Injection molding system and method

Abstract

The invention discloses an injection molding method, and provides a molding device and a runner plate above the molding device. The molding apparatus 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 runner plate comprises a first runner and a second runner which can be communicated with the mold cavity and extend in the runner plate. A distributor is disposed within the runner plate, and the distributor has a channel connectable to the first runner or the second runner. A mixture is ejected into the mold cavity through the channel and the first flow channel, and the first mixture does not flow into the mold cavity through the channel and the second flow channel. A foam article is formed from the mixture within the mold cavity.

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 preventing waste residue or waste from being formed in a flow channel of a flow channel plate. Background Art

[0002] Foamed polymer materials have many advantages, such as high strength, low weight, impact resistance, thermal insulation, etc. Foamed products 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 product.

[0003] However, it is necessary to improve the smooth flow of the mixture in the injection molding system to ensure that the molding of the foamed product is not affected. Therefore, there is still a need for improvements in the structure of the injection molding system and the method for making the foamed product. Summary of the invention

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

[0005] According to a specific embodiment of the present invention, an injection molding method is provided. The injection molding method includes: providing a molding device and a flow channel plate located above the molding device, wherein the molding device includes a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold, and the flow channel plate includes a first and a second flow channel communicating with the mold cavity and extending in the flow channel plate; placing a first distributor in the flow channel plate, wherein the first distributor has a channel that can connect the first flow channel or the second flow channel; injecting a first mixture into the mold cavity through the channel and the first flow channel, wherein the first mixture does not flow into the mold cavity through the channel and the second flow channel; and forming a first foamed product from the first mixture in the mold cavity.

[0006] According to a specific embodiment of the present invention, an injection molding method is provided. The injection molding method includes: providing a molding device and a flow channel plate located above the molding device, wherein the molding device includes a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold, and the flow channel plate includes first and second flow channels communicating with the mold cavity and extending in the flow channel plate; inserting a first plug into the first flow channel; injecting a first mixture into the mold cavity through the second flow channel, wherein the first mixture does not flow into the mold cavity through the first flow channel; and forming a first foamed product from the first mixture in the mold cavity.

[0007] According to a specific embodiment of the present invention, an injection molding system is provided. The injection molding system includes a molding device, a runner plate, and a distributor. The molding device includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold. The runner plate is arranged above the molding device, and includes a first runner and a second runner that can be communicated with the mold cavity and extend in the runner plate. The distributor is placed in the runner plate and has a channel that can connect the first runner or the second runner. The distributor is configured to prevent a mixture from flowing into the mold cavity through one of the first runner and the second runner, and to allow the mixture to flow into the mold cavity through the channel and the other of the first runner and the second runner.

[0008] Simple diagram description

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

[0010] Figure 1 A schematic diagram of an injection molding system according to some embodiments of the present invention;

[0011] Figure 2 and Figure 3 A front perspective view of an injection molding system according to some embodiments of the present invention;

[0012] Figure 4 The flow channel plate along some embodiments of the present invention is illustrated Figure 2 A top view of the section along the A-A' line;

[0013] Figure 5 The injection molding system according to some embodiments of the present invention is Figure 2 Side perspective view of the middle B-B' line;

[0014] Figure 6 A front perspective view of an injection molding system according to some embodiments of the present invention;

[0015] Figure 7 and Figure 8 The flow channel plate along some embodiments of the present invention is illustrated Figure 6 A top view of the section along the A-A' line;

[0016] Fig. 9 A front perspective view of an injection molding system according to some embodiments of the present invention;

[0017] Fig.10 The flow channel plate along some embodiments of the present invention is illustrated Fig. 9A top view of the section along the A-A' line;

[0018] Fig.11 A front perspective view of an injection molding system according to some embodiments of the present invention;

[0019] Fig.12 and Fig.13 The flow channel plate along some embodiments of the present invention is illustrated Fig.11 A top view of the section along the A-A' line;

[0020] Fig.14 A front perspective view of an injection molding system according to some embodiments of the present invention;

[0021] Fig.15 and Fig.16 The flow channel plate along some embodiments of the present invention is illustrated Fig.14 A top view of the section along the A-A' line;

[0022] Fig.17 A flowchart showing an injection molding method according to some embodiments of the present invention;

[0023] Figures 18 to 22 As an example, a specific embodiment of the present invention is described Fig.17 Schematic cross-sectional view of the demonstration stage of the injection molding method;

[0024] Fig.23 A flowchart showing an injection molding method according to some embodiments of the present invention;

[0025] Figures 24 to 32 As an example, a specific embodiment of the present invention is described Fig.23 Schematic cross-section of a demonstration stage of the injection molding method. Implementation

[0027] [Cross reference to related applications]

[0028] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 585,971 filed on September 28, 2023, and U.S. Patent Application Serial No. 18 / 748,101 filed on June 20, 2024, the entire contents of which are incorporated herein by reference.

[0029] The following description provides many different specific embodiments or examples for implementing different features in the provided subject matter. Specific examples of components and configurations are described below to simplify the present invention. Of course, these are only examples and are not restrictive. 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 directly contacted, and may also include specific embodiments in which additional features can be formed between the first and second features so that the first and second features are not directly contacted. In addition, the present invention may repeat reference numbers and / or letters in various examples. The purpose of this repetition is simplicity and clarity, and does not in itself represent the relationship between the various specific embodiments and / or configurations discussed.

[0030] Furthermore, spatially relative terms, such as "below," "beneath," "beneath," "above," and the like, may be used herein to facilitate describing the relationship of one element or feature to another element or feature, as illustrated in the figures. Such spatially relative terms 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 terms used herein interpreted accordingly.

[0031] Although the numerical ranges and parameters describing the broad scope of the present invention are approximate, the numerical values ​​disclosed in the specific examples are reported as accurately as possible. However, any numerical value originally contains certain errors caused by the standard deviation found in the corresponding test measurement. In addition, as used herein, the term "about" generally refers to within 10%, 5%, 1% or 0.5% of a known value or range. Alternatively, when considered by a skilled technician, the term "about" means within the acceptable standard error of the mean value. Except in the operating / working examples, or unless otherwise explicitly stated, all numerical ranges, quantities, values ​​and percentages described herein, such as material quantities, durations, temperatures, operating conditions, quantity ratios, etc., should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise indicated, the numerical parameters described in the present invention and the attached patent scope are approximate values ​​that can be changed as needed. At least, each numerical parameter should be interpreted according to the number of significant figures reported and by applying ordinary rounding techniques. In this article, the range can be expressed from one endpoint to another or between two endpoints. Unless otherwise stated, all ranges disclosed herein are inclusive of the endpoints.

[0032] Figure 1 Schematic diagram of an injection molding system 100 according to some embodiments of the present invention. The injection molding system 100 includes a melting unit 110, a mixing unit 120, an injection unit 130, an ejector 101 that can communicate with the injection unit 130, a flow channel plate 103 embedded with a flow channel, and a molding device 105 that can communicate with the flow channel in the flow channel plate 103.

[0033] The melting unit 110 is configured to produce a polymer material (e.g., thermoplastic polyurethane (TPU), polyurethane (PU), plastic, etc.) in a molten state. The polymer material is then delivered to the mixing unit 120 through at least one delivery channel 112. The mixing unit 120 is configured to produce a mixture of the polymer material and a physical foaming agent (e.g., gaseous nitrogen, carbon dioxide, supercritical fluid, etc.), which is foamable or slightly foamable. The mixture is then delivered to the injection unit 130 through at least one delivery channel 122. The injection unit 130 is configured to discharge the mixture to the molding device 105 through the injection unit 130 and the flow channel plate 103.

[0034] Figure 2 FIG. 1 is a front perspective view of an injection molding system 100 according to some embodiments of the present invention.

[0035] In some embodiments, the molding device 105 is configured to form an article comprising a polymer material. In some embodiments, the molding device 105 includes a first mold 105c, a second mold 105d, at least one feed port 105a passing through the second mold 105d, and at least one mold cavity 105b defined by the first mold 105c and the second mold 105d when the molding device 105 is in a closed state (i.e., the first mold 105c is engaged with the second mold 105d). In some embodiments, the first mold 105c is a lower mold, and the second mold 105d is an upper mold and is disposed above the first mold 105c. In some embodiments, each mold cavity 105b can be connected to at least one feed port 105a. In some embodiments, the article is formed inside the molding device 105 by physical foaming. The mixture is physically foamed and then forms a foamed article. In some embodiments, the article is a part of footwear (e.g., an outer sole, an inner sole, a midsole, etc.) or any other product.

[0036] In some embodiments, the ejector 101 has an outlet 101a for discharging the mixture. In some embodiments, the ejector 101 is coupled to the manifold plate 103. In some embodiments, the outlet 101a may be coupled to and communicated with the inlet 103a of the manifold plate 103. The mixture may flow from the outlet 101a to the inlet 103a, respectively, and flow along the manifold 103c to the plurality of outlets 103b of the manifold 103c. In some embodiments, the mixture may flow from the ejector 101 through the manifold plate 103 and the corresponding feed port 105a into each cavity 105b. In some embodiments, the mixture may flow into the mold cavities 105b-1 and 105b-2 via the feed ports 105a-1 and 105a-2, respectively. The mixture will be distributed into each manifold 103c and then enter the corresponding mold cavity 105b.

[0037] In some embodiments, each outlet 103b may be in communication with at least one mold cavity 105b defined by the molding device 105. In some embodiments, the molding device 105 includes a plurality of mold cavities 105b-1 and 105b-2. Figure 2 The embodiment of FIG. 1 shows two mold cavities 105 b - 1 and 105 b - 2 , however it is not intended to limit the number of mold cavities 105 b in the molding device 105 .

[0038] In some embodiments, the gate 104 is disposed at the outlet 103b of the runner plate 103. The gate 104 is configured to control the flow (e.g., flow rate, flow rate, etc.) of the mixture into the mold cavity 105b through the outlet 103b. In some embodiments, when the gate 104 is opened or partially opened, the mixture can flow into the mold cavity 105b through the outlet 103b, and when the gate 104 is closed, the mixture cannot flow into the mold cavity 105b through the outlet 103b. The state of the gate 104 can be switched automatically or manually.

[0039] Figure 3 is a front perspective view of an injection molding system 100 according to some embodiments of the present invention. Figure 3 In an embodiment of the present invention, the injection molding system 100 further includes a runner 102 that can be engaged with the ejector 101. The outlet 101a of the ejector 101 can be engaged with the inlet 102a of the runner 102, so that the mixture can flow from the ejector 101 into the runner 102. In some embodiments, the runner 102 is at least partially surrounded by the runner plate 103. In some embodiments, the runner 102 is placed on the runner 103c. The runner 102 is configured to facilitate the engagement of the ejector 101 with the runner plate 103. The mixture can flow from the inlet 102a of the runner 102 to the outlet 102b. In some embodiments, the outlet 102b of the runner 102 can be engaged with and communicated with the inlet 103a of a plurality of runners 103c. The mixture can flow from the inlet 103a along the runner 103c to the plurality of outlets 103b of the runner 103c, respectively. In some embodiments, the mixture may flow from the ejector 101 through the runner 102, the runner plate 103 and the corresponding feed port 105a into each mold cavity 105b, such as Figure 3 As shown inside.

[0040] Figure 4 The flow channel plate 103 according to some embodiments of the present invention is illustrated along Figure 2 103c. In some embodiments, the flow channel plate 103 can be heated by a heater, a coil, etc. to maintain the flow channel 103c at a certain temperature and allow the mixture to remain in a flowable state. In some embodiments, each flow channel 103c extends within the flow channel plate 103. Each flow channel 103c connects the inlet 103a to the corresponding outlet 103b. Figure 4Six flow channels 103c extending in the flow channel plate 103 are shown, however, it is not intended to limit the number of flow channels 103c in the flow channel plate 103. In addition, it is not intended to limit the construction or design of the flow channels 103c. In some embodiments, the inlet 103a is connected to the flow channels 103c-1, 103c-2, 103c-3, 103c-4, 103c-5 and 103c-6. In some embodiments, the flow channels 103c-1, 103c-2, 103c-3, 103c-4, 103c-5 and 103c-6 are respectively connected to the outlets 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, 103b-6.

[0041] The flow channels 103c have the same or different sizes (e.g., width, diameter, length, etc.). In some embodiments, the flow channels 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 have the same width, the same diameter, and the same length. In some embodiments, the flow channels 103c are divided into a plurality of groups having different sizes, and each group of flow channels 103c has a separate size (e.g., width, diameter, length, etc.).

[0042] Figure 5 The injection molding system 100 according to some embodiments of the present invention is Figure 2 Side perspective view of line B-B'. Figure 5 In the specific embodiment of FIG. 1 , the mixture can flow from the ejector 101 into the mold cavity 105b-1 through the outlets 103b-1, 103b-3 and 103b-5 of the manifold plate 103 and the corresponding feed ports 105a-1, 105a-3 and 105a-5. Figure 5 It is illustrated that each mold cavity 105b corresponds to three outlets 103b, however, it is not intended to limit the number of outlets 103b corresponding to one mold cavity 105b.

[0043] Figure 6 is a front perspective view of an injection molding system 100 according to some embodiments of the present invention. Figure 6 In the specific embodiment, the plug 106 is placed in the flow channel plate 103 . Figure 7 The flow channel plate 103 according to some embodiments of the present invention is illustrated along Figure 6 Top view of the section along line A-A'.

[0044] In some embodiments, the plug 106 is a plastic block, a metal block, etc. In some embodiments, the plug 106 is inserted into the flow channel 103c so that the mixture cannot flow through the flow channel 103c. In some embodiments, the plug 106 is temporarily fixed inside the flow channel 103c and can be removed from the flow channel 103c. For example, the plug 106 is placed in the flow channel 103c-1 so that the mixture cannot flow into the mold cavity 105b-1 through the flow channel 103c-1, while the mixture can still flow into the mold cavity 105b-1 through other flow channels 103c-3 and 103c-5. In some embodiments, the plug 106 can be placed or removed when the flow channel plate 103 is engaged with the molding device 105. In some embodiments, the plug 106 can be placed or removed when the flow channel plate 103 is disengaged from the molding device 105. In some embodiments, when the plug 106 has been removed from the flow channel plate 103 Figure 3 When the runner 102 is removed, the plug 106 may be placed or removed.

[0045] When the mixture is ejected into the mold cavity 105b, some of the mixture may remain in the flow channel 103c (for example, because the mixture has viscosity, etc.). The mixture remaining in the flow channel 103c may prevent or even prevent the mixture subsequently injected from the ejector 101 from flowing through the flow channel 103c. That is, the mixture ejected next time may not flow or may not flow smoothly into the mold cavity 105b. Since the plug 106 can be placed or removed when necessary, the mixture can be prevented from forming a slug or waste in the flow channel 103c, and the residual mixture can be prevented from remaining in the flow channel 103c for a long time. In addition, by simply adding or removing the plug 106, the number of flow channels 103c to be used can be easily adjusted without changing to another flow channel plate 103 of a different configuration. As a result, manufacturing costs and manpower can be saved. In some embodiments, the plug 106 can be placed or removed manually or remotely.

[0046] Figure 8 Multiple plugs 106 are shown to be placed in flow channels 103c-1 and 103c-4, respectively. It should be understood that the number of plugs 106 is not intended to be limited. In some embodiments, plugs 106 can be placed or removed manually or by a robot arm, etc. In some embodiments, plugs 106 are replaced regularly. For example, after removing a plug from flow channel 103c-1, another plug is reinserted into flow channel 103c-1.

[0047] Fig. 9 is a front perspective view of an injection molding system 100 according to some embodiments of the present invention. Fig. 9 In a specific embodiment, the distributor 107 is placed inside the flow channel plate 103 . Fig.10 The flow channel plate 103 according to some embodiments of the present invention is illustrated along Fig. 9 Top view of the section along line A-A'.

[0048] In some embodiments, the mixture can be distributed to each flow channel 103c through the distributor 107. In some embodiments, the mixture can be evenly distributed to each flow channel 103c through the distributor 107. In some embodiments, the distributor 107 includes an inlet 107a, a plurality of outlets 107b, and a plurality of channels 107c between the inlet 107a and the outlets 107b. The inlet 107a of the distributor 107 is connected to the inlet 103a of the flow channel plate 103, so that the mixture can flow from the ejector 101 through the distributor 107 into the flow channel 103c. Each channel 107c corresponds to an outlet 107b. Fig.10 In a specific embodiment, six channels 107c-1, 107c-2, 107c-3, 107c-4, 107c-5 and 107c-6 are respectively connected to outlets 107b-1, 107b-2, 107b-3, 107b-4, 107b-5 and 107b-6. It should be understood that the number of channels 107c is not limited as long as the number of channels 107c corresponds to the number of outlets 107b. In some embodiments, the distributor 107 is a separator, etc. In some embodiments, the distributor 107 can be rotated relative to the flow channel 103c and the flow channel plate 103. In some embodiments, the distributor 107 can be rotated manually or remotely. In some embodiments, the distributor 107 can be rotated by a robot arm, etc. In some embodiments, the size (e.g., width, diameter, length, etc.) of the flow channel 103c is substantially larger than the size of the channel 107c.

[0049] In some embodiments, the distributor 107 is temporarily fixed inside the flow channel 103c and can be removed from the flow channel 103c. When a stream of mixture is injected into the mold cavity 105b, some of the mixture may remain in the flow channel 103c because the mixture is viscous. Then, the mixture remaining in the flow channel 103c may cool and solidify, resulting in preventing or even preventing the next stream of mixture from flowing through the channel 107c. That is, the next injected mixture may not flow or may not flow smoothly into the mold cavity 105b. This problem can be solved by simply removing the distributor 107 from the flow channel plate 103 and replacing it with another new distributor 107. Since the distributor 107 can be placed or removed when needed, it can be avoided that the residual mixture remains in the flow channel 103c for a long time. In addition, by simply changing the distributor 107 of different configurations (such as a different number of channels 107c, etc.), the number of flow channels 103c used can be easily adjusted without replacing another flow channel plate 103. As a result, manufacturing costs and manpower can be saved. In some embodiments, the dispenser 107 can be placed or removed manually or remotely. In some embodiments, the dispenser 107 can be placed or removed by a robotic arm or the like.

[0050] Fig.11is a front perspective view of an injection molding system 100 according to some embodiments of the present invention. Fig.11 In a specific embodiment, the stopper 108 is placed within the channel 107 c of the distributor 107 . Fig.12 The flow channel plate 103 according to some embodiments of the present invention is illustrated along Fig.11 Top view of the section along line A-A'.

[0051] In some embodiments, the stopper 108 is inserted into the channel 107c of the distributor 107 so that the mixture cannot flow through the channel 107c. In some embodiments, the stopper 108 is a plastic block, a metal block, etc. In some embodiments, the stopper 108 is temporarily fixed inside the channel 107c and can be removed from the channel 107c. For example, the stopper 108 is placed in the channel 107c-1 so that the mixture cannot flow into the mold cavity 105b-1 through the channel 107c-1 and the flow channel 103c-1, while the mixture can still flow into the mold cavity 105b-1 through the channels 107c-3 and 107c-5 and the corresponding flow channels 103c-3 and 103c-5. Since the stopper 108 can be placed or removed when necessary, the mixture can be prevented from forming a slug or waste in the flow channel 103c, and the residual mixture can be minimized or avoided from remaining in the flow channel 103c. Furthermore, by simply adding or removing the stopper 108, the number of flow channels 103c to be used can be easily adjusted without changing to another flow channel plate 103. As a result, manufacturing costs and manpower can be saved.

[0052] Fig.13 The flow channel plate 103 according to some embodiments of the present invention is illustrated along Fig.11 A top view of the cross section along the A-A' line. Fig.13 In a specific embodiment, more blocks 108 are placed in channels 107c-1 and 107c-6, respectively. It should be understood that the number of blocks 108 is not intended to be limited. In some embodiments, the blocks 108 can be placed or removed manually or remotely. In some embodiments, the blocks 108 can be placed or removed by a robot arm or the like.

[0053] In some embodiments, rather than placing stops 108 within channels 107c of distributor 107 to prevent the mixture from flowing through channels 107c, distributor 107 is configured to have a smaller number of channels 107c (eg, compared to the number of flow passages 103c).

[0054] Fig.14 FIG. 1 is a front perspective view of an injection molding system 100 according to some embodiments of the present invention. Fig.15 The flow channel plate 103 according to some embodiments of the present invention is illustrated along Fig.14 Top view of the section along line A-A'.

[0055] exist Fig.14 and Fig.15 In a specific embodiment, the distributor 107 is configured to have a smaller number of channels 107c. For example, the distributor 107 does not have a channel 107c-1 (e.g., Fig.13 103c-1). In other words, the distributor 107 is designed to block the flow channel 103c-1. In this specific embodiment, when the distributor 107 is placed in the flow channel plate 103, the channels 107c-2 to 103c-6 are configured to align with the flow channels 103c-2 to 103c-6, but not with the flow channel 103c-1.

[0056] In some embodiments, the distributor 107 can be rotated within the flow channels 103c so that the distributor 107 is designed to block one or more flow channels 103c. Fig.15 If the distributor 107 in FIG. 1 is rotated clockwise (e.g., about 15°), the flow channel 103c-5 is blocked by the distributor 107, and the flow channel 103c-1 becomes connected to the channel 107c-3. Therefore, the mixture flowing through the flow channel 103c can be selected by rotating the distributor 107. In some embodiments, the distributor 107 can have various configurations.

[0057] Fig.16 Another configuration of the distributor 107 according to some embodiments of the present invention is illustrated. Fig.16 In the embodiment, the distributor 107 has four channels 107c, so that two flow channels 103c are blocked. It should be understood that the number of channels 107c is not intended to be limited. Fig.16 When the distributor 107 in the embodiment is rotated clockwise (for example, about 15°), the flow channels 103c-5 and 103c-4 are blocked by the distributor 107, while the flow channels 103c-1, 103c-2, 103c-3 and 103c-6 become connectable to the corresponding channels 107c-3, 107c-4, 107c-5 and 107c-6.

[0058] Fig.17 The flowchart of the injection molding method 200 is shown according to some embodiments of the present invention. The injection molding method 200 includes operations S210 to S250, and the description and illustration are not considered to be limiting on the order of the operations S210 to S250. Figures 18 to 22 2 is a schematic cross-sectional view of various stages of the injection molding method 200. In some embodiments, the operations of the injection molding method 200 can be repeated and automatically performed. In some embodiments, the injection molding method 200 comprises Figure 1 The injection molding system 100 is performed.

[0059] In operation S210, a molding device 105 and a flow channel plate 103 are provided. In some embodiments, the molding device 105 includes a first mold 105c, a second mold 105d, and a mold cavity 105b defined by the first mold 105c and the second mold 105d being engaged with each other, and the flow channel plate 103 includes a plurality of flow channels 103c extending inside. In operation S220, a plug is inserted into a first flow channel 103c of the flow channels 103c. In operation S230, the injection unit 130 is configured to inject the mixture from the mixing unit 120 into the mold cavity 105b of the molding device 105 through the injector 101 and the flow channels 103c other than the first flow channel 103c (i.e., the flow channel 103c into which the plug has been inserted), and then a foamed product is formed from the mixture in operation S240. It should be noted that the mixture from the injection unit 130 cannot flow into the mold cavity 105b through the first flow channel 103c. In operation S250, after the foamed product is formed, the plug is removed from the first flow channel 103c of the flow channel plate 103. When the flow channel plate 103 is arranged on the molding device 105, the plug may be inserted into or removed from the flow channel 103c.

[0060] In some embodiments, before inserting the plug in operation S220 or after removing the plug in operation S250, the injection unit 130 is configured to inject the mixture (or another mixture) into the mold cavity 105b through the injector 101 and all the flow channels 103c, and then form another foamed product from the mixture.

[0061] In some embodiments, after the foamed article is formed in operation S240 , an additional plug is inserted into one of the flow channels 103 c other than the first flow channel, and then operation S250 is performed or omitted for the next shot (or next injection) of the mixture.

[0062] Fig.18 FIG. 1 is a front perspective view of an injection molding system 100 according to some embodiments of the present invention. The injection molding system 100 includes an injector 101, a flow channel plate 103, and a molding device 105. The injector 101 is then coupled to the flow channel plate 103, and the molding device 105 is coupled to the flow channel plate 103, as shown in FIG. Fig.19 The first mold 105c of the molding device 105 is engaged with the second mold 105d of the molding device 105, as shown. Fig.19 As shown. The molding device 105 is in a closed configuration. When the first mold 105c is joined with the second mold 105d, at least one mold cavity 105b is formed. In some embodiments, the outlet 101a of the ejector 101 is aligned with the outlet 103b of the flow channel plate 103, so that the ejector 101 can be connected to the mold cavity 105b via the flow channel plate 103. In some embodiments, the outlets 103b-1 and 103b-2 can be connected to the mold cavities 105b-1 and 105b-2, respectively.

[0063] In some embodiments, the plug 106 is inserted into the flow channel 103c extending in the flow channel plate 103. Fig. 20 In some embodiments, the plug 106 is inserted into the flow channel 103c-1, as shown in FIG. Fig. 20 and Figure 7 In some embodiments, the plug 106 is inserted before or after the flow channel plate 103 and the molding device 105 are joined. After the plug 106 is inserted, the mixture M is ejected from the ejector 101 through the flow channel plate 103 into the mold cavity 105b, as shown in FIG. Fig.21 In some embodiments, the injected mixture M is injected into the mold cavity 105b-1 through the flow channels 103c-3 and 103c-5, and injected into the mold cavity 105b-2 through the flow channels 103c-2, 103c-4 and 103c-6, as shown in FIG. Figure 7 In some embodiments, the gates 104 at the outlets 103b-3 and 103b-5 can be adjusted to allow a faster flow rate or a larger amount of the mixture M to flow into the mold cavity 105b-1. In some embodiments, the gates 104 at the outlets 103b-2, 103b-4, and 103b-6 can be adjusted to allow a slower flow rate or a smaller amount of the mixture M to flow into the mold cavity 105b-2.

[0064] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. Fig. 22 As shown, after the first mold 105c is separated from the second mold 105d, the foamed product is taken out of the molding device 105. In some embodiments, the plug 106 is removed from the flow channel 103c, as shown in FIG. Fig. 22 shown.

[0065] Fig.23 The flowchart of the injection molding method 300 is shown according to some embodiments of the present invention. The injection molding method 300 includes operations S310 to S350, and the description and illustration are not considered to be limiting on the order of the operations S310 to S350. Figures 24 to 32 3 is a schematic cross-sectional view of various stages of the injection molding method 300. In some embodiments, the operations of the injection molding method 300 can be repeated and automatically performed. In some embodiments, the injection molding method 300 comprises Figure 1 The injection molding system 100 is performed.

[0066] In operation S310, a molding device 105 and a flow channel plate 103 are provided. In some embodiments, the molding device 105 includes a first mold 105c, a second mold 105d, and a mold cavity 105b defined by the first mold 105c and the second mold 105d being engaged with each other, and the flow channel plate 103 includes first and second flow channels 103c extending inside. In operation S320, a distributor is placed in the flow channel plate 103, and the distributor has a channel that can be connected to the first or second flow channel 103c. In addition, the channel can be aligned with the first flow channel or the second flow channel. In operation S330, the injection unit 130 is configured to inject the mixture from the mixing unit 120 into the mold cavity 105b of the molding device 105 through the injector 101, the channel and the first flow channel 103c, and then form a foamed product from the mixture in operation S340. It should be noted that the mixture from the injection unit 130 cannot flow into the mold cavity 105b through the channel and the second flow channel 103c. In operation S350, after the foamed product is formed, the dispenser is removed from the manifold plate 103. When the manifold plate 103 is arranged on the molding device 105, the dispenser may be inserted into or removed from the manifold plate 103.

[0067] In some embodiments, before placing the dispenser in operation S320, the ejection unit 130 is configured to eject the mixture (or another mixture) into the mold cavity 105b through the ejector 101 and the first and second flow channels 103c, and then form another foamed product from the mixture. In some embodiments, after removing the dispenser from the flow channel plate 103, an additional dispenser is placed in the flow channel plate 103, and the additional dispenser is in a different configuration than the removed dispenser.

[0068] In some embodiments, when the distributor is placed in the flow channel plate 103, the channel of the distributor is aligned with the first flow channel, and the channel is not aligned with the second flow channel. In some embodiments, when the distributor is placed in the flow channel plate 103 for the next injection of the mixture, the distributor can be rotated relative to the flow channel plate 103. For example, after rotating the distributor, the channel of the distributor changes from being aligned with the first flow channel to being aligned with the second flow channel, and the channel is not aligned with the first flow channel.

[0069] In some embodiments, the injection molding method 300 includes inserting the distributor 107 into the flow channel 103c, such as Fig.24 As shown. In some embodiments, the distributor 107 is inserted before or after the manifold plate 103 and the molding device 105 are joined. In some embodiments, the inlet 103a of the manifold plate 103 is aligned with the inlet 107a of the distributor 107, and the outlet 107b of the distributor 107 is connected to the outlet 103b of the manifold plate 103. After the distributor 107 is inserted, the mixture M is ejected from the ejector 101 through the manifold plate 103 into the mold cavity 105b, as shown. Fig.25In some embodiments, the injected mixture M is injected into the mold cavity 105b-1 through the flow channels 103c-1, 103c-3 and 103c-5, and injected into the mold cavity 105b-2 through the flow channels 103c-2, 103c-4 and 103c-6, as shown in FIG. Fig.25 and Fig.10 In some embodiments, the distributor 107 evenly distributes the injection of the mixture M to the flow channels 103c-1, 103c-2, 103c-3, 103c-4, 103c-5 and 103c-6. In this way, the amount of the mixture M entering the mold cavity 105b-1 is substantially the same as the amount of the mixture M entering the mold cavity 105b-2, as shown in FIG. Fig.25 shown.

[0070] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M is physically foamed to become a foamed product. After the foamed product is formed, the foamed product is taken out of the molding device. In some embodiments, if the distributor 107 is no longer needed, if it needs to be replaced with another distributor 107 with a different configuration, or if it needs to be replaced with another new distributor 107, etc., the distributor 107 is removed from the flow channel 103c.

[0071] In some embodiments, the injection molding method 300 includes inserting the stopper 108 into the channel 107c of the distributor 107, such as Fig.26 In some embodiments, the stopper 108 is inserted before or after the flow channel plate 103 and the molding device 105 are joined. In some embodiments, the injected mixture M is injected into the mold cavity 105b-1 through the flow channels 103c-3 and 103c-5, and injected into the mold cavity 105b-2 through the flow channels 103c-2, 103c-4 and 103c-6, as shown in FIG. Fig. 27 In some embodiments, the gates 104 at the outlets 103b-3 and 103b-5 can be adjusted to allow a faster flow rate or a larger amount of the mixture M to flow into the mold cavity 105b-1. In some embodiments, the gates 104 at the outlets 103b-2, 103b-4, and 103b-6 can be adjusted to allow a slower flow rate or a smaller amount of the mixture M to flow into the mold cavity 105b-2.

[0072] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is taken out of the molding device. In some embodiments, if the stopper 108 is no longer needed, it is removed from the dispenser 107.

[0073] In some embodiments, the distributor 107 rotates when necessary (e.g., the flow channel 103c to be used is selected as needed, etc.). For example, the distributor 107 (together with the stopper 108) rotates clockwise so that the flow channel 103c-2 is blocked, such as Fig.28 and 29 shown. Fig.29 Example Fig.28 After the rotation, the injected mixture M is injected into the mold cavity 105b-1 through the flow channels 103c-1, 103c-3 and 103c-5, and injected into the mold cavity 105b-2 through the flow channels 103c-4 and 103c-6, as shown in FIG. Fig.30 As shown. In some embodiments, the gates 104 at the outlets 103b-4 and 103b-6 can be adjusted to allow a faster flow rate or a larger amount of the mixture M to flow into the mold cavity 105b-2. In some embodiments, the gates 104 at the outlets 103b-1, 103b-3, and 103b-5 can be adjusted to allow a slower flow rate or a smaller amount of the mixture M to flow into the mold cavity 105b-1. After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is taken out of the molding device.

[0074] In some embodiments, a distributor 107 of different configurations is inserted into the flow channel 103c, such as Fig.31 and Fig.16 In some embodiments, the distributor 107 is inserted before or after the ejector 101 and the flow channel plate 103 are joined. In some embodiments, the distributor 107 is inserted before or after the first mold 105c and the second mold 105d are joined. Fig.31 and Fig.16 The illustrated partition plate 107 does not have the channels 107c-1 and 107c-2. Thus, the mixture M is ejected into the mold cavity 105b-1 via the flow channels 103c-3 and 103c-5, and ejected into the mold cavity 105b-2 via the flow channels 103c-4 and 103c-6, as shown in FIG. Fig.32 As shown. In some embodiments, the distributor 107 evenly distributes the shot of the mixture M to the runners 103c-3, 103c-4, 103c-5 and 103c-6. After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is taken out of the molding device. In some embodiments, the distributor 107 is removed from the runner 103c.

[0075] According to a specific embodiment of the present invention, a replaceable plug or a replaceable distributor is used in an injection molding system. In some embodiments, the plug is inserted into the runner of the manifold plate to block the runner when necessary and prevent the formation of slugs or waste in the runner. In some embodiments, the distributor is placed between the runner and the runner of the manifold plate to guide the molding material to the selected runner, easily change the number of runners used in the manifold plate, and easily remove the molding material residues remaining in the manifold plate.

[0076] The features of several specific embodiments are summarized above so that those skilled in the art can better understand the various aspects of the present invention. Those skilled in the art should understand that they can easily use the present invention as a basis for designing or modifying other operations and structures to achieve the same purpose and / or achieve 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 present invention, and that various changes, substitutions and modifications can be made without departing from the spirit and scope of the present invention.

[0077] Furthermore, the scope of the present invention is not limited to the specific embodiments of the procedures, machines, manufactures, compositions of matter, components, methods and steps described in the specification. From the disclosure of the present invention, it will be readily apparent to those skilled in the art that procedures, machines, manufactures, compositions of matter, components, methods or steps that currently exist or will be developed in the future can be used in accordance with the present invention to perform the same functions as the corresponding embodiments described herein or obtain substantially the same results. Therefore, it is intended that the scope of the attached claims include such procedures, machines, manufactures, compositions of matter, components, methods and steps within their scope.

[0078] Explanation of symbols

[0079] 100: Injection molding system

[0080] 101: Ejector

[0081] 101a, 103b, 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, 103b-6, 107b, 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, 107b-6: Exit

[0082] 102: Runner

[0083] 102a: Entrance

[0084] 102b: Exit

[0085] 103: Runner plate

[0086] 103a, 107a: Entrance

[0087] 103c, 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, 103c-6: flow channel

[0088] 104: Gate

[0089] 105: Molding device

[0090] 105a, 105a-1, 105a-2, 105a-3, 105a-5: feed port

[0091] 105b, 105b-1, 105b-2: Cavity

[0092] 105c: First mold

[0093] 105d: Second mold

[0094] 106: Plug

[0095] 107: Allocator

[0096] 107c, 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, 107c-6: Channel

[0097] 108: Block

[0098] 110: Melting unit

[0099] 112: Transport channel

[0100] 120: Mixing unit

[0101] 122: Transport channel

[0102] 130: Injection unit

[0103] 200, 300: Injection molding method.

Claims

1. An injection molding method, characterized in that: include: A molding device and a flow channel plate located above the molding device are provided, wherein the molding device comprises a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold, and the flow channel plate comprises a first flow channel and a second flow channel communicating with the mold cavity and extending in the flow channel plate; A first distributor is placed inside the flow channel plate, wherein the first distributor has a channel that can be connected to the first flow channel or the second flow channel; Injecting a first mixture into the mold cavity through the channel and the first flow channel, wherein the first mixture does not flow into the mold cavity through the channel and the second flow channel; and A first foamed article is formed from the first mixture within the mold cavity.

2. The injection molding method according to claim 1, characterized in that Further including: After the first foamed product is formed, removing the first distributor from the flow channel plate; as well as Place the second distributor into the flow channel plate, The configuration of the second distributor is different from that of the first distributor.

3. The injection molding method according to claim 1, characterized in that Placing the first distributor into the flow channel plate further comprises: The channel is aligned with the first flow channel and the channel is not aligned with the second flow channel.

4. The injection molding method according to claim 1, wherein: Further including: A stopper is inserted into the channel after forming the first foamed article.

5. The injection molding method according to claim 1, characterized in that Further including: Rotating the first distributor in the flow channel plate; Injecting a third mixture into the mold cavity through the channel and the second flow channel, wherein the third mixture does not flow into the mold cavity through the channel and the first flow channel; and A third foamed article is formed from the third mixture within the mold cavity.

6. An injection molding method, characterized in that: include: A molding device and a flow channel plate located above the molding device are provided, wherein the molding device comprises a first mold, a second mold located above the first mold, and a mold cavity defined by the first mold and the second mold, and the flow channel plate comprises a first flow channel and a second flow channel communicating with the mold cavity and extending in the flow channel plate; inserting a first plug into the first flow channel; Injecting the first mixture into the mold cavity through the second flow channel, wherein the first mixture does not flow into the mold cavity through the first flow channel; and A first foamed article is formed from the first mixture within the mold cavity.

7. The injection molding method according to claim 6, characterized in that include: After the first foamed article is formed, removing the first plug from the first flow channel; as well as After the first foamed article is formed, a second plug is inserted into the second flow channel.

8. The injection molding method according to claim 7, characterized in that Further comprising after the first plug is removed: injecting the second mixture into the mold cavity through the first flow channel and the second flow channel; and A second foamed article is formed from the second mixture within the mold cavity.

9. An injection molding system, characterized in that: include: A molding device comprising a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold; a flow channel plate, disposed above the molding device, and comprising a first flow channel and a second flow channel that can communicate with the mold cavity and extend in the flow channel plate; as well as a distributor, which is placed in the flow channel plate and has a channel that can connect to the first flow channel or the second flow channel, The distributor is configured to prevent the mixture from flowing into the mold cavity through one of the first flow channel and the second flow channel, and to allow the mixture to flow into the mold cavity through the channel and the other of the first flow channel and the second flow channel.

10. The injection molding system of claim 9, wherein: The distributor is rotatable relative to the flow channel plate and can be inserted into and removed from the flow channel plate.

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