Injection molding system and injection molding method

Abstract

An injection molding system includes a supply unit configured to supply a flowable mixture, an injection unit in communication with the supply unit, wherein the injection unit includes an outlet configured to discharge the flowable mixture, a molding device configured to receive the flowable mixture from the outlet and including a mold cavity and a feed port in communication with the mold cavity and engaged with the outlet, and a support device disposed between the injection unit and the molding device and configured to facilitate engagement of the injection unit and the molding device. The support device includes a first element coupled to the injection unit and a second element disposed on the molding device. The second element includes a channel configured to receive a protrusion of the first element, the protrusion of the first element being slidable within and along the channel of the second element.

Description

[0001] Cross-referencing related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 379,255, filed October 12, 2022, and U.S. Patent Application No. 18 / 451,073, filed August 16, 2023, the full contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to an injection molding system and an injection molding method, and more particularly to an injection molding system and injection molding method for manufacturing foamed polymer articles. Background Technology

[0004] Foamed polymer products offer numerous advantages, such as high strength, light weight, impact resistance, and good sound and heat insulation. These products can be injection molded or extruded into molded parts of predetermined shapes. For example, after melting polymer materials and mixing them with a foaming agent in an extrusion system to form a flowable mixture, this mixture is injected or extruded into a molding apparatus to form the desired foamed polymer product. The performance and quality of foamed polymer products can be improved by adjusting the structure and configuration of the injection molding system. Summary of the Invention

[0005] One object of the present invention is to provide an injection molding system and an injection molding method.

[0006] According to a specific embodiment of the present invention, an injection molding system is disclosed. The injection molding system includes: a supply unit configured to supply a flowable mixture of a polymer material and a foaming agent; an injection unit communicatively connected to the supply unit, wherein the injection unit includes an outlet disposed remotely from the supply unit and configured to discharge the flowable mixture; a molding device configured to receive the flowable mixture from the outlet, and including a mold cavity and an opening communicatively connected to the mold cavity and correspondingly engaging with the outlet; and a support device configured to facilitate engagement of the injection unit and the molding device. The support device includes a first element connected to the injection unit and a second element disposed on the molding device. The second element includes a groove configured to receive a protrusion of the first element, the protrusion of the first element being slidable within and along the groove of the second element.

[0007] According to a specific embodiment of the present invention, an injection molding method is disclosed. The molding method includes: providing an injection molding system, wherein the injection molding system includes an injection unit and a molding device, the injection unit including an outlet configured to discharge a flowable material, and the molding device being configured to receive the flowable material from the outlet, and including a mold cavity and an opening communicatively connected to the mold cavity and correspondingly engaging with the outlet; providing a support device configured to facilitate engagement of the injection unit and the molding device, wherein the support device includes a first element connected to the injection unit and a second element disposed on the molding device; aligning a protrusion of the first element with a groove of the second element; moving the molding device toward the injection unit such that the protrusion of the first element slides along the groove of the second element; engaging the outlet with the opening when the protrusion of the first element engages with the groove of the second element; and injecting the flowable material into the mold cavity.

[0008] Simple illustration

[0009] The present invention can be best understood from the following detailed description when read in conjunction with the accompanying drawings. It should be noted that, in accordance with industry standard practice, the various components are not drawn to scale. In fact, for clarity of explanation, the dimensions of many components may be arbitrarily enlarged or reduced.

[0010] Figure 1 This is a schematic diagram of an injection molding system according to some specific embodiments of the present invention.

[0011] Figure 2 The diagram illustrates a portion of an injection molding system according to some specific embodiments of the present invention.

[0012] Figure 3 A schematic top view of a portion of an injection molding system according to some specific embodiments of the present invention is shown.

[0013] Figure 4 The diagram illustrates a portion of an injection molding system according to some specific embodiments of the present invention.

[0014] Figure 5 The following is a schematic cross-sectional view illustrating a portion of an injection molding system according to some specific embodiments of the present invention.

[0015] Figure 6 The following is a flowchart illustrating an injection molding method according to some specific embodiments of the present invention.

[0016] Figures 7 to 18 A side view or schematic cross-sectional view of an injection molding system during one or more injection molding process manufacturing stages according to some specific embodiments of the present invention.

[0017] Figure 19 This is a schematic diagram of an injection molding system according to some specific embodiments of the present invention.

[0018] Figure 20 The diagram illustrates a portion of an injection molding system according to some specific embodiments of the present invention.

[0019] Figure 21 A schematic top view of a portion of an injection molding system according to some specific embodiments of the present invention is shown.

[0020] Figure 22 The diagram illustrates a portion of an injection molding system according to some specific embodiments of the present invention.

[0021] Figure 23 The following is a schematic cross-sectional view illustrating a portion of an injection molding system according to some specific embodiments of the present invention.

[0022] Figure 24 The following is a flowchart illustrating an injection molding method according to some specific embodiments of the present invention.

[0023] Figures 25 to 36 A side view or schematic cross-sectional view of an injection molding system during one or more injection molding process manufacturing stages according to some specific embodiments of the present invention.

[0024] Figure 37 The following is a flowchart illustrating an injection molding method according to some specific embodiments of the present invention. Implementation

[0025] The following disclosure provides numerous different specific embodiments or examples for implementing various features of the provided subject matter. Specific examples of components and configurations are described below to simplify the invention. Of course, these are merely examples and are not intended to be limiting. For example, the following description of forming a first feature on or above 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 do not directly contact each other. Furthermore, reference numerals and / or letters may be repeated in the 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.

[0026] In addition, this document may use spatial terms such as "below," "under," "below," "above," and "above" to describe the relationship between one element or feature and another, as shown 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 descriptors used herein may be interpreted accordingly.

[0027] While the numerical ranges and parameters described in this disclosure are approximate, the values ​​disclosed in specific examples are reported as precisely as possible. However, any numerical value inherently contains some error due to the standard deviation necessarily found in the corresponding test measurement. Additionally, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, when considered by a person skilled in the art, the term "about" means within the acceptable standard error of the average. Except in operational / working examples, or unless expressly stated otherwise, all numerical ranges, quantities, values, and percentages disclosed herein, such as material quantities, durations, temperatures, operating conditions, quantity ratios, etc., should be understood to be modified by the term "about" in all cases. Therefore, unless indicated to the contrary, the numerical parameters set forth in this invention and the appended claims are approximate values ​​that may vary as needed. At a minimum, each numerical parameter should be interpreted according to the number of significant figures reported and by applying common rounding techniques. In this document, a range may be expressed as from one endpoint to another or between two endpoints. Unless otherwise stated, all ranges disclosed herein include endpoints.

[0028] Generally speaking, the appearance and physical properties of foamed polymer products are directly affected by the injection molding process. Therefore, the design of the injection molding system must take into account the injection conditions of the flowable mixture entering the molding device from the injection unit, so that the flowable mixture can be injected into the molding device completely and effectively, thereby forming foamed polymer products with the desired quality.

[0029] Figure 1 A schematic perspective view illustrating a first injection molding system 100 according to a specific embodiment of the present invention. In some specific embodiments, reference is made to... Figure 1 The first injection molding system 100 includes an injection unit 101 and a molding device 102. The injection unit 101 is engageable with the molding device 102. In some embodiments, the first injection molding system 100 further includes a flowable mixture supply unit 103 communicatively connected to the injection unit 101. In some embodiments, the flowable mixture supply unit 103 is configured to generate a flowable mixture and supply it to the injection unit 101.

[0030] In some embodiments, the flowable mixture includes polymeric materials such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), and thermoplastic polyester elastomers (TPEE). In some embodiments, the flowable mixture includes recyclable materials. In some embodiments, the flowable mixture further includes a blowing agent. In some embodiments, the blowing agent may be any type of chemical or physical blowing agent known to those skilled in the art. In some embodiments, the blowing 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 flowable mixture comprises a polymeric material in a molten state and a blowing agent in a liquid or supercritical fluid state mixed with the polymeric material. In some embodiments, the flowable mixture is a molding material.

[0031] In some specific embodiments, the flowable mixture supply unit 103 of the first injection molding system 100 includes an extruder (not shown) for converting polymer material into a molten state, and a mixer (not shown) for mixing a foaming agent into the polymer material. The polymer material can flow from the extruder into the mixer.

[0032] In some embodiments, the ejection unit 101 includes an ejector 101a. In some embodiments, the ejection unit 101 may include more than one ejector 101a. In some embodiments, the ejector 101a is configured to receive a flowable mixture from the flowable mixture supply unit 103 and discharge the flowable mixture from the outlet 101c. In some embodiments, the ejector 101a is configured as a discharge channel, and the outlet 101c is arranged at the distal end of the ejector 101a and configured to discharge the flowable mixture.

[0033] In some embodiments, the ejector 101a may communicate with a mixer or a flowable mixture supply unit 103. In some embodiments, the flowable mixture is discharged from the ejector 101a into the molding apparatus 102. The ejector 101a may engage with the molding apparatus 102. The ejector 101a may extend toward and retract from the molding apparatus 102. In some embodiments, the ejector 101a may extend / retract vertically in a first direction as indicated by arrow A. In some embodiments, the ejector 101a may extend / retract via a hydraulic mechanism 101e. In some embodiments, the hydraulic mechanism 101e is attached to the ejector 101a. In some embodiments, the hydraulic mechanism 101e is arranged between the flowable mixture supply unit 103 and the ejector 101a.

[0034] In some embodiments, the support device 105 is configured to facilitate engagement between the injection unit 101 and the molding device 102. In some embodiments, the support device 105 is disposed above the molding device 102. In some embodiments, the support device 105 includes a first element 101b disposed adjacent to the ejector 101a. In some embodiments, the first element 101b is connected to the injection unit 101. The first element 101b may extend toward and retract from the molding device 102. In some embodiments, the first element 101b may extend / retract perpendicularly in a second direction as indicated by arrow B. In some embodiments, this first direction is parallel to the second direction.

[0035] In some embodiments, the first element 101b can extend / retract along a track 101f via a motor (not shown). In some embodiments, the track 101f is arranged between the flowable mixture supply unit 103 and the first element 101b. In some embodiments, the ejector 101a and the first element 101b can extend / retract independently of each other. The ejector 101a and the first element 101b can be displaced relative to each other. In some embodiments, the ejector 101a and the first element 101b can be displaced individually or together. In some embodiments, the first element 101b is T-shaped. In some embodiments, the first element 101b includes a protrusion 101d capable of engaging with the molding device 102. In some embodiments, the protrusion 101d of the first element 101b is arranged at the distal end of the flowable mixture supply unit 103.

[0036] In some embodiments, the injection unit 101 is arranged above the molding apparatus 102. In some embodiments, both the ejector 101a and the first element 101b are arranged above the molding apparatus 102. In some embodiments, the molding apparatus 102 is configured to receive a flowable mixture discharged from the ejector 101a through the outlet 101c.

[0037] In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d that can engage with the first mold 102c. In some embodiments, the first mold 102c is an upper mold, and the second mold 102d is a lower mold. In some embodiments, the molding apparatus 102 includes a cavity (not shown) defined by the first mold 102c and the second mold 102d, and an opening (not shown) communicating with the cavity and correspondingly engaging with an outlet 101c.

[0038] Figure 2 A schematic perspective view illustrating the second element 102s of the support device 105, and Figure 3 A schematic top view illustrating the second element 102s is shown. In some specific embodiments, refer to... Figures 1 to 3 The support device 105 includes a second element 102s disposed on the molding device 102 and engageable with the first element 101b. In some embodiments, the second element 102s may engage with the molding device 102. In some embodiments, the second element 102s may engage with the first mold 102c. In some embodiments, the second element 102s is removably attached to the molding device 102. In some embodiments, the second element 102s includes a groove 102e defined by a protrusion 102f.

[0039] In some embodiments, both the groove 102e and the protrusion 102f are laterally elongated. The groove 102e is configured to receive a protrusion 101d of the first element 101b in the injection unit 101. The protrusion 101d of the first element 101b can engage with the protrusion 102f. In some embodiments, the protrusion 101d of the first element 101b can slide within and along the groove 102e of the second element 102s. In some embodiments, the length L1 of the groove 102e is equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the groove 102e is greater than the thickness T1 of the protrusion 101d of the first element 101b. In some embodiments, the protrusion 102f includes a first portion 102x and a second portion 102y, and the protrusion 101d of the first element 101b is disposed between the first portion 102x and the second portion 102y of the protrusion 102f.

[0040] In some embodiments, the second element 102s includes a groove 102g configured to receive an outlet 101e. In some embodiments, the groove 102g is disposed within the second element 102s and extends laterally along the second element 102s. In some embodiments, the groove 102g is parallel to the protrusion 102f and the groove 102e. In some embodiments, the groove 102g is disposed between a first portion 102x and a second portion 102y of the protrusion 102f. The groove 102g is configured to receive an outlet 101c or end portion of the ejector 101a of the ejection unit 101. The outlet 101c or end portion of the ejector 101a is slidable within and along the groove 102g. In some embodiments, an opening 102h is disposed within the groove 102g. The opening 102h extends through the second element 102s.

[0041] In some embodiments, the opening 102h accommodates the outlet 101c or end of the ejector 101a. The outlet 101c or end of the ejector 101a is movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is significantly larger than the width W2 of the outlet 101c of the ejector 101a. In some embodiments, the width W3 of the opening 102h is equal to the width W2 of the outlet 101c of the ejector 101a.

[0042] In some embodiments, the width W4 of the groove 102g is significantly larger than the width W3 of the opening 102h. In some embodiments, a step 102k is formed within the groove 102g and adjacent to the opening 102h. In some embodiments, when the molding apparatus 102 receives a flowable mixture, the outlet 101c or end of the ejector 101a may be arranged on the step 102k. In some embodiments, the width W3 of the opening 102h is substantially smaller than the width W2 of the outlet 101c of the ejector 101a, and the outlet 101c or end of the ejector 101a may be arranged on the step 102k when the outlet 101c or end of the ejector 101a engages with the second element 102s. In some embodiments, when the outlet 101c or end of the ejector 101a engages with the second element 102s, the outlet 101c covers the opening 102h.

[0043] In some embodiments, a first sensor 102l is disposed within a groove 102e and configured to sense the contact between the protrusion 101d of the first element 101b and the second element 102s. In some embodiments, the first sensor 102l is disposed at the middle of the groove 102e. In some embodiments, the first sensor 102l is disposed within the groove 102e and adjacent to the opening 102h. The first sensor 102l is not limited to any particular type, as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of first sensors 102l are disposed within the groove 102e, and the first sensors 102l are configured to sense the position and contact between the protrusion 101d and the groove 102e. The number and position of the plurality of first sensors 102l are not particularly limited; for example, they can be configured at any position of the protrusion 102f and within the groove 102e; however, the invention is not limited thereto.

[0044] In some embodiments, the second sensor 102m is arranged within the groove 102g and configured to sense contact between the outlet 101c and the forming device 102. In some embodiments, the second sensor 102m is arranged within the groove 102g and adjacent to the opening 102h. The second sensor 102m is not limited to any particular type, as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are arranged within the groove 102g, and the second sensors 102m are configured to sense the position and contact between the outlet 101c and the groove 102g. The number and position of the plurality of second sensors 102m are not particularly limited; for example, they can be configured at any position in the groove 102g; however, the invention is not limited thereto.

[0045] In some specific embodiments, the molding device 102 can be in an open state and a closed state. When the molding device 102 is in the closed state, the first mold 102c engages with the second mold 102d. Figure 4 A schematic perspective view of the molding apparatus 102 in the closed state is shown, and Figure 5 A schematic cross-sectional view of the molding apparatus 102 in the closed state is shown.

[0046] In some specific embodiments, reference is made to Figure 4 and Figure 5When the molding device 102 is in the closed state, the mold cavity 102i is defined by the first mold 120c and the second mold 102d. In some embodiments, the mold cavity 102i is configured to receive a flowable mixture from the injector 101a through an opening 102h of the second element 102s. When the molding device 102 is in the closed state, the mold cavity 102i can only be accessed through the feed port 102j. When the molding device 102 is in the open state, the mold cavity 102i can be accessed through the gap (not shown) between the first mold 102c and the second mold 102d. In some embodiments, the molding device 102 includes a feed port 102j that communicates with the mold cavity 102i. In some embodiments, the feed port 102j is located at and penetrates the first mold 102c. In some embodiments, when the second element 102s is positioned above the molding apparatus 102, the opening 102h is aligned with the feed inlet 102j, allowing the flowable mixture to flow from the ejector 101a into the mold cavity 102i through the opening 102h and the feed inlet 102j. In some embodiments, when viewed from a top view of the second element 102s positioned above the molding apparatus 102, the opening 102h overlaps with the feed inlet 102j.

[0047] In some embodiments, the forming device 102 is arranged on a carrier (not shown) and is movable with the carrier. In some embodiments, a plurality of forming devices 102 are arranged on the carrier, and the forming devices 102 are arranged in a straight line, row, column, arc, curve, or any other suitable configuration. In some embodiments, the carrier is rotatable.

[0048] In some specific embodiments, refer back to Figure 1 , Figure 2 and Figure 3 The support device 105 further includes a third element 101g connected to the injection unit 101, and a second element 102s configured to receive the first element 101b and the third element 101g. In some specific embodiments, both the first element 101b and the third element 101g are configured to be received by a first portion 102x and a second portion 102y of the protrusion 102f.

[0049] In some embodiments, the third element 101g is arranged adjacent to the ejector 101a. In some embodiments, the third element 101g is connected to the ejection unit 101. In some embodiments, the ejector 101a is arranged between the first element 101b and the third element 101g. The third element 101g may engage with the second element 102s. The third element 101g may extend toward and retract from the second element 102s. In some embodiments, the third element 101g may extend / retract vertically in a second direction as indicated by arrow B.

[0050] In some embodiments, the third element 101g can extend / retract along the track 101f via a motor (not shown). In some embodiments, the track 101f is arranged between the flowable mixture supply unit 103 and the third element 101g. In some embodiments, the third element 101g and the first element 101b can extend / retract independently of each other. The third element 101g and the first element 101b can be displaced relative to each other. In some embodiments, the third element 101g and the ejector 101a can extend / retract independently of each other. The third element 101g and the ejector 101a can be displaced relative to each other. In some embodiments, the third element 101g and the first element 101b can be displaced individually or together. In some embodiments, the third element 101g is T-shaped. In some embodiments, the third element 101g includes a protrusion 101h capable of engaging with the second element 102s. In some embodiments, the protrusion 101h can engage with the groove 102e. In some embodiments, the protruding portion 101h of the third element 101g is arranged at the distal end of the flowable mixture supply unit 103. In some embodiments, the configuration of the third element 101g is similar to or different from the configuration of the first element 101b.

[0051] In this invention, a first injection molding method 200 is also disclosed. The first injection molding method 200 includes a number of operations, and the description and illustrations are not intended to be a limitation on the order of operations. Figure 6 This is a specific embodiment of the first injection molding method 200. In some specific embodiments, the first injection molding method 200 includes multiple operations (201 to 212). Figures 7 to 18 This is a schematic cross-sectional view illustrating many stages of the first injection molding method according to some specific embodiments of the present invention. In some specific embodiments, the first injection molding method 200 comprises, as... Figures 1 to 5 The first injection molding system 100 shown and discussed above is implemented.

[0052] In operation 201, please refer to Figure 7A first injection molding system 100 is provided, comprising an injection unit 101, a molding device 102, and a support device 105. In some embodiments, the first injection molding system 100 includes the injection unit 101, molding device 102, and support device 105 as described above. The molding device 102 is in a closed state. The opening 102h of the second element 102s is aligned with the feed port 102j of the molding device 102, allowing entry into the mold cavity 102i through the opening 102h and the feed port 102j. In some embodiments, the molding device 102 is arranged on a carrier (not shown) and is movable with the carrier. In some embodiments, several molding devices 102 are arranged on the carrier.

[0053] In operation 202, the protrusion 101d of the first element 101b of the support device 105 is aligned with the groove 102e of the second element 102s of the support device 105. In operation 203, the outlet 101c is aligned with the recess 102g of the second element 102s configured to receive the outlet 101c. In some embodiments, the alignment of the protrusion 101d of the first element 101b with the groove 102e of the second element 102s and the alignment of the outlet 101c with the recess 102g are performed simultaneously. In some embodiments, the forming device 102 is arranged below the second element 102s during the alignment of the protrusion 101d of the first element 101b with the groove 102e of the second element 102s.

[0054] In some specific embodiments, the ejector 101a and the first element 101b are vertically displaced along arrows A and B, respectively, so as to be horizontally aligned with the groove 102g and the trench 102e, respectively. Figure 7 As shown. In some embodiments, the ejector 101a moves upward or downward to align the outlet 101c with the groove 102g horizontally. In some embodiments, the first element 101b moves upward or downward to align the protrusion 101d with the groove 102e horizontally. Alternatively or simultaneously, the second element 102s shifts along arrow C and / or arrow D to align horizontally with the protrusion 101d of the first element 101b and the outlet 101c or end of the ejector 101a. In some embodiments, the second element 102s moves upward, downward, forward, or backward to align the groove 102e with the protrusion 101d horizontally and the groove 102g with the outlet 101c or end of the ejector 101a horizontally.

[0055] In some embodiments, the protrusion 101h of the third element 101g is aligned with the groove 102e of the second element 102s. In some embodiments, the process of aligning the protrusion 101h of the third element 101g with the groove 102e of the second element 102s is similar to the process of aligning the protrusion 101d of the first element 101b with the groove 102e of the second element 102s, and for the sake of brevity, repeated descriptions are omitted. In some embodiments, the alignment of the protrusion 101d of the first element 101b with the groove 102e of the second element 102s and the alignment of the protrusion 101h of the third element 101g with the groove 102e are performed simultaneously.

[0056] In operation 204, refer to Figure 8 and Figure 9 The second element 102s is shifted toward the injection unit 101 so that the protrusion 101d of the first element 101b slides along the groove 102e of the second element 102s. In operation 205, the outlet 101c slides into the groove 102g.

[0057] In some specific embodiments, after horizontal alignment, the second element 102s moves along arrow E toward the ejection unit 101, such as... Figure 8 As shown. Or, after horizontal alignment, as... Figure 8 As shown, the injection unit 101 moves toward the second element 102s along arrow L. In some specific embodiments, after the second element 102s and the injection unit 101 are horizontally aligned, the molding apparatus 102 moves toward the second element 102s and the injection unit 101. In other words, the molding apparatus 102 is movable, while the injection unit 101 and the second element 102s are fixed relative to the molding apparatus 102.

[0058] Figure 9 for Figure 8 A schematic cross-sectional view of the first injection molding system 100. In some embodiments, the protrusion 101d of the first element 101b slides along the groove 102e, and the outlet 101c or end of the ejector 101a slides along the groove 102g. In some embodiments, the protrusion 101h of the third element 101g slides along the groove 102e. Figure 9 As shown, the protrusion 102f is configured opposite to the protrusion 101d of the first element 101b. In some specific embodiments, the protrusion 101d of the first element 101b and the protrusion 101h of the third element 101g are both arranged between the first portion 102x and the second portion 102y of the protrusion 102f.

[0059] In some embodiments, during operations 204 and 205, the first element 101b, the third element 101g, and the ejector 101a do not contact the second element 102s. In some embodiments, the outlet 101c or end of the ejector 101a is surrounded by a groove 102g and does not contact the step 102k within the groove 102g. In some embodiments, the first distance D1 between the bottom surface of the protrusion 101d and the second element 102s is substantially greater than the second distance D2 between the outlet 101c and the bottom surface of the groove 102g.

[0060] In operation 206, the injection unit 101 and the support device 105 are repositioned to be positioned above the molding device 102. See also, in some specific embodiments... Figure 10 After the ejector 101a is aligned with the opening 102h and the ejector 101a, the first element 101b moves toward the molding device 102 along arrow F, as... Figure 10 As shown. In some embodiments, the molding device 102 is moved until the support device 105 overlaps with the molding device 102, and the ejector 101a is perpendicularly aligned with the feed port 102j of the molding device 102. In some embodiments, the molding device 102 is moved by rotating the carrier (not shown) that carries the molding device 102.

[0061] In operation 207, refer to Figure 11 The outlet 101c extends toward the forming device 102 so that the outlet 101c engages with the opening 102h.

[0062] In some specific embodiments, after the ejector 101a is aligned with the opening 102h, as... Figure 11 As shown, the ejector 101a and the first element 101b move along arrow F toward the molding apparatus 102 until the outlet 101c of the ejector 101a contacts the second element 102s. In some embodiments, the outlet 101c engages with the opening 102h and contacts the step 102k. In some embodiments, the ejector 101a and the first element 101b move together. When the outlet 101c of the ejector 101a contacts the second element 102s, the entire first element 101b still does not contact the second element 102s, as... Figure 11 As shown. In some specific embodiments, the third element 101g is moved together in operation 207. Figure 11 (Not shown in the image) and the first element 101b. In some embodiments, the contact between the second element 102s and the outlet 101c is sensed by a second sensor 102m disposed within the groove 102g. In some embodiments, the contact between the second element 102s and the outlet 101c is continuously sensed.

[0063] In operation 208, refer to Figure 12 The first element 101b is displaced away from the second element 102s, while the first element 101b is received by the second element 102s. In some specific embodiments, the protrusion 101d of the first element 101b is moved to abut against the protrusion 102f of the second element 102s, while the protrusion 101d of the first element 101b is received by the groove 102e of the second element 102s.

[0064] In some specific embodiments, after the outlet 101c contacts the second element 102s, such as Figure 12 As shown, the first element 101b moves away from the second element 102s along arrow G until the protrusion 101d of the first element 101b contacts the protrusion 102f of the second element 102s. In some specific embodiments, the ejector 101a remains stationary as the first element 101b moves upward, as... Figure 12 As shown. As a result, the first element 101b engages with the second element 102s. In some embodiments, the contact between the second element 102s and the first element 101b is sensed by a first sensor 102l disposed on the protrusion 102f and within the groove 102e. In some embodiments, the contact between the second element 102s and the first element 101b is sensed by the first sensor 102l. In some embodiments, the first sensor 102l senses the contact between the protrusion 102f and the protrusion 101d of the first element 101b. In some embodiments, the contact between the second element 102s and the first element 101b is sensed continuously.

[0065] In some specific embodiments, the third element 101g is moved together in operation 208. Figure 12 Not shown in the image. Figure 8 (shown in the image) and the first element 101b. In some specific embodiments, the protruding portion 101h of the third element 101g (shown in the image) Figure 12 Not shown in the image. Figure 8 (As shown in the diagram) the third element 101g moves to abut against the protrusion 102f of the second element 102s, while the protrusion 101h of the third element 101g is received by the groove 102e of the second element 102s. In some embodiments, the contact between the protrusion 101h of the third element 101g and the protrusion 102f of the second element 102s is sensed by the first sensor 102l.

[0066] See operation 209. Figure 13 The flowable mixture 104 is injected into the mold cavity 102i of the molding device 102.

[0067] In some specific embodiments, after the protruding portion 101d contacts the protrusion 102f, the flowable mixture 104 is injected into the mold cavity 102i, such as... Figure 13 As shown. The flowable mixture 104 is discharged from the outlet 101c of the injector 101a, through the opening 102h and the inlet 102j of the molding device 102, into the mold cavity 102i. In some embodiments, the flowable mixture 104 is supplied by a flowable mixture supply unit 103 connected to the injector 101a. In some embodiments, the composition of the flowable mixture 104 is similar to that of the flowable mixture prepared by the supply unit 103 described above; therefore, for the sake of brevity, repeated descriptions are omitted.

[0068] In some embodiments, during the injection of the flowable mixture 104, the outlet 101c engages with the opening 102h and contacts the step 102k, and the protrusion 101d of the first element 101b abuts against the protrusion 102f of the second element 102s. During the injection of the flowable mixture 104 into the mold cavity 102i via the ejector 101a, an injection force I is generated toward the second element 102s and / or the molding device 102. In some embodiments, the injection force I acts on the second element 102s and / or the molding device 102 to push the second element 102s and / or the molding device 102 away from the injection unit 101, and thus generates a reaction force C from the protrusion 102f acting on the protrusion 101d. During the injection of the flowable mixture 104, the protrusion 101d abuts against the protrusion 102f. Therefore, it is essential to ensure the engagement of the first element 101b and the second element 102s, as well as the engagement of the outlet 101c and the inlet 102j. This minimizes or even prevents the flow of the flowable mixture 104 out of the mold cavity 102i.

[0069] In operation 210, refer to Figure 14 After the flowable material 104 is ejected, the first element 101b is displaced toward the second element 102s. In some specific embodiments, after the flowable material 104 is ejected, the protrusion 101d of the first element 101b disengages from the protrusion 102f of the second element 102s, while the protrusion 101d of the first element 101b is received by the groove 102e of the second element 102s.

[0070] In some specific embodiments, after the flowable mixture 104 is ejected, the first element 101b moves along the path shown in the figure. Figure 14 Arrow H indicates that the first element 101b is disengaged from the second element 102s. In some embodiments, the protrusion 101d moves away from the protrusion 102f. In some embodiments, the first element 101b moves toward the molding apparatus 102 to disengage from the protrusion 102f. In some embodiments, the ejector 101a remains stationary as the first element 101b moves downwards. Figure 14As shown. In some specific embodiments, the first sensor 102l senses the separation of the protrusion 102f from the protrusion 101d of the first element 101b.

[0071] In some specific embodiments, the third element 101g is moved together in operation 210. Figure 14 Not shown in the image. Figure 8 (shown in the diagram) and the first element 101b. In some specific embodiments, after the flowable material 104 is ejected, the protrusion 101h of the third element 101g (shown in the diagram) is... Figure 14 Not shown in the image. Figure 8 (As shown in the figure) it shifts toward the second element 102s. In some specific embodiments, the separation of the protrusion 101h of the third element 101g from the protrusion 102f of the second element 102s is sensed by the first sensor 102l.

[0072] In operation 211, refer to Figure 15 The ejector 101a is displaced away from the molding apparatus 102. In some specific embodiments, after the flowable material 104 is ejected, the outlet 101c retracts from the molding apparatus 102.

[0073] In some specific embodiments, after the first element 101b is detached from the second element 102s, such as Figure 15 As shown, the ejector 101a moves away from the molding apparatus 102 along arrow J until the outlet 101c of the ejector 101a no longer contacts the second element 102s. In some embodiments, the separation of the ejector 101a and the groove 102g is sensed by the second sensor 102m. In some embodiments, the ejector 101a and the first element 101b move away from the molding apparatus 102 along arrow J. In some embodiments, the ejector 101a and the first element 101b move together. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g move together.

[0074] In operation 212, refer to Figure 16 and Figure 17 The second element 102s and the molding device 102 are moved away from the injection unit 101, or the injection unit 101 is moved away from the molding device 102.

[0075] In some embodiments, after the first element 101b and the ejector 101a disengage from the second element 102s, the second element 102s and the molding device 102 are displaced away from the injection unit 101. Alternatively, after the first element 101b and the ejector 101a disengage from the second element 102s, the injection unit 101 is displaced away from the molding device 102. In some embodiments, the second element 102s and the molding device 102 move horizontally away from the first element 101b and the ejector 101a along arrow K, such as... Figure 16 As shown. Alternatively, the first element 101b and the ejector 101a move horizontally along arrow M away from the second element 102s and the molding device 102, as shown. Figure 16 As shown. Figure 17 For example, after the second element 102s is moved away from the ejection unit 101, the ejection unit 101 and the second element 102s move away from each other.

[0076] In operation 212, refer to Figure 18 The molding device 102 is moved away from the second element 102s, or the second element 102s is moved away from the molding device 102.

[0077] In some embodiments, after the molding device 102 disengages from the second element 102s, the molding device 102 shifts away from the second element 102s. In some embodiments, the molding device 102 shifts away from the second element 102s by rotating a carrier (not shown) held or arranged below the molding device 102. Alternatively, after the second element 102s disengages from the molding device 102, the injection unit 101, the molding device 102, and the second element 102s separate from each other. In some embodiments, the molding device 102 moves horizontally away from the second element 102s. Alternatively, the second element 102s moves horizontally away from the molding device 102. Figure 18 For example, after the molding device 102 is moved away from the second element 102s, the second element 102s and the molding device 102 move away from each other.

[0078] Figure 19 A schematic perspective view illustrating a second injection molding system 300 according to a specific embodiment of the present invention. In some embodiments, reference is made to... Figure 19The second injection molding system 300 includes an injection unit 101, a molding device 102, and a support device 105 disposed between the injection unit 101 and the molding device 102. In some embodiments, the second injection molding system 300 further includes a flowable mixture supply unit 103 communicatively connected to the injection unit 101. In some embodiments, the flowable mixture supply unit 103 is configured to generate and supply a flowable mixture to the injection unit 101. In some embodiments, the flowable mixture includes polymeric materials such as ethylene vinyl acetate (EVA), styrene-ethylene-butene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the flowable mixture includes recyclable materials. In some embodiments, the flowable mixture further includes a foaming agent.

[0079] In some specific embodiments, the flowable mixture supply unit 103 of the second injection molding system 300 includes an extruder (not shown) for converting polymer material into a molten state, and a mixer (not shown) for mixing a foaming agent into the polymer material. The polymer material can flow from the extruder into the mixer.

[0080] In some embodiments, the injection unit 101 includes a plurality of ejectors 101a disposed between a first element 101b and a third element 101g of the support device 105. In some embodiments, the support device 105 supports the ejectors 101a. In some embodiments, each ejector 101a is configured to receive a flowable mixture from a flowable mixture supply unit 103 and discharge the flowable mixture from its outlet 101c. In some embodiments, each ejector 101a may communicate with a mixer or a flowable mixture supply unit 103. In some embodiments, the flowable mixture is discharged from the ejector 101a into the molding device 102. Each ejector 101a may engage with a second element 102s of the support device 105. In some embodiments, all ejectors 101a are engaged with the second element 102s. In some embodiments, each ejector 101a may extend / retract vertically in a first direction as indicated by arrow A. In some embodiments, the ejectors 101a can extend / retract independently of each other. In some embodiments, each ejector 101a can extend / retract via a hydraulic mechanism 101e. In some embodiments, the movement of each ejector 101a is actuated and controlled by a hydraulic mechanism 101e.

[0081] In some embodiments, the support device 105 is configured to facilitate engagement between the injection unit 101 and the molding device 102. In some embodiments, the support device 105 includes a first element 101b, a third element 101g disposed near the ejector 101a, and a second element 102s disposed on the molding device 102. In some embodiments, both the first element 101b and the third element 101g are engageable with the second element 102s. The first element 101b and the third element 101g are respectively extendable toward and retractable from the molding device 102. In some embodiments, each of the first element 101b and the third element 101g is vertically extendable / retractable in a second direction as indicated by arrow B. In some embodiments, each of the first element 101b and the third element 101g can extend / retract along a track 101f via a motor (not shown) or the like. In some embodiments, each of the first element 101b and the third element 101g moves along the track 101f, and the movement of each of the first element 101b and the third element 101g is actuated and controlled by a motor. In some embodiments, the first direction and the second direction are parallel.

[0082] In some embodiments, the ejector 101a, the first element 101b, and the third element 101g extend / retract independently of each other. The ejector 101a, the first element 101b, and the third element 101g may be displaced relative to each other. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g may be displaced individually or together. In some embodiments, all ejectors 101a move together with each other, and the first element 101b and the third element 101g move together with each other. In some embodiments, each of the first element 101b and the third element 101g is T-shaped. In some embodiments, the first element 101b includes a protrusion 101d that engages with the second element 102s, and the third element 101g includes a protrusion 101h that engages with the second element 102s.

[0083] In some embodiments, the injection unit 101 is arranged above the molding apparatus 102. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g are arranged above the molding apparatus 102. In some embodiments, the molding apparatus 102 is configured to receive a flowable mixture discharged from the ejector 101a through the outlet 101c.

[0084] In some embodiments, the molding apparatus 102 includes a first mold 102c and a second mold 102d that can engage with the first mold 102c. In some embodiments, the first mold 102c is an upper mold, and the second mold 102d is a lower mold. In some embodiments, a second element 102s can engage with the first mold 102c. In some embodiments, the molding apparatus 102 is arranged on a carrier (not shown) and is movable with the carrier. In some embodiments, a plurality of molding apparatuses 102 are arranged on the carrier, and the molding apparatuses are arranged in a straight line, row, column, arc, curve, or any other suitable configuration. In some embodiments, the carrier is rotatable.

[0085] Figure 20 A schematic perspective view of the second element 102s is shown, and Figure 21 A schematic top view illustrating the second element 102s is shown. In some specific embodiments, refer to... Figures 19 to 21 The support device 105 includes a second element 102s that can engage with the first element 101b and the third element 101g. In some embodiments, the second element 102s is arranged on the molding device 102. In some embodiments, the second element 102s includes a groove 102e defined by a protrusion 102f and a groove 102o defined by a protrusion 102p.

[0086] In some embodiments, the grooves 102e, 102o and the protrusions 102f, 102p are all laterally elongated. The groove 102e is configured to receive the protrusion 101d of the first element 101b in the support device 105. The groove 102o is configured to receive the protrusion 101f of the third element 101g in the support device 105. In some embodiments, the protrusion 101d of the first element 101b is slidable within and along the groove 102e of the second element 102s, and the protrusion 101f of the third element 101g is slidable within and along the groove 102o of the second element 102s. In some embodiments, the length L1 of the groove 102e and the length L2 of the groove 102o are each equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the groove 102e of the second element 102s is greater than the thickness T1 of the protrusion 101d of the first element 101b, and the height H2 of the groove 102o of the second element 102s is greater than the thickness T2 of the protrusion 101h of the third element 101g. In some embodiments, each of the protrusion 101d of the first element 101b and the protrusion 101h of the third element 101g is T-shaped and configured to be received in the grooves 102e and 102o, respectively.

[0087] In some embodiments, the molding apparatus 102 includes a groove 102g configured to receive an outlet 101e. In some embodiments, the groove 102g is disposed on and extends laterally along the second element 102s. In some embodiments, the groove 102g is parallel to protrusions 102f and 102p. The groove 102g is configured to receive an outlet 101c of the injection unit 101 or an end of the ejector 101a. The outlet 101c or end of the ejector 101a may be within and slide along the groove 102g. In some embodiments, an opening 102h is disposed within the groove 102g. In some embodiments, the opening 102h extends through the second element 102s. The outlet 101c or end of the ejector 101a may be received by the opening 102h. The outlet 101c or end of the ejector 101a may be movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is significantly greater than the total width W2 of the outlets 101c of the ejector 101a. In some embodiments, all outlets 101c of the ejector 101a are received by the opening 102h.

[0088] In some embodiments, a first sensor 102l is disposed within a groove 102e and configured to sense the contact between the protrusion 101d and the groove 102e, and a third sensor 102q is disposed within a groove 102o and configured to sense the contact between the protrusion 101h and the groove 102o. In some embodiments, the first sensor 102l is disposed at the middle of the groove 102e, and the third sensor 102q is disposed at the middle of the groove 102o. The first sensor 102l and the third sensor 102q are not limited to any particular type, as long as they can sense pressure and provide pressure information.

[0089] In some embodiments, a plurality of first sensors 102l are arranged within a groove 102e, and the first sensors 102l are configured to sense the position and contact between the protrusion 101d and the groove 102e. In some embodiments, a plurality of third sensors 102q are arranged within a groove 102o, and the third sensors 102q are all configured to sense the position and contact between the protrusion 101h and the groove 102o. The number and position of the plurality of third sensors 102q are not particularly limited; for example, they can be configured at any position of the protrusion 102p and within the groove 102o; however, the invention is not limited thereto.

[0090] In some embodiments, a step 102k is formed within a groove 102g and adjacent to an opening 102h. In some embodiments, a second sensor 102m is disposed within the groove 102g and configured to sense contact between the outlet 101c and the groove 102g.

[0091] In some embodiments, the second sensor 102m is arranged within the opening 102h. The second sensor 102m is not limited to any particular type, as long as it can sense pressure and provide pressure information. In some embodiments, multiple second sensors 102m are arranged within the opening 102h, and the second sensors 102m are configured to sense the position and contact between the outlet 101c and the forming device 102. The number and position of the multiple second sensors 102m are not particularly limited; for example, they can be configured at any position in the opening 102h; however, the invention is not limited thereto.

[0092] In some specific embodiments, the molding device 102 can be in an open state and a closed state. When the molding device 102 is in the closed state, the first mold 102c engages with the second mold 102d. Figure 22 A schematic perspective view of the molding apparatus 102 in the closed state is shown, and Figure 23 A schematic cross-sectional view of the molding apparatus 102 in the closed state is shown. In some embodiments, when the molding apparatus 102 is in the closed state, the mold cavity 102i is defined by a first mold 102c and a second mold 102d. In some embodiments, the first mold 102c and the second mold 102d define more than one mold cavity 102i. In some embodiments, the mold cavities 102i are isolated from each other. In some embodiments, the mold cavity 102i is configured to receive a flowable mixture from the injector 101a through an opening 102h of the second element 102s and a feed port 102j. When the molding apparatus 102 is in the closed state, the mold cavity 102i can only be accessed through the feed port 102j. When the molding apparatus 102 is in the open state, the mold cavity 102i can be accessed through the gap (not shown) between the first mold 102c and the second mold 102d. In some embodiments, the molding apparatus 102 includes a feed port 102j that communicates with the mold cavity 102i. In some embodiments, the feed inlet 102j is arranged at and penetrates the first mold 102c. In some embodiments, the molding apparatus 102 includes multiple feed inlets 102j, such as... Figure 22 and Figure 23 As shown. The feed inlets 102j correspond to the mold cavities 102i. In some embodiments, when the second element 102s is arranged above the molding device 102, the opening 102h is aligned with the feed inlets 102j, allowing the flowable mixture to flow from the injector 101a into the mold cavity 102i through the openings 102h and the feed inlets 102j. In some embodiments, the opening 102h is arranged above all the feed inlets 102j. In some embodiments, when viewed from a top view of the second element 102s arranged above the molding device 102, the opening 102h overlaps with the feed inlets 102j.

[0093] In this invention, a second injection molding method 400 is also disclosed. The second injection molding method 400 includes a number of operations, and the description and illustrations are not intended to be a limitation on the order of operations. Figure 24 This is a specific embodiment of the second injection molding method 400. In some specific embodiments, the second injection molding method 400 includes multiple operations (401 to 413). Figures 25 to 36 This is a schematic cross-sectional view illustrating many stages of the second injection molding method according to some specific embodiments of the present invention. In some specific embodiments, the second injection molding method 400 comprises, as... Figures 19 to 23 The second injection molding system 300 shown and discussed above is implemented.

[0094] In operation 401, please refer to Figure 25 A second injection molding system 300 is provided, comprising an injection unit 101, a molding device 102, and a support device 105. In some specific embodiments, the second injection molding system 300 includes the injection unit 101, molding device 102, and support device 105 as described above. The molding device 102 is in a closed state. The opening 102h of the second element 102s is aligned with a plurality of feed ports 102j of the molding device 102, allowing entry into the mold cavity 102i through the opening 102h and the feed ports 102j.

[0095] In operation 402, the protrusion 101d of the first element 101b of the support device 105 is aligned with the first groove 102e of the second element 102s of the support device 105. In operation 403, the protrusion 101h of the third element 101g of the support device is aligned with the second groove 102e of the second element 102s. In operation 404, a plurality of outlets 101c are aligned with the recess 102g of the second element 102s configured to receive the outlets 101c. In some specific embodiments, the alignment of the protrusion 101d of the first element 101b with the first groove 102e of the second element 102s, the alignment of the protrusion 101h of the third element 101g with the second groove 102e of the second element 102s, and the alignment of the outlets 101c with the recess 102g are all performed simultaneously.

[0096] In some specific embodiments, the ejector 101a is vertically displaced along arrow A to be horizontally aligned with the groove 102g, and the first element 101b and the third element 101g are vertically displaced along arrow B to be horizontally aligned with the first groove 102e and the second groove 102e, respectively. Figure 25As shown. In some embodiments, the ejector 101a moves upward or downward to be horizontally aligned with the groove 102g. In some embodiments, the first element 101b and the third element 101g move upward or downward to be horizontally aligned with the first groove 102e and the second groove 102e, respectively. Alternatively or simultaneously, the forming device 102 shifts along arrow C and / or arrow D to be horizontally aligned with the protrusion 101d of the first element 101b, the protrusion 101h of the third element 101g, and the outlet 101c or end of the ejector 101a. In some embodiments, the forming device 102 moves upward, downward, forward, and / or backward to align the first groove 102e horizontally with the protrusion 101d, the second groove 102e horizontally with the protrusion 101h, and the groove 102g horizontally with the outlet 101c or end of the ejector 101a.

[0097] In operation 405, refer to Figure 26 and Figure 27 The ejection unit 101 is shifted so that the protrusion 101d of the first element 101b slides along the first groove 102e of the second element 102s, and the protrusion 101h of the third element 101g slides along the second groove 102e of the second element 102s. In operation 406, the outlet 101c slides into the groove 102g.

[0098] In some specific embodiments, after horizontal alignment, the second element 102s moves along arrow E toward the ejection unit 101, such as... Figure 26 As shown. Or, after horizontal alignment, as... Figure 26 As shown, the ejection unit 101 moves along arrow L toward the second element 102s. Figure 27 for Figure 26 A schematic cross-sectional view of the second injection molding system 300. In some embodiments, the first element 101b slides along the first groove 102e, the third element 101g slides along the second groove 102e, and the outlet 101c or end of the ejector 101a slides along the groove 102g. In some embodiments, the second element 102s is moved until the first element 101b is arranged within the first groove 102e, the third element 101g is arranged within the second groove 102e, and the outlet 101c or end of the ejector 101a is perpendicularly aligned with the opening 102h. Figure 27As shown, protrusion 102f is arranged opposite to the protrusion 101d of the first element 101b, and protrusion 102p is arranged opposite to the protrusion 101h of the third element 101g. The first element 101b, the third element 101g, and the ejector 101a do not contact the second element 102s. In some embodiments, the outlet 101c of the ejector 101a is aligned with the opening 102h. In some embodiments, the distance D3 between the bottom surface of the protrusion 101h and the second element 102s is substantially greater than the distance D4 between the end of the outlet 101c and the top surface of the forming device 102.

[0099] In operation 407, the molding device 102 is moved toward the injection unit 101 and the support device 105 to be positioned below the support device 105. In some specific embodiments, see [link to specific embodiments]. Figure 28 After the ejector 101a is aligned with the opening 102h, the ejector 101a and the first element 101b move toward the molding device 102 along arrow F, as shown. Figure 28 As shown. In some embodiments, the molding device 102 is moved until the support device 105 covers the molding device 102, and the ejector 101a is perpendicularly aligned with the inlet 102j of the molding device 102. In some embodiments, the molding device 102 is moved, for example, by rotating a carrier (not shown) arranged under the molding device 102. In some embodiments, the molding device 102 is moved until the outlet 101c or end of the ejector 101a is perpendicularly aligned with the inlet 102j of the molding device 102.

[0100] In operation 408, refer to Figure 29 The outlet 101c extends toward the molding device 102 so that the outlet 101c engages with the molding device 102.

[0101] In some specific embodiments, after the ejector 101a is aligned with the opening 102h, as... Figure 28 As shown, the ejector 101a, the first element 101b, and the third element 101g move along arrow F toward the molding apparatus 102 until the outlet 101c of the ejector 101a contacts the second element 102s. In some embodiments, the outlet 101c contacts the first mold 102c. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g move together. When the outlet 101c of the ejector 101a contacts the first mold 102c, the entire first element 101b and the entire third element 101g still do not contact the second element 102s, as... Figure 29As shown. In some embodiments, the contact between the molding device 102 and the outlet 101c is sensed by a second sensor 102m disposed within the groove 102g. In some embodiments, the contact between the molding device 102 and the outlet 101c is sensed continuously.

[0102] In operation 409, refer to Figure 30 The first element 101b and the third element 101g are shifted away from the second element 102s, while the first element 101b and the third element 101g are received by the second element 102s. In some specific embodiments, the protrusion 101d of the first element 101b is moved to abut against the protrusion 102f of the second element 102s, while the protrusion 101d of the first element 101b is received by the first groove 102e of the second element 102s, and when the protrusion 101h of the third element 101g is received by the second groove 102e of the second element 102s, the protrusion 101h of the third element 101g is moved to abut against the protrusion 102p of the second element 102s.

[0103] In some specific embodiments, after the outlet 101c contacts the forming device 102, the first element 101b and the third element 101g move away from the second element 102s along arrow G, such as... Figure 30 As shown, until the protrusion 101d of the first element 101b and the protrusion 101h of the third element 101g contact the protrusions 102f and 102p of the second element 102s, respectively. In some specific embodiments, when the first element 101b and the third element 101g move upward, the ejector 101a remains stationary, as... Figure 30 As shown, both the first element 101b and the third element 101g are coupled to the second element 102s.

[0104] In some embodiments, the contact between the second element 102s and the first element 101b is sensed by a first sensor 102l. In some embodiments, the first sensor 102l senses the contact between the protrusion 102f and the protrusion 101d of the first element 101b. In some embodiments, the contact between the second element 102s and the first element 101b is sensed continuously. In some embodiments, the contact between the second element 102s and the third element 101g is sensed by a third sensor 102q disposed on the protrusion 102p and within the second groove 102e. In some embodiments, the contact between the second element 102s and the third element 101g is sensed by the third sensor 102q. In some embodiments, the third sensor 102q senses the contact between the protrusion 102p and the protrusion 101h of the third element 101g. In some embodiments, the contact between the second element 102s and the third element 101g is sensed continuously.

[0105] In operation 410, see Figure 31 The flowable mixture 104 is injected into the mold cavity 102i of the molding device 102.

[0106] In some specific embodiments, after the protrusion 101d contacts the protrusion 102f and the protrusion 101h contacts the protrusion 102p, the flowable mixture 104 is injected into the mold cavity 102i, such as... Figure 31 As shown. The flowable mixture 104 is discharged from the outlet 101c of the injector 101a through the opening 102h and the inlet 102j into the mold cavity 102i. In some embodiments, the flowable mixture 104 is supplied by a flowable mixture supply unit 103 connected to the injector 101a. In some embodiments, the composition of the flowable mixture 104 is similar to that of the flowable mixture prepared by the supply unit 103 described above; therefore, for the sake of brevity, repeated descriptions are omitted.

[0107] In some embodiments, during the injection of the flowable mixture 104, the outlet 101c engages with the molding device 102, the protrusion 101d of the first element 101b abuts against the protrusion 102f of the second element 102s, and the protrusion 101h of the third element 101g abuts against the protrusion 102p of the fourth element 102o. During the injection of the flowable mixture 104 into the mold cavity 102i via the ejector 101a, an injection force I is generated toward the molding device 102. In some embodiments, the injection force I acts on the molding device 102 to push it away from the injection unit 101, and thus generates a reaction force C from the protrusion 102f acting on the protrusion 101d. During the injection of the flowable mixture 104, the protrusion 101d abuts against the protrusion 102f and the protrusion 101h abuts against the protrusion 102p. Therefore, it is essential to ensure the engagement of the first element 101b and the second element 102s, the engagement of the third element 101g and the second element 102s, and the engagement of the outlet 101c and the inlet 102j. This minimizes or even prevents the flow of the flowable mixture 104 out of the mold cavity 102i.

[0108] In operation 411, refer to Figure 32After the flowable material 104 is ejected, the first element 101b and the third element 101g are displaced toward the second element 102s. In some specific embodiments, after the flowable material 104 is ejected, the protrusion 101d of the first element 101b disengages from the protrusion 102f of the second element 102s and the protrusion 101h of the third element 101g disengages from the protrusion 102p of the second element 102s, while the protrusion 101d of the first element 101b is received by the first groove 102e of the second element 102s and the protrusion 101h of the third element 101g is received by the second groove 102e of the second element 102s.

[0109] In some specific embodiments, after the flowable mixture 104 is ejected, the first element 101b and the third element 101g move along the path shown in the figure. Figure 32 Arrow H indicates that the first element 101b is disengaged from the second element 102s. In some embodiments, protrusion 101d moves away from protrusion 102f, and protrusion 101h moves away from protrusion 102p. In some embodiments, the first element 101b moves toward the molding device 102 to disengage from protrusion 102f, and the third element 101g moves toward the molding device 102 to disengage from protrusion 102p. In some embodiments, the ejector 101a remains stationary as the first element 101b and the third element 101g move downwards. Figure 32 As shown. In some specific embodiments, the separation of the protrusion 102f from the protrusion 101d of the first element 101b is sensed by the first sensor 102l, and the separation of the protrusion 102p from the protrusion 101h of the third element 101g is sensed by the third sensor 102q.

[0110] In operation 412, refer to Figure 33 The ejector 101a is displaced away from the molding apparatus 102. In some specific embodiments, after the flowable material 104 is ejected, the outlet 101c retracts from the molding apparatus 102.

[0111] In some specific embodiments, after the first element 101b and the third element 101g are detached from the second element 102s, as... Figure 33As shown, the ejector 101a moves away from the molding device 102 along arrow J until the outlet 101c of the ejector 101a no longer contacts the molding device 102. In some embodiments, the separation of the ejector 101a and the molding device 102 is sensed by a second sensor 102m. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g move away from the molding device 102 along arrow J. In some embodiments, the ejector 101a, the first element 101b, and the third element 101g move together.

[0112] In operation 413, refer to Figure 34 and Figure 35 The molding device 102 is moved away from the injection unit 101, or the injection unit 101 is moved away from the molding device 102.

[0113] In some embodiments, after the ejector 101a, the first element 101b, and the third element 101g disengage from the second element 102s, the molding apparatus 102 moves away from the injection unit 101. Alternatively, after the ejector 101a, the first element 101b, and the third element 101g disengage from the second element 102s, the injection unit 101 moves away from the second element 102s. In some embodiments, the molding apparatus 102 moves horizontally along arrow K away from the ejector 101a, the first element 101b, and the third element 101g, as... Figure 34 As shown. Alternatively, the ejector 101a, the first element 101b, and the third element 101g move horizontally along arrow M away from the second element 102s and the molding device 102, as shown. Figure 34 As shown. Figure 35 For example, after the second element 102s is moved away from the ejection unit 101, the ejection unit 101 and the second element 102s move away from each other.

[0114] In some embodiments, after the molding device 102 disengages from the second element 102s, the molding device 102 moves away from the second element 102s. In some embodiments, the molding device 102 moves horizontally away from the second element 102s along arrow K, such as... Figure 35 As shown. In some embodiments, the molding device 102 is displaced away from the second element 102s by rotating a carrier (not shown) arranged below the molding device 102, and another molding device (not shown) may be arranged below the second element 102s. Alternatively, after the second element 102s disengages from the molding device 102, the injection unit 101, the molding device 102, and the second element 102s separate from each other. In some embodiments, the molding device 102 moves horizontally away from the second element 102s. Alternatively, the second element 102s moves horizontally away from the molding device 102. Figure 36For example, after the molding device 102 is moved away from the second element 102s, the second element 102s and the molding device 102 move away from each other.

[0115] In this invention, a third injection molding method 500 is also disclosed. The third injection molding method 500 includes a number of operations, and the description and illustrations are not intended to be a limitation on the order of operations. Figure 37 This is a specific embodiment of the third injection molding method 500. In some embodiments, the third injection molding method 500 includes multiple operations (501 to 506). In some embodiments, the third injection molding method 500 is performed by, for example... Figures 1 to 5 The first injection molding system 100 shown or as Figures 19 to 23 The second injection molding system 300 shown and discussed above is implemented.

[0116] In operation 501, an injection molding system is provided, wherein the injection molding system includes an injection unit and a molding device, the injection unit including an outlet configured to discharge a flowable material, and the molding device being configured to receive the flowable material from the outlet, and including a mold cavity and a feed port communicatively connected to the mold cavity and correspondingly engaging with the outlet.

[0117] In operation 502, a support device is provided configured to facilitate engagement of the injection unit with the molding apparatus, wherein the support device includes a first element connected to the injection unit and a second element disposed on the molding apparatus.

[0118] In operation 503, the protrusion of the first element is aligned with the groove of the second element.

[0119] In operation 504, the injection unit is shifted so that the protrusion of the first element slides along the groove of the second element.

[0120] In operation 505, when the protrusion of the first element engages with the groove of the second element, the outlet is displaced in the opening of the second element to engage with the inlet.

[0121] In operation 506, the flowable material is injected into the mold cavity.

[0122] One aspect of the present invention relates to an injection molding system. The injection molding system includes: a supply unit configured to supply a flowable mixture of a polymer material and a blowing agent; an injection unit communicatively connected to the supply unit, wherein the injection unit includes an outlet disposed remotely from the supply unit and configured to discharge the flowable mixture; a molding device configured to receive the flowable mixture from the outlet, and including a mold cavity and a feed port communicatively connected to the mold cavity and engaging with the outlet; and a support device disposed between the injection unit and the molding device, and configured to facilitate engagement between the injection unit and the molding device. The support device includes a first element connected to the injection unit and a second element disposed on the molding device. The second element includes a first groove configured to receive a protrusion of the first element, the protrusion of the first element being slidable within and along the first groove of the second element.

[0123] In some embodiments, the second element includes an opening configured to receive the outlet of the ejection unit. In some embodiments, the second element further includes a protrusion defining a first groove, and both the first groove and the protrusion extend laterally. In some embodiments, the protrusion of the first element can engage with the protrusion and can slide within the groove. In some embodiments, the second element further includes a groove configured to receive the outlet, and the groove extends laterally along the second element and parallel to the first groove. In some embodiments, the outlet can slide within and along the groove. In some embodiments, the second element further includes an opening disposed within the groove. In some embodiments, a first sensor is disposed within the first groove and configured to sense contact between the protrusion and the first groove. In some embodiments, a second sensor is disposed within the groove and configured to sense contact between the outlet and the groove. In some embodiments, the height of the first groove is greater than the thickness of the protrusion of the first element. In some embodiments, the support device further includes a third element connected to the injection unit, and the first groove is configured to receive the first element and the third element. In some embodiments, the support device further includes a third element connected to the injection unit, and the second element further includes a second groove configured to receive the third element.

[0124] One aspect of the present invention relates to an injection molding method. The molding method includes: providing an injection molding system, wherein the injection molding system includes an injection unit and a molding device, the injection unit including an outlet configured to discharge a flowable material, and the molding device configured to receive the flowable material from the outlet, and including a mold cavity and a feed port communicatively connected to the mold cavity and correspondingly engaging with the outlet; providing a support device configured to facilitate engagement of the injection unit with the molding device, wherein the support device includes a first element connected to the injection unit and a second element disposed on the molding device; aligning a protrusion of the first element with a groove of the second element; displacing the injection unit such that the protrusion of the first element slides along the groove of the second element; when the protrusion of the first element engages with the groove of the second element, displacing the outlet in an opening of the second element such that the outlet engages with the feed port; and injecting the flowable material into the mold cavity.

[0125] In some embodiments, the method further includes aligning the outlet with a groove configured to receive the outlet, the groove extending laterally along the second element and parallel to the groove; and sliding the outlet into the groove. In some embodiments, the alignment of the protrusion of the first element with the groove of the second element and the alignment of the outlet with the groove are performed simultaneously. In some embodiments, the method further includes extending the outlet toward the molding apparatus to engage the outlet with the feed port; and retracting the outlet away from the molding apparatus after ejecting flowable material. In some embodiments, the method further includes: moving the protrusion of the first element to abut against a protrusion of the second element, while the protrusion of the first element is received by the groove of the second element; and disengaging the protrusion of the first element from the groove of the second element after ejecting flowable material, wherein the groove is defined by the protrusion. In some embodiments, the first element moves away from the molding apparatus to abut against the protrusion and moves toward the molding apparatus to disengage from the protrusion. In some embodiments, the method further includes: after injecting the flowable material, moving the protrusion of the first element toward the molding apparatus, while the protrusion of the first element is received by the groove of the second element; wherein the injection unit remains stationary as the support device moves toward the molding apparatus. In some embodiments, during the injection of the flowable material, the protrusion of the first element abuts against a protrusion of the second element, and the outlet communicates with the inlet.

[0126] The above outlines the features of several specific embodiments to enable those skilled in the art to better understand the various aspects of the invention. Those skilled in the art should understand that they can readily use this invention as the basis for designing or modifying other programs and structures to achieve the same purpose and / or realize the same advantages of the specific embodiments described herein. Those skilled in the art should also recognize 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.

[0127] Furthermore, the scope of this invention is not limited to the specific embodiments of the procedures, machines, manufactures, compositions of matter, means, methods, and steps described in this specification. 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, means, methods, or steps can be used to perform the same functions or obtain substantially the same results as the corresponding embodiments described herein. Therefore, the appended claims are intended to include such procedures, machines, manufactures, compositions of matter, means, methods, and steps within their scope.

[0128] Symbol Explanation

[0129] 100: First Injection Molding System

[0130] 101: Injection Unit

[0131] 101a: Injector

[0132] 101b: First Element

[0133] 101c: Export

[0134] 101d, 101h: Prominent parts

[0135] 101e: Hydraulic mechanism

[0136] 101f: Orbit

[0137] 101g: Third element

[0138] 102: Molding device

[0139] 102c: First mold

[0140] 102d: Second mold

[0141] 102e: Trench

[0142] 102o: Trench; Fourth element

[0143] 102f, 102p: Protrusions

[0144] 102g: Groove

[0145] 102h: Opening

[0146] 102i: Mold cavity

[0147] 102j: Feed inlet

[0148] 102k: Steps

[0149] 102l: First sensor

[0150] 102m: Second sensor

[0151] 102s: Second element

[0152] 102x: Part 1

[0153] 102y: Part Two

[0154] 103: Flowable mixture supply unit; supply unit

[0155] 104: Flowable mixtures; Flowable materials

[0156] 105: Support device

[0157] 200: First Injection Molding Method

[0158] 201-212, 401-413, 501-506: Operation

[0159] 300: Second Injection Molding System

[0160] 400: Second Injection Molding Method

[0161] 500: Third Injection Molding Method

[0162] C: Reaction force

[0163] D1: First Distance

[0164] D2: Second distance

[0165] D3, D4: Distance

[0166] H1, H2: Height

[0167] I: Ejection force

[0168] L1, L2: Length

[0169] T1, T2: Thickness

[0170] W1, W2, W3, W4: Width.

Claims

1. An injection molding system, characterized in that, include: A supply unit configured to supply a flowable mixture of polymer material and foaming agent; An injection unit that can communicate with the supply unit, wherein the injection unit includes an outlet disposed remotely from the supply unit and configured to discharge the flowable mixture; A forming apparatus configured to receive the flowable mixture from the outlet and comprising: One mold cavity; and A feed inlet, which can communicate with the mold cavity and engage with the outlet; and A support device is disposed between the injection unit and the molding device, and is configured to facilitate engagement between the injection unit and the molding device. The support device includes a first element connected to the injection unit and a second element disposed on the molding device. The second element includes a first groove configured to receive a laterally elongated portion of the first element. The protruding portion of the first element can slide within the first groove of the second element and along the lateral elongation direction of the first groove of the second element.

2. The injection molding system according to claim 1, characterized in that, The second element includes an opening configured to receive the outlet of the ejection unit.

3. The injection molding system according to claim 1, characterized in that, The second element further includes a groove configured to receive the outlet, and the groove extends laterally along the second element and parallel to the first groove.

4. The injection molding system according to claim 3, characterized in that, The outlet can slide within and along the groove.

5. The injection molding system according to claim 3, characterized in that, The second element further includes an opening disposed within the groove.

6. The injection molding system according to claim 1, characterized in that, The support device further includes a third element connected to the injection unit, and the first groove is configured to receive the first element and the third element.

7. The injection molding system according to claim 1, characterized in that, The support device further includes a third element connected to the injection unit, and the second element further includes a second groove configured to receive the third element.

8. An injection molding method, characterized in that, include: An injection molding system is provided, wherein the injection molding system includes an injection unit and a molding device, the injection unit includes an outlet configured to discharge a flowable material, and the molding device is configured to receive the flowable material from the outlet, and includes a mold cavity and a feed port communicatively connected to the mold cavity and correspondingly engaged with the outlet. A support device is provided, which is configured to facilitate engagement of the injection unit with the molding device, wherein the support device includes a first element connected to the injection unit and a second element disposed on the molding device; Align the protruding portion of the first element with the groove of the second element, wherein the groove of the second element extends laterally; The injection unit is shifted so that the protruding portion of the first element slides along the lateral elongation direction of the groove of the second element; When the protruding portion of the first element engages with the groove of the second element, the outlet is displaced in an opening of the second element so that the outlet engages with the inlet; as well as The flowable material is injected into the mold cavity.

9. The method according to claim 8, characterized in that, further include: The outlet is aligned with a groove configured to receive the outlet, the groove extending laterally along the second element and parallel to the groove; as well as Slide the outlet into the groove.

10. The method according to claim 8, characterized in that, further include: The protrusion of the first element is moved to abut against a protrusion of the second element, while the protrusion of the first element is received by the groove of the second element; as well as After the flowable material is ejected, the protruding portion of the first element disengages from the groove of the second element. The groove is defined by the protrusion.

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