Molding apparatus and molding method

Abstract

A molding device and a molding method are disclosed. The molding device includes an upper mold, a lower mold, and an intermediate mold. The lower mold is disposed below the upper mold. The intermediate mold is disposed between the upper mold and the lower mold. The intermediate mold is movably attached to the lower mold by a position control mechanism.

Description

[0001] Cross-referencing related applications

[0002] This application claims priority to U.S. non-provisional application No. 17 / 731,764, filed April 28, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to a molding apparatus and a molding method thereof, and more particularly, to a molding apparatus and a molding method suitable for injection molding or extrusion molding. Background Technology

[0004] Foamed polymer parts offer numerous advantages, such as high strength, light weight, impact resistance, and good sound and heat insulation. These foamed polymer parts can be molded into predetermined shapes using injection molding or extrusion molding. For example, after melting a polymer material and mixing it with a foaming agent to form a mixture through an injection molding machine, pressure is applied to the molten polymer to inject or extrude it into the mold cavity of a mold to form the desired foamed polymer part. The properties or characteristics and applications of foamed polymer parts can be altered by changing the composition of the mixture and adjusting the molding method.

[0005] Typically, the appearance and physical properties of foamed polymer parts are directly affected by the molding process. Therefore, mold design must consider the flowability of the mixture, ensuring that it is evenly, quickly, and uniformly distributed within the mold cavity during the molding process, and that the density and uniformity of air bubbles within the mixture are high, thus maintaining the original physical properties. Despite the many advantages and applications of molded foamed polymer parts, their drawbacks remain unresolved limitations. Summary of the Invention

[0006] One object of the present invention is to provide a molding apparatus and a molding method.

[0007] According to a specific embodiment of the present invention, a molding apparatus is disclosed. The molding apparatus includes an upper mold, a lower mold, and an intermediate mold. The lower mold is disposed below the upper mold. The intermediate mold is disposed between the upper mold and the lower mold. The intermediate mold is movably attached to the lower mold via a position control mechanism.

[0008] According to one embodiment of the present application, a molding method is disclosed. The molding method includes: (a) providing a lower mold and an intermediate mold movably attached to the lower mold; (b) engaging an upper mold with the lower mold to define a receiving space, and disposing the intermediate mold within the receiving space, wherein the upper mold, the intermediate mold, and the lower mold collectively define a mold cavity; (c) injecting a material into the mold cavity and at least partially around the intermediate mold; and (d) forming an article from the material. BRIEF DESCRIPTION OF DRAWINGS

[0009] The application will be best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features are not drawn to scale. On the contrary, the dimensions of the various features can be arbitrarily inflated or deflated in order to make the figures more visually clear.

[0010] FIG. 1A is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application.

[0011] FIG. 1B is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application. FIG. 1A

[0012] FIG. 2A is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application.

[0013] FIG. 2B is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application. FIG. 2A

[0014] FIG. 3A is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application.

[0015] FIG. 3B is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application. FIG. 3A

[0016] FIG. 4A is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application.

[0017] FIG. 4B is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application. FIG. 4A

[0018] FIG. 5A is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application.

[0019] FIG. 5B is a schematic perspective view of a molding apparatus in one or more manufacturing stages of a molding method according to some embodiments of the present application.​​​​FIG. 5A side view of the molding device in

[0020] FIG. 6A schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0021] FIG. 6B schematic perspective view of FIG. 6A side view of the molding device in

[0022] FIG. 7 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0023] FIG. 8 schematic perspective view of the article according to some embodiments of the application.

[0024] FIG. 9 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0025] FIG. 10 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0026] FIG. 11 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0027] FIG. 12 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0028] FIG. 13 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0029] FIG. 14 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0030] FIG. 15 schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0031] FIG. 16A schematic perspective view of a molding device in one or more manufacturing stages of a molding method according to some embodiments of the application.

[0032] FIG. 16B schematic perspective view ofFIG. 16A side view of the forming device in

[0033] FIG. 17A schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application.

[0034] FIG. 17B schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application. FIG. 18A side view of the forming device in

[0035] FIG. 18B schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application.

[0036] FIG. 19A schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application. FIG. 19B side view of the forming device in

[0037] FIG. 20 schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application.

[0038] FIG. 21 schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application. FIGS. 1A-8 side view of the forming device in

[0039] FIG. 8 schematic perspective view of a forming device in one or more manufacturing stages of a forming method according to some embodiments of the present application.

[0040] FIG. 1A flowchart of a forming method according to some embodiments of the present application. DETAILED DESCRIPTION

[0041] The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. The following description is not to be taken in a limiting sense, but is made merely for the purpose of providing some examples of the present application. For example, forming a first feature on or over a second feature in the following description can include embodiments where the first and second features are formed directly on one another, and can also include embodiments where additional features can be formed between the first and second features such that the first and second features are not directly on one another. Furthermore, the present application can be repeated with various example numbers and / or letters. This repetition is for the purpose of simplicity and clarity and does not itself represent a relationship between the various embodiments and / or configurations discussed.

[0042] Moreover, spatially relative terms, such as "beneath", "below", "lower", "above", "upper", and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The devices can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative terms used herein are to be interpreted accordingly.

[0043] Notwithstanding that the numerical ranges and parameters setting forth the broadest scope of the application are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, as used herein, the term "about" is intended to encompass a temperature ± 10% of the stated temperature. Alternatively, the term "about" when used, in connection with a numerical value, is intended to encompass a range of values that fall within 10% of a value stated therein (e.g., about 50% would include a range of values from 45% to 55%). Alternatively, the term "about" is intended to encompass a range of values that fall within an acceptable standard deviation of the mean value when such a term is considered by those of ordinary skill in the art. Unless otherwise clear from context, all numerical ranges that are herein expressly incorporated - such as ranges of material amounts, time durations, temperatures, operating conditions, ratios of amounts, and the like - are to be understood to be modified by the term "about" in all instances. Accordingly, unless indicated to the contrary, numerical parameters set forth in the present specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the present application. At the very least, each numerical parameter should be construed in light of the number of significant figures and by applying ordinary rounding techniques. In this respect, ranges can be expressed in terms of "from" and "to" when it is intended that an included limit is not to be included. Unless otherwise indicated, all ranges disclosed herein are inclusive of the endpoints.

[0044] FIG. 1B An exemplary forming process for manufacturing an article according to some embodiments of the present application is described. In some embodiments, the process is used to manufacture an article 6 as shown. FIG. 1A An exemplary forming process for manufacturing an article according to some embodiments of the present application is described. In some embodiments, the process is used to manufacture an article 6 as shown.

[0045] Reference is made to FIG. 1B and FIG. 1A which provide a forming device 1. FIG. 1A is a schematic perspective view of a forming device 1 in a first manufacturing stage according to some embodiments of the present application. FIG. 1B is a side view of the forming device 1 in FIG. 3A The forming device 1 can include an upper mold 2, a lower mold 3, an intermediate mold 4, and a position control mechanism 5.

[0046] In some embodiments, the upper mold 2 can correspond to the lower mold 3 in certain configurations or states (such as size, shape, etc.). The upper mold 2 can be placed on the lower mold 3 and engaged with the lower mold 3. In some embodiments, the preparation of the molding device 1 includes transporting the lower mold 3 toward the upper mold 2. Thus, the lower mold 3 should be configured below the upper mold 2 for use in subsequent steps. In some embodiments, the upper mold 2 can be aligned with the lower mold 3. In some embodiments, the upper mold 2 can be aligned with the lower mold 3 and the intermediate mold 4. In some embodiments, the upper mold 2 can be aligned with the lower mold 3 and the intermediate mold 4 and the mold cavity 14. FIG. 3B and FIG. 3A In some embodiments, the molding device 1 is in an open configuration or open state as exemplified in the embodiments within

[0047] The upper mold 2 can have a top surface 21 and a bottom surface 22 opposite the top surface 21. The upper mold 2 can define a recess 23 and a channel 24. The bottom surface 22 of the upper mold 2 can face the lower mold 3 and the intermediate mold 4. The recess 23 of the upper mold 2 can be recessed from the bottom surface 22 of the upper mold 2. The configuration or state (e.g., size or shape) of the recess 23 of the upper mold 2 can correspond to the configuration or state (e.g., size or shape) of the intermediate mold 4. The recess 23 of the upper mold 2 can include a first inner surface 231 and a second inner surface 232. The second inner surface 232 can extend between the first inner surface 231 and the bottom surface 22 of the upper mold 2. The first inner surface 231 and the second inner surface 232 can be substantially conformal to the intermediate mold 4.

[0048] In some embodiments, the channel 24 can extend through the upper mold 2 and can have an opening 241 on the top surface 21 of the upper mold 2. In some embodiments, when the molding device 1 is in a closed configuration as exemplified in the embodiments within FIG. 3B and FIG. 3A The channel 24 can be in communication with the recess 23 or the mold cavity 14 of the upper mold 2. Alternatively, the channel 24 can be in communication with the recess 23 of the upper mold 2. Thus, the recess 23 of the upper mold 2 can be accessible through the channel 24. For simplicity and clarity, only one channel 24 is exemplified, but it can be understood that any suitable number of channels 24 can be configured on the upper mold 2. In some embodiments, the number of channels 24 is the same as the number of recesses 23 of the upper mold 2. In some embodiments, the number of recesses 23 of the upper mold 2 exceeds the number of channels 24. In some embodiments, the number of channels 24 exceeds the number of recesses 23 of the upper mold 2.

[0049] In some embodiments, the channel 24 can not be configured on the upper mold 2, but when the molding device 1 is in a closed configuration as exemplified in the embodiments within FIG. 3B and FIG. 3AIn the closed configuration, the channels 24 can be configured on the lower mold 3 to access the recess 33 or the mold cavity 14 of the lower mold 3. In some embodiments, when the molding device 1 is in the closed configuration as shown in FIG. 1, the channels 24 can be configured on the side walls of the lower mold 3, on the bottom of the lower mold 3, or on any other suitable portion of the lower mold 3 as long as the channels 24 can be in communication with the mold cavity 14. FIG. 3B and FIG. 1A In the closed configuration or closed state as shown in FIG. 1, the channels 24 can be configured on the side walls of the lower mold 3, on the bottom of the lower mold 3, or on any other suitable portion of the lower mold 3 as long as the channels 24 can be in communication with the mold cavity 14.

[0050] The lower mold 3 can be configured below the upper mold 2. The lower mold 3 can have a top surface 31 and a bottom surface 32 opposite the top surface 31. The lower mold 3 can define a recess 33 and a bore structure 34. The top surface 31 of the lower mold 3 can face the upper mold 2 and the middle mold 4. The recess 33 of the lower mold 3 can be recessed from the top surface 31 of the lower mold 3. The configuration (e.g., size or shape) of the recess 33 of the lower mold 3 can correspond to the configuration (e.g., size or shape) of the bottom surface of the middle mold 4. The recess 33 of the lower mold 3 can be positioned just below the middle mold 4. When the molding device 1 is in the closed configuration as shown in FIG. 1, the recess 33 of the lower mold 3 can be a portion of the mold cavity 14. FIG. 1B and FIG. 3A In the closed configuration or closed state as shown in FIG. 1, the recess 33 of the lower mold 3 can be a portion of the mold cavity 14.

[0051] In some embodiments, the bore structure 34 can be configured outside of the recess 33 of the lower mold 3. As such, the bore structure 34 can not be in communication with the recess 33 of the lower mold 3. As such, the recess 33 of the lower mold 3 can not be accessible through the bore structure 34. In some embodiments, the bore structure 34 can or can not extend through the lower mold 3. The bore structure 34 can include a first bore 341 and a second bore 342 in communication with each other. The first bore 341 can have an opening on the top surface 31 of the lower mold 3. The second bore 342 can be positioned below the first bore 341. The second bore 342 can have a size (e.g., width or diameter) smaller than the size (e.g., width or diameter) of the first bore 341 to form a stepped structure 343.

[0052] For simplicity and clarity, only the bore structure 34 is illustrated, but it can be appreciated that any suitable number of bore structures 34 can be configured at the lower mold 3. In some embodiments, the bore structure 34 can be used to accommodate a portion of the position control mechanism 5. As such, the number of bore structures 34 can be equal to the number of position control mechanisms 5. In some embodiments, the number of bore structures 34 can be two or three, which can balance or substantially evenly support the downward pressure exerted on the position control mechanisms 5 and the middle mold 4 from the upper mold 2.

[0053] An intermediate mold 4 can be disposed between the upper mold 2 and the lower mold 3, and can be moveably attached to the lower mold 3 via a position control mechanism 5. The intermediate mold 4 can move between the upper mold 2 and the lower mold 3. In some embodiments, the intermediate mold 4 can move between the upper mold 2 and the lower mold 3 due to the operation of the position control mechanism 5. In some embodiments, the position control mechanism 5 can drive or actuate the intermediate mold 4 to move along the direction between the upper mold 2 and the lower mold 3, or to move along the height of the molding apparatus 1. It is understood that the maximum displacement of the intermediate mold 4 is limited by the position control mechanism 5. That is, the gap or distance between the intermediate mold 4 and the lower mold 3 is controlled by the position control mechanism 5. Furthermore, the gap or distance between the intermediate mold 4 and the upper mold 2 is not controlled by the position control mechanism 5.

[0054] like FIG. 3B and FIG. 1A As shown, the intermediate mold 4 may include a main body portion 41 and a shoe last portion 42. The main body portion 41 may be connected to the rear end of the shoe last portion 42. In some specific embodiments, the main body portion 41 and the shoe last portion 42 are integrally formed into a single structure. The main body portion 41 may have a top surface 411 and a bottom surface 412 opposite to the top surface 411. The shoe last portion 42 may have a top surface 421, a bottom surface 422 opposite to the top surface 421, and an outer surface 423 extending between the top surface 421 and the bottom surface 422. Furthermore, the shoe last portion 42 may define at least one recess 43 recessed from the outer surface 423. When the molding apparatus 1 is in such a position... FIG. 1B and FIG. 1A In the closed configuration shown, the recess 43 of the intermediate mold 4 may be part of the mold cavity 14. In some embodiments, the at least one recess 43 may include a plurality of recesses 43 that communicate with each other and extend to the bottom surface 422 of the shoe last 42. In some embodiments, the shoe last 42 may further define at least one bottom recess (not shown) recessed from the bottom surface 422 of the shoe last 42.

[0055] The top surface 421 of the shoe last 42 may be substantially flush with or coplanar with the top surface 411 of the main body 41. Therefore, the top surface of the intermediate mold 4 may include the top surface 421 of the shoe last 42 and the top surface 411 of the main body 41. Furthermore, the bottom surface 422 of the shoe last 42 may be substantially flush with or coplanar with the bottom surface 412 of the main body 41. Therefore, the bottom surface of the intermediate mold 4 may include the bottom surface 422 of the shoe last 42 and the bottom surface 412 of the main body 41. Therefore, the maximum thickness of the shoe last 42 may be approximately equal to the maximum thickness of the main body 41 and the maximum thickness of the intermediate mold 4.

[0056] The position control mechanism 5 can be connected or attached to the bottom surface 412 of the main body portion 41 of the intermediate mold 4. The position control mechanism 5 can drive or actuate the intermediate mold 4 to move upwardly to create a gap G between the top surface 31 of the lower mold 3 and the bottom surface of the intermediate mold 4 (including the bottom surface 422 of the last portion 42 and the bottom surface 412 of the main body portion 41) when the forming device 1 is in the open configuration. That is, the position control mechanism 5 can create relative movement between the intermediate mold 4 and the lower mold 3. As shown in FIG. 1B and FIG. 8 The forming device 1 is in the open configuration, and the gap G reaches a maximum value.

[0057] In some embodiments, a portion of the position control mechanism 5 can be housed in the aperture structure 34 of the lower mold 3. Thus, when the forming device 1 is in the closed configuration, the entire position control mechanism 5 can be housed in the aperture structure 34 of the lower mold 3, and the bottom surface 412 of the main body portion 41 can be in contact with the top surface 31 of the lower mold 3.

[0058] As shown in FIG. 8 and FIG. 2A The position control mechanism 5 can include at least a top rod 51 and a resilient mechanism 52. The top rod 51 can be a pin, a pillar, a post, or a column, and can be used to guide the direction of movement of the intermediate mold 4. The top rod 51 can have an upper end connected or attached to the bottom surface 412 of the main body portion 41 of the intermediate mold 4, and a lower end extending through the first aperture 341 of the aperture structure 34 and into the second aperture 342 of the aperture structure 34. The resilient mechanism 52 can be used to control or drive the top rod 51. For example, the resilient mechanism 52 can be a spring or an elastomer surrounding the top rod 51. The resilient mechanism 52 can have an upper end connected or attached to the bottom surface 412 of the main body portion 41 of the intermediate mold 4, and a lower end connected or attached to the stepped structure 343 of the aperture structure 34 of the lower mold 3. When a downward force is applied on the intermediate mold 4 to drive the intermediate mold 4 to move downwardly to compress the resilient mechanism 52, the resilient potential is stored in the compressed resilient mechanism 52. Once the downward force is released, the resilient potential will push the intermediate mold 4 to move upwardly. It can be appreciated that the position control mechanism 5 can be a piston or other suitable mechanism having a compression stage and a rebound stage. In some embodiments, the resilient mechanism 52 can be omitted, and the lower end of the top rod 51 can be connected to a suitable actuator. Thus, the movement of the top rod 51 can not be controlled by the resilient potential.

[0059] In some embodiments, the intermediate mold 4 can be separable from the lower mold 3 and the position control mechanism 5. It can be appreciated that the size or appearance of the article 6 FIG. 2B may correspond to the size or appearance of the intermediate mold 4. Thus, in order to manufacture different articles 6 having different sizes or different appearances, the intermediate mold 4 can be replaced by a different intermediate mold having a different size or a different appearance.FIG. 2A Different intermediate molds 4 having different sizes or different appearances can be employed and changed. Upon changing the intermediate mold 4, the recess 33 of the lower mold 3 and the recess 23 of the upper mold 2 can be changed accordingly.

[0060] Please refer to FIG. 2B and FIG. 2A The distance between the upper mold 2 and the lower mold 3 is gradually reduced. FIG. 2A is a schematic perspective view of the molding apparatus 1 in a second manufacturing stage according to some embodiments of the present application. FIG. 2B is a side view of the molding apparatus 1 in FIG. 2A . As shown in FIG. 2B and FIG. 3A , relative movement occurs between the upper mold 2 and the lower mold 3. In some embodiments, the position of the upper mold 2 can be fixed, and the lower mold 3 and the intermediate mold 4 can move together toward the upper mold 2. In some embodiments, the position of the lower mold 3 and the intermediate mold 4 can be fixed, and the upper mold 2 can move toward the lower mold 3 and the intermediate mold 4. In some embodiments, the lower mold 3 and the upper mold 2 move toward each other. In some embodiments, the lower mold 3 and the upper mold 2 move toward each other, and the intermediate mold 4 moves toward the upper mold 2. FIG. 3B and FIG. 3A , the intermediate mold 4 is in contact with the upper mold 2, but the lower mold 3 has not yet contacted the upper mold 2. That is, the intermediate mold 4 has contacted the upper mold 2 before the lower mold 3 contacts the upper mold 2. For example, the intermediate mold 4 can be accommodated in the recess 23 of the upper mold 2. The first inner surface 231 of the upper mold 2 can contact the top surface of the intermediate mold 4 (including the top surface 421 of the last portion 42 and the top surface 411 of the main body portion 41). The second inner surface 232 of the upper mold 2 can contact the outer surface 423 of the intermediate mold 4. In some embodiments, the bottom surface of the intermediate mold 4 (including the bottom surface 422 of the last portion 42 and the bottom surface 412 of the main body portion 41) can be substantially coplanar with the bottom surface 22 of the upper mold 2. At this time, the gap G between the top surface 31 of the lower mold 3 and the bottom surface of the intermediate mold 4 does not change.

[0061] Please refer to FIG. 3B and FIG. 3A , the relative movement between the upper mold 2 and the lower mold 3 continues until the distance between the upper mold 2 and the lower mold 3 is reduced to zero. FIG. 3A is a schematic perspective view of the molding apparatus 1 in a third manufacturing stage according to some embodiments of the present application. FIG. 3B is a side view of the molding apparatus 1 in FIG. 3AA side view of the molding apparatus 1. In some embodiments, the upper mold 2 can be fixed in position, the intermediate mold 4 can abut against the upper mold 2, and the lower mold 3 can move toward the upper mold 2. In some embodiments, the lower mold 3 can be fixed in position, and the upper mold 2 and the intermediate mold 4 can move together toward the lower mold 3. In some embodiments, the lower mold 3 and the upper mold 2 move toward each other. Thus, the gap G between the top surface 31 of the lower mold 3 and the bottom surface of the intermediate mold 4 is reduced to zero. The upper mold 2 can apply a downward force to the intermediate mold 4 to move the intermediate mold 4 downward, thereby pressing the elastic mechanism 52. Therefore, elastic potential energy is stored in the compressed elastic mechanism 52.

[0062] like FIG. 3B and FIG. 4A As shown, the molding apparatus 1 is in a closed configuration, with the upper mold 2 and the lower mold 3 engaged. The bottom surface 22 of the upper mold 2 and the bottom surface 412 of the main body 41 can contact the top surface 31 of the lower mold 3. Thus, the upper mold 2 and the lower mold 3 together define a receiving space 12 for accommodating the intermediate mold 4. It is understood that the receiving space 12 can be substantially the same as the recess 23 of the upper mold 2. The entire intermediate mold 4 is configured and accommodated within the receiving space 12. Furthermore, the upper mold 2, the intermediate mold 4, and the lower mold 3 together define a mold cavity 14. The mold cavity 14 is configured to accommodate a material and allow the material to be molded into a molded article having a predetermined shape. The channel 24 of the upper mold 2 communicates with the mold cavity 14. In some specific embodiments, the opening 241 of the channel 24 can be coupled to an injection molding machine or an extrusion molding machine, so that the material can be injected / extruded from the injection molding machine or the extrusion molding machine into the mold cavity 14 and formed into a predetermined shape therein.

[0063] like FIG. 4B and FIG. 4A As shown, the mold cavity 14 may include a first portion 141 and a second portion 142 that are in communication with each other. The first portion 141 may be defined by the second inner surface 232 of the upper mold 2 and the sidewall of the recess 43 of the shoe last portion 42. It is understood that the first portion 141 of the mold cavity 14 may be substantially the same as the recess 43 of the shoe last portion 42. Furthermore, the second portion 142 may be defined by the sidewall of the recess 33 of the lower mold 3, the bottom surface of the intermediate mold 4 (including the bottom surface 422 of the shoe last portion 42 and the bottom surface 412 of the main body portion 41), and the bottom surface 22 of the upper mold 2. It is understood that the second portion 142 of the mold cavity 14 may be substantially the same as the recess 33 of the lower mold 3.

[0064] Please refer to FIG. 4B and FIG. 4A Material 60 can be injected into mold cavity 14 through opening 241 of channel 24. Material 60 can at least partially surround or encircle intermediate mold 4. Alternatively, material 60 can surround or encircle at least a portion of intermediate mold 4.FIG. 5A is a schematic perspective view of the molding device 1 in a fourth manufacturing stage according to some embodiments of the present application. FIG. 5B is a side view of the molding device 1 in FIG. 5A In some embodiments, the material 60 is injected into the mold cavity 14 when the molding device 1 is in a closed state or when the upper mold 2 and the lower mold 3 are engaged with each other. In some embodiments, the material 60 can include thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the material 60 is a foamable material or a low-foam material. In some embodiments, the material 60 can be a non-foam material. In some embodiments, the material 60 can fill the mold cavity 14 (including the first portion 141 and the second portion 142).

[0065] The article 6 is then integrally formed from the material 60. The article 6 can be a shoe such as a slipper, a flip-flop, or a sandal. The article 6 can include a base 62 (e.g., a sole portion) and at least one upper portion 61 (e.g., a strap portion). The upper portion 61 of the article 6 can be formed from a first portion of the material 60 disposed in the first portion 141 of the mold cavity 14. The base 62 of the article 6 can be formed from a second portion of the material 60 disposed in the second portion 142 of the mold cavity 14. In addition, an additional pin 63 can be formed from a third portion of the material 60 disposed in the channel 24. The additional pin 63 can be connected to the upper portion 61 of the article 6.

[0066] Referring to FIG. 5B and FIG. 5A the lower mold 3 is separated from the upper mold 2. FIG. 3A is a schematic perspective view of the molding device 1 in a fifth manufacturing stage according to some embodiments of the present application. FIG. 3B is a side view of the molding device 1 in FIG. 3A The relative movement between the upper mold 2 and the lower mold 3 occurs, and the distance between the upper mold 2 and the lower mold 3 gradually increases. At this time, the article 6 can remain on or be attached to the intermediate mold 4, and the additional pin 63 can still be attached to the article 6. In some embodiments, the position of the upper mold 2 can be fixed, and only the lower mold 3 can be moved away from the upper mold 2. Meanwhile, the intermediate mold 4 can abut against the upper mold 2 and can not move. The relative movement of the intermediate mold 4 and the lower mold 3 can be achieved by the pushing force exerted by the position control mechanism 5 on the intermediate mold 4. This pushing force is converted from the elastic potential energy stored in the pressurized elastic mechanism 52 of FIG. 3B and FIG. 6A The relative movement of the intermediate mold 4 and the lower mold 3 can be achieved by the pushing force exerted by the position control mechanism 5 on the intermediate mold 4. This pushing force is converted from the elastic potential energy stored in the pressurized elastic mechanism 52 of

[0067] In some embodiments, the position of the lower mold 3 can be fixed, and the upper mold 2 and the intermediate mold 4 can be moved away from the lower mold 3 together. Meanwhile, the intermediate mold 4 can abut against the upper mold 2 and can be moved together with the upper mold 2. The relative movement between the intermediate mold 4 and the lower mold 3 can be achieved by the pushing force applied to the intermediate mold 4 by the position control mechanism 5. This pushing force is converted from the elastic potential energy stored in the compressed elastic mechanism 52. FIG. 6B and FIG. 6A The elastic potential energy stored in the compressed elastic mechanism 52.

[0068] Please refer to FIG. 6B and FIG. 6A The relative movement between the upper mold 2 and the lower mold 3 continues until the upper mold 2 is separated from the intermediate mold 4. FIG. 6B is a schematic perspective view of the molding device 1 in the sixth manufacturing stage according to some embodiments of the present application. FIG. 7 is a side view of the molding device 1 in FIG. 7 At this time, the article 6 can remain on the intermediate mold 4. In some embodiments, the position of the upper mold 2 can be fixed, and the lower mold 3 and the intermediate mold 4 are moved away from the upper mold 2 due to the limitation of the maximum displacement of the intermediate mold 4 by the position control mechanism 5 attached to the lower mold 3. In some embodiments, the position of the lower mold 3 can be fixed, and the upper mold 2 can be moved away from the lower mold 3 and the intermediate mold 4. As shown in FIG. 7 , the distance between the intermediate mold 4 and the upper mold 2 can be greater than the distance between the intermediate mold 4 and the lower mold 3.

[0069] Please refer to FIG. 8 , the article 6 can be separated from the upper side of the intermediate mold 4. FIG. 8 is a schematic side view of the molding device 1 in the seventh manufacturing stage according to some embodiments of the present application. As shown in FIGS. 9-15 , the article 6 can be separated from the intermediate mold 4 through the space between the intermediate mold 4 and the upper mold 2. As can be understood, the gap G between the top surface 31 of the lower mold 3 and the bottom surface of the intermediate mold 4 can facilitate the separation of the article 6.

[0070] Then, the additional pin 63 can be removed from the article 6, thereby obtaining the article 6 as shown in FIG. 8 .

[0071] FIG. 9 is a schematic perspective view of the article 6 according to some embodiments of the present application. The article 6 can include a base 62 and at least one upper portion 61 connected to the base 62. The base 62 and the upper portion 61 can be simultaneously and integrally formed. Therefore, there is no interface between the base 62 and the upper portion 61.

[0072] FIG. 9An exemplary molding method for manufacturing an article according to some embodiments of the present application is described. In some embodiments, the method is used to manufacture an article 6 as shown. FIG. 1A

[0073] Please refer to FIG. 1B , a molding apparatus 1a is provided. FIG. 9 The molding apparatus 1a is similar to the molding apparatus 1 of FIG. 9 and FIG. 1A except that the intermediate mold 4a is inverted. The molding apparatus 1a can include an upper mold 2a, a lower mold 3a, an intermediate mold 4a, and a position control mechanism 5a. In FIG. 1B the illustrated embodiment, the molding apparatus 1a is in an open configuration.

[0074] The upper mold 2a can have a top surface 21 and a bottom surface 22 opposite the top surface 21. The upper mold 2a can define a recess 23a and at least one channel 24. The bottom surface 22 of the upper mold 2a can face the lower mold 3a and the intermediate mold 4a. The recess 23a of the upper mold 2a can be recessed from the bottom surface 22 of the upper mold 2a. The state (e.g., size or shape) of the recess 23a of the upper mold 2a can correspond to the state (e.g., size or shape) of the top surface 421 of the intermediate mold 4a. The position of the recess 23a of the upper mold 2a can be just above the intermediate mold 4a. FIG. 11 The recess 23a of the upper mold 2a can be the same as the recess 33 of the lower mold 3 of FIG. 11 and FIG. 9 .

[0075] In some embodiments, the channel 24 can extend through the upper mold 2a and can have an opening 241 on the top surface 21 of the upper mold 2a. In some embodiments, when the molding apparatus 1a is in a closed state as shown in FIG. 1A , the channel 24 can communicate with the recess 23a of the upper mold 2a or the mold cavity 14a. Alternatively, the channel 24 can communicate with the recess 23a of the upper mold 2a. Thus, the recess 23a of the upper mold 2a can be accessible through the channel 24.

[0076] The lower mold 3a can be disposed underneath the upper mold 2a. The lower mold 3a can have a top surface 31 and a bottom surface (not shown) opposite the top surface 31. The lower mold 3a can define a recess 33a and a bore structure 34a. The top surface 31 of the lower mold 3a can face the upper mold 2a and the intermediate mold 4a. The recess 33a of the lower mold 3a can be recessed from the top surface 31 of the lower mold 3a.

[0077] The state (e.g., size or shape) of the recess 33a of the lower mold 3a can correspond to the state (e.g., size or shape) of the intermediate mold 4a. When the molding apparatus 1a is in a closed state as shown in FIG. 1B ​In the closed state shown, the recess 33a of the lower mold 3a can be part of the mold cavity 14a. The recess 33a of the lower mold 3a may include a first inner surface 331a and a second inner surface 332a. The second inner surface 332a may extend between the first inner surface 331a and the top surface 31 of the lower mold 3a. The first inner surface 331a and the second inner surface 332a are substantially conformal to the intermediate mold 4a. FIG. 9 The recess 33a of the lower mold 3a can be with FIG. 1A and FIG. 1B The recess 23 of the upper mold 2 is the same.

[0078] In some embodiments, the hole structure 34a may be disposed below and communicate with the recess 33a of the lower mold 3a. In some embodiments, the hole structure 34a may be used to accommodate at least a portion of the position control mechanism 5a.

[0079] An intermediate mold 4a can be configured between the upper mold 2a and the lower mold 3a, and can be movably attached to the lower mold 3a via a position control mechanism 5a. The operation of the position control mechanism 5a allows the intermediate mold 4a to move between the upper mold 2a and the lower mold 3a. In some embodiments, the position control mechanism 5a can drive or actuate the intermediate mold 4a to move along the direction between the upper mold 2a and the lower mold 3a, or to move along the height of the molding apparatus 1a. It is understood that the maximum displacement of the intermediate mold 4a is limited by the position control mechanism 5a. That is, the gap or distance between the intermediate mold 4a and the lower mold 3a is controlled by the position control mechanism 5a. Furthermore, the gap or distance between the intermediate mold 4a and the upper mold 2a is not controlled by the position control mechanism 5a.

[0080] FIG. 9 The intermediate mold 4a can be similar to FIG. 9 and FIG. 11 The intermediate mold 4 is different in that it can be omitted. FIG. 9 and FIG. 9 The main body 41, and FIG. 10 The middle mold 4a is inverted. (Example) FIG. 10 As shown, the intermediate mold 4a may include a shoe last portion 42. The shoe last portion 42 may have a top surface 421, a bottom surface 422 opposite to the top surface 421, and an outer surface 423 extending between the top surface 421 and the bottom surface 422. Furthermore, the shoe last portion 42 may define at least one recess 43 recessed from the outer surface 423. When the molding apparatus 1a is in the position as shown... FIG. 11 In the closed state shown, the recess 43 of the intermediate mold 4a can be part of the mold cavity 14a.

[0081] The position control mechanism 5a can be connected to or attached to the bottom surface 422 of the shoe last 42 of the intermediate mold 4a. The position control mechanism 5a can drive or actuate the intermediate mold 4a to move upward, so that when the molding device 1a is in an open configuration, a gap G is created between the top surface 31 of the lower mold 3a and the bottom surface 422 of the shoe last 42. That is, the position control mechanism 5a can generate relative movement between the intermediate mold 4a and the lower mold 3a. FIG. 11 As shown, the molding device 1a is in an open configuration, and the gap G reaches its maximum value.

[0082] In some specific embodiments, a portion of the position control mechanism 5a may be accommodated in the hole structure 34a of the lower mold 3a. Thus, when the molding apparatus 1a is in a closed configuration, the entire position control mechanism 5a can be accommodated in the hole structure 34a of the lower mold 3a.

[0083] like FIG. 11 As shown, the position control mechanism 5a may include a push rod 51, an elastic mechanism 52, and a fixed bracket 53. The push rod 51 may be a pin, a column, a pillar, or a cylinder, and may be used to guide the movement direction of the intermediate mold 4a. The upper end of the push rod 51 may be connected to or attached to the bottom surface 422 of the shoe last portion 42 of the intermediate mold 4a, and the lower end of the push rod 51 may extend into the hole structure 34a and slide within the hole structure 34a. The elastic mechanism 52 may be used to control the movement of the push rod 51 or drive the push rod 51. For example, the elastic mechanism 52 may be a spring or elastic body placed in the hollow portion of the push rod 51. The upper end of the elastic mechanism 52 may be connected to or attached to the bottom surface 422 of the shoe last portion 42 of the intermediate mold 4a, and the lower end of the elastic mechanism 52 may be connected to or attached to the fixed bracket 53. When a downward force is applied to the intermediate mold 4a to drive it downward and press against the elastic mechanism 52, elastic potential energy is stored in the compressed elastic mechanism 52. Once the downward force is released, the elastic potential energy will push the intermediate mold 4a upward. It is understood that the position control mechanism 5a may be a piston or other suitable mechanism having a compression phase and a springback phase. In some specific embodiments, the elastic mechanism 52 may be omitted, and the lower end of the push rod 51 may be connected to a suitable actuator. Therefore, the movement of the push rod 51 may not be controlled by the elastic potential energy.

[0084] Please refer to this. FIG. 1A The distance between the upper mold 2a and the lower mold 3a gradually decreases. Relative movement occurs between the upper mold 2a and the lower mold 3a. In some embodiments, the position of the upper mold 2a can be fixed, and the lower mold 3a and the intermediate mold 4a can move together toward the upper mold 2a. In some embodiments, the positions of the lower mold 3a and the intermediate mold 4a can be fixed, and the upper mold 2a can move toward the lower mold 3a and the intermediate mold 4a. In some embodiments, the lower mold 3a and the upper mold 2a move toward each other. FIG. 1BAt this stage, the intermediate mold 4a is in contact with the upper mold 2a, but the lower mold 3a is not yet in contact with the upper mold 2a. At this time, the gap G between the top surface 31 of the lower mold 3a and the bottom surface 422 of the last portion 42 of the intermediate mold 4a does not change.

[0085] Please refer to FIG. 12 The relative movement between the upper mold 2a and the lower mold 3a continues until the distance between the upper mold 2a and the lower mold 3a is reduced to zero. In some embodiments, the position of the upper mold 2a can be fixed, the intermediate mold 4a can abut against the upper mold 2a, and the lower mold 3a can move toward the upper mold 2a. In some embodiments, the position of the lower mold 3a can be fixed, the upper mold 2a and the intermediate mold 4a can move together toward the lower mold 3a. In some embodiments, the lower mold 3a and the upper mold 2a move toward each other. In this way, the gap G between the top surface 31 of the lower mold 3a and the bottom surface 422 of the intermediate mold 4a is reduced to zero. The upper mold 2a can apply a downward force to the intermediate mold 4a to drive the intermediate mold 4a to move downward, thereby compressing the elastic mechanism 52. Therefore, the elastic potential energy is stored in the compressed elastic mechanism 52.

[0086] As FIG. 13 shown, the molding device 1a is in a closed state, and the upper mold 2a is engaged with the lower mold 3a. The bottom surface 22 of the upper mold 2a can contact the top surface 31 of the lower mold 3a. In this way, the upper mold 2a and the lower mold 3a can jointly define a receiving space 12a for accommodating the intermediate mold 4a. It can be understood that the receiving space 12a can be substantially the same as the recessed portion 33a of the lower mold 3a. For example, the intermediate mold 4a can be accommodated in the recessed portion 33a of the lower mold 3a. The first inner surface 331a of the lower mold 3a can contact the bottom surface 422 of the last portion 42 of the intermediate mold 4a. The second inner surface 332a of the lower mold 3a can contact the outer surface 423 of the intermediate mold 4a. In some embodiments, the top surface 421 of the last portion 42 of the intermediate mold 4a can be substantially coplanar with the top surface 31 of the lower mold 3a.

[0087] In addition, the upper mold 2a, the intermediate mold 4a, and the lower mold 3a can jointly define a mold cavity 14a. The mold cavity 14a is configured to accommodate a material and allow the material to be formed into a molded article having a predetermined shape by molding. The passage 24 of the upper mold 2a is in communication with the mold cavity 14a. In some embodiments, the opening 241 of the passage 24 can be coupled to an injection molding machine or an extrusion molding machine, so that the material can be injected / extruded from the injection molding machine or the extrusion molding machine into the mold cavity 14a and formed into a predetermined shape therein.

[0088] FIG. 11 The mold cavity 14a of the molding device 1a can be similar to FIG. 11 and FIG. 14The mold cavity 14a can be defined by the second inner surface 332a of the upper mold 2a and the sidewall of the recess 43 of the last portion 42. It can be appreciated that the first portion 141a of the mold cavity 14a can be substantially identical to the recess 43 of the last portion 42. In addition, the second portion 142a can be defined by the sidewall of the recess 23a of the upper mold 2a, the top surface 421 of the last portion 42 of the middle mold 4a, and the top surface 31 of the lower mold 3a. It can be appreciated that the second portion 142a of the mold cavity 14a can be substantially identical to the recess 23a of the upper mold 2a.

[0089] Referring to FIG. 14 , the material 60 can be injected into the mold cavity 14a through the opening 241 of the channel 24. The material 60 can at least partially surround or encircle the middle mold 4a. In some embodiments, the material 60 fills the mold cavity 14a (including the first portion 141a and the second portion 142a). The article 6 is then integrally formed from the material 60. The article 6 can be a shoe such as a slipper, a flip-flop, or a sandal. The article 6 can include a base portion 62 (e.g., a sole portion) and at least one upper portion 61 (e.g., a strap portion). The upper portion 61 of the article 6 can be formed from a first portion of the material 60 disposed in the first portion 141a of the mold cavity 14a. The base portion 62 of the article 6 can be formed from a second portion of the material 60 disposed in the second portion 142a of the mold cavity 14a. In addition, at least one additional pin 63 can be formed from a third portion of the material 60 disposed in the channel 24. The additional pin 63 can be connected to the base portion 62 of the article 6.

[0090] Referring to FIG. 15 , the lower mold 3a is separated from the upper mold 2a. Relative movement between the upper mold 2a and the lower mold 3a occurs, and the distance between the upper mold 2a and the lower mold 3a gradually increases. At this time, the article 6 can remain on or be attached to the middle mold 4a, and the plurality of additional pins 63 can still be attached to the article 6. In some embodiments, the position of the upper mold 2a can be fixed, and only the lower mold 3a can be moved away from the upper mold 2a. At this time, the middle mold 4a can abut against the upper mold 2a without moving. The relative movement of the middle mold 4a and the lower mold 3a can be achieved by the pushing force exerted by the position control mechanism 5a on the middle mold 4a. This pushing force is converted from the elastic potential energy stored in the compressed elastic mechanism 52. FIG. 15

[0091] ​In some embodiments, the lower mold 3a is stationary and the upper mold 2a and the intermediate mold 4a are moved away from the lower mold 3a. In this case, the intermediate mold 4a can abut the upper mold 2a and move with the upper mold 2a. The relative movement between the intermediate mold 4a and the lower mold 3a can be achieved by the pushing force applied to the intermediate mold 4a by the position control mechanism 5a. This pushing force is converted from the elastic potential energy stored in the compressed elastic mechanism 52. FIG. 8

[0092] Referring to FIGS. 16A-20 , the relative movement between the upper mold 2a and the lower mold 3a continues until the upper mold 2a is separated from the intermediate mold 4a. At the same time, the object 6 can be left on the intermediate mold 4a. In some embodiments, the upper mold 2a is stationary and the lower mold 3a and the intermediate mold 4a are moved away from the upper mold 2a due to the limitation of the maximum displacement of the intermediate mold 4a by the position control mechanism 5a attached to the lower mold 3a. In some embodiments, the lower mold 3a is stationary and the upper mold 2a is moved away from the lower mold 3a and the intermediate mold 4a. As shown in FIG. 8 , the distance between the intermediate mold 4a and the upper mold 2a can be greater than the distance between the intermediate mold 4a and the lower mold 3a.

[0093] Referring to FIG. 16A , the object 6 can be separated from the upper side of the intermediate mold 4a. As shown in FIG. 16B , the object 6 can be separated from the intermediate mold 4a through the space between the intermediate mold 4a and the upper mold 2a. It can be understood that the gap G between the top surface 31 of the lower mold 3a and the bottom surface 422 of the intermediate mold 4a can facilitate the separation of the object 6.

[0094] Then, the additional pin 63 can be removed from the object 6, resulting in the object 6 as shown in FIG. 1A .

[0095] FIG. 1B An exemplary molding method for manufacturing an object according to some embodiments of the present application is provided. In some embodiments, the method is used to manufacture the object 6 as shown in FIG. 17A .

[0096] Referring to FIG. 17B and FIG. 18A , a molding device 1b is provided. FIG. 18B and FIG. 19A The molding device 1b of FIG. 19B and FIG. 20 ​Similar to the forming apparatus 1, the difference lies in that the shoe last portion 42 of the intermediate mold 4b may further define at least one notch 44 and an opening 45 that is recessed from the outer surface 423 and communicates with the notch 43. The position of the channel 24 of the upper mold 2 may correspond to the opening 45. The depth of the notch 44 may be less than the depth of the notch 43. The depth of the opening 45 may be greater than the depth of both the notch 44 and the notch 43.

[0097] Please refer to this. FIG. 8 and FIG. 21 The molding device 1b is in a closed configuration. The notch 44, opening 45, and recess 43 of the intermediate mold 4b may be part of the mold cavity 14.

[0098] Please refer to this. FIG. 21 and FIG. 1A Material 60 can be injected into mold cavity 14 through opening 241 of channel 24. Then, article 6 is integrally formed from material 60. Article 6 may include base 62 (e.g., a sole portion), at least one upper portion 61 (e.g., a strap portion), at least one strap 64, and a protrusion 65. Furthermore, at least one additional pin 63 may be formed on the protrusion 65. That is, the protrusion 65 may be below the additional pin 63. Furthermore, base 62, upper portion 61, strap 64, protrusion 65, and additional pin 63 may be integrally formed and formed simultaneously. Upper portion 61 may be connected to base 62. Base 63 may be connected to strap 64, additional pin 63 may be connected to strap 64, and strap 64 may be connected to upper portion 61. The thickness of protrusion 65 may be greater than the thickness of strap 64 and upper portion 61. The thickness of strap 64 may be less than the thickness of upper portion 61.

[0099] Please refer to FIG. 1B and FIG. 3A The lower mold 3 separates from the upper mold 2.

[0100] Please refer to FIG. 3B Item 6 can be separated from the upper side of the intermediate mold 4b.

[0101] Then, the additional pin 63, protrusion 65, and strip 64 can be removed from the object 6, thereby obtaining as follows: FIG. 4A The object 6 is shown. In some embodiments, the additional pin 63, protrusion 65, and strip 64 are removed from the object 6 by cutting or shearing the strip 64.

[0102] FIG. 4B A flowchart illustrating a molding method according to some specific embodiments of the present invention is shown below. FIG. 4A As shown, molding method 70 may include the following steps.

[0103] In some embodiments, the method 70 can include a step S71 of providing a lower mold and an intermediate mold movably attached to the lower mold. For example, as shown in FIG. 4B and ​ a molding apparatus 1 is provided. The molding apparatus 1 can include an upper mold 2, a lower mold 3, an intermediate mold 4, and a position control mechanism 5. The intermediate mold 4 is movably attached to the lower mold 3 by the position control mechanism 5.

[0104] In some embodiments, the method 70 can include a step S72 of engaging an upper mold with the lower mold to define a receiving space, and disposing the intermediate mold within the receiving space, wherein the upper mold, the intermediate mold, and the lower mold collectively define a mold cavity. For example, as shown in ​ and ​ the upper mold 2 and the lower mold 3 are engaged to define a receiving space 12, and the intermediate mold 4 is disposed within the receiving space 12. The upper mold 2, the intermediate mold 4, and the lower mold 3 collectively define a mold cavity 14.

[0105] In some embodiments, the method 70 can include a step S73 of injecting material into the mold cavity and at least partially around or about the intermediate mold. For example, as shown in ​ and ​ material 60 is injected into the mold cavity 14, and the material 60 is around or about at least a portion of the intermediate mold 4.

[0106] In some embodiments, the method 70 can include a step S74 of forming an article from the material. For example, as shown in ​ and ​ the article 6 is formed from the material 60.

[0107] The foregoing summary of features of several embodiments has been presented with sufficient particularity that one of ordinary skill in the art can readily duplicate the features. It is to be understood that while numerous forms of the application have been shown and described, modifications and substitutions can be made by those skilled in the art without deviating from the spirit and scope of the application. Accordingly, it is the intent that no limitation be placed on the scope of the application beyond that which is set forth in the following claims.

[0108] Furthermore, the scope of the application is not intended to be limited to the particular embodiments of the program, machine, manufacture, composition of matter, means, methods and steps described in the specification. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not restrictive. Those skilled in the art will appreciate variations from the teachings of the present disclosure. For example, the present application can be used in other devices, systems, applications, and methods than those described herein. Those skilled in the art will appreciate that the application can be practiced with embodiments other than those explicitly described, without departing from the spirit or scope of the present disclosure. The title of this patent is indicative of all such alternative implementations. Accordingly, the disclosure of the present application is intended to be given in terms of the figures and description contained herein, and the application of the principles of the present application as specifically ascertained from the claims that follow, and should not be limited to the specific embodiments described herein.

[0109] Symbol explanation

[0110] 1, 1a, 1b molding device

[0111] 2, 2a upper mold

[0112] 3, 3a lower mold

[0113] 4, 4a intermediate mold

[0114] 5, 5a position control mechanism

[0115] 6 article

[0116] 12, 12a accommodation space

[0117] 14, 14a mold cavity

[0118] 21, 31, 411, 421 top surface

[0119] 22, 32, 412, 422 bottom surface

[0120] 23, 33, 23a, 33a recess

[0121] 24 passage

[0122] 34, 34a hole structure

[0123] 41 main body portion

[0124] 42 last portion

[0125] 43 recess

[0126] 44 notch

[0127] 45 opening

[0128] 51 top rod

[0129] 52 elastic mechanism

[0130] 60 material

[0131] 61 upper portion

[0132] 62 base

[0133] 63 additional pin

[0134] 64 strip

[0135] 65 protrusion

[0136] 70 forming method

[0137] 141, 141a first portion

[0138] 142, 142a second portion

[0139] 231, 331a first inner surface

[0140] 232, 332a second inner surface

[0141] 241, 45 opening

[0142] 341 first hole

[0143] 342 second hole

[0144] 343 stepped structure

[0145] 423 outer surface

Claims

1. A molding apparatus comprising: an upper mold; a lower mold disposed below the upper mold, the lower mold defining a bore structure that is recessed from a top surface of the lower mold; and an intermediate mold disposed between the upper mold and the lower mold and movably attached to the lower mold by a position control mechanism, wherein the position control mechanism includes at least a plunger and a resilient mechanism for controlling movement of the plunger, an upper end of the plunger being attached to a bottom surface of a body portion of the intermediate mold, and a lower end of the plunger extending through a first bore of the bore structure of the lower mold and into a second bore of the bore structure.

2. The molding apparatus of claim 1, wherein the upper mold and the lower mold collectively define a receiving space for receiving the intermediate mold when the molding apparatus is in a closed configuration.

3. The molding apparatus of claim 1, wherein the upper mold, the intermediate mold, and the lower mold collectively define a mold cavity when the molding apparatus is in a closed configuration.

4. The molding apparatus of claim 1, wherein the plunger of the position control mechanism is fixed to the bottom surface of the body portion of the intermediate mold, and the intermediate mold moves simultaneously with the plunger.

5. The molding apparatus of claim 1, wherein the entire position control mechanism is received in the bore structure of the lower mold when the molding apparatus is in a closed configuration, and a bottom surface of the upper mold and the bottom surface of the body portion of the intermediate mold contact a top surface of the lower mold.

6. A molding method comprising: (a) providing a lower mold and an intermediate mold movably attached to the lower mold, wherein the lower mold defines a bore structure that is recessed from a top surface of the lower mold, wherein a position control mechanism creates a gap between the top surface of the lower mold and a bottom surface of the intermediate mold, wherein the position control mechanism includes at least a plunger and a resilient mechanism for controlling movement of the plunger, an upper end of the plunger being attached to a bottom surface of a body portion of the intermediate mold, and a lower end of the plunger extending through a first bore of the bore structure of the lower mold and into a second bore of the bore structure; (b) engaging an upper mold with the lower mold to define a receiving space, and disposing the intermediate mold within the receiving space, wherein the upper mold, the intermediate mold, and the lower mold collectively define a mold cavity; (c) injecting a material into the mold cavity and at least partially around the intermediate mold; and (d) forming an article from the material.

7. The method of claim 6, further comprising: (e) disengaging the lower mold from the upper mold; and (f) separating the intermediate mold from the upper mold.

8. The method of claim 7, further comprising: (g) separating the article from an upper side of the intermediate mold.

9. The method of claim 8, wherein in (d) the article includes a base portion, at least an upper portion, at least a strap, and an additional pin, the upper portion being connected to the base portion, the strap being connected to the upper portion, and the additional pin being connected to the strap.

10. The method of claim 9, further comprising: (h) Remove the additional pin and the strip.

Images