Injection molding system and injection molding method

Abstract

An injection molding system is provided. The mixing unit is configured to mix the flowable polymeric material with the blowing agent to form a mixture. The fluid supply unit is configured to provide a blowing agent to the mixing unit. The fluid supply unit includes an injection outlet coupled to the mixing unit, a compressor configured to generate a blowing agent, an injection valve disposed between the injection outlet and the compressor and configured to receive the blowing agent from the compressor via a first passage, and a cleaning mechanism configured to clean the injection valve. The cleaning mechanism includes a control valve coupled to the compressor via a second passage and to the injection valve via a third passage connected to the first passage, and an actuation device configured to actuate the control valve. A blowing agent may flow to the injection valve via the control valve.

Description

Technical Field

[0001] This disclosure relates to injection molding systems and injection molding methods, and particularly to a cleaning mechanism for the fluid supply unit of an injection molding system and an injection molding method for performing a cleaning process in the fluid supply unit. Background Technology

[0002] Foamed polymers offer numerous advantages, such as high strength, low weight, impact resistance, thermal insulation, and more. Foamed articles can be manufactured using injection molding or extrusion molding. For example, in an injection molding system, the polymer is melted and mixed with a foaming agent to form a mixture. Force or pressure is then applied to this mixture to inject or extrude it into a mold cavity, where it foams and cools to form a foamed article.

[0003] However, residues may accumulate within the injection molding system during product formation. The presence of these residues can adversely affect product quality, leading to defects and increasing maintenance needs and downtime. Therefore, improvements to the injection molding system and its operation are necessary to facilitate residue removal. Summary of the Invention

[0004] This disclosure discloses an injection molding system and an injection molding method.

[0005] According to one embodiment of this disclosure, an injection molding system is provided. The injection molding system includes a mixing unit and a fluid supply unit. The mixing unit is configured to mix a flowable polymeric material with a blowing agent to form a mixture. The fluid supply unit is configured to supply the blowing agent to the mixing unit. The fluid supply unit includes an injection outlet coupled to the mixing unit, a compressor configured to generate the blowing agent, an injection valve disposed between the injection outlet and the compressor and configured to receive the blowing agent from the compressor via a first channel, and a cleaning mechanism configured to clean the injection valve. The cleaning mechanism includes a control valve coupled to the compressor via a second channel and coupled to the injection valve via a third channel connected to the first channel, and an actuation device configured to actuate the control valve. The blowing agent can flow to the injection valve via the second channel, the third channel, and the flow control valve.

[0006] According to one embodiment of this disclosure, an injection molding method is provided. The injection molding method includes: supplying a foaming agent from a compressor of a fluid supply unit to a mixing unit via an injection valve of the fluid supply unit through a first channel of the fluid supply unit; mixing a flowable polymeric material with the foaming agent to form a mixture in the mixing unit coupled to the fluid supply unit; and cleaning the injection valve by a cleaning mechanism of the fluid supply unit during or after the mixture formation. Cleaning the injection valve by the cleaning mechanism further includes: actuating a control valve of the cleaning mechanism, the cleaning mechanism being connected to the compressor via a second channel and to the first channel via a third channel; and supplying the foaming agent from the compressor to the injection valve via the second channel, the control valve, and the third channel. Attached Figure Description

[0007] The various aspects of this disclosure can be better understood through the following detailed description and accompanying drawings. It should be noted that, in accordance with industry standard practice, the various components are not drawn to scale. In fact, for the sake of clarity in discussion, the dimensions of the various components may be arbitrarily increased or decreased.

[0008] Figure 1 This is an injection molding system according to some embodiments of the present disclosure.

[0009] Figure 2 This is an injection molding system according to some embodiments of the present disclosure.

[0010] Figure 3 According to some embodiments disclosed herein Figure 1 and Figure 2 Fluid supply unit of the injection molding system.

[0011] Figure 4 This is a method 400 for operating an injection molding system according to some embodiments of the present disclosure.

[0012] Figure 5 The cleaning procedure is performed according to some embodiments of this disclosure to clean. Figure 3 The method of using an injection valve. Detailed Implementation

[0013] [Cross-references to related applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 689,862, filed September 3, 2024, and U.S. Patent Application No. 19 / 208,537, filed May 14, 2025, the entire contents of which are incorporated herein by reference.

[0014] The following disclosure provides numerous different embodiments or examples to implement different components of the provided object. Specific examples of components and arrangements are described below to simplify this disclosure. These are, of course, merely examples and not intended to be limiting. For example, the following description of a first component formed above or on a second component may include embodiments where the first and second components are in direct contact, or embodiments where an additional component is formed between the first and second components such that the first and second components may not be in direct contact. Furthermore, reference numerals and / or letters may be repeated in various examples in this disclosure. This repetition is for simplicity and clarity and does not represent a relationship between the various embodiments and / or configurations discussed.

[0015] In addition, this document may use spatial relative terms such as “below,” “under,” “below,” “above,” “above,” and similar terms to describe the relationship between one element or component and another element or component(s) as shown in the figure. These spatial relative terms are intended to cover the different orientations of the device in use or operation, as well as the orientations depicted in the figures. The device may be turned to different orientations (rotated 90 degrees or other orientations), and the spatial relative descriptive terms used herein may be interpreted accordingly.

[0016] While the numerical ranges and parameters disclosed herein are approximate, the values ​​listed in the specific examples have been stated as precisely as possible. However, any numerical value inherently contains some error due to the standard deviation found in the respective test measurements. Furthermore, the term "about" as used herein generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, "about" means within an acceptable standard error of the average value, in the opinion of someone skilled in the art. Except in the operational / processing examples, or unless expressly stated otherwise, all numerical ranges, quantities, values, and percentages disclosed herein, such as material quantities, time durations, temperatures, operating conditions, quantity ratios, and similar items, should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise indicated, the numerical parameters listed in this disclosure and the appended claims are approximate values ​​that may be changed as needed. At a minimum, each numerical parameter should be interpreted according to the number of significant figures stated and the application of common rounding techniques. The range herein may be expressed as from one endpoint to the other or between the two endpoints. Unless otherwise specified, all scopes disclosed herein include endpoints.

[0017] Figure 1This is an injection molding system 100A according to some embodiments of the present disclosure. The injection molding system 100A includes a melting unit 101, a fluid supply unit 102, a mixing unit 103, and an injection unit 104. The melting unit 101 is coupled to the mixing unit 103 via at least one delivery channel 151. In some embodiments, the melting unit 101 is configured to receive a raw polymeric material, heat and melt the raw polymeric material to become a flowable polymeric material (i.e., in a molten state), and discharge the flowable polymeric material. The flowable polymeric material is then conveyed to the mixing unit 103 via the delivery channel 151. In some embodiments, the flowable polymeric material includes ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPU), thermoplastic polyesterelastomer (TPEE), or similar materials.

[0018] A fluid supply unit 102 is coupled to a mixing unit 103 via at least one delivery channel 152. In some embodiments, the fluid supply unit 102 is configured to supply fluid to the mixing unit 103. In some embodiments, the fluid supply unit 102 is configured to convert an inert gas (e.g., carbon dioxide or nitrogen) into a supercritical state and supply the supercritical fluid to the mixing unit 103. In some embodiments, the fluid supplied by the fluid supply unit 102 is a chemical or physical blowing agent. The blowing agent is then delivered to the mixing unit 103 via the delivery channel 152.

[0019] Mixing unit 103 is configured to mix a flowable polymeric material from melting unit 101 with a fluid (e.g., a supercritical foaming agent) from fluid supply unit 102 to form a mixture. In some embodiments, mixing unit 103 includes a mixing chamber and a mixing screw located within the mixing chamber. The flowable polymeric material and the fluid are delivered to the mixing chamber, and then the flowable polymeric material and the fluid are mixed by the mixing screw to form a mixture within the mixing chamber. In some embodiments, the mixing screw is configured to rotate, thereby mixing (or blending) the flowable polymeric material and the fluid to form a mixture.

[0020] Mixing unit 103 is coupled to injection unit 104 via at least one delivery channel 153. In some embodiments, the mixing screw of mixing unit 103 is configured to rotate, thereby delivering the mixture to injection unit 104 via delivery channel 153. Injection unit 104 is configured to receive the mixture from mixing unit 103 and discharge the mixture from injection unit 104. In some embodiments, injection unit 104 includes at least one syringe for injecting the mixture from injection unit 104.

[0021] Figure 2 This is an injection molding system 100B according to some embodiments of the present disclosure. Compared to Figure 1 The injection molding system 100A and injection molding system 100B further include a mold assembly 105. The injection unit 104 is in communication with the mold assembly 105 via at least one syringe 154. In some embodiments, the mold assembly 105 is configured to receive a mixture from the injection unit 104 and form an article within the mold assembly 105. In some embodiments, the mold assembly 105 includes at least one feed section (not shown) through which the mixture flows and a mold cavity (not shown) for receiving and holding the mixture. In some embodiments, the mixture is injected into the mold cavity by the injection unit 104 via the feed section. In some embodiments, after the mixture is injected into the mold cavity, the mixture undergoes a physical foaming process within the mold cavity to become a foamed article.

[0022] Figure 3 According to some embodiments disclosed herein Figure 1 and Figure 2 A fluid supply unit 102 is provided in the injection molding system. In some embodiments, the fluid supply unit 102 includes a first gas source 106, a compressor 108, an injection valve 110, and an injection outlet 109. In some embodiments, the first gas source 106 is connected to the compressor 108 and configured to supply gas G1 to the compressor 108. In some embodiments, gas G1 may contain nitrogen, carbon dioxide, or similar gases. In some embodiments, the compressor 108 is configured to receive gas G1 (e.g., nitrogen, carbon dioxide, or similar gases) from the first gas source 106 and then compress or pressurize gas G1 to become a specific gas. In some embodiments, the specific gas is a physical blowing agent in a supercritical state for use in subsequent physical foaming processes.

[0023] In some embodiments, a physical blowing agent is discharged from compressor 108 to injection valve 110 via first channel 118. In some embodiments, the physical blowing agent discharged from compressor 108 flows to injection outlet 109 via injection valve 110. Figure 1 and Figure 2As shown, the injection outlet 109 is connected to the mixing unit 103 via the delivery channel 152. Physical blowing agent is supplied from the compressor 108 to the mixing unit 103 via the injection valve 110, the injection outlet 109, and the delivery channel 152. In some embodiments, the injection valve 110 is configured to control the flow of the physical blowing agent. When the injection valve 110 is open, the physical blowing agent is allowed to pass through the injection valve 110 and flow into the mixing unit 103. When the injection valve 110 is closed, the physical blowing agent is blocked by the injection valve 110 and cannot flow into the mixing unit 103. In some embodiments, the injection valve 110 is a gate valve, plug valve, ball valve, or similar device.

[0024] In some embodiments, a metering unit 115 is disposed within a first channel 118 and located between the compressor 108 and the injection valve 110. The metering unit 115 is configured to measure the flow rate of the physical blowing agent passing through and / or the amount of physical blowing agent entering the mixing unit 103 over a period of time. In some embodiments, a first check valve 117 is disposed within the first channel 118 and located between the metering unit 115 and the injection valve 110. The first check valve 117 is configured to prevent backflow of the physical blowing agent or any other fluid from the mixing unit 103 to the compressor 108, or from the injection valve 110 to the metering unit 115.

[0025] In some embodiments, the first channel 118 is divided into sub-channels 118a, 118b, and 118c. The metering unit 115 is connected to the compressor 108 via sub-channel 118a and to the first check valve 117 via sub-channel 118b. The first check valve 117 is connected to the injection valve 110 via sub-channel 118c. In some embodiments, sub-channel 118a is implemented using a high-pressure pipe and has explosion-proof capability. In some embodiments, sub-channels 118b and 118c are implemented using seamless steel pipes.

[0026] After the physical foaming agent is supplied to the mixing unit 103, it is mixed with the flowable polymeric material provided by the melting unit 101 within the mixing unit 103 to form a mixture comprising both the physical foaming agent and the flowable polymeric material. After the mixture is formed in the mixing unit 103, it is injected into the mold cavity of the mold assembly 105 via the injection unit 104. The mixture then undergoes a physical foaming process within the mold cavity to become a foamed article.

[0027] During operation of injection molding systems 100A or 100B, unwanted materials (such as residues, dirt, or the like) may accumulate on or around injection valve 110. These unwanted materials may adhere to injection valve 110, thus adversely affecting its performance or operation. Therefore, cleaning of injection valve 110 is necessary (e.g., by removing the unwanted materials or similar methods). In other words, injection valve 110 requires a cleaning procedure to avoid reducing the performance of injection molding systems 100A and 100B. In some embodiments, monitoring device 250 is positioned adjacent to injection valve 110 and configured to monitor the amount of unwanted material accumulated. In some embodiments, sensor 260 is positioned adjacent to injection valve 110 and configured to sense the presence of unwanted material.

[0028] exist Figure 3 In this embodiment, the fluid supply unit 102 further includes a cleaning mechanism 200 for cleaning the injection valve 110. In some embodiments, the cleaning mechanism 200 is adjacent to and coupled to the injection valve 110. In some embodiments, the cleaning mechanism 200 is connected to the injection valve 110 via a third channel 113. In some embodiments, the cleaning mechanism 200 is configured to perform a cleaning procedure to clean the injection valve 110 when the monitoring device 250 or the sensor 260 determines that cleaning is required. Because the cleaning mechanism 200 is implemented in the fluid supply unit 102, the injection valve 110 can be easily cleaned without removing the injection valve 110 and the channels around it. Therefore, fluid leakage from the fluid supply unit 102 or the injection molding system 100A or 100B can be prevented.

[0029] In some embodiments, the cleaning mechanism 200 includes an actuator 112 and a control valve 111 connected to the actuator 112. The actuator 112 is configured to receive a signal Ctrl and output force according to the control signal Ctrl to actuate the control valve 111. In some embodiments, the signal Ctrl is manually input, such as by an operator pressing a button, an operator touching a computer screen connected to the actuator 112, or similar means. In some embodiments, the actuator 112 is automatically operated, and the force is automatically output. In some embodiments, the actuator 112 is automatically controlled by a computer program, such as a programmable logic controller (PLC) or similar device. In some embodiments, the signal Ctrl is remotely and / or wirelessly input.

[0030] In some embodiments, the actuator 112 operates automatically at predetermined intervals. For example, the actuator 112 operates automatically once every 10 minutes. In some embodiments, the actuator 112 is a hydraulic cylinder, a pneumatic cylinder, a motor, or a similar device. In some embodiments, a second gas source 107 is connected to the actuator 112. In some embodiments, the second gas source 107 is configured to supply a second gas G2 (e.g., air or the like) to the actuator 112. In some embodiments, the second gas G2 is a compressed or pressurized gas for actuating the actuator 112. In some embodiments, the second gas G2 is supplied to the actuator 112 when a signal Ctrl is received manually or automatically. In some embodiments, the first gas G1 is different from the second gas G2. For example, the first gas G1 is nitrogen, while the second gas G2 is air.

[0031] In some embodiments, when the actuating device 112 receives the second gas G2, a force is output from the actuating device 112. In some embodiments, this force is provided to actuate the control valve 111, for example, to open or close the control valve 111. In some embodiments, the control valve 111 is rotated by the actuating device 112 by a predetermined angle to be opened or closed. In some embodiments, the control valve 111 is configured to control fluid flow. In some embodiments, when the control valve 111 is opened, fluid flow is permitted, and when the control valve 111 is closed, fluid flow is blocked. In some embodiments, the control valve 111 is automatically opened by the actuating device 112 at predetermined intervals. For example, the control valve 111 is automatically opened once every 10 minutes by the actuating device 112. In some embodiments, the control valve 111 is automatically opened by the actuating device 112 for a predetermined period of time. For example, the control valve 111 is open for 10 seconds and then closed. In some embodiments, the control valve 111 is a gate valve, plug valve, ball valve, or similar device.

[0032] In some embodiments, during the cleaning process, a physical foaming agent may flow from the compressor 108 through the second channel 119 and along the third channel 113 to the injection valve 110 via control valve 111. In some embodiments, when control valve 111 is opened, the physical foaming agent is allowed to flow from the compressor 108 through the second channel 119 and along the third channel 113 to the injection valve 110.

[0033] When cleaning of injection valve 110 is required, a cleaning procedure is performed, and then control valve 111 is opened to allow physical foaming agent to flow through control valve 111 and be blown toward injection valve 110, so that injection valve 110 is cleaned by the physical foaming agent from the opened control valve 111. During the cleaning procedure, physical foaming agent can blow away unwanted material on or around injection valve 110.

[0034] In some embodiments, during the cleaning procedure, injection valve 110 is closed, preventing the physical foaming agent from flowing from compressor 108 to injection valve 110 via metering unit 115 along first channel 118. In some embodiments, during the cleaning procedure, injection valve 110 is opened, allowing the physical foaming agent to flow from compressor 108 to injection valve 110 via metering unit 115 along first channel 118. In some embodiments, the physical foaming agent is allowed to flow via control valve 111 to clean injection valve 110 for a predetermined period. For example, the physical foaming agent flows via control valve 111 to clean injection valve 110 for approximately 10 seconds.

[0035] In some embodiments, a second check valve 116 is disposed within a third channel 113 and located between a control valve 111 and an injection valve 110. The second check valve 116 is configured to prevent backflow of the physical foaming agent or any other fluid from the injection valve 110 to the control valve 111 or from the injection valve 110 to the compressor 108. In some embodiments, when the injection valve 110 is open and the physical foaming agent is permitted to flow via the open injection valve 110 to the mixing unit 103, the second check valve 116 is configured to prevent the physical foaming agent from flowing to the control valve 111. In some embodiments, a first check valve 117 is configured to prevent the physical foaming agent from flowing through or to the metering unit 115 during a cleaning procedure in which the control valve 111 is open and the physical foaming agent is permitted to flow to and clean the injection valve 110.

[0036] In some embodiments, the third channel 113 is divided into sub-channels 113a and 113b by a second check valve 116. The second check valve 116 is connected to the control valve 111 via sub-channel 113a and to the first check valve 117 via sub-channel 113b. The first check valve 117 is connected to the first channel 118 via sub-channel 118b. In some embodiments, sub-channels 113a and 113b are implemented using seamless steel pipes.

[0037] After the cleaning procedure of injection valve 110, physical foaming agent is blocked from flowing from compressor 108 to injection valve 110 via control valve 111. In some embodiments, force is output from actuator 112 to close control valve 111, such that physical foaming agent from compressor 108 is blocked from flowing through third channel 113.

[0038] Figure 4 This is an operation of an injection molding system (e.g., according to some embodiments of this disclosure) Figure 1 The injection molding system 100A and Figure 2 Method 400 for injection molding system 100B.

[0039] In operation S410, a physical blowing agent from the fluid supply unit 102 is provided (or supplied) to the mixing unit 103. Simultaneously, a flowable polymeric material from the melting unit 101 is also provided to the mixing unit 103. In some embodiments, the physical blowing agent is discharged from the fluid supply unit 102 to the mixing unit 103 via the injection outlet 109. In some embodiments, the physical blowing agent is discharged from the compressor 108 to the mixing unit 103 via the first channel 118, the injection valve 110, and the injection outlet 109. In some embodiments, a metering unit 115 is disposed within the first channel 118 and configured to measure the flow rate of the passing physical blowing agent and / or the amount of physical blowing agent entering the mixing unit 103 over a period of time.

[0040] In operation S420, the physical foaming agent from fluid supply unit 102 is mixed with the flowable polymeric material from melting unit 101 in mixing unit 103 to form a mixture in mixing unit 103. In operation S430, cleaning mechanism 200 performs a cleaning procedure to clean the injection valve during or after mixture formation. In some embodiments, the cleaning procedure is performed when the amount of unwanted material accumulated on or around injection valve 110 exceeds a critical value, or when unwanted material is sensed to be present in injection valve 110.

[0041] In some embodiments, the method 400 of operating the injection molding system further includes injecting the mixture in the mixing unit 103 into the mold assembly 105 via the injection unit 104. In some embodiments, the mixture is injected into a mold cavity of the mold assembly 105 via the injection unit 104. In some embodiments, the method 400 of operating the injection molding system further includes foaming the mixture within the mold assembly 105 to form a foamed article. The mixture undergoes a physical foaming process within the mold cavity to form a foamed article. After the physical foaming process, the foamed article is removed from the mold cavity.

[0042] Figure 5 This is for cleaning according to some embodiments of the present disclosure. Figure 3 A method 500 for cleaning the injection valve 110. In some embodiments, the method 500 for cleaning the injection valve 110 is performed during or after the formation of a mixture. In some embodiments, the method 500 is performed by... Figure 3 The cleaning mechanism 200 of the injection molding system performs (e.g.) Figure 1 Injection molding system 100A or Figure 2 Injection molding system 100B (in the middle).

[0043] In operation S510, control valve 111 is actuated (or opened) by actuator 112. In some embodiments, control valve 111 is connected to compressor 108 via second channel 119 and control valve 111 is connected to first channel 118 via third channel 113. In some embodiments, control valve 111 is actuated by actuator 112 when signal Ctrl is received by actuator 112.

[0044] In operation S520, a physical foaming agent is supplied from compressor 108 to injection valve 110 via second channel 119, control valve 111, and third channel 113 to clean injection valve 110 by removing unwanted material from it. In some embodiments, actuation device 112 is configured to actuate control valve 111 to open, thereby allowing physical foaming agent to flow from compressor 108 to injection valve 110 via control valve 111 to purge and clean injection valve 110.

[0045] In step S530, control valve 111 is deactivated when the cleaning procedure is complete. In some embodiments, control valve 111 is closed by actuator 112 when cleaning of injection valve 110 is complete. In some embodiments, control valve 111 is automatically closed by actuator 112 after a predetermined period. In some embodiments, control valve 111 is manually closed by actuator 112, i.e., by an operator inputting signal Ctrl into actuator 112 to close control valve 111.

[0046] In some embodiments, injection valve 110 is closed during the cleaning procedure so that the physical foaming agent does not flow through injection valve 110 and metering unit 115. In some embodiments, injection valve 110 is opened during the cleaning procedure so that the physical foaming agent flows through injection valve 110 and metering unit 115. In some embodiments, the cleaning procedure is performed after the physical foaming agent is supplied to mixing unit 103.

[0047] In some embodiments, the cleaning of injection valve 110 continues for a predetermined period (e.g., several seconds, several minutes, or similar time) during the cleaning procedure. In some embodiments, injection valve 110 is closed during the cleaning procedure, so that physical foaming agent is not allowed to flow from first channel 118 through metering unit 115 and injection valve 110 into mixing unit 103. In some embodiments, injection valve 110 is opened during the cleaning procedure, thus allowing physical foaming agent to flow from first channel 118 through metering unit 115 and injection valve 110 into mixing unit 103.

[0048] In some embodiments, after cleaning the injection valve 110, the process of supplying physical foaming agent from the compressor 108 to the injection valve 110 and injection outlet 109 into the mixing unit 103 via the first channel 118 and metering unit 115 resumes operation. The physical foaming agent can be discharged from the compressor 108 via the first channel 118 and can flow to the mixing unit 103 via the injection valve 110 and injection outlet 109.

[0049] According to an embodiment, the injection valve 110 can be easily cleaned by using the cleaning mechanism 200 in the fluid supply unit 102 without removing the injection valve 110 and its surrounding channels. Therefore, leakage of fluid from the fluid supply unit 102 or the injection molding system 100A or 100B can be prevented.

[0050] The foregoing has outlined components of several embodiments to enable those skilled in the art to better understand the various aspects of this disclosure. Those skilled in the art should understand that they can readily design or modify other processes and structures based on this disclosure to achieve the same purpose and / or realize the same advantages as the embodiments described herein. Those skilled in the art should also understand that such equivalent constructions do not depart from the spirit and scope of this disclosure, and that they can make various changes, substitutions, and adjustments without departing from the spirit and scope of this disclosure.

[0051] Furthermore, the scope of this application is not intended to be limited to the specific embodiments of the processes, machines, manufacturing, composition of matter, methods, means, and steps described in the specification. Those skilled in the art will readily understand from the disclosure of this invention that existing or subsequently developed processes, machines, manufacturing, composition of matter, means, methods, or steps can perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein. Therefore, the appended claims are intended to include such processes, machines, manufacturing, composition of matter, means, methods, and steps within their scope.

[0052] Symbol Explanation 100A: Injection Molding System 100B: Injection Molding System 101: Melting Unit 102: Fluid Supply Unit 103: Hybrid Unit 104: Injection Unit 105: Mold Device 106: First Gas Source 107: Second gas source 108: Compressor 109: Injection exit 110: Injection valve 111: Control valve 112: Actuation device 113: Third Channel 113a: Sub-channel 113b: Subchannel 115: Measuring Unit 116: Second check valve 117: First check valve 118: First Channel 118a: Sub-channel 118b: Subchannel 118c: Subchannel 119: Second Channel 151: Conveyor Channel 152: Conveyor Channel 153: Conveying Channel 154: Syringe 200: Cleaning agencies 250: Monitoring device 260: Sensor Ctrl: Signal G1: Gas G2: Gas 400: Method S410: Operation S420: Operation S430: Operation 500: Methods S510: Operation S520: Operation S530: Operation.

Claims

1. An injection molding system characterized by, comprising: a mixing unit configured to mix a flowable polymeric material with a blowing agent to form a mixture; and a fluid supply unit configured to provide the blowing agent to the mixing unit, and comprising: an injection outlet coupled to the mixing unit; a compressor configured to generate the blowing agent; an injection valve disposed between the injection outlet and the compressor and configured to receive the blowing agent from the compressor via a first channel; and a cleaning mechanism configured to clean the injection valve, and comprising: a control valve coupled to the compressor via a second channel and to the injection valve via a third channel connected to the first channel; and an actuating device configured to actuate the control valve, wherein the blowing agent is flowable to the injection valve via the second channel, the third channel, and the control valve.

2. The injection molding system of claim 1, wherein The fluid supply unit further comprises: a metering unit disposed between the compressor and the injection valve and configured to measure a flow rate of the blowing agent through the first channel; and a first one-way valve disposed within the first channel between the compressor and the injection valve and configured to prevent the blowing agent from flowing from the injection valve to the compressor.

3. The injection molding system of claim 1, wherein The cleaning mechanism further comprises: a second one-way valve disposed within the third channel between the control valve and the injection valve and configured to prevent the blowing agent from flowing from the injection valve to the control valve.

4. The injection molding system of claim 1, wherein Further comprising: a first gas source connected to the compressor and configured to provide a first gas to the compressor to generate the blowing agent.

5. The injection molding system of claim 1, wherein The cleaning mechanism further comprises: a second gas source connected to the actuating device and configured to provide a second gas to the actuating device to actuate the control valve.

6. The injection molding system of claim 1, wherein The cleaning mechanism further comprises: a monitoring device disposed adjacent to the injection valve and configured to monitor an accumulation amount of unwanted material accumulated on or around the injection valve; or a sensor disposed adjacent to the injection valve and configured to sense a presence of the unwanted material.

7. An injection molding method characterized by, comprising: providing a blowing agent from a compressor of a fluid supply unit to a mixing unit via an injection valve of the fluid supply unit through a first channel of the fluid supply unit; mixing a flowable polymeric material with the blowing agent to form a mixture in the mixing unit coupled to the fluid supply unit; and cleaning the injection valve by a cleaning mechanism of the fluid supply unit during or after the mixture is formed, wherein cleaning the injection valve by the cleaning mechanism further comprises: actuating a control valve of the cleaning mechanism, wherein the cleaning mechanism is connected to the compressor via a second channel and to the first channel via a third channel; and providing the blowing agent from the compressor to the injection valve via the second channel, the control valve, and the third channel.

8. The injection molding method of claim 7, wherein Cleaning the injection valve by the cleaning mechanism of the fluid supply unit during or after the mixture is formed further comprises: deactivating the control valve when the cleaning of the injection valve is completed, such that the blowing agent is unable to flow from the compressor to the injection valve along the control valve.

9. The injection molding method of claim 7, wherein Further comprising: measuring a flow rate of the blowing agent through the first channel by a metering unit of the fluid supply unit; By a first one-way valve disposed between the metering unit and the injection valve, the blowing agent is blocked from flowing from the injection valve to the metering unit during cleaning of the injection valve; and By a second one-way valve disposed between the control valve and the injection valve, the blowing agent is blocked from flowing from the injection valve to the control valve when the blowing agent is discharged from the compressor to the mixing unit via the first passage.

10. The injection molding method of claim 7, wherein Cleaning the injection valve by the cleaning mechanism further comprises: monitoring an accumulation amount of unwanted material accumulated on or around the injection valve, or sensing a presence of the unwanted material; and cleaning the injection valve by the cleaning mechanism when the accumulation amount of the unwanted material is greater than a threshold value or the unwanted material is present.

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