Injection molding device, injection molding method and product formed by injection molding device and injection molding method

Abstract

The invention provides an injection molding method. A molding device is arranged, and the injection molding device comprises a first mold, a second mold above the first mold and a mold cavity defined by the first mold and the second mold. And the first mixture is ejected into the mold cavity through the first feeding hole. A first component is formed from the first mixture. And the second mixture is ejected into the mold cavity through the second feeding hole. A second component is formed from the second mixture. The second component is at least partially in contact with the first component, and the first component and the second component have different physical properties.

Description

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS]

[0002] This application claims priority to U.S. Patent Application No. 19 / 087,570, filed March 23, 2025, and U.S. Provisional Patent Application No. 63 / 673,187, filed July 19, 2024, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present invention relates to an injection molding apparatus, an injection molding method, and an article formed thereby, and in particular, to an injection molding apparatus that implements an injection molding method to form an article that includes more than one portion having different physical or functional characteristics. BACKGROUND

[0004] Foamed polymer materials have many advantages, such as high strength, light weight, impact resistance, thermal insulation, etc. Foamed articles can be manufactured by injection molding or extrusion molding. For example, after a polymer material is melted and mixed with a foaming agent to form a mixture, a 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 within the cavity to form the foamed article.

[0005] However, it is necessary to improve the characteristics of the foamed article made by the injection molding system, such as to have different portions of the foamed article having different characteristics. Therefore, there is still a need to improve the structure of the injection molding system and the method of making the foamed article. SUMMARY

[0006] The present invention discloses an injection molding apparatus, an injection molding method, and an article formed thereby.

[0007] According to one embodiment of the present invention, an injection molding method is provided. The injection molding method includes: providing an injection molding apparatus including a first mold and a second mold, wherein the first mold includes a recessed depression recessed into the first mold, and the second mold includes a feed port extending through the second mold; engaging the first mold with the second mold to form a mold cavity defined by the first mold and the second mold, wherein the mold cavity is in communication with the recessed depression and the feed port; injecting a flowable material through the feed port into the mold cavity to fill the recessed depression and the mold cavity; and foaming the flowable material into a foamed article.

[0008] According to one embodiment of the present application, a method of molding is provided. The method of molding includes providing a molding apparatus including a first mold and a second mold, wherein the first mold includes a cooling mechanism embedded in the first mold and the second mold includes a feed opening extending through the second mold; engaging the first mold with the second mold to form a mold cavity defined by the first mold and the second mold; injecting flowable material through the feed opening into the mold cavity; operating the cooling mechanism to cool the flowable material surrounding the cooling mechanism; and foaming the flowable material into a foamed article.

[0009] According to one embodiment of the present application, a foamed article is provided. The foamed article includes a first surface, a second surface opposite the first surface, and a third surface between the first surface and the second surface. The foamed article includes a first trace disposed on the first surface and a second trace disposed on the second surface opposite and vertically aligned with the first trace. BRIEF DESCRIPTION OF DRAWINGS

[0010] Aspects of the application are best understood from the following detailed description when read in conjunction with the accompanying drawings. It is noted that, for the purposes of illustration, practices in the industry are such that various components are not drawn to scale. Indeed, the dimensions of the various components can be arbitrarily inflated or deflated for clarity.

[0011] Figure 1 schematic view of an injection molding apparatus according to one embodiment of the present application in an open state;

[0012] Figure 2 schematic view of an injection molding apparatus according to one embodiment of the present application in a closed state;

[0013] Figure 3 schematic cross-sectional view illustrating engagement of an injector with a feed opening according to one embodiment of the present application;

[0014] Figure 4 schematic cross-sectional view illustrating injection of flowable material from an injector through an injection port and a feed opening into a mold cavity according to one embodiment of the present application;

[0015] Figures 5 to 8 schematic cross-sectional view illustrating a demonstration phase of the method of molding according to one embodiment of the present application;

[0016] Figures 9 to 12 schematic view of a foamed article according to one embodiment of the present application;

[0017] Figure 13 schematic view of an injection molding apparatus according to one embodiment of the present application;

[0018] Figure 14 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0019] Figure 15 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0020] Figure 16 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0021] Figures 17 to 20 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0022] Figures 21 to 24 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0023] Figure 25 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0024] Figure 26 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application; Figure 25 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0025] Figure 27 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0026] Figures 28 to 29 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0027] Figures 30 to 34 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0028] Figure 35 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0029] Figure 36 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application; Figure 35 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0030] Figure 37 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application; Figure 35 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0031] Figures 38 to 42 schematic cross-sectional view illustrating the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0032] Figure 43 schematic view of an injection molding apparatus according to one embodiment of the present application;

[0033] Figure 44 schematic view of the first mold along Figure 43 the FF' line;

[0034] Figures 45 to 48 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0035] Figures 49 to 52 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0036] Figures 53 to 54 schematic view of an injection molding apparatus according to one embodiment of the present application;

[0037] Figures 55 to 58 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0038] Figure 59 schematic view of an injection molding apparatus according to one embodiment of the present application;

[0039] Figures 60 to 66 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0040] Figure 67 schematic view of an injection molding apparatus according to one embodiment of the present application;

[0041] Figure 68 schematic view of the injection molding apparatus along Figure 67 the GG' line;

[0042] Figure 69 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0043] Figures 70 to 71 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0044] Figures 72 to 76 schematic view of an exemplary stage of the injection molding method according to one embodiment of the present application;

[0045] Figure 77 schematic view of an injection molding apparatus according to one embodiment of the present application;

[0046] Figure 78 schematic view of the injection molding apparatus alongFigure 77 schematic top view cross-sectional view of the HH' line;

[0047] Figure 79 schematic cross-sectional view to illustrate the engagement of the ejector with the feed opening according to one embodiment of the present application;

[0048] Figures 80 to 81 schematic cross-sectional view to illustrate the demonstration phase of the injection molding method according to one embodiment of the present application;

[0049] Figures 82 to 85 schematic view of the foamed article according to one embodiment of the present application. DETAILED DESCRIPTION

[0050] The following detailed description provides many different specific details for the purpose of providing a thorough understanding of the different features of the provided subject matter. However, it will be apparent to those skilled in the art that the described features can be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the described subject matter. For example, the following description can form a first feature on or over a second feature in the description. This can include embodiments where the first and second features are in direct contact, and can also include embodiments where additional features can be formed between the first and second features such that the first and second features are not in direct contact. Furthermore, the present application can refer to various examples using corresponding reference numerals and / or letters. Such repetition is for the purpose of simplicity and clarity and does not itself serve as an indication that the described features are in any way related.

[0051] Moreover, spatially relative terms, such as "beneath", "below", "lower", "above", "upper", and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The devices can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0052] Notwithstanding that the numerical ranges and parameters setting forth the broadest scope of the application are approximations, the numerical values disclosed in specific examples herein are to be considered to be approximations. Any numerical value, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Also, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of the value or range specified. Alternatively, the term "about" when used in connection with a quantity is intended to modify that quantity by the relative tolerances inherent in the devices, materials, and / or methodologies used to determine or calculate that quantity. Except in operating / working examples, or unless otherwise explicitly indicated, all numerical ranges, quantities, values, and percentages disclosed herein are to be construed as modified by the term "about". Therefore, unless otherwise indicated, the numerical parameters in the present application and the appended claims are approximations. At the very least, each numerical parameter should be construed in light of the number of significant figures and by applying ordinary rounding techniques. In this context, a range listed as from X to Y is understood to include X and Y. Unless otherwise indicated, all ranges disclosed herein are inclusive of the endpoints.

[0053] In some embodiments, the first injection molding device 100 is in an open state. Figure 1 A first injection molding device 100 in an open state is illustrated in FIG. 1. In some embodiments, the first injection molding device 100 is used to form a foamed article. The first injection molding device 100 includes a first mold 101 and a second mold 102 that can be engaged with the first mold 101. In some embodiments, the first mold 101 is disposed underneath the second mold 102. In some embodiments, the first mold 101 is a lower mold and the second mold 102 is an upper mold. The first injection molding device 100 includes a feed opening 104 to pass a flowable material therethrough. In some embodiments, the feed opening 104 is disposed at the first mold 101 or the second mold 102. Although the feed opening 104 is illustrated as being disposed at the second mold 102, it is understood that it is not limited thereto. In some embodiments, the first injection molding device 100 includes a well 105 recessed into the first mold 101 or the second mold 102. Although the well 105 is illustrated as being recessed into the first mold 101, it is understood that it is not limited thereto. Figure 1 A first injection molding device 100 in an open state is illustrated in FIG. 1. In some embodiments, the first injection molding device 100 is used to form a foamed article. The first injection molding device 100 includes a first mold 101 and a second mold 102 that can be engaged with the first mold 101. In some embodiments, the first mold 101 is disposed underneath the second mold 102. In some embodiments, the first mold 101 is a lower mold and the second mold 102 is an upper mold. The first injection molding device 100 includes a feed opening 104 to pass a flowable material therethrough. In some embodiments, the feed opening 104 is disposed at the first mold 101 or the second mold 102. Although the feed opening 104 is illustrated as being disposed at the second mold 102, it is understood that it is not limited thereto. In some embodiments, the first injection molding device 100 includes a well 105 recessed into the first mold 101 or the second mold 102. Although the well 105 is illustrated as being recessed into the first mold 101, it is understood that it is not limited thereto. Figure 1The exemplary well 105 is disposed at and recessed into the first mold 101, but it is understood that it is not limited thereto. In some embodiments, the well 105 is used to temporarily secure material. In some embodiments, the well 105 is a cold shot, a cold well, or the like. In some embodiments, the width Wl of the feed opening 104 is substantially different or the same as the width W2 of the well 105. In some embodiments, the width Wl is substantially greater or less than the width W2. In some embodiments, the ratio of the width W2 to the height H2 of the well 105 is about 1 : 1 to about 1 : 1.5. In some embodiments, the width W2 is about 5 mm to about 10 mm.

[0054] Figure 2 The exemplary first injection molding apparatus 100 is shown in a closed state, wherein the first mold 101 is engaged with the second mold 102. In some embodiments, a mold cavity 103 is formed when the first injection molding apparatus 100 is in the closed state. The mold cavity 103 is used to secure material. The feed opening 104 can be in communication with the mold cavity 103. In some embodiments, the feed opening 104 is vertically aligned with the well 105 when the first injection molding apparatus 100 is in the closed state.

[0055] In some embodiments, the injection molding method includes a number of steps as exemplified in Figures 1 to 12 The first injection molding apparatus 100 is used to implement the injection molding method.

[0056] The injection molding method includes providing a first injection molding apparatus 100 including a first mold 101 and a second mold 102 as shown in Figure 1 engaging the first mold 101 with the second mold 102 as shown in Figure 2 In some embodiments, the injection molding method includes engaging an injector 108 with the feed opening 104 as shown in Figure 3As shown. In some embodiments, the ejector 108 engages with the inlet 104 before or after the first mold 101 engages with the second mold 102. In some embodiments, the ejection port 108a of the ejector 108 engages with the inlet 104 before or after the first mold 101 engages with the second mold 102. In some embodiments, the ejector 108 is used to eject flowable material through the ejection port 108a and the inlet 104 into the mold cavity 103. In some embodiments, the ejector 108 is connected to a mixing unit for mixing polymer material with a foaming agent. In some embodiments, the flowable material is a mixture of polymer material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and foaming agent (e.g., physical foaming agent, such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture may undergo physical foaming treatment within the mold cavity 103. The mixture in the mold cavity 103 becomes a foamed product after physical foaming treatment.

[0057] The injection molding method includes injecting a flowable material into a first injection molding apparatus 100. Figure 4 For example, flowable material 106' has been ejected from ejector 108 into mold cavity 103 through injection port 108a and feed port 104. In some specific embodiments, Figures 5 to 7 The flow of the flowable material 106' is illustrated. In some specific embodiments, when the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 to the well 105, such as... Figure 5 As indicated by arrow A. Thus, some flowable material 106' is arranged within the well 105. Then, the flowable material 106' continues to flow towards the side walls of the mold cavity 103, as... Figure 6 As indicated by arrow B. In some embodiments, after the well 105 is filled with the flowable material 106', the flowable material 106' continues to flow towards the side walls of the mold cavity 103. In some embodiments, the flowable material 106' eventually fills the mold cavity 103, as shown in the image. Figure 7 As shown inside. After the flowable material 106' is injected, the flowable material 106' undergoes physical foaming within the mold cavity 103 to become a foamed product 106, as shown. Figure 4 As shown inside.

[0058] The injection molding method includes disengaging the first mold 101 from the second mold 102 to open the first injection molding apparatus 100. Figure 8An open condition of the first injection molding apparatus 100 after the exemplary foamed article 106 is formed. In some embodiments, the injection outlet 108a of the injector 108 is disengaged from the feed opening 104 before or after the first mold 101 and the second mold 102 are disengaged. After the first injection molding apparatus 100 is opened, the foamed article 106 is removed from the first injection molding apparatus 100, as shown in Figure 8 and Figure 9 .

[0059] The injection molding method includes forming an article through a foaming process. Figure 9 An exemplary foamed article 106 formed by the first injection molding apparatus 100. In some embodiments, the foamed article 106 includes a first protrusion 107 and a second protrusion 109. In some embodiments, the first protrusion 107 and the second protrusion 109 are vertically aligned. In some embodiments, the first protrusion 107 corresponds to and complements at least a portion of the well 105, and the second protrusion 109 corresponds to and complements at least a portion of the feed opening 104.

[0060] In some embodiments, the first protrusion 107 and the second protrusion 109 have been removed, as shown in Figures 10 to 12 . Figure 10 is a schematic side view of the foamed article 106, Figure 11 is a schematic bottom view of the foamed article 106, and Figure 12 is a schematic top view of the foamed article 106. In some embodiments, the first protrusion 107 and the second protrusion 109 are removed through cutting, trimming, grinding, or any other suitable process. As a result, a first modified mark 107' is formed on the bottom surface of the foamed article 106, and a second modified mark 109' is formed on the top surface of the foamed article 106. In some embodiments, the first modified mark 107' and the second modified mark 109' do not include a skin layer, as the skin layer is damaged or removed during the modification process. In some embodiments, the foamed article 106 is a component of an article of footwear, such as an outsole, etc.

[0061] Referring again to Figure 5 , because the flowable material 106' first flows into and fills the well 105, and then fills the mold cavity 103, the flow mark around the first protrusion 107 and on the top surface of the foamed article 106 is non-existent or minimized. Also, the flowable material 106' in the first injection molding apparatus 100 is uniformly foamed, such that the distribution of pores inside the foamed article 106 is more uniform, and the overall density of the foamed article 106 is more uniform.

[0062] Alternatively, a second injection molding apparatus 200 is used, as shown in Figures 13 to 24As shown inside. In some specific embodiments, the second injection molding apparatus 200 is similar to the first injection molding apparatus 100, except that the number of wells 105 and feed inlets 104 differs. For example... Figure 13 As shown in the illustration, in some embodiments, the second injection molding apparatus 200 includes a plurality of wells 105 and a plurality of feed ports 104 corresponding to each well 105. In some embodiments, each well 105 corresponds to one feed port 104. In some embodiments, each well 105 is vertically aligned with its corresponding feed port 104.

[0063] Figure 14 An example is shown where the ejector 108 engages with the second injection molding apparatus 200. In some embodiments, the ejector 108 engages with the inlet 104 before or after the first mold 101 engages with the second mold 102. In some embodiments, the ejector 108 includes a plurality of injection ports 108a that can engage with one of the inlets 104. Alternatively, as... Figure 15 As shown, a plurality of ejectors 108 are engaged with a second injection molding apparatus 200. In some embodiments, each ejector 108 has an injection port 108a, and the injection port 108a can be engaged with a feed port 104.

[0064] For simplicity and clarity, the ejector 108, which engages with the second injection molding apparatus 200, is illustrated in the following figures to describe subsequent steps. However, it should be understood that... Figure 14 The ejector 108 can also implement the subsequent steps in a similar manner.

[0065] When the ejector 108 engages with the second injection molding device 200, the flowable material 106' is ejected from the ejector 108 through the injection port 108a and the feed port 104 into the mold cavity 103, such as Figure 16 As shown inside. In some specific embodiments, Figures 17 to 19 The flow of the flowable material 106' is illustrated. In some specific embodiments, when the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 to the well 105, such as... Figure 17 As shown by the middle arrow A, similar to the description above or Figure 5 As shown in the diagram. In this way, some flowable material 106' is arranged within the well 105. Then, the flowable material 106' continues to flow towards the side walls of the mold cavity 103, as... Figure 18 As shown by arrow B in the image, it is similar to the description above. Figure 6 As shown. In some specific embodiments, the flowable material 106' is ultimately filled into the mold cavity 103, such as... Figure 19The flowable material 106' is physically foamed within the mold cavity 103 to become a foamed article 106 after the flowable material 106' is ejected, as shown in Figure 16 The foamed article 106 is formed by the second injection molding device 200, as shown in

[0066] After the foamed article 106 is formed, the second injection molding device 200 is opened to remove the foamed article 106, as shown in Figure 20 The foamed article 106 is formed by the second injection molding device 200, as shown in Figure 8 The manner described above or Figure 21 The foamed article 106 is formed by the second injection molding device 200, as shown in Figure 9 In some embodiments, the first protrusion 107 and the second protrusion 109 have been removed, as shown in Figures 22 to 24 The manner described above or Figures 10 to 12 The manner described above or Figure 22 is a schematic side view of the foamed article 106, Figure 23 is a schematic bottom view of the foamed article 106, and Figure 24 is a schematic top view of the foamed article 106.

[0067] In some embodiments, a third injection molding device 300 is used to implement another injection molding method having multiple steps, as shown in Figures 25 to 34 The third injection molding device 300 is in an open state, as shown in Figure 25 The third injection molding device 300 includes a first mold 101, a second mold 102, and a feed port 104, which are similar to those in the first injection molding device 100 or the second injection molding device 200. Figure 25 Only one feed port 104 is shown, but it is understood that more than one feed port 104 can be included. In some embodiments, the third injection molding device 300 includes a plurality of recesses 110 (having a width W3 and a height H3) recessed in the first mold 101 or the second mold 102. Although Figure 25 The recesses 110 are shown arranged at and recessed in the first mold 101, but it is understood that they are not limited thereto. In some embodiments, the recesses 110 have been used to temporarily secure a material. Figure 26 is a schematic top cross-sectional view of the third injection molding device 300 along the CC' line in Figure 25 In some embodiments, the recesses 110 are positioned according to a predetermined pattern or randomly positioned. In some embodiments, the recesses 110 are located near one side (e.g., left side, right side, front, back, etc.) of the third injection molding device 300.

[0068] Figure 27A third injection molding apparatus 300 in a closed state is illustrated, where the first mold 101 is engaged with the second mold 102. In some embodiments, a mold cavity 103 is formed when the third injection molding apparatus 300 is in a closed state. In some embodiments, the injector 108 is engaged with the third injection molding apparatus 300 before or after the third injection molding apparatus 300 is closed. In some embodiments, the injection outlet 108a of the injector 108 is engaged with the feed port 104, such that the flowable material can flow from the injector 108 through the injection outlet 108a and the feed port 104 into the mold cavity 103.

[0069] After the injector 108 is engaged, the flowable material 106' flows into the mold cavity 103, as illustrated in Figure 28 In some embodiments, the flowable material 106' fills the recess 110. In some embodiments, the flowable material 106' is a mixture of a polymeric material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and a blowing agent (e.g., a physical blowing agent, such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture can undergo a physical foaming process within the mold cavity 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process.

[0070] Figure 29 An open condition of the third injection molding apparatus 300 after the foamed article 106 is formed is illustrated. In some embodiments, the injection outlet 108a of the injector 108 is disengaged from the feed port 104 before or after the first mold 101 is engaged with the second mold 102. After the first injection molding apparatus 100 is opened, the foamed article 106 is removed from the third injection molding apparatus 300, as illustrated in Figure 29 and Figure 30 In some embodiments, the foamed article 106 is removed from the third injection molding apparatus 300 by a robotic arm 112.

[0071] Figure 30 and Figure 31 A foamed article 106 formed by the third injection molding apparatus 300 is illustrated. Figure 30 is a schematic side view of the foamed article 106, and Figure 31 is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 corresponds to and complements at least a portion of the feed port 104, and the third protrusion 111 corresponds to and complements at least a portion of the recess 110.

[0072] In some embodiments, the second protrusion 109 and the third protrusion 111 have been removed, as illustrated in Figures 32 to 34 In some embodiments, the foamed article 106 is removed from the third injection molding apparatus 300 by a robotic arm 112. Figure 32 is a schematic side view of the foamed article 106,Figure 33 is a schematic top view of the foamed article 106, and Figure 34 is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 and the third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable process. As a result, a second modified trace 109' is formed on the top surface of the foamed article 106, and a third modified trace 111' is formed on the bottom surface of the foamed article 106. In some embodiments, the second modified trace 109' and the third modified trace 111' do not include a skin layer, as the skin layer is damaged or removed during the modification process. In some embodiments, the foamed article 106 is a component of an article of footwear, such as an outsole, or the like. Because the flowable material 106' first flows into and fills the recess 110, and then fills the mold cavity 103, flow traces on the surface of the foamed article 106 are not present or are minimized. Also, the flowable material 106' within the fourth injection molding apparatus 400 is uniformly foamed, such that the distribution of pores within the foamed article 106 is more uniform, and the overall density of the foamed article 106 is more uniform.

[0073] Alternatively, a fourth injection molding apparatus 400 is used, as shown in Figures 35 to 42 In some embodiments, the fourth injection molding apparatus 400 is similar to the third injection molding apparatus 300, except that the recess 110 is also disposed at the second mold 102. Figure 35 is a schematic side view of the fourth injection molding apparatus 400, Figure 36 is a schematic top view of the first mold 101 along the line DD' in Figure 35 is a schematic top cross-sectional view of the first mold 101 along the line DD' in Figure 37 is a schematic top view of the second mold 102 along the line EE' in Figure 35 is a schematic top cross-sectional view of the second mold 102 along the line EE' in

[0074] After the flowable material 106' flows into the mold cavity 103 of the fourth injection molding apparatus 400, the flowable material 106' is physically foamed into a foamed article 106, as shown in Figure 38 and Figure 39 . Figure 38 is a schematic side view of the foamed article 106, and Figure 39This is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 and some third protrusions 111 are located on the top surface of the foamed article 106. In some embodiments, some third protrusions 111 are located on the bottom surface of the foamed article 106. In some embodiments, some third protrusions 111 are located on the side surface of the foamed article 106. In some embodiments, the number of third protrusions 111 is different from the number of second protrusions 109. In some embodiments, the number of third protrusions 111 is greater than the number of second protrusions 109. In some embodiments, the number of third protrusions 111 is 3 or less. In some embodiments, the number of third protrusions 111 is 1, 2, or 3.

[0075] In some specific embodiments, the second protrusion 109 and the third protrusion 111 have been removed, such as Figures 40 to 42 As shown inside. Figure 40 This is a schematic side view of the foamed product 106. Figure 41 This is a schematic top view of the foamed product 106, and Figure 42 This is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 and the third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable treatment. Thus, a second finishing mark 109' is formed on the top surface of the foamed article 106, and a third finishing mark 111' is formed on the bottom surface of the foamed article 106. In some embodiments, the third protrusion 111 and the second protrusion 109 are removed, resulting in the third finishing mark 111' and the second finishing mark 109', respectively. In some embodiments, the surface area of ​​each of the third finishing marks 111' is substantially smaller than the surface area of ​​the second finishing mark 109'.

[0076] In some specific embodiments, the fifth injection molding apparatus 500 is used to perform, for example... Figures 43 to 52 The diagram shows another injection molding method with multiple steps. In some specific embodiments, the fifth injection molding apparatus 500 is similar to the third injection molding apparatus 300 and the first injection molding apparatus 100, and the fifth injection molding apparatus 500 is a composite of the third injection molding apparatus 300 and the first injection molding apparatus 100. Figure 43 This is a schematic side view of the fifth injection molding apparatus 500, and Figure 44 For along Figure 43 A schematic top cross-sectional view of the first mold 101 of the FF' line. In some specific embodiments, the first mold 101 includes a well 105 and a plurality of recesses 110, and the second mold 102 includes a feed inlet 104 perpendicularly aligned with the well 105.

[0077] In some embodiments, as Figure 43 shown, the fifth injection molding device 500 is closed and the injector 108 is engaged with the fifth injection molding device 500, the flowable material 106' flows from the injector 108 into the mold cavity 103, as Figure 45 shown. In some embodiments, Figures 46 to 48 the flow of the flowable material 106' is exemplified. In some embodiments, as the flowable material 106' is ejected from the ejection port 108a of the injector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 toward the well 105, as indicated by arrow A in Figure 46 , in a manner similar to that described above or Figure 5 shown. In this way, some of the flowable material 106' is disposed within the well 105. The flowable material 106' then continues to flow toward the two sidewalls of the mold cavity 103, as indicated by arrow B in Figure 47 , in a manner similar to that described above or Figure 6 shown. In some embodiments, the flowable material 106' eventually fills the mold cavity 103, as shown in Figure 48 . After the flowable material 106' is ejected, the flowable material 106' undergoes physical foaming within the mold cavity 103 to become the foamed article 106, as shown in Figure 45 and Figure 49 . Figure 49 is a schematic side view of the foamed article 106. In some embodiments, the foamed article 106 includes a first protrusion 107, a second protrusion 109, and a third protrusion 111. In some embodiments, the first protrusion 107 and the third protrusion 111 are located on the bottom surface of the foamed article 106, and the second protrusion 109 is located on the top surface of the foamed article 106.

[0078] In some embodiments, the first protrusion 107, the second protrusion 109, and the third protrusion 111 have been removed, as shown in Figures 50 to 52 . Figure 50 is a schematic side view of the foamed article 106, Figure 51 is a schematic top view of the foamed article 106, and Figure 52 is a schematic bottom view of the foamed article 106. In some embodiments, the first protrusion 107, the second protrusion 109, and the third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable process. As a result, a second modified trace 109' is formed on the top surface of the foamed article 106, and a first modified trace 107' and a third modified trace 111' are formed on the bottom surface of the foamed article 106.

[0079] In some embodiments, a sixth injection molding device 600 is used to implement the method as Figures 53 to 58Another injection molding method having multiple steps is shown. Figure 53 A sixth injection molding apparatus 600 in an open state is illustrated. The sixth injection molding apparatus 600 includes a first mold 101 and a second mold 102 engageable with the first mold 101. The sixth injection molding apparatus 600 includes a feed opening 104 to pass a flowable material therethrough. In some embodiments, the feed opening 104 is disposed at the first mold 101 or the second mold 102. In some embodiments, the sixth injection molding apparatus 600 includes a cooling mechanism 601 disposed on the first mold 101 or the second mold 102. Although the cooling mechanism 601 is illustrated as being disposed at the first mold 101, it is understood that it is not limited thereto. In addition, although only one cooling mechanism 601 is disposed in the sixth injection molding apparatus 600, it is understood that the number of cooling mechanisms 601 is not limited. Figure 53 A sixth injection molding apparatus 600 in an open state is illustrated. The sixth injection molding apparatus 600 includes a first mold 101 and a second mold 102 engageable with the first mold 101. The sixth injection molding apparatus 600 includes a feed opening 104 to pass a flowable material therethrough. In some embodiments, the feed opening 104 is disposed at the first mold 101 or the second mold 102. In some embodiments, the sixth injection molding apparatus 600 includes a cooling mechanism 601 disposed on the first mold 101 or the second mold 102. Although the cooling mechanism 601 is illustrated as being disposed at the first mold 101, it is understood that it is not limited thereto. In addition, although only one cooling mechanism 601 is disposed in the sixth injection molding apparatus 600, it is understood that the number of cooling mechanisms 601 is not limited.

[0080] In some embodiments, the cooling mechanism 601 is to provide cooling of a portion of the flowable material when the flowable material is disposed on or over the first mold 101. In some embodiments, the cooling mechanism 601 allows a liquid (e.g., coolant, water, etc.) to flow through or circulate to cool a portion of the first mold 101 or to cool a portion of the flowable material disposed on or over the first mold 101. In some embodiments, the cooling mechanism 601 is an electric cooler, a cooling device, etc.

[0081] Figure 54 A sixth injection molding apparatus 600 in a closed state is illustrated, in which the first mold 101 is engaged with the second mold 102. In some embodiments, a mold cavity 103 is formed when the sixth injection molding apparatus 600 is in the closed state. The mold cavity 103 is to hold material. The feed opening 104 can be in communication with the mold cavity 103. In some embodiments, the injector 108 is engaged with the feed opening 104 before or after the first mold 101 is engaged with the second mold 102. In some embodiments, the injection outlet 108a of the injector 108 is engaged with the feed opening 104 before or after the first mold 101 is engaged with the second mold 102. In some embodiments, the injector 108 is to inject a flowable material through the injection outlet 108a and the feed opening 104 into the mold cavity 103. In some embodiments, the flowable material is a mixture of a polymeric material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and a blowing agent (e.g., a physical blowing agent, such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture can undergo a physical foaming process within the mold cavity 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process.

[0082] Figure 55For example, flowable material 106' is ejected from ejector 108 into mold cavity 103 through injection port 108a and feed port 104. In some embodiments, before or during the ejection of flowable material 106' into mold cavity 103, the temperature of the sixth injection molding apparatus 600 is raised before ejection of flowable material 106' and maintained at a first predetermined temperature during ejection of flowable material 106' to facilitate the flow of flowable material 106' into mold cavity 103. In some embodiments, the first predetermined temperature is about 30°C to about 40°C. In some embodiments, after ejection of flowable material 106', the temperature of flowable material 106' inside mold cavity 103 is substantially equal to the first predetermined temperature.

[0083] After the flowable material 106' is injected, it undergoes physical foaming within the mold cavity 103 to become a foamed product 106, such as... Figure 56 As shown in the diagram. In some embodiments, after the flowable material 106' is injected and during the foaming of the flowable material 106' within the mold cavity 103, a cooling mechanism 601 is activated to cool the flowable material 106' surrounding the cooling mechanism 601. In some embodiments, the cooling mechanism 601 operates to cool the flowable material 106' from a first predetermined temperature to a second predetermined temperature. In some embodiments, the second predetermined temperature is substantially below 25°C. In some embodiments, the second predetermined temperature is approximately 20°C. In some embodiments, the duration for which the cooling mechanism 601 cools the flowable material 106' surrounding the cooling mechanism 601 from the first predetermined temperature to the second predetermined temperature is substantially less than 2 seconds.

[0084] After the flowable material 106' is cooled by the cooling mechanism 601 and foamed, a foamed article 106 with a surface layer 602 is formed. The surface layer 602 is formed from the flowable material 106' surrounding the cooling mechanism 601. In some embodiments, the thickness of the surface layer 602 is from about 0.5 mm to about 5 mm. In some embodiments, a density gradient exists within the surface layer 602, i.e., the density of the surface layer 602 gradually increases from the interior to the exterior of the foamed article 106. In some embodiments, the surface layer 602 has a lower degree of physical foaming than the rest of the foamed article 106. That is, the rest of the foamed article 106 has a higher degree of physical foaming than the surface layer 602. In some embodiments, the density of the surface layer 602 is different from the density of the rest of the foamed article 106. In some embodiments, the density of the surface layer 602 is substantially greater than the density of the rest of the foamed article 106. In some specific embodiments, the density of the surface layer 602 is substantially equal to or greater than 0.2 g / cm³. 3while the density of the remainder of the foamed article 106 is substantially less than 0.2 g / cm 3 In some embodiments, the density of the skin layer 602 is substantially equal to or greater than 0.22 g / cm 3 while the density of the remainder of the foamed article 106 is substantially equal to or less than 0.16 g / cm 3 In some embodiments, the skin layer 602 has a higher abrasion resistance than the remainder of the foamed article 106 because the density of the skin layer 602 is higher than the density of the remainder of the foamed article 106.

[0085] Figure 57 An open configuration of the sixth injection molding apparatus 600 is illustrated after the foamed article 106 having the skin layer 602 is formed. In some embodiments, the exit 108a of the injector 108 is disengaged from the feed opening 104 before or after the first mold 101 and the second mold 102 are disengaged. After the sixth injection molding apparatus 600 is opened, the foamed article 106 having the skin layer 602 is removed from the sixth injection molding apparatus 600, as illustrated in Figure 57 In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable process, as illustrated in Figure 58

[0086] In some embodiments, the foamed article 106 is a component of an article of footwear, such as an outsole, or the like. In some embodiments, the skin layer 602 is exposed to the ambient environment without an adhesive or other component covering the skin layer 602.

[0087] In some embodiments, a seventh injection molding apparatus 700 is used to implement another injection molding method having multiple steps, as illustrated in Figures 59 to 66 In some embodiments, the seventh injection molding apparatus 700 is similar to the first injection molding apparatus 100 and the sixth injection molding apparatus 600, and the seventh injection molding apparatus 700 is a composite of the first injection molding apparatus 100 and the sixth injection molding apparatus 600. Figure 59 A schematic side view of the seventh injection molding apparatus 700 in a closed configuration is illustrated. In some embodiments, the first mold 101 includes a well 105 and a cooling mechanism 601, and the second mold 102 includes a feed opening 104 that is vertically aligned with the well 105.

[0088] ​In some embodiments, prior to or while the flowable material 106' is ejected into the mold cavity 103, the temperature of the seventh ejection molding device 700 is increased prior to ejection of the flowable material 106' and maintained at a first predetermined temperature during ejection of the flowable material 106' to facilitate the flow of the flowable material 106' into the mold cavity 103. In some embodiments, the first predetermined temperature is about 30 °C to about 40 °C. In some embodiments, the temperature of the flowable material 106' inside the mold cavity 103 is substantially equal to the first predetermined temperature after the flowable material 106' is ejected.

[0089] In some embodiments, as shown in FIG. 7, the seventh ejection molding device 700 is closed and the ejector 108 is engaged with the seventh ejection molding device 700. In some embodiments, the flowable material 106' flows from the ejector 108 into the mold cavity 103, as shown in FIG. 8. In some embodiments, the flow of the flowable material 106' is exemplified in FIG. 8. In some embodiments, as the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 toward the well 105, as shown by arrow A in FIG. 8, in a manner similar to that described above or shown in FIG. 6. In this way, some of the flowable material 106' is disposed within the well 105. Then, the flowable material 106' continues to flow toward the two sidewalls of the mold cavity 103, as shown by arrow B in FIG. 8, in a manner similar to that described above or shown in FIG. 7. In some embodiments, the flowable material 106' eventually fills the mold cavity 103, as shown in FIG. 9. Figure 59 Figure 60 Figures 61 to 63 Figure 61 Figure 5 Figure 62 Figure 6 Figure 63

[0090] In some embodiments, after the flowable material 106' is ejected and during foaming of the flowable material 106' within the mold cavity 103, the cooling mechanism 601 operates, as shown in FIG. 10. The cooling mechanism 601 can operate to cool the flowable material 106' surrounding the cooling mechanism 601. In some embodiments, the cooling mechanism 601 operates to cool the flowable material 106' from the first predetermined temperature to a second predetermined temperature. In some embodiments, the second predetermined temperature is substantially less than 25 °C. In some embodiments, the second predetermined temperature is about 20 °C. In some embodiments, the cooling mechanism 601 cools the flowable material 106' surrounding the cooling mechanism 601 from the first predetermined temperature to the second predetermined temperature in a duration of time that is substantially less than 2 seconds. Figure 64

[0091] After the flowable material 106' is foamed and cooled, a foamed article 106 having a skin 602 is formed, as shown in FIG. 11.​​​​​​​​​Figure 60 The skin layer 602 is formed from the flowable material 106' surrounding the cooling mechanism 601. In some embodiments, the skin layer 602 has a thickness of about 0.5 mm to about 5 mm. In some embodiments, there is a density gradient within the skin layer 602, i.e., the density of the skin layer 602 gradually increases from the interior of the foamed article 106 to the exterior of the foamed article 106. In some embodiments, the skin layer 602 has a lower degree of physical foaming than the rest of the foamed article 106. That is, the rest of the foamed article 106 has a higher degree of physical foaming than the skin layer 602. In some embodiments, the density of the skin layer 602 is different from the density of the rest of the foamed article 106. In some embodiments, the density of the skin layer 602 is substantially greater than the density of the rest of the foamed article 106. In some embodiments, the density of the skin layer 602 is substantially equal to or greater than 0.2 g / cm3, while the density of the rest of the foamed article 106 is substantially less than 0.2 g / cm3. 3 In some embodiments, the density of the skin layer 602 is substantially equal to or greater than 0.22 g / cm3, while the density of the rest of the foamed article 106 is substantially equal to or less than 0.16 g / cm3. 3 In some embodiments, the density of the skin layer 602 is substantially equal to or greater than 0.22 g / cm3, while the density of the rest of the foamed article 106 is substantially equal to or less than 0.16 g / cm3. 3 In some embodiments, the density of the skin layer 602 is substantially equal to or greater than 0.22 g / cm3, while the density of the rest of the foamed article 106 is substantially equal to or less than 0.16 g / cm3. 3 In some embodiments, the skin layer 602 has a higher abrasion resistance than the rest of the foamed article 106 because the density of the skin layer 602 is higher than the density of the rest of the foamed article 106.

[0092] Figure 65 After the foamed article 106 having the skin layer 602 is formed, the seventh injection molding apparatus 700 is opened. In some embodiments, the exit 108a of the injector 108 is detached from the feed opening 104 before or after the first mold 101 and the second mold 102 are detached. After the seventh injection molding apparatus 700 is opened, the foamed article 106 having the skin layer 602 is removed from the seventh injection molding apparatus 700, as shown in FIG. 6D. Figure 65 In some embodiments, the first protrusion 107 and the second protrusion 109 are removed by cutting, trimming, grinding, or any other suitable process, as shown in FIG. 6E. Figure 66 In some embodiments, the foamed article 106 is a component of an article of footwear, such as an outsole, or the like. In some embodiments, the skin layer 602 is exposed to the ambient environment without an adhesive or other component covering the skin layer 602.

[0093] In some embodiments, an eighth injection molding apparatus 800 is used to implement another injection molding method having multiple steps, as shown in FIG. 7. Figures 67 to 76 In some embodiments, an eighth injection molding apparatus 800 is used to implement another injection molding method having multiple steps, as shown in FIG. 7. Figure 67An eighth injection molding device 800 in an open state is illustrated. In some embodiments, the eighth injection molding device 800 includes a first mold 101, a second mold 102, and a feed port 104, which are similar to those in the first injection molding device 100 or the second injection molding device 200. Figure 67 Only one feed port 104 is illustrated, but it is understood that more than one feed port 104 can be included. In some embodiments, the eighth injection molding device 800 includes a plurality of recesses 110 recessed within the first mold 101 or the second mold 102. Although Figure 67 The recesses 110 are illustrated as being disposed at and recessed within the first mold 101, but it is understood that they are not limited thereto. In some embodiments, the recesses 110 have been used to temporarily secure a material. Figure 68 The eighth injection molding device 800 is configured to move along a path P8, which is similar to the path P1 of the first injection molding device 100 or the path P2 of the second injection molding device 200. Figure 67 A schematic top cross-sectional view along the line GG' is illustrated. In some embodiments, the recesses 110 are disposed in a predetermined pattern, such as being arranged in a matrix. In some embodiments, the recesses 110 are located near one side (e.g., left side, right side, front, back, etc.) of the eighth injection molding device 800. In some embodiments, the recesses 110 are laterally offset from the sidewall of the first mold 101 by about 0.8 to 1.6 centimeters. In some embodiments, the recesses 110 have a height H4 of about 0.3 millimeters and a width W4 of about 0.3 millimeters.

[0094] Figure 69 The eighth injection molding device 800 in a closed state is illustrated, in which the first mold 101 is engaged with the second mold 102. In some embodiments, a mold cavity 103 is formed when the eighth injection molding device 800 is in the closed state. In some embodiments, the injector 108 is engaged with the eighth injection molding device 800 before or after the eighth injection molding device 800 is closed. In some embodiments, the injection outlet 108a of the injector 108 is engaged with the feed port 104, such that flowable material can flow from the injector 108 through the injection outlet 108a and the feed port 104 into the mold cavity 103.

[0095] After the injector 108 is engaged, flowable material 106' flows into the mold cavity 103, as illustrated in FIG. 8C. Figure 70The flowable material 106' fills the recess 110 in some embodiments. In some embodiments, the flowable material 106' is a mixture of a polymeric material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and a blowing agent (e.g., a physical blowing agent such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture can undergo a physical foaming process within the mold cavity 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process. In some embodiments, the flowable material 106' flows through the feed port 104 and the mold cavity 103 as the flowable material 106' is ejected from the ejection port 108a of the ejector 108. In some embodiments, the recess 110 interferes with the flow of the polymer to disrupt air bubbles under the skin (inside the product) during the flow of the flowable material 106', thus improving the contact surface (corresponding to the recess 110) of the product. In comparative examples, an additional rubbing or abrading step is employed to make the contact surface smooth, but this rubbing or abrading step can not be necessary for the injection molding method of the present disclosure due to the presence of the recess 110.

[0096] Figure 71 An open configuration of the eighth injection molding apparatus 800 after the exemplary foamed article 106 is formed. In some embodiments, the ejection port 108a of the ejector 108 is disengaged from the feed port 104 before or after the first mold 101 is disengaged from the second mold 102. After the first injection molding apparatus 100 is opened, the foamed article 106 is removed from the eighth injection molding apparatus 800, as shown in Figure 71 and Figure 72 as shown in.

[0097] Figure 72 and Figure 73 An exemplary foamed article 106 formed by the eighth injection molding apparatus 800. Figure 72 is a schematic side view of the foamed article 106, and Figure 73 is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 corresponds to and complements at least a portion of the feed port 104, and the third protrusion 111 corresponds to and complements at least a portion of the recess 110.

[0098] In some embodiments, the second protrusion 109 has been removed, as shown in Figures 74 to 76 is a schematic side view of the foamed article 106, Figure 74 is a schematic side view of the foamed article 106, Figure 75 is a schematic top view of the foamed article 106, and Figure 76This is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable treatment. Therefore, a second finishing mark 109' is formed on the top surface of the foamed article 106. In some embodiments, the second finishing mark 109' does not include the surface layer, as the surface layer may be damaged or removed during the finishing process. In some embodiments, the foamed article 106 is a component of footwear, such as an outsole. Because the flowable material 106' first flows into and fills the recess 110 before filling the mold cavity 103, flow marks are absent or minimized on the surface of the foamed article 106. Furthermore, the flowable material 106' within the eighth injection molding apparatus 800 undergoes uniform foaming, resulting in a more uniform pore distribution within the foamed article 106 and a more uniform overall density.

[0099] In some specific embodiments, the ninth injection molding apparatus 900 is used to perform, for example... Figures 77 to 85 The diagram shows another injection molding method with multiple steps. Figure 77 A ninth injection molding apparatus 900 in the open state is illustrated. In some specific embodiments, the ninth injection molding apparatus 900 includes a first mold 101, a second mold 102, and a feed port 104, which are similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. Figure 77 Only one feed port 104 is shown, but it should be understood that more than one feed port 104 may be included. In some specific embodiments, the ninth injection molding apparatus 900 includes a protrusion 112 projecting from the first mold 101 or the second mold 102. Although Figure 77 As illustrated, protrusion 112 is arranged and protrudes from the first mold 101, but it should be understood that it is not limited thereto. In some specific embodiments, protrusion 112 is used to temporarily disrupt the flow of material using horizontal protrusion 112x and vertical protrusion 112y, and to temporarily retain the material within recess 113. Figure 78 For the ninth injection molding device 900 along Figure 77 A schematic top cross-sectional view of line HH'. In some embodiments, the protrusions 112 are formed according to a predetermined pattern, for example, the protrusions 112 are formed in a matrix. In some embodiments, the protrusions 112 are located near one side (e.g., left, right, front, rear, etc.) of the ninth injection molding apparatus 900. In some embodiments, the protrusions 112 are laterally offset from the sidewall of the first mold 101 by approximately 0.8 to 1.6 cm. In some embodiments, the bottom height H5 of the protrusions 112 is approximately 0.3 mm, the height H6 of the horizontal protrusions 112x at the bottom of the protrusions 112 is approximately 0.3 mm, and the height H7 of the vertical protrusions 112y at the bottom of the protrusions 112 is approximately 0.15 mm.

[0100] Figure 79 The ninth injection molding apparatus 900 is illustrated in a closed state, with the first mold 101 engaged with the second mold 102. In some embodiments, a mold cavity 103 is formed when the ninth injection molding apparatus 900 is in the closed state. In some embodiments, the injector 108 is engaged with the ninth injection molding apparatus 900 before or after the ninth injection molding apparatus 900 is closed. In some embodiments, the injection outlet 108a of the injector 108 is engaged with the feed port 104, such that flowable material can flow from the injector 108 through the injection outlet 108a and the feed port 104 into the mold cavity 103.

[0101] After the injector 108 is engaged, flowable material 106' flows into the mold cavity 103, as illustrated in Figure 80 In some embodiments, the flowable material 106' fills the recess 113. In some embodiments, the flowable material 106' is a mixture of a polymeric material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and a blowing agent (e.g., a physical blowing agent, such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture can undergo a physical foaming process within the mold cavity 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process. In some embodiments, as the flowable material 106' is ejected from the injection outlet 108a of the injector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103. In some embodiments, during the flow of the flowable material 106', the protrusions 112 and the recess 113 disrupt the flow of the polymer to break the air bubbles below the surface (inside the product), thus improving the contact surface (corresponding to the protrusions 112 and the recess 113) of the product. In comparative examples, an additional rubbing or grinding step is employed to make the contact surface smooth, but due to the presence of the protrusions 112 and the recess 113, the rubbing or grinding step can not be necessary for the injection molding method of the present disclosure.

[0102] Figure 81 The ninth injection molding apparatus 900 is illustrated in an open state after the foamed article 106 is formed. In some embodiments, the injection outlet 108a of the injector 108 is disengaged from the feed port 104 before or after the first mold 101 is disengaged from the second mold 102. After the first injection molding apparatus 100 is opened, the foamed article 106 is removed from the ninth injection molding apparatus 900, as illustrated in Figure 81 and Figure 82 .

[0103] Figure 82 and Figure 83 The foamed article 106 formed by the ninth injection molding apparatus 900 is illustrated. Figure 82FIG. 1 is a schematic side view of a foamed article 106, and Figure 83 FIG. 2 is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a recess 114. In some embodiments, the second protrusion 109 corresponds to and complements at least a portion of the feed opening 104, and the recess 114 corresponds to and complements at least a portion of the protrusion 112.

[0104] In some embodiments, the second protrusion 109 has been removed, as shown in Figures 84 to 85 Figure 84 FIG. 4 is a schematic top view of the foamed article 106, and Figure 85 FIG. 5 is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable process. As a result, a second modification mark 109' is formed on the top surface of the foamed article 106. In some embodiments, the second modification mark 109' does not include a skin layer, as the skin layer is damaged or removed during the modification process. In some embodiments, the foamed article 106 is a component of an article of footwear, such as an outsole. Because the flowable material 106' first flows into and fills the recess 113 to form the recess 114, and then fills the mold cavity 103, flow marks on the surface of the foamed article 106 are not present or are minimized. Also, the flowable material 106' in the ninth injection molding apparatus 900 is uniformly foamed, such that the distribution of pores within the foamed article 106 is more uniform, and the overall density of the foamed article 106 is more uniform.

[0105] Symbol Explanation

[0106] 100: first injection molding apparatus

[0107] 101 : first mold

[0108] 102: second mold

[0109] 103: mold cavity

[0110] 104: feed opening

[0111] 105: well

[0112] 106: foamed article

[0113] 106': flowable material

[0114] 107: first protrusion

[0115] 107': first modification mark

[0116] 108: injector

[0117] 108a: injection port​

[0118] 109: second protrusion

[0119] 109': second modification trace

[0120] 110, 113, 114: recess

[0121] 111: third protrusion

[0122] 111 ': third modification trace

[0123] 112: protrusion

[0124] 112x: horizontal protrusion

[0125] 112y: vertical protrusion

[0126] 200: second injection molding device

[0127] 300: third injection molding device

[0128] 400: fourth injection molding device

[0129] 500: fifth injection molding device

[0130] 600: sixth injection molding device

[0131] 601: cooling mechanism

[0132] 602: skin layer

[0133] 700: seventh injection molding device

[0134] 800: eighth injection molding device

[0135] 900: ninth injection molding device

[0136] H2, H3, H4, H5, H6, H7: height

[0137] W1, W2, W3, W4: width

Claims

1. A molding method characterized by, including: providing a molding apparatus comprising a first mold and a second mold, wherein the first mold comprises a recess indented into the first mold and the second mold comprises a feed port extending through the second mold; engaging the first mold with the second mold to form a mold cavity defined by the first mold and the second mold, wherein the mold cavity is in communication with the recess and the feed port; injecting a flowable material through the feed port into the mold cavity to fill the recess and the mold cavity; and foaming the flowable material into a foamed article.

2. The method of claim 1, wherein, The feed port is aligned with the recess.

3. The method of claim 1, wherein, The foamed article comprises a first protrusion within the recess, The molding method further comprises: removing the first protrusion from the foamed article, wherein, after removal, a first decorative mark corresponding to the first protrusion is formed on the foamed article. The foamed article comprises a second protrusion within the feed port, 4. The method of claim 3, wherein, The molding method further comprises: removing the second protrusion from the foamed article, wherein, after removal, a second decorative mark corresponding to the second protrusion is formed on the foamed article, wherein the first protrusion is aligned with the second protrusion. including:

5. A molding method characterized by, providing a molding apparatus comprising a first mold and a second mold, wherein the first mold or the second mold comprises a cooling mechanism embedded into the first mold and the second mold comprises a feed port extending through the second mold; engaging the first mold with the second mold to form a mold cavity defined by the first mold and the second mold; injecting a flowable material through the feed port into the mold cavity; operating the cooling mechanism to cool the flowable material surrounding the cooling mechanism; and foaming the flowable material into a foamed article. The foamed article has a skin layer adjacent to the cooling mechanism, and the skin layer has a density gradient gradually increasing from an interior of the foamed article to an exterior of the foamed article.

6. The method of claim 5, wherein, The method further comprises:

7. The method of claim 5, wherein, adjusting the molding apparatus to a first predetermined temperature before the flowable material is injected; maintaining the molding apparatus at the first predetermined temperature during the injection of the flowable material, wherein the operation of the cooling mechanism comprises cooling the flowable material surrounding the cooling mechanism from the first predetermined temperature to a second predetermined temperature substantially lower than the first predetermined temperature. The first mold comprises a recess indented into the first mold and coupled with the mold cavity, the flowable material flows into the recess during the injection of the flowable material into the mold cavity, and the foamed article comprises a first protrusion within the recess, wherein a density of the skin layer is substantially greater than a density of the first protrusion.

8. The method of claim 6, wherein, including:

9. A foamed article characterized by, a first surface, a second surface opposite the first surface, and a third surface between the first surface and the second surface; a first mark disposed on the first surface, and a second mark disposed on the second surface, opposite the first mark and vertically aligned with the first mark. further comprising:

10. The foamed article of claim 9, wherein, a skin layer exposed through the first surface, the second surface, or the third surface, ​ wherein the skin layer has a wear resistance greater than the wear resistance of the remainder of the foamed article, and the skin layer has a density gradient that gradually increases from the interior of the foamed article to the exterior of the foamed article.

Images