Injection molding method and assembly of polymer components

Abstract

An injection molding method is provided. A molding apparatus is provided that includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold. The first mixture is ejected into the mold cavity through the first gate. A first component is formed from the first mixture. The second mixture is ejected into the mold cavity through the second gate. A second component is formed from the second mixture. The second component is at least partially in contact with the first component, and the first component and the second component have different physical properties.

Description

Technical Field

[0001] The present invention relates to an injection molding system and an injection molding method, and more particularly to an injection molding system and an injection molding method for forming an assembly including polymer components having different physical or functional properties. Background Art

[0002] Foamed polymer materials have many advantages, such as high strength, low weight, impact resistance, thermal insulation, etc. Foamed objects can be manufactured by injection molding or extrusion molding. For example, after the polymer material is melted and mixed with a foaming agent to form a mixture, force or pressure is applied to the mixture to inject or extrude the mixture into a cavity of a mold, and the mixture is foamed and cooled in the cavity to form the foamed object.

[0003] However, it is necessary to improve the properties of foamed articles made by injection molding systems, such as making different parts of the foamed articles have different properties. Therefore, it is necessary to improve the structure of injection molding systems and methods for making foamed articles. Summary of the invention

[0004] The present invention discloses an injection molding system and an injection molding method.

[0005] According to a specific embodiment of the content disclosed in the present invention, an injection molding method is provided. The injection molding method includes: providing a molding device including a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold; injecting a first mixture into the mold cavity through a first gate; forming a first component from the first mixture; injecting a second mixture into the mold cavity through a second gate; and forming a second component from the second mixture. The second component is at least partially in contact with the first component, and the first component and the second component have different physical properties.

[0006] According to a specific embodiment of the content disclosed in the present invention, an injection molding method is provided. The injection molding method includes: providing a molding device including a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold; injecting a first mixture into the mold cavity through a first gate; forming a first component from the first mixture; injecting a second mixture into the mold cavity through a second gate; and forming a second component from the second mixture. The second component is separated from the first component, and the first component and the second component have different physical properties.

[0007] According to one embodiment of the present disclosure, a polymer component assembly is provided. The assembly includes a first polymer component having a first surface layer; and a second polymer component having a second surface layer in contact with the first surface layer. The density of the first surface layer is greater than the central portion of the first polymer component, and the density of the second surface layer is greater than the central portion of the second polymer component, and a visible boundary line exists between the first surface layer and the second surface layer. Simple diagram description

[0009] The various aspects of the present disclosure are best understood from the following embodiments when read together with the accompanying drawings. It should be noted that, in accordance with standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or decreased for the sake of clarity of discussion.

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

[0011] Figure 2 is a flow chart showing an injection molding method according to some specific embodiments of the disclosure of the present invention;

[0012] Figure 3 Some specific embodiments of the present invention are shown in FIG. Figure 1 A schematic diagram of the forming device;

[0013] Figures 4 to 10 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional views of exemplary stages in the injection molding method;

[0014] Figures 11 to 16 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional views of exemplary stages in the injection molding method;

[0015] Figures 17 to 21 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional views of exemplary stages in the injection molding method;

[0016] Figure 22 to Figure 26 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional views of exemplary stages in the injection molding method;

[0017] Figures 27 to 31 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2Schematic cross-sectional views of exemplary stages in the injection molding method;

[0018] Figure 32 to Figure 39 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional views of exemplary stages in the injection molding method;

[0019] Figure 40 to Figure 43 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional views of exemplary stages in the injection molding method; and

[0020] Fig.44 and Fig.45 A specific embodiment of the content disclosed in the present invention is shown in FIG. Figure 2 Schematic cross-sectional view of exemplary stages in the injection molding method. Implementation

[0022] Cross-reference to related applications:

[0023] This application claims priority to U.S. Provisional Patent Application No. 63 / 518,107 filed on August 8, 2023, and U.S. Patent Application No. 18 / 664,326 filed on May 15, 2024, the entire contents of both applications are incorporated herein by reference.

[0024] The following disclosure provides many different embodiments or examples for implementing the different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the disclosure of the present invention. Of course, these are merely examples and are not intended to be limiting. For example, in the following description, the formation of a first feature on or above a second feature may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the disclosure of the present invention may repeat reference numerals and / or letters in the various examples. This repetition is for the purpose of simplicity and clarity of representation, and does not itself specify the relationship between the various embodiments and / or configurations discussed.

[0025] Furthermore, spatially relative terms such as "beneath," "below," "lower," "above," "upper," and the like may be used herein for convenience to describe the relationship of one element or feature to another element or feature 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 device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[0026] Although the numerical ranges and parameters describing the broad scope of the disclosed content are approximate, the numerical values ​​described in the specific examples are reported as accurately as possible. However, any numerical value inherently contains certain errors that are necessarily caused by the standard deviation found in the respective test measurements. In addition, as used herein, the term "about" generally means within 10%, 5%, 1% or 0.5% of a given value or range. Alternatively, the term "about" means within the acceptable standard error of the mean value when considered by a person of ordinary skill in the art. Unlike in the operating / operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values ​​and percentages (such as for the material amounts, durations, temperatures, operating conditions, ratios of amounts, and the like disclosed herein) should be understood to be modified by the term "about" in all instances. Accordingly, unless otherwise indicated, the numerical parameters set forth in the present disclosure and the appended claims are approximate values ​​that may vary as desired. At a minimum, each numerical parameter should be understood in view of the number of significant digits reported and by applying ordinary rounding techniques. Ranges may be expressed herein as from one endpoint to another, or between two endpoints. All ranges disclosed herein include the endpoints unless otherwise specified.

[0027] Figure 1 1 is a schematic diagram of an injection molding system 10 according to some specific embodiments of the present invention. The injection molding system 10 includes a mixing unit 120, an injection unit 110 and a molding device 100.

[0028] The mixing unit 120 is configured to generate a mixture of a polymer material and a physical foaming agent. The mixture is then transported to the ejection unit 110 through at least one delivery pipe 122. The ejection unit 110 is configured to discharge the mixture. The mixture is then discharged through one or more discharge pipes 111 of the ejection unit engaged with the molding device 100. The mixture can flow from the ejection unit 110 to the molding device 100. The molding device 100 is configured to form an article containing a polymer material. In some specific embodiments, the article is formed inside the molding device 100 by physical foaming. The mixture undergoes physical foaming and then forms a foamed article. In some specific embodiments, the article is a part of footwear (such as an outer sole, an inner sole, a midsole, etc.) or any other product.

[0029] Figure 2 1 is a flow chart showing an injection molding method 20 according to some specific embodiments of the present disclosure. The injection molding method 20 includes operations S210 to S270, and the description and the illustrated diagrams are not considered to be limiting to the order of operations S210 to S270. Figures 3 to 45 2 is a schematic cross-sectional view of various stages of the injection molding method 20. In some embodiments, the operations of the injection molding method 20 are repeatable and automatic.

[0030] In some embodiments, the injection molding method 20 is performed by Figure 1 The injection molding system 10 is performed. In operation S210, a molding device 100 including a mold cavity defined by the first mold and the second mold engaged with each other is provided. In operation S220, the injection unit 110 is configured to inject the first mixture from the mixing unit 120 into the mold cavity of the molding device 100 through the first gate and the corresponding discharge pipe 111 of the molding device 100, and then the first component is formed from the first mixture in operation S230. In operation S240, the injection unit 110 is configured to inject the second mixture from the mixing unit 120 into the mold cavity of the molding device 100 through the second gate and the corresponding discharge pipe 111 of the molding device 100, and then the second component is formed from the second mixture in operation S250. In operation S260 , the injection unit 110 is configured to inject the third mixture from the mixing unit 120 into the mold cavity of the molding device 100 through the third gate and the corresponding discharge pipe 111 of the molding device 100 , and then a third component is formed from the third mixture in operation S270 .

[0031] In some embodiments, operations S220 and S230 are replaced with additional operations in which the first component is preformed and placed in the mold cavity of the molding device 100. Corresponding to the additional operation, the third mixture and the second mixture are the same. In some embodiments, the mold cavity is defined by the second mold, and the fourth component is held by the first mold.

[0032] In some embodiments, the flow rates of the first, second and third mixtures are the same or different. In some embodiments, the first, second and third mixtures are different so that the first, second and third components have different physical properties. The first, second and third components are formed in different regions or portions of the article. In some embodiments, the second component is at least partially in contact with the first and third components, that is, the second component is sandwiched by the first and third components. In some embodiments, the second component is separated from the first component by the third component.

[0033] In some embodiments, the second mixture is softer than the first mixture, and the third mixture is softer than the second mixture. In some embodiments, the harder mixture is shot first, and the softer mixture is shot later.

[0034] In order to illustrate the concepts and injection molding method 20 disclosed in the present invention, various specific embodiments are provided below. However, the disclosure of the present invention is not intended to be limited to the specified specific embodiments. In addition, the elements, conditions or parameters illustrated in different specific embodiments can be combined or modified to form different combinations of specific embodiments, as long as the elements, parameters or conditions used are not contradictory. For ease of illustration, reference numerals with similar or identical functions and properties are repeated in different specific embodiments and figures.

[0035] Figure 3 Some specific embodiments of the present invention are disclosed in the Figure 1 Schematic diagram of a molding device 100. The molding device 100 includes a first mold 101 and a second mold 102. The first mold 101 is engaged with the second mold 102. When the first mold 101 is engaged with the second mold 102, the molding device 100 is in a closed state. In some specific embodiments, the first mold 101 is a lower mold, and the second mold 102 is an upper mold, and the first mold 101 is under the second mold 102. In some specific embodiments, the molding device 100 includes a mold cavity 103, which is defined by the first mold 101 and the second mold 102 when the first mold 101 and the second mold 102 are engaged. The mold cavity 103 is configured to hold the mixture, or the article formed from the mixture.

[0036] In some specific embodiments, the mold cavity 103 can be divided into a first sub-cavity 103a, a second sub-cavity 103b, and a third sub-cavity 103c by at least one partition 104. Adjacent two of the first sub-cavity 103a, the second sub-cavity 103b, and the third sub-cavity 103c are separated by the partition 104. For example, the first sub-cavity 103a and the second sub-cavity 103b are separated from each other by the first partition 104a, and the second sub-cavity 103b and the third sub-cavity 103c are separated from each other by the second partition 104b. In some specific embodiments, the partition 104 is movable relative to the first mold 101 or the second mold 102. In some specific embodiments, the partition 104 can be manually or automatically extended or retracted in the mold cavity 103.

[0037] In some embodiments, the diaphragm 104 protrudes from the first mold 101 or the second mold 102. In some embodiments, the diaphragm 104 can be extended into the mold cavity 103, or retracted therefrom. For example, the diaphragm 104 can be extended from the first mold 101 into the mold cavity 103, or retracted from the mold cavity 103 into the first mold 101.

[0038] In some embodiments, the first sub-cavity 103a is defined by the first mold 101, the second mold 102, and the first partition 104a. Moreover, the second sub-cavity 103b is defined by the first mold 101, the second mold 102, the first partition 104a and the second partition 104b, and the third sub-cavity 103c is defined by the first mold 101, the second mold 102 and the second partition 104b. In some embodiments, when the first partition 104a and the second partition 104b are inside the mold cavity 103, the first sub-cavity 103a, the second sub-cavity 103b and the third sub-cavity 103c cannot be connected to each other, such as Figure 3 In some specific embodiments, the first partition 104a and the second partition 104b have the same or different thicknesses in the X direction and have the same height in the Z direction. Moreover, the first sub-cavity 103a, the second sub-cavity 103b and the third sub-cavity 103c have the same or different widths in the X direction and have the same height in the Z direction. In some specific embodiments, the first sub-cavity 103a, the second sub-cavity 103b and the third sub-cavity 103c have the same length in the Y direction.

[0039] In some specific embodiments, the gate 105 is disposed at the first mold 101 or the second mold 102. When the discharge pipe 111 is engaged with the molding device 100, the gate 105 is configured to receive the discharge pipe 111 from the first mold 101 or the second mold 102. Figure 1 The mixture is discharged from the discharge pipe 111 of the injection unit 110. The mixture can flow into the mold cavity 103 through the gate 105. Figure 1In this specific embodiment, when the first partition 104a and the second partition 104b are disposed in the mold cavity 103, there are a first gate 105a, a second gate 105b and a third gate 105c that can be communicated with the first sub-cavity 103a, the second sub-cavity 103b and the third sub-cavity 103c, respectively. In some specific embodiments, each of the first sub-cavity 103a, the second sub-cavity 103b and the third sub-cavity 103c corresponds to one or more gates 105. In some specific embodiments, the first gate 105a, the second gate 105b and the third gate 105c have the same or different widths in the X direction. In some specific embodiments, the first gate 105a, the second gate 105b and the third gate 105c allow fluids to flow at the same or different flow rates.

[0040] Figures 4 to 10 The first embodiment of the present invention is disclosed in Figure 2 Schematic cross-sectional view of exemplary stages in an injection molding method 20.

[0041] exist Figure 4 In some embodiments, the first mold 101 is joined with the second mold 102, and the first partition 104a is disposed in the mold cavity 103. In some embodiments, the first partition 104a is disposed by extending the first partition 104a from the first mold 101 to the second mold 102. In some embodiments, the joining of the first mold 101 and the second mold 102 is performed before or after the disposition of the first partition 104a. In some embodiments, after the joining of the first mold 101 and the second mold 102 and the disposition of the first partition 104a, the first gas is injected into the first sub-cavity 103a to increase the pressure inside the first sub-cavity 103a. In some embodiments, the first gas is air or the like. In some embodiments, the first sub-cavity 103a is defined by the first mold 101, the second mold 102, and the first partition 104a.

[0042] As in Figure 2 In the operation S220 of FIG. 1 , the first mixture M1′ is injected into the first sub-cavity 103a through the first gate 105a. In some specific embodiments, the first mixture M1′ is injected into the first sub-cavity 103a filled with the first gas. In some specific embodiments, Figure 1The discharge pipe 111 is connected to the first gate 105a, and then the first mixture M1' is ejected from the discharge pipe 111 through the first gate 105a into the first sub-cavity 103a. In some specific embodiments, the first mixture M1' includes a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid or the like). In some specific embodiments, the first mixture M1' is foamable or slightly foamable.

[0043] In some embodiments, after the first mixture M1' is ejected, the first mixture M1' undergoes physical foaming in the first sub-cavity 103a to become the first component M1, as described in the operation S230. In some embodiments, during the physical foaming of the first mixture M1' and / or after the formation of the first component M1, the pressure inside the first sub-cavity 103a is reduced by discharging at least a portion of the first gas from the first sub-cavity 103a and / or discharging a portion of the physical foaming agent released from the first mixture M1' from the first sub-cavity 103a. In some embodiments, after the physical foaming of the first mixture M1', the first component M1 having a first surface layer 106a is formed. The first surface layer 106a is adjacent to or in contact with the first partition 104a. The first surface layer 106a has a higher density than the central portion of the first component M1 away from the first partition 104a. The first skin layer 106a has a lower degree of physical foaming than the central portion of the first component M1. In other words, the central portion of the first component M1 undergoes a higher degree of physical forming than the peripheral portion of the first component M1. In some specific embodiments, the first skin layer 106a has a thickness of less than 0.5 mm.

[0044] In some specific embodiments, after the first component M1 is formed, the first separator 104a is as follows Figure 5 104a is removed from the mold cavity 103 as shown in . In some embodiments, the first baffle 104a is withdrawn from the mold cavity 103 by retracting the first baffle 104a away from the second mold 102 and returning it to the first mold 101. In some embodiments, after the removal of the first baffle 104a, Figure 5 As shown in FIG. 1 , a second sub-cavity 103b, a second partition plate 104b and a second mold 102 defined by the first component M1 are formed. Furthermore, Figure 5 The second sub-cavity 103b is in the X direction. Figure 3In some embodiments, after the removal of the first partition 104a, the second partition 104b is disposed in the mold cavity 103. In some embodiments, before the injection of the first mixture M1', the second partition 104b is disposed in the mold cavity 103. In some embodiments, the second partition 104b is disposed by extending the second partition 104b from the first mold 101 to the second mold 102. In some embodiments, the joining of the first mold 101 and the second mold 102 is performed before or after the disposition of the second partition 104b.

[0045] In some embodiments, the second gas is injected into the second sub-chamber 103b to increase the pressure inside the second sub-chamber 103b after the second partition 104b is set. In some embodiments, the second gas is air or the like.

[0046] exist Figure 6 In, as in Figure 2 As described in the operation S240 of , the second mixture M2' is injected into the second sub-cavity 103b through the second gate 105b. It should be noted that the first baffle 104a is removed from the mold cavity 103 before the second mixture M2' is injected. In some specific embodiments, the second mixture M2' is injected into the second sub-cavity 103b filled with the second gas. In some specific embodiments, Figure 1 The discharge pipe 111 is connected to the second gate 105b, and then the second mixture M2' is ejected from the discharge pipe 111 through the second gate 105b into the second sub-cavity 103b. In some specific embodiments, the second mixture M2' includes a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid or the like). In some specific embodiments, the second mixture M2' is foamable or slightly foamable. In some specific embodiments, the first mixture M1' and the second mixture M2' include the same or different materials. In some specific embodiments, the first mixture M1' and the second mixture M2' have different physical properties, such as density, hardness, Young's modulus, etc. In some specific embodiments, the second mixture M2' is softer than the first mixture M1'. In some specific embodiments, the first mixture M1' is denser than the second mixture M2'. In some embodiments, the first surface layer 106a of the first component M1 is in contact with the second mixture M2'.

[0047] In some specific embodiments, after the second mixture M2' is ejected, the second mixture M2' undergoes physical foaming in the second sub-cavity 103b to become the second component M2, such as Figure 2 . In some embodiments, during the physical foaming of the second mixture M2' and / or after the formation of the second component M2, the pressure inside the second sub-chamber 103b is reduced by discharging at least a portion of the second gas from the second sub-chamber 103b and / or discharging a portion of the physical foaming agent released from the second mixture M2' from the second sub-chamber 103b. In some embodiments, after the physical foaming of the second mixture M2', the second component M2 having a second surface layer 106b is formed. In some embodiments, the second surface layer 106b is adjacent to or in contact with the second partition 104b. In some embodiments, the second surface layer 106b is in contact with the first surface layer 106a of the first component M1. The second surface layer 106b has a higher density than the central portion of the second component M2 away from the second partition 104b. The second surface layer 106b has a lower degree of physical foaming than the central portion. In other words, the central portion of the second component M2 undergoes a higher degree of physical forming than the peripheral portion of the second component M2. In some specific embodiments, the second skin layer 106b has a thickness of less than 0.5 mm.

[0048] In some specific embodiments, after the second component M2 is formed, the second separator 104b is as follows Figure 7 102 is removed from the mold cavity 103. In some embodiments, the second baffle 104b is withdrawn from the mold cavity 103 by retracting the second baffle 104b away from the second mold 102 and returning it to the first mold 101. In some embodiments, after the second baffle 104b is removed, the third sub-cavity 103c defined by the second assembly M2, the first mold 101 and the second mold 102 is as shown. Figure 7 Furthermore, Figure 7 The third sub-cavity 103c is in the X direction. Figure 3 The sub-cavity 103c is wider.

[0049] In some embodiments, after the second partition plate 104b is removed, the third gas is injected into the third sub-chamber 103c to increase the pressure inside the third sub-chamber 103c. In some embodiments, the third gas is air or the like.

[0050] exist Figure 8 In, as in Figure 2In the operation S260 of FIG. 1 , the third mixture M3′ is injected into the third sub-cavity 103c through the third gate 105c. In some specific embodiments, the third mixture M3′ is injected into the third sub-cavity 103c filled with the third gas. In some specific embodiments, Figure 1 The discharge pipe 111 is engaged with the third gate 105c, and then the third mixture M3' is ejected from the discharge pipe 111 through the third gate 105c into the third sub-cavity 103c. In some specific embodiments, the third mixture M3' includes a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid or the like). In some specific embodiments, the third mixture M3' is foamable or slightly foamable. In some specific embodiments, the first mixture M1', the second mixture M2' and the third mixture M3' include the same or different materials. In some specific embodiments, the first mixture M1', the second mixture M2' and the third mixture M3' have different physical properties, such as density, hardness, etc. In some specific embodiments, the third mixture M3' is softer than the second mixture M2' and the first mixture M1'. In some embodiments, the second mixture M2' and the first mixture M1' are denser than the third mixture M3'. In some embodiments, the second surface layer 106b of the second component M2 is in contact with the third mixture M3'.

[0051] In some specific embodiments, after the third mixture M3' is injected, the third mixture M3' undergoes physical foaming in the third sub-cavity 103c to become the third component M3, such as Figure 2. In some embodiments, during the physical foaming of the third mixture M3' and / or after the third component M3 is formed, the pressure inside the third sub-chamber 103c is reduced by discharging at least a portion of the third gas from the third sub-chamber 103c and / or discharging a portion of the physical foaming agent released from the third mixture M3' from the third sub-chamber 103c. In some embodiments, after the physical foaming of the third mixture M3', the third component M3 having a third surface layer 106c is formed. In some embodiments, the third surface layer 106c is adjacent to or in contact with the second component M2. In some embodiments, the second surface layer 106b of the second component M2 is in contact with the third surface layer 106c of the third component M3. The third surface layer 106c has a higher density than the central portion of the third component M3. The third surface layer 106c has a lower degree of physical foaming than the central portion. In other words, the central portion of the third component M3 undergoes a higher degree of physical forming than the peripheral portion of the third component M3. In some embodiments, the third surface layer 106c has a thickness of less than 0.5 mm.

[0052] exist Fig. 9 In the embodiment, after the third component M3 is formed, the first mold 101 is separated from the second mold 102. After the third component M3 is formed, a product (or assembly) 107 having the first component M1, the second component M2 and the third component M3 is formed, and the second component M2 is sandwiched between the first component M1 and the third component M3. The product 107 is formed in the mold cavity 103. In some specific embodiments, after the first mold 101 and the second mold 102 are separated, the product 107 is as follows Fig.10 , the mold is removed from the mold cavity 103. In some specific embodiments, the operations described above can be automatically repeated and performed.

[0053] In some embodiments, the first component M1 is directly attached to the second component M2, and the second component M2 is directly attached to the third component M3. In other words, no additional components or materials (such as adhesives or the like) are disposed between the first component M1 and the second component M2, and between the second component M2 and the third component M3. In some embodiments, the article 107 has various densities or hardnesses.

[0054] exist Fig.10In the specific embodiment, the top surfaces of the first component M1, the second component M2, and the third component M3 are formed at the same level defined by the second mold 102, and the bottom surfaces of the first component M1, the second component M2, and the third component M3 are formed at the same level defined by the first mold 101. In some specific embodiments, the top surfaces of the first component M1, the second component M2, and the third component M3 are formed at different levels. In some specific embodiments, the bottom surfaces of the first component M1, the second component M2, and the third component M3 are formed at different levels. In some specific embodiments, the first component M1, the second component M2, and the third component M3 have the same or different thicknesses. Furthermore, the first component M1 is separated from the second component M2 and the third component M3.

[0055] In some embodiments, the article 107 includes a visible boundary line between two adjacent components. For example, the first visible boundary line 108a exists between the first component M1 and the second component M2, and the second visible boundary line 108b exists between the second component M2 and the third component M3. In some embodiments, from the top view of the article 107, the first visible boundary line 108a and the second visible boundary line 108b are respectively a straight line, a curve, an arc (spline), a fold line (polyline), etc. In some embodiments, the first visible boundary line 108a extends on the top surface of the first component M1 and the second component M2, and the second visible boundary line 108b extends on the top surface of the second component M2 and the third component M3. In some embodiments, the first visible boundary line 108a extends from the top surfaces of the first component M1 and the second component M2 to the bottom surfaces, and the second visible boundary line 108b extends from the top surfaces of the second component M2 and the third component M3 to the bottom surfaces.

[0056] Figures 11 to 16 The second embodiment of the present invention is shown in FIG. Figure 2 Schematic cross-sectional view of exemplary stages in the injection molding method 20. In the second embodiment, the third component M3 is formed before the second component M2 is formed.

[0057] exist Fig.11In the embodiment, the first mold 101 is joined to the second mold 102, and the first partition 104a and the second partition 104b are disposed in the mold cavity 103. The mold cavity 103 is divided into a first sub-cavity 103a, a second sub-cavity 103b and a third sub-cavity 103c by the first partition 104a and the second partition 104b. Moreover, the second sub-cavity 103b is defined by the first mold 101, the second mold 102 and the first partition 104a and the second partition 104b, and the third sub-cavity 103c is defined by the first mold 101, the second mold 102 and the second partition 104b.

[0058] As in Figure 2 As described in the operation S220 of the embodiment, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a. After the first mixture M1' is injected, the first mixture M1' undergoes physical foaming in the first sub-cavity 103a to become the first component M1, as described in the operation S230. In some specific embodiments, the first component M1 includes a first surface layer 106a, which is adjacent to or in contact with the first partition 104a.

[0059] exist Fig.12 In, as in Figure 2 As described in the operation S240 of the embodiment, after the first component M1 is formed, the third mixture M3' is injected into the third sub-cavity 103c through the third gate 105c. After the third mixture M3' is injected, the third mixture M3' undergoes physical foaming to become the third component M3, as described in the operation S250. In some specific embodiments, the third component M3 includes a third surface layer 106c, which is adjacent to or in contact with the second partition 104b.

[0060] In some specific embodiments, Figure 8 Compared with the third component M3 in the third sub-cavity 103c, the third component M3 is Fig.12 The second component M2 is formed before it is formed. Furthermore, Fig.12 The third component M3 has a ratio in the X direction Figure 8 In other words, by adjusting the formation sequence of the third component M3, the third component M3 may have different sizes.

[0061] exist Fig.13 In the embodiment, after the third component M3 is formed, the first partition 104a and the second partition 104b are removed from the mold cavity 103 simultaneously or sequentially. After the first partition 104a and the second partition 104b are removed, the second sub-cavity 103b is defined by the first mold 101, the second mold 102, the first component M1 and the second component M2. Therefore, Fig.12 The second sub-cavity 103b is in the X direction. Fig.13 The sub-cavity 103b is wider.

[0062] exist Fig.14 In, as in Figure 2 As described in operation S260 of the embodiment, the second mixture M2' is ejected into the second sub-cavity 103b. In some embodiments, the second mixture M2' is in contact with the first component M1 and the third component M3. In some embodiments, the second mixture M2' undergoes physical foaming to become the second component M2, such as in Figure 2 In some embodiments, the second component M2 includes a second surface layer 106b adjacent to or in contact with the first component M1 and the third component M3.

[0063] In some specific embodiments, Figure 6 Compared with the second component M2 in the second sub-cavity 103b, the second component M2 is Fig.14 After the third component M3 is formed. Furthermore, Fig.14 The second component M2 has a ratio in the X direction Figure 6 In other words, by adjusting the formation order of the second component M2, the second component M2 may have different sizes.

[0064] After the second component M2 is formed, the product 107 is as follows Fig.15 The product 107 is formed as shown in Fig.16 After the first mold 101 and the second mold 102 are disengaged, they are taken out from the mold cavity 103. In some specific embodiments, the second component M2 is softer than the first component M1 and the third component M3. In some specific embodiments, the first component M1 and the third component M3 are denser than the second component M2. In some specific embodiments, the steps described above can be automatically repeated and performed.

[0065] Figures 17 to 21 The third embodiment of the present invention is shown in FIG. Figure 2 Schematic cross-sectional view of an exemplary stage in the injection molding method 20 of . In the third embodiment, the second baffle 104b and the third component M3 are removed. Therefore, no third subcavity 103c exists in the mold cavity 103, and the third component M3 is not present in the product 107. In some embodiments, the first baffle 104a and one of the first component M1 and the second component M2 are removed.

[0066] exist Fig.17 In the embodiment, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a. Figure 2 In some embodiments, the first sub-cavity 103a is defined by the first mold 101, the second mold 102, and the first partition 104a. After the first component M1 is formed as described in the operation S230, Fig.18 As shown in FIG. 1 , the first separator 104a is removed.

[0067] exist Fig.19 In the embodiment, after the first partition 104a is removed, the second mixture M2' is injected into the second sub-cavity 103b through one or more of the second gate 105b and the third gate 105c, as shown in Figure 2 In some embodiments, the second sub-cavity 103b is defined by the first component M1, the first mold 101, and the second mold 102. In some embodiments, the second mixture M2' flows through the second gate 105b and the third gate 105c at the same or different flow rates. In some embodiments, the second mixture M2' undergoes physical foaming to become the second component M2, such as in Figure 2 In some embodiments, the second component M2 includes a second surface layer 106b adjacent to or in contact with the first component M1. Fig.19 In the specific embodiment, the second component M2 has a width in the X direction that is wider than the first component M1.

[0068] exist Fig. 20 In the embodiment, the product 107 is formed after the second component M2 is formed. The product 107 is formed in the Fig.21 After the first mold 101 and the second mold 102 are separated, they are taken out from the mold cavity 103. In some specific embodiments, the second component M2 is softer than the first component M1. In some specific embodiments, the first component M1 is denser than the second component M2.

[0069] Figure 22 to Figure 26 The fourth embodiment of the present invention is shown in FIG. Figure 2 Schematic cross-sectional view of an exemplary stage in the injection molding method 20. In the fourth embodiment, the baffles 104 are skipped, that is, the first baffle 104a and the second baffle 104b are not disposed in the mold cavity 103.

[0070] exist Fig. 22 In the embodiment, the first mixture M1' is injected into the mold cavity 103 through the first gate 105a (in Figure 2 Then, the first mixture M1′ undergoes physical foaming to become the first component M1 (in operation S220). Figure 2In operation S230 of the present invention, the gas is injected into the mold cavity 103 before the injection of the first mixture M1' to increase the pressure inside the mold cavity 103. After the first component M1 is formed, the first skin layer 106a is formed. In some embodiments, the first skin layer 106a is configured to prevent the subsequent mixture injected into the mold cavity 103 from mixing with the first mixture M1' or the first component M1. In some embodiments, during or after the physical foaming of the first mixture M1', a portion of the gas released from the first mixture M1' and / or a portion of the physical foaming agent is discharged from the mold cavity 103.

[0071] exist Fig.23 In the embodiment, after the first component M1 is formed, the second mixture M2' is injected into the mold cavity 103 through the second gate 105b, as shown in Figure 2 In some embodiments, gas is injected into the mold cavity 103 before the second mixture M2' is injected to increase the pressure inside the mold cavity 103. The second mixture M2' is in contact with the first component M1. Then, the second mixture M2' undergoes physical foaming to become the second component M2, as in Figure 2 After the second component M2 is formed, a second skin layer 106b is formed. In some embodiments, the second skin layer 106b is configured to prevent the subsequent mixture injected into the mold cavity 103 from mixing with the second mixture M2' or the second component M2. In some embodiments, during or after the physical foaming of the second mixture M2', a portion of the gas released from the second mixture M2' and / or a portion of the physical foaming agent is discharged from the mold cavity 103.

[0072] exist Fig.24 In the embodiment, after the second component M2 is formed, the third mixture M3' is injected into the mold cavity through the third gate 105c, as shown in Figure 2 In some embodiments, gas is injected into the mold cavity 103 before the third mixture M3' is injected to increase the pressure inside the mold cavity 103. The third mixture M3' is in contact with the second component M2. Then, the third mixture M3' undergoes physical foaming to become the third component M3, as shown in Figure 2After the third component M3 is formed, a third skin layer 106c is formed. In some embodiments, the third skin layer 106c is configured to prevent mixing with the second mixture M2' or the second component M2. In some embodiments, during or after the physical foaming of the third mixture M3', a portion of the gas released from the third mixture M3' and / or a portion of the physical foaming agent is discharged from the mold cavity 103.

[0073] exist Fig.25 In the embodiment, the product 107 is formed, and the product 107 can be Fig.26 After the first mold 101 and the second mold 102 are separated, they are taken out from the mold cavity 103. As described above, the product 107 includes a first visible boundary line 108a between the first component M1 and the second component M2, and a second visible boundary line 108b between the second component M2 and the third component M3.

[0074] Figures 27 to 31 The fifth embodiment of the present invention is shown in FIG. Figure 2 Schematic cross-sectional view of an exemplary stage in the injection molding method 20 of FIG. In the fifth embodiment, the first component M1 is surrounded by the second component M2 in the article 107. In some embodiments, the second gate 105b is removed from the second mold 102.

[0075] exist Fig. 27 In the embodiment, the first component M1 is placed in the second sub-cavity 103b defined by the first partition 104a, the second partition 104b, the first mold 101 and the second mold 102. In some specific embodiments, the first component M1 is temporarily fixed in the second sub-cavity 103b by the first partition 104a and the second partition 104b. Furthermore, a portion of the second sub-cavity 103b is not filled with the first component M1.

[0076] In some embodiments, after the first component M1 is placed, the second mixture M2' is as follows Fig.28, and is injected into the first sub-cavity 103a and the third sub-cavity 103c as shown in . In some specific embodiments, the gas is injected into the first sub-cavity 103a and / or the third sub-cavity 103c before the second mixture M2' is injected to increase the pressure inside the first sub-cavity 103a and / or the third sub-cavity 103c. In some specific embodiments, the second mixture M2' is injected into the first sub-cavity 103a and the third sub-cavity 103c through the first gate 105a and the third gate 105c, respectively. In some specific embodiments, the second mixture M2' is injected into the first sub-cavity 103a and the third sub-cavity 103c at the same time. In some specific embodiments, the second mixture M2' is injected into the first sub-cavity 103a and the third sub-cavity 103c sequentially.

[0077] In some specific embodiments, when the second mixture M2' almost fills or completely fills the first sub-cavity 103a and the third sub-cavity 103c, the first partition 104a and the second partition 104b are withdrawn from the mold cavity 103. In some specific embodiments, after the withdrawal of the first partition 104a and the second partition 104b, the second mixture M2' flows into the second sub-cavity 103b to form a mold cavity 103. Fig.29 , contacting the first component M1 as shown in . Then, the second mixture M2' undergoes physical foaming to become the second component M2. After the second component M2 is formed, the second surface layer 106b is formed. In some specific embodiments, during or after the physical foaming process of the second mixture M2', a portion of the gas released from the second mixture M2' and / or a portion of the physical foaming agent are discharged from the mold cavity 103. In a fifth specific embodiment, the second component M2 and the first component M1 have different heights in the Z direction. The top surface of the first component M1 is lower than the top surface of the second component M2. Furthermore, the second component M2 overlaps the top surface of the first component M1 in the Z direction (as viewed from a top view of the product 107), and the top surface of the first component M1 is surrounded by the second component M2.

[0078] In some embodiments, the article 107 is Fig.30 , and the product 107 can be formed as shown in Fig.31 After the first mold 101 and the second mold 102 are separated, they are taken out from the mold cavity 103. In some specific embodiments, the second component M2 is softer than the first component M1. In some specific embodiments, the first component M1 is denser than the second component M2.

[0079] Figure 32 to Figure 39 The sixth embodiment of the present invention is shown in FIG. Figure 2Schematic cross-sectional view of an exemplary stage in the injection molding method 20 of FIG. In the sixth embodiment, the first component M1 is surrounded by the second component M2 in the article 107. In some embodiments, the second gate 105b is removed from the second mold 102.

[0080] exist Fig.32 In the molding device 100, a first mold 101 is formed; and a second mold 102a is joined with the first mold 101. The fourth mold cavity 103d is formed when the first mold 101 is joined with the second mold 102a. The fourth mold cavity 103d is defined by the first mold 101 and the second mold 102a. In some embodiments, the fourth mixture M4' is injected into the fourth mold cavity 103d through the fourth gate 105d. In some embodiments, the fourth gas is injected into the fourth mold cavity 103d before the fourth mixture M4' is injected to increase the pressure inside the fourth mold cavity 103d. In some embodiments, the fourth mixture M4' includes a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid or the like). In some embodiments, the fourth mixture M4' is foamable or slightly foamable.

[0081] In some embodiments, after the injection of the fourth mixture M4', the fourth mixture M4' undergoes physical foaming in the fourth mold cavity 103d to become the fourth component M4. In some embodiments, during the physical foaming of the fourth mixture M4' and / or after the fourth component M4 is formed, the pressure inside the fourth mold cavity 103d is reduced by discharging at least a portion of the fourth gas from the fourth mold cavity 103d and / or discharging a portion of the physical foaming agent released from the fourth mixture M4' from the fourth mold cavity 103d. In some embodiments, after the physical foaming of the fourth mixture M4', the fourth component M4 having a fourth surface layer 106d is formed. The fourth surface layer 106d has a higher density than the central portion of the fourth component M4. The fourth surface layer 106d has a lower degree of physical foaming than the central portion. In some embodiments, the fourth surface layer 106d has a thickness of less than 0.5 mm.

[0082] exist Fig.33In some embodiments, after the fourth component M4 is formed, the second mold 102a is removed and then replaced with the third mold 102b. In some embodiments, the first partition 104a and the second partition 104b extend between the fourth component M4 and the third mold 102b. In some embodiments, the first partition 104a and the second partition 104b are extendable and retractable from the third mold 102b. In some embodiments, the mold cavity 103 is further defined by the fourth component M4 disposed in the first mold 101 and the third mold 102b.

[0083] exist Fig.33 In the embodiment, after the first partition plate 104a is set, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a, as shown in Figure 2 In some embodiments, the first sub-cavity 103a is defined by the third mold 102b, the fourth component M4 and the first partition plate 104a.

[0084] In some specific embodiments, the first gas is injected into the first sub-chamber 103a before the first mixture M1' is injected to increase the pressure inside the first sub-chamber 103a. In some specific embodiments, after the first mixture M1' is injected, the first mixture M1' undergoes physical foaming in the first sub-chamber 103a to become the first component M1, such as Figure 2 In some embodiments, after the first component M1 is formed, the first separator 104a is as follows Fig.34 Remove as shown in .

[0085] exist Fig.35 In the embodiment, the second mixture M2' is injected into the second sub-cavity 103b through the second gate 105b, as shown in Figure 2 In some embodiments, the second gas is injected into the second sub-cavity 103b before the second mixture M2' is injected to increase the pressure inside the second sub-cavity 103b. In some embodiments, the second sub-cavity 103b is defined by the first component M1, the fourth component M4, the second partition 104b and the third mold 102b. In some embodiments, after the second mixture M2' is injected, the second mixture M2' undergoes physical foaming in the second sub-cavity 103b to become the second component M2, as shown in Figure 2 In some embodiments, after the second component M2 is formed, the second separator 104b is as follows Fig.36 Remove as shown in .

[0086] exist Fig.37In the embodiment, after the second component M2 is formed, the third mixture M3' is injected into the third sub-cavity 103c through the third gate 105c, as shown in Figure 2 In some embodiments, the third sub-cavity 103c is defined by the second component M2, the fourth component M4, and the third mold 102b. In some embodiments, the third gas is injected into the third sub-cavity 103c before the third mixture M3' is injected to increase the pressure inside the third sub-cavity 103c. In some embodiments, after the third mixture M3' is injected, the third mixture M3' undergoes physical foaming in the third sub-cavity 103c to become the third component M3, as shown in FIG. Figure 2 As described in operation S270 of .

[0087] In some specific embodiments, after the third component M3 is formed, the first mold 101 is as follows Fig.38 After the third component M3 is formed, the product 107 having the first component M1, the second component M2, the third component M3 and the fourth component M4 is as shown in FIG. Fig.39 The product 107 is formed in the mold cavity defined by the first mold 101 and the third mold 102b. In some specific embodiments, after the first mold 101 and the third mold 102b are separated, the product 107 is as shown in FIG. Fig.39 As shown in FIG. , the mold is removed from the mold cavity.

[0088] In some specific embodiments, the first component M1 is directly attached to the second component M2, and the second component M2 is directly attached to the third component M3. In other words, no additional components or materials (such as adhesives or the like) are provided between the first component M1 and the second component M2, and between the second component M2 and the third component M3. In some specific embodiments, the fourth component M4 is separable / detachable from the first component M1, the second component M2, and the third component M3. In some specific embodiments, the fourth component M4 has a recess / protrusion that can be connected to the first component M1, the recess / protrusion of the second component M2, and / or the recess / protrusion of the third component M3, so that the fourth component M4 can be attached to the first component M1, the second component M2, and / or the third component M3.

[0089] In some specific embodiments, the fourth surface layer 106d is in contact with the bottom surfaces of the first component M1, the second component M2, and the third component M3. The second component M2 is surrounded by the first component M1, the fourth component M4, and the third component M3. The first component M1 is surrounded by the fourth component M4 and the second component M2. The side surface of the first component M1 (such as the first surface layer 106a on the left side) is in contact with the fourth surface layer 106d of the fourth component M4. Moreover, the third component M3 is surrounded by the fourth component M4 and the second component M2. The side surface of the third polymer component (such as the third surface layer 106c on the right side) is in contact with the fourth surface layer 106d of the fourth component M4.

[0090] In some embodiments, the article 107 includes a visible boundary line between two adjacent components. For example, the first visible boundary line 108a exists between the first component M1 and the second component M2, and the second visible boundary line 108b exists between the second component M2 and the third component M3. In some embodiments, from the top view of the article 107, the first visible boundary line 108a and the second visible boundary line 108b are respectively straight lines, curves, arcs, broken lines, etc.

[0091] In some embodiments, the article 107 has various densities or hardnesses. In some embodiments, the fourth component M4 is harder and denser than the first component M1, the second component M2, and the third component M3. In some embodiments, the third component M3 is softer than the second component M2 and the first component M1. In some embodiments, the first component M1 is denser than the second component M2 and the third component M3.

[0092] Figure 40 to Figure 43 FIG. 7 is a diagram showing a seventh specific embodiment according to the disclosure of the present invention. Figure 2 Schematic cross-sectional view of exemplary stages in the injection molding method 20. In this seventh embodiment, the operations of the injection unit 110 are shown.

[0093] As described above, the injection molding system 10 includes the mixing unit 120, the injection unit 110, and the molding apparatus 100. The mixing unit 120 is configured to generate a mixture of a polymer material and a physical foaming agent. Then, the mixture is delivered to the injection unit 110.

[0094] exist Fig.40In the embodiment, the injection unit 110 is configured to discharge the mixture. Then, the mixture is discharged through one or more discharge pipes 111a, 111b and 111c of the injection unit 110 coupled to the molding device 100. The mixture may flow from the injection unit 110 to the molding device 100. In some embodiments, the mixture may flow from the injection unit 110 through the discharge pipes 111a, 111b and 111c and the first gate 105a, the second gate 105b and the third gate 105c to the mold cavity 103. In some embodiments, each discharge pipe corresponds to an individual gate. For example, the discharge pipes 111a, 111b and 111c correspond to the first gate 105a, the second gate 105b and the third gate 105c, respectively. In some embodiments, the partition plate 104 is disposed in the mold cavity 103.

[0095] In some embodiments, the flow rate of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c is individually adjustable. In some embodiments, the amount of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c is individually adjustable. In some embodiments, the flow rate or the amount of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c is controlled by a central processor (not shown).

[0096] In some embodiments, the flow rate / amount of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c may be synchronized with each other. For example, the flow rate / amount of the mixture flowing out of the discharge pipe 111a is set or determined (manually or automatically), and then the flow rate / amount of the mixture flowing out of each of the remaining parts of the discharge pipes 111b and 111c is automatically set to be the same as the flow rate / amount of the mixture flowing out of the discharge pipe 111a. As a result, the flow rate / amount of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c is synchronized. In some embodiments, such synchronization is automatically performed by the central processor.

[0097] In some embodiments, the flow rate / amount of the mixture flowing out of one of the discharge pipes 111a is set (manually or automatically) to a predetermined rate / amount, and then the flow rate / amount of the mixture flowing out of each of the remaining portions of the discharge pipes 111b and 111c is adjusted (to be the same or different) based on the predetermined rate / amount. As a result, the flow rate / amount of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c are related to each other. In some embodiments, such adjustments are automatically and instantly performed by the central processor. For example, if the flow rate / amount of the mixture flowing out of one of the discharge pipes 111a is changed (manually or automatically), the flow rate / amount of the mixture flowing out of each of the remaining portions of the discharge pipes 111b and 111c is also instantly changed.

[0098] In some embodiments, the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c has the same or different materials. In some embodiments, the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c has the same or different physical properties (such as density, hardness, etc.). In some embodiments, the discharge pipes 111a, 111b, and 111c have the same or different physical properties (such as density, hardness, etc.). Fig.41 The same mixture M′ is shown flowing out into the mold cavity 103 .

[0099] In some specific embodiments, the exhaust pipes 111a, 111b and 111c are as follows: Fig.42 As shown in the figure, different first mixtures M1', second mixtures M2' and third mixtures M3' are respectively discharged into the mold cavity 103 at the same flow rate / amount, such as operation S220, operation S240 and operation S260 are performed simultaneously. In some specific embodiments, the flow rate / amount of the first mixture M1' flowing out of the discharge pipe 111a is set, and the flow rates / amounts of the second mixtures M2' and third mixtures M3' flowing out of the discharge pipes 111b and 111c, respectively, are set by the central processor to be the same as the flow rate / amount of the first mixture M1' flowing out of the discharge pipe 111a.

[0100] In some specific embodiments, the exhaust pipes 111a, 111b and 111c are as follows: Fig.43As shown in the figure, the first mixture M1', the second mixture M2' and the third mixture M3' are flowed out into the mold cavity 103 in different amounts. For example, the flow rate / amount of the first mixture M1' flowing out from the discharge pipe 111a is set, and then the flow rates / amounts of the second mixture M2' and the third mixture M3' flowing out from the discharge pipes 111b and 111c, respectively, are set by the central processor based on the flow rate / amount of the first mixture M1' flowing out from the discharge pipe 111a. Furthermore, if the flow rate / amount of the second mixture M2' is greater than the flow rates / amounts of the first mixture M1' and the third mixture M3', the second component M2 has a wider width in the X direction than the first component M1 and the third component M3.

[0101] Similar to the seventh specific embodiment, in the first to sixth specific embodiments, the flow rates / amounts of the first mixture M1', the second mixture M2' and the third mixture M3' can be controlled by the central processor so that the flow rates / amounts of the first mixture M1', the second mixture M2' and the third mixture M3' are the same or different.

[0102] Fig.44 and Fig.45 The eighth embodiment of the present invention is shown in FIG. Figure 2 Schematic cross-sectional view of exemplary stages in the injection molding method 20. In this eighth specific embodiment, the operations of the injection unit 110 are shown.

[0103] exist Fig.44 , the injection unit 110 is configured to discharge the mixture. The mixture is discharged through one or more discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f of the injection unit 110 coupled to the molding device 100. The mixture may flow from the injection unit 110 into the molding device 100. In some specific embodiments, the mixture may flow from the injection unit 110 into the mold cavity 103 through the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f and the first gate 105a, the second gate 105b, the third gate 105c, the fourth gate 105d, the gate 105e, and the gate 105f, respectively.

[0104] The molding device 100 includes a mold cavity 103, which is defined by a first mold 101 and a second mold 102. In some specific embodiments, the mold cavity 103 includes a first sub-cavity 103a; and a second sub-cavity 103b, which is separated from the first sub-cavity 103a. The first sub-cavity 103a cannot be connected to the second sub-cavity 103b. In some specific embodiments, the volume of the first sub-cavity 103a is substantially the same as the volume of the second sub-cavity 103b. In some specific embodiments, the first sub-cavity 103a can be connected to the first gate 105a, the second gate 105b and the third gate 105c, and the second sub-cavity 103b can be connected to the fourth gate 105d, the gate 105e and the gate 105f. However, it is not intended to limit the number of gates corresponding to one sub-cavity.

[0105] In some embodiments, if one of the exhaust pipes 111a, 111b, 111c, 111d, 111e, and 111f is set or adjusted, the rest of the exhaust pipes 111a, 111b, 111c, 111d, 111e, and 111f are also adjusted accordingly. In some embodiments, the adjustment of the rest of the exhaust pipes 111a, 111b, 111c, 111d, 111e, and 111f is performed immediately after the setting / adjustment of one of the exhaust pipes 111a, 111b, 111c, 111d, 111e, and 111f. In some embodiments, such subsequent adjustments are automatically and instantly performed by a central processor (not shown).

[0106] For example, a parameter associated with the discharge pipe 111a (such as a flow rate, an amount of a mixture, an ejection force provided to the mixture for discharge, or the like) is set to a first value, and then a parameter associated with another discharge pipe 111d is adjusted based on the first value. In some embodiments, the parameter associated with the discharge pipe 111a is associated with the parameter associated with the other discharge pipe 111d at a first ratio, so that the parameter associated with the other discharge pipe 111d can be derived based on the first ratio and can be adjusted to the derived result. For example, if the first ratio is 1, the parameter associated with the discharge pipe 111d will be adjusted to be the same as the parameter associated with the discharge pipe 111a.

[0107] In some embodiments, if the parameter associated with the discharge pipe 111a is adjusted, the parameters of the discharge pipes 111b and 111c are adjusted accordingly. In some embodiments, the parameter associated with the discharge pipe 111a is associated with the parameter of the discharge pipe 111b at a second ratio. For example, when the parameter associated with the discharge pipe 111a is set to the first value, then the parameter of the discharge pipe 111b is adjusted according to the first value and the second ratio. In some embodiments, the parameter associated with the discharge pipe 111a is associated with the parameter associated with the discharge pipe 111c at a third ratio. For example, when the parameter associated with the discharge pipe 111a is set to the first value, then the parameter of the discharge pipe 111c is adjusted according to the first value and the third ratio. Or, in some embodiments, the parameter associated with the discharge pipe 111b is associated with the parameter associated with the discharge pipe 111c at a fourth ratio. Thus, after obtaining the parameter associated with the discharge pipe 111b, the parameter is associated with the discharge pipe 111c according to the fourth ratio.

[0108] Similarly, in some embodiments, if the parameter associated with the discharge pipe 111d is adjusted, the parameters of the discharge pipes 111e and 111f are adjusted accordingly. In some embodiments, the parameter associated with the discharge pipe 111d is associated with the parameter associated with the discharge pipe 111e at a fifth ratio. For example, when the parameter associated with the discharge pipe 111d is set to the second value, then the parameter of the discharge pipe 111e is adjusted according to the second value and the fifth ratio. In some embodiments, the parameter associated with the discharge pipe 111d is associated with the parameter of the discharge pipe 111f at a sixth ratio. For example, when the parameter associated with the discharge pipe 111d is set to the second value, then the parameter of the discharge pipe 111f is adjusted according to the second value and the sixth ratio. Alternatively, in some embodiments, the parameter associated with the discharge pipe 111e is associated with the parameter associated with the discharge pipe 111f at a seventh ratio. Thus, after obtaining the parameter associated with the discharge pipe 111e, the parameter associated with the discharge pipe 111f is adjusted according to the seventh ratio.

[0109] In some specific embodiments, the mixture M' is then discharged from the discharge pipes 111a, 111b, 111c, 111d, 111e and 111f, and as Fig.45As shown in the figure, the mixture M' enters the first sub-cavity 103a and the second sub-cavity 103b through the first gate 105a, the second gate 105b, the third gate 105c, the fourth gate 105d, the gate 105e and the gate 105f respectively. The mixture is discharged according to the adjustment result described above. In some specific embodiments, after the mixture M' is ejected, the mixture M' undergoes physical foaming in the first sub-cavity 103a and the second sub-cavity 103b to become the component M. In some specific embodiments, the components M have substantially the same size, weight, density, etc.

[0110] According to the embodiments of the present disclosure, the injection molding method is used to form articles with multiple hardness / density. By removing the partitions 104 and / or controlling the flow rates of the mixtures, the mixtures with different physical properties are injected into the mold cavity 103 to form the article 107, thereby reducing the manufacturing time of the article including more than one part with different physical or functional properties.

[0111] The foregoing summarizes the features of several specific embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art will appreciate that they may easily use the present disclosure as a basis for designing or modifying other programs and structures in order to perform the same purposes and / or achieve the same advantages as the specific embodiments described herein. Those skilled in the art will also appreciate that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and modifications may be made herein without departing from the spirit and scope of the present disclosure.

[0112] Furthermore, the scope of the present invention is not intended to be limited to the specific embodiments of the procedures, machines, manufactures, compositions of matter, means, methods and steps described in this specification. Thus, one of ordinary skill in the art will readily understand from the disclosure of the present invention that procedures, machines, manufactures, compositions of matter, means, methods or steps currently existing or to be developed later that perform substantially the same functions as the corresponding embodiments described herein or achieve substantially the same results may be utilized in accordance with the present invention. Accordingly, the appended claims are intended to include within their scope such procedures, machines, manufactures, compositions of matter, means, methods and steps.

[0113] Explanation of symbols

[0114] 10: Injection molding system

[0115] 20: Injection molding method

[0116] 100: Molding device

[0117] 101: The first mold

[0118] 102, 102a: Second mold

[0119] 102b: The third mold

[0120] 103: Mold cavity

[0121] 103a: First sub-chamber

[0122] 103b: Second sub-chamber

[0123] 103c: The third sub-chamber

[0124] 103d: Fourth mold cavity

[0125] 104: Partition

[0126] 104a: First partition

[0127] 104b: Second partition

[0128] 105, 105e, 105f: Gate

[0129] 105a: First gate

[0130] 105b: Second gate

[0131] 105c: The third gate

[0132] 105d: The fourth gate

[0133] 106a: First surface layer

[0134] 106b: Second surface

[0135] 106c: Third surface

[0136] 106d: Fourth Surface

[0137] 107: Products

[0138] 108a: First visible border line

[0139] 108b: Second visible border line

[0140] 110: Injection unit

[0141] 111, 111a, 111b, 111c, 111d, 111e, 111f: Exhaust pipe

[0142] 120: Mixing unit

[0143] 122: Pipeline

[0144] M: Component

[0145] M': mixture

[0146] M1: First Component

[0147] M1': First mixture

[0148] M2: Second Component

[0149] M2': Second mixture

[0150] M3: The third component

[0151] M3': The third mixture

[0152] M4: The fourth component

[0153] M4': The fourth mixture

[0154] S210, S220, S230, S240, S250, S260, S270: operation.

Claims

1. An injection molding method, characterized in that: Include: A molding device is provided, the molding device comprising a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold; injecting a first mixture into the mold cavity through a first gate; forming a first component from the first mixture; injecting a second mixture into the mold cavity through a second gate; and forming a second component from the second mixture, The second component is at least partially in contact with the first component, and the first component and the second component have different physical properties.

2. The injection molding method according to claim 1, characterized in that Further including: The mold cavity is divided into a first sub-cavity and a second sub-cavity by a first partition plate, The first partition is removable, and the first sub-cavity of the mold cavity is defined by the first mold, the second mold and the first partition.

3. The injection molding method according to claim 1, wherein: Further including: The mold cavity is divided into a first sub-cavity, a second sub-cavity and a third sub-cavity by a first partition and a second partition, wherein the first partition and the second partition are removable, the first sub-cavity is defined by the first mold, the second mold and the first partition, and the second sub-cavity is defined by the first mold, the second mold and the second partition; removing the first baffle from the mold cavity before injecting the second mixture into the second subcavity of the mold cavity, wherein the first component is at least partially in contact with the first baffle before removing the first baffle from the mold cavity; removing the second separator from the mold cavity after injecting the second mixture into the second subcavity of the mold cavity; as well as A third mixture is injected through a third gate into the third subcavity defined by the first mold, the second mold and the second assembly.

4. The injection molding method according to claim 1, wherein: Further including: The first mixture is controlled to flow through the first gate and the second mixture is controlled to flow through the second gate at the same or different flow rates.

5. The injection molding method according to claim 1, characterized in that Further including: Providing the molding device including the first mold and a third mold located above the first mold; injecting a third mixture into another mold cavity defined by the first mold and the third mold through a third gate disposed in the third mold; forming a third component from the third mixture; and before the first mixture is injected into the mold cavity through the first gate, replacing the third mold with the second mold, The mold cavity is further defined by the second mold and the third component disposed in the first mold.

6. An injection molding method, characterized in that: include: A molding device is provided, the molding device comprising a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold; injecting a first mixture into the mold cavity through a first gate; forming a first component from the first mixture; injecting a second mixture into the mold cavity through a second gate; and forming a second component from the second mixture, The second component is separated from the first component, and the first component and the second component have different physical properties.

7. The injection molding method according to claim 6, characterized in that Further including: The mold cavity is divided into a first sub-cavity and a second sub-cavity by a first partition plate and a second partition plate, wherein the first partition and the second partition are removable, and The first sub-cavity of the mold cavity is defined by the first mold, the second mold, and the first partition, and the second sub-cavity of the mold cavity is defined by the first mold, the second mold, and the second partition.

8. An assembly of polymer components, characterized in that: include: a first polymer component having a first surface layer; as well as a second polymer component having a second surface layer in contact with the first surface layer, The first surface layer has a density greater than the central portion of the first polymer component, the second surface layer has a density greater than the central portion of the second polymer component, and a visible boundary line exists between the first surface layer and the second surface layer.

9. The assembly of claim 8, wherein: Further including: a third polymer component having a third surface layer, The third surface layer is in contact with a fourth surface layer of the second polymer component.

10. The assembly of claim 9, wherein: Further including: a fourth polymer component having a fifth surface layer, The fifth surface layer is in contact with the bottom surfaces of the first polymer component, the second polymer component and the third polymer component, and a first side surface of the first polymer component and a second side surface of the third polymer component are in contact with the fifth surface layer.

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