Method of manufacturing article using an injection molding system

Abstract

A method of manufacturing an article includes providing a forming device having a first mold and a second mold; arranging an assembly between the first mold and the second mold, wherein the assembly comprises a hollow space and an opening communicated with the hollow space; joining the opening to the first mold or the second mold; and joining the first mold to the second mold to form a mold cavity surrounding the assembly, in which the opening is joined to a feed port of the molding device, the feed port being communicable to the hollow space. The method further includes ejecting a molding material through the feed port and the opening into the hollow space, wherein the molding material includes a polymeric material and a blowing agent; and foaming the molding material to form a foamed member. The foaming member contacts an inner surface of the assembly.

Description

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS]

[0002] This application claims priority to U.S. Patent Provisional Application Serial No. 63 / 617,410 filed on January 3, 2024 and U.S. Patent Application Serial No. 18 / 900,906 filed on September 30, 2024, the entire contents of which are incorporated by reference. Technical Field

[0003] The present invention relates to an article and a method for manufacturing the same, and in particular, to an article including a foamed member in contact with a component and a method for manufacturing the same. Background Art

[0004] Articles comprising a foamed component and an assembly attached to at least a portion of the foamed component have many advantages, such as high strength, low weight, impact resistance, etc. The article can be made by bonding the foamed component and the assembly so that the adhesive is disposed between the foamed component and the assembly. However, there is a need for improved articles comprising a foamed component and an assembly and methods for making the article. Summary of the invention

[0005] An object of the present invention is to provide a product and a method for making the same.

[0006] According to one embodiment of the present invention, a method for manufacturing an article is disclosed. The method includes providing a molding device having a first mold and a second mold; disposing a component between the first mold and the second mold, wherein the component includes a hollow space and an opening connected to the hollow space. The opening is engaged with the first mold or the second mold; the first mold is engaged with the second mold to form a mold cavity surrounding the component, wherein the opening is engaged with a feed port of the molding device, and the feed port can be connected to the hollow space. The method further includes ejecting a molding material through the feed port and the opening into the hollow space, wherein the molding material includes a polymer material and a foaming agent; and foaming the molding material to form a foaming component. The foaming component contacts the inner surface of the component.

[0007] According to one embodiment of the present invention, a method for manufacturing an article is disclosed. The method includes providing a molding device having a first mold and a second mold; arranging a component between the first mold and the second mold, wherein the component includes a hollow space and an opening connected to the hollow space. Engaging the opening to the first mold or the second mold; engaging the first mold to the second mold to form a mold cavity surrounding the component, wherein the opening is engaged to a feed port of the molding device, and the feed port is connected to the hollow space, the feed port is arranged at a side wall of the molding device, and the component is arranged in the mold cavity. The method further includes ejecting a molding material through the feed port and the opening into the hollow space. Foaming the molding material to form a foamed component. During the formation of the foamed component, the hollow space expands within the mold cavity. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The best way to understand the various aspects of the present invention is to read it in conjunction with the accompanying drawings. It should be noted that, in accordance with industry standard practice, the various features are not drawn to scale. In fact, for the sake of clarity of discussion, the dimensions of the various features may be arbitrarily increased or decreased.

[0009] Figure 1 FIG. is a schematic diagram of an injection molding system according to an embodiment of the present invention.

[0010] Figure 2 is Figure 1 a partial schematic view of an injection molding system according to an embodiment of the present invention in.

[0011] Figure 2A is composed of Figure 2 an enlarged view of a part of an injection molding system according to an embodiment of the present invention surrounded by a dashed line in.

[0012] Figure 3 FIG. is a schematic diagram of an injection molding system according to an embodiment of the present invention.

[0013] Figure 4 is a flowchart showing a method of manufacturing an article according to an embodiment of the present invention.

[0014] Figure 5A and Figure 5B is a flowchart showing a method of manufacturing an article according to an embodiment of the present invention.

[0015] Figures 6 to 8 and Figures 11 to 15 are schematic diagrams showing exemplary operations of a method of manufacturing an article according to an embodiment of the present invention.

[0016] Figure 9 and Figure 10 are partial schematic views of an injection molding system according to an embodiment of the present invention.

[0017] Figure 16 and Figure 17 are schematic diagrams showing an exemplary article according to an embodiment of the present invention.

[0018] Figures 18 to 24 is a schematic cross-sectional view showing exemplary operations of a method of manufacturing an article according to an embodiment of the present invention. EMBODIMENTS

[0019] The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. Specific examples of components and configurations described below are intended to simplify the present invention. Of course, these are merely examples and are not intended to be limiting. For example, in the following description, embodiments in which a first feature is formed to cover a second feature or on top of the second feature may include embodiments in which the first and second features are formed in direct contact, and 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. Additionally, the present invention may repeat reference numerals and / or letters in the various examples. Such repetition is for the purpose of simplicity and clarity and does not in itself affect the relationship between the various embodiments and / or configurations being discussed.

[0020] In addition, for ease of description, spatially relative terms such as "below", "beneath", "lower", "above", "upper", etc. may be used herein to describe the relationship of one element or feature to another element or feature in the drawings. In addition to the orientation depicted in the figures, spatially relative terms are intended to encompass different orientations of the device in use or operation. The device can be oriented in other ways (rotated 90 degrees or in other orientations) and the spatially relative descriptors used herein can be interpreted accordingly.

[0021] Although the numerical ranges and parameters setting forth the broad scope of the present invention are approximations, the numerical values set forth in the specific embodiments are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in the corresponding testing measurements. In addition, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, the term "about" means within the standard error of the mean that is acceptable when considered by a person of ordinary skill in the art. Except in the operating / working examples, or unless otherwise expressly stated, all numerical ranges, amounts, values, and percentages, such as those of the amounts of materials, durations of time, temperatures, operating conditions, ratios of amounts, etc. disclosed herein, are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the present invention and the appended claims are approximations that can vary as desired. At the very least, each numerical parameter should be construed in light of the reported number of significant digits and by applying ordinary rounding techniques. Ranges can be expressed herein as from one endpoint to another endpoint or between two endpoints. All ranges disclosed herein include the endpoints unless otherwise indicated.

[0022] Figure 1 is a schematic diagram of an injection molding system 200 according to an embodiment of the present invention. As Figure 1As shown, the injection molding system 200 includes an extrusion system 110 and a molding device 100. The extrusion system 110 is configured to produce a molding material of a polymer material and a foaming agent. In some embodiments, the molding material is foamable or slightly foamed.

[0023] In some embodiments, the polymer material includes a high molecular weight polymer. In some embodiments, the polymer material includes ethylene vinyl acetate (EVA), styrene-ethylene-butene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the polymer material includes a foamable material. In some embodiments, the foaming agent is a physical or chemical additive that releases a gas, thereby forming pores in the resulting foamed polymer product. In some embodiments, the foaming agent is a physical foaming agent. Physical foaming agents include atmospheric gases (such as nitrogen or carbon dioxide), hydrocarbons, chlorofluorocarbons, noble gases, or combinations thereof. The foaming agent can be supplied in any flowable physical state, such as a gas, a liquid, or a supercritical fluid (SCF).

[0024] Figure 2 is a schematic diagram of the extrusion system 110 according to various aspects of the present invention in some embodiments. The extrusion system 110 includes a melting unit 120, a mixing unit 130, a foaming agent supply unit 140, and an injection unit 150. In some embodiments, the extrusion system 110 further includes a first flow control element 161, a second flow control element 162, and a monitoring module 180.

[0025] In some embodiments, referring to Figure 2 , the melting unit 120 is configured to convey the polymer material. In some embodiments, the melting unit 120 includes a pressure chamber 121, a first feed channel 122, a first discharge channel 123, and a pushing member 124. In some embodiments, the melting unit 120 further includes a feed hopper 125.

[0026] In some embodiments, the first feed channel 122 and the first discharge channel 123 are respectively disposed at two ends of the pressure chamber 121. In some embodiments, the first feed channel 122 communicates with the internal space 1211 of the pressure chamber 121, and the first discharge channel 123 communicates with the external space of the pressure chamber 121, wherein the first feed channel 122 is used to convey the polymer material to the internal space 1211 of the pressure chamber 121. In some embodiments, the feed hopper 125 is configured to convey the polymer material to the internal space 1211 of the pressure chamber 121 through the first feed channel 122.

[0027] The pushing member 124 is configured to convey the polymeric material from the first feed channel 122 to the first discharge channel 123. In some embodiments, the pushing member 124 is disposed within the internal space 1211 of the pressurizing cartridge 121. In some embodiments, the pushing member 124 is disposed within the internal space 1211 of the pressurizing cartridge 121, between the first feed channel 122 and the first discharge channel 123, and is configured to force the polymeric material towards the first discharge channel 123. In some embodiments, the pushing member 124 is rotatable relative to the pressurizing cartridge 121. In some embodiments, the rotation of the pushing member 124 conveys the polymeric material from the first feed channel 122 to the first discharge channel 123. In some embodiments, the pushing member 124 is non-movable in a direction parallel to the longitudinal axis of the pressurizing cartridge 121.

[0028] In some embodiments, the length of the pushing member 124 extends along the length of the pressurizing cartridge 121, the ratio of the distance D1 between the inner sidewall 1212 of the pressurizing cartridge 121 and the pushing member 124 to the diameter D2 of the pushing member 124 is in the range of about 1:1500 to about 1:4500, and the polymeric material melted by the melting unit 120 can be uniform. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the pressurizing cartridge 121 and the pushing member 124 is substantially equal to or less than 0.3 millimeters. In some embodiments, the shortest distance D1 between the inner sidewall 1212 of the pressurizing cartridge 121 and the pushing member 124 is between 0.01 and 0.05 mm.

[0029] The mixing unit 130 is configured to receive the polymeric material from the melting unit 120 and is configured to mix the polymeric material with a foaming agent and form a molded material of the polymeric material and the foaming agent. The mixing unit 130 includes a hollow mixing cartridge 131, a second feed channel 132, a second discharge channel 133, and a mixing rotor 134.

[0030] The second feed channel 132 and the second discharge channel 133 are respectively disposed at two ends of the mixing cartridge 131. In some embodiments, the second feed channel 132 is configured to convey the polymeric material. In some embodiments, the second discharge channel 133 is configured to discharge the molded material.

[0031] The mixing rotor 134 is configured to mix the polymer material with the foaming agent to form a molding material in the mixing chamber 131. In some embodiments, the mixing rotor 134 is disposed in the mixing chamber 131. In some embodiments, the mixing rotor 134 is disposed between the second feed channel 132 and the second discharge channel 133 within the mixing chamber 131 to stir the molding material within the mixing chamber. The mixing rotor 134 is rotatable to mix the polymer material with the foaming agent and convey the molding material of the polymer material and the foaming agent from the second feed channel 132 to the second discharge channel 133. In some embodiments, the mixing rotor 134 is immovable in a direction parallel to the longitudinal axis of the mixing chamber 131.

[0032] In some embodiments, the length of the mixing rotor 134 extends along the length of the hollow mixing chamber 131, and the ratio of the shortest distance D3 between the inner sidewall 1311 of the hollow mixing chamber 131 and the mixing rotor 134 to the diameter D4 of the mixing rotor 134 is in the range of about 1:1500 to about 1:4500, and the molding material prepared by the extrusion system 110 can be uniform. In some embodiments, the molding material can be divided into multiple parts, and the ratio of the foaming agent to the polymer material of each part of the molding material prepared by the extrusion system 110 is substantially constant. In some embodiments, the ratio of the polymer material to the foaming agent in the first part of the molding material is substantially equal to the ratio of the polymer material to the foaming agent in the second part of the molding material. In some embodiments, the shortest distance D3 between the inner sidewall 1311 of the hollow mixing chamber 131 and the mixing rotor 134 is substantially equal to or less than 0.3 millimeters. In some embodiments, the shortest distance D3 between the inner sidewall 1311 of the hollow mixing chamber 131 and the mixing rotor 134 is 0.01 to 0.09 mm.

[0033] Figure 2A is a partial enlarged view of an extrusion system according to an aspect of the present invention in some embodiments. In order to mix the molten polymer material and the foaming agent evenly in the mixing chamber 131, in some embodiments, please refer to Figure 2 and Figure 2A, the hybrid rotor 134 also includes a cylindrical columnar body 1341 rotatably disposed within the mixing cartridge 131, and a groove portion 1342 annularly disposed on the periphery of the columnar body 1341. Thus, when the columnar body 1341 rotates, the groove portion 1342 agitates the polymer material and the blowing agent to achieve the desired mixing effect. In some embodiments, the shortest distance D3 is the shortest distance between the groove portion 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131. In some embodiments, when the shortest distance D3 is the shortest distance between the groove portion 1342 and the inner sidewall 1311 of the hollow mixing cartridge 131, the range of the shortest distance D3 is from 0.01 to 0.09 mm. In some embodiments, the diameter D4 of the hybrid rotor 134 ranges from 45 to 75 mm.

[0034] In some embodiments, when the shortest distance D3 is substantially less than 0.01 mm, the predetermined amount of blowing agent in the molding material is substantially greater than 0.8 / cm3. In some embodiments, if the blowing agent in the predetermined amount of the molding material is substantially greater than 0.8 / cm3, the bubble density in the predetermined amount of the molded material after foaming is substantially greater than 180,000 bubbles / cm3.

[0035] In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is between 1:1500 and 1:4500, the uniformity of the blowing agent to the polymer material is optimized. In other words, the mixing of the blowing agent and the polymer material by the hybrid rotor 134 is uniform and consistent. In some embodiments, when the ratio of the shortest distance D3 to the diameter D4 is between 1:1500 and 1:4500, the ratio range of the blowing agent to the polymer material in the pre-determined amount of the molding material is from 4:1 to 3:1. In some embodiments, the ratio of the blowing agent to the polymer material in the pre-determined amount of the molding material is about 1:1. In some embodiments, if the ratio of the blowing agent to the polymer material in the pre-determined amount of the molding material is between 4:1 and 3:1, then the ratio of the bubbles to the polymer material in the pre-determined amount of the molded material after foaming is also between 4:1 and 3:1. In some embodiments, the ratio of the bubbles to the polymer material in the pre-determined amount of the molded material after foaming is about 4:1.

[0036] In some embodiments, the melting unit 120 includes a hollow pressurized cartridge 121 configured to accommodate the polymer material and having a first pressure, and the mixing unit 130 includes a hollow mixing cartridge 131 having a second pressure. In some embodiments, to prevent backflow, the first pressure is greater than the second pressure. In some embodiments, through the difference between the first pressure and the second pressure, the polymer material is drawn from the melting unit 120 to the mixing unit 130.

[0037] The foaming agent supply unit 140 is connected to the mixing unit 130 and configured to deliver a foaming agent to the mixing unit 130. In some embodiments, the foaming agent supply unit 140 is located between the first flow control element 161 and the second flow control element 162. In some embodiments, the foaming agent supply unit 140 is arranged adjacent to the first flow control element 161 and away from the second flow control element 162.

[0038] In some embodiments, a foaming agent source (not shown) is connected to the foaming agent supply unit 140 and configured to supply any type of foaming agent known to those of ordinary skill in the art. In some embodiments, the foaming agent is in a supercritical fluid state after being introduced into the mixing unit 130 through the foaming agent supply unit 140.

[0039] In some embodiments, the first flow control element 161 is provided at the first hole 171 that connects the melting unit 120 to the mixing unit 130. The first hole 171 is configured to introduce the polymer material from the melting unit 120 into the mixing unit 130. The first hole 171 is located between the melting unit 120 and the mixing unit 130. In some embodiments, the first hole 171 is configured to introduce the polymer material from the pressure chamber 121 of the melting unit 120 into the mixing chamber 131 of the mixing unit 130. In some embodiments, the polymer material can be transported and / or suctioned from the melting unit 120 to the mixing unit 130 through the first hole 171 by the pressure difference between the first pressure and the second pressure.

[0040] In some embodiments, the first flow control element 161 is provided between the melting unit 120 and the mixing unit 130 and configured to control the flow of the polymer material from the melting unit 120 to the mixing unit 130. The first flow control element 161 can be a valve, a movable cover, etc.

[0041] In some embodiments, the first flow control element 161 is configured to switch between an open configuration and a closed configuration. The open configuration of the first flow control element 161 allows the polymer material to flow from the melting unit 120 into the mixing unit 130, and the closed configuration of the first flow control element 161 prevents the polymer material from flowing back from the mixing unit 130 to the melting unit 120.

[0042] In some embodiments, the first flow control element 161 is configured to maintain a pressure difference between the melting unit 120 and the mixing unit 130. In some embodiments, the first flow control element 161 is configured to maintain the pressure difference between the melting unit 120 and the mixing unit 130 by switching between an open configuration and a closed configuration, such that the polymeric material cannot flow back from the mixing chamber 131 of the mixing unit 130 to the pressurized chamber 121 of the melting unit 120. In some embodiments, the first flow control element 161 is configured to adjust the first pressure and / or the second pressure so as to maintain the pressure difference between the first pressure and the second pressure. In some embodiments, when the first pressure is similar to the second pressure, the first flow control element 161 is in the closed configuration.

[0043] In some embodiments, the injection unit 150 is configured to receive the molding material discharged from the second discharge channel 133 of the mixing unit 130 and discharge the molding material from the injection unit 150. In some embodiments, the injection unit 150 is configured to inject the molding material, and the discharge channel 111 can communicate with the injection unit 150.

[0044] In some embodiments, the injection unit 150 includes a hollow metering chamber 151 configured to accommodate the molding material. The metering chamber 151 has a hollow internal space 1511, wherein the internal space 1511 communicates with the second discharge channel 133 for accommodating the molding material. The injection unit 150 further includes a connecting channel 152 that communicates with the internal space 1511 of the metering chamber 151, and a discharging member 153 slidably disposed in the internal space 1511 of the metering chamber 151 for discharging the molding material out of the metering chamber 151 via an outlet 154.

[0045] Return reference Figure 1 , in some embodiments, the injection unit 150 is configured to discharge the molding material into the molding device 100 through the discharge channel 111 corresponding to one extrusion system 110. In some embodiments, the discharge channel 111 communicating with the injection unit 150 can be engaged with the molding device 100 and is configured to discharge the molding material into the cavity 103 of the molding device 100. The molding material flows from the extrusion system 110 into the discharge channel 111.

[0046] In some embodiments, the discharge channel 111 has an outlet 111o away from the injection unit 150. The discharge channel 111 can be moved, extended, or retracted from the molding device 100. In some embodiments, the outlet 111o of the discharge channel 111 can extend into and retract from the molding device 111. The molding device 100 includes a cavity 103 and a feed port 104 that communicates with the cavity 103 and correspondingly engages with the outlet 111o.

[0047] In some embodiments, the molding device 100 includes a first mold 101 and a second mold 102. The first mold 101 can be joined to the second mold 102. When the first mold 101 is joined to the second mold 102, the molding device 100 is in a closed configuration. In some embodiments, the first mold 101 is a lower mold, the second mold 102 is an upper mold, and the first mold 101 is located below the second mold 102. In some embodiments, when the first mold 101 is joined to the second mold 102, a cavity 103 of the molding device 100 is defined by the first mold 101 and the second mold 102. The cavity 103 is configured to receive a molding material or a foamed member formed from the molding material.

[0048] In some embodiments, a feed port 104 can be joined to an outlet 111o. The feed port 104 is disposed at the first mold 101 or the second mold 102. In some embodiments, as Figure 1 shown, the feed port 104 is disposed on one side of the molding device 100. In some embodiments, the feed port 104 is disposed at a first sidewall 101s of the first mold 101 or a second sidewall 102s of the second mold 102. The feed port 104 is configured to receive a molding material from a discharge channel 111 of the injection unit 150 when the discharge channel 111 is joined to the molding device 100. The molding material can flow into the cavity 103 via the feed port 104. In some embodiments, the feed port 104 allows the molding material to flow through at a predetermined flow rate.

[0049] In some embodiments, the injection molding system 200 includes a support device 114 configured to fix the discharge channel 111 to the molding device 100. In some embodiments, the support device 114 includes a first element 1141 and a second element 1142. In some embodiments, the first element 1141 protrudes from the extrusion system 110 and the second element 1142 is disposed on the molding device 100.

[0050] The molding device 100 further includes one or more pressure regulating systems 106. In some embodiments, the molding device 100 can include different numbers of pressure regulating systems 106 or no pressure regulating system 106. In some embodiments, a connection point 107 is connected to the cavity 103. In some embodiments, an inner sidewall 105a or an inner bottom wall 105b of the cavity 103 includes the connection point 107. In some embodiments, the connection point 107 is configured to allow a fluid or a gas to enter or leave the cavity 103.

[0051] The pressure regulating system 106 may include a first gas conduit 1061, a second gas conduit 1062, a gas source 1063, a first valve 1064, a second valve 1065, and a pressure sensing unit 1066. In some embodiments, one end of the first gas conduit 1061 is joined to the inner sidewall 105a or the inner bottom wall 105b of the molding device 100. In some embodiments, one end of the first gas conduit 1061 is joined to the connection point 107, and the other end of the first gas conduit 1061 is joined to the gas source 1063. In some embodiments, the gas source 1063 is configured to supply a fluid or a gas, and a suitable fluid or gas may be supplied as needed; for example, the fluid or gas may be air, an inert gas, etc., but the present invention is not limited thereto.

[0052] There are no particular limitations on the position, shape, and number of the connection points 107, and they can be adjusted as needed. In some embodiments, the connection point 107 is a hole. In some embodiments, the connection point 107 is provided at the inner sidewall 105a or the inner bottom wall 105b of the molding device 100 and penetrates the first mold 101. In some embodiments, the connection point 107 is configured to supply and discharge gas, wherein when the first valve 1064 is open and the second valve 1065 is closed, a fluid or gas is supplied to the cavity 103; when the first valve 1064 is closed and the second valve 1065 is open, at least a part of the fluid or gas in the cavity 103 is discharged.

[0053] In some embodiments, the feed port 104 is provided at the inner sidewall 105a of the molding device 100. In some embodiments, the feed port 104 and the connection point 107 are set relative to the cavity 103; by way of example and not limitation, the feed port 104 is provided on one side of the inner sidewall 105a, and the connection point 107 is provided on the opposite side of the inner sidewall 105a. In some embodiments, the feed port 104 is away from the connection point 107.

[0054] The first valve 1064 is provided at the first gas conduit 1061 for controlling whether the gas from the gas source 1063 enters the cavity 103 via the first gas conduit 1061 and the connection point 107. The second gas conduit 1062 is joined to the mold and communicates with the cavity 103. In some embodiments, the second gas conduit 1062 is joined to the connection point 107. The second valve 1065 is provided at the second gas conduit 1062 for controlling whether the gas from the cavity 103 is discharged via the second gas conduit 1062 through the connection point 107.

[0055] In some embodiments, the second gas conduit 1062 is joined to the first gas conduit 1061 and the connection point 107. In some embodiments, one end of the second gas conduit 1062 communicates with a space having a pressure lower than the pressure within the cavity 103; for example, the external environment or a negative pressure space; however, the present invention is not limited thereto. There is no particular limitation on the position where the second gas conduit 1062 is connected to the first gas conduit 1061; for example, the two may be connected at one end adjacent to the end where the first gas conduit 1061 is connected to the connection point 107. In some embodiments, the first valve 1064 and the second valve 1065 are not opened simultaneously.

[0056] The pressure sensing unit 1066 is configured to sense the pressure within the cavity 103. In some embodiments, the properties of the foamed polymer are affected by the pore size and distribution on the polymer, and the pore size and distribution are related to temperature, pressure, and feed rate. The pressure sensing unit 1066 is not limited to any specific type as long as it can sense the pressure and provide pressure data after sensing the pressure within the cavity 103. The pressure regulation system 106 changes the conditions for gas to leave / enter the cavity 103 based on the pressure data, thereby regulating the pressure within the cavity 103 such that the resulting foamed polymer product has an ideal predetermined shape and properties.

[0057] In some embodiments, the pressure sensing unit 1066 is disposed in the cavity 103, the first gas conduit 1061, or the second gas conduit 1062. In some embodiments, the pressure sensing unit 1066 is disposed within the cavity 103 and away from the feed port 104. In some embodiments, the pressure regulation system 106 has a plurality of pressure sensing units 1066. The number and position of the plurality of pressure sensing units 1066 are not specifically limited; for example, the plurality of pressure sensing units 1066 may be spaced apart on the inner sidewall of the cavity 103, and / or anywhere within the first gas conduit 1061, and / or anywhere within the second gas conduit 1062; however, the present invention is not limited thereto.

[0058] In some embodiments, the injection molding system 200 also includes a control system 109. The control system 109 is used to control the extrusion system 110, the discharge channel 111, and the molding device 100. In some embodiments, the control system 109 instantaneously and automatically controls the extrusion system 110, the discharge channel 111, and the molding device 100. In some embodiments, the control system 109 instantaneously controls the pressure regulation system 106.

[0059] In some embodiments, the control system 109 includes a central processor 1091 and a plurality of sensors 1092 electrically connected to or communicable with the central processor 1091. In some embodiments, the sensors 109 are placed throughout the injection molding system 200 and configured to sense at least one processing condition (e.g., the flow rate or viscosity of the molding material via the discharge channel 111, the amount of molding material discharged from the discharge channel 111, the pressure within the cavity 103, etc.) at a predetermined position in the injection molding system 200 (e.g., the order of extrusion into the molding device 100, the arrangement of the discharge channel 111 with the molding device 100, the outlet 111o, the feed port 104, and the cavity 103, etc.). In some embodiments, the sensors 1092 are configured to detect the processing conditions and transmit signals or data based on the detected processing conditions to the central processor 1091 for further analysis.

[0060] In some embodiments, the control system 109 controls which molding device 100 the discharge channel 111 docks with. In some embodiments, a cable 1093 is electrically connected between the control system 109, the extrusion system 110, the discharge channel 111, and the molding device 100. The cable 1093 is configured to transmit signals from the molding device 100 to the extrusion system 110 and the discharge channel 111.

[0061] In some embodiments, the control system 109 is configured to process the pressure data detected by the pressure sensing unit 1066 for adjusting the mixing conditions of the extrusion system 110 and the extrusion amount and time of the discharge channel 111. In some embodiments, the pressure sensing unit 1066 provides pressure data to the control system 109, and the control system 109 adjusts the first valve 1064 and the second valve 1065 according to the pressure data. In some embodiments, the control system 109 instantaneously adjusts the gas entering and leaving the cavity 103 according to the pressure data, and adjusts the time and amount of the molding material injected from the discharge channel 111 into the cavity 103, such that during the injection molding process, the injection amount and injection rate are within an appropriate or predetermined range, and the pressure in the cavity 103 is always within an appropriate or predetermined pressure range. In some embodiments, the control system 109 also controls the feeding condition of the feed port 104 and the gas supply of the gas source 1063. In some embodiments, the control system 109 is electrically connected to the first valve 1064, the second valve 1065, the pressure sensing unit 1066, and the feed port 104.

[0062] Figure 3 is a schematic diagram of an injection molding system 300 according to an embodiment of the present invention. As Figure 3As shown, the injection molding system 300 includes an extrusion system 110 having an injection unit 150 and a molding device 100. In some embodiments, a feed port 104 is provided between the first mold 101 and the second mold 102. In some embodiments, the feed port 104 includes a first partial port 104a located at the first mold 101 and a second partial port 104b located at the second mold 102, and when the molding device 100 is in a closed configuration, the first partial port 104a is aligned with the second partial port 104b. In some embodiments, the first partial port 104a is configured as a recess at the first sidewall 101s of the first mold 101, and the second partial port 104b is configured as a recess at the second sidewall 102s of the second mold 102.

[0063] In the present invention, a method of manufacturing an article is disclosed. In some embodiments, injection molding is performed through this method. This method includes a plurality of operations, and it is not considered that the description and illustration will limit the operation sequence. Figure 4 is a flowchart showing an injection molding method according to an embodiment of the present invention. In some embodiments, as Figure 4 shown, manufacturing Figure 16 and Figure 17 the article 119 shown includes the following steps.

[0064] Step 401 includes providing a molding device for the first mold and the second mold. Step 402 includes disposing a component between the first mold and the second mold, where the component includes a hollow space and an opening communicating with the hollow space. Step 403 includes joining the opening to the first mold or the second mold. Step 404 includes joining the first mold to the second mold to form a cavity surrounding the component, where the opening is joined to the feed port of the molding device, and the feed port of the molding device can communicate with the hollow space.

[0065] Step 405 includes injecting a molding material through the feed port and the opening into the hollow space, where the molding material includes a polymer material and a foaming agent. Step 406 includes foaming the molding material to form a foamed member. In some embodiments, the feed port is provided at the sidewall of the molding device. In some embodiments, the foamed member contacts the inner surface 112c of the component. In some embodiments, the hollow space expands within the cavity during the formation of the foamed member.

[0066] The method 400 is not limited to the above embodiments. In some embodiments, manufacturing Figure 16 and Figure 17 the article 119 shown uses any one of the above injection molding systems 200 and 300 as Figures 1 to 3 shown.

[0067] Figure 5A and Figure 5Bis a flowchart showing an injection molding method according to an embodiment of the present invention. In some embodiments, as Figure 5A and Figure 5B shown, the method of manufacturing article 500 includes the following steps.

[0068] According to some embodiments of the present invention, a method of manufacturing an article is disclosed. In some embodiments, method 500 uses the above-mentioned Figures 1 to 3 shown injection molding systems 200 and 300. Figure 5A and Figure 5B is a flowchart of method 500 according to some embodiments. Method 500 includes a plurality of operations (501 to 512), and the description and illustration are not considered as a limitation on the order of operations. Additional steps may be provided before, during, and after the operations shown in Figure 5A and 5B shown, and some of the operations described below may be replaced or eliminated in other embodiments of method 500. The order of operations may be interchanged.

[0069] Figures 6 to 8 and Figures 11 to 15 are schematic cross-sectional views of one or more operations of method 500 for manufacturing an article according to some embodiments of the present invention. Figure 9 and Figure 10 are schematic views of a part of an injection molding system according to an embodiment of the present invention. Figure 16 and Figure 17 are schematic cross-sectional views showing article 119 manufactured by method 500 according to some embodiments of the present invention. Method 500 starts with operation 501. Operation 501 includes providing an extrusion system 110, which is configured to produce Figure 12 the molding material 113’ shown in Figure 2 and has a melting unit 120 and a mixing unit 130 shown in

[0070] Method 500 continues with operation 502. Operation 502 includes providing a discharge channel 111 communicable with the extrusion system 110. The discharge channel 111 includes an outlet 111o, which is provided at the distal end of the extrusion system 110 and is configured to discharge the molding material 113’.

[0071] In some embodiments, referring to Figure 6, the molding device 100 includes a second mold 102 and a first mold 101, which is relative to the second mold 102. In some embodiments, the second mold 102 is the upper mold and the first mold 101 is the lower mold. In some embodiments, the second mold 102 and the first mold 101 are disengaged from each other. In some embodiments, the second mold 102 and the first mold 101 can be complementarily aligned with each other and positioned so as to be disengaged from each other. In some embodiments, the first mold 101 or the second mold 102 includes a feed port 104. In some embodiments, the feed port 104 is provided at the first side wall 101s of the first mold 101 or at the second side wall 102s of the second mold 102.

[0072] The method 500 proceeds to operations 504 and 505. Operation 504 includes disposing the component 112 between the first mold 101 and the second mold 102, wherein the component 112 includes a hollow space 112a and an opening 112b communicating with the hollow space 112a. Operation 505 includes engaging the opening 112b with the first mold 101 or the second mold 102. In some embodiments, operations 504 and 505 of the method 500 are similar to operations 402 and 403 of the method 400.

[0073] Reference Figure 7 , the component 112 is placed at the first mold 101 or the second mold 102. In some embodiments, the component 112 is disposed within the first partial cavity 103a of the first mold 101 and is at least partially in contact with the first mold 101. In some embodiments, the component 112 is in contact with one or more inner side walls 105a of the first mold 101. In some embodiments, the second mold 102 has a second partial cavity 103b corresponding to the first partial cavity 103a.

[0074] In some embodiments, the component 112 is flexible, elastic or stretchable. In some embodiments, the component 112 is cloth, fabric, textile, etc. In some embodiments, the component 112 is breathable.

[0075] The method 500 proceeds to operation 506. Operation 506 includes engaging the first mold 101 with the second mold 102 to form a cavity 103 surrounding the component 112, wherein the opening 112b is engaged with the feed port 104 of the molding device 100, and the feed port 104 communicates with the hollow space 112a. In some embodiments, operation 506 of the method 500 is similar to operation 404 of the method 400. In some embodiments, the feed port 104 is provided at the inner side wall 105a of the molding device 100.

[0076] In some embodiments, reference Figure 8, a cavity 103 is defined when the second mold 102 and the first mold 101 are positioned complementary to each other. The cavity 103 can be defined by the first cavity 103a of the first mold 101 and the second cavity 103b of the second mold 102. In some embodiments, the inner sidewall 105a of the molding device 100 is curved. In some embodiments, the inner sidewall 105a of the molding device 100 is a concave surface, a convex surface, or a curved surface including a combination of a concave surface and a convex surface. In some embodiments, when the opening 112b engages with the feed port 104, the opening 112b and a part of the component 112 adjacent to the opening 112b are set within the feed port 104, and a part of the component 112 is inserted into the feed port 104. When the opening 112b engages with the feed port 104, the component 112 is placed at the first mold 101 and / or the second mold 102. As a result, when the opening 112b engages with the feed port 104, the feed port 104 can communicate with the hollow space 112a.

[0077] After the component 112 is placed at the first mold 101 or the second mold 102, the first mold 101 engages with the second mold 102, as Figure 8 shown. When the first mold 101 engages with the second mold 102, the molding device 100 is in a closed configuration. When the first mold 101 engages with the second mold 102, the first partial cavity 103a and the second partial cavity 103b combine to form the cavity 103. The component 112 is surrounded by the molding device 100 and is located within the cavity 103.

[0078] The method 500 proceeds to operation 507. Operation 507 includes engaging the discharge channel 111 with the feed port 104 before or after the first mold 101 engages with the second mold 102.

[0079] Returning to the reference Figure 7 , the extrusion system 110 and the discharge channel 111 are away from the molding device 100. In some embodiments, before the outlet 111o engages with the feed port 104 of the molding device 100, the discharge channel 111 moves to a first position adjacent to the molding device 100. In some embodiments, the discharge channel 111 moves to a first position adjacent to the molding device 100. At the first position, the discharge channel 111 is aligned with the feed port 104 of the molding device 100. In some embodiments, the distance between the outlet 111o and the feed port 104 is greater than 0. In some embodiments, at the first position, the discharge channel 111 is aligned with the feed port 104.

[0080] In some embodiments, referring to Figure 8, after aligning the discharge channel 111 with the feed inlet 104, the discharge channel 111 moves towards the molding device 100 to be received by the feed inlet 104, and then the outlet 111o is docked to the feed inlet 104. In some embodiments, the discharge channel 111 moves towards the molding device 100 to be received by the feed inlet 104. In some embodiments, the discharge channel 111 moves towards the molding device 100 to be received by the feed inlet 104.

[0081] In some embodiments, before or after the first mold 101 engages with the second mold 102, the discharge channel 111 engages with the feed inlet 104. When the outlet 111o is docked to the feed inlet 104, the outlet 111o and the feed inlet 104 form a fluid path for the molding material 113', such that the discharge channel 111 communicates with the hollow space 112a through the feed inlet 104 and the opening 112b. In some embodiments, when the discharge channel 111 engages with the feed inlet 104, the discharge channel 111 partially protrudes into the feed inlet 104. In some embodiments, when the opening 112b engages with the feed hole 104, the opening 112b and a part of the component 112 adjacent to the opening 112b are disposed within the feed hole 104.

[0082] The outlet 111o must be tightly engaged with the feed inlet 104 to prevent the molding material 113' from leaking out of the molding device 100. In some embodiments, the method 500 includes fixing the discharge channel 111 to the molding device 100. In some embodiments, a force is provided by the support device 114 to prevent the extrusion system 110 from detaching from the molding device 100.

[0083] In some embodiments, when the extrusion system 110 injects the molding material 113' into the molding device 100, the molding device 100 may generate a reaction force opposite to the injection direction, and this reaction force may be transmitted to the discharge channel 111 and the extrusion system 110, such that the discharge channel 111 can easily detach from the molding device 100. In some embodiments, the support device 114 can support against the reaction force opposite to the injection direction.

[0084] In some embodiments, the discharge channel 111 is fixed to the molding device 100 by engaging a first element 1141 of the support device 114 with a second element 1142 of the support device 114 to fix the discharge channel 111 to the molding device 100, where the first element 1141 protrudes from the extrusion system 110 and the second element 1142 is disposed on the molding device 100. In some embodiments, the support device 114 provides a force after engagement to prevent the discharge channel 111 from detaching from the molding device 100.

[0085] Figure 9 is a schematic diagram of a part of an injection molding system 200 according to an embodiment of the present invention. In some embodiments, seeFigure 9 The support device 114 includes a first element 1141 and a second element 1142 configured to engage with each other, where the first element 1141 protrudes from the extrusion system 110 or the discharge channel 111, and the second element 1142 is provided on the molding device 100, but the present invention is not limited thereto. In some embodiments, the first element 1141 and the second element 1142 can be clamped to each other; for example, the second element 1142 is configured to receive the first element 1141.

[0086] In some embodiments, the support device 114 is provided adjacent to the cavity 103 of the molding device 100. In some embodiments, the first element 1141 is provided on the discharge channel 111, and the second element 1142 is provided on the molding device 100. In some embodiments, the first element 1141 is a part of the extrusion system 110 or the discharge channel 111, and the second element 1142 is a part of the molding device 100. In some embodiments, the first element 1141 is a part of the extrusion system 110 and is provided adjacent to the discharge channel 111. In some embodiments, the first element 1141 and the second element 1142 can engage with each other, thereby enabling the discharge channel 111 to be tightly engaged with the molding device 100.

[0087] In some embodiments, in order to prevent the extrusion system 110 and the molding device 100 from disengaging during the injection process, the engaged first element 1141 is subjected to a force against the second element 1142. This force can be equal to or greater than a threshold value. This threshold value can be adjusted according to the pressures in the cavity 103 and the hollow space 112a and the diameter of the outlet 111o or according to other factors.

[0088] The position and number of the first element 1141 can be adjusted as needed and are not particularly limited. The position and number of the second element 1142 can also be adjusted according to requirements and are not particularly limited. In some embodiments, the position and number of the second element 1142 correspond to the position and number of the first element 1141. In one embodiment, the first element 1141 can be provided on the discharge groove 111 or at any suitable position adjacent to the discharge channel 111, and the second element 1142 can be provided at any suitable position on the molding device 100.

[0089] Figure 10 is a schematic diagram of a part of an injection molding system 200 according to an embodiment of the present invention. In some embodiments, please refer to Figure 10, the support device 114 can be in either a locked state or an unlocked state. In the unlocked state, the first element 1141 enters the corresponding second element 1142 but is not yet locked to the second element 1142. In other words, when the support device 114 is in the unlocked state, the first element 1141 can still be withdrawn from the second element 1142. In the locked state, the first element 1141 enters and locks the corresponding second element 1142, such that the first element 1141 cannot be withdrawn from the second element 1142. Figure 10 Figure 11 shows the support device 114 in the locked state. The support device 114 can be manually or automatically operated and controlled. The support device 114 can be switched between the manual and automatic states.

[0090] In some embodiments, the first element 1141 is rotatably fixed to the extrusion system 110. In some embodiments, the first element 1141 includes an extension portion 1143 and an arm portion 1144. The extension portion 1143 and the arm portion 1144 can rotate in the direction shown by the arrow A. The extension portion 1143 is fixed to the extrusion system 110 and extends along the first direction Z towards the second mold 102. The arm portion 1144 is joined to the extension portion 1143 and extends along a second direction X that is substantially orthogonal to the first direction Z or along a third direction Y that is substantially orthogonal to the first direction Z. In some embodiments, the first element 1141 has an inverted T shape. After the first element 1141 enters the second element 1142, through the rotation of the arm portion 1144 of the first element 1141, the support device 114 changes from the unlocked state to the locked state. In some embodiments, the first element 1141 is locked to the second element 1142 by rotating the arm portion 1144 of the first element 1141 by approximately 90 degrees. Figure 10 Figure 12 shows that after the arm portion 1144 is rotated by approximately 90 degrees, the arm portion 1144 is locked to the second element 1142. Thus, the support device 114 is in the locked state, the discharge channel 111 is tightly joined to the molding device 100, and then the molding material 113' can be ejected from the extrusion system 110 and the discharge channel 111 into the molding device 100.

[0091] In some embodiments, refer to Figures 8 to 10, turn the support device 114 to the locked state and fix the discharge channel 111 to the molding device 100. For example, rotate the first element 1141 of the support device 114 relative to and within the second element 1142 of the support device 114 while engaging the outlet 111o with the feed port 114. In some embodiments, when the outlet 111o is docked to the feed port 114, the first element 1141 enters the second element 1142 and then locks with the second element 1142. In some embodiments, the discharge channel 111 is fixed to the molding device 100 by rotating the extension 1143 and the arm 1144 of the first element 1141 of the support device 114. The extension 1143 is fixed to the extrusion system 110 and extends toward the molding device 100 in the first direction Z, and the arm 1144 is connected to the extension 1143 and extends in a second direction X different from the first direction Z.

[0092] In some embodiments, referring to Figure 11 , method 500 also includes injecting gas G into the cavity 103 and / or the hollow space 112a after the first mold 101 is engaged with the second mold 102, thereby increasing the pressure in the cavity 103 and / or the hollow space 112a. In some embodiments, before injecting the molding material 103' into the cavity 103, gas is injected through the pressure regulating system 106 connected to the cavity 103 until it is sensed that the cavity 103 has a first predetermined pressure. In some embodiments, gas G is injected into the cavity 103 via the first gas conduit 1061. In some embodiments, gas G can be any suitable gas as required; for example, air; however, the present invention is not limited thereto. In some embodiments, after the outlet 111o is engaged with the feed port 114, the pressure in the cavity 103 of the molding device 100 is adjusted to the first predetermined pressure. After the molding device 100 has the first predetermined pressure, injection begins. In some embodiments, gas G is air or the like.

[0093] In some embodiments, the pressure sensing unit 1066 senses that the pressure in the cavity 103 is atmospheric pressure. In some embodiments, the first valve 1064 is opened so that gas G is injected into the cavity 103 via the first gas conduit 1061. In some embodiments, when the feed port 114 is closed, gas G is injected into the cavity 103 through the pressure regulating system 106. In some embodiments, gas G is injected into the cavity 103 through the feed port 104.

[0094] In some embodiments, during the injection of gas G into cavity 103, the pressure in cavity 103 is continuously sensed. In some embodiments, pressure sensing unit 1066 continuously senses the pressure in cavity 103 and injects gas G into cavity 103 until it is sensed that cavity 103 has a first preset pressure. Then, the first valve 1064 and the second valve 1065 of pressure regulating system 106 are closed, and the injection of gas G into cavity 103 is stopped. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure.

[0095] In some embodiments, cavity 103 has a first predetermined pressure before operation 508, and the first valve 1064 and the second valve 1065 of pressure regulating system 106 are closed.

[0096] In some embodiments, method 500 includes operation 508, and operation 508 includes injecting molding material 113' from extrusion system 110 into hollow space 112a through feed port 104 and opening 112b, where molding material 113' includes a polymer material and a foaming agent. In some embodiments, operation 508 of method 500 is similar to operation 405 of method 400.

[0097] In some embodiments, molding material 113' is made by extrusion system 110, discharged from injection unit 150, and flows into hollow space 112a of assembly 112 via discharge channel 111, feed port 104, and opening 112b. In some embodiments, see Figure 12 , molding material 113' is injected into cavity 103 through outlet 111o and feed port 104. In some embodiments, during the injection of molding material 113', discharge channel 111 is at least partially surrounded by molding device 100.

[0098] In some embodiments, a single injection of molding material 113' is made to fill the entire hollow space 112a. Since assembly 112 is elastic, assembly 112 and hollow space 112a can expand during or after the injection of molding material 113' into hollow space 112a. The volume of hollow space 112a increases during or after the injection of molding material 113'. In some embodiments, after the injection of molding material 113' into hollow space 112a, hollow space 112a continues to expand due to the physical foaming of molding material 113' within hollow space 112a.

[0099] In some embodiments, in operation 508, during the injection of the molding material 113' into the hollow space 112a, the pressure in the cavity 103 changes rapidly, and the pressure sensing unit 1066 continuously senses the pressure within the cavity 103. In some embodiments, the molding material 113' is injected into the hollow space 112a from the feed port 104, and a first predetermined pressure is applied to the molding material 113'. In some embodiments, the molding material 113' and the gas G are disposed in the cavity 103 or the hollow space 112a, and the molding material 113' expands and foams within the hollow space 112a.

[0100] In some embodiments, the molding material 113' is injected into the hollow space 112a from the feed port 104 and the opening 112b, thereby increasing the pressure in the cavity 103. In some embodiments, the pressure in the cavity 103 of the molding device 100 rises above the first predetermined pressure. In some embodiments, the pressure in the cavity 103 of the molding device 100 rises from the first predetermined pressure to the second predetermined pressure.

[0101] In some embodiments, after the molding material 113' is injected into the hollow space 112a within the cavity 103 having the first predetermined pressure, due to the increase in the pressure within the cavity 103, the setting of the second predetermined pressure can ensure that the cavity 103 is maintained within an appropriate pressure range. In some embodiments, when the cavity 103 reaches the second predetermined pressure, the injection of the molding material 113' into the hollow space 112a is stopped.

[0102] In some embodiments, the process of injecting the molding material 113' into the hollow space 112a within the cavity 103 having the first predetermined pressure lasts less than 3 seconds. In some embodiments, since the cavity 103 has the first predetermined pressure, the filling of the molding material 113' can last less than 0.5 seconds. During or upon completion of the injection, the pressure sensing unit 1066 immediately senses the pressure within the cavity 103 and provides pressure data so that the pressure regulating system 106 can regulate the pressure within the cavity 103 based on the pressure data. Therefore, the pressure within the cavity 103 can be maintained within a predetermined pressure range. In some embodiments, during the injection process, the temperature of the discharge channel 111 is higher than the temperature of the molding device 100. In some embodiments, a force is applied to the first mold 101 and / or the second mold 102 during or after the injection of the molding material 113' in order to maintain the cavity 103 or the hollow space 112a at a predetermined pressure level. In some embodiments, the pressure level is suitable for physical foaming.

[0103] In some embodiments, method 500 includes operation 509 and operation 510. Operation 509 includes foaming the molding material 113' to form the foamed member 113, wherein during the formation of the foamed member 113, the foamed member 113 expands within the mold cavity 103. Operation 510 includes expanding the assembly 112 during or after injecting the molding material 113' into the hollow space 112a. In some embodiments, operation 509 of method 500 is similar to operation 406 of method 400.

[0104] In some embodiments, after injecting the molding material 113', the molding material 113' undergoes physical foaming as shown in Figure 13 to become the foamed member 113 as shown in Figure 14 . Referring to Figure 13 and Figure 14 , the assembly 112 expands during the formation of the foamed member 113 until the assembly 112 contacts the inner wall 105 of the mold cavity. In some embodiments, the hollow space 112a expands until the assembly 112 is fully in contact with the inner wall 105 of the mold cavity 103.

[0105] In some embodiments, during the physical foaming of the molding material 113' or after the formation of the foamed member 113, method 500 further includes discharging at least a portion of the gas G from the mold cavity 103 and / or the hollow space 112a. In some embodiments, after injecting the gas G into the mold cavity 103, a portion of the gas G is discharged from the mold cavity 103. In some embodiments, during operations 509 and 510, when the molding material 113' foams in the hollow space 112a or the foamed member 113 is formed, the gas G is discharged from the mold cavity 103 through the pressure regulating system 106 in less than 1 second. Due to the discharge of a portion of the gas G, the molding material 113' in the mold cavity 103 after the foaming process can have a lower density. In some embodiments, the gas G is discharged from the mold cavity 103 via the connection point 107. In some embodiments, the pressure in the mold cavity 103 is reduced from a second predetermined pressure.

[0106] In some embodiments, the pressure in the mold cavity 103 and / or the hollow space 112a is reduced to a third predetermined pressure by discharging a portion of the gas G. Discharging a portion of the gas G from the mold cavity 103 and / or the hollow space 112a reduces the pressure in the mold cavity 103 or the hollow space 112a, and / or discharges a portion of the physical blowing agent released from the molding material 113' from the mold cavity 103 and / or the hollow space 112a.

[0107] In some embodiments, when the pressure sensing unit 1066 senses that the pressure in the cavity 103 is greater than a second preset pressure, a part of the gas G in the cavity 103 is discharged until the pressure in the cavity 103 is within a predetermined pressure range. In some embodiments, the predetermined pressure range is between a first predetermined pressure and a second predetermined pressure. In some embodiments, the second valve 1065 is opened and a part of the gas G in the cavity 103 is discharged via the second gas conduit 1062.

[0108] In some embodiments, method 500 includes operation 511. Operation 511 includes separating the first mold 101 and the second mold 102 after the foamed member 113 is formed.

[0109] In some embodiments, refer to Figure 15 , after the foamed member 113 is formed, before or after the first mold 101 and the second mold 102 are separated, the discharge channel 111 is separated from the feed port 104. A product 119 including the foamed member 113 and the component 112 is formed in the cavity 103, as Figure 14 shown. The foamed member 119 is in direct contact with the inner surface 112c of the component 112. The product 119 thus formed does not contain an adhesive.

[0110] The outlet 111o is separated from the feed port 104. The molding device 100 changes from a closed configuration ( Figure 8 and Figures 11 to 14 ) to an open configuration.

[0111] In some embodiments, method 500 includes operation 512. Operation 512 includes removing the product 119 including the component 112 and the foamed member 113 from the molding device 100.

[0112] In some embodiments, refer to Figure 16 , after the first mold 101 and the second mold 102 are separated, the product 119 can be taken out from the cavity 103. In some embodiments, after the product 119 is formed, then the product 119 is taken out from the first mold 101. In some embodiments, the product 119 is manually picked up by a human, or automatically picked up by a robot, a robotic arm, a fixture, etc.

[0113] In some embodiments, method 500 also includes trimming one side of the product 119. Refer to Figure 17 , trimming the side of the product 119 results in placing the product 119 having the foamed member 113 between a first part 112d of the component 112 and a second part 112e of the component 112 separated from the first part 112d.

[0114] In some embodiments, the thickness of component 112 is significantly less than the thickness of the foaming member 113. In some embodiments, the total thickness T of the article 119 is substantially less than 2 mm. In some embodiments, the total thickness T of the article 119 is substantially less than 1 mm. In some embodiments, the thickness of the foaming member 113 is substantially less than 1 mm. In some embodiments, the thickness of the foaming member 113 is substantially less than 0.5 mm. The foaming member 113 is directly attached to the first part 112d and the second part 112e, with no additional components or materials (such as adhesives, etc.) provided therebetween. In some embodiments, component 112 is softer than foaming member 113. In some embodiments, the density of the foaming member 113 is about 0.05 to about 0.5.

[0115] In some embodiments, method 500 includes the following operations. In some embodiments, the following steps may be repeated and performed automatically. In some embodiments, method 500 uses the injection molding system 300 as described above Figure 3 as shown. Figures 18 to 24 is a schematic cross-sectional view of one or more operations of a method 500 for manufacturing an article according to some embodiments of the present invention.

[0116] In some embodiments, at the beginning of operation 503, an injection unit 150 and a molding device 100 are provided, as Figure 18 shown. The molding device 100 is in an open configuration, where the discharge channel 111 is disengaged from the feed port 104, and the first mold 101 is disengaged from the second mold 102.

[0117] In some embodiments, the feed port 104 includes a first partial port 104a at the first sidewall 101s of the first mold 101 and a second partial port 104b at the second sidewall 102s of the second mold 102. In some embodiments, when the molding device 100 is in an open configuration, the first partial port 104a and the second partial port 104b are disengaged from each other, as Figure 18 shown.

[0118] In some embodiments, in operation 504, component 112 is set between the first mold 101 and the second mold 102, as Figure 19 shown. In some embodiments, the opening 112b faces the first partial port 104a or the second partial port 104b, and the opening 112b can be engaged with the first partial port 104a and / or the second partial port 104b.

[0119] In some embodiments, in operation 505, refer to Figure 20, a feed port 104 is formed after the first mold 101 and the second mold 102 are joined. In some embodiments, the feed port is formed when the molding device 100 is in a closed configuration. The formation of the feed port 104 is caused, and when the opening 112b is joined to the feed port 104, the feed port 104 can communicate with the hollow space 112a. In some embodiments, the formation of the feed port 104 and the joining of the opening 112b to the thus-formed feed port 104 are carried out simultaneously.

[0120] In some embodiments, in operation 507, refer to Figure 21 , the discharge channel 111 is joined to the feed port 104 and contacts the first mold 101 and the second mold 102. In some embodiments, before or after the first mold 101 and the second mold 102 are joined, as Figure 20 shown, the discharge channel 111 is joined to the feed port 104 in a manner similar to that described above or Figure 11 shown. In some embodiments, the discharge channel 111 is fixed to the molding device 100. In some embodiments, after the first mold 101 and the second mold 102 are joined, a gas is injected into the cavity 103 and / or the hollow space 112a, thereby increasing the pressure inside the cavity 103 and / or the hollow space 112a. In some embodiments, the gas G is air or the like. In some embodiments, a force is applied to the first mold 101 and / or the second mold 102 during or after injecting the molding material 113' so as to maintain the cavity 103 and / or the hollow space 112a at a predetermined pressure level suitable for physical foaming.

[0121] In some embodiments, in operation 508, refer to Figure 21 and Figure 22 , after the first mold 101 and the second mold 102 are joined, the molding material 113' is injected into the hollow space 112a in a manner similar to that described above or Figure 12 and 13 shown. In some embodiments, before injecting the molding material 113' into the hollow space 112a, the gas G is injected into the hollow space 112a or the cavity 103. The molding material 113' is discharged from the injection unit 150 and flows into the hollow space 112a of the assembly 112 via the discharge channel 111, the feed port 104, and the opening 112b. In some embodiments, the molding material 113' is injected once to fill the entire hollow space 112a.

[0122] In some embodiments, in operation 509, refer to Figure 22 and Figure 23 , after injecting the molding material 113', the molding material 113' is in a manner similar to that described above or Figure 13 and Figure 14In a manner similar to that shown in [reference], it undergoes physical foaming within the cavity 103 to become the foamed member 113. In some embodiments, during the physical foaming of the molding material 113' or after the formation of the foamed member 113, the pressure inside the cavity 103 and / or the hollow space 112a is reduced by discharging at least a portion of the gas G from the cavity 103 and / or the hollow space 112a, and / or a portion of the physical blowing agent released from the molding material 113' is discharged from the cavity 103 and / or the hollow space 112a.

[0123] In some embodiments, in operation 510, still referring to Figure 22 and Figure 23 , since the component 112 is elastic, the molding material 113' can expand during or after injecting the molding material 113' into the hollow space 112a. The volume of the hollow space 112a increases during or after injecting the molding material 113'. In some embodiments, the hollow space 112a expands until the component 112 is in full contact with the inner wall 105 of the cavity 103, as Figure 22 shown. In some embodiments, after injecting the molding material 113' into the hollow space 112a, the hollow space 112a continues to expand due to the physical foaming of the molding material 113' within the hollow space 112a.

[0124] In some embodiments, in operation 510, referring to Figure 24 , after the foamed member 113 is formed within the cavity 103, the first mold 101 is disengaged from the second mold 102 in a manner similar to that described above or Figure 15 shown in [reference]. In some embodiments, the disengagement of the discharge channel 111 from the feed port 104 can be performed before or after the disengagement of the first mold 101 and the second mold 102. The resulting article 119 is similar to the article Figure 16 shown. In some embodiments, after removing the article 119 from the cavity 103, the sides of the article 119 are trimmed as Figure 17 shown. This results in the formation of an article 119 having a foamed member 113 between the first part 112d of the component 112 and the second part 112e of the component 112.

[0125] The features of several embodiments are outlined 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 readily use the present invention as a basis for designing or modifying other processes and structures to achieve the same purposes and / or implement the same advantages as the embodiments presented herein. Those skilled in the art should also recognize that such equivalent constructs do not depart from the spirit and scope of the present invention. And they can make various changes, substitutions, and alterations without departing from the spirit and scope of the present invention.

[0126] In addition, the scope of the present invention is not intended to be limited to the specific embodiments of the processes, machines, manufactures, compositions of matter, apparatuses, methods, and steps described in the specification. Those of ordinary skill in the art will readily understand from the disclosure of the present invention that processes, machines, manufactures, compositions of matter, tools, methods, or steps that exist currently or will be developed in the future can, in accordance with the present invention, be used to perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein. Therefore, the appended claims are intended to embrace such processes, machines, manufactures, compositions of matter, apparatuses, methods, and steps within their scope.

[0127] Symbolic Explanation

[0128] 100: Molding device

[0129] 101: First mold

[0130] 101s: First side wall

[0131] 102: Second mold

[0132] 102s: Second side wall

[0133] 103: Mold cavity

[0134] 103a: First partial mold cavity

[0135] 103b: Second partial mold cavity

[0136] 104: Feed port

[0137] 104a: First partial port

[0138] 104b: Second partial port

[0139] 105: Inner wall

[0140] 105a: Inner side wall

[0141] 105b: Inner bottom wall

[0142] 106: Pressure regulation system

[0143] 107: Connection point

[0144] 109: Control system

[0145] 110: Extrusion system

[0146] 111: Discharge channel

[0147] 111o: Outlet

[0148] 112: Component

[0149] 112a: Hollow space

[0150] 112b: Opening

[0151] 112c: Inner surface

[0152] 112d: First part

[0153] 112e: Second part

[0154] 113’: Molding material

[0155] 114: Support device

[0156] 119: Product

[0157] 120: Melting unit

[0158] 121: Pressurizing chamber

[0159] 122: First feed channel

[0160] 123: First discharge channel

[0161] 124: Pushing member

[0162] 125: Feed hopper

[0163] 130: Mixing unit

[0164] 131: Hollow mixing chamber

[0165] 132: Second feed channel

[0166] 133: Second discharge channel

[0167] 134: Mixing rotor

[0168] 140: Blowing agent supply unit

[0169] 150: Injection unit

[0170] 151: Metering cylinder

[0171] 152: Connecting channel

[0172] 153: Discharge member

[0173] 154: Outlet

[0174] 161: First flow control element

[0175] 162: Second flow control element

[0176] 171: First hole

[0177] 180: Monitoring module

[0178] 200: Injection molding system

[0179] 300: Injection Molding System

[0180] 400: Method

[0181] 401: Step

[0182] 402: Step

[0183] 403: Step

[0184] 404: Step

[0185] 405: Step

[0186] 406: Step

[0187] 500: Product / Method

[0188] 501: Step

[0189] 502: Step

[0190] 503: Step

[0191] 504: Step

[0192] 505: Step

[0193] 506: Step

[0194] 507: Step

[0195] 508: Step

[0196] 509: Step

[0197] 510: Step

[0198] 511: Step

[0199] 512: Step

[0200] 1061: First Gas Duct

[0201] 1062: Second Gas Duct

[0202] 1063: Gas Source

[0203] 1064: First Valve

[0204] 1065: Second Valve

[0205] 1066: Pressure Sensing Unit

[0206] 1091: Central Processing Unit

[0207] 1092: Sensor

[0208] 1093: Cable

[0209] 1141: First element

[0210] 1142: Second element

[0211] 1143: Extension part

[0212] 1144: Arm part

[0213] 1211: Internal space

[0214] 1212: Inner side wall

[0215] 1311: Inner side wall

[0216] 1341: Columnar body

[0217] 1342: Groove part

[0218] 1511: Internal space

[0219] A: Arrow

[0220] D1: Distance

[0221] D2: Diameter

[0222] D3: Shortest distance

[0223] D4: Diameter

[0224] G: Gas

[0225] T: Overall thickness.

Claims

1. A method of manufacturing an article, comprising: Providing a molding device having a first mold and a second mold; Placing a component between the first mold and the second mold, wherein the component includes a hollow space and an opening that communicates with the hollow space; Joining the opening to the first mold or the second mold; Joining the first mold to the second mold to form a cavity surrounding the component, wherein the opening is joined to a feed port of the molding device, and the feed port is communicable with the hollow space; Injecting a molding material through the feed port and the opening into the hollow space, wherein the molding material includes a polymeric material and a foaming agent; and Foaming the molding material to form a foamed member, wherein the foamed member contacts an inner surface of the component.

2. The method according to claim 1, further comprising: Causing the component to expand during or after injecting the molding material into the hollow space, wherein the component expands until it contacts an inner sidewall of the cavity.

3. The method according to claim 1, wherein the feed port is formed after joining the first mold to the second mold.

4. The method according to claim 1, wherein the feed port is provided on a first sidewall of the first mold or a second sidewall of the second mold.

5. The method according to claim 1, wherein the feed port is provided between the first mold and the second mold, the feed port includes a first partial port at the first mold and a second partial port at the second mold, and the first partial port is aligned with the second partial port when the molding device is in a closed configuration.

6. The method according to claim 1, further comprising, before injecting the molding material: After joining the first mold and the second mold, injecting a gas into the cavity or the hollow space to increase the pressure inside the cavity or the hollow space.

7. The method according to claim 1, further comprising, after injecting the molding material: Discharging a gas from the cavity or the hollow space to reduce the pressure inside the cavity or the hollow space.

8. A method of manufacturing an article, comprising: Providing a molding device having a first mold and a second mold; Placing a component between the first mold and the second mold, wherein the component includes a hollow space and an opening that connects to the hollow space; Joining the opening to the first mold or the second mold; Joining the first mold to the second mold to form a cavity surrounding the component, wherein the opening is joined to a feed port of the mold device, the feed port is communicable with the hollow space, the feed port is provided at a sidewall of the mold device, and the component is placed in the cavity; Injecting a molding material through the feed port and the opening into the hollow space; and Foaming the molding material to form a foamed member, wherein during foaming of the foamed member, the hollow space expands in the cavity.

9. The method according to claim 8, further comprising: After the foamed member has been foamed, uncoupling the first mold and the second mold, and Removing the article including the component and the foamed member from the molding device.

10. The method according to claim 8, wherein when the opening is engaged with the feed port, a part of the component adjacent to the opening is inserted into the feed port.

Images