second Component

[0153] 50 emission channels

[0154] 51 Exports

[0155] 70 Insulator

[0156] 100 Injection Molding System

[0157] 120 Melting Unit

[0158] 121 Pressure Tray

[0159] 122 First Feed Channel

[0160] 123 First Emission Channel

[0161] 124 Propelling Components

[0162] 125 feed hopper

[0163] 130 Hybrid Unit

[0164] 131 Hollow Mixing Container

[0165] 132 Second Feed Channel

[0166] 133 Second Emission Channel

[0167] 134 Hybrid Rotor

[0168] 140 foaming agent supply units

[0169] 150 injection units

[0170] 151 Hollow Metering Box

[0171] 152 Connection Channel

[0172] 153 Emission Components

[0173] 154 Exports

[0174] 161 First flow control element

[0175] 162 Second Flow Control Element

[0176] 171 First Interface

[0177] 180 monitoring module

[0178] 211 First Surface

[0179] 212 Second Surface

[0180] 213 Sidewall

[0181] 214 Through Hole

[0182] 215 concavity

[0183] 216 Protrusion

[0184] 217 First Floor

[0185] 218 Second Floor

[0186] 221 First foaming component

[0187] 222 Second foaming component

[0188] 321 Upper mold cavity

[0189] 331 Lower mold cavity

[0190] 332 Inner Wall

[0191] 333 Inner wall

[0192] 334 inner bottom wall

[0193] 341, 71, 322 Opening

[0194] 351 Feed opening

[0195] 352 Guiding Channel

[0196] 361 First Gas Conduit

[0197] 362 Second Gas Conduit

[0198] 363 Gas Source

[0199] 364 First Valve

[0200] 365 Second Valve

[0201] 366 Pressure Sensing Unit

[0202] 367 Joint Point

[0203] Support units 371, 372, and 373

[0204] Markers 374, 375, and 376

[0205] 411 Slender section

[0206] 412 Arm Section

[0207] 700 methods

[0208] Operations 701, 702, 703, 704, and 705

[0209] Interior space of 1211 and 1511

[0210] 1212 Inner wall

[0211] 1311 Inner wall

[0212] 1341 columnar body

[0213] 1342 concave part

[0214] Distances of D1, D2, D3, D4, D5, D6

[0215] G gas

[0216] H1, H2 height

[0217] Lengths of L1, L2, and L3

[0218] M1 First Material

[0219] M2 Second Material

Claims

1. A semi-finished footwear product, comprising: A core includes a first surface, a second surface opposite to the first surface, and a sidewall located between the first surface and the second surface; A first foamed component covers the entire sidewall, the entire second surface, and a first portion of the first surface; and A second foamed component covers a second portion of the first surface and is surrounded by the first foamed component. The second foaming component is separated from the sidewall and the second surface, and the core is completely surrounded by the first foaming component and the second foaming component.

2. The footwear semi-finished product as claimed in claim 1, wherein the core includes a recess recessed into the core and disposed on the first surface, the second surface, or the sidewall.

3. The footwear semi-finished product as claimed in claim 1, further comprising a component disposed above the core and the first foaming member, and a portion of the first foaming member being disposed between the component and the core.

4. A method for manufacturing semi-finished footwear, comprising: A molding apparatus is provided, wherein the molding apparatus includes a first mold and a second mold corresponding to the first mold, the first mold including an inner wall and a support member protruding from the inner wall; A core is disposed on the support member, wherein the core includes a first surface, a second surface opposite to the first surface, and a sidewall located between the first surface and the second surface; The second mold is joined to the first mold to form a mold cavity defined by the first mold and the second mold, wherein the core is disposed in the mold cavity; A first material is injected into the mold cavity; The first material is foamed to form a first foamed component, wherein the first foamed component covers the entire sidewall, the entire second surface, and a first portion of the first surface; The support member is retracted into the first mold or removed from the mold cavity to expose the second portion of the first surface from the first foaming member; and A second material is injected into the mold cavity to form a second foamed component on the second portion of the first surface. The second foaming component is separated from the sidewall and the second surface, and the core is completely surrounded by the first foaming component and the second foaming component.

5. The method of claim 4, further comprising: The first material is injected into the mold cavity through the feed port located in the first mold or the second mold.

6. The method of claim 4, wherein the support member is retracted when or after the first material is injected into the mold cavity, and the second material is injected into the mold cavity after the support member is retracted.

7. The method of claim 4, further comprising: A mark is formed on the first foamed component at the position corresponding to the support component.

8. The method of claim 4, further comprising: During or after the first material is foamed, a gas is discharged from the mold cavity to reduce the pressure in the mold cavity to a predetermined pressure.

9. The method of claim 4, wherein at least a portion of the first material is disposed in a recess or a through-hole of the core.

10. The method of claim 4, wherein when the core is disposed on the support member, the second portion of the first surface contacts the support member.

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