Injection molding system

Abstract

An injection molding system is provided. The injection molding system comprises a molding device. The molding apparatus includes a first mold, a second mold covering the first mold, and an intermediate mold interposed between the first mold and the second mold. The second mold includes a support unit extendable from and retractable into the second mold and facing toward the first mold. The interseed mold includes an outer middle mold and an inner middle mold surrounded by and movable relative to the outer middle mold.

Description

Technical Field

[0001] This invention relates to an injection molding system, and more particularly to an injection molding system for forming articles comprising multiple components. Background Technology

[0002] Foamed polymer materials offer numerous advantages, such as high strength, low weight, impact resistance, and thermal insulation. Foamed products 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 a mold cavity. The mixture foams and cools within the mold cavity to form a foamed product.

[0003] However, it is necessary to improve the formation of multiple articles (e.g., in pairs), each article comprising more than one component with different physical or functional properties. Therefore, improvements are needed in the structure of injection molding systems and methods for manufacturing foamed articles.

[0004] new content

[0005] This work reveals an injection molding system.

[0006] According to an embodiment of the present invention, an injection molding method is provided. The injection molding method includes: providing a molding apparatus, wherein the molding apparatus includes a first mold, a second mold covering the first mold, and an intermediate mold between the first mold and the second mold; disposing a first component on the second mold; after the first component is disposed on the second mold, engaging the intermediate mold with the first mold and the second mold to form a mold cavity; injecting a polymer material into the mold cavity to surround the first component; and obtaining an article formed using the polymer material and the first component.

[0007] According to an embodiment of the present invention, an injection molding system is provided. The injection molding system includes a molding apparatus, which includes a first mold, a second mold covering the first mold, and an intermediate mold located between the first mold and the second mold. The second mold includes a support unit that can extend from and retract into the second mold and faces the first mold. The intermediate mold includes an outer intermediate mold and an inner intermediate mold surrounded by the outer intermediate mold and movable relative to the outer intermediate mold.

[0008] Simple Explanation of the Diagram

[0009] The best way to understand each aspect of this work is to refer to the accompanying drawings. It should be noted that, in accordance with industry standard practice, each feature is not drawn to scale. In fact, for clarity of discussion, the dimensions of each feature can be increased or decreased at will.

[0010] Figure 1 This is a schematic perspective view of an injection molding system according to an embodiment of the invention.

[0011] Figure 2 This is a schematic perspective view of a molding apparatus in a closed configuration according to an embodiment of the invention.

[0012] Figure 3A and Figure 3B The bottom view and front perspective view of the upper mold according to an embodiment of this invention are shown respectively.

[0013] Figure 4A and Figure 4B Top view and front perspective view of the molding apparatus in an open configuration according to an embodiment of the invention are shown respectively.

[0014] Figure 5 This is a schematic top view of an injection molding system according to an embodiment of the invention.

[0015] Figure 6 This is a flowchart illustrating an injection molding method according to an embodiment of the present invention.

[0016] Figure 7 This is a top view of the core component to be placed on the upper mold according to an embodiment of the invention.

[0017] Figure 8A and Figure 8B The bottom view and front perspective view of the upper mold according to an embodiment of the invention are shown respectively, with the core components configured (or placed) on the upper mold.

[0018] Figure 9 This is a top view of the bottom component to be placed on the lower mold according to an embodiment of the invention.

[0019] Figure 10A and Figure 10B The top view and front perspective view of the molding apparatus according to an embodiment of the present invention are shown respectively, with the bottom component configured (or placed) on the molding apparatus.

[0020] Figure 11A and Figure 11B The top view and front perspective view of the molding apparatus according to an embodiment of the present invention are shown respectively, with the bottom component configured (or placed) on the molding apparatus.

[0021] Figure 12A , Figure 12B and Figure 12C Perspective views, top views, and front perspective views of the molded object to be closed according to an embodiment of this invention are shown respectively.

[0022] Figure 13A , Figure 13B and Figure 13C Perspective views, front perspective views, and side perspective views of a molding apparatus in a closed configuration according to an embodiment of the invention are shown respectively.

[0023] Figure 14A and Figure 14B The front and side perspective views of the molding apparatus according to an embodiment of the present invention are shown respectively, in which polymer material is injected into a mold cavity to form an article.

[0024] Figure 15 A perspective view of an article of manufacture according to an embodiment of the present invention is shown.

[0025] Figure 16 A side perspective view of a molding apparatus including an inner mold according to an embodiment of the present invention is shown. Implementation

[0026] [Cross-references to related applications]

[0027] This application claims priority to U.S. Provisional Patent Application No. 63 / 550,631, filed February 7, 2024, and U.S. Patent Application No. 18 / 822,509, filed September 3, 2024, the entire contents of which are incorporated herein by reference.

[0028] The following disclosure provides numerous different embodiments or examples of various features for implementing the provided subject matter. Specific examples of components and configurations described below are intended to simplify the invention. Of course, these are merely examples and are not intended to be limiting. For example, embodiments in which a first feature is formed to cover or over a second feature may include embodiments where the first and second features are formed in direct contact, and embodiments in which additional features may be formed between the first and second features such that the first does not directly contact the second feature. Additionally, reference numerals and / or letters may be repeated in each example. Such repetition is for simplicity and clarity and does not in itself affect the relationship between the various embodiments and / or configurations discussed.

[0029] Furthermore, for ease of description, spatially related terms such as "below," "below," "lower part," "above," and "upper part" are used herein to describe the relationship between one element or feature and another in the diagram. In addition to the orientations depicted in the diagrams, spatially related terms are intended to cover different orientations of the device during use or operation. The device can be pointed in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein are interpreted accordingly.

[0030] While the numerical ranges and parameters set forth in this invention are approximate, the values ​​described in the specific embodiments are reported as precisely as possible. However, any numerical value inherently contains a certain degree of error, which is necessarily caused by the standard deviation found in the corresponding test measurement. Furthermore, as used herein, the term "about" generally means within 10%, 5%, 1%, or 0.5% of a known value or range. Alternatively, the term "about" means within an acceptable standard error of the average value when considered by a person skilled in the art. Except in operational / working embodiments, or unless expressly stated otherwise, all numerical ranges, quantities, values, and percentages, such as those concerning the amount of material disclosed herein, the duration of time, temperature, operating conditions, ratios of quantities, etc., should be understood to be modified by the term "about" in all cases. Therefore, unless indicated to the contrary, the numerical parameters set forth in this invention and the appended claims are approximate values ​​that may be changed as needed. At a minimum, each numerical parameter should be interpreted according to the number of significant figures reported and the application of general rounding techniques. Ranges herein may be expressed as from one endpoint to another or between two endpoints. Unless otherwise stated, all ranges disclosed herein include endpoints.

[0031] Figure 1 This is a schematic perspective view of an injection molding system 100 according to an embodiment of the present invention. The injection molding system 100 includes a molding device 10 in an open configuration. The injection molding system 100 also includes a position control mechanism 20 configured to control the molding device 10 in an open or closed configuration, such as... Figure 2 As shown. In some embodiments, the position control mechanism 20 is configured to be adjacent to the molding device 10.

[0032] In some embodiments, the molding apparatus 10 includes an upper mold 11, a lower mold 13, an outer middle mold (or side mold) 15 disposed between the upper mold 11 and the lower mold 13, and a plurality of mold cavities 19 for forming an article 30 defined by the upper mold 11, the lower mold 13, and the outer middle mold 15. For simplicity and clarity, a first mold cavity 19a and a second mold cavity 19b are shown; however, it will be understood that any suitable number of mold cavities 19 may be configured in the molding apparatus 10. In some embodiments, the upper mold 11 corresponds to the lower mold 13 in some configuration (e.g., size, shape, etc.). The upper mold 11 may be placed on and engaged with the outer middle mold 15. In some embodiments, the provision of the molding apparatus 10 includes conveying the outer middle mold 15 toward the lower mold 13, followed by setting the upper mold 11 to cover the outer middle mold 15, and these movements are controlled by a position control mechanism 20. In some embodiments, the upper mold 11 is aligned with the lower mold 13. In some embodiments, the upper mold 11 is configured to cover the outer middle mold 15 and is movable relative to the outer middle mold 15, engaging with the outer middle mold 15. The outer middle mold 15 is configured to cover the lower mold 13 and is movable relative to the lower mold 13, engaging with the lower mold 13.

[0033] In some embodiments, the upper mold 11 includes a plurality of feed holes 12. In some embodiments, each feed hole 12 extends through the upper mold 11 and has an opening 121 disposed on the top surface of the upper mold 11. In some embodiments, when the molding apparatus 10 is in a closed configuration, the feed holes 12 may communicate with the mold cavity 19.

[0034] In some embodiments, the mold cavity 19 may be accessed via the feed port 12. For simplicity and clarity, Figure 2 The upper mold 11 has six feed holes 12 on its top surface. However, it is understood that any suitable number of feed holes 12 can be provided on the upper mold 11. In some embodiments, the feed holes 12 are not provided on the upper mold 11, but on the lower mold 13 or the outer middle mold 15, for entering the mold cavity 19. In some embodiments, the feed holes 12 can be provided in any other suitable location, as long as the feed holes 12 can communicate with the mold cavity 19. For example, some feed holes 12 are provided on the upper mold 11, and the remaining feed holes 12 are provided on the lower mold 13 and / or the outer middle mold 15.

[0035] In some embodiments, the injection molding system 100 also includes an extrusion system (not shown) configured to cover the molding apparatus 10 and a discharge groove (not shown). In some embodiments, the extrusion system is configured to produce a mixture of polymer material and a foaming agent. In some embodiments, the discharge groove may communicate with the extrusion system and include an outlet disposed remotely from the extrusion system, and is configured to discharge the mixture through a feed port 12 into the molding apparatus 10. In some embodiments, the molding apparatus 10 is configured to receive the mixture from the outlet of the discharge groove. In some embodiments, the feed port 12 may communicate with a mold cavity 19 and may engage with the outlet.

[0036] In this creative embodiment, along Figure 2 The side perspective view of the components of the molding apparatus 10 is obtained by line I-I', and along... Figure 2 Line II-II' provides a front perspective view of the components of the molding apparatus 10.

[0037] Figure 3A and Figure 3B A bottom view and a front perspective view of the upper mold 11 according to an embodiment of the present invention are shown respectively. The upper mold 11 has a bottom surface 111 and a top surface 112. When the molding apparatus 10 is in a closed configuration, the bottom surface 111 of the upper mold 11 faces the outer middle mold 15. Two sealing rings 16 are provided on the bottom surface 111 of the upper mold 11. The two sealing rings 16 include a first sealing ring 16a and a second sealing ring 16b that are separated from each other. In some embodiments, the number of sealing rings 16 is the same as the number of mold cavities 19. Each sealing ring 16 corresponds to a separate mold cavity 19.

[0038] In some embodiments, the upper mold 11 has a plurality of feed holes 12. In some embodiments, the feed holes 12 include one or more first feed holes 12a and one or more second feed holes 12b. From the bottom view, the first feed holes 12a are disposed within the first sealing ring 16a, and the second feed holes 12b are disposed within the second sealing ring 16b, as shown below. Figure 3AAs shown. Each first feed hole 12a has a first opening (or first gate) 121a disposed at the upper mold 11. Each first opening 121a is configured to extend through the upper mold 11 and communicate with the first mold cavity 19a when the molding device 10 is in a closed configuration. Each second feed hole 12b has a second opening (or second gate) 121b disposed at the upper mold 11. The second opening 121b is configured to extend through the upper mold 11 and communicate with the second mold cavity 19b when the molding device 10 is in a closed configuration. In some embodiments, the number of first feed holes 12a is equal to the number of second feed holes 12b. In some embodiments, the first openings 121a are arranged in a first straight line (not shown) at the same spacing, and the second openings 121b are arranged in a second straight line (not shown) at the same spacing. In some embodiments, the second straight line is parallel to the first straight line. Figure 3A The embodiment shows three first openings 121a and three second openings 121b, however, it is not intended to limit the number of openings 121 in the upper mold 11.

[0039] In some embodiments, the upper mold 11 has a plurality of support units 14. One end of each support unit 14 is located inside the upper mold 11, and the other end of each support unit 14 protrudes from the bottom surface 111 of the upper mold 11. In some embodiments, the support unit 14 is a nail, screw, or post. In some embodiments, the support unit 14 includes one or more first support units 14a and one or more second support units 14b. From the bottom view, the protrusion of the first support unit 14a is disposed within the first sealing ring 16a, and from the bottom view, the protrusion of the second support unit 14b is located within the second sealing ring 16b, as shown below. Figure 3A As shown. In some embodiments, the number of first support units 14a is equal to the number of second support units 14b. In some embodiments, the first support units 14a are arranged in a third straight line (not shown) with the same spacing, and the second support units 14b are arranged in a fourth straight line (not shown) with the same spacing. In some embodiments, the fourth straight line is parallel to the third straight line and / or the first and second straight lines of the opening 121. Figure 3A The embodiment shows two first support units 14a and two second support units 14b, however, it is not intended to limit the number of support units 14 in the upper mold 11.

[0040] In some embodiments, the third straight line of the support unit 14 overlaps with the fourth straight line and the first and second straight lines of the opening 121. In some embodiments, the third and fourth straight lines of the support unit 14 do not overlap with the first and second straight lines of the opening 121. In some embodiments, the number of support units 14 is less than the number of feed holes 12. In some embodiments, the number of support units 14 is the same as the number of feed holes 12. In some embodiments, viewed from the bottom view, each support unit 14 is disposed between the openings 121 of two adjacent feed holes 12. For example, each first support unit 14a is disposed between two adjacent first openings 121a, and each second support unit 14b is disposed between two adjacent second openings 121b, as shown. Figure 3A As shown.

[0041] Figure 4A and Figure 4B A top view and a front perspective view of the molding apparatus 10 in the open configuration according to an embodiment of the present invention are shown respectively. Figure 4A and Figure 4B The middle mold 15 and the lower mold 13 of the molding device 10 are shown in the image.

[0042] The outer mold 15 includes a first portion 151 and a second portion 152. The first portion 151 and the first slider 171 are adjacent to each other and can be engaged, and the second portion 152 and the second slider 172 are adjacent to each other and can be engaged. In some embodiments, the first portion 151 and the second portion 152 are movable and separable, and the first slider 171 and the second slider 172 are movable and separable. In some embodiments, the second portion 152 and the first portion 151 are movable relative to each other, and the first slider 171 and the second slider 172 are movable relative to each other. In some embodiments, the first slider 171 and the second slider 172 are the inner mold 17 of the molding apparatus 10.

[0043] In some embodiments, the lower mold 13 includes a first portion 131, a second portion 132, and a third portion 133. The first portion 131 and the second portion 132 are disposed on opposite sides of the third portion 133. In some embodiments, a first groove 115a is formed on the first portion 131, and a second groove 115b is formed on the second portion 132. A first slider 171 and a second slider 172 are disposed to cover the third portion 133 and are located between the first portion 131 and the second portion 132. In some embodiments, the first portion 151 and the first slider 171 of the outer middle mold 15 are disposed to cover the first portion 131 of the lower mold 13, and the second portion 152 and the second slider 172 of the outer middle mold 15 are disposed to cover the second portion 132 of the lower mold 13. In some embodiments, the first slider 171 is at least partially surrounded by the first portion 151 of the outer middle mold 15, and the second slider 172 is at least partially surrounded by the second portion 152 of the outer middle mold 15.

[0044] In some embodiments, when the molding apparatus 10 is in a closed configuration, the upper mold 11, the first portion 131 of the lower mold 13, the first portion 151 of the outer middle mold 15, and the first slider 171 define a first mold cavity 19a, and the upper mold 11, the second portion 132 of the lower mold 13, the second portion 152 of the outer middle mold 15, and the second slider 172 define a second mold cavity 19b. In some embodiments, when the molding apparatus 10 is in a closed configuration, the first portion 151 of the outer middle mold 15 and the first slider 171 are attached to each other and engage to seal the first mold cavity 19a. Similarly, when the molding apparatus 10 is in a closed configuration, the second portion 152 of the outer middle mold 15 and the second slider 172 are attached to each other and engage to seal the second mold cavity 19b.

[0045] In some embodiments, when the molding apparatus 10 is in the open configuration, the outer mold 15 and the inner mold 17 are separated from each other. For example, when the molding apparatus 10 is in the open configuration, the first portion 151 of the outer mold 15 is separated from the first slider 171, and the article 30a formed in the first mold cavity 19a can be easily removed from the first mold cavity 19a. Similarly, when the molding apparatus 10 is in the open configuration, the second portion 152 of the outer mold 15 is separated from the second slider 172, and the article 30b formed in the second mold cavity 19b can be easily removed from the second mold cavity 19b. When the molding apparatus 10 is in the open configuration, the first groove 115a and the second groove 115b on the lower mold 13 are exposed. In some embodiments, the article 30 is removed from the molding apparatus 10 by a human or a robotic arm (not shown).

[0046] In some embodiments, when the molding apparatus 10 is in the open configuration, there is a gap G1 between the first portion 151 and the second portion 152. In some embodiments, the first portion 151 is positioned away from the first slider 171 to extend the first mold cavity 19a, and the second portion 152 is positioned away from the second slider 172 to extend the second mold cavity 19b. In some embodiments, the first portion 151 and the first slider 171 are positioned away from each other to extend the first mold cavity 19a, and the second portion 152 is positioned away from each other to extend the second mold cavity 19b. In some embodiments, when the molding apparatus 10 is in the open configuration, the first mold cavity 19a and the second mold cavity 19b have been extended.

[0047] In some embodiments, when the molding apparatus 10 is in the open configuration, there is a gap G3 between the first slider 171 and the second slider 172. In some embodiments, the gap G3 is smaller than the gap G1. In some embodiments, there is no gap G3 between the first slider 171 and the second slider 172, that is, the first slider 171 is in contact with the second slider 172.

[0048] In some embodiments, by Figure 1 The position control mechanism 20 controls the movement of the upper mold 11 and the outer middle mold 15. In some embodiments, the position control mechanism 20 is connected to or attached to the upper mold 11 and the outer middle mold 15. In some embodiments, the position control mechanism 20 can be used to move the upper mold 11 toward the outer middle mold 15 and the lower mold 13. In some embodiments, the position control mechanism 20 drives or actuates the upper mold 11 away from the outer middle mold 15, so that the molding apparatus 10 is in an open configuration. It is understood that the maximum displacement of the upper mold 11 is limited by the position control mechanism 20. In some embodiments, the position control mechanism 20 is used to move the outer middle mold 15 to cover the lower mold 13, and then the upper mold 11 is placed to cover the outer middle mold 15, such that the outer middle mold 15 engages with the upper mold 11 and the lower mold 13.

[0049] In some embodiments, the position control mechanism 20 is configured to drive or actuate the upper mold 11 to move upward when the molding apparatus 10 is in an open configuration. In some embodiments, the position control mechanism 20 is used to generate relative movement between the upper mold 11 and the outer middle mold 15. In some embodiments, the position control mechanism 20 is used to separate the first portion 151 and the second portion 152 of the outer middle mold 15 when the molding apparatus 10 is in an open configuration. In some embodiments, the position control mechanism 20 is used to generate relative movement between the first portion 151 of the outer middle mold 15 and the first slider 171, and relative movement between the second portion 152 of the outer middle mold 15 and the second slider 172.

[0050] Figure 5 This is a schematic top view of an injection molding system according to an embodiment of the present invention. Figure 5 In this injection molding system, a first carrier 101 and a second carrier 102 disposed adjacent to the first carrier 101 are included. In some embodiments, the first carrier 101 and the second carrier 102 are both annular. In some embodiments, the first carrier 101 can rotate about a first center C1 and along a first direction R1, and the second carrier 102 can rotate about a second center C2 and along a second direction R2. In some embodiments, each of the first carrier 101 and the second carrier 102 can rotate clockwise or counterclockwise. The first carrier 101 and the second carrier 102 rotate along the first direction R1 and the second direction R2, respectively. In some embodiments, the first carrier 101 and the second carrier 102 rotate at predetermined intervals. In some embodiments, the first carrier 101 and the second carrier 102 rotate independently or simultaneously. In some embodiments, the first direction R1 and the second direction R2 can be the same as or different from each other. In some embodiments, the first carrier 101 and the second carrier 102 are automatically operated and controlled. In some embodiments, the first vehicle 101 and the second vehicle 102 may communicate with each other through any suitable communication protocol, such as a programmable logic control (PLC) protocol.

[0051] In some embodiments, a plurality of molding stations 200 are configured at a first carrier 101 and a second carrier 102. In some embodiments, the molding station 200 includes a plurality of first molding stations 200a configured at the first carrier 101 and a plurality of second molding stations 200b configured at the second carrier 102. In some embodiments, a molding apparatus 10 including a first upper mold 11a, an outer middle mold 15, and a lower mold 13 is disposed in the first molding station 200a, and a molding apparatus 10 including a second upper mold 11b, an outer middle mold 15, and a lower mold 13 is disposed in the second molding station 200b. In some embodiments, the configuration of the first upper mold 11a is different from the configuration of the second upper mold 11b. In some embodiments, the configuration of the outer middle mold 15 and the lower mold 13 at the first molding station 200a is the same as the configuration of the outer middle mold 15 and the lower mold 13 at the second molding station 200b.

[0052] exist Figure 5In this injection molding system, a first ejector 104 adjacent to a first carrier 101 and a second ejector 105 adjacent to a second carrier 102 are also included. The first ejector 104 is configured to cover one of the first molding stations 200a and to discharge first polymer material into a mold cavity 19, which is defined by a lower mold 13, an outer middle mold 15, and a first upper mold 11a of one of the first molding stations 200a. Similarly, the second ejector 105 is configured to cover one of the second molding stations 200b and to discharge second polymer material into a mold cavity 19, which is defined by a lower mold 13, an outer middle mold 15, and a second upper mold 11b of one of the second molding stations 200b. In some embodiments, a first polymer material may flow from the first ejector 104 through the first feed hole 12a and the second feed hole 12b of the first upper mold 11a into the first mold cavity 19a and the second mold cavity 19b, and a second polymer material may flow from the second ejector 105 through the first feed hole 12a and the second feed hole 12b of the second upper mold 11b into the first mold cavity 19a and the second mold cavity 19b.

[0053] In some embodiments, the injection molding system 100 includes a bridging mechanism 103 disposed between a first carrier 101 and a second carrier 102. The bridging mechanism 103 connects the first carrier 101 and the second carrier 102, and transfers the lower mold 13 and the outer / middle mold 15 from the first carrier 101 to the second carrier 102 or from the second carrier 102 to the first carrier 101. In some embodiments, it can be derived from... Figure 5 The injection molding system removes and disassembles the bridging mechanism 103. The bridging mechanism 103 can be operated independently of the first carrier 101 and the second carrier 102.

[0054] Figure 6 A flowchart of an injection molding method 300 according to an embodiment of the present invention is shown. The injection molding method 300 includes operations S310 to S360, and the description and illustrations are not to be construed as limiting the order of operations S310 to S360. Figures 7 to 16 These are schematic top views, perspective views, or cross-sectional views of various stages of the injection molding method 300. In some embodiments, the operations of the injection molding method 300 can be repeated and performed automatically. In some embodiments, by Figure 1 Injection molding system 100 and Figure 5 The injection molding system executes injection molding method 300.

[0055] In operation S310, a molding apparatus 10 is provided, including an upper mold 11, a lower mold 13, and an outer middle mold 15 disposed between the upper mold 11 and the lower mold 13. In operation S320, a core component 32 is positioned on the upper mold 11. In operation S330, a bottom component 34 is positioned on the lower mold 13. In operation S340, the outer middle mold 15 engages with the upper mold 11 and the lower mold 13 to form a mold cavity 19. In operation S350, polymer material is injected into the mold cavity 19 to attach the bottom component and surround the core component. In operation S360, an article comprising the polymer material, the core component, and the bottom component is obtained from the mold cavity 19. In some embodiments, the execution order of operations S320 and S330 may be interchanged. The core component 32 and the bottom component 34 will be described later.

[0056] To illustrate the concept of this invention and the injection molding method 300, various embodiments are provided below. However, this invention is not intended to be limited to any particular embodiment. Furthermore, the elements, conditions, or parameters shown in different embodiments can be combined or modified to form different combinations of embodiments, as long as the elements, parameters, or conditions used do not conflict. For ease of explanation, reference numerals having similar or identical functions and characteristics are repeated in different embodiments and drawings.

[0057] As described above, the molding apparatus 10 also includes an inner mold 17, which includes a first slider 171 and a second slider 172. In some embodiments, the molding apparatus 10 includes more than two mold cavities 19. In some embodiments, a first mold cavity 19a is defined by an upper mold 11, a lower mold 13, a first slider 171, and a first portion 151 of an outer mold 15, and a second mold cavity 19b is defined by an upper mold 11, a lower mold 13, a second slider 172, and a second portion 152 of an outer mold 15.

[0058] Figure 7 This is a top view of the core component 32 to be placed on the upper mold 11 according to an embodiment of the present invention. In some embodiments, the core component 32 has one or more openings 321. The core component 32 includes a first core component 32a and a second core component 32b. In some embodiments, the core component 32 is a pair of insoles, a pair of air-cushioned insoles, a pair of footpads, or any other suitable component of footwear. In some embodiments, the first core component 32a is a left insole, and the second core component 32b is a right insole. In some embodiments, the number of openings 321a of the first core component 32a is equal to the number of openings 321b of the second core component 32b.

[0059] In some embodiments, openings 321a are arranged at equal intervals on a fifth straight line (not shown), and openings 321b are arranged at equal intervals on a sixth straight line (not shown). In some embodiments, the fifth straight line is parallel to the sixth straight line. Figure 7 The embodiment shows three openings 321a and three second openings 321b, however, it is not intended to limit the number of openings 321 in the core component 32.

[0060] In some embodiments, core component 32 includes a polymer material, such as ethylene vinyl acetate copolymer (EVA), styrene-ethylene-butene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, core component 32 is a non-foamed component. In some embodiments, core component 32 includes recyclable material. Alternatively, in some embodiments, core component 32 is a foamed component. In some embodiments, the foamed component includes a polymer material and a foaming agent. In some embodiments, the stiffness of the non-foamed component is greater than the stiffness of the foamed component.

[0061] Figure 8A and Figure 8B The bottom view and front perspective view of the upper mold 11 according to an embodiment of the present invention are shown respectively, with the core component 32 disposed on the upper mold 11. In some embodiments, the first core component 32a is fixed to the upper mold 11 by a first support unit 14a, and the second core component 32b is fixed to the upper mold 11 by a second support unit 14b. In some embodiments, the support unit 14 does not penetrate the core component 32. In some embodiments, the support unit 14 penetrates the core component 32. In some embodiments, each support unit 14 is at least partially surrounded by the core component 32.

[0062] In some embodiments, when the core component 32 is fixed by the support unit 14, there is a gap G2 between the upper mold 11 and the core component 32. In some embodiments, the upper mold 11 further includes an inner core, and there is a gap G2 between the inner core of the upper mold 11 and the core component 32. In some embodiments, when the core component 32 is disposed on the upper mold 11, the opening 321 of the core component 32 overlaps with the opening 121 of the upper mold 11. For example, when the first core component 32a is disposed on the upper mold 11 through the first support unit 14a, from the bottom view, the opening 321a of the first core component 32a may completely or partially overlap with the opening 121a of the upper mold 11. Similarly, when the second core component 32b is disposed on the upper mold 11 through the second support unit 14b, from the bottom view, the opening 321b of the second core component 32b may completely or partially overlap with the opening 121b of the upper mold 11. In some embodiments, the opening 321 of the core component 32 does not overlap with the opening 121 of the upper mold 11. In some embodiments, the core component 32 is mounted on the upper mold 11 by a person or robotic arm (not shown).

[0063] Figure 9 This is a top view of the bottom component 34 to be placed on the lower mold 13 according to an embodiment of the present invention. In some embodiments, the bottom component 34 includes a first bottom component 34a and a second bottom component 34b. In some embodiments, the bottom component 34 is a pair of outsoles, a pair of insoles, or any other suitable component of footwear. In some embodiments, the first bottom component 34a is the left outsole, and the second bottom component 34b is the right outsole.

[0064] In some embodiments, the bottom component 34 comprises a polymer material, such as EVA, SEBS, TPU, TPEE, etc. In some embodiments, the bottom component 34 comprises a recyclable material. In some embodiments, the bottom component 34 is non-foamable or foamable. In some embodiments, the bottom component 34 further comprises a blowing agent. In some embodiments, the blowing agent can be any type of chemical or physical blowing agent known to those skilled in the art. In some embodiments, the blowing agent is a supercritical fluid. Supercritical fluids may include inert gases, such as carbon dioxide or nitrogen in a supercritical state. In some embodiments, the bottom component 34 is made of a molding material comprising a polymer material and a blowing agent.

[0065] In some embodiments, Figure 7The material of the core component 32 is different from that of the bottom component 34. In some embodiments, the thickness of the core component 32 is less than the thickness of the bottom component 34. In some embodiments, the area of ​​the core component 32 is less than the area of ​​the bottom component 34. For example, the area of ​​the first core component 32a is less than the area of ​​the first bottom component 34a. In some embodiments, the outline of the core component 32 is similar to the outline of the bottom component 34, and the perimeter of the core component 32 is less than the perimeter of the bottom component 34.

[0066] Figure 10A and Figure 10B A top view and a front perspective view of the molding apparatus 10 according to an embodiment of the present invention are shown, showing the bottom component 34 disposed on the molding apparatus 10. Figure 10A and Figure 10B The image shows the outer middle mold 15, sliders 171 and 172, and lower mold 13 of the molding apparatus 10, with the outer middle mold 15 in an open configuration. Furthermore, a bottom assembly 34 is mounted on the lower mold 13.

[0067] In some embodiments, when the outer mold 15 is opened, the first portion 151 and the second portion 152 of the outer mold 15 move away from each other to form a gap G1 between the first portion 151 and the second portion 152. In some embodiments, when the first portion 151 moves away from the second portion 152, the first slider 171 and the second slider 172 move closer to each other, thereby making it easy to place the bottom component 34 on the lower mold 13.

[0068] In some embodiments, a first bottom component 34a is disposed in a first groove 115a, and a second bottom component 34b is disposed in a second groove 115b. In some embodiments, the outline of the first bottom component 34a is formed to match the shape of the first groove 115a, and the outline of the second bottom component 34b is formed to match the shape of the second groove 115b. For example, the first groove 115a completely fills the first bottom component 34a, and the second groove 115b completely fills the second bottom component 34b. In some embodiments, the outline of the first bottom component 34a is smaller than the shape of the first groove 115a, and the outline of the second bottom component 34b is smaller than the shape of the second groove 115b. For example, the first bottom component 34a does not completely fill the first groove 115a, and the second bottom component 34b does not completely fill the second groove 115b. In some embodiments, the bottom component 34 is placed on the lower mold 13 by a person or a robotic arm (not shown).

[0069] Figure 11A and Figure 11B Top and front perspective views of a molding apparatus 10 according to some embodiments of the present invention are shown, with a bottom component 34 disposed on the molding apparatus 10. Figure 11A and Figure 11B The image shows the outer middle mold 15, sliders 171 / 172 and lower mold 13 of the molding apparatus 10, with the outer middle mold 15 in a closed configuration.

[0070] In some embodiments, after the bottom component 34 is positioned on the lower mold 13, the first portion 151 and the second portion 152 of the outer middle mold 15 move to engage, such that the gap G1 between the first portion 151 and the second portion 152 decreases when the outer middle mold 15 is closed. In some embodiments, after the first portion 151 engages with the second portion 152, the first slider 171 and the second slider 172 move away from each other, such that the first slider 171 moves to engage with the first portion 151, and the second slider 172 moves to engage with the second portion 152, and then the gap G3 increases. In some embodiments, when the outer middle mold 15 is in a closed configuration, only a portion of the third portion 133 of the lower mold 13 is exposed when viewed from above. For example, the third portion 133 is exposed from the gap G3 between the first slider 171 and the second slider 172. In some embodiments, when the outer middle mold 15 is in a closed configuration, the gap G1 is less than or equal to the gap G3.

[0071] In some embodiments, when the outer mold 15 is in a closed configuration, the bottom surface of the first mold cavity 19a is defined by the first bottom assembly 34a, and one side of the first mold cavity 19a is formed by the engaged first portion 151 and the engaged first slider 171 of the outer mold 15. Similarly, the bottom surface of the second mold cavity 19b is defined by the second bottom assembly 34b, and one side of the second mold cavity 19b is formed by the engaged second portion 152 and the engaged second slider 172 of the outer mold 15.

[0072] In some embodiments, the position control mechanism 20 controls the movement of the first portion 151 and the second portion 152, and also controls the spacing G1. In some embodiments, when the first portion 151 and the second portion 152 move, the first slider 171 and the second slider 172 may move accordingly. In some embodiments, the position control mechanism 20 controls minute movements of the first slider 171 and the second slider 172, and also controls the spacing G3.

[0073] Figure 12A , Figure 12B and Figure 12C Perspective view, top view and front perspective view of the molding device 10 to be closed according to an embodiment of the present invention are shown respectively.

[0074] In some embodiments, after the bottom component 34 is placed on the lower mold 13, the position control mechanism 20 is used to drive or actuate the upper mold 11, on which the core component 32 is placed, to move downward to close the molding device 10.

[0075] Figure 13A , Figure 13B and Figure 13C Perspective views, front perspective views, and side perspective views of the molding apparatus 10 in a closed configuration according to an embodiment of the present invention are shown respectively.

[0076] In some embodiments, when the molding apparatus 10 is in a closed configuration, a mold cavity 19 is formed, with each core component 32 disposed within a corresponding mold cavity 19 and not in contact with the outer middle mold 15, sliders 171 or 172, lower mold 13, and bottom component 34. In some embodiments, a first mold cavity 19a is defined by the upper mold 11, the first bottom component 34a, the first portion 151 of the outer middle mold 15, and the first slider 171. The first core component 32a is disposed within the first mold cavity 19a and suspended by the first support unit 14a. In some embodiments, a second mold cavity 19b is defined by the upper mold 11, the second bottom component 34b, the second portion 152 of the outer middle mold 15, and the second slider 172. The second core component 32b is disposed within the second mold cavity 19b and suspended by the second support unit 14b. In some embodiments, the first core component 32a completely overlaps the first bottom component 34a, and the second core component 32b completely overlaps the second bottom component 34b.

[0077] Figure 14A and 14B The front and side perspective views of a molding apparatus 10 according to some embodiments of the present invention are shown, in which polymer material M1 is injected into a mold cavity 19 to form an article 30. Figure 15 A perspective view of article 30 according to an embodiment of the present invention is shown.

[0078] In some embodiments, polymer material M1 is injected into a first mold cavity 19a through an opening 121a of a first feed hole 12a to form an article 30a, and polymer material M1 is injected into a second mold cavity 19b through an opening 121b of a second feed hole 12b to form an article 30b. In some embodiments, polymer material M1 comprises thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, polymer material comprises a physical foaming agent, such as a supercritical fluid. In some embodiments, the physical foaming agent is gaseous nitrogen, carbon dioxide, etc. In some embodiments, polymer material M1 is foamable, non-foamable, or slightly foamable. In some embodiments, polymer material M1 comprises a dye. In some embodiments, the density of the core component 32 is higher than the density of the bottom component 34 and polymer material M1. In some embodiments, polymer material M1 forms a layer that completely fills the first mold cavity 19a and the second mold cavity 19b. In some embodiments, more than one type of polymer material is injected into the first mold cavity 19a and the second mold cavity 19b. In some embodiments, different polymer materials are simultaneously injected into the first mold cavity 19a and the second mold cavity 19b, respectively.

[0079] In some embodiments, polymer material M1 is injected into mold cavity 19 to attach bottom component 34. In some embodiments, polymer material M1 flows through opening 321 of core component 32 to bottom component 34. In some embodiments, core component 32 is completely surrounded by polymer material M1. In some embodiments, multiple polymer materials are sequentially injected into mold cavity 19 to form multiple material layers in mold cavity 19, with core component 32 disposed between different material layers.

[0080] In some embodiments, the spacing G2 between the upper mold 11 and the core component 32 (e.g.) Figure 8B The value of M1 is zero, and the polymer material M1 partially surrounds the core component 32. For example, the polymer material M1 surrounds the bottom and sides of the core component 32, such that the top of the core component 32 is exposed in the article 30.

[0081] In some embodiments, different polymer materials are injected into the mold cavity 19 through separate feed holes 12. For example, see... Figure 14B The first polymer material is injected into the second mold cavity 19b through the opening 121b of the left second feed hole 12b, the second polymer material is injected into the second mold cavity 19b through the opening 121b of the middle second feed hole 12b, and the third polymer material is injected into the second mold cavity 19b through the opening 121b of the right second feed hole 12b.

[0082] In some embodiments, the polymer material M1 is further injected into the mold cavity 19 through the feed hole (not shown) of the outer mold 15.

[0083] In some embodiments, the support unit 14 is retractable or movable, and retracts into the upper mold 11, thereby separating from the core component 32 after the polymer material M1 is injected into the mold cavity 19 or after the core component 32 is surrounded by the polymer material M1.

[0084] In some embodiments, after articles 30a and 30b are formed within the molding apparatus 10, articles 30a and 30b are removed from the first mold cavity 19a and the second mold cavity 19b, respectively. In some embodiments, the molding apparatus 10 is in an open configuration when article 30 is removed. In some embodiments, article 30 includes a bottom component 34 and a top component formed of a core component 32 and a polymer material M1. In some embodiments, the bottom component 34 is separated from the core component 32 using the polymer material M1. In some embodiments, article 30 is adhesive-free.

[0085] In some embodiments, after the article 30 is formed, the upper mold 11 is separated from the outer middle mold 15 and the lower mold 13, so that the article 30 can be removed from the outer middle mold 15 and the lower mold 13. In some embodiments, before removing the upper mold 11 and the article 30 from the outer middle mold 15, the first portion 151 and the second portion 152 of the outer middle mold 15 are moved away from each other to increase the distance G1 between the first portion 151 and the second portion 152, such as... Figure 10A As shown, the article 30 can be separated from the outer mold 15 and can be easily removed from the mold cavity 19.

[0086] In some embodiments, the upper mold 11 also includes an inner core. In some embodiments, the mold cavity is defined by the inner core of the upper mold 11, the lower mold 13, the outer middle mold 15, and the slider 171 or 172. In some embodiments, the top surface of the article 30 has a groove formed by the inner core of the upper mold 11.

[0087] Figure 16 A side perspective view of a molding apparatus 10 including an inner mold 113 according to an embodiment of the present invention is shown. In some embodiments, when the molding apparatus 10 is in an open configuration, the inner mold 113 is attached to the upper mold 11. In some embodiments, a mold cavity 19 is defined by the inner mold 113, the upper mold 11, the lower mold 13, the outer middle mold 15, and the inner middle mold 17. In some embodiments, the inner mold 113 includes a shoe last. In some embodiments, a polymer material M1 is injected into the mold cavity 19 to form a layer between the inner mold 113 and the bottom component 34. In some embodiments, a component (or core component 32) is attached to the inner mold 113, and the polymer material M1 is injected into the mold cavity 19 to form a layer between the component attached to the inner mold 113 and the bottom component 34. This layer is formed by physical foaming of the polymer material M1 inside the mold cavity 19.

[0088] The foregoing has outlined the features of several embodiments to enable those skilled in the art to better understand the various aspects of this invention. Those skilled in the art will understand that they can readily use this invention as the basis for designing or modifying other processes and structures to achieve the same purposes and / or advantages as the embodiments described herein. Those skilled in the art should also recognize that such equivalent constructions do not depart from the spirit and scope of this invention, and that various changes, substitutions, and modifications can be made without departing from the spirit and scope of this invention.

[0089] Furthermore, the scope of this invention is not intended to be limited to specific embodiments of the processes, machines, manufactures, compositions of matter, apparatuses, methods, and steps described in the specification. Those skilled in the art will readily understand from the disclosure of this invention that existing or future processes, machines, manufactures, compositions of matter, tools, methods, or steps, according to this invention, can be used to perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein. Therefore, the appended claims are intended to include such processes, machines, manufactures, compositions of matter, apparatuses, methods, and steps within their scope.

[0090] Symbol Explanation

[0091] 10: Molding device

[0092] 11: Upper mold

[0093] 11a: First upper mold

[0094] 11b: Second upper mold

[0095] 12: Feed port

[0096] 12a: First feed hole

[0097] 12b: Second feed port

[0098] 13: Lower mold

[0099] 14: Support Unit

[0100] 14a: First support unit

[0101] 14b: Second support unit

[0102] 15: Outer and middle molds

[0103] 16: Sealing ring

[0104] 16a: First sealing ring

[0105] 16b: Second sealing ring

[0106] 17: Inner mold

[0107] 19: Mold cavity

[0108] 19a: First mold cavity

[0109] 19b: Second mold cavity

[0110] 20: Position control mechanism

[0111] 30, 30a, 30b: Products

[0112] 32: Core Components

[0113] 32a: First Core Component

[0114] 32b: Second Core Component

[0115] 34: Bottom Component

[0116] 34a: First bottom component

[0117] 34b: Second bottom component

[0118] 100: Injection Molding System

[0119] 101: The First Vehicle

[0120] 102: Second Vehicle

[0121] 103: Bridging mechanism

[0122] 104: First ejector

[0123] 105: Second ejector

[0124] 111: Bottom surface

[0125] 112: Top surface

[0126] 113: Inner mold

[0127] 115a: First groove

[0128] 115b: Second groove

[0129] 121, 121a, 121b: Opening

[0130] 131: Part One

[0131] 132: Part Two

[0132] 133: Part Three

[0133] 151: Part One

[0134] 152: Part Two

[0135] 171: First slider

[0136] 172: Second slider

[0137] 200: Molding Station

[0138] 200a: First Molding Station

[0139] 200b: Second Molding Station

[0140] 300: Injection Molding Method

[0141] 321, 321a, 321b: Opening

[0142] C1: First Center

[0143] C2: Second Center

[0144] G1-G3: Spacing

[0145] I-I': line

[0146] II-II': Line

[0147] M1: Polymer material

[0148] R1: First direction

[0149] R2: Second direction

[0150] S310-S360: Operation.

Claims

1. An injection molding system, characterized in that, include: The molding apparatus includes a first mold, a second mold mounted on the first mold, and an intermediate mold located between the first mold and the second mold. The second mold includes a support unit that can extend from and retract into the second mold and face the first mold. The intermediate mold includes an outer intermediate mold and an inner intermediate mold, the inner intermediate mold being surrounded by the outer intermediate mold and movable relative to the outer intermediate mold.

2. The injection molding system as described in claim 1, characterized in that, Further includes: A position control mechanism is configured to control the movement of the intermediate mold so that the intermediate mold engages with the first mold and the second mold.

3. The injection molding system as described in claim 2, characterized in that, The second mold moves to the intermediate mold and the first mold via the position control mechanism.

4. The injection molding system as described in claim 1, characterized in that, The outer mold includes a first part and a second part movable relative to the first part, and the inner mold includes a first slider and a second slider movable relative to the first slider.

5. The injection molding system as described in claim 4, characterized in that, The first portion of the outer mold is movable relative to the first slider, and the second portion of the outer mold is movable relative to the second slider.

6. The injection molding system as described in claim 4, characterized in that, The first slider and the second slider move closer to or further away from each other.

7. The injection molding system as described in claim 4, characterized in that, The first mold includes a first part, a second part, and a third part, with the first part and the second part of the first mold located on opposite sides of the third part of the first mold.

8. The injection molding system as described in claim 7, characterized in that, The first slider and the second slider are disposed on the third part of the first mold and located between the first part and the second part of the first mold.

9. The injection molding system as claimed in claim 4, characterized in that, The first slider is at least partially surrounded by the first portion of the outer mold, and the second slider is at least partially surrounded by the second portion of the outer mold.

10. The injection molding system as claimed in claim 1, characterized in that, The second mold further includes a sealing ring, and the support unit is located within the sealing ring.

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