Injection molding system

Abstract

The utility model discloses an injection molding system. The injection molding system comprises a molding device, a runner plate and a distributor. The forming apparatus includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold. The runner plate is arranged above the forming device and comprises a first runner and a second runner which can be communicated with the mold cavity and extend in the runner plate. A distributor is disposed within the runner plate and has a channel connectable to the first runner or the second runner, and the distributor is configured to prevent the mixture from flowing into the mold cavity through one of the first runner and the second runner and to allow the mixture to flow into the mold cavity through the channel and the other of the first runner and the second runner.

Description

Technical Field

[0001] This creation relates to an injection molding system, and more particularly to an injection molding system for preventing waste residue or waste material from forming within the runners of a runner plate. Background Art

[0002] Foamed polymer materials have many advantages, such as high strength, low weight, impact resistance, heat insulation, etc. Foamed products can be manufactured by injection molding or extrusion molding. For example, after melting a polymer material and mixing it with a foaming agent to form a mixture, a force or pressure is applied to the mixture to inject or extrude the mixture into the cavity of a mold, and the mixture is allowed to foam and cool within the cavity to form the foamed product.

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

[0004] This creation discloses an injection molding system.

[0005] According to a specific embodiment of this creation, the injection molding system includes a molding device, a runner plate, and a distributor. The molding device includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold joined to the first mold. The runner plate is arranged above the molding device and includes a first runner and a second runner that can communicate with the mold cavity and extend within the runner plate. The distributor is placed within the runner plate and has a channel that can connect to the first runner or the second runner. The distributor is configured to prevent the mixture from flowing into the mold cavity through one of the first runner and the second runner, and to allow the mixture to flow into the mold cavity through the channel and the other of the first runner and the second runner.

[0006] According to a specific embodiment of this creation, an injection molding system is provided. The injection molding system includes a molding device, a runner plate, and a plug. The molding device includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold joined to the first mold. The runner plate is disposed above the molding device and includes a plurality of runners that can communicate with the mold cavity and extend within the runner plate. The plug is disposed in a first runner of the runners. The first plug is configured to prevent the mixture from flowing into the mold cavity through the first runner. Description of the Drawings

[0007] This aspect of the creation can be best understood from the following detailed description when read in conjunction with the accompanying drawings. It should be noted that, in accordance with standard practice in the industry, the various components are not drawn to scale. In fact, for clarity, the dimensions of many components may be arbitrarily enlarged or reduced.

[0008] Figure 1 Schematic diagram of an injection molding system according to some embodiments of the present creation;

[0009] Figure 2 and Figure 3 Front perspective view of the injection molding system according to some embodiments of the present creation;

[0010] Figure 4 Illustrating the runner plate according to some embodiments of the present creation along Figure 2 Top-down sectional view along line A - A' in

[0011] Figure 5 Side perspective view of the injection molding system according to some embodiments of the present creation along Figure 2 line B - B' in

[0012] Figure 6 Front perspective view of the injection molding system according to some embodiments of the present creation;

[0013] Figure 7 and Figure 8 Illustrating the runner plate according to some embodiments of the present creation along Figure 6 Top-down sectional view along line A - A' in

[0014] Figure 9 Front perspective view of the injection molding system according to some embodiments of the present creation;

[0015] Figure 10 Illustrating the runner plate according to some embodiments of the present creation along Figure 9 Top-down sectional view along line A - A' in

[0016] Figure 11 Front perspective view of the injection molding system according to some embodiments of the present creation;

[0017] Figure 12 and Figure 13 Illustrating the runner plate according to some embodiments of the present creation along Figure 11 Top-down sectional view along line A - A' in

[0018] Figure 14 Front perspective view of the injection molding system according to some embodiments of the present creation;

[0019] Figure 15 and Figure 16 Illustrating the runner plate according to some embodiments of the present creation alongFigure 14 Top-down sectional view along line A-A' in

[0020] Figure 17 Flowchart showing an injection molding method according to some embodiments of the present creation;

[0021] Figures 18 to 22 Illustrating according to a specific embodiment of the present creation Figure 17 Schematic sectional view of the demonstration stage of the injection molding method in

[0022] Figure 23 Flowchart showing an injection molding method according to some embodiments of the present creation;

[0023] Figures 24 to 32 Illustrating according to a specific embodiment of the present creation Figure 23 Schematic sectional view of the demonstration stage of the injection molding method in Embodiment

[0024] [Cross-reference to related applications]

[0025] This application claims the priority of U.S. Provisional Patent Application No. 63 / 585,971, filed on September 28, 2023, and U.S. Patent Application No. 18 / 748,101, filed on June 20, 2024, the entire contents of which are incorporated herein by reference.

[0026] The following description provides many different specific embodiments or examples for implementing different features in the provided subject matter. Specific examples of components and configurations are provided below to simplify the present creation. Of course, these are only examples and not restrictive. For example, in the following description, forming a first feature on or above a second feature may include specific embodiments in which the first and second features are in direct contact, and may also include specific embodiments in which additional features may be formed between the first and second features such that the first and second features are not in direct contact. In addition, the present creation may repeat reference numerals and / or letters in various examples. The purpose of this repetition is to be simple and clear, and does not itself indicate the relationship between the various specific embodiments and / or configurations discussed.

[0027] In addition, spatially relative terms such as "under", "below", "beneath", "above", "over", etc. may be used herein to facilitate the description of the relationship between one element or feature and another element or feature, as shown in the figures. Such spatially relative terms also encompass different orientations of the device during use or operation, in addition to the orientation depicted in the figures. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative terms used herein may be interpreted accordingly.

[0028] Although the numerical ranges and parameters setting forth the broad scope of this creation are approximations, the numerical values disclosed in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily caused by the standard deviation found in the corresponding test measurements. Additionally, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, when considered by a person skilled in the art, the term "about" means within the acceptable standard error of the mean. Except in the operating / working examples, or unless otherwise expressly stated, all numerical ranges, amounts, values, and percentages set forth herein, such as amounts of materials, durations, temperatures, operating conditions, quantity ratios, and the like, are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in this creation and in the appended claims are approximations that may vary as desired. At the very least, each numerical parameter should be construed in light of the number of significant digits reported and by applying ordinary rounding techniques. In this document, ranges may be expressed as from one endpoint to another endpoint or between two endpoints. Unless otherwise stated, all ranges disclosed herein include the endpoints.

[0029] Figure 1 FIG. is a schematic diagram of an injection molding system 100 according to some embodiments of the present creation. The injection molding system 100 includes a melting unit 110, a mixing unit 120, an injection unit 130, an injector 101 communicable with the injection unit 130, a runner plate 103 embedded with runners, and a molding device 105 communicable with the runners within the runner plate 103.

[0030] The melting unit 110 is configured to produce a polymeric material in a molten state (e.g., thermoplastic polyurethane (TPU), polyurethane (PU), plastic, etc.). The polymeric material is then conveyed to the mixing unit 120 through at least one conveying channel 112. The mixing unit 120 is configured to produce a mixture of the polymeric material and a physical foaming agent (e.g., gaseous nitrogen, carbon dioxide, supercritical fluid, etc.), which mixture is foamable or slightly foamed. The mixture is then conveyed to the injection unit 130 through at least one conveying channel 122. The injection unit 130 is configured to discharge the mixture to the molding device 105 through the injection unit 130 and the runner plate 103.

[0031] Figure 2 FIG. is a front perspective view of an injection molding system 100 according to some embodiments of the present creation.

[0032] In some embodiments, the molding device 105 is configured to form an article comprising a polymeric material. In some embodiments, the molding device 105 includes a first mold 105c, a second mold 105d, at least one feed port 105a passing through the second mold 105d, and at least one mold cavity 105b defined by the first mold 105c and the second mold 105d when the molding device 105 is in a closed state (i.e., the first mold 105c is engaged with the second mold 105d). In some embodiments, the first mold 105c is a lower mold, and the second mold 105d is an upper mold and is disposed above the first mold 105c. In some embodiments, each mold cavity 105b can communicate with at least one feed port 105a. In some embodiments, the article is formed inside the molding device 105 by physical foaming. The mixture undergoes physical foaming and then forms a foamed article. In some embodiments, the article is part of footwear (such as an outsole, insole, midsole, etc.) or any other product.

[0033] In some embodiments, the ejector 101 has an outlet 101a for discharging the mixture. In some embodiments, the ejector 101 is engaged with the runner plate 103. In some embodiments, the outlet 101a can be joined and communicate with the inlet 103a of the runner plate 103. The mixture can flow from the outlet 101a to the inlet 103a respectively and flow along the runner 103c towards the multiple outlets 103b of the runner 103c. In some embodiments, the mixture can flow from the ejector 101 into each mold cavity 105b through the runner plate 103 and the corresponding feed port 105a. In some embodiments, the mixture can flow into the mold cavities 105b-1 and 105b-2 via the feed ports 105a-1 and 105a-2 respectively. The mixture will be distributed into each runner 103c and then enter the corresponding mold cavity 105b.

[0034] In some embodiments, each outlet 103b can communicate with at least one mold cavity 105b defined by the molding device 105. In some embodiments, the molding device 105 includes multiple mold cavities 105b-1 and 105b-2. Figure 2 The embodiments show two mold cavities 105b-1 and 105b-2, however, it is not intended to limit the number of mold cavities 105b in the molding device 105.

[0035] In some embodiments, the gate 104 is provided at the outlet 103b of the runner plate 103. The gate 104 is configured to control the flow of the mixture through the outlet 103b into the mold cavity 105b (such as flow rate, flow volume, etc.). In some embodiments, when the gate 104 is open or partially open, the mixture can flow through the outlet 103b into the mold cavity 105b, while when the gate 104 is closed, the mixture cannot flow through the outlet 103b into the mold cavity 105b. The state of the gate 104 can be switched automatically or manually.

[0036] Figure 3 A front perspective view of an injection molding system 100 according to some embodiments of the present creation. In Figure 3 an embodiment, the injection molding system 100 further includes a runner 102 that can be engaged with an injector 101. The outlet 101a of the injector 101 can be engaged with the inlet 102a of the runner 102, so that the mixture can flow from the injector 101 into the runner 102. In some embodiments, the runner 102 is at least partially surrounded by a runner plate 103. In some embodiments, the runner 102 is placed above the runner 103c. The runner 102 is configured to facilitate the engagement between the injector 101 and the runner plate 103. The mixture can flow from the inlet 102a of the runner 102 to the outlet 102b. In some embodiments, the outlet 102b of the runner 102 can be connected and communicated with the inlets 103a of a plurality of runners 103c. The mixture can flow along the runners 103c from the inlets 103a to the outlets 103b of the runners 103c respectively. In some embodiments, the mixture can flow from the injector 101 through the runner 102, the runner plate 103, and the corresponding feed ports 105a into each cavity 105b, as Figure 3 shown therein.

[0037] Figure 4 An example shows a top cross-sectional view of the runner plate 103 along the Figure 2 A-A' line in. In some embodiments, the runner plate 103 can be heated through heaters, coils, etc. to maintain the runner 103c at a certain temperature and allow the mixture to remain in a flowable state. In some embodiments, each runner 103c extends within the runner plate 103. Each runner 103c connects the inlet 103a to the corresponding outlet 103b. Figure 4 Six runners 103c extending within the runner plate 103 are shown, however, it is not intended to limit the number of runners 103c within the runner plate 103. In addition, it is not intended to limit the structure or design of the runner 103c. In some embodiments, the inlet 103a is connected to runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6. In some embodiments, runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 are respectively connected to outlets 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, 103b-6.

[0038] The runner 103c has the same or different dimensions (such as width, diameter, length, etc.). In some embodiments, the runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 have the same width, the same diameter, and the same length. In some embodiments, the runner 103c is divided into multiple groups with different dimensions, and each group of runners 103c has individual dimensions (such as width, diameter, length, etc.).

[0039] Figure 5 A side perspective view of the injection molding system 100 along the Figure 2 line B - B' in some embodiments of the present creation. In Figure 5 a specific embodiment, the mixture can flow from the injector 101 into the mold cavity 105b-1 through the outlets 103b-1, 103b-3, and 103b-5 of the runner plate 103 and the corresponding feed ports 105a-1, 105a-3, and 105a-5. Figure 5 It is illustrated that each mold cavity 105b corresponds to three outlets 103b, however, it is not intended to limit the number of outlets 103b corresponding to one mold cavity 105b.

[0040] Figure 6 A front perspective view of the injection molding system 100 in some embodiments of the present creation. In Figure 6 a specific embodiment, the plug 106 is placed into the runner plate 103. Figure 7 Illustrating a top sectional view of the runner plate 103 along the Figure 6 line A - A' in some embodiments of the present creation.

[0041] In some embodiments, the plug 106 is a plastic block, a metal block, etc. In some embodiments, the plug 106 is inserted into the runner 103c such that the mixture cannot flow through the runner 103c. In some embodiments, the plug 106 is temporarily fixed inside the runner 103c and can be removed from the runner 103c. For example, the plug 106 is placed in the runner 103c-1 such that the mixture cannot flow through the runner 103c-1 into the mold cavity 105b-1, while the mixture can still flow into the mold cavity 105b-1 through the other runners 103c-3 and 103c-5. In some embodiments, the plug 106 can be placed or removed when the runner plate 103 is engaged with the molding device 105. In some embodiments, the plug 106 can be placed or removed when the runner plate 103 is disengaged from the molding device 105. In some embodiments, when the Figure 3 sprue 102 has been removed from the runner plate 103, the plug 106 can be placed or removed.

[0042] When the mixture is ejected into the mold cavity 105b, some of the mixture may remain in the runner 103c (for example because the mixture is viscous, etc.). The mixture remaining in the runner 103c may avoid or even prevent the mixture subsequently injected from the ejector 101 from flowing through the runner 103c. That is, the mixture ejected next time may not be able to flow or may not be able to smoothly flow into the mold cavity 105b. Since the plug 106 can be placed or removed when necessary, a slug or waste of the mixture in the runner 103c can be prevented, and the remaining mixture can be prevented from staying in the runner 103c for a long time. In addition, by simply adding or removing the plug 106, the number of runners 103c to be used can be easily adjusted without changing to another runner plate 103 of a different structure. As a result, manufacturing costs and labor can be saved. In some embodiments, the plug 106 can be placed or removed manually or remotely.

[0043] Figure 8 Illustrates that a plurality of plugs 106 are respectively placed in the runners 103c-1 and 103c-4. It should be understood that the number of plugs 106 is not intended to be limited. In some embodiments, the plug 106 can be placed or removed manually or by a robotic arm, etc. In some embodiments, the plug 106 is replaced regularly. For example, after removing the plug from the runner 103c-1, another plug is reinserted into the runner 103c-1.

[0044] Figure 9 Is a front perspective view of the injection molding system 100 according to some embodiments in the present creation. In Figure 9 In a specific embodiment, the dispenser 107 is placed inside the runner plate 103. Figure 10 Illustrates a top cross-sectional view of the runner plate 103 along the Figure 9 line A-A' in

[0045] In some embodiments, the mixture can be distributed to each runner 103c through the dispenser 107. In some embodiments, the mixture can be evenly distributed to each runner 103c through the dispenser 107. In some embodiments, the dispenser 107 includes an inlet 107a, a plurality of outlets 107b, and a plurality of channels 107c between the inlet 107a and the outlets 107b. The inlet 107a of the dispenser 107 is connected to the inlet 103a of the runner plate 103, so that the mixture can flow from the ejector 101 through the dispenser 107 into the runner 103c. Each channel 107c corresponds to an outlet 107b. In Figure 10In a specific embodiment, six channels 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, and 107c-6 are respectively connected to outlets 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, and 107b-6. It should be understood that the number of channels 107c is not limited, as long as the number of channels 107c corresponds to the number of outlets 107b. In some embodiments, the dispenser 107 is a splitter or the like. In some embodiments, the dispenser 107 can rotate relative to the flow channel 103c and the flow channel plate 103. In some embodiments, the dispenser 107 can be rotated manually or remotely. In some embodiments, the dispenser 107 can be rotated by a robotic arm or the like. In some embodiments, the size (e.g., width, diameter, length, etc.) of the flow channel 103c is substantially larger than the size of the channel 107c.

[0046] In some embodiments, the dispenser 107 is temporarily fixed inside the flow channel 103c and can be removed from the flow channel 103c. When a mixture is ejected into the mold cavity 105b, some of the mixture may remain in the flow channel 103c because the mixture is viscous. Then, the mixture remaining in the flow channel 103c may cool and solidify, resulting in avoiding or even preventing the next mixture from flowing through the channel 107c. That is, the mixture ejected next time may not flow or may not smoothly flow into the mold cavity 105b. This problem can be solved by simply removing the dispenser 107 from the flow channel plate 103 and replacing it with another new dispenser 107. Since the dispenser 107 can be placed or removed when needed, residual mixture can be prevented from remaining in the flow channel 103c for a long time. In addition, by simply changing the dispenser 107 with different configurations (e.g., different numbers of channels 107c, etc.), the number of flow channels 103c used can be easily adjusted without replacing another flow channel plate 103. As a result, manufacturing costs and labor can be saved. In some embodiments, the dispenser 107 can be placed or removed manually or remotely. In some embodiments, the dispenser 107 can be placed or removed by a robotic arm or the like.

[0047] Figure 11 Is a front perspective view of the injection molding system 100 according to some embodiments in the present creation. In Figure 11 In a specific embodiment, the stopper 108 is placed inside the channel 107c of the dispenser 107. Figure 12 Illustrates a top cross-sectional view of the flow channel plate 103 along the Figure 11 A-A' line in.

[0048] In some embodiments, the stopper 108 is inserted into the channel 107c of the dispenser 107 such that the mixture cannot flow through the channel 107c. In some embodiments, the stopper 108 is a plastic block, a metal block, etc. In some embodiments, the stopper 108 is temporarily fixed inside the channel 107c and can be removed from the channel 107c. For example, the stopper 108 is placed in the channel 107c-1 such that the mixture cannot flow through the channel 107c-1 and the runner 103c-1 into the mold cavity 105b-1, while the mixture can still flow through the channels 107c-3 and 107c-5 and the corresponding runners 103c-3 and 103c-5 into the mold cavity 105b-1. Since the stopper 108 can be placed or removed when necessary, the formation of slugs or waste of the mixture in the runner 103c can be prevented, and the residual mixture remaining in the runner 103c can be minimized or avoided. In addition, by simply adding or removing the stopper 108, the number of runners 103c to be used can be easily adjusted without changing to another runner plate 103. As a result, manufacturing costs and labor can be saved.

[0049] Figure 13 Illustrative top view sectional view of the runner plate 103 along the Figure 11 A-A' line in. In Figure 13 specific embodiments, more stoppers 108 are respectively placed in the channels 107c-1 and 107c-6. It should be understood that the number of stoppers 108 is not intended to be limited. In some embodiments, the stopper 108 can be placed or removed manually or remotely. In some embodiments, the stopper 108 can be placed or removed by a robotic arm or the like.

[0050] In some embodiments, instead of placing the stopper 108 in the channel 107c of the dispenser 107 to prevent the mixture from flowing through the channel 107c, the dispenser 107 is configured to have a smaller number of channels 107c (e.g., compared to the number of runners 103c).

[0051] Figure 14 Front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. Figure 15 Illustrative top view sectional view of the runner plate 103 along the Figure 14 A-A' line in.

[0052] In Figure 14 and Figure 15 specific embodiments, the dispenser 107 is configured to have a smaller number of channels 107c. For example, the channel 107c-1 does not exist in the dispenser 107 (as shown in Figure 13As shown, no mixture can flow into the flow channel 103c-1. In other words, the dispenser 107 is designed to block the flow channel 103c-1. In this specific embodiment, when the dispenser 107 is placed in the flow channel plate 103, the channels 107c-2 to 170c-6 are configured to align with the flow channels 103c-2 to 103c-6, but not with the flow channel 103c-1.

[0053] In some embodiments, the dispenser 107 can rotate within the flow channel 103c such that the dispenser 107 is designed to block one or more of the flow channels 103c. For example, if Figure 15 the dispenser 107 in [description omitted] rotates clockwise (e.g., about 15°), the flow channel 103c-5 is blocked by the dispenser 107, and the flow channel 103c-1 becomes communicable with the channel 107c-3. Therefore, the mixture flowing through the flow channel 103c can be selected by rotating the dispenser 107. In some embodiments, the dispenser 107 can have various configurations.

[0054] Figure 16 Illustrates another configuration of the dispenser 107 according to some embodiments of the present invention. In Figure 16 it, the dispenser 107 has four channels 107c, so that two flow channels 103c are blocked. It should be understood that the number of channels 107c is not intended to be limited. If Figure 16 the dispenser 107 in [description omitted] rotates clockwise (e.g., about 15°), the flow channels 103c-5 and 103c-4 are blocked by the dispenser 107, and the flow channels 103c-1, 103c-2, 103c-3, and 103c-6 become communicable with the corresponding channels 107c-3, 107c-4, 107c-5, and 107c-6.

[0055] Figure 17 Is a flowchart showing an injection molding method 200 according to some embodiments of the present invention. The injection molding method 200 includes operations S210 to S250, and the description and illustration are not considered to limit the order of operations S210 to S250. Figures 18 to 22 Are schematic cross-sectional views of various stages of the injection molding method 200. In some embodiments, the operations of the injection molding method 200 can be repeated and automatically performed. In some embodiments, the injection molding method 200 is performed by Figure 1 the injection molding system 100 of [description omitted].

[0056] In operation S210, a molding device 105 and a runner plate 103 are provided. In some embodiments, the molding device 105 includes a first mold 105c, a second mold 105d, and a cavity 105b defined by the engagement of the first mold 105c and the second mold 105d with each other, and the runner plate 103 includes a plurality of runners 103c extending therein. In operation S220, a plug is inserted into a first runner 103c of the runners 103c. In operation S230, the injection unit 130 is configured to inject a mixture from the mixing unit 120 into the cavity 105b of the molding device 105 through the injector 101 and the runners 103c other than the first runner 103c (i.e., the runner 103c into which the plug has been inserted), and then in operation S240, a foamed product is formed from the mixture. It should be noted that the mixture from the injection unit 130 cannot flow into the cavity 105b through the first runner 103c. In operation S250, after the foamed product is formed, the plug is removed from the first runner 103c of the runner plate 103. When the runner plate 103 is disposed on the molding device 105, the plug can be inserted into or removed from the runner.

[0057] In some embodiments, before the plug is inserted in operation S220 or after the plug is removed in operation S250, the injection unit 130 is configured to inject a mixture (or another mixture) into the cavity 105b through the injector 101 and all the runners 103c, and then another foamed product is formed from the mixture.

[0058] In some embodiments, after the foamed product is formed in operation S240, an additional plug is inserted into one of the runners 103c other than the first runner, and then operation S250 is performed or ignored for the next injection (or next shot) of the mixture.

[0059] Figure 18 A front perspective view of an injection molding system 100 according to some embodiments of the present invention. The injection molding system 100 includes an injector 101, a runner plate 103, and a molding device 105. Then the injector 101 is engaged with the runner plate 103, and the molding device 105 is engaged with the runner plate 103, as Figure 19 shown. The first mold 105c of the molding device 105 is engaged with the second mold 105d of the molding device 105, as Figure 19 shown. The molding device 105 is in a closed configuration. When the first mold 105c and the second mold 105d are engaged, at least one cavity 105b is formed. In some embodiments, the outlet 101a of the injector 101 is aligned with the outlet 103b of the runner plate 103 such that the injector 101 can communicate with the cavity 105b via the runner plate 103. In some embodiments, the outlets 103b-1 and 103b-2 can communicate with the cavities 105b-1 and 105b-2, respectively.

[0060] In some embodiments, the plug 106 is inserted into the flow channel 103c extending within the flow channel plate 103, as Figure 20 shown. In some embodiments, the plug 106 is inserted into the flow channel 103c-1, as Figure 20 and Figure 7 shown. In some embodiments, the plug 106 is inserted before or after the flow channel plate 103 and the molding device 105 are joined. After the plug 106 is inserted, the mixture M is ejected from the injector 101 through the flow channel plate 103 into the mold cavity 105b, as Figure 21 shown. In some embodiments, the ejected mixture M is ejected into the mold cavity 105b-1 through the flow channels 103c-3 and 103c-5, and into the mold cavity 105b-2 through the flow channels 103c-2, 103c-4, and 103c-6, as Figure 7 shown. In some embodiments, the gates 104 at the outlets 103b-3 and 103b-5 can be adjusted to allow a faster flow rate or a larger amount of the mixture M to flow into the mold cavity 105b-1. In some embodiments, the gates 104 at the outlets 103b-2, 103b-4, and 103b-6 can be adjusted to allow a slower flow rate or a smaller amount of the mixture M to flow into the mold cavity 105b-2.

[0061] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, as Figure 22 shown, after the first mold 105c is separated from the second mold 105d, the foamed product is removed from the molding device 105. In some embodiments, the plug 106 is removed from the flow channel 103c, as Figure 22 shown.

[0062] Figure 23 FIG. 300 is a flowchart showing an injection molding method 300 according to some embodiments of the present invention. The injection molding method 300 includes operations S310 to S350, and the description and illustration are not considered to limit the order of operations S310 to S350. Figures 24 to 32 FIG. 301 is a schematic cross-sectional view of each stage of the injection molding method 300. In some embodiments, the operations of the injection molding method 300 can be repeated and automatically performed. In some embodiments, the injection molding method 300 is performed by Figure 1 the injection molding system 100.

[0063] In operation S310, a molding device 105 and a runner plate 103 are provided. In some embodiments, the molding device 105 includes a first mold 105c, a second mold 105d, and a cavity 105b defined by the engagement of the first mold 105c and the second mold 105d with each other, and the runner plate 103 includes first and second runners 103c extending therein. In operation S320, a dispenser is placed within the runner plate 103, and the dispenser has a passage that can be connected to the first or second runner 103c. Additionally, the passage can be aligned with the first runner or the second runner. In operation S330, an injection unit 130 is configured to inject a mixture from a mixing unit 120 into the cavity 105b of the molding device 105 through an injector 101, the passage, and the first runner 103c, and then a foamed product is formed from the mixture in operation S340. It should be noted that the mixture from the injection unit 130 cannot flow into the cavity 105b through the passage and the second runner 103c. In operation S350, after the foamed product is formed, the dispenser is removed from the runner plate 103. When the runner plate 103 is disposed on the molding device 105, the dispenser can be inserted into or removed from the runner plate 103.

[0064] In some embodiments, before placing the dispenser in operation S320, the injection unit 130 is configured to inject a mixture (or another mixture) into the cavity 105b through the injector 101 and the first and second runners 103c, and then another foamed product is formed from the mixture. In some embodiments, after removing the dispenser from the runner plate 103, an additional dispenser is placed within the runner plate 103, and the additional dispenser is in a different configuration from the removed dispenser.

[0065] In some embodiments, when the dispenser is placed within the runner plate 103, the passage of the dispenser is aligned with the first runner and not aligned with the second runner. In some embodiments, when the dispenser is placed within the runner plate 103 for the next injection of the mixture, the dispenser can be rotated relative to the runner plate 103. For example, after rotating the dispenser, the passage of the dispenser changes from being aligned with the first runner to being aligned with the second runner and is not aligned with the first runner.

[0066] In some embodiments, the injection molding method 300 includes inserting a dispenser 107 into the runner 103c, as Figure 24 shown. In some embodiments, the dispenser 107 is inserted before or after the runner plate 103 and the molding device 105 are engaged. In some embodiments, an inlet 103a of the runner plate 103 is aligned with an inlet 107a of the dispenser 107, and an outlet 107b of the dispenser 107 can communicate with an outlet 103b of the runner plate 103. After inserting the dispenser 107, the mixture M is injected from the injector 101 through the runner plate 103 into the cavity 105b, as Figure 25As shown. In some embodiments, the ejected mixture M is ejected into the mold cavity 105b-1 via the runners 103c-1, 103c-3, and 103c-5, and is ejected into the mold cavity 105b-2 via the runners 103c-2, 103c-4, and 103c-6, as Figure 25 and Figure 10 shown. In some embodiments, the dispenser 107 evenly distributes the shots of the mixture M to the runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6. Thus, the amount of the mixture M entering the mold cavity 105b-1 is substantially the same as the amount of the mixture M entering the mold cavity 105b-2, as Figure 25 shown.

[0067] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is removed from the molding device. In some embodiments, if the dispenser 107 is no longer needed, if another dispenser 107 with a different configuration needs to be replaced, or if the dispenser 107 needs to be replaced with another new dispenser 107, etc., the dispenser 107 is removed from the runner 103c.

[0068] In some embodiments, the injection molding method 300 includes inserting a stopper 108 into the channel 107c of the dispenser 107, as Figure 26 shown. In some embodiments, the stopper 108 is inserted before or after the runner plate 103 and the molding device 105 are joined. In some embodiments, the ejected mixture M is ejected into the mold cavity 105b-1 via the runners 103c-3 and 103c-5, and is ejected into the mold cavity 105b-2 via the runners 103c-2, 103c-4, and 103c-6, as Figure 27 shown. In some embodiments, the gates 104 at the outlets 103b-3 and 103b-5 can be adjusted to allow a faster flow rate or a larger amount of the mixture M to flow into the mold cavity 105b-1. In some embodiments, the gates 104 at the outlets 103b-2, 103b-4, and 103b-6 can be adjusted to allow a slower flow rate or a smaller amount of the mixture M to flow into the mold cavity 105b-2.

[0069] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is removed from the molding device. In some embodiments, if the stopper 108 is no longer needed, it is removed from the dispenser 107.

[0070] In some embodiments, the dispenser 107 rotates as necessary (e.g., to select a runner 103c to be used as needed, etc.). For example, the dispenser 107 (together with the stopper 108) rotates clockwise so that the runner 103c-2 is blocked, as Figure 28 and 29 shown. Figure 29 Illustrated Figure 28 is a top-down sectional view along line A-A'. After rotation, the ejected mixture M is ejected into the mold cavity 105b-1 via the runners 103c-1, 103c-3, and 103c-5, and is ejected into the mold cavity 105b-2 via the runners 103c-4 and 103c-6, as Figure 30 shown. In some embodiments, the gates 104 of the outlets 103b-4 and 103b-6 can be adjusted to allow a faster flow rate or a larger amount of the mixture M to flow into the mold cavity 105b-2. In some embodiments, the gates 104 at the outlets 103b-1, 103b-3, and 103b-5 can be adjusted to allow a slower flow rate or a smaller amount of the mixture M to flow into the mold cavity 105b-1. After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is removed from the molding device.

[0071] In some embodiments, dispensers 107 with different configurations are inserted into the runner 103c, as Figure 31 and Figure 16 shown. In some embodiments, the dispenser 107 is inserted before or after the ejector 101 and the runner plate 103 are joined. In some embodiments, the dispenser 107 is inserted before or after the first mold 105c and the second mold 105d are joined. In some embodiments, as Figure 31 and Figure 16 shown, the partition plate 107 does not have the channels 107c-1 and 107c-2. Thus, the mixture M is ejected into the mold cavity 105b-1 via the runners 103c-3 and 103c-5, and is ejected into the mold cavity 105b-2 via the runners 103c-4 and 103c-6, as Figure 32 shown. In some embodiments, the dispenser 107 evenly distributes the ejected material of the mixture M to the runners 103c-3, 103c-4, 103c-5, and 103c-6. After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming to become a foamed product. After the foamed product is formed, the foamed product is removed from the molding device. In some embodiments, the dispenser 107 is removed from the runner 103c.

[0072] According to specific embodiments of the present creation, a replaceable plug or a replaceable dispenser is used in an injection molding system. In some embodiments, the plug is inserted into the runner of the runner plate to block the runner when necessary and prevent the formation of slugs or waste in the runner. In some embodiments, the dispenser is placed between the sprue and the runner of the runner plate to guide the molding material into the selected runner, easily change the number of runners used in the runner plate, and easily remove the residues of the molding material remaining in the runner plate.

[0073] The features of several specific embodiments are outlined above, so that those skilled in the art can better understand various aspects of the present creation. Those skilled in the art should understand that they can easily use the present creation as a basis for designing or modifying other operations and structures to achieve the same purpose and / or achieve the same advantages as the specific embodiments described herein. Those skilled in the art should also recognize that such equivalent structures do not depart from the spirit and scope of the present creation, and various changes, substitutions, and alterations can be made without departing from the spirit and scope of the present creation.

[0074] Furthermore, the scope of the present creation is not limited to the specific embodiments of the procedures, machines, manufactures, compositions of matter, components, methods, and steps described in this specification. From the disclosure of the present creation, those skilled in the art will easily understand that, in accordance with the present creation, procedures, machines, manufactures, compositions of matter, components, methods, or steps that perform the same functions or achieve substantially the same results as the corresponding specific embodiments described herein can be used with those that already exist or will be developed in the future. Therefore, it is desirable that such appended patent claims include such procedures, machines, manufactures, compositions of matter, components, methods, and steps within their scope.

[0075] Symbolic Explanation

[0076] 100: Injection Molding System

[0077] 101: Injector

[0078] 101a, 103b, 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, 103b-6, 107b, 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, 107b-6: Outlet

[0079] 102: Sprue

[0080] 102a: Inlet

[0081] 102b: Outlet

[0082] 103: Runner Plate

[0083] 103a, 107a: Inlet

[0084] 103c, 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, 103c-6: Runner

[0085] 104: Gate

[0086] 105: Molding device

[0087] 105a, 105a-1, 105a-2, 105a-3, 105a-5: Inlet

[0088] 105b, 105b-1, 105b-2: Mold cavity

[0089] 105c: First mold

[0090] 105d: Second mold

[0091] 106: Plug

[0092] 107: Distributor

[0093] 107c, 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, 1037-6: Channel

[0094] 108: Block

[0095] 110: Melting unit

[0096] 112: Conveying channel

[0097] 120: Mixing unit

[0098] 122: Conveying channel

[0099] 130: Injection unit

[0100] 200, 300: Injection molding methods

Claims

1. An injection molding system, characterized in that, Comprising: A molding device, including a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold joined to the first mold; A runner plate, disposed above the molding device, and including a first runner and a second runner that can communicate with the mold cavity and extend within the runner plate; And A dispenser, placed within the runner plate and having a passage that can connect to the first runner or the second runner, wherein the dispenser is configured to prevent the mixture from flowing into the mold cavity through one of the first runner and the second runner, and allow the mixture to flow into the mold cavity through the passage and the other of the first runner and the second runner.

2. The injection molding system according to claim 1, wherein The passage is aligned with the first runner or the second runner.

3. The injection molding system according to claim 1, wherein Further comprising: A stopper is disposed in the passage to prevent the mixture from passing through the passage.

4. The injection molding system according to claim 3, characterized in that, The stopper is a plastic block or a metal block.

5. The injection molding system according to claim 1, characterized in that, The dispenser can rotate relative to the runner plate and can be inserted into and removed from the runner plate.

6. The injection molding system according to claim 1, wherein The sizes of the first runner and the second runner are substantially larger than the size of the passage.

7. An injection molding system, characterized in that, Comprising: A molding device, including a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold joined to the first mold; A runner plate, disposed above the molding device, and including a plurality of runners that can communicate with the mold cavity and extend within the runner plate; and A plug, disposed in a first runner of the plurality of runners, wherein the plug is configured to prevent the mixture from flowing into the mold cavity through the first runner.

8. The injection molding system according to claim 7, wherein When the runner plate is disposed above the molding device, the plug can be inserted into and removed from the first runner.

9. The injection molding system according to claim 7, wherein, The plug is a plastic block or a metal block.

10. The injection molding system according to claim 7, wherein, The second mold includes at least one feed port communicating with the mold cavity.

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