Assembly of polymer components

Abstract

An assembly of polymeric components is provided. The assembly of polymer components includes a first polymer component having a first skin layer; and a second polymer component having a second skin layer in contact with the first skin layer. The density of the first skin layer is greater than a central portion of the first polymeric component and the density of the second skin layer is greater than a central portion of the second polymeric component, and a visible boundary line is present between the first skin layer and the second skin layer.

Description

Technical Field

[0001] The present invention discloses an assembly of polymer components, and more particularly an assembly of polymer components formed by an injection molding system. Background Art

[0002] Foamed polymer materials offer numerous advantages, such as high strength, low weight, impact resistance, and thermal insulation. Foamed objects can be manufactured through injection molding or extrusion molding. For example, after melting a polymer material and mixing it with a foaming agent to form a mixture, force or pressure is applied to the mixture to inject or extrude it into the cavity of a mold, where the mixture is allowed to foam and cool to form the foamed object.

[0003] However, it is necessary to improve the properties of foamed articles produced by injection molding systems, such as giving different parts of the foamed article different properties. Therefore, it is necessary to improve the structure of injection molding systems and the methods for manufacturing foamed articles.

[0004] new content

[0005] According to a specific embodiment of the present invention, a polymer component assembly is provided. The assembly includes a first polymer component having a first surface layer; and a second polymer component having a second surface layer in contact with the first surface layer. The density of the first surface layer is greater than that of a central portion of the first polymer component, and the density of the second surface layer is greater than that of a central portion of the second polymer component, and a visible boundary line exists between the first surface layer and the second surface layer.

[0006] Simple Explanation of the Diagram

[0007] The various forms of the content disclosed in this work are best understood from the following embodiments when read in conjunction with the accompanying drawings. It should be noted that, according to industry standard practice, the various features are not drawn to scale. In fact, the dimensions of these various features may be arbitrarily increased or decreased for clarity of discussion.

[0008] Figure 1 This is a schematic diagram showing an injection molding system according to some specific embodiments disclosed in this invention;

[0009] Figure 2 This is a flowchart showing some specific embodiments of the injection molding method according to the content disclosed in this invention;

[0010] Figure 3 This illustrates some specific embodiments of the content disclosed in this work. Figure 1 A schematic diagram of the molding device;

[0011] Figures 4 to 10This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method;

[0012] Figures 11 to 16 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method;

[0013] Figures 17 to 21 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method;

[0014] Figures 22 to 26 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method;

[0015] Figures 27 to 31 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method;

[0016] Figures 32 to 39 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method;

[0017] Figures 40 to 43 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method; and

[0018] Figure 44 and Figure 45 This is to show a specific embodiment of the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method. Implementation

[0019] Interactive reference to relevant applications:

[0020] This application claims priority to U.S. Provisional Patent Application No. 63 / 518,107, filed August 8, 2023, and U.S. Patent Application No. 18 / 664,326, filed May 15, 2024, the entire contents of which are incorporated herein by reference.

[0021] The following disclosure provides numerous different specific embodiments or examples for implementing various features of the provided object. Specific examples of components and arrangements are described below to simplify the disclosure of this invention. Of course, these are merely examples and are not intended to be limiting. For example, in the following description, the formation of a first feature on or above a second feature may include embodiments in which these first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between these first and second features, such that the first and second features may not be in direct contact. Furthermore, reference numerals and / or letters may be repeated in these various examples. Such repetition is for simplification and clarity and does not, in itself, define the relationship between the various embodiments and / or configurations discussed.

[0022] Furthermore, spatially related terms such as "beneath," "below," "lower," "above," "upper," and the like may be used in the text for ease of explanation to illustrate the relationship between one element or feature and another, as illustrated in the figures. In addition to the orientation depicted in the figures, these spatially related terms are intended to cover different orientations of the device in use or operation. The device may be oriented in other ways (rotated 90 degrees or otherwise), and these spatially relative descriptors used in the text may also be interpreted accordingly.

[0023] While the numerical ranges and parameters described in this broad category are approximate, the values ​​presented in these specific examples are reported as precisely as possible. However, any numerical value inherently contains a certain degree of error, necessarily resulting from the standard deviation observed in these respective test measurements. Furthermore, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term "about" means within the acceptable standard error of the average value, as considered by one of ordinary skill in the art. Unlike in these operational / work examples, or unless otherwise expressly specified, all such numerical ranges, quantities, values, and percentages (such as those used for quantities of material, durations, temperatures, operating conditions, ratios of quantities, and the like disclosed herein) should be understood to be modified by the term "about" in all instances. Therefore, unless otherwise indicated, the numerical parameters set forth in the disclosure of this invention and in the appended claims are approximate values ​​that may vary as desired. At least, each numerical parameter should be understood in light of the number of significant digits reported and by applying general rounding techniques. A range may be expressed herein as from one endpoint to another, or between two endpoints. All ranges disclosed herein include these endpoints unless otherwise specified.

[0024] Figure 1 This is a schematic diagram of an injection molding system 10 according to some specific embodiments disclosed in this invention. The injection molding system 10 includes a mixing unit 120, an injection unit 110, and a molding apparatus 100.

[0025] Mixing unit 120 is configured to generate a mixture of polymer material and a physical foaming agent. This mixture is then conveyed to injection unit 110 via at least one delivery conduit 122. Injection unit 110 is configured to discharge the mixture. The mixture is then discharged through one or more discharge conduits 111 of the injection unit, which is coupled to molding device 100. The mixture can flow from injection unit 110 into molding device 100. Molding device 100 is configured to form an article containing polymer material. In some embodiments, the article is physically foamed within molding device 100. 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.

[0026] Figure 2This is a flowchart illustrating an injection molding method 20 according to some specific embodiments disclosed herein. The injection molding method 20 includes operations S210 to S270, and the description and these illustrative figures are not intended to limit the order of operations S210 to S270. Figures 3 to 45 This is a schematic cross-sectional view of the various stages of injection molding method 20. In some specific embodiments, these operations of injection molding method 20 are automatically repeatable and performed.

[0027] In some specific embodiments, the injection molding method 20 is composed of Figure 1 The injection molding system 10 performs the process. In operation S210, a molding apparatus 100 is provided, comprising a mold cavity defined by the first mold and the second mold that are engaged with each other. In operation S220, the injection unit 110 is configured to inject a first mixture from the mixing unit 120 into the mold cavity of the molding apparatus 100 through a first gate and a corresponding discharge pipe 111, and then a first polymer assembly (hereinafter referred to as the first assembly) is formed from the first mixture in operation S230. In operation S240, the injection unit 110 is configured to inject a second mixture from the mixing unit 120 into the mold cavity of the molding apparatus 100 through a second gate and a corresponding discharge pipe 111, and then a second polymer assembly (hereinafter referred to as the second assembly) is formed from the second mixture in operation S250. In operation S260, injection unit 110 is configured to inject a third mixture from mixing unit 120 into the mold cavity of molding device 100 through a third gate and a corresponding discharge pipe 111 of molding device 100, and then a third polymer component (hereinafter referred to as the third component) is formed from the third mixture in operation S270.

[0028] In some embodiments, operations S220 and S230 are additional operations in which the first component is pre-formed and placed into the mold cavity of the molding apparatus 100. Corresponding to this additional operation, the third mixture and the second mixture are identical. In some embodiments, the mold cavity is defined by the second mold, and the fourth polymer component (hereinafter referred to as the fourth component) is held by the first mold.

[0029] In some embodiments, the flow rates / flow rates of the first, second, and third mixtures are the same or different. In some embodiments, the first, second, and third mixtures are different so that the first, second, and third components have different physical properties. The first, second, and third components are formed in different regions or portions of the article. In some embodiments, the second component is at least partially in contact with the first and third components, i.e., the second component is sandwiched between the first and third components. In some embodiments, the second component is separated from the first component by the third component.

[0030] In some embodiments, the second mixture is softer than the first mixture, and the third mixture is softer than the second mixture. In some embodiments, the harder mixture is ejected first, and the softer mixture is ejected later.

[0031] To illustrate the concepts and injection molding method 20 disclosed herein, various specific embodiments are provided below. However, the content disclosed herein is not intended to be limited to the specified specific embodiments. Furthermore, the elements, conditions, or parameters illustrated in different specific embodiments are combinations or modifications that can be used to form different combinations of specific embodiments, provided that the elements, parameters, or conditions used do not conflict. For ease of illustration, reference numerals with similar or identical functions and properties are repeated in different specific embodiments and figures.

[0032] Figure 3 These are some specific embodiments based on the content disclosed in this work. Figure 1 A schematic diagram of a molding apparatus 100. The molding apparatus 100 includes a first mold 101 and a second mold 102. The first mold 101 engages with the second mold 102. When the first mold 101 is engaged with the second mold 102, the molding apparatus 100 is in a closed state. In some embodiments, the first mold 101 is a lower mold, and the second mold 102 is an upper mold, with the first mold 101 located below the second mold 102. In some embodiments, the molding apparatus 100 includes a mold cavity 103, which is defined by the first mold 101 and the second mold 102 when the first mold 101 is engaged with the second mold 102. The mold cavity 103 is configured to hold the mixture or the article formed from the mixture.

[0033] In some embodiments, the mold cavity 103 is divisible into a first sub-cavity 103a, a second sub-cavity 103b, and a third sub-cavity 103c by at least one partition 104. Adjacent sub-cavities 103a, 103b, and 103c are separated by partitions 104. For example, the first sub-cavity 103a and 103b are separated from each other by a first partition 104a, while the second sub-cavity 103b and 103c are separated from each other by a second partition 104b. In some embodiments, the partition 104 is movable relative to the first mold 101 or the second mold 102. In some embodiments, the partition 104 is manually or automatically extended or retracted within the mold cavity 103.

[0034] In some embodiments, the partition 104 protrudes from the first mold 101 or the second mold 102. In some embodiments, the partition 104 is extendable into or retractable from the mold cavity 103. For example, the partition 104 is extendable from the first mold 101 into the mold cavity 103, or retractable from the mold cavity 103 into the first mold 101.

[0035] In some specific embodiments, the first sub-cavity 103a is defined by the first mold 101, the second mold 102, and the first partition 104a. Furthermore, the second sub-cavity 103b is defined by the first mold 101, the second mold 102, the first partition 104a, and the second partition 104b, while the third sub-cavity 103c is defined by the first mold 101, the second mold 102, and the second partition 104b. In some specific embodiments, when the first partition 104a and the second partition 104b are inside the mold cavity 103, the first sub-cavity 103a, the second sub-cavity 103b, and the third sub-cavity 103c cannot communicate with each other, such as... Figure 3 As shown in the diagram. In some embodiments, the first partition 104a and the second partition 104b have the same or different thicknesses in the X direction and the same height in the Z direction. Furthermore, the first sub-cavity 103a, the second sub-cavity 103b, and the third sub-cavity 103c have the same or different widths in the X direction and the same height in the Z direction. In some embodiments, the first sub-cavity 103a, the second sub-cavity 103b, and the third sub-cavity 103c have the same length in the Y direction.

[0036] In some specific embodiments, the gate 105 is located at the first mold 101 or the second mold 102. When the discharge pipe 111 is engaged with the molding apparatus 100, the gate 105 is configured to receive material from the mold. Figure 1 The mixture is discharged through the discharge pipe 111 of the injection unit 110. This mixture can flow into the mold cavity 103 through the gate 105. Figure 1In this specific embodiment, when the first partition 104a and the second partition 104b are disposed within the mold cavity 103, there are first gates 105a, second gates 105b, and third gates 105c that can communicate with the first sub-cavity 103a, the second sub-cavity 103b, and the third sub-cavity 103c, respectively. In some specific embodiments, each of the first sub-cavity 103a, the second sub-cavity 103b, and the third sub-cavity 103c corresponds to one or more gates 105. In some specific embodiments, the first gate 105a, the second gate 105b, and the third gate 105c have the same or different widths in the X direction. In some specific embodiments, the first gate 105a, the second gate 105b, and the third gate 105c allow fluids to flow through at the same or different flow rates.

[0037] Figures 4 to 10 This is a first specific embodiment based on the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in injection molding method 20.

[0038] exist Figure 4 In this design, a first mold 101 engages with a second mold 102, and a first partition 104a is disposed within a mold cavity 103. In some embodiments, the first partition 104a is provided by extending the first partition 104a from the first mold 101 to the second mold 102. In some embodiments, the engagement of the first mold 101 and the second mold 102 occurs before or after the placement of the first partition 104a. In some embodiments, after the engagement of the first mold 101 and the second mold 102 and the placement of the first partition 104a, a first gas is ejected into a first sub-cavity 103a to increase the pressure inside the first sub-cavity 103a. In some embodiments, the first gas is air or the like. In some embodiments, the first sub-cavity 103a is defined by the first mold 101, the second mold 102, and the first partition 104a.

[0039] As in Figure 2 As described in operation S220, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a. In some specific embodiments, the first mixture M1' is injected into the first sub-cavity 103a filled with the first gas. In some specific embodiments, Figure 1The discharge pipe 111 is connected to the first gate 105a, and the first mixture M1' is then injected from the discharge pipe 111 through the first gate 105a into the first sub-cavity 103a. In some embodiments, the first mixture M1' comprises a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid, or the like). In some embodiments, the first mixture M1' is foamable or slightly foamable.

[0040] In some embodiments, after the first mixture M1' is ejected, the first mixture M1' undergoes physical foaming within the first sub-cavity 103a to become the first component M1, as described in operation S230. In some embodiments, during the physical foaming process of the first mixture M1' and / or after the formation of the first component M1, the pressure inside the first sub-cavity 103a is reduced by discharging at least a portion of the first gas from the first sub-cavity 103a and / or discharging a portion of the physical foaming agent released from the first mixture M1' from the first sub-cavity 103a. In some embodiments, after the physical foaming of the first mixture M1', the first component M1 is formed having a first surface layer 106a. The first surface layer 106a is adjacent to or in contact with the first partition 104a. The first surface layer 106a has a higher density than the central portion of the first component M1 away from the first partition 104a. The first surface layer 106a has a lower degree of physical foaming than the central portion of the first component M1. In other words, the central portion of the first component M1 undergoes a higher degree of physical shaping than the peripheral portion of the first component M1. In some specific embodiments, the first surface layer 106a has a thickness of less than 0.5 mm.

[0041] In some specific embodiments, after the first component M1 is formed, the first partition 104a is as follows: Figure 5 The first partition 104a is removed from the mold cavity 103 as shown. In some embodiments, the first partition 104a is removed from the mold cavity 103 by retracting the first partition 104a away from the second mold 102 and returning it to the first mold 101. In some embodiments, after this removal of the first partition 104a, the following is... Figure 5 The diagram shows the formation of a second sub-cavity 103b, a second partition 104b, and a second mold 102, defined by the first component M1. Furthermore, Figure 5 The second sub-cavity 103b is in the X direction compared to Figure 3The sub-cavity 103b is wider. In some embodiments, the second partition 104b is disposed within the mold cavity 103 after the removal of the first partition 104a. In some embodiments, the second partition 104b is disposed within the mold cavity 103 before the injection of the first mixture M1'. In some embodiments, the second partition 104b is disposed by extending the second partition 104b from the first mold 101 to the second mold 102. In some embodiments, the engagement of the first mold 101 and the second mold 102 is performed before or after the placement of the second partition 104b.

[0042] In some embodiments, the second gas is injected into the second sub-cavity 103b to increase the pressure inside the second sub-cavity 103b after the second partition 104b is disposed. In some embodiments, the second gas is air or the like.

[0043] exist Figure 6 In, such as in Figure 2 As described in operation S240, the second mixture M2' is injected into the second sub-cavity 103b through the second gate 105b. It should be noted that the first partition 104a is removed from the mold cavity 103 before the second mixture M2' is injected. In some embodiments, the second mixture M2' is injected into the second sub-cavity 103b filled with the second gas. In some embodiments, Figure 1 The discharge pipe 111 is connected to the second gate 105b, and the second mixture M2' is then injected from the discharge pipe 111 through the second gate 105b into the second sub-cavity 103b. In some embodiments, the second mixture M2' comprises a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid, or the like). In some embodiments, the second mixture M2' is foamable or slightly foamable. In some embodiments, the first mixture M1' and the second mixture M2' comprise the same or different materials. In some embodiments, the first mixture M1' and the second mixture M2' have different physical properties, such as density, hardness, Young's modulus, etc. In some embodiments, the second mixture M2' is softer than the first mixture M1'. In some embodiments, the first mixture M1' is denser than the second mixture M2'. In some specific embodiments, the first surface layer 106a of the first component M1 is in contact with the second mixture M2'.

[0044] In some specific embodiments, after the second mixture M2' is ejected, the second mixture M2' undergoes physical foaming within the second sub-cavity 103b to become the second component M2, as in... Figure 2 As described in operation S250. In some embodiments, during the physical foaming process of the second mixture M2' and / or after the formation of the second component M2, the pressure inside the second sub-cavity 103b is reduced by discharging at least a portion of the second gas from the second sub-cavity 103b and / or discharging a portion of the physical foaming agent released from the second mixture M2' from the second sub-cavity 103b. In some embodiments, after the physical foaming of the second mixture M2', the second component M2 with a second surface layer 106b is formed. In some embodiments, the second surface layer 106b is adjacent to or in contact with the second partition 104b. In some embodiments, the second surface layer 106b is in contact with the first surface layer 106a of the first component M1. The second surface layer 106b has a higher density than the central portion of the second component M2 away from the second partition 104b. The second surface layer 106b has a lower degree of physical foaming than the central portion. In other words, the central portion of the second component M2 undergoes a higher degree of physical shaping than the peripheral portion of the second component M2. In some specific embodiments, the second surface layer 106b has a thickness of less than 0.5 mm.

[0045] In some specific embodiments, after the second component M2 is formed, the second partition 104b is as follows: Figure 7 The second partition 104b is removed from the mold cavity 103 as shown. In some embodiments, the second partition 104b is removed from the mold cavity 103 by retracting the second partition 104b away from the second mold 102 and returning it to the first mold 101. In some embodiments, after the second partition 104b is removed, the third sub-cavity 103c defined by the second component M2, the first mold 101, and the second mold 102 is as shown. Figure 7 As shown in the diagram. Furthermore, Figure 7 The third sub-cavity 103c is in the X direction compared to Figure 3 The subcavity of 103c is wider.

[0046] In some embodiments, after the second partition 104b is removed, a third gas is injected into the third sub-cavity 103c to increase the pressure inside the third sub-cavity 103c. In some embodiments, the third gas is air or the like.

[0047] exist Figure 8 In, such as in Figure 2As described in operation S260, the third mixture M3' is injected into the third sub-cavity 103c through the third gate 105c. In some specific embodiments, the third mixture M3' is injected into the third sub-cavity 103c filled with the third gas. In some specific embodiments, Figure 1 The discharge pipe 111 is connected to the third gate 105c, and the third mixture M3' is then injected from the discharge pipe 111 through the third gate 105c into the third sub-cavity 103c. In some embodiments, the third mixture M3' comprises a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid, or the like). In some embodiments, the third mixture M3' is foamable or slightly foamable. In some embodiments, the first mixture M1', the second mixture M2', and the third mixture M3' comprise the same or different materials. In some embodiments, the first mixture M1', the second mixture M2', and the third mixture M3' have different physical properties, such as density, hardness, etc. In some embodiments, the third mixture M3' is softer than the second mixture M2' and the first mixture M1'. In some embodiments, the second mixture M2' and the first mixture M1' are denser than the third mixture M3'. In some embodiments, the second surface layer 106b of the second component M2 in contact with the third mixture M3' may be referred to as the fourth surface layer.

[0048] In some specific embodiments, after the third mixture M3' is ejected, the third mixture M3' undergoes physical foaming within the third sub-cavity 103c to become the third component M3, as in Figure 2As described in operation S270. In some embodiments, during the physical foaming process of the third mixture M3' and / or after the formation of the third component M3, the pressure inside the third sub-cavity 103c is reduced by discharging at least a portion of the third gas from the third sub-cavity 103c and / or discharging a portion of the physical foaming agent released from the third mixture M3' from the third sub-cavity 103c. In some embodiments, after the physical foaming of the third mixture M3', the third component M3 with a third surface layer 106c is formed. In some embodiments, the third surface layer 106c is adjacent to or in contact with the second component M2. In some embodiments, the second surface layer 106b of the second component M2 is in contact with the third surface layer 106c of the third component M3. The third surface layer 106c has a higher density than the central portion of the third component M3. The third surface layer 106c has a lower degree of physical foaming than the central portion. In other words, the central portion of the third component M3 undergoes a higher degree of physical shaping than the peripheral portion of the third component M3. In some specific embodiments, the third surface layer 106c has a thickness of less than 0.5 mm.

[0049] exist Figure 9 In this process, after the third component M3 is formed, the first mold 101 is detached from the second mold 102. Following the formation of the third component M3, an article (or assembly) 107 is formed having the first component M1, the second component M2, and the third component M3, with the second component M2 sandwiched between the first component M1 and the third component M3. The article 107 is formed within the mold cavity 103. In some specific embodiments, after the first mold 101 and the second mold 102 are detached, the article 107 is as follows... Figure 10 The image shows the part being removed from mold cavity 103. In some specific embodiments, the operations described above are automatically repeatable and performed.

[0050] In some embodiments, the first component M1 is directly attached to the second component M2, and the second component M2 is directly attached to the third component M3. In other words, no additional components or materials (such as adhesives or the like) are disposed between the first component M1 and the second component M2, and between the second component M2 and the third component M3. In some embodiments, the article 107 has various densities or hardnesses.

[0051] exist Figure 10In this specific embodiment, the top surfaces of the first component M1, the second component M2, and the third component M3 are formed on the same layer defined by the second mold 102, while the bottom surfaces of the first component M1, the second component M2, and the third component M3 are formed on the same layer defined by the first mold 101. In some specific embodiments, these top surfaces of the first component M1, the second component M2, and the third component M3 are formed on different layers. In some specific embodiments, these bottom surfaces of the first component M1, the second component M2, and the third component M3 are formed on different layers. In some specific embodiments, the first component M1, the second component M2, and the third component M3 have the same or different thicknesses. Furthermore, the first component M1 is separated from the second component M2 and the third component M3.

[0052] In some embodiments, article 107 includes a visible boundary line between two adjacent components. For example, a first visible boundary line 108a exists between the first component M1 and the second component M2, while a second visible boundary line 108b exists between the second component M2 and the third component M3. In some embodiments, viewed from a top view of article 107, the first visible boundary line 108a and the second visible boundary line 108b are respectively a straight line, a curve, a spline, a polyline, etc. In some embodiments, the first visible boundary line 108a extends over the top surfaces of the first component M1 and the second component M2, while the second visible boundary line 108b extends over the top surfaces of the second component M2 and the third component M3. In some embodiments, the first visible boundary line 108a extends from the top surfaces of the first component M1 and the second component M2 to the bottom surfaces, while the second visible boundary line 108b extends from the top surfaces of the second component M2 and the third component M3 to the bottom surfaces.

[0053] Figures 11 to 16 This is a second specific embodiment showing the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in injection molding method 20. In this second embodiment, the third component M3 is formed prior to the formation of the second component M2.

[0054] exist Figure 11In this design, the first mold 101 is engaged with the second mold 102, and the first partition 104a and the second partition 104b are disposed within the mold cavity 103. The mold cavity 103 is divided into a first sub-cavity 103a, a second sub-cavity 103b, and a third sub-cavity 103c by the first partition 104a and the second partition 104b. Furthermore, the second sub-cavity 103b is defined by the first mold 101, the second mold 102, and the first partition 104a and the second partition 104b, while the third sub-cavity 103c is defined by the first mold 101, the second mold 102, and the second partition 104b.

[0055] As in Figure 2 As described in operation S220, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a. After injection, the first mixture M1' undergoes physical foaming within the first sub-cavity 103a to become the first component M1, as described in operation S230. In some specific embodiments, the first component M1 includes a first surface layer 106a adjacent to or in contact with the first partition 104a.

[0056] exist Figure 12 In, such as in Figure 2 As described in operation S240, after the first component M1 is formed, the third mixture M3' is injected into the third sub-cavity 103c through the third gate 105c. After the third mixture M3' is injected, it undergoes physical foaming to become the third component M3, as described in operation S250. In some specific embodiments, the third component M3 includes a third surface layer 106c that is adjacent to or in contact with the second partition 104b.

[0057] In some specific embodiments, with formed in Figure 8 Compared to the third component M3 in the third sub-cavity 103c, the third component M3 is... Figure 12 The second component M2 is formed before it is formed. Furthermore, Figure 12 The third component M3 has a greater ratio in the X direction than Figure 8 The third component M3 has a wider width. In other words, by adjusting the formation order of the third component M3, the third component M3 may have different sizes.

[0058] exist Figure 13 In this process, after the third component M3 is formed, the first partition 104a and the second partition 104b are removed from the mold cavity 103 simultaneously or sequentially. After the removal of the first partition 104a and the second partition 104b, the second sub-cavity 103b is defined by the first mold 101, the second mold 102, the first component M1, and the second component M2. Therefore, Figure 12 The second sub-cavity 103b is in the X direction compared to Figure 13 The subcavity 103b is wider.

[0059] exist Figure 14 In, such as in Figure 2 As described in operation S260, the second mixture M2' is injected into the second sub-cavity 103b. In some embodiments, the second mixture M2' is in contact with the first component M1 and the third component M3. In some embodiments, the second mixture M2' undergoes physical foaming to become the second component M2, as in... Figure 2 As described in operation S270. In some specific embodiments, the second component M2 includes a second surface layer 106b that is adjacent to or in contact with the first component M1 and the third component M3.

[0060] In some specific embodiments, with formed in Figure 6 Compared to the second component M2 in the second sub-cavity 103b, the second component M2 is... Figure 14 The third component M3 is formed after it is formed. Furthermore, Figure 14 The second component M2 has a greater ratio in the X direction than Figure 6 The second component M2 has a wider width. In other words, by adjusting the formation order of the second component M2, the second component M2 may have different sizes.

[0061] After the second component M2 is formed, the article 107 is as follows Figure 15 As shown in the figure. Article 107 is formed in the manner shown in the figure. Figure 16 After the first mold 101 and the second mold 102 are separated, they are removed from the mold cavity 103. In some embodiments, the second component M2 is softer than the first component M1 and the third component M3. In some embodiments, the first component M1 and the third component M3 are denser than the second component M2. In some embodiments, the steps described above are automatically repeatable and can be performed.

[0062] Figures 17 to 21 This is a third specific embodiment showing the content disclosed in this work. Figure 2 A schematic cross-sectional view of an exemplary stage in injection molding method 20. In this third embodiment, the second partition 104b and the third component M3 are removed. Therefore, no third sub-cavity 103c exists within the mold cavity 103, and the third component M3 is not present in the article 107. In some embodiments, the first partition 104a and one of the first component M1 and the second component M2 are removed.

[0063] exist Figure 17 In this process, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a, as shown in... Figure 2 This is described in operation S220. In some specific embodiments, the first sub-cavity 103a is defined by the first mold 101, the second mold 102, and the first partition 104a. After the first component M1 is formed as described in operation S230, it is as follows: Figure 18 The first partition 104a is removed as shown in the diagram.

[0064] exist Figure 19 In the process, after the first partition 104a is removed, the second mixture M2' is injected into the second sub-cavity 103b through one or more of the second gate 105b and the third gate 105c, as shown in Figure 2 This is described in operation S240. In some embodiments, the second sub-cavity 103b is defined by the first component M1, the first mold 101, and the second mold 102. In some embodiments, the second mixture M2' flows through the second gate 105b and the third gate 105c at the same or different flow rates. In some embodiments, the second mixture M2' undergoes physical foaming to become the second component M2, as described in... Figure 2 As described in operation S250. In some specific embodiments, the second component M2 includes a second surface layer 106b, which is adjacent to or in contact with the first component M1. Figure 19 In this specific embodiment, the second component M2 has a wider width in the X direction than the first component M1.

[0065] exist Figure 20 In this process, article 107 is formed after the second component M2 is formed. Article 107 is formed as follows: Figure 21 After the first mold 101 and the second mold 102 are separated, they are removed from the mold cavity 103. In some embodiments, the second component M2 is softer than the first component M1. In some embodiments, the first component M1 is denser than the second component M2.

[0066] Figures 22 to 26 This is a fourth specific embodiment showing the content disclosed in this invention. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method 20. In this fourth embodiment, the partitions 104 are omitted, that is, the first partition 104a and the second partition 104b are not provided in the mold cavity 103.

[0067] exist Figure 22 In the process, the first mixture M1' is injected into the mold cavity 103 through the first gate 105a (in Figure 2 In operation S220), the first mixture M1' then undergoes physical foaming to become the first component M1 (in Figure 2(In operation S230). In some embodiments, gas is injected into the mold cavity 103 prior to the injection of the first mixture M1' to increase the pressure inside the mold cavity 103. After the formation of the first component M1, a first surface layer 106a is formed. In some embodiments, the first surface layer 106a is configured to prevent subsequent injections of the mixture into the mold cavity 103 from mixing with the first mixture M1' or the first component M1. In some embodiments, during or after the physical foaming process of the first mixture M1', a portion of the gas released from the first mixture M1' and / or a portion of the physical foaming agent is discharged from the mold cavity 103.

[0068] exist Figure 23 In this process, after the first component M1 is formed, the second mixture M2' is injected into the mold cavity 103 through the second gate 105b, as shown in... Figure 2 As described in operation S240. In some specific embodiments, the gas is injected into the mold cavity 103 before the second mixture M2' is injected to increase the pressure inside the mold cavity 103. The second mixture M2' is in contact with the first component M1. The second mixture M2' then undergoes physical foaming to become the second component M2, as described in... Figure 2 As described in operation S250. After the formation of the second component M2, a second surface layer 106b is formed. In some embodiments, the second surface layer 106b is configured to prevent the mixture subsequently injected into the mold cavity 103 from mixing with the second mixture M2' or the second component M2. In some embodiments, during or after the physical foaming process of the second mixture M2', a portion of the gas released from the second mixture M2' and / or a portion of the physical foaming agent is discharged from the mold cavity 103.

[0069] exist Figure 24 In the process, after the second component M2 is formed, the third mixture M3' is injected into the mold cavity through the third gate 105c, as in Figure 2 As described in operation S260. In some specific embodiments, the gas is injected into the mold cavity 103 before the third mixture M3' is injected to increase the pressure inside the mold cavity 103. The third mixture M3' is in contact with the second component M2. The third mixture M3' then undergoes physical foaming to become the third component M3, as described in... Figure 2As described in operation S270. After the formation of the third component M3, a third surface layer 106c is formed. In some embodiments, the third surface layer 106c is configured to prevent mixing with the second mixture M2' or the second component M2. In some embodiments, during or after the physical foaming process of the third mixture M3', a portion of the gas released from the third mixture M3' and / or a portion of the physical foaming agent is discharged from the mold cavity 103.

[0070] exist Figure 25 In this context, article 107 is formed, and article 107 can be manufactured as follows: Figure 26 After the first mold 101 and the second mold 102 are separated, the product is removed from the mold cavity 103. As explained above, the article 107 includes a first visible boundary line 108a between the first component M1 and the second component M2, and a second visible boundary line 108b between the second component M2 and the third component M3.

[0071] Figures 27 to 31 This is a fifth specific embodiment showing the content disclosed in this invention. Figure 2 A schematic cross-sectional view of an exemplary stage in injection molding method 20. In this fifth embodiment, the first component M1 is surrounded by the second component M2 in the article 107. In some embodiments, the second gate 105b is removed from the second mold 102.

[0072] exist Figure 27 In this embodiment, the first component M1 is placed into a second sub-cavity 103b defined by a first partition 104a, a second partition 104b, a first mold 101, and a second mold 102. In some specific embodiments, the first component M1 is temporarily fixed in the second sub-cavity 103b by the first partition 104a and the second partition 104b. Furthermore, a portion of the second sub-cavity 103b is not filled with the first component M1.

[0073] In some specific embodiments, after the first component M1 is placed, the second mixture M2' is as follows: Figure 28The gas is injected into the first sub-cavity 103a and the third sub-cavity 103c, as shown in the diagram. In some embodiments, the gas is injected into the first sub-cavity 103a and / or the third sub-cavity 103c before the second mixture M2' is injected, to increase the pressure inside the first sub-cavity 103a and / or the third sub-cavity 103c. In some embodiments, the second mixture M2' is injected into the first sub-cavity 103a and the third sub-cavity 103c through the first gate 105a and the third gate 105c, respectively. In some embodiments, the second mixture M2' is injected into the first sub-cavity 103a and the third sub-cavity 103c simultaneously. In some embodiments, the second mixture M2' is injected into the first sub-cavity 103a and the third sub-cavity 103c sequentially.

[0074] In some specific embodiments, when the second mixture M2' almost or completely fills the first sub-cavity 103a and the third sub-cavity 103c, the first partition 104a and the second partition 104b are withdrawn from the mold cavity 103. In some specific embodiments, after the withdrawal of the first partition 104a and the second partition 104b, the second mixture M2' flows into the second sub-cavity 103b as follows: Figure 29 The first component M1 is shown in contact with the second mixture M2'. The second mixture M2' then undergoes physical foaming to become the second component M2. After the formation of the second component M2, a second surface layer 106b is formed. In some embodiments, during or after the physical foaming of the second mixture M2', a portion of the gas released from the second mixture M2' and / or a portion of the physical foaming agent is discharged from the mold cavity 103. In a fifth embodiment, the second component M2 and the first component M1 have different heights in the Z direction. The top surface of the first component M1 is lower than the top surface of the second component M2. Furthermore, the second component M2 overlaps the top surface of the first component M1 in the Z direction (as seen from the top view of article 107), and the top surface of the first component M1 is surrounded by the second component M2.

[0075] In some specific embodiments, article 107 is as follows Figure 30 The form shown is formed, and article 107 is capable of being formed as shown. Figure 31 After the first mold 101 and the second mold 102 are separated, they are removed from the mold cavity 103. In some embodiments, the second component M2 is softer than the first component M1. In some embodiments, the first component M1 is denser than the second component M2.

[0076] Figures 32 to 39 This is a sixth specific embodiment showing the content disclosed in this invention. Figure 2A schematic cross-sectional view of an exemplary stage in injection molding method 20. In this sixth embodiment, the first component M1 is surrounded by the second component M2 in the article 107. In some embodiments, the second gate 105b is removed from the second mold 102.

[0077] exist Figure 32 In this molding apparatus 100, a first mold 101 and a second mold 102a are engaged with the first mold 101. A fourth mold cavity 103d is formed when the first mold 101 is engaged with the second mold 102a. The fourth mold cavity 103d is defined by the first mold 101 and the second mold 102a. In some embodiments, a fourth mixture M4' is injected into the fourth mold cavity 103d through a fourth gate 105d. In some embodiments, a fourth gas is injected into the fourth mold cavity 103d before the fourth mixture M4' is injected to increase the pressure inside the fourth mold cavity 103d. In some embodiments, the fourth mixture M4' comprises a polymer material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or the like) and a physical foaming agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid, or the like). In some embodiments, the fourth mixture M4' is foamable or slightly foamable.

[0078] In some embodiments, after the injection of the fourth mixture M4', the fourth mixture M4' undergoes physical foaming within the fourth mold cavity 103d to become the fourth component M4. In some embodiments, during the physical foaming process of the fourth mixture M4' and / or after the formation of the fourth component M4, the pressure inside the fourth mold cavity 103d is reduced by discharging at least a portion of the fourth gas from the fourth mold cavity 103d and / or discharging a portion of the physical foaming agent released from the fourth mixture M4' from the fourth mold cavity 103d. In some embodiments, after the physical foaming of the fourth mixture M4', the fourth component M4 is formed having a fifth surface layer 106d. The fifth surface layer 106d has a higher density than the central portion of the fourth component M4. The fifth surface layer 106d has a lower degree of physical foaming than the central portion. In some embodiments, the fifth surface layer 106d has a thickness of less than 0.5 mm.

[0079] exist Figure 33In this embodiment, after the fourth component M4 is formed, the second mold 102a is removed and replaced by the third mold 102b. In some embodiments, the first partition 104a and the second partition 104b extend between the fourth component M4 and the third mold 102b. In some embodiments, the first partition 104a and the second partition 104b are extendable and retractable from the third mold 102b. In some embodiments, the mold cavity 103 is further defined by the fourth component M4 disposed in the first mold 101 and the third mold 102b.

[0080] exist Figure 33 In the process, after the first partition 104a is set, the first mixture M1' is injected into the first sub-cavity 103a through the first gate 105a, as in Figure 2 This operation is described in S220. In some specific embodiments, the first sub-cavity 103a is defined by the third mold 102b, the fourth component M4, and the first partition 104a.

[0081] In some embodiments, the first gas is injected into the first sub-cavity 103a before the first mixture M1' is injected, in order to increase the pressure inside the first sub-cavity 103a. In some embodiments, after the first mixture M1' is injected, the first mixture M1' undergoes physical foaming within the first sub-cavity 103a to become the first component M1, as in... Figure 2 This is described in operation S230. In some specific embodiments, after the first component M1 is formed, the first partition 104a is as follows: Figure 34 The removal shown in the image.

[0082] exist Figure 35 In the process, the second mixture M2' is injected into the second sub-cavity 103b through the second gate 105b, as shown in... Figure 2 As described in operation S240. In some embodiments, the second gas is injected into the second sub-cavity 103b before the second mixture M2' is injected to increase the pressure inside the second sub-cavity 103b. In some embodiments, the second sub-cavity 103b is defined by the first component M1, the fourth component M4, the second partition 104b, and the third mold 102b. In some embodiments, after the second mixture M2' is injected, the second mixture M2' undergoes physical foaming within the second sub-cavity 103b to become the second component M2, as described in... Figure 2 As described in operation S250. In some specific embodiments, after the second component M2 is formed, the second partition 104b is as follows: Figure 36 The removal shown in the image.

[0083] exist Figure 37In this process, after the second component M2 is formed, the third mixture M3' is injected into the third sub-cavity 103c through the third gate 105c, as in Figure 2 As described in operation S260. In some embodiments, the third sub-cavity 103c is defined by the second component M2, the fourth component M4, and the third mold 102b. In some embodiments, the third gas is injected into the third sub-cavity 103c before the third mixture M3' is injected to increase the pressure inside the third sub-cavity 103c. In some embodiments, after the third mixture M3' is injected, the third mixture M3' undergoes physical foaming within the third sub-cavity 103c to become the third component M3, as described in... Figure 2 As described in operation S270.

[0084] In some specific embodiments, after the third component M3 is formed, the first mold 101 is as follows: Figure 38 As shown, it is detached from the third mold 102b. After the third component M3 is formed, the article 107 having the first component M1, the second component M2, the third component M3, and the fourth component M4 is as follows. Figure 39 The product 107 is formed as shown. It is formed within a mold cavity defined by the first mold 101 and the third mold 102b. In some specific embodiments, after the separation of the first mold 101 and the third mold 102b, the product 107 is as shown. Figure 39 The image shows the part removed from the mold cavity.

[0085] In some embodiments, the first component M1 is directly attached to the second component M2, and the second component M2 is directly attached to the third component M3. In other words, no additional components or materials (such as adhesives or the like) are disposed between the first component M1 and the second component M2, or between the second component M2 and the third component M3. In some embodiments, the fourth component M4 is separable / detachable from the first component M1, the second component M2, and the third component M3. In some embodiments, the fourth component M4 has recesses / protrusions that can be attached to the first component M1, the second component M2, and / or the third component M3.

[0086] In some specific embodiments, the fifth surface layer 106d is in contact with the bottom surfaces of the first component M1, the second component M2, and the third component M3. The second component M2 is surrounded by the first component M1, the fourth component M4, and the third component M3. The first component M1 is surrounded by the fourth component M4 and the second component M2. The side surface of the first component M1 (such as the first surface layer 106a on the left side) is in contact with the fifth surface layer 106d of the fourth component M4. Furthermore, the third component M3 is surrounded by the fourth component M4 and the second component M2. The side surface of the third polymer component (such as the third surface layer 106c on the right side) is in contact with the fifth surface layer 106d of the fourth component M4.

[0087] In some specific embodiments, the article 107 includes a visible boundary line between two adjacent components. For example, a first visible boundary line 108a exists between the first component M1 and the second component M2, while a second visible boundary line 108b exists between the second component M2 and the third component M3. In some specific embodiments, viewed from a top view of the article 107, the first visible boundary line 108a and the second visible boundary line 108b are respectively a straight line, a curve, an arc, a broken line, etc.

[0088] In some embodiments, the article 107 has various densities or hardnesses. In some embodiments, the fourth component M4 is harder and denser than the first component M1, the second component M2, and the third component M3. In some embodiments, the third component M3 is softer than the second component M2 and the first component M1. In some embodiments, the first component M1 is denser than the second component M2 and the third component M3.

[0089] Figures 40 to 43 This is the seventh specific embodiment showing the content disclosed in this invention. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method 20. In this seventh embodiment, these operations of the injection unit 110 are shown.

[0090] As described above, the injection molding system 10 includes a mixing unit 120, an injection unit 110, and a molding apparatus 100. The mixing unit 120 is configured to generate a mixture of polymer material and a physical foaming agent. This mixture is then conveyed to the injection unit 110.

[0091] exist Figure 40In this process, injection unit 110 is configured to discharge the mixture. The mixture is then discharged through one or more discharge pipes 111a, 111b, and 111c of injection unit 110, which is coupled to molding apparatus 100. The mixture can flow from injection unit 110 into molding apparatus 100. In some embodiments, the mixture can flow from injection unit 110 into mold cavity 103 through these discharge pipes 111a, 111b, and 111c and first gate 105a, second gate 105b, and third gate 105c. In some embodiments, each discharge pipe corresponds to an individual gate. For example, these discharge pipes 111a, 111b, and 111c correspond to first gate 105a, second gate 105b, and third gate 105c, respectively. In some embodiments, a partition 104 is provided in mold cavity 103.

[0092] In some embodiments, the flow rate of the mixture exiting each of the discharge pipes 111a, 111b, and 111c is individually adjustable. In some embodiments, the amount of the mixture exiting each of the discharge pipes 111a, 111b, and 111c is individually adjustable. In some embodiments, the flow rate or amount of the mixture exiting each of the discharge pipes 111a, 111b, and 111c is controlled by a central processing unit (not shown).

[0093] In some embodiments, the flow rate / volume of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c can be synchronized with each other. For example, the flow rate / volume of the mixture flowing out of discharge pipe 111a is set or determined (manually or automatically), and then the flow rate / volume of the mixture flowing out of each of the remaining portions of the discharge pipes 111b and 111c is automatically set to be the same as the flow rate / volume of the mixture flowing out of discharge pipe 111a. As a result, the flow rate / volume of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c is synchronized. In some embodiments, such synchronization is performed automatically by the central processing unit.

[0094] In some embodiments, the flow rate / volume of the mixture flowing out of one of the discharge pipes 111a is (manually or automatically) set to a predetermined rate / volume, and then the flow rate / volume of the mixture flowing out of each of the remaining portions of the discharge pipes 111b and 111c is adjusted (to be the same or different) based on this predetermined rate / volume. As a result, the flow rate / volume of the mixture flowing out of each of the discharge pipes 111a, 111b, and 111c is correlated with each other. In some embodiments, such adjustments are performed automatically and instantaneously by the central processing unit. For example, if the flow rate / volume of the mixture flowing out of one of the discharge pipes 111a is changed (manually or automatically), then the flow rate / volume of the mixture flowing out of each of the remaining portions of the discharge pipes 111b and 111c is also changed instantaneously.

[0095] In some embodiments, the mixture flowing from each of the discharge pipes 111a, 111b, and 111c is made of the same or different materials. In some embodiments, the mixture flowing from each of the discharge pipes 111a, 111b, and 111c is made of the same or different physical properties (e.g., density, hardness, etc.). In some embodiments, the discharge pipes 111a, 111b, and 111c are as follows: Figure 41 The same mixture M' is shown flowing out into mold cavity 103.

[0096] In some specific embodiments, the discharge pipes 111a, 111b, and 111c are as follows: Figure 42 The diagram shows different first mixtures M1', second mixtures M2', and third mixtures M3' flowing into mold cavity 103 at the same flow rate / volume, such as operations S220, S240, and S260 being performed simultaneously. In some specific embodiments, the flow rate / volume of the first mixture M1' flowing out from discharge pipe 111a is set, and the flow rates / volumes of the second mixtures M2' and third mixtures M3' flowing out from the discharge pipes 111b and 111c are set by the central processing unit to be the same as the flow rate / volume of the first mixture M1' flowing out from discharge pipe 111a.

[0097] In some specific embodiments, the discharge pipes 111a, 111b, and 111c are as follows: Figure 43The diagram shows that a first mixture M1', a second mixture M2', and a third mixture M3' flow into the mold cavity 103 in different amounts. For example, the flow rate / amount of the first mixture M1' flowing out from the discharge pipe 111a is set, and the flow rates / amounts of the second mixture M2' and the third mixture M3' flowing out from the discharge pipes 111b and 111c, respectively, are set by the central processing unit based on the flow rate / amount of the first mixture M1' flowing out from the discharge pipe 111a. Furthermore, if the flow rate / amount of the second mixture M2' is greater than the flow rates / amounts of the first mixture M1' and the third mixture M3', then the second component M2 has a wider width in the X direction than the first component M1 and the third component M3.

[0098] Similar to the seventh embodiment, in these first to sixth embodiments, the flow rates / amounts of the first mixture M1', the second mixture M2', and the third mixture M3' are controllable by the central processing unit so that the flow rates / amounts of the first mixture M1', the second mixture M2', and the third mixture M3' are the same or different.

[0099] Figure 44 and Figure 45 This is the eighth specific embodiment showing the content disclosed in this invention. Figure 2 A schematic cross-sectional view of an exemplary stage in the injection molding method 20. In this eighth embodiment, these operations of the injection unit 110 are shown.

[0100] exist Figure 44 In this embodiment, the injection unit 110 is configured to discharge the mixture. The mixture is discharged through one or more discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f of the injection unit 110, which is coupled to the molding apparatus 100. The mixture can flow from the injection unit 110 into the molding apparatus 100. In some specific embodiments, the mixture can flow from the injection unit 110 into the mold cavity 103 through the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f, and through the first gate 105a, second gate 105b, third gate 105c, fourth gate 105d, gate 105e, and gate 105f, respectively.

[0101] The molding apparatus 100 includes a mold cavity 103 defined by a first mold 101 and a second mold 102. In some embodiments, the mold cavity 103 includes a first sub-cavity 103a and a second sub-cavity 103b, which is separate from the first sub-cavity 103a. The first sub-cavity 103a is not in communication with the second sub-cavity 103b. In some embodiments, the volume of the first sub-cavity 103a is substantially the same as the volume of the second sub-cavity 103b. In some embodiments, the first sub-cavity 103a is in communication with a first gate 105a, a second gate 105b, and a third gate 105c, while the second sub-cavity 103b is in communication with a fourth gate 105d, a gate 105e, and a gate 105f. However, it is not intended to limit the number of gates corresponding to a sub-cavity.

[0102] In some embodiments, if one of the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f is set or adjusted, the remaining portions of the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f are also adjusted accordingly. In some embodiments, this adjustment of the remaining portions of the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f is performed immediately after one of the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f is set / adjusted. In some embodiments, such subsequent adjustments are performed automatically and immediately by a central processing unit (not shown).

[0103] For example, a parameter associated with discharge pipe 111a (such as flow rate, amount of mixture, ejection force supplied to the mixture for discharge, or the like) is set to a first value, and then a parameter associated with another discharge pipe 111d is adjusted based on that first value. In some specific embodiments, the parameter associated with discharge pipe 111a is related to the parameter associated with another discharge pipe 111d at a first ratio, so the parameter associated with the other discharge pipe 111d can be derived based on the first ratio and is therefore adjustable to the derived result. For example, if the first ratio is 1, then the parameter associated with discharge pipe 111d will be adjusted to be the same as the parameter associated with discharge pipe 111a.

[0104] In some embodiments, if the parameter associated with discharge pipe 111a is adjusted, then the parameters of discharge pipes 111b and 111c are adjusted accordingly. In some embodiments, the parameter associated with discharge pipe 111a is associated with the parameter of discharge pipe 111b at a second ratio. For example, when the parameter associated with discharge pipe 111a is set to the first value, then the parameter of discharge pipe 111b is adjusted according to the first value and the second ratio. In some embodiments, the parameter associated with discharge pipe 111a is associated with the parameter associated with discharge pipe 111c at a third ratio. For example, when the parameter associated with discharge pipe 111a is set to the first value, then the parameter of discharge pipe 111c is adjusted according to the first value and the third ratio. Alternatively, in some embodiments, the parameter associated with discharge pipe 111b is associated with the parameter associated with discharge pipe 111c at a fourth ratio. Thus, after obtaining the parameter associated with discharge pipe 111b, the parameter is associated with discharge pipe 111c according to the fourth ratio.

[0105] Similarly, in some embodiments, if the parameter associated with discharge pipe 111d is adjusted, then the parameters of discharge pipes 111e and 111f are adjusted accordingly. In some embodiments, the parameter associated with discharge pipe 111d is associated with the parameter associated with discharge pipe 111e at a fifth ratio. For example, when the parameter associated with discharge pipe 111d is set to a second value, then the parameter of discharge pipe 111e is adjusted according to the second value and the fifth ratio. In some embodiments, the parameter associated with discharge pipe 111d is associated with the parameter of discharge pipe 111f at a sixth ratio. For example, when the parameter associated with discharge pipe 111d is set to the second value, then the parameter of discharge pipe 111f is adjusted according to the second value and the sixth ratio. Alternatively, in some embodiments, the parameter associated with discharge pipe 111e is associated with the parameter associated with discharge pipe 111f at a seventh ratio. Thus, after obtaining the parameter associated with discharge pipe 111e, the parameter associated with discharge pipe 111f is adjusted according to the seventh ratio.

[0106] In some specific embodiments, the mixture M' is then discharged from the discharge pipes 111a, 111b, 111c, 111d, 111e, and 111f, and as... Figure 45The mixture shown enters the first sub-cavity 103a and the second sub-cavity 103b respectively through the first gate 105a, the second gate 105b, the third gate 105c, the fourth gate 105d, the gate 105e, and the gate 105f. The mixture is discharged according to the adjustment results described above. In some embodiments, after the mixture M' is ejected, it undergoes physical foaming in the first sub-cavity 103a and the second sub-cavity 103b to become component M. In some embodiments, these components M have substantially the same size, weight, density, etc.

[0107] According to the specific embodiments disclosed herein, this injection molding method is used to form articles with multiple hardnesses / densities. By removing the partitions 104 and / or controlling the flow rates of the mixtures, the mixtures with different physical properties are injected into the mold cavity 103 to form the article 107, thereby reducing the manufacturing time of the article, which includes more than one part with different physical or functional properties.

[0108] The foregoing outlines the features of several specific embodiments to enable those skilled in the art to better understand the features disclosed herein. Those skilled in the art should understand that they may readily use the disclosure herein as a basis for designing or modifying other programs and structures in order to perform the same purposes and / or achieve the same advantages of the specific embodiments described herein. Those skilled in the art should also recognize that such equivalent constructions do not depart from the spirit and scope of the disclosure herein, and that various changes, substitutions, and modifications may be made therein without departing from the spirit and scope of the disclosure.

[0109] Furthermore, the scope of this invention is not intended to be limited to the specific embodiments of the procedures, machines, manufactures, compositions of matter, means, methods, and steps described in this specification. As will be readily apparent from the disclosure of this invention, existing or soon-to-be-developed procedures, machines, manufactures, compositions of matter, means, methods, or steps that substantially perform the same functions or achieve substantially the same results as the corresponding embodiments described herein may be utilized based on the disclosure of this invention. Accordingly, the appended claims are intended to encompass such procedures, machines, manufactures, compositions of matter, means, methods, and steps within their scope.

[0110] Explanation of symbols

[0111] 10: Injection Molding System

[0112] 20: Injection Molding Method

[0113] 100: Molding device

[0114] 101: First Mold

[0115] 102, 102a: Second mold

[0116] 102b: Third mold

[0117] 103: Mold cavity

[0118] 103a: First subcavity

[0119] 103b: Second subcavity

[0120] 103c: Third subcavity

[0121] 103d: Fourth mold cavity

[0122] 104: Partition

[0123] 104a: First partition

[0124] 104b: Second partition

[0125] 105, 105e, 105f: Gate

[0126] 105a: First gate

[0127] 105b: Second gate

[0128] 105c: Third gate

[0129] 105d: Fourth gate

[0130] 106a: First surface layer

[0131] 106b: Second surface layer

[0132] 106c: Third surface layer

[0133] 106d: Fifth Surface Layer

[0134] 107: Products

[0135] 108a: First visible boundary line

[0136] 108b: Second visible boundary line

[0137] 110: Injection Unit

[0138] 111, 111a, 111b, 111c, 111d, 111e, 111f: Discharge pipes

[0139] 120: Hybrid Unit

[0140] 122: Delivery pipeline

[0141] M: Component

[0142] M': Mixture

[0143] M1: First Component

[0144] M1': First mixture

[0145] M2: Second Component

[0146] M2': Second mixture

[0147] M3: Third Component

[0148] M3': Third mixture

[0149] M4: Fourth Component

[0150] M4': Fourth mixture

[0151] S210, S220, S230, S240, S250, S260, S270: Operation.

Claims

1. An assembly of polymer components, characterized in that, include: A first polymer component having a first surface layer; as well as A second polymer component having a second surface layer in contact with the first surface layer. The density of the first surface layer is greater than that of the central portion of the first polymer component, and the density of the second surface layer is greater than that of the central portion of the second polymer component, and a visible boundary line exists between the first surface layer and the second surface layer.

2. The polymer component assembly according to claim 1, characterized in that, The visible boundary line extends on the top surfaces of the first polymer assembly and the second polymer assembly.

3. The polymer component assembly according to claim 1, characterized in that, The visible boundary line extends from the top surface of the first polymer component and the second polymer component to the bottom surface of the first polymer component and the second polymer component.

4. The polymer component assembly according to claim 1, characterized in that, The top surfaces of the first polymer component and the second polymer component are formed on the same or different layers.

5. The polymer component assembly according to claim 4, characterized in that, The top surface of the first polymer component is lower than the top surface of the second polymer component, and from a top view of the assembly, the second polymer component overlaps the top surface of the first polymer component.

6. The polymer component assembly according to claim 1, characterized in that, From a top view of the assembly, the visible boundary line can be a straight line, a curve, an arc, or a broken line.

7. The polymer component assembly according to claim 1, characterized in that, further include: A third polymer component having a third surface layer, The third surface layer is in contact with a fourth surface layer of the second polymer component.

8. The polymer component assembly according to claim 7, characterized in that, The first polymer component is separated from the third polymer component by the second polymer component, and the first polymer component, the second polymer component, and the third polymer component have the same or different thicknesses.

9. The polymer component assembly according to claim 7, characterized in that, further include: A fourth polymer component having a fifth surface layer, The fifth surface layer is in contact with the bottom surfaces of the first polymer component, the second polymer component, and the third polymer component, and a first side surface of the first polymer component and a second side surface of the third polymer component are in contact with the fifth surface layer.

10. The polymer component assembly according to claim 1, characterized in that, The first surface layer and the second surface layer have a thickness of less than 0.5 mm.

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