Forming device and foaming component

Abstract

The utility model discloses a forming device and a foaming component. The forming device comprises: a mold having a mold cavity; the feeding hole extends into the mold cavity; the channel is connected to the feeding hole and can be communicated with the die cavity; and an opening coupled to the channel and communicable with the mold cavity wherein the feed port is disposed above the mold cavity and the opening is disposed at a side of the mold cavity.

Description

TECHNICAL FIELD

[0001] The present utility model relates to a molding device and a foamed member, in particular to a molding device and a foamed member made by the molding device. BACKGROUND

[0002] Foamed polymer products have many advantages, such as high strength, light weight, impact resistance, good sound and heat insulation, etc. The foamed polymer products can be made into molded products with predetermined shapes by injection molding or extrusion molding. For example, after the polymer material is melted and mixed with a foaming agent to form a mixture by an injection molding machine, the molten polymer is applied by applying pressure so as to be injected or extruded into a mold cavity of a mold to form the desired foamed polymer product. The properties and applications of the foamed polymer product can be changed by changing the composition of the mixture and adjusting the molding method.

[0003] Generally, the appearance and physical properties of the foamed polymer product are directly affected by the molding process, therefore, the design of the mold must consider the flowability of the mixture so that during the forming process, the mixture can be uniformly, quickly and evenly distributed in the mold cavity, and the distribution density of the bubble holes in the mixture is high and uniform, thereby maintaining the original physical properties. Although the foamed polymer product formed using the mold has many advantages and applications, its disadvantages are still the unbroken limits and restrictions. SUMMARY

[0004] An object of the present utility model is to provide a molding device and a foamed member.

[0005] According to one embodiment of the present utility model, a molding device is disclosed. The molding device includes a mold having a mold cavity, a feed inlet extending into the mold, a channel connected to the feed inlet and being in communication with the mold cavity, and an opening connected to the channel and being in communication with the mold cavity, wherein the feed inlet is disposed above the mold cavity and the opening is disposed on a side of the mold cavity.

[0006] According to one embodiment of the present utility model, a foamed member is disclosed. The foamed member is made by the molding device, and the foamed member includes a body portion having a top surface, a bottom surface opposite to the top surface, and a sidewall between the top surface and the bottom surface, and a finishing mark disposed at the sidewall of the body portion, wherein the finishing mark is visually different from the rest of the body portion. BRIEF DESCRIPTION OF DRAWINGS

[0007] The present inventive concept is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is noted that the various components were not necessarily drawn to scale. In fact, the dimensions of some of the components can have been arbitrarily increased or decreased for the sake of clarity. It is intended that every module and every full size component illustrated is at least implied. But it is intended that forms of the present inventive concept that are totally implied are equally within the scope of the present inventive concept.

[0008] Figure 1 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0009] Figure 2 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0010] Figure 3 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0011] Figure 4 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0012] Figure 5 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0013] Figure 6 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0014] Figure 7 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0015] Figure 8 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept; Figure 7 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0016] Figure 9 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept; Figure 7 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0017] Figure 10 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept; Figure 7 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0018] Figure 11 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept; Figure 8 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0019] Figure 12 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept; Figure 7 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0020] Figure 13 Fig. 1 is a schematic view of a molding device according to one embodiment of the present inventive concept;

[0021] Figure 14 Fig. 1 is a schematic cross-sectional view of a forming device in a closed configuration according to an embodiment of the present application; Figure 13 Fig. 2 is a schematic cross-sectional view of the forming device in the closed configuration according to the embodiment of Fig. 1 ;

[0022] Figure 15 Fig. 3 is a schematic cross-sectional view of the forming device in an open configuration according to the embodiment of Fig. 1 ; Figure 13 Fig. 4 is a schematic cross-sectional view of the forming device in the open configuration according to the embodiment of Fig. 1 ;

[0023] Figure 16 Fig. 5 is a schematic top view of the forming device according to the embodiment of Fig. 1 ; Figure 13

[0024] Figure 17 Fig. 6 is a schematic cross-sectional view of the forming device along the line AA' according to the embodiment of Fig. 1 ; Figure 14

[0025] Fig. 7 is a schematic cross-sectional view of the forming device in the open configuration according to the embodiment of Fig. 1 ; Figure 18 Figure 13 Fig. 8 is a schematic cross-sectional view of the forming device in the open configuration according to the embodiment of Fig. 1 ;

[0026] Figure 19 Fig. 9 is a schematic view of a forming device in a closed configuration according to a further embodiment of the present application;

[0027] Figure 20 Fig. 10 is a schematic cross-sectional view of the forming device in the closed configuration according to the embodiment of Fig. 9; Figure 19

[0028] Fig. 11 is a schematic cross-sectional view of the forming device in an open configuration according to the embodiment of Fig. 9; Figure 21 Figure 19 Fig. 12 is a schematic top view of the forming device according to the embodiment of Fig. 9;

[0029] Figure 22 Figure 20 Fig. 13 is a schematic cross-sectional view of the forming device along the line AA' according to the embodiment of Fig. 9;

[0030] Figure 23 Fig. 14 is a schematic cross-sectional view of the forming device in the open configuration according to the embodiment of Fig. 9; Figure 13

[0031] Fig. 15 is a schematic view of a forming device in a closed configuration according to a further embodiment of the present application; Figure 24

[0032] Fig. 16 is a schematic cross-sectional view of the forming device in the closed configuration according to the embodiment of Fig. 15; Figure 25 Figure 24 Fig. 17 is a schematic cross-sectional view of the forming device in an open configuration according to the embodiment of Fig. 15;

[0033] Figure 26 Figure 24 Fig. 18 is a schematic cross-sectional view of the forming device in the open configuration according to the embodiment of Fig. 15;

[0034] Figure 27 Fig. 19 is a schematic top view of the forming device according to the embodiment of Fig. 15; Figure 24

[0035] Figure 28 ​​​​​​​Fig. 1 is a schematic view of a forming device according to a specific embodiment of the present application in an open configuration; Figure 25 Fig. 2 is a schematic cross-sectional view of the forming device along the line AA' in Fig. 1 ;

[0036] Figure 29 Fig. 3 is a schematic view of the forming device according to a specific embodiment of the present application in a closed configuration; Figure 24 Fig. 4 is a schematic cross-sectional view of the forming device in the closed configuration;

[0037] Figure 30 Fig. 5 is a schematic view of the forming device according to a specific embodiment of the present application in an open configuration; Fig. 6 is a schematic cross-sectional view of the forming device along the line AA' in Fig. 5;

[0038] Figure 31 Fig. 7 is a schematic view of the forming device according to a specific embodiment of the present application in a closed configuration; Figure 30 Fig. 8 is a schematic cross-sectional view of the forming device in the closed configuration;

[0039] Figure 32 Fig. 9 is a schematic view of the forming device according to a specific embodiment of the present application in an open configuration; Figure 30 Fig. 10 is a schematic cross-sectional view of the forming device in the open configuration;

[0040] Figure 33 Fig. 11 is a schematic top view of the forming device; Figure 30 Fig. 12 is a schematic cross-sectional view of the forming device along the line AA' in Fig. 11 ;

[0041] Figure 34 Fig. 13 is a schematic view of the forming device according to a specific embodiment of the present application in an open configuration; Figure 31 Fig. 14 is a schematic cross-sectional view of the forming device along the line AA' in Fig. 13;

[0042] Figure 35 Fig. 15 is a schematic view of the forming device according to a specific embodiment of the present application in a closed configuration; Figure 30 Fig. 16 is a schematic cross-sectional view of the forming device in the closed configuration;

[0043] Figure 36 Fig. 17 is a flow chart illustrating a forming method according to a specific embodiment of the present application;

[0044] Figures 37-41 Fig. 18 is a schematic cross-sectional view of a forming method demonstration phase; Figure 43 Figure 36 Fig. 19 is a schematic cross-sectional view of a forming method demonstration phase;

[0045] Figure 42 Fig. 20 is a schematic isometric view of a foamed member manufactured by the forming method; Figures 44-51 Figure 36 Fig. 21 is a schematic isometric view of a foamed member manufactured by the forming method;

[0046] Figures 52-55 Fig. 22 is a schematic cross-sectional view of a forming method demonstration phase; Figure 36

[0047] Fig. 23 is a schematic cross-sectional view of a forming method demonstration phase; Figures 56-58 Figure 36 Fig. 24 is a schematic isometric view of a foamed member manufactured by the forming method;

[0048] Figures 59-62 ​​To illustrate one specific embodiment according to the present application Figure 30 schematic cross-sectional view of a forming method demonstration phase.

[0049] Figures 63-65 To illustrate one specific embodiment according to the present application Figure 36 schematic isometric view of a foamed member manufactured by the forming method. DETAILED DESCRIPTION

[0050] [CROSS-REFERENCE TO RELATED APPLICATIONS]

[0051] This application claims the benefit of U.S. Patent Application No. 18 / 748,126, filed June 20, 2024, which is incorporated herein by reference in its entirety.

[0052] The following description provides many different specific details about the many different possible implementations of the provided subject matter. However, it will be apparent to one of ordinary skill in the art that the provided subject matter can be practiced without these specific details. In some instances, well-known structures and components are not described in detail or are presented in simple block diagram form in order to avoid obscuring the present application. For example, the following description can form a first feature on or over a second feature in the following description. This can include embodiments in which the first and second features are in direct contact, and can also include embodiments in which additional features can be formed between the first and second features such that the first and second features are not in direct contact. Furthermore, the present application can refer to a number of unit operations and / or methods in various examples. This is by no means a limitation. The present application contemplates methods that can include, consist essentially of, or consist of, any of the described unit operations, alone or in combination with addition operations. In addition, the present application can refer to reference numerals and / or letters which can be repeated in various examples. Such repetition is for the sake of simplicity and clarity and does not itself convey a relationship between the various embodiments and / or configurations discussed.

[0053] Moreover, spatially relative terms, such as "beneath", "below", "lower", "above", "upper", and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The devices can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0054] While the numerical ranges and parameters setting forth the broad scope of the present application are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a value or range. Alternatively, the term "about" when used in connection with a quantity is intended to modify that quantity by an acceptable margin of error, when viewed in the light of the number of reported significant figures and by employing ordinary rounding techniques. Unless otherwise clear from context, all numerical ranges, amounts, values and percentages, such as amounts of materials, durations, temperatures, operational conditions, proportions, etc., set forth in this document are to be interpreted as approximations based on the teaching of the specification to the uncertainties inherent in any measurements actually made or reasonably expected to be made by the skilled artisan. Accordingly, unless indicated otherwise, the numerical parameters set forth in the present new application and attached claims are approximations that can vary depending upon the requirements of the new application and the specific embodiments thereof. At the very least, each numerical parameter should at least be construed in light of the number of significant figures and by applying ordinary rounding techniques. In this document, the terms "range" or "range of" are used interchangeably with "between," unless otherwise clear from context. All ranges disclosed herein are inclusive of the endpoints.

[0055] Figure 1 FIG. 1 is a schematic view of a first molding device 100 according to one embodiment of the present application. The molding device 100 includes a mold 10 and a pressure regulating system 20. The mold 10 has a mold cavity 13, a feed port 14 in communication with the mold cavity 13, and an inner sidewall 16 defining the mold cavity 13. In some embodiments, the mold 10 has a junction 15 connected to the mold cavity 13. In some embodiments, the inner sidewall 16 of the mold cavity 13 has the junction 15. The mold cavity 13 is configured to receive a material and allow the material to be formed into a molded article having a predetermined shape by molding. In some embodiments, the feed port 14 is coupled to an injection molding machine or an extrusion molding machine such that the material can be injected / extruded from the injection molding machine or the extrusion molding machine into the mold cavity 13 and formed into the predetermined shape therein. In some embodiments, the junction 15 is configured to allow fluid or gas to enter or exit the mold cavity 13.

[0056] The pressure regulating system 20 includes a first gas conduit 21, a second gas conduit 22, a gas source 23, a first valve 24, a second valve 25, and a pressure sensing unit 26. One end of the first gas conduit 21 is coupled to the junction 15 and the other end is coupled to the gas source 23. In some embodiments, the gas source 23 is configured to supply a fluid or a gas, wherein a suitable fluid or gas can be supplied as desired; for example, the fluid or gas can be air, inert gas, etc., but the present application is not limited thereto.

[0057] In some embodiments, the mold 10 includes a first mold half 11 and a second mold half 12, wherein the second mold half 12 cooperates with the first mold half 11 and defines a mold cavity 13 between the first mold half 11 and the second mold half 12. In some embodiments, the feed port 14 is disposed at the first mold half 11. In some embodiments, the junction 15 is disposed at the second mold half 12.

[0058] The location, shape, and number of the junctions 15 are not particularly limited and can be adjusted as desired. In some embodiments, the junction 15 is a hole. In some embodiments, the junction 15 is disposed at the inner side wall 16 or the inner bottom wall 17 of the second mold half 12 and penetrates the second mold half 12. In some embodiments, the junction 15 is configured to be an inlet and an outlet, wherein the junction 15 is configured to be an inlet when the first valve 24 is open and the second valve 25 is closed and the junction 15 is configured to be an outlet when the first valve 24 is closed and the second valve 25 is open. In some embodiments, the junction 15 is not configured to be an inlet and an outlet at the same time. In some embodiments, the junction 15 is configured to supply and exhaust a gas, wherein the junction 15 is configured to supply a fluid or a gas into the mold cavity 13 when the first valve 24 is open and the second valve 25 is closed and the junction 15 is configured to exhaust at least a portion of the fluid or the gas from the mold cavity 13 when the first valve 24 is closed and the second valve 25 is open.

[0059] The location, shape, and number of the feed port 14 are not particularly limited and can be adjusted as desired. In some embodiments, the feed port 14 is disposed at the inner top wall 111 or the inner side wall 16 of the first mold half 11 and penetrates the first mold half 11. In some embodiments, the feed port 14 and the junction 15 are oppositely disposed with respect to the mold cavity 13; by way of example but not limited thereto, the feed port 14 is disposed at the inner top wall 111 of the first mold half 11 and the junction 15 is disposed at the inner bottom wall 17 of the second mold half 12. In some embodiments, the feed port 14 is disposed at the inner top wall 111 of the first mold half 11 and the junction 15 is disposed at the inner side wall 16 of the second mold half 12. In some embodiments, the feed port 14 is disposed at the inner side wall of the first mold half 11 and the junction 15 is disposed at the inner side wall 16 of the second mold half 12 and is located at the other side opposite to the feed port 14. In some embodiments, the feed port 14 is distal to the junction 15.

[0060] The first valve 24 is disposed at the first gas conduit 21 and is configured to control whether a gas from the gas source 23 enters the mold cavity 13 through the first gas conduit 21 and the junction 15. The second gas conduit 22 is connected to the junction 15. The second valve 25 is disposed at the second gas conduit 22 and is configured to control whether a gas from the mold cavity 13 is exhausted through the second gas conduit 22 via the junction 15.

[0061] In some embodiments, one end of the second gas conduit 22 is connected to the first gas conduit 21 and to the junction 15 through the first gas conduit 21. In some embodiments, the other end of the second gas conduit 22 is in communication with a space having a pressure less than the pressure in the mold cavity; for example, the external environment or a negative pressure space; however, the present application is not limited thereto. The location at which the second gas conduit 22 is connected to the first gas conduit 21 is not particularly limited; for example, the two can be connected at an end adjacent to the end of the first gas conduit 21 that is connected to the junction 15. In some embodiments, the first valve 24 is disposed between the gas source 23 and the second gas conduit 22. In this way, when it is desired to vent the mold cavity 13, the first valve 24 is closed and the second valve 25 is opened, such that gas enters the second gas conduit 22 from the junction 15. When it is desired to fill the mold cavity 13 with gas, the second valve 25 is closed and the first valve 24 is opened, such that gas enters the first gas conduit 21 from the gas source 23 and then enters the mold cavity 13 through the junction 15. In some embodiments, the first valve 24 and the second valve 25 are not opened at the same time.

[0062] The pressure sensing unit 26 is configured to sense the pressure in the mold cavity 13. In some embodiments, the properties of the foamed polymer are affected by the pore size and distribution of the polymer, which are related to temperature, pressure, and feed rate. The pressure sensing unit 26 is not limited to any particular type, as long as it can sense pressure and provide pressure information after sensing the pressure in the mold cavity 13. The pressure regulating system 20 changes the conditions under which gas exits / enters the mold cavity 13 based on the pressure information, thereby adjusting the pressure in the mold cavity 31, and thus the mold foamed article obtained thereby has a desired predetermined shape and properties.

[0063] In some embodiments, the pressure sensing unit 26 is disposed within the mold cavity 13. In some embodiments, the pressure sensing unit 26 is disposed at the inner side wall 16, the first gas conduit 21, or the second gas conduit 22. In some embodiments, the pressure sensing unit 26 is disposed at the inner side wall 16 of the mold cavity 13 and is distanced from the feed port 14. In some embodiments, the pressure regulating system 20 has a plurality of pressure sensing units 26, and the number and location of the pressure sensing units 26 are not particularly limited; for example, they can be arranged at the inner side wall 16 of the mold cavity 13 and spaced apart from each other, and / or at any location in the first gas conduit 21, and / or at any location in the second gas conduit 22; however, the present application is not limited thereto.

[0064] In some embodiments, the molding device 100 further comprises a control system 30. The control system 30 is configured to control the pressure of the pressure regulating system 20 and the mold cavity 13. In some embodiments, the pressure sensing unit 26 provides pressure information to the control system 30, and the control system 30 adjusts the first valve 24 and the second valve 25 according to the pressure information. In some embodiments, the control system 30 adjusts the conditions of the gas entering / leaving the mold cavity 13 according to the pressure information in real time, so that the pressure in the mold cavity 13 is always within a suitable or predetermined pressure range during the mold foaming process. In some embodiments, the control system 30 further controls the feeding conditions of the feeding port 14 and the gas supply conditions of the gas source 23. In some embodiments, the control system 30 is electrically connected to the first valve 24, the second valve 25, the pressure sensing unit 26, and the feeding port 14.

[0065] Figures 2-4 A schematic view of a molding device according to an embodiment of the present application, Figure 5 are provided to illustrate embodiments of different configurations of the junction 15, the first gas conduit 21, and the second gas conduit 22, and how the junction 15 is arranged in correspondence with the first gas conduit 21 and the second gas conduit 22 in various configurations. In some embodiments, Figure 2 The second molding device 200 shown is similar to Figure 1 the first molding device 100. In some embodiments, as shown, Figure 2 the second gas conduit 22 of the second molding device 200 is connected to the middle portion of the first gas conduit 21. In some embodiments, the second gas conduit 22 is connected to the first gas conduit 21 at a position closer to the end of the first gas conduit 21 connected to the gas source.

[0066] In some embodiments, Figure 3 The third molding device 300 shown is similar to Figure 1 the first molding device 100. In some embodiments, as shown, Figure 3As shown, the junction 15 of the third molding device 300 is a hole, which includes a first opening 151 and a second opening 152, wherein the first opening 151 is connected with the first gas conduit 21 and the second opening 152 is in communication with the second gas conduit 22. In some embodiments, the first opening 151 is configured to intake gas and the second opening 152 is configured to exhaust gas. The positions of the first opening 151 and the second opening 152 are not particularly limited as long as they are separated from each other. In some embodiments, the first opening 151 is distanced from the second opening 152. In some embodiments, the first opening 151 and the second opening 152 are oppositely arranged relative to the feed port 14. In some embodiments, both the first opening 151 and the second opening 152 are arranged at the bottom surface 17 of the mold cavity 13. In some embodiments, both the first opening 151 and the second opening 152 are arranged at the inner side wall 16 of the mold cavity 13.

[0067] In some embodiments, Figure 4 The fourth molding device 400 shown inside is similar to Figure 3 the third molding device 300 shown. In some embodiments, as Figure 4 shown, the first opening 151 of the fourth molding device 400 has a plurality of first holes 153 and the second opening 152 has a plurality of second holes 154. In some embodiments, the plurality of first holes 153 are respectively connected with the first gas conduit 21 and the plurality of second holes 154 are respectively connected with the second gas conduit 22. In some embodiments, the number of the second holes 154 is greater than the number of the first holes 153. The positions of the plurality of first holes 153 and the plurality of second holes 154 are not particularly limited; they can be alternately arranged or respectively arranged at different regions inside the mold cavity 13. In some embodiments, the end of the first gas conduit 21 connected with the mold cavity 13 has a plurality of first guide channels 211, wherein each first guide channel 211 is connected with a corresponding first hole 153 and the first gas conduit 21. In some embodiments, the end of the second gas conduit 22 connected with the mold cavity 13 has a plurality of second guide channels 221, wherein each second guide channel 221 is connected with a corresponding second hole 154 and the second gas conduit 22.

[0068] In some embodiments, as Figure 5 shown, the first opening 151 of the fourth molding device 400 is arranged at the middle of the mold cavity and the second opening 152 is arranged at the periphery of the mold cavity. In some embodiments, the plurality of second holes 154 surround the first opening 151. In some embodiments, both the first hole 151 and the plurality of second holes 154 are arranged at the bottom surface 17 of the mold cavity 13. In some embodiments, the diameter of each second hole 154 is smaller than the diameter of the first hole 151.

[0069] Figure 6To illustrate a flowchart of the molding method according to one embodiment of the present application. In some embodiments, as shown in FIG. 6, the molding method 600 includes the following steps. Figure 6

[0070] Step 61 : providing a mold, wherein the mold includes a mold cavity, a feed inlet in communication with the mold cavity, a junction connected to the mold cavity, and an inner sidewall defining the mold cavity.

[0071] Step 62: sensing the pressure in the mold cavity and injecting gas into the mold cavity through the junction until a first predetermined pressure in the mold cavity is sensed.

[0072] Step 63: sensing the pressure in the mold cavity and filling the material into the mold cavity having the first predetermined pressure from the feed inlet.

[0073] Step 64: discharging a portion of the gas in the mold cavity through the junction.

[0074] The molding method is not limited to the above embodiments. In some embodiments, as shown in FIG. 6, the molding method 600 uses any of the molding devices 100, 200, 300, 400 described above. Figures 1-5

[0075] In some embodiments, the molding method 600 includes step 61 : providing a mold 10, wherein the mold 10 includes a mold cavity 13, a feed inlet 14 in communication with the mold cavity, and a junction 15 connected to the mold cavity. In some embodiments, as shown in FIG. 6, the mold 10 is the mold 10 of any of the molding devices 100, 200, 300, 400. Figures 1-5

[0076] In some embodiments, at the beginning of step 62, the pressure sensing unit 26 senses the pressure in the mold cavity 13 to be atmospheric pressure. In some embodiments, in step 62, the first valve 24 has been opened, so that the gas is injected from the gas source 23 into the mold cavity 13 through the first gas conduit 21 and the junction 15. In some embodiments, during the process of injecting the gas into the mold cavity 13, the pressure in the mold cavity 13 is continuously sensed. In some embodiments, when the first valve 24 is opened, the second valve 25 is closed, so that the gas is injected from the first gas conduit 21 into the mold cavity 13. In some embodiments, the pressure sensing unit 26 continuously senses the pressure in the mold cavity and injects the gas into the mold cavity 13 until the mold cavity 13 is sensed to have a first predetermined pressure; then, the first valve 24 is closed and the injection of the gas into the mold cavity 13 is stopped. In some embodiments, the first predetermined pressure is greater than atmospheric pressure. In some embodiments, the first predetermined pressure is less than atmospheric pressure.

[0077] ​​​In some embodiments, the gas is any suitable gas, for example, air, depending on the requirements. However, the present application is not limited thereto.

[0078] In some embodiments, in step 63, the pressure sensing unit 26 continuously senses the pressure in the mold cavity 13 during the process of filling the material into the mold cavity 31. In some embodiments, the material is injected into the mold cavity 13 from the feed port 14, thereby increasing the pressure in the mold cavity 13. In some embodiments, the pressure in the mold cavity 13 is increased from a first predetermined pressure. In some embodiments, the pressure in the mold cavity 13 is increased from the first predetermined pressure to a second predetermined pressure.

[0079] In some embodiments, the material includes a mixture. In some embodiments, the mixture includes a high molecular weight polymer and a blowing agent. In some embodiments, the blowing agent is a physical or chemical additive that releases gas during heating, thereby forming pores. Since the vaporization process of the physical or chemical additive is very strict, and the temperature distribution of the entire foamed polymer product is not uniform, the foamed polymer product thus obtained has a flat shape and has larger pores. However, the molding method of the present application can sense and adjust the pressure in the mold cavity 13 at any time, and the foamed polymer product thus obtained can have a significantly increased thickness, and has pores that are more uniformly and densely distributed. In some embodiments, the blowing agent is a physical additive. In some embodiments, the blowing agent is a supercritical fluid (SCF).

[0080] In some embodiments, the first predetermined pressure and the second predetermined pressure can be adjusted according to the properties of the material. For materials with lower strength, the first predetermined pressure is higher, and for materials with higher strength, the first predetermined pressure is lower. In some embodiments, after the material is filled into the mold cavity 13 with the first predetermined pressure, the pressure in the mold cavity 13 is increased, and therefore, the setting of the second predetermined pressure ensures that the mold cavity 31 is kept within a suitable pressure range. In some embodiments, when the mold cavity 13 reaches the second predetermined pressure, the filling of the material into the mold cavity 13 is stopped.

[0081] In some embodiments, step 64 includes discharging part of the gas in the mold cavity after the gas is injected into the mold cavity 13 and the filling of the material into the mold cavity 13 is completed. In some embodiments, in step 64, the second valve 25 is opened, the first valve 24 is closed, and the gas is allowed to enter the second gas conduit 22, thereby discharging the gas in the mold cavity 13.

[0082] In some embodiments, when the pressure in the mold cavity 13 is sensed to be greater than the second predetermined pressure, a portion of the gas in the mold cavity 13 is vented through the junction 15 until the pressure within the mold cavity 13 is within the predetermined pressure range. In some embodiments, the predetermined pressure range is between the first predetermined pressure and the second predetermined pressure.

[0083] In some embodiments, the process of filling the material from the feed port 14 into the mold cavity 13 having the first predetermined pressure is only for 0.5 to 1 second until the filling of the material is completed, thus the pressure within the mold cavity 13 changes dramatically during the filling. During the filling or at the completion of the filling, the pressure sensing unit 26 senses the pressure within the mold cavity 13 in real time and provides the pressure information, so that the pressure regulating system 20 is able to adjust the state of the gas entering or leaving the mold cavity 13 according to the pressure information, thus is able to maintain the pressure within the mold cavity 31 within the predetermined pressure range between the first predetermined pressure.

[0084] In some embodiments, the method includes using the control system 30 to control the gas injection into the mold cavity 13 and to control the venting of a portion of the gas within the mold cavity 13 according to the pressure within the mold cavity 13 sensed by the pressure sensing unit 26. In some embodiments, the control system 30 receives the pressure information provided by the pressure sensing unit 26 and controls the switching state of the first valve 24 and the second valve 25 and controls the feeding state of the feed port 14 (including but not limited to the feeding time of the feed port 14, the feeding rate, etc.) according to the pressure information.

[0085] In summary, the molding device and the molding method of the present application, by using a molding device including a mold and a pressure regulating system connected to the mold, wherein the pressure regulating system includes a pressure sensing unit arranged to sense the pressure within the mold cavity, allowing the mold cavity to have a first predetermined pressure before feeding, and allowing the pressure within the mold cavity to be adjusted in real time according to the feeding condition and the sensing result of the pressure sensing unit when the molding method of the present application is operated, so that the mold formed product manufactured thereby has a satisfactory appearance and quality.

[0086] Figure 7 Fig. 5 is a schematic side view of a molding device 500 according to one embodiment of the present application, Figure 8 Fig. 6 is a schematic cross-sectional view of the molding device 500 in a closed configuration, and Figure 9 Fig. 7 is a schematic cross-sectional view of the molding device in an open configuration. The molding device 500 includes a mold having a first mold 501 and a second mold 502 disposed above the first mold 501. The first mold 501 is engageable with the second mold 502. When the molding device 500 is in the closed configuration, the first mold 501 is engaged with the second mold 502, as shown in Figure 7 and Figure 8The first mold 501 and the second mold 502 are shown in a closed configuration. In some embodiments, the first mold 501 is a lower mold and the second mold 502 is an upper mold.

[0087] The mold cavity 503 is defined by the first mold 501 and the second mold 502. The mold cavity 503 is formed when the molding apparatus 500 is in the closed configuration. The mold cavity 503 is configured to receive and hold a mixture that can flow into the mold cavity 503. In some embodiments, the mixture includes a polymeric material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and a blowing agent (e.g., a physical blowing agent such as carbon dioxide, nitrogen, supercritical fluid, etc.) that can be injected into the mold cavity 503. The mixture can undergo a foaming process within the mold cavity 503. The mixture within the mold cavity 503 becomes a foamed article after the foaming process.

[0088] The molding apparatus 500 includes a feed port 504 disposed at the first mold 501 or the second mold 502. The feed port 504 is configured to receive an exit channel of an injection unit or an injector. In some embodiments, the exit channel of the injection unit can engage with the feed port 504. In some embodiments, when the exit channel of the injection unit engages with the feed port 504, a mixture including a polymeric material and a blowing agent can be injected into the mold cavity 503. The mixture can flow from the injection unit into the mold cavity 503 through the feed port 504. In some embodiments, the feed port 504 is disposed at a top surface of the first mold 501 or a top surface 502a of the second mold 502. In some embodiments, the feed port 504 extends vertically into the first mold 501 or the second mold 502.

[0089] The molding apparatus 500 includes a channel 505 disposed at the first mold 501 or the second mold 502. The channel 505 is configured to allow a mixture including a polymeric material and a blowing agent to flow through. The channel 505 connects the feed port 504 to the mold cavity 503. The channel 505 can be in communication with the feed port 504 and the mold cavity 503. In some embodiments, the channel 505 includes multiple portions 505a, 505b that extend within the first mold 501 or the second mold 502.

[0090] Figure 10 shows a top view, and Figure 7 shows a top view, and Figure 11 shows a top view, and Figure 8A cross-sectional view of the AA' line. In some embodiments, the channel 505 comprises a first portion 505a and a second portion 505b connected to the first portion 505a. The mixture can flow from the injection unit through the discharge channel of the injection unit, the feed port 504, the first portion 505a, and the second portion 505b into the mold cavity 503. In some embodiments, one end of the first portion 505a is connected to the feed port 504 and the other end of the first portion 505a is connected to the second portion 505b. In some embodiments, the mixture can flow obliquely along the first portion 505a. In some embodiments, the first portion 505a is not parallel to the feed port 504, i.e., there is an angle a between the first portion 505a and the feed port 504. In some embodiments, the angle a is greater than 90° but less than 180°. In some embodiments, one end of the second portion 505b is connected to the first portion 505a and the other end of the second portion 505b is connected to the mold cavity 503.

[0091] In some embodiments, the second portion 505b extends substantially perpendicular to the feed port 504. In some embodiments, the second portion 505b extends substantially parallel to the top surface 502a. In some embodiments, there is an angle b between the first portion 505a and the second portion 505b. In some embodiments, the angle b is less than 90°. In some embodiments, the angle a is substantially greater than the angle b. In some embodiments, the second portion 505b has a tapered configuration that tapers from the mold cavity 503 to the periphery of the first mold 501 or the second mold 502. In some embodiments, the second portion 505b is a flat taper. In some embodiments, the width of the opening 503a along the first mold 501 or the second mold 502 and disposed between the mold cavity 503 and the second portion 505b is substantially greater than the width or diameter of the first portion 505a. In some embodiments, the width of the opening 503a is substantially greater than the width or diameter of the feed port 504. In some embodiments, the opening 503a is disposed at the side of the mold cavity 503. In some embodiments, the opening 503a is disposed at the inner side wall 502f of the second mold 502. In some embodiments, the inner side wall 502f is substantially perpendicular to the top surface 502a of the second mold 502.

[0092] Figure 12 Display Figure 9a cross-sectional view of the first mold 501 and the second mold 502. In some embodiments, the first mold 501 includes a plurality of separable parts, and the second mold 502 also includes a plurality of separable parts. For simplicity and clarity, only the second mold 502 is shown and described as having separable parts, but it should be understood that the first mold 501 can have a similar configuration as the second mold 502. In some embodiments, when the molding apparatus 500 is in the open configuration, the second mold 502 can be separated into several parts, as shown in FIG. 5B. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d. The first part 502b, the second part 502c, and the third part 502d can be separable from one another. In some embodiments, a channel 505 is formed when the first part 502b is engaged with the second part 502c, as shown in FIG. 5C, or when the molding apparatus 500 is in the closed configuration, as shown in FIG. 5D. In some embodiments, a first portion 505a and a second portion 505b of the channel 505 are formed when the first part 502b is engaged with the second part 502c. In some embodiments, the first part 502b and the second part 502c are mold parts of the molding apparatus 500. Figure 9 In some embodiments, the second mold 502 includes a third part 502d. In some embodiments, the feed port 504 is disposed at the third part 502d. In some embodiments, the feed port 504 extends through the third part 502d. In some embodiments, the first part 502b, the second part 502c, and the third part 502d are engaged with one another, as shown in FIG. 5E, or the molding apparatus 500 is in the closed configuration, as shown in FIG. 5F, the feed port 504 is coupled to the channel 505. In some embodiments, the third part 502d is disposed above the first part 502b and the second part 502c. In some embodiments, after the first part 502b, the second part 502c, and the third part 502d are engaged, as shown in FIG. 5E, or the molding apparatus 500 is in the closed configuration, as shown in FIG. 5F, the feed port 504 is coupled to the channel 505. In some embodiments, the first part 502b, the second part 502c, and the third part 502d are engaged with one another, as shown in FIG. 5E, or the molding apparatus 500 is in the closed configuration, as shown in FIG. 5F, the feed port 504 is in communication with the mold cavity 503 through the channel 505. In this way, the mixture can flow from the feed port 504 through the channel 505 into the mold cavity 503. In some embodiments, the feed port 504 can be engaged with a discharge channel of an injection unit, such that the mixture can be injected from the injection unit into the mold cavity 503 through the channel 505. Figure 9 Figure 8

[0093] Figure 9 Figure 8 Figure 9 Figure 9 Figure 8

[0094] ​​​​​​​​Figure 13 This is a schematic side view of a molding apparatus 800 according to a specific embodiment of the present invention. Figure 14 This is a schematic cross-sectional view of the molding apparatus 800 in a closed configuration, and Figure 15 This is a schematic cross-sectional view of the molding device 800 in the open configuration. Figure 16 show Figure 13 A top view, and Figure 17 Display along Figure 14 A cross-sectional view of line AA'. The forming device 800 is similar to the one described above. Figures 7-11 The molding apparatus 500 shown herein. In some embodiments, the molding apparatus 800 includes more than one channel 505. In some embodiments, the molding apparatus 800 includes a first channel 505-1 and a second channel 505-2 similar to the first channel 505-1. In some embodiments, the first channel 505-1 is configured symmetrically to the second channel 505-2.

[0095] In some embodiments, the first channel 505-1 includes a first portion 505a and a second portion 505b, and the second channel 505-2 includes a third portion 505c and a fourth portion 505d. In some embodiments, the first portion 505a is similar to the third portion 505c, and the second portion 505b is similar to the fourth portion 505d. In some embodiments, the feed port 504 is connected to the first channel 505-1 and the second channel 505-2. In some embodiments, the mold cavity 503 is connected to the first channel 505-1 and the second channel 505-2 via a first opening 503a-1 and a second opening 503a-2, respectively. In some embodiments, both the first opening 503a-1 and the second opening 503a-2 are arranged at the inner sidewall 502f of the second mold 502. In some embodiments, the inner sidewall 502f is substantially perpendicular to the top surface 502a of the second mold 502. In some embodiments, the first angle α1 between the feed inlet 504 and the first portion 505a is substantially equal to the second angle α2 between the feed inlet 504 and the third portion 505c. In some embodiments, the third angle β1 between the first portion 505a and the second portion 505b is substantially equal to the fourth angle β2 between the third portion 505c and the fourth portion 505d. In some embodiments, the mixture can flow from the feed inlet 504 through the first portion 505a and the second portion 505b, and / or through the third portion 505c and the fourth portion 505d to the mold cavity 503.

[0096] Figure 18 show Figure 15 An exploded cross-sectional view. In some specific embodiments, when the molding device 800 is in the open configuration, the second mold 502 can be divided into several parts, such as...Figure 15 Or as shown in Figure 18. In some specific embodiments, the second mold 502 includes a first part 502b, a second part 502c, a third part 502d, and a fourth part 502e. The first part 502b, the second part 502c, the third part 502d, and the fourth part 502e are separable from each other. In some specific embodiments, such as Figure 15 When the first part 502b, the second part 502c, and the fourth part 502e shown are joined together, or as... Figure 14 When the molding apparatus 800 is in a closed configuration, a first channel 505-1 and a second channel 505-2 are formed. In some embodiments, when the first part 502b, the second part 502c, and the fourth part 502e are engaged with each other, a first portion 505a and a second portion 505b of the first channel 505-1 and a third portion 505c and a fourth portion 505d of the second channel 505-2 are formed. In some embodiments, the first part 502b, the second part 502c, the third part 502d, and the fourth part 502e are mold parts of the molding apparatus 800.

[0097] Figure 19 This is a schematic side view of a molding apparatus 700 according to a specific embodiment of the present invention. Figure 20 This is a schematic cross-sectional view of the molding device 700 in an open configuration. Figure 21 show Figure 19 A top view, and Figure 22 Display along Figure 20 A cross-sectional view of line AA'. The molding apparatus 700 is similar to the one described above. Figures 7-18 The molding apparatus 500 or 800 shown herein. In some embodiments, the molding apparatus 700 includes more than one channel 505. In some embodiments, the molding apparatus 700 includes a first channel 505-1, a second channel 505-2, a third channel 505-3, and a fourth channel 505-4. In some embodiments, the first channel 505-1 is arranged symmetrically with respect to the second channel 505-2, and the third channel 505-3 is arranged symmetrically with respect to the fourth channel 505-4.

[0098] In some embodiments, the first channel 505-1 includes a first portion 505a and a second portion 505b, the second channel 505-2 includes a third portion 505c and a fourth portion 505d, the third channel 505-3 includes a fifth portion 505e and a sixth portion 505f, and the fourth channel 505-4 includes a seventh portion 505g and an eighth portion 505h. In some embodiments, the first portion 505a, the third portion 505c, and the fifth portion 505e are similar to each other, and the second portion 505b, the fourth portion 505d, and the sixth portion 505f are similar to each other. In some embodiments, the feed port 504 is connected to the first channel 505-1, the second channel 505-2, the third channel 505-3, and the fourth channel 505-4. In some embodiments, the mold cavity 503 is connected to the first channel 505-1, the second channel 505-2, the third channel 505-3, and the fourth channel 505-4 through a first opening 503a-1, a second opening 503a-2, a third opening 503a-3, and a fourth opening 503a-4, respectively. In some embodiments, the first opening 503a-1, the second opening 503a-2, the third opening 503a-3, and the fourth opening 503a-4 are all arranged at the inner sidewall 502f of the second mold 502. In some embodiments, the inner sidewall 502f is substantially perpendicular to the top surface 502a of the second mold 502.

[0099] Figure 23 show Figure 20 An exploded cross-sectional view. In some specific embodiments, when the molding device 700 is in the open configuration, the second mold 502 can be divided into several parts, such as... Figure 20 As shown. In some specific embodiments, the second mold 502 includes a first part 502b, a second part 502c, a third part 502d, a fourth part 502e, and a fifth part 502f. The first part 502b, the second part 502c, the third part 502d, the fourth part 502e, and the fifth part 502f are separable from each other. In some specific embodiments, such as Figure 20 When the first part 502b, the second part 502c, the third part 502d, the fourth part 502e, and the fifth part 502f shown are joined together, or as... Figure 19 When the molding apparatus 800 is in a closed configuration, it forms a first channel 505-1, a second channel 505-2, a third channel 505-3, and a fourth channel 505-4. In some specific embodiments, the first part 502b, the second part 502c, the third part 502d, the fourth part 502e, and the fifth part 502f are mold parts of the molding apparatus 700.

[0100] Figure 24 This is a schematic side view of a molding apparatus 1000 according to a specific embodiment of the present invention.Figure 25 This is a schematic cross-sectional view of the molding apparatus 1000 in a closed configuration, and Figure 26 This is a schematic cross-sectional view of the molding device 1000 in the open configuration. Figure 27 show Figure 24 A top view, and Figure 28 Display along Figure 25 A cross-sectional view of line AA' in the middle. The forming device 1000 is similar to the one described above. Figures 7-23 The molding apparatus shown inside is 500, 700 or 800.

[0101] In some embodiments, channel 505 includes a first portion 505a and a second portion 505b. In some embodiments, the first portion 505a is located at the second mold 502, and the second portion 505b is located at the first mold 501. The second portion 505b is a recess 501a of the first mold 501 and is recessed into the first mold 501. In some embodiments, the mixture can flow from the inlet 504 through the first portion 505a and the second portion 505b to the mold cavity 503.

[0102] Figure 29 show Figure 25 An exploded cross-sectional view. In some specific embodiments, when the molding apparatus 1000 is in the open configuration, the second mold 502 can be divided into several parts, such as... Figure 29 As shown. In some embodiments, the second mold 502 includes a first part 502b and a second part 502c that are separable from each other. In some embodiments, when the first part 502b and the second part 502c are engaged with each other, and as shown... Figure 25 When the forming device 1000 shown is in the closed configuration, channel 505 is formed.

[0103] Figure 30 This is a schematic side view of a molding apparatus 1001 according to a specific embodiment of the present invention. Figure 31 This is a schematic cross-sectional view of the molding apparatus 1001 in a closed configuration, and Figure 32 This is a schematic cross-sectional view of the molding device 1001 in the open configuration. Figure 33 show Figure 30 A top view, and Figure 34 Display along Figure 30 A cross-sectional view of line AA'. The forming apparatus 1001 is similar to the one described above. Figure 7The molding apparatus 500, 700, 800, or 1000 shown in Figure 29. In some embodiments, the molding apparatus 1001 includes one or more inlets 504 and one or more channels 505. In some embodiments, the molding apparatus 1001 includes a first channel 505-1 and a second channel 505-2 similar to the first channel 505-1. In some embodiments, the first channel 505-1 is arranged symmetrically to the second channel 505-2.

[0104] In some embodiments, the first channel 505-1 includes a first portion 505a and a second portion 505b, and the second channel 505-2 includes a third portion 505c and a fourth portion 505d. In some embodiments, the first portion 505a is similar to the third portion 505c, and the second portion 505b is similar to the fourth portion 505d. In some embodiments, the first portion 505a and the third portion 505c are located at the second mold 502, and the second portion 505c and the fourth portion 505d are located at the first mold 501 and recessed into the first mold 501. The second portion 505c and the fourth portion 505d are recesses 501a of the first mold 501. The first portion 505a and the third portion 505c extend within the first mold 501.

[0105] In some embodiments, the third angle β1 between the first portion 505a and the second portion 505b is substantially equal to or substantially different from the fourth angle β2 between the third portion 505c and the fourth portion 505d. In some embodiments, the third angle β1 and the fourth angle β2 are each equal to or less than approximately 90°. In some embodiments, the first portion 505a is substantially perpendicular to the second portion 505b, and the third portion 505c is substantially perpendicular to the fourth portion 505d.

[0106] In some embodiments, the first inlet 504-1 and the second inlet 504-2 are respectively connected to the first channel 505-1 and the second channel 505-2. In some embodiments, the mixture may flow from the first inlet 504-1 to the mold cavity 503 via the first portion 505a and the second portion 505b, and / or from the second inlet 504-2 to the mold cavity 503 via the third portion 505c and the fourth portion 505d.

[0107] Figure 35 show Figure 30 An exploded cross-sectional view. In some specific embodiments, when the molding device 1001 is in the open configuration, the second mold 502 can be divided into several parts, such as... Figure 35The second mold 502 includes a first part 502b, a second part 502c, and a third part 502e. The first part 502b, the second part 502c, and the third part 502e can be separated from each other. In some embodiments, the first part 502b, the second part 502c, and the third part 502e are joined to each other as shown in FIG. 5B. In some embodiments, the first part 502b, the second part 502c, and the third part 502e are joined to each other when the first mold 501 and the second mold 502 are joined to each other. Figure 35 The first channel 505-1 and the second channel 505-2 are formed when the first part 502b, the second part 502c, the third part 502e, and the first mold 501 are joined to each other and the molding device 1001 is in the closed configuration. Figure 36 A flowchart of a molding method 900 according to one embodiment of the present application is shown in FIG. 9. In some embodiments, the molding method 900 includes steps 901-908.

[0108] In some embodiments, the molding method 900 includes a step 901 of providing a molding device 500 and an injection unit 506, as shown in FIG. 10A. In some embodiments, the molding device 500 is similar to the molding device described above or illustrated in any of the figures. In some embodiments, the injection unit 506 is disposed on top of the molding device 500. The molding device 500 is initially in the open configuration, as shown in FIG. 10B. Figure 37 In some embodiments, the injection unit 506 includes an injector 507 for holding and injecting the mixture, and an ejection channel 508 for ejecting the mixture from the injector 507 out of the injection unit 506. In some embodiments, the molding device 500 is similar to the molding device described above or illustrated in any of the figures. In some embodiments, the injection unit 506 is disposed on top of the molding device 500. The molding device 500 is initially in the open configuration, as shown in FIG. 10B. Figures 7-11 In some embodiments, the injection unit 506 includes an injector 507 for holding and injecting the mixture, and an ejection channel 508 for ejecting the mixture from the injector 507 out of the injection unit 506. In some embodiments, the molding device 500 is similar to the molding device described above or illustrated in any of the figures. In some embodiments, the injection unit 506 is disposed on top of the molding device 500. The molding device 500 is initially in the open configuration, as shown in FIG. 10B. Figure 37 In some embodiments, the injection unit 506 includes an injector 507 for holding and injecting the mixture, and an ejection channel 508 for ejecting the mixture from the injector 507 out of the injection unit 506. In some embodiments, the molding device 500 is similar to the molding device described above or illustrated in any of the figures. In some embodiments, the injection unit 506 is disposed on top of the molding device 500. The molding device 500 is initially in the open configuration, as shown in FIG. 10B.

[0109] In some embodiments, the molding method 900 includes a step 902 of joining the ejection channel 508 of the injection unit 506 to the feed port 504 of the molding device 500, and a step 903 of joining the first mold 501 to the second mold 502 of the molding device 500, as shown in FIG. 10C. In some embodiments, step 902 is performed before step 903, and vice versa. In some embodiments, the molding device 500 is in the closed configuration after the first mold 501 and the second mold 502 are joined. In some embodiments, the mold cavity 503 is formed after the first mold 501 and the second mold 502 are joined. The mixture can flow from the injection unit 506 into the mold cavity 503 through the feed port 504 and the channels 505. Figure 38 In some embodiments, the molding method 900 includes a step 904 of injecting the mixture M' into the mold cavity 503, as shown in FIG. 10D.

[0110] Figure 39 ​As shown. The mixture M' is ejected from the ejector 507 into the mold cavity 503 through the discharge channel 505, the inlet 504, and the channel 505. In some embodiments, the mixture M' flows into the mold cavity 503 sequentially from the inlet 504, the first portion 505a, and the second portion 505b of the channel 505. In some embodiments, the mixture M' enters the molding apparatus 500 via the inlet 504 and exits the molding apparatus 500 through the opening 503a communicating with the mold cavity 503. In some embodiments, the opening 503a is arranged at the inner sidewall 502f of the second mold 502, and the inlet 504 is arranged at the top surface 502a of the second mold 502. In some embodiments, the top surface 502a is substantially orthogonal to the inner sidewall 502f.

[0111] In some embodiments, after the mixture M' is injected into the mold cavity 503, the mixture M' undergoes a physical foaming step 905 within the mold cavity 503 inside the molding apparatus 500. After the physical foaming of the mixture M', the mixture M' becomes a foamed component M, as in step 906. In some embodiments, the foamed component M includes a main portion M1 and residual portions M2 and M3 protruding from the main portion M1. In some embodiments, the dimensions of the main portion M1 substantially correspond to the dimensions of the mold cavity 503, and the dimensions of the residual portions M2 and M3 substantially correspond to the dimensions of the channel 505 and the feed port 504. In some embodiments, the residual portions M2 and M3 include a first residual portion M2 and a second residual portion M3 connected to the first residual portion M2. In some embodiments, the dimensions of the first residual portion M2 substantially correspond to the dimensions of the first portion 505a and the feed port 504, and the dimensions of the second residual portion M3 substantially correspond to the dimensions of the second portion 505b.

[0112] In some specific embodiments, the molding method 900 includes step 907 of disengaging the first mold 501 from the second mold 502 after forming the foamed component M, such as... Figure 40 As shown. When the molding device 500 is in the open configuration, as... Figure 40 As shown in the diagram. In some embodiments, the molding method 900 includes step 908 of removing the foamed component M from the mold cavity 503 after the first mold 501 has disengaged from the second mold 502. In some embodiments, the discharge channel 508 disengages from the feed port 504 after the foamed component M has been formed, or when the molding apparatus 500 is in an open configuration.

[0113] In some specific embodiments, such as Figure 41 When the molding device 500 shown inside is in the open configuration, it is similar to the above or Figure 12As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 12 As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 41 As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or

[0114] As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 42 As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or

[0115] As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 43 As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 44 As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or

[0116] As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 30 As illustrated in FIG. 32, the second mold 502 of the molding device 500 can be divided into several parts. In some embodiments, the second mold 502 includes a first part 502b, a second part 502c, and a third part 502d, similar to the above or Figure 45The remaining portions M2 and M3 are shown removed. In some embodiments, the remaining portions M2 and M3 are removed by cutting, trimming, grinding, or any other suitable process. In some embodiments, the second remaining portion M3 is removed from the main portion Ml, resulting in a foamed member M comprising the main portion Ml, as shown in Figure 45 In some embodiments, a trimming mark M4 is formed after the second remaining portion M3 is removed. In some embodiments, the trimming mark M4 is a region on the main portion Ml. In some embodiments, the trimming mark M4 is visible, i.e., the trimming mark M4 is visually distinct from the rest of the main portion Ml surrounding the trimming mark M4.

[0117] In some embodiments, the trimming mark M4 is disposed at the sidewall M8 of the main portion Ml substantially orthogonal to the top surface M6 and the bottom surface M7 of the main portion Ml. In some embodiments, the top surface M6 is opposite the bottom surface M7.

[0118] In some embodiments, the rest of the main portion Ml includes a skin, while the trimming mark M4 does not include a skin because the skin originally present at the trimming mark M4 has been damaged or removed by the removal process. In some embodiments, the rest of the main portion Ml has a density substantially lower than the density of the trimming mark M4 because the physical foaming at the trimming mark M4 is incomplete. In other words, the degree of physical foaming at the trimming mark M4 is less than the degree of physical foaming of the rest of the main portion Ml. In some embodiments, because the skin at the trimming mark M4 is damaged during the cutting process, the trimming mark M4 is more absorbent of liquid (e.g., water, etc.) than the rest of the main portion Ml. In some embodiments, the trimming mark M4 is more absorbent of liquid (e.g., water, etc.) than the top surface M6 and the bottom surface M7 of the main portion Ml. In other words, liquid can easily enter the main portion Ml via the trimming mark M4, but not via the top surface M6 and the bottom surface M7. In some embodiments, the rest of the main portion Ml is not absorbent of liquid, while the trimming mark M4 is absorbent of liquid. In some embodiments, the rest of the sidewall M8 surrounds the trimming mark M4. In some embodiments, the rest of the sidewall M8 is not absorbent of liquid, while the trimming mark M4 is absorbent of liquid. In some embodiments, the trimming mark M4 does not have a skin, while the skin is present over the rest of the top surface M6, the bottom surface M7, and the sidewall M8 surrounding the trimming mark M4.

[0119] In some embodiments, a visible boundary line M5 is formed on the sidewall M8 of the body portion M1 and surrounds the body portion M1. In some embodiments, the visible boundary line M5 is a parting line of the molding apparatus 500, and corresponds to the junction of the first mold 501 and the second mold 502 around the mold cavity 503. In some embodiments, as shown in FIG. 6, the first and second remaining portions M2, M3 are separated from the body portion M1 when the molding apparatus 500 is opened. In some embodiments, as shown in FIG. 7, the body portion M1 and the second remaining portion M3 are removed from the molding apparatus 500 after the molding apparatus 500 is opened. In some embodiments, as shown in FIG. 8, the body portion M1 and the first remaining portion M2 are removed from the molding apparatus 500 after the molding apparatus 500 is opened. Figure 45 The foamed member M shown in FIG. 6 is a component of an article of footwear, such as an outsole, or the like.

[0120] Alternatively, in some embodiments, the molding method 900 is implemented using the molding apparatus 800 described above and shown in FIG. 9, and after the molding apparatus 800 is opened, the foamed member M is removed from the molding apparatus 800, as shown in FIG. 10. Figures 13-17 Figure 34 The foamed member M shown in FIG. 10 is similar to the foamed member M shown in FIG. 6. In some embodiments, the foamed member M includes two first remaining portions M2 and two second remaining portions M3 that protrude from the body portion M1. In some embodiments, one of the first remaining portions M2 and one of the second remaining portions M3 joined to the one of the first remaining portions M2 correspond to the first channel 505-1, and the other of the first remaining portions M2 and the other of the second remaining portions M3 joined to the other of the first remaining portions M2 correspond to the second channel 505-2. Figure 40 Figure 42 In some embodiments, the first remaining portions M2 are separated from the body portion M1 and the second remaining portions M3 when or after the molding apparatus 800 is opened, which is similar to the process shown in FIG. 6. In some embodiments, as shown in FIG. 11, the body portion M1 and the second remaining portions M3 are removed from the molding apparatus 800, which is similar to the foamed member M shown in FIG. 7. In some embodiments, as shown in FIG. 12, the foamed member M is removed from the molding apparatus 800, which is similar to the foamed member M shown in FIG. 8. After the foamed member M is removed, as shown in FIG. 13, the remaining portions M2, M3 are removed, which is similar to the foamed member M shown in FIG. 9, except that the foamed member M has two trim marks M4.

[0121] In some embodiments, the first remaining portions M2 are separated from the body portion M1 and the second remaining portions M3 when or after the molding apparatus 800 is opened, which is similar to the process shown in FIG. 6. In some embodiments, as shown in FIG. 11, the body portion M1 and the second remaining portions M3 are removed from the molding apparatus 800, which is similar to the foamed member M shown in FIG. 7. In some embodiments, as shown in FIG. 12, the foamed member M is removed from the molding apparatus 800, which is similar to the foamed member M shown in FIG. 8. After the foamed member M is removed, as shown in FIG. 13, the remaining portions M2, M3 are removed, which is similar to the foamed member M shown in FIG. 9, except that the foamed member M has two trim marks M4. Figure 43 Figure 47 Figure 44 Figure 47 Figure 46 Figure 48 Figure 45

[0122] Alternatively, in some embodiments, the molding method 700 is implemented using the molding apparatus 700 described above and shown in FIG. 7, and after the molding apparatus 700 is opened, the foamed member M is removed from the molding apparatus 700, as shown in FIG. 8. Figures 19-22 Figure 49 Figure 49 The foamed member M shown in FIG. 8 is similar to the foamed member M shown in FIG. 7. In some embodiments, the foamed member M includes two first remaining portions M2 and two second remaining portions M3 that protrude from the body portion M1. In some embodiments, one of the first remaining portions M2 and one of the second remaining portions M3 joined to the one of the first remaining portions M2 correspond to the first channel 505-1, and the other of the first remaining portions M2 and the other of the second remaining portions M3 joined to the other of the first remaining portions M2 correspond to the second channel 505-2. Figure 42 ​​​​​​​​​​​The foamed component M shown is similar. In some embodiments, the foamed component M includes four first remaining portions M2 and four second remaining portions M3 protruding from the main body portion M1. In some embodiments, the first of the first remaining portion M2 and the first of the second remaining portion M3 connected to the first remaining portion M2 correspond to a first channel 505-1, the second of the first remaining portion M2 and the second of the second remaining portion M3 connected to the first remaining portion M2 correspond to a second channel 505-2, the third of the first remaining portion M2 and the third of the second remaining portion M3 connected to the third of the first remaining portion M2 correspond to a third channel 505-3, and the fourth of the first remaining portion M2 and the fourth of the second remaining portion M3 connected to the fourth of the first remaining portion M2 correspond to a fourth channel 505-4.

[0123] In some specific embodiments, when or after the molding device 700 is turned on, the first remaining portion M2 separates from the main body portion M1 and the second remaining portion M3, which is consistent with... Figure 43 The processing shown is similar. In some specific embodiments, such as Figure 50 As shown, the main body M1 and the second remaining part M3 can be removed, which is consistent with... Figure 44 The foamed component M shown is similar. For example... Figure 49 or Figure 50 After removing the foamed component M as shown, as Figure 51 The remaining parts M2 and M3 have been removed, except for the four trimming marks M4, which are similar to... Figure 45 The foaming component M shown is similar.

[0124] In some specific embodiments, the molding method 900 is as follows: Figures 52-55 The molding apparatus 1000 shown is used for implementation. In some specific embodiments, the injection unit 506 is arranged on the molding apparatus 1000. The molding apparatus 1000 is initially in an open configuration, such as... Figure 52 As shown inside. In some specific embodiments, the discharge channel 508 of the injection unit 506 engages with the feed port 504 of the molding apparatus 1000, and the first mold 501 engages with the second mold 502 of the molding apparatus 1000, as shown inside. Figure 53 As shown. In some specific embodiments, the mixture M' is injected into the mold cavity 503, as... Figure 54 As shown inside. In some specific embodiments, after the mixture M' is injected into the mold cavity 503, the mixture M' undergoes physical foaming in the mold cavity 503 inside the molding apparatus 1000.

[0125] After the mixture M' undergoes physical foaming, the mixture M' becomes the foamed component M, such as... Figure 55 As shown inside. After forming the foamed component M, as...Figure 55 As shown, the molding device 1000 is opened by disengaging the parts of the molding device 1000 from each other and by disengaging the first mold 501 from the second mold 502. After the molding device 1000 is opened, the foamed component M can be easily removed from the mold cavity 503. Figure 56 The foaming component M shown is... Figure 42 The foamed components shown are similar. In some specific embodiments, such as... Figure 57 and Figure 58 As shown, the remaining parts M2 and M3 have been removed, respectively with Figure 44 and Figure 45 Similar to the example. In some specific embodiments, the visible boundary line M5 is formed on the sidewall M8, and the trimming mark M4 is located at or below the visible boundary line M5.

[0126] In some specific embodiments, the molding method 900 is as follows: Figures 59-62 The molding apparatus 1001 shown is used for implementation. In some specific embodiments, the injection unit 506 is arranged on the molding apparatus 1001. The molding apparatus 1001 is initially in an open configuration, such as... Figure 59 As shown inside. In some specific embodiments, the discharge channel 508 of the injection unit 506 engages with the feed port 504 of the molding device 1001, and the first mold 501 engages with the second mold 502 of the molding device 1001, as shown inside. Figure 60 As shown. In some specific embodiments, the two discharge channels 508-1 and 508-2 are connected to the feed ports 504-1 and 504-2, respectively.

[0127] In some specific embodiments, the mixture M' is injected into the mold cavity 503, such as... Figure 61 As shown inside. The mixture M' flows into the mold cavity 503 through the inlet 504 from the outlet 508. In some specific embodiments, after the mixture M' is injected into the mold cavity 503, the mixture M' undergoes physical foaming within the mold cavity 503 inside the molding apparatus 1001. After the mixture M' has physically foamed, the mixture M' becomes a foamed component M, such as... Figure 62 As shown inside. After forming the foamed component M, as... Figure 62 As shown, the molding device 1001 is opened by disengaging the parts of the molding device 1001 from each other and by disengaging the first mold 501 from the second mold 502. After the molding device 1001 is opened, the foamed component M can be easily removed from the mold cavity 503. Figure 63 The foaming component M shown is... Figure 56 The foamed components shown are similar. In some specific embodiments, such as... Figure 64 and Figure 65 As shown, the remaining parts M2 and M3 have been removed, respectively with Figure 57 and Figure 58Similar to the line in the middle of the first embodiment. In some embodiments, a visible boundary line M5 is formed on the side wall M8, and the trimming mark M4 is located at or below the visible boundary line M5.

[0128] The features of the several embodiments summarized above make the application better understood by those skilled in the art. Those skilled in the art will readily understand that they can readily use the application as a basis for designing or modifying other operations and structures for carrying out the same purposes and / or achieving the same advantages of the embodiments introduced herein. Those skilled in the art will also readily appreciate that such equivalent constructions do not depart from the spirit and scope of the application, and that they can make various changes, substitutions and alterations without departing from the spirit and scope of the application.

[0129] Furthermore, the scope of the application is not intended to be limited to the particular embodiments of the program, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure herein, programs, machines, manufactures, compositions of matter, means, methods, or steps presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized according to the present application. Accordingly, the appended claims are intended to include within their scope such programs, machines, manufactures, compositions of matter, means, methods, or steps.

[0130] Symbol explanation

[0131] 10: mold

[0132] 11: first mold base

[0133] 12: second mold base

[0134] 13, 503: mold cavity

[0135] 14, 504: feed port

[0136] 15: joint

[0137] 16: inner side wall

[0138] 17: inner bottom wall

[0139] 20: pressure regulating system

[0140] 21: first gas conduit

[0141] 22: second gas conduit

[0142] 23: gas source

[0143] 24: first valve

[0144] 25: second valve

[0145] 26: pressure sensing unit

[0146] 30: control system

[0147] 100: first molding device

[0148] 151: first opening

[0149] 152: second opening

[0150] 153: first hole

[0151] 154: second hole

[0152] 200: second molding device

[0153] 211: first guide channel

[0154] 221: second guide channel

[0155] 300: third molding device

[0156] 400: fourth molding device

[0157] 500, 800, 700, 1000, 1001: molding device

[0158] 501: first mold

[0159] 502: second mold

[0160] 502a: top surface

[0161] 502b: first part

[0162] 502c: second part

[0163] 502d: third part

[0164] 502e: fourth part

[0165] 502f: inner side wall

[0166] 502f: fifth part

[0167] 503a: opening

[0168] 503a-1: first opening

[0169] 503a-2: second opening

[0170] 503a-3: third opening

[0171] 503a-4: fourth opening

[0172] 504-1: first inlet

[0173] 504-2: second inlet

[0174] 505: channel

[0175] 505-1: first channel

[0176] 505-2: second channel

[0177] 505-3: third channel

[0178] 505-4: fourth channel

[0179] 505a: first portion

[0180] 505b: second portion

[0181] 505c: third portion

[0182] 505d: fourth portion

[0183] 505e: fifth portion

[0184] 505f: sixth portion

[0185] 505g: seventh portion

[0186] 505h: eighth portion

[0187] 506: ejection unit

[0188] 507: ejector

[0189] 508: discharge channel

[0190] 600, 900: molding method

[0191] M: foamed member

[0192] M': mixture

[0193] M1: main portion

[0194] M2, M3: remaining portion

[0195] M4: finishing mark

[0196] M6: top surface

[0197] M7: bottom surface

[0198] M8: side wall

Claims

1. A molding apparatus characterized by comprising: The molding device comprises: a mold having a mold cavity; a feed opening extending into the mold; a channel connected to the feed opening and communicable with the mold cavity; and an opening connected to the channel and communicable with the mold cavity, wherein the feed opening is disposed above the mold cavity and the opening is disposed on a side of the mold cavity. The mold comprises a top surface above the mold cavity and an inner sidewall bounding the mold cavity, and the feed opening extends from the top surface toward the mold cavity.

2. The molding apparatus of claim 1, wherein The top surface is perpendicular to the inner sidewall.

3. The forming device of claim 2, wherein The channel comprises a first portion and a second portion connected to and disposed below the first portion.

4. The molding apparatus of claim 1 wherein, A first angle between the feed opening and the first portion is substantially greater than a second angle between the first portion and the second portion.

5. The forming device of claim 4, wherein The channel connects the feed opening and the opening.

6. The molding apparatus of claim 1 wherein, 7. A foamed article made by the molding device of any one of claims 1 to 6, the foamed article comprising: a body portion having a top surface, a bottom surface opposite the top surface, and a sidewall between the top surface and the bottom surface; and a trim mark disposed at the sidewall of the body portion, wherein the trim mark is visually distinct from a remainder of the body portion. The trim mark is liquid absorbent, the remainder of the body portion is not liquid absorbent, the trim mark is free of a skin, and the skin is present at the top surface, the bottom surface, and the remainder of the sidewall surrounding the trim mark. The remainder of the body portion is substantially less dense than the trim mark.

8. The foamed article of claim 7, wherein The trim mark is not present at the top surface and the bottom surface.

9. The foamed article of claim 7, wherein ​ 10. The foamed article of claim 7, wherein ​

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