Injection molded products

Abstract

The present invention provides an injection-molded article comprising a first component and a second component, the second component surrounding the first component, wherein the surface of the first component is in direct contact with the surface of the second component to attach the second component to the first component.

Description

Technical Field

[0001] This invention relates to an injection molding method, particularly to an injection molding method performed by an injection molding apparatus, and especially to an injection molding method for forming an article comprising more than one part having different physical or functional properties. Background Technology

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

[0003] However, it is necessary to improve the properties of foamed products manufactured by injection molding systems, such as giving different parts of the foamed product different properties. Therefore, it is still necessary to improve the structure of the injection molding system and the method of manufacturing foamed products. Utility Model Content

[0004] According to a specific embodiment of the present invention, an injection-molded article includes a first component and a second component, the second component surrounding the first component, wherein the surface of the first component is in direct contact with the surface of the second component to attach the second component to the first component.

[0005] According to a specific embodiment of the present invention, an injection molding method is provided. The injection molding method includes: providing a first mold, a second mold, a third mold fixedly attached to the second mold, and a first component at least partially surrounding the third mold; engaging the first mold and the second mold to form a mold cavity defined by the first mold, the second mold, the third mold, and the first component; injecting a flowable material into the mold cavity; foaming the flowable material to form a second component; detaching the first mold from the second mold; and separating the first component and the second component from the third mold, wherein the second component is attached to the first component during and after the detachment and separation.

[0006] In some embodiments, the flowable material comes into contact with the first component during foaming. In some embodiments, the second component is directly attached to the first component. In some embodiments, the third mold is attachable to the second mold and separable from it. In some embodiments, the first component is fixedly attached to the third mold before separation. In some embodiments, both the first and second components are attached to the third mold during and after the separation. In some embodiments, the third component is placed into the first mold before engagement.

[0007] According to a specific embodiment of the present invention, an injection molding method is provided. The injection molding method includes: joining a first mold and a second mold to form a first mold cavity; injecting a first flowable material into the first mold cavity; foaming the first flowable material to form a first component within the first mold cavity; detaching the first mold from the second mold; replacing the second mold with a third mold; joining the first mold and the third mold to form a second mold cavity defined by the first mold, the third mold, a fourth mold fixedly attached to the third mold, and a third component at least partially surrounding the fourth mold; injecting a second flowable material into the second mold cavity; foaming the second flowable material to form a second component within the second mold cavity; detaching the first mold from the third mold; and separating the first component, the second component, and the third component from the fourth mold, wherein during and after the detachment of the first mold from the third mold, the first component is attached to the second component, and the second component is attached to the third component.

[0008] In some embodiments, the second flowable material is in direct contact with the first and third components during foaming. In some embodiments, the third component is fixedly attached to the fourth mold before the first mold engages with the third mold. In some embodiments, the first component is located within the first mold during replacement of the second mold with the third mold and during engagement of the first mold with the third mold. In some embodiments, an external force is applied to the first component during disengagement of the first mold from the second mold to retain the first component within the first mold. In some embodiments, the external force is provided by pressing the first component against the first mold. In some embodiments, the first component is pressed against the first mold by a pin extending from the second mold. In some embodiments, the external force is provided by ejecting gas toward the first component and the first mold. In some embodiments, the external force is provided by drawing the first component toward the first mold. In some embodiments, during the disengagement of the first mold from the second mold, the first component is retained in the first mold by friction between the engraved surface of the first mold and the engraved surface of the first component that is complementary to the engraved surface of the first mold. In some embodiments, during and after the disengagement of the first mold from the second mold, the engraved surface of the first mold contacts the engraved surface of the first component. In some embodiments, replacing the second mold with the third mold includes moving the second mold away from the first mold and moving the third mold above the first mold, or moving the first mold away from the second mold and toward the third mold. In some embodiments, during and after the disengagement of the first mold from the third mold, the first component, the second component, and the third component are attached to the fourth mold. Attached Figure Description

[0009] The best understanding of this invention can be obtained from the following detailed description when read in conjunction with the accompanying drawings. It should be noted that, in accordance with industry standard practice, the various components are not drawn to scale. In fact, for clarity, the dimensions of many components may be arbitrarily enlarged or reduced.

[0010] Figure 1 A flowchart illustrating the injection molding method according to some specific embodiments of the present invention is provided;

[0011] Figures 2 to 9 Example based on a specific embodiment of the present invention Figure 1 A schematic cross-sectional view of the demonstration stage of the injection molding method;

[0012] Figure 10 A flowchart illustrating the injection molding method according to some specific embodiments of the present invention is provided.

[0013] Figures 11 to 25Example based on a specific embodiment of the present invention Figure 10 A schematic cross-sectional view of the demonstration stage of the injection molding method;

[0014] Figure 26 This is a schematic perspective view of a molding apparatus according to some specific embodiments of the present invention;

[0015] Figure 27 This is a schematic perspective view of a molding apparatus according to some specific embodiments of the present invention;

[0016] Figure 28 A schematic top view of a portion of a molding apparatus according to some specific embodiments of the present invention;

[0017] Figure 29 This is a schematic cross-sectional view of a part of a molding apparatus according to some specific embodiments of the present invention;

[0018] Figure 30 This is a schematic perspective view of a molding apparatus according to some specific embodiments of the present invention;

[0019] Figure 31 This is a schematic perspective view of a molding apparatus according to some specific embodiments of the present invention;

[0020] Figure 32 This is a schematic perspective view of a molding apparatus according to some specific embodiments of the present invention;

[0021] Figure 33 This is a schematic perspective view of a molding apparatus according to some specific embodiments of the present invention;

[0022] Figure 34 This is a schematic cross-sectional view of a part of a molding apparatus according to some specific embodiments of the present invention;

[0023] Figure 35 This is a schematic cross-sectional view of a part of a molding apparatus according to some specific embodiments of the present invention;

[0024] Figure 36 This is a schematic top view of an injection molding system according to some specific embodiments of the present invention;

[0025] Figure 37 This is a schematic perspective view of an injection molding system according to some specific embodiments of the present invention;

[0026] Figure 38 A flowchart illustrating a molding method according to some specific embodiments of the present invention;

[0027] Figure 39 A flowchart illustrating a molding method according to some specific embodiments of the present invention;

[0028] Figures 40-41 , Figures 43-45 , Figure 48 and Figure 49 A schematic perspective view of a portion of an injection molding system used in a method for manufacturing articles according to some specific embodiments of the present invention;

[0029] Figure 42 , Figure 46 , Figure 47 A schematic cross-sectional view illustrating an exemplary operation in a molding method according to a specific embodiment of the present invention;

[0030] Figure 50 A schematic perspective view of an article manufactured using a method for manufacturing an article according to some specific embodiments of the present invention. Detailed Implementation

[0031] [Cross-referencing related applications]

[0032] This application claims priority to U.S. Patent Application No. 19 / 063,333, filed February 26, 2025, and U.S. Provisional Patent Application No. 63 / 666,255, filed July 1, 2024, and is a continuation-in-part (CIP) of U.S. Patent Application No. 18 / 582,693, filed February 21, 2024, which claims priority to U.S. Provisional Patent Application No. 63 / 498,265, filed April 25, 2023, and U.S. Provisional Patent Application No. 63 / 585,970, filed September 28, 2023, which are incorporated herein by reference in their entirety.

[0033] The following description provides many different specific embodiments or examples for implementing various features of the provided object. Specific examples of components and configurations are described below to simplify the present invention. Of course, these are merely examples and are not intended to be limiting. For example, the following description of forming a first feature on or above a second feature may include specific embodiments in which the first and second features are formed in direct contact, and may also include specific embodiments in which an additional feature may be formed between the first and second features such that the first and second features do not directly contact each other. Furthermore, reference numerals and / or words may be repeated in the various examples of the present invention. This repetition is for simplicity and clarity and does not in itself imply a relationship between the various specific embodiments and / or configurations discussed.

[0034] In addition, this document may use spatial terms such as "below," "under," "below," "above," and "above" to describe the relationship between one element or feature and another, as shown in the figures. Besides the orientations depicted in the figures, such spatial terms also cover different orientations of the device during use or operation. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial descriptors used herein may be interpreted accordingly.

[0035] While the numerical ranges and parameters described in the broad scope of this invention are approximate, the values ​​disclosed in the specific examples are reported as precisely as possible. However, any numerical value inherently contains some error due to the standard deviation necessarily 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, when considered by a person skilled in the art, the term "about" means within the acceptable standard error of the average. Except in operational / working examples, or unless expressly stated otherwise, all numerical ranges, quantities, values, and percentages disclosed herein, such as material quantities, durations, temperatures, operating conditions, quantity ratios, etc., should be understood to be modified by the term "about" in all cases. Therefore, unless indicated to the contrary, the numerical parameters described in this invention and the appended claims are approximate values ​​that may vary as needed. At a minimum, each numerical parameter should be interpreted according to the number of significant figures reported and by applying common rounding techniques. In this document, a range may be expressed as from one endpoint to another or between two endpoints. Unless otherwise stated, all ranges disclosed herein include endpoints.

[0036] Figure 1 The following is a flowchart illustrating an injection molding method 1000 according to some specific embodiments of the present invention. The injection molding method 1000 includes steps 1001 to 1006, and the illustrations and examples are not intended to be considered as a limitation on the order of steps 1001 to 1006. Figures 1 to 9 This is a schematic cross-sectional view of the various stages of the injection molding method 1000. In some embodiments, the steps of the injection molding method 1000 can be repeated. In some embodiments, the steps of the injection molding method 1000 can be executed automatically.

[0037] In step 1001, a first mold 101, a second mold 102, a third mold 103, and a first component 105 are arranged, as follows: Figure 2 and Figure 3 As shown inside. Figure 2 and Figure 3An injection molding apparatus 100 is illustrated, configured to perform injection molding method 1000 and form an article. The injection molding apparatus 100 includes a first mold 101, a second mold 102, and a third mold 103. In some embodiments, the first mold 101 is a lower mold, the second mold 102 is an upper mold, and the third mold is an intermediate mold. In some embodiments, the second mold 102 is located above the first mold 101, and the third mold 103 is located between the first mold 101 and the second mold 102. In some embodiments, the third mold 103 may be attached to and detached from the first mold 101 or the second mold 102. Although... Figure 1 The third mold 103 is exemplified as being fixedly attached to the second mold 102, but it should be understood that the third mold 103 may also be fixedly attached to either the first mold 101 or the second mold 102. In some embodiments, the third mold 103 may be movable relative to the first mold 101 and the second mold 102. In some embodiments, the third mold 103 is a shoe last, etc.

[0038] like Figure 2 and Figure 3 As shown, the injection molding apparatus 100 is in the open state, and the first mold 101 is disengaged from the second mold 102. The injection molding apparatus 100 includes a feed inlet 104 configured to allow flowable material to pass through. In some embodiments, the feed inlet 104 is located at either the first mold 101 or the second mold 102. Although Figure 1 For example, the feed inlet 104 is located at the second mold 102, but it is understood that the feed inlet 104 may be located at the first mold 101, the second mold 102, or between the first mold 101 and the second mold 102. In some embodiments, the feed inlet 104 extends through the first mold 101 and / or the second mold 102.

[0039] Figure 3 For example, the first component 105 is placed at the third mold 103. In some embodiments, when the injection molding apparatus 100 is in the open state, the first component 105 is placed on the third mold 103. In some embodiments, the first component 105 is temporarily attached to the third mold 103. In some embodiments, the first component 105 is a footwear component such as an upper or sock. In some embodiments, the first component 105 is non-foamable. In some embodiments, the first component 105 at least partially surrounds the third mold 103.

[0040] In step 1002, the first mold 101 and the second mold 102 are joined to form a mold cavity 107, as shown below. Figure 4 As shown inside. Figure 4An injection molding apparatus 100 is shown in a closed state, with a second mold 102 positioned above and engaged with a first mold 101. In some embodiments, after a first component 105 is placed on a third mold 103, the first mold 101 engages with the second mold 102 to form a mold cavity 107. After the first mold 101 and the second mold 102 are engaged, a mold cavity 107 is formed, defined by the first mold 101, the second mold 102, the third mold 103, and the first component 105. The mold cavity 107 is configured to retain material.

[0041] In some embodiments, the ejector 108 engages with the inlet 104 of the injection molding apparatus 100. In some embodiments, the outlet 108a of the ejector 108 engages with the inlet 104 before or after forming the mold cavity 107. The inlet 104 may communicate with the mold cavity 107. In some embodiments, the ejector 108 is configured to inject flowable material into the mold cavity 107 through the outlet 108a and the inlet 104. In some embodiments, the ejector 108 is connected to a mixing unit (not shown) for mixing a polymeric material with a blowing agent to form a mixture of polymeric material and blowing agent. This mixture formed by the mixing unit is then supplied to the ejector 108 for subsequent injection.

[0042] In some embodiments, the flowable material is a mixture of a polymer and a blowing agent. In some embodiments, the polymer includes polyurethane (PU), thermoplastic polyurethane (TPU), etc. In some embodiments, the blowing agent is a physical or chemical blowing agent. In some embodiments, the blowing agent includes carbon dioxide, nitrogen, etc. In some embodiments, the blowing agent is in a supercritical fluid state. In some embodiments, the flowable material is foamable or microfoamable.

[0043] In step 1003, the flowable material 106' is injected into the mold cavity 107, such as... Figure 5As shown in the diagram. In some embodiments, the flowable material 106' is ejected from the ejector 108 into the mold cavity 107 through the outlet 108a and the inlet 104. In some embodiments, the flowable material 106' surrounds the first component 105 and the third mold 103. In some embodiments, the flowable material 106' partially or completely fills the mold cavity 107. In some embodiments, the flowable material 106' is in direct contact with the first component 105. In some embodiments, there is no adhesive between the flowable material 106' and the first component 105. In some embodiments, there is an adhesive between the flowable material 106' and the first component 105. In some embodiments, the adhesive is applied to the outer surface of the first component 105 (i.e., the surface facing the mold cavity 107) before the first mold 101 is engaged with the second mold 102.

[0044] In step 1004, the flowable material 106' is foamed to become the second component 106, such as... Figure 5 As shown inside. After the flowable material 106' is injected, it undergoes physical foaming within the mold cavity 107 to become the second component 106. The second component 106 is a foamed component. In some embodiments, the flowable material 106' comes into contact with the first component 105 during foaming. In some embodiments, the flowable material 106' and the second component 106 have similar volumes. In some embodiments, the second component 106 is directly attached to the first component 105. In some embodiments, there is no adhesive between the second component 106 and the first component 105. In some embodiments, there is an adhesive between the second component 106 and the first component 105.

[0045] In step 1005, the first mold 101 separates from the second mold 102, as follows: Figure 6 As shown inside. The injection molding apparatus 100 is opened after the second component 106 is formed. In some embodiments, after the second component 106 is formed, the outlet 108a of the ejector 108 disengages from the inlet 104. In some embodiments, after the second component 106 is formed, the first mold 101 disengages from the second mold 102. In some embodiments, the first component 105 is attached to the second component 106, and both the first component 105 and the second component 106 are temporarily attached to the third mold 103 or the second mold 102. In some embodiments, during or after the first mold 101 disengages from the second mold 102, the first component 105 and the second component 106 are temporarily attached to the third mold 103 or the second mold 102. In some embodiments, during or after the second mold 102 disengages from the first mold 101, the first component 105 is permanently attached to the third mold 103. During or after disengagement, the second component 106 is attached to the first component 105.

[0046] In step 1006, the first component 105 and the second component 106 are separated from the third mold 103, as follows: Figure 7 As shown in the diagram. An article 200 comprising a first component 105 and a second component 106 is formed and then removed from the injection molding apparatus 100. The article 200 comprising the first component 105 and the second component 106 can be separated from the third mold 103 and / or the second mold 102. In some embodiments, the article 200 comprising the first component 105 and the second component 106 is separated from the injection molding apparatus 100 and removed after the first mold 101 has disengaged from the second mold 102. During or after separation, the second component 106 is attached to the first component 105. In some embodiments, the first component 105 is fixedly attached to the third mold 103 before separation.

[0047] In some embodiments, the surface of the first component 105 is in direct contact with the surface of the second component 106 without any adhesive. In some embodiments, an adhesive is applied to attach the first component 105 to the second component 106, and vice versa. In some embodiments, the adhesive is applied to the first component 105 before the second component 106 is formed. In some embodiments, the adhesive is applied to either the first component 105 or the second component 106 after the second component 106 is formed. In some embodiments, the second component 106 surrounds the first component 105. In some embodiments, the first component 105 is an upper, shoe, etc. In some embodiments, the article 200 is part of footwear (e.g., outsole, insole, midsole, etc.) or any other product. In some embodiments, the article 200 is footwear, shoe, etc.

[0048] In some specific embodiments, before the first mold 101 and the second mold 102 are joined (i.e., step 1002), the third component 109 is arranged inside the first mold 101, such as... Figure 8 As shown inside. In some embodiments, the first component 105 is placed on the third mold 103 before, after, or simultaneously with the placement of the third component 109. In some embodiments, after the placement of the third component 109, the first mold 101 engages with the second mold 102 to form a mold cavity 107, similar to... Figure 4 In some specific embodiments, the mold cavity 107 is defined by a first mold 101, a second mold 102, a first component 105, and a third component 109.

[0049] In some specific embodiments, after the first mold 101 and the second mold 102 are joined, the flowable material 106' fills the mold cavity 107, similar to... Figure 5In some embodiments, the flowable material 106' is disposed on the third component 109. In some embodiments, the flowable material 106' directly contacts the first component 105 and the third component 109. After the flowable material 106' is injected, it undergoes physical foaming within the mold cavity 107 to become the second component 106, similar to... Figure 6 In some specific embodiments, the first component 105 is directly attached to the second component 106, and the third component 109 is also directly attached to the second component 106.

[0050] After the second component 106 is formed, an article 200' comprising the first component 105, the second component 106, and the third component 109 is formed, as follows: Figure 9 As shown. The article 200' can be separated from the third mold 103 and / or the second mold 102. In some embodiments, after the first mold 101 separates from the second mold 102, the article 200', including the first component 105, the second component 106, and the third component 109, is separated from and removed from the injection molding apparatus 100. In some embodiments, the surface of the first component 105 is in direct contact with the surface of the second component 106 without any adhesive. In some embodiments, the surface of the second component 106 is in direct contact with the surface of the third component 109 without any adhesive.

[0051] In some embodiments, an adhesive is applied to attach the first component 105 to the second component 106, and vice versa. In some embodiments, the adhesive is applied to the first component 105 before the second component 106 is formed. In some embodiments, the adhesive is applied to either the first component 105 or the second component 106 after the second component 106 is formed. In some embodiments, the adhesive is applied to attach the second component 106 to the third component 109, and vice versa. In some embodiments, the adhesive is applied to the third component 109 before the second component 106 is formed. In some embodiments, the adhesive is applied to either the second component 106 or the third component 109 after the second component 106 is formed. In some embodiments, the second component 106 surrounds the first component 105. In some embodiments, the density of the second component 106 is less than the density of the third component 109. In some embodiments, the third component 109 is more wear-resistant than the second component 106. In some embodiments, the first component 105 is an upper, shoe collar, midsole, etc. In some embodiments, the third component 109 is an outsole, etc. In some embodiments, the article 200' is footwear, shoes, etc.

[0052] Figure 10The following is a flowchart illustrating an injection molding method 2000 according to some specific embodiments of the present invention. The injection molding method 2000 includes steps 2001 to 2010, and the illustrations and examples are not intended to be considered as limitations on the order of steps 2001 to 2010. Figures 11 to 25 This is a schematic cross-sectional view of the various stages of the injection molding method 2000. In some embodiments, the steps of the injection molding method 2000 can be repeated. In some embodiments, the steps of the injection molding method 2000 can be executed automatically.

[0053] In step 2001, the first mold 101 and the second mold 302 are joined to form the first mold cavity 307, as shown below. Figure 11 and Figure 12 As shown inside. Figure 11 Example: Another injection molding apparatus 300 is configured to perform injection molding method 2000 and form an article. Injection molding apparatus 300 includes a first mold 101 and a second mold 302. For example... Figure 11 As shown, the injection molding apparatus 300 is in the open state, and the first mold 101 is disengaged from the second mold 302. In some embodiments, the first mold 101 is a lower mold, and the second mold 302 is an upper mold. The injection molding apparatus 300 includes a feed inlet 304, which is configured to allow flowable material to pass through. In some embodiments, the feed inlet 304 is located at either the first mold 101 or the second mold 302. Although Figure 11 The example shows the feed inlet 304 at the second mold 302, but it should be understood that it is not limited to this.

[0054] Figure 12 Example: Injection molding apparatus 300 is in a closed state, and ejector 108 engages with inlet 304 of injection molding apparatus 300. In some embodiments, outlet 108a of ejector 108 engages with inlet 304 before or after the formation of first mold cavity 307. Inlet 304 may communicate with first mold cavity 307. In some embodiments, ejector 108 is configured to inject flowable material through outlet 108a and inlet 304 into first mold cavity 307. In some embodiments, the flowable material is a mixture of polymer material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and foaming agent (e.g., physical foaming agent, such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture may undergo physical foaming treatment within first mold cavity 307. The mixture within first mold cavity 307 becomes a foamed component after physical foaming treatment. In some specific embodiments, the flowable material comprises a polymeric material and is not foamed.

[0055] In step 2002, the third flowable material 109' is injected into the first mold cavity 307, such as... Figure 13 As shown in the diagram. In some embodiments, the third flowable material 109' is ejected from the ejector 108 into the first mold cavity 307 through the outlet 108a and the inlet 304. In some embodiments, the third flowable material 109' fills the first mold cavity 307. In some embodiments, the third flowable material 109' partially or completely fills the first mold cavity 307.

[0056] In step 2003, the third flowable material 109' is foamed to form the third component 109 within the first mold cavity 307, such as Figure 13 As shown inside. After the third flowable material 109' is injected, it undergoes physical foaming within the first mold cavity 307 to become the third component 109. The third component 109 is a foamed component. In some specific embodiments, the third component 109 is a non-foamed component.

[0057] In step 2004, the first mold 101 disengages from the second mold 302, as follows: Figure 14 As shown inside. In some embodiments, the injection molding apparatus 300 is opened after the third component 109 is formed. In some embodiments, after the third component 109 is formed, the outlet 108a of the ejector 108 disengages from the inlet 304.

[0058] In some embodiments, an external force is applied to the third component 109 during the opening of the injection molding apparatus 300, such that the third component 109 is not pulled up and remains in the first mold 101 when the second mold 302 disengages from the first mold 101. In some embodiments, the external force is applied to the third component 109 through the pin 110, such as... Figure 15 As shown in the diagram. In some embodiments, when the second mold 302 disengages from the first mold 101, the pin 110 contacts and presses against the third component 109. The pin 110 provides external force by pressing the third component 109 against the first mold 101. In some embodiments, the external force provided by the pin 110 is sufficient to retain the third component 109 within the first mold 101. In some embodiments, the pin 110 can extend from and retract from the second mold 302.

[0059] In some specific embodiments, external force is applied to the third component 109 through gas ejection, such as... Figure 16 As shown in the diagram. In some specific embodiments, during the disengagement of the second mold 302 from the first mold 101, gas 111 or a fluid such as air is ejected or blown toward the third component 109 or the first mold 101, such that the third component 109 is not pulled up and remains in the first mold 101 when the second mold 302 disengages from the first mold 101.

[0060] In some specific embodiments, the external force is applied to the third component 109 through attraction, such as Figure 17 As shown in the diagram. In some embodiments, a suction force 112 is applied to the third component 109 during the detachment of the second mold 302 from the first mold 101, such that the third component 109 is not pulled up and remains in the first mold 101 when the second mold 302 detaches from the first mold 101. In some embodiments, the suction force 112 is used to attract gas or fluid drawn from the first mold 101.

[0061] In some specific embodiments, the external force is applied to the third component 109 through simultaneous ejection and attraction, such as... Figure 18 As shown inside. In some specific embodiments, gas 111 or fluid is ejected and blown toward the third component 109 or the first mold 101, and suction 112 draws the gas or fluid out of the first mold 101 during the detachment of the second mold 302 from the first mold 101, such that the third component 109 is not pulled up and remains in the first mold 101 when the second mold 302 is detached from the first mold 101.

[0062] In some embodiments, when the second mold 302 detaches from the first mold 101, the third component 109 is not pulled up, but remains in the first mold 101 through the engraved surface of the third component 109. In some embodiments, the engraved surface 109a of the third component 109 (e.g., Figure 14 (As shown) Sufficient friction is provided to allow the third component 109 to remain temporarily in the first mold 101 when the second mold 302 disengages from the first mold 101. In some embodiments, the engraved surface 109a of the third component 109 is formed by a complementary engraved pattern 101a of the first mold 101 during the formation of the third component 109. The complementary engraved pattern 101a of the first mold 101 contacts the outer surface of the third component 109 to engrave the outer surface of the third component 109 as the engraved surface 109a of the third component 109. In some embodiments, the complementary engraved pattern 101a of the first mold 101 contacts the engraved surface 109a of the third component 109 during and after the disengagement of the first mold 101 from the second mold 302.

[0063] The third component 109 is not formed through the injection molding device 300, but is formed outside the injection molding device 300 in advance. Figure 19 and Figure 20 This example illustrates placing a third component 109 into a first mold 101. In some specific embodiments, the third component 109 is formed outside the first mold 101, and then the third component 109 is placed inside the first mold 101, such as... Figure 20 As shown inside.

[0064] In step 2005, the second mold 302 is replaced with another second mold 102, such as... Figure 21 As shown inside. In some specific embodiments, after the injection molding apparatus 300 forms the third component 109 or after the third component 109 is placed inside the first mold 101, the second mold 302 is replaced with the second mold 102 to form the injection molding apparatus 100, as shown inside. Figure 21 As shown. In some embodiments, replacing the second mold 302 with the second mold 102 includes moving the second mold 302 away from the first mold 101 and moving the second mold 102 above the first mold 101, or moving the first mold 101 away from the second mold 302 and towards the second mold 102. In some embodiments, the second mold 102 is placed above the first mold 101 and the third component 109. For example... Figure 21 As shown in the image, the injection molding device 100 is in the open state, and the first mold 101 is separated from the second mold 102.

[0065] In some embodiments, the first mold 101 is a lower mold, the second mold 102 is an upper mold, and the third mold 103 is an intermediate mold. In some embodiments, the second mold 102 is located above the first mold 101, and the third mold 103 is located between the first mold 101 and the second mold 102. In some embodiments, the third mold 103 may be attached to or detached from the first mold 101 or the second mold 102. Although Figure 21 Example: A third mold 103 is attached to a second mold 102, but it should be understood that it is not limited thereto. In some embodiments, the third mold 103 may be movable relative to the first mold 101 and the second mold 102. In some embodiments, the third mold 103 is a shoe last, etc. The injection molding apparatus 100 includes a feed port 104 configured to allow flowable material to pass through. In some embodiments, the feed port 104 is located at either the first mold 101 or the second mold 102. Although Figure 21 The example shows the feed inlet 104 at the second mold 102, but it should be understood that it is not limited thereto.

[0066] In some specific embodiments, the first component 105 is arranged at the third mold 103, such as... Figure 21 As shown in the diagram. In some embodiments, when the injection molding apparatus 100 is in the open state, the first component 105 is placed on the third mold 103. In some embodiments, the first component 105 is fixedly attached to the third mold 103 before the first mold 101 is engaged with the second mold 302. In some embodiments, the first component 105 is temporarily attached to the third mold 103. In some embodiments, the third component 109 is located within the first mold 101 during the replacement of the second mold 302 with the second mold 102.

[0067] In some embodiments, the first component 105 is a footwear component such as an upper or sock. In some embodiments, the first component 105 is non-foamable. In some embodiments, the first component 105 at least partially surrounds the third mold 103. In some embodiments, the first component 105 is placed on the third mold 103 before, after, or simultaneously with the placement of the third component 109. In some embodiments, the third component 109 is formed before or after the placement of the first component 105.

[0068] In step 2006, the first mold 101 and the second mold 102 are joined to form the second mold cavity 107, as shown below. Figure 22 As shown in the diagram. In some embodiments, the second mold cavity 107 is defined by a first mold 101, a second mold 102, a third mold 103 fixedly attached to the second mold 102, and a first component 105 at least partially surrounding the third mold 103. In some embodiments, the third component 109 is located within the first mold 101 during engagement of the second mold 102 and the first mold 101. Figure 22 Example: Injection molding apparatus 100 is in a closed state, and ejector 108 engages with inlet 104 of injection molding apparatus 100. In some embodiments, after first component 105 is placed in third mold 103 and after third component 109 is placed or formed, first mold 101 engages with second mold 102 to form second mold cavity 107. In some embodiments, mold cavity 107 is defined by first mold 101, second mold 102, first component 105, and third component 109. Second mold cavity 107 is configured to retain material.

[0069] In some embodiments, before or after the formation of the second mold cavity 107, the outlet 108a of the ejector 108 engages with the inlet 104. The inlet 104 may communicate with the second mold cavity 107. In some embodiments, the ejector 108 is configured to eject flowable material through the outlet 108a and the inlet 104 into the second mold cavity 107. In some embodiments, the flowable material is a mixture of a polymer material (e.g., polyurethane (PU), thermoplastic polyurethane (TPU), etc.) and a foaming agent (e.g., a physical foaming agent, such as carbon dioxide, nitrogen, supercritical fluid, etc.). The mixture is foamable or slightly foamable. The mixture may undergo a physical foaming process within the mold cavity 107. The mixture within the mold cavity 107 becomes a foamed component after the physical foaming process.

[0070] In step 2007, the flowable material 106' is injected into the second mold cavity 107, such as... Figure 23As shown in the diagram. In some embodiments, the flowable material 106' is ejected from the ejector 108 into the second mold cavity 107 through the outlet 108a and the inlet 104. In some embodiments, the flowable material 106' surrounds the first component 105 and the third mold 103. In some embodiments, the flowable material 106' is disposed on the third component 109. In some embodiments, the flowable material 106' directly contacts the first component 105 and the third component 109.

[0071] In step 2008, the flowable material 106' is foamed to form the second component 106 within the second mold cavity 107, such as Figure 23 As shown inside. After the flowable material 106' is injected, it undergoes physical foaming within the second mold cavity 107 to become the second component 106. In some embodiments, during this foaming process, the flowable material 106' is in direct contact with the first component 105 and the third component 109. The second component 106 is a foamed component. In some embodiments, the flowable material 106' and the second component 106 have similar volumes. In some embodiments, the first component 105 is directly attached to the second component 106, and the third component 109 is also directly attached to the second component 106.

[0072] In step 2009, the first mold 101 separates from the second mold 102, as follows: Figure 24 As shown inside. Figure 24 This example illustrates the opening of the injection molding apparatus 100 after the formation of the second component 106. During and after the first mold 101 disengages from the second mold 102, the first component 105 is attached to the second component 106, and the second component 106 is attached to the third component 109. In some embodiments, after the formation of the second component 106, the outlet 108a of the ejector 108 disengages from the inlet 104. In some embodiments, after the formation of the second component 106, the first mold 101 disengages from the second mold 102. In some embodiments, the first component 105 is attached to the second component 106, and the third component 109 is attached to the second component 106. In some embodiments, the first component 105, the second component 106, and the third component 109 are temporarily attached to either the third mold 103 or the second mold 102. In some specific embodiments, during or after the first mold 101 is detached from the second mold 102, the first component 105, the second component 106, and the third component 109 are temporarily attached to the third mold 103 or the second mold 102.

[0073] In step 2010, the first component 105, the second component 106, and the third component 109 are separated from the second mold 102 and / or the third mold 103, as follows: Figure 25 As shown inside. Figure 25An example is shown of an article 400 formed and removed from the injection molding apparatus 100. The article 400, comprising a first component 105, a second component 106, and a third component 109, can be separated from the third mold 103 and / or the second mold 102. In some embodiments, the article 400, comprising the first component 105, the second component 106, and the third component 109, is separated and removed from the injection molding apparatus 100 after the first mold 101 has disengaged from the second mold 102.

[0074] In some embodiments, surface 105a of the first component 105 is in direct contact with surface 106a of the second component 106 without any adhesive. In some embodiments, surface 106b of the second component 106 is in direct contact with surface 109a of the third component 109 without any adhesive. In some embodiments, adhesive is applied to attach the first component 105 to the second component 106, and vice versa. In some embodiments, adhesive is applied to the first component 105 before the second component 106 is formed. In some embodiments, adhesive is applied to either the first component 105 or the second component 106 after the second component 106 is formed. In some embodiments, adhesive is applied to attach the second component 106 to the third component 109, and vice versa. In some embodiments, adhesive is applied to the third component 109 before the second component 106 is formed. In some specific embodiments, after the second component 106 is formed, an adhesive is applied to the second component 106 or the third component 109.

[0075] In some embodiments, the second component 106 surrounds the first component 105. In some embodiments, the density of the second component 106 is less than the density of the third component 109. In some embodiments, the third component 109 is more wear-resistant than the second component 106. In some embodiments, the first component 105 is an upper, shoe collar, midsole, etc. In some embodiments, the third component 109 is an outsole, etc. In some embodiments, the article 400 is footwear, shoes, etc.

[0076] Figure 25 This is a schematic perspective view of the molding apparatus 100 in a closed state according to some specific embodiments of the present invention, and Figure 26 This is a schematic perspective view of the molding apparatus 100 in the open state.

[0077] In some embodiments, the molding apparatus 100 includes a first mold 11a and a second mold 14, a first mold cavity 19a, and a position control mechanism 20. The first mold 11a serves as an upper mold, and the second mold 14 includes a lower mold 13 and an outer middle mold 15 disposed between the first mold 11a and the lower mold 13. When the first mold 11a and the second mold 14 are arranged opposite each other, the first mold 11a and the second mold 14 together define the first mold cavity 19a for forming an article (not shown). The position control mechanism 20 is attached to the first mold 11a and the second mold 14, and the first mold 11a and the second mold 14 are movable independently via the position control mechanism 20.

[0078] In some embodiments, a first mold 11a, a lower mold 13, and an outer intermediate mold 15 define a first mold cavity 19a. In some embodiments, in certain configurational aspects, such as size, shape, etc., the first mold 11a corresponds to a second mold 14. The first mold 11a can be placed on and engaged with the outer intermediate mold 15. In some embodiments, the setting of the molding apparatus 100 includes conveying the outer intermediate mold 15 toward the lower mold 13, and then positioning the first mold 11a above the outer intermediate mold 15. In some embodiments, the first mold 11a is aligned with the lower mold 13. In some embodiments, such as Figure 26 As shown, the molding device 100 is in the open state. In some specific embodiments, the first mold 11a is arranged above the outer middle mold 15, is movable relative to the outer middle mold 15 and can engage with it, and the outer middle mold 15 is arranged above the lower mold 13, is movable relative to it and can engage with it.

[0079] Figure 27 A schematic top view showing a portion of the molding apparatus 100 in a closed state. Figure 28 For along Figure 27 A cross-sectional view of a portion of the forming apparatus 100 for the IV-IV' line. In some embodiments, the outer middle mold 15 of the second mold 14 includes a first portion 151 and a second portion 152 that are adjacent to each other and engageable with each other. In some embodiments, the first portion 151 and the second portion 152 are movable and separable from each other. The first portion 151 and the second portion 152 can move toward or away from each other. In some embodiments, the extension 151a of the first portion 151 and the extension 152a of the second portion 152 surround the lower mold 13. The lower mold 13 can be stationary relative to the first portion 151 and the second portion 152. In some embodiments, when the forming apparatus 100 is in the closed state, the first portion 151 and the second portion 152 are attached to each other and engage to seal the first mold cavity 19a. In some embodiments, when the forming apparatus 100 is in the open state (e.g., Figure 26As shown, the first portion 151 and the second portion 152 are separated from each other, and the article (not shown) formed in the first mold cavity 19a can be easily removed from the first mold cavity 19a. In some embodiments, the first portion 151 slides away from the second portion 152 to extend the first mold cavity 19a. In some embodiments, the first mold cavity 19a is in an extended state when the molding apparatus 100 is in this open state.

[0080] In some specific embodiments, refer again Figure 25 and Figure 26 The first mold 11a can rotate about a first axis C1 via the hinge 24 of the position control mechanism 20. In some embodiments, the first mold 11a can tilt by rotating about the first axis C1. In some embodiments, when the first mold 11a tilts (e.g. Figure 26 As shown, a first angle σ1 exists between the bottom surface of the first mold 11a and the top surface 131 of the lower mold 13. In some embodiments, the first angle σ1 is between 0 and 90 degrees. In some embodiments, the first angle σ1 is between 10 and 80 degrees. In some embodiments, the first mold 11a can rotate about a first axis C1 and along a first direction R1. The first direction R1 is clockwise or counterclockwise.

[0081] In some embodiments, the second mold 14 can move linearly along the track 25 of the position control mechanism 20. In some embodiments, the outer middle mold 15 and the lower mold 13 are arranged on the platform 23 and can move linearly along the track 25 of the position control mechanism 20, thereby controlling the first distance D1 between the first mold 11a and the second mold 14. In some embodiments, when the molding device 100 is in the closed state, the platform 23 can press the second mold 14 against the first mold 11a, for example, pressing the outer middle mold 15 and the lower mold 13 against the first mold 11a.

[0082] Figure 29 , Figure 30 , Figure 31 and Figure 32 This is a schematic perspective view of a molding apparatus 200 according to some specific embodiments of the present invention. Figure 33 This is a schematic perspective view of a portion of a molding apparatus 200 according to some specific embodiments of the present invention. For ease of illustration, reference numerals having similar or identical functions and characteristics are repeated in different embodiments and drawings.

[0083] In some specific embodiments, reference is made to Figure 29 , Figure 30 , Figure 31 and Figure 32The molding apparatus 200 is similar to the molding apparatus 100 and further includes a third mold 11c attached to and movable by the position control mechanism 20. The third mold 11c can be placed on and engaged with the outer intermediate mold 15. In some embodiments, setting the molding apparatus 200 includes conveying the outer intermediate mold 15 toward the lower mold 13, and then positioning either the first mold 11a or the third mold 11c above the outer intermediate mold 15. In some embodiments, the third mold 11c can be aligned with the lower mold 13. The third mold 11c can rotate about a first axis C1 via a hinge 24 of the position control mechanism 20, and can rotate about a second axis C2 orthogonal to the first axis C1 via a pivot 26 of the position control mechanism 20. The first mold 11a and the third mold 11c can rotate together about the second axis C2. In some embodiments, the first mold 11a can rotate about the second axis C2 via the pivot 26 of the position control mechanism 20.

[0084] In some embodiments, the molding apparatus 200 includes a first mold 11a, a second mold 14, a third mold 11c, a fourth mold 17a, a fifth mold 17b, and a position control mechanism 20. In some embodiments, the first mold 11a and the third mold 11c are attached to the position control mechanism 20, and the second mold 14, including an outer middle mold 15 and a lower mold 13, is arranged on the platform 23 of the position control mechanism 20.

[0085] In some specific embodiments, the molding apparatus 100 (e.g. Figure 26 (As shown) and the molding apparatus 200 each further include a fourth mold 17a attached to the first mold 11a. In some embodiments, when the first mold 11a is arranged opposite to the second mold 14 and the fourth mold 17a is surrounded by the first mold cavity 19a, the first mold cavity 19a is defined by the first mold 11a, the second mold 14 and the fourth mold 17a. In some embodiments, the fourth mold 17a includes a shoe last.

[0086] In some embodiments, the molding apparatus 200 further includes a fifth mold 17b attached to the third mold 11c. In some embodiments, the fifth mold 17b includes a shoe last. The position control mechanism 20 is configured to move the first mold 11a and the fourth mold 17a relative to the second mold 14, and to move the third mold 11c and the fifth mold 17b relative to the second mold 14. The first mold 11a and the third mold 11c are movably attached to the second mold 14 under the action of the position control mechanism 20.

[0087] In some embodiments, the position control mechanism 20 drives or actuates the first mold 11a and the third mold 11c to move toward or away from the second mold 14. It is understood that the maximum displacement of the first mold 11a relative to the outer mold 15, and the maximum displacement of the third mold 11c relative to the outer mold 15, are both limited by the position control mechanism 20. In some embodiments, the first distance D1 between the first mold 11a and the second mold 14 is controlled by the position control mechanism 20.

[0088] In some embodiments, the position control mechanism 20 is configured to drive or actuate the first mold 11a upward when the molding device 200 is in the open state, so that a first distance D1 is generated between the second mold 14 and the first mold 11a. In some embodiments, the position control mechanism 20 is configured to generate relative movement between the first mold 11a and the second mold 14. Figure 32 As shown, the molding device 200 is in the open state, and the first distance D1 reaches its maximum value. In some embodiments, the position control mechanism 20 is configured to drive or actuate the third mold 11c upward when the molding device 200 is in the open state, so as to create a gap (not shown) between the second mold 14 and the third mold 11c. In some embodiments, the position control mechanism 20 is configured to generate relative movement between the third mold 11c and the second mold 14.

[0089] In some specific embodiments, the position control mechanism 20 can rotate about the second axis C2 and along the second direction R2, and as the position control mechanism 20 rotates about the second axis C2, the first mold 11a and the third mold 11c can be sequentially positioned above the second mold 14. The second direction R2 is clockwise or counterclockwise. In some specific embodiments, refer to... Figure 31 and Figure 32 From a top-down viewpoint, when the first mold 11a is positioned above and aligned with the second mold 14 (including the lower mold 13 and the outer middle mold 15), the third mold 11c is laterally offset from the second mold 14. In some specific embodiments, from a top-down viewpoint, when the third mold 11c is positioned above and aligned with the second mold 14, the first mold 11a is laterally offset from the second mold 14 (not shown).

[0090] In some embodiments, the first mold 11a and the third mold 11c are rotatable about a first axis C1 and along a first direction R1. In some embodiments, during the rotation of the first mold 11a and the third mold 11c about the first axis C1, the third angle σ3 is fixed. In some embodiments, the position control mechanism 20 is attached to the first end 11d of the first mold 11a and configured to tilt the first mold 11a relative to the second mold 14. In some embodiments, the position control mechanism 20 is configured to tilt the first mold 11a relative to the lower mold 13 and the outer middle mold 15, so that the second end 11e of the first mold 11a moves higher than the first end 11d of the first mold 11a (e.g., ...). Figure 29 and Figure 30 (As shown). When the first distance D1 between the first mold 11a and the outer middle mold 15 is greater than or equal to zero, the first mold 11a can be tilted via the position control mechanism 20. In some embodiments, before the fourth mold 17a tilts, the bottom surface of the first mold 11a is parallel to the top surface of the outer middle mold 15. In some embodiments, the position control mechanism 20 is configured to generate a relative tilt between the fourth mold 17a and the outer middle mold 15. In some embodiments, when the first mold 11a and the fourth mold 17a tilt (e.g. Figure 29 and Figure 30 As shown, a first angle σ1 exists between the first mold 11a and the second mold 14. In some embodiments, the first angle σ1 is between 0 and 90 degrees. In some embodiments, the first angle σ1 is between 20 and 70 degrees. In some embodiments, when the position control mechanism 20 rotates around the second axis C2, the first angle σ1 is 45 degrees.

[0091] In some embodiments, the position control mechanism 20 is attached to the first end 11f of the third mold 11c and configured to tilt the third mold 11c relative to the second mold 14. In some embodiments, the position control mechanism 20 is configured to tilt the third mold 11c relative to the second mold 14 such that the second end 11g of the third mold 11c moves higher than the first end 11f of the third mold 11c. The third mold 11c can be tilted via the position control mechanism 20 when the gap (not shown) between the third mold 11c and the second mold 14 is greater than or equal to zero. In some embodiments, before the third mold 11c tilts, the bottom surface of the third mold 11c is parallel to the top surface of the outer middle mold 15. In some embodiments, the position control mechanism 20 is configured to generate a relative tilt between the third mold 11c and the outer middle mold 15. In some embodiments, when the third mold 11c tilts relative to the fifth mold 17b, a second angle σ2 exists between the third mold 11c and the second mold 14. In some embodiments, the second angle σ2 is between 0 and 90 degrees. In some embodiments, the second angle σ2 is between 20 and 70 degrees. In some embodiments, when the position control mechanism 20 rotates about the second axis C2, the second angle σ2 is 45 degrees.

[0092] In some specific embodiments, reference is made to Figure 29 and Figure 30 The fourth mold 17a includes a first end 173 and a second end 174 opposite to the first end 173. The position control mechanism 20 is configured to tilt the fourth mold 17a relative to the second mold 14 so that the second end 174 of the fourth mold 17a moves higher than the first end 173 of the fourth mold 17a.

[0093] In some embodiments, when the first mold 11a and the third mold 11c are attached to the position control mechanism 20, a third angle σ3 exists between the first mold 11a and the third mold 11c. In some embodiments, the third angle σ3 is between 0 and 180 degrees. In some embodiments, the third angle σ3 is between 40 and 140 degrees. In some embodiments, the third angle σ3 is 90 degrees when the position control mechanism 20 rotates about the second axis C2. In some embodiments, the third angle σ3 is fixed during the rotation of the first mold 11a and the third mold 11c about the second axis C2. In some embodiments, the third angle σ3 changes during the rotation of the first mold 11a and the third mold 11c about the second axis C2. In other words, during the rotation of the first mold 11a and the third mold 11c about the second axis C2, at least one of the first mold 11a and the third mold 11c can rotate about the first axis C1.

[0094] Figure 33 and Figure 34This is a cross-sectional view of a portion of the molding apparatus 200. In some embodiments, the first mold 11a and the third mold 11c are configured differently. In some embodiments, the first mold 11a and the third mold 11c are configured similarly. In some embodiments, please refer to... Figure 33 When the first mold 11a and the second mold 14 are arranged opposite each other and the fourth mold 17a is surrounded by the first mold cavity 19a, the first mold cavity 19a is defined by the first mold 11a, the outer middle mold 15, the fourth mold 17a and the lower mold 13, and the molding apparatus 200 is in a first closed state. In some specific embodiments, when the first mold 11a and the second mold 14 are arranged opposite each other, the third mold 11c is offset from the first mold 11a at approximately a right angle.

[0095] In some embodiments, the first feed port 12a extends through the first mold 11a. In some embodiments, the first mold 11a includes the first feed port 12a. The first feed port 12a has an opening 121a disposed on the first mold 11a. In some embodiments, the second mold 14 includes the first feed port 12a. In some embodiments, the outer middle mold 15 or the lower mold 13 includes the first feed port 12a. In some embodiments, when the molding device 200 is in the first closed state, such as Figure 33 As shown in the diagram, the first feed port 12a can be connected to the first mold cavity 19a.

[0096] Alternatively, in some embodiments, the material may enter the first mold cavity 19a via a plurality of first inlets 12a. For simplicity and clarity, two first inlets 12a are illustrated, but it will be understood that any suitable number of first inlets 12a may be provided at the first mold 11a. In some embodiments, the first inlets 12a are not provided at the first mold 11a, but are instead located at the lower mold 13 or the outer middle mold 15 for entering and exiting the first mold cavity 19a. In some embodiments, each first inlet 12a may be located at the first mold 11a, the top surface 131 of the lower mold 13, the inner sidewall 153 of the outer middle mold 15, or any other suitable location, provided that the first inlet 12a communicates with the first mold cavity 19a.

[0097] In some embodiments, the molding apparatus 200 further includes one or more pressure regulating systems 16. In some embodiments, the pressure regulating system 16 is attached to the second mold 14. In some embodiments, the pressure regulating system 16 is attached to the lower mold 13 or the outer / middle mold 15. In some embodiments, when the first mold 11a is arranged opposite the second mold 14, the pressure regulating system 16, including a gas conduit 161 and engagement points 167, is connected to the first mold cavity 19a and the gas conduit 161. In some embodiments, the second mold 14 is provided with a plurality of engagement points 167 and connected to the first mold cavity 19a. In some embodiments, the engagement points 167 are configured to allow fluid or gas to enter or exit the first mold cavity 19a. The position, shape, and number of engagement points 167 are not particularly limited and can be adjusted as needed. In some embodiments, each engagement point 167 is an orifice. In some embodiments, the engagement points 167 are configured to supply or discharge gas.

[0098] In some embodiments, the pressure regulating system 16 further includes a pressure sensing unit (not shown) configured to sense the pressure within the first mold cavity 19a. The pressure sensing unit (not shown) is not limited to any particular type, as long as it can sense pressure and provide pressure information after sensing the pressure within the first mold cavity 19a. The pressure regulating system 16 adjusts the pressure within the first mold cavity 19a by changing the conditions for gas to leave / enter the first mold cavity 19a based on the pressure information provided by the pressure sensing unit (not shown), thereby obtaining a component with a desired predetermined shape and properties. In some embodiments, the pressure sensing unit (not shown) is disposed within the first mold cavity 19a.

[0099] In some embodiments, one end of the first gas conduit 161 is connected to the junction 167, and the other end of the first gas conduit 161 is connected to the gas controller 163. In some embodiments, the gas controller 163 is configured to supply or discharge a fluid or gas, wherein a suitable fluid or gas can be supplied or discharged as needed; for example, the fluid or gas may be air, an inert gas, etc., but the present invention is not limited thereto.

[0100] In some specific embodiments, reference is made to Figure 34 When the molding device 200 is in the second closed state, the third mold 11c, the outer middle mold 15, the lower mold 13, and the fifth mold 17b define the second mold cavity 19b. In some specific embodiments, when the third mold 11c is arranged opposite to the second mold 14, the first mold 11a and the third mold 11c are offset at approximately a right angle.

[0101] In some embodiments, the second feed port 12b extends through the third mold 11c. In some embodiments, the third mold 11c includes the second feed port 12b. The second feed port 12b has an opening 121b disposed on the third mold 11c. In some embodiments, the second mold 14 includes the second feed port 12b. In some embodiments, when the third mold 11c and the second mold 14 are arranged opposite each other and the fifth mold 17b is surrounded by the second mold cavity 19b, the second feed port 12b can communicate with the second mold cavity 19b, and the molding device 200 is in a second closed state, such as... Figure 34 As shown.

[0102] Alternatively, in some embodiments, the material can enter the second mold cavity 19b via multiple second inlets 12b. For simplicity and clarity, two second inlets 12b are illustrated, but it will be understood that any suitable number of second inlets 12b can be provided at the third mold 11c. In some embodiments, the second inlets 12b are not provided at the third mold 11c, but are instead located at the lower mold 13 or the outer middle mold 15 to enter and exit the second mold cavity 19b. In some embodiments, each second inlet 12b can be located at the third mold 11c, the top surface 131 of the lower mold 13, the inner sidewall 153 of the outer middle mold 15, or any other suitable location, provided that the second inlet 12b communicates with the second mold cavity 19b.

[0103] In some embodiments, when the third mold 11c is arranged opposite to the second mold 14, a pressure regulating system 16, including a gas conduit 161 and a connection point 167, is connected to the second mold cavity 19b and the gas conduit 161. In some embodiments, the second mold 14 is provided with a plurality of connection points 167 and is connected to the second mold cavity 19b. In some embodiments, the connection points 167 are configured to allow fluid or gas to enter or exit the second mold cavity 19b.

[0104] In some embodiments, the pressure regulating system 16 further includes a pressure sensing unit (not shown) configured to sense the pressure within the second mold cavity 19b. The pressure sensing unit (not shown) is not limited to any particular type, as long as it can sense pressure and provide pressure information after sensing the pressure within the second mold cavity 19b. The pressure regulating system 16 adjusts the pressure within the second mold cavity 19b by changing the conditions for gas to leave / enter the second mold cavity 19b based on the pressure information provided by the pressure sensing unit (not shown), thereby obtaining a component with a desired predetermined shape and properties. In some embodiments, the pressure sensing unit (not shown) is disposed within the second mold cavity 19b.

[0105] Figure 35This is a top view of an injection molding system 300 according to some specific embodiments of the present invention. Figure 36 This is a schematic perspective view of an injection molding system 300 according to some specific embodiments of the present invention.

[0106] In some specific embodiments, reference is made to Figure 35 and Figure 36 The injection molding system 300 includes a carrier 101c having a plurality of molding stations 400, and each molding station 400 is configured to carry either a molding device 100 or a molding device 200. In some specific embodiments, Figures 29 to 32 The illustrated molding apparatus 200 is arranged in one of the molding stations 400 and includes a position control mechanism 20, a first mold 11a, a third mold 11c, and a second mold 14 held by the position control mechanism 20. The position control mechanism 20 is configured to move the first mold 11a, the second mold 14, and the third mold 11c individually.

[0107] The first injection station 21 is located near the carrier 101c and is configured to inject the first polymer material into the first mold cavity 19a of the molding apparatus 200. The first mold cavity 19a of the molding apparatus 200 is defined by the first mold 11a and the second mold 14, which includes the outer and middle molds 15 and the lower mold 13. In some specific embodiments, the second injection station 22 is located near the carrier 101c and is separate from the first injection station 21. The second injection station 22 is configured to inject the second polymer material into the second mold cavity 19b of the molding apparatus 200, which is defined by the second mold 14 and the third mold 11c.

[0108] In some embodiments, the molding station 400 is disposed on the carrier 101c, and multiple molding devices 200 are arranged above the carrier 101c and respectively disposed in the molding station 400. In some embodiments, the first injection station 21 and the second injection station 22 are both arranged near the carrier 101c and above the two molding stations 400.

[0109] In some embodiments, the first injection station 21 includes a first extrusion system (not shown) and a first discharge channel (not shown) disposed above a molding station 400. In some embodiments, the first polymeric material produced by the first injection station 21 is a mixture of a first polymeric material and a first foaming agent. In some embodiments, the first discharge channel may communicate with the first extrusion system and includes a first outlet disposed remotely from the first extrusion system, configured to discharge the first polymeric material into the molding apparatus 200 through a first feed port 12a. In some embodiments, the molding apparatus 200 is configured to receive the first polymeric material from the first outlet of the first discharge channel. In some embodiments, the first feed port 12a may communicate with a first mold cavity 19a and engage with the first outlet. In some embodiments, the first polymeric material is non-foamable or microfoamable.

[0110] In some embodiments, the second injection station 22 includes a second extrusion system (not shown) and a second discharge channel (not shown) disposed above a molding station 400. In some embodiments, the second polymeric material produced by the second injection station 22 is a mixture of the second polymeric material and a second foaming agent. In some embodiments, the second discharge channel may communicate with the second extrusion system and includes a second outlet disposed remotely from the second extrusion system, and is configured to discharge the second polymeric material into the molding apparatus 200 through a second feed port 12b. In some embodiments, the molding apparatus 200 is configured to receive the second polymeric material from the second outlet of the second discharge channel. In some embodiments, the second feed port 12b may communicate with a second mold cavity 19b and engage with the second outlet. In some embodiments, the second polymeric material is non-foamable or microfoamable.

[0111] In some embodiments, the carrier 101c is annular. In some embodiments, the carrier 101c can rotate about a third center C3 and along a third direction R3. In some embodiments, the carrier 101c can rotate clockwise or counterclockwise. In some embodiments, the carrier 101c rotates at predetermined intervals.

[0112] In some embodiments, the first delivery station 21 and the second delivery station 22 are separate from each other. In some embodiments, there is a predetermined distance between the first delivery station 21 and the second delivery station 22. In some embodiments, the first delivery station 21 and the second delivery station 22 operate and are controlled automatically. In some embodiments, the first delivery station 21 and the second delivery station 22 can communicate with each other through any suitable communication protocol (e.g., Programmable Logic Control (PLC) protocol).

[0113] In this new invention, a molding method M10 is also disclosed. Figure 37 The present invention is a flowchart of a molding method M10 according to some specific embodiments thereof. Method M10 includes a number of operations: (O101) providing a molding apparatus having a first mold, a second mold, and a third mold; (O102) engaging the first mold with the second mold to form a first mold cavity defined by the first mold and the second mold; (O103) injecting a first polymeric material into the first mold cavity to form a first layer from the first polymeric material in the first mold cavity; (O104) disengaging the first mold from the second mold via a position control mechanism; (O105) engaging the third mold with the second mold to form a second mold cavity defined by the second mold, the third mold, and the fourth mold; (O106) injecting a second polymeric material into the second mold cavity and onto the first layer to form an article including the first layer and a second layer made of the second polymeric material; and (O107) disengaging the third mold from the second mold via the position control mechanism. In some specific embodiments, method M10 includes using molding apparatus 200.

[0114] In this new invention, a molding method M20 is also disclosed. Figure 38 This is a flowchart of method M20 of a molding method according to some specific embodiments of the present invention. Method M20 includes a number of operations: (O201) providing a molding apparatus having a first mold, a second mold, and a third mold; (O202) engaging the first mold and the second mold to form a first mold cavity defined by the first mold and the second mold; (O203) injecting a first polymeric material into the first mold cavity to form a first layer from the first polymeric material in the first mold cavity; (O204) injecting a second polymeric material into the first mold cavity to form a second layer from the second polymeric material in the first mold cavity; (O205) disengaging the first mold from the second mold via a position control mechanism. (O206) Arrange a component in a fifth mold attached to the third mold; (O207) Join the third mold with the second mold to form a second mold cavity defined by the second mold, the third mold, and the fifth mold; (O208) Inject a third polymeric material into the second mold cavity and onto the first and second layers to form an article comprising the first layer, the second layer, and a third layer made of the third polymeric material; (O209) Disengage the third mold from the second mold via the position control mechanism; and (O210) Obtain the article comprising the first layer, the second layer, and the component from the molding apparatus.

[0115] In some specific embodiments, the molding method M20 includes using a molding apparatus 200. The method comprises numerous operations, and the illustrations and examples are not intended to limit the order of operations. Figures 29 to 49 This is a schematic perspective view of one or more operations of the molding method M20 according to some specific embodiments of the present invention.

[0116] In some specific embodiments, Figure 35 and Figure 36 The image illustrates an injection molding system 300 operating O201 according to some specific embodiments of the present invention, method M20. In some embodiments, molding method M20 includes operation O201, which includes providing a molding apparatus 200 having a first mold 11a, a second mold 14, a third mold 11c, and a position control mechanism 20. In some embodiments, the second mold 14 includes a lower mold 13 and an outer middle mold 15, and a fourth mold 17a is attached to the first mold 11a. In some embodiments, such as... Figure 29 , Figure 30 , Figure 31 and Figure 32 The molding apparatus 200 is provided or received as shown. In some embodiments, the molding apparatus 200 is configured to form an article. In some embodiments, the molding apparatus 200 includes a pressure regulating system 16 having a junction 167, a gas conduit 161, and a pressure sensing unit (not shown).

[0117] In some specific embodiments, please refer to Figure 39 During operation O201, the molding apparatus 200 is in the open state. In some embodiments, during operation O201, the first mold 11a and the second mold 14 are separated from each other. In some embodiments, the first mold 11a is moved vertically to a first position above the second mold 14. At this first position, the first mold 11a is aligned with the second mold 14 of the molding apparatus 200. In some embodiments, the first distance D1 between the first mold 11a and the second mold 14 is greater than 0.

[0118] In some embodiments, the position control mechanism 20 moves the first mold 11a toward or away from the second mold 14. In some embodiments, the position control mechanism 20 moves the second mold 14, disposed on the platform 23, toward or away from the first mold 11a. In some embodiments, the position control mechanism 20 holds a third mold 11c offset from the second mold 14. In some embodiments, the molding method M20 includes hingedly rotating the first mold 11a toward the second mold 14, or linearly moving the second mold 14 toward the first mold 11a, to engage the first mold 11a with the second mold 14. In some embodiments, the molding method M20 includes pivoting the first mold 11a and the third mold 11c to position either the first mold 11a or the third mold 11c above the second mold 14.

[0119] In some specific embodiments, reference is made to Figure 40 A carrier 101c is provided having multiple molding stations 400, each molding station 400 including a molding device 200. In some embodiments, the molding device 200 is arranged within one of the molding stations 400 of the carrier 101c. In some embodiments, a first injection station 21 configured to inject a first polymeric material into the molding device 200 and a second injection station 22 configured to inject a second polymeric material into the molding device 200 are provided, and both injection stations are arranged adjacent to the carrier 101c.

[0120] In some specific embodiments, the molding method M20 includes operation O202, which includes engaging a first mold 11a with a second mold 14 to form a first mold cavity 19a defined by the first mold 11a and the second mold 14.

[0121] In some specific embodiments, the position control mechanism 20 hinges the first mold 11a toward the second mold 14 about the first axis C1 and along the first direction R1, or linearly moves the second mold 14 toward the first mold 11a, so that the first mold 11a engages with the second mold 14. The first direction R1 is clockwise or counterclockwise.

[0122] In some embodiments, the position control mechanism 20 pivots the first mold 11a and the third mold 11c about a second axis C2 and along a second direction R2 to position either the first mold 11a or the third mold 11c above the second mold 14. The second direction R2 is clockwise or counterclockwise. In some embodiments, the pivot rotation and the hinge rotation are performed sequentially and separately.

[0123] In some specific embodiments, reference is made to Figure 41 In the molding apparatus 200, the first mold 11a, the lower mold 13, the outer and middle molds 15, and the fourth mold 17a are in a first closed state, and the third mold 11c is held by the position control mechanism 20. In some specific embodiments, from a top view, the third mold 11c and the second mold 14 are laterally offset.

[0124] In some embodiments, the second angle σ2 between the third mold 11c and the second mold 14 ranges from 0 to 90 degrees. In some embodiments, the second angle σ2 is 90 degrees when the molding device 200 is in the first closed state. In some embodiments, the third angle σ3 between the first mold 11a and the third mold 11c ranges from 0 to 180 degrees. In some embodiments, the third angle σ3 is 90 degrees when the molding device 200 is in the first closed state.

[0125] In some specific embodiments, the molding method M20 includes operation O203, which includes injecting a first polymeric material into a first mold cavity 19a to form a first layer M1 from the first polymeric material in the first mold cavity 19a.

[0126] Still refer to Figure 41 The first polymeric material is injected into the first mold cavity 19a through a first feed port 12a. In some embodiments, the first polymeric material includes thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the first polymeric material includes 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, the first polymeric material is foamable, non-foamable, or slightly foamable. In some embodiments, the first polymeric material includes a first dye. In some embodiments, the first polymeric material forms a first layer M1 in the first mold cavity 19a. In some embodiments, the first layer M1 is formed between the first mold 11a and the lower mold 13. In some embodiments, the first layer M1 is formed between the fourth mold 17a and the lower mold 13.

[0127] In some embodiments, the pressure within the first mold cavity 19a is sensed before the first polymer material is injected. In some embodiments, a first gas (not shown) is injected into the first mold cavity 19a through the junction 167 before the first polymer material is injected, until the first mold cavity 19a is sensed to have a first predetermined pressure.

[0128] In some embodiments, the method further includes sensing the pressure within the first mold cavity 19a and filling the first polymer material from the first inlet 12a into the first mold cavity 19a having a first predetermined pressure. In some embodiments, the method further includes discharging a portion of a first gas (not shown) from the first mold cavity 19a through the junction 167.

[0129] In some embodiments, when the molding apparatus 200 is in a first closed state, a first force is applied to the second mold 14 toward the first mold 11a to facilitate engagement of the first mold 11a and the second mold 14. In some embodiments, the first force is applied to the second mold 14 before the first gas is injected into the first mold cavity 19a, or before the first polymer material is injected into the first mold cavity 19a. In some embodiments, the first force is applied to the second mold 14 during the injection of the first gas into the first mold cavity 19a, or during the injection of the first polymer material into the first mold cavity 19a. In some embodiments, the platform 23 provides the first force to the second mold 14.

[0130] In some embodiments, the molding apparatus 200 is arranged on the carrier 101c, and both the first extrusion system (not shown) and the molding apparatus 200 are arranged in the first injection station 21, and the first polymer material is injected from the first extrusion system into the molding apparatus 200 in the first injection station 21. In some embodiments, the first polymer material is injected into the molding apparatus 200 through a first mold 11a.

[0131] In some embodiments, at the first injection station 21, the first die 11a is attached to the outer middle die 15, and the third die 11c, held by the position control mechanism 20, is arranged away from the outer middle die 15. In some embodiments, the first die 11a is arranged below the first extrusion system. In some embodiments, the third die 11c is arranged above the position control mechanism 20.

[0132] In some specific embodiments, the molding method M20 includes operation O204, which includes injecting a second polymeric material into a first mold cavity 19a to form a second layer M2 from the second polymeric material in the first mold cavity 19a.

[0133] Still refer to Figure 41 The second polymeric material is injected into the first mold cavity 19a through a first feed port 12a. In some embodiments, both the first and second polymeric materials are injected into the first mold cavity 19a. In some embodiments, the second polymeric material includes thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the second polymeric material includes 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, the second polymeric material is foamable, non-foamable, or slightly foamable. In some embodiments, the second polymeric material includes a second dye. The second dye may be similar to or different from the first dye. In some embodiments, both the first and second polymeric materials are non-foamable. In some embodiments, both the first and second polymeric materials are slightly foamable. In some embodiments, the composition of the second polymeric material is similar to or different from the composition of the first polymeric material. In some embodiments, both the first and second polymeric materials have different physical properties, such as different densities.

[0134] In some embodiments, the second polymer material forms a second layer M2 adjacent to the first layer M1. In some embodiments, the second layer M2 is connected to the first layer M1. In some embodiments, the second layer M2 is spaced apart from the first layer M1. In some embodiments, the second layer M2 is formed between the first mold 11a and the lower mold 13. In some embodiments, the second layer M2 is formed between the fourth mold 17a and the lower mold 13. In some embodiments, the first polymer material and the second polymer material are injected simultaneously. In some embodiments, the first layer M1 and the second layer M2 are formed simultaneously. In some embodiments, the first layer M1 and the second layer M2 have different physical properties, such as different densities. The first layer M1 and the second layer M2 may be the same or different colors.

[0135] In some embodiments, the pressure within the first mold cavity 19a is sensed before the second polymer material is injected. In some embodiments, a second gas (not shown) is injected into the first mold cavity 19a through the junction 167 before the second polymer material is injected, until the first mold cavity 19a is sensed to have a second predetermined pressure.

[0136] In some embodiments, the molding method M20 further includes sensing the pressure within the first mold cavity 19a and filling the first mold cavity 19a with a second predetermined pressure from the first feed port 12a. In some embodiments, the molding method M20 further includes discharging a portion of a second gas (not shown) from the first mold cavity 19a through the joint 167. In some embodiments, the second predetermined pressure is the same as the first predetermined pressure.

[0137] In some embodiments, a second force is applied to the second mold 14 before the second gas is injected into the first mold cavity 19a, or before the second polymer material is injected into the first mold cavity 19a. In some embodiments, a second force is applied to the second mold 14 during the injection of the second gas into the first mold cavity 19a, or during the injection of the second polymer material into the first mold cavity 19a.

[0138] In some embodiments, the molding device 200 is arranged on the carrier 101c, and both the first extrusion system (not shown) and the molding device 200 are arranged in the first injection station 21, and the second polymer material is injected from the first extrusion system into the molding device 200 in the first injection station 21. In some embodiments, the second polymer material is injected into the molding device 200 through the first mold 11a.

[0139] In some embodiments, after the first layer M1 and the second layer M2 are formed, a third mold cavity 19c is formed within the molding apparatus 200. In some specific embodiments, the volume of the third mold cavity 19c is smaller than the volume of the first mold cavity 19a. In some specific embodiments, the volume of the third mold cavity 19c is greater than zero.

[0140] In some specific embodiments, the molding method M20 includes operation O205, which includes disengaging the first mold 11a from the second mold 14 via the position control mechanism 20.

[0141] In some specific embodiments, reference is made to Figure 42 After the first layer M1 and the second layer M2 are formed in the molding apparatus 200, the first mold 11a is removed from the second mold 14, the first layer M1 and the second layer M2. In some specific embodiments, the second mold 14, the first layer M1 and the second layer M2 are transferred together with the rotation of the carrier 101c.

[0142] In some embodiments, the molding apparatus 200 is activated after the first layer M1 and the second layer M2 are formed. In some embodiments, the second force is stopped being applied to the molding apparatus 200 before the first mold 11a separates from the second mold 14. In some embodiments, after the first layer M1 and the second layer M2 are formed, the first mold 11a is moved away from the second mold 14, exposing the first layer M1 and the second layer M2.

[0143] In some specific embodiments, during movement, the molding device 200 is in an open state, such as... Figure 42 As shown in the diagram. In some embodiments, during movement, the first mold 11a and the second mold 14 are separated from each other. In some embodiments, the first mold 11a moves vertically back to a first position above the second mold 14. At this first position, the first mold 11a is aligned with the second mold 14 of the molding apparatus 200. In some embodiments, a first distance D1 between the first mold 11a and the second mold 14 is greater than 0. In some embodiments, the position control mechanism 20 moves the first mold 11a away from the second mold 14. In some embodiments, the position control mechanism 20 moves the second mold 14, arranged on the platform 23, away from the first mold 11a by moving the platform 23 along the track 25.

[0144] In some specific embodiments, refer again Figure 40 After the first layer M1 and the second layer M2 are formed, the molding apparatus 200 moves from the first injection station 21 toward the second injection station 22. In some specific embodiments, the carrier 101c rotates about a third center C3 and along a third direction R3 to move the molding apparatus 200 from the first injection station 21 toward the second injection station 22.

[0145] In some specific embodiments, reference is made to Figure 43 After the first mold 11a and the second mold 14 separate from each other, the position control mechanism 20 tilts the first mold 11a and the third mold 11c. In some specific embodiments, the first mold 11a and the third mold 11c can rotate about a first axis C1 and along a first direction R1.

[0146] In some specific embodiments, a first angle σ1 exists between the bottom surface of the first mold 11a and the top surface of the second mold 14, a second angle σ2 exists between the bottom surface of the third mold 11c and the top surface of the second mold 14, and a third angle σ3 exists between the first mold 11a and the third mold 11c. In some specific embodiments, the first angle σ1 and the second angle σ2 are both 45 degrees, and the third angle σ3 is 90 degrees.

[0147] In some specific embodiments, the first mold 11a and the third mold 11c are tilted by a position control mechanism 20, and the position control mechanism 20 rotates about the second axis C2, causing the third mold 11c to move toward the second mold 14 and the first mold 11a to move away from the second mold 14, such as... Figure 43 As shown inside.

[0148] In some specific embodiments, the molding method M20 includes operation O206, which includes arranging component 175 in a fifth mold 17b attached to the third mold 11c.

[0149] In some embodiments, component 175 is attached to a fifth mold 17b. In some embodiments, component 175 is placed on the fifth mold 17b. In some embodiments, component 175 is conformally fitted to the fifth mold 17b. In some embodiments, component 175 comprises a third polymeric material. In some embodiments, component 175 is permeable to a gas or fluid (e.g., air, supercritical fluid, inert gas, nitrogen, carbon dioxide, etc.). In some embodiments, component 175 comprises fibers. In some embodiments, component 175 is an insole, upper, or any other suitable footwear component.

[0150] In some embodiments, a barrier layer (not shown) is provided between component 175 and the fifth mold 17b. In some embodiments, the barrier layer (not shown) is attached to the inner surface of component 175 before component 175 is placed on the fifth mold 17b. After component 175 is placed on the fifth mold 17b, the inner surface of component 175 and the barrier layer (not shown) are positioned above the fifth mold 17b. In some embodiments, the barrier layer (not shown) is conformal to component 175. In some embodiments, the barrier layer (not shown) is a TPU film.

[0151] In some specific embodiments, reference is made to Figure 44 After the position control mechanism 20 rotates about the second axis C2 to move the third mold 11c toward the second mold 14, the first mold 11a and the third mold 11c rotate about the first axis C1 and along the first direction R1 until the third mold 11c is in a second position above the second mold 14, and the first mold 11a is above the position control mechanism 20. At this second position, the third mold 11c is aligned with the second mold 14 of the molding apparatus 200. In some embodiments, the second distance D2 between the third mold 11c and the second mold 14 is greater than 0. In some embodiments, both the second angle σ2 and the third angle σ3 are 90 degrees.

[0152] In some embodiments, the position control mechanism 20 moves the third mold 11c toward the second mold 14. In some embodiments, the position control mechanism 20 moves the second mold 14, which is arranged on the platform 23, toward the third mold 11c.

[0153] In some embodiments, the molding apparatus 200, comprising a lower mold 13, an outer and middle mold 15, a first layer M1, and a second layer M2, is conveyed to and arranged in a second injection station 22. In some embodiments, a second extrusion system (not shown) and the molding apparatus 200 are arranged in the second injection station 22 after the carrier 101c has rotated.

[0154] In some specific embodiments, the fifth mold 17b and component 175 are moved to a predetermined position above the first layer M1 and the second layer M2 (e.g., Figure 44 (As shown), then the first mold 11a, the fifth mold 17b, and the assembly 175 move toward the first layer M1 and the second layer M2 until the fifth mold 17b engages with the second mold 14. In some embodiments, the forming device 200 is arranged below the second extrusion system.

[0155] In some specific embodiments, the molding method M20 includes operation O207, which includes engaging a third mold 11c with a second mold 14 to form a second mold cavity 19b defined by the second mold 14, the third mold 11c and the fifth mold 17b.

[0156] In some specific embodiments, the position control mechanism 20 hinges the third mold 11c toward the second mold 14 about the first axis C1 and along the first direction R1, or linearly moves the second mold 14 toward the third mold 11c, so that the third mold 11c engages with the second mold 14.

[0157] In some embodiments, the position control mechanism 20 pivots the first mold 11a and the third mold 11c about the second axis C2 and along the second direction R2 to position the third mold 11c above the second mold 14. In some embodiments, the pivoting rotation and the hinged rotation are performed sequentially and separately.

[0158] In some specific embodiments, reference is made to Figure 45 The third mold 11c and the fifth mold 17b engage with the second mold 14 to form a second mold cavity 19b. In some embodiments, the molding apparatus 200 including the second mold cavity 19b is in a second closed state. In some embodiments, component 175 is disposed within the second mold cavity 19b. In some embodiments, component 175 surrounds the fifth mold 17b and is located above the first layer M1 and the second layer M2. In some embodiments, component 175 is surrounded by the second mold 14. In some embodiments, component 175 is disposed between the fifth mold 17b and the second mold 14. In some embodiments, the second mold cavity 19b is defined by component 175, the first layer M1, and the second layer M2.

[0159] In some embodiments, the two ends 176, 177 of component 175 are attached to the outer mold 15. In some embodiments, a barrier layer (not shown) is configured to prevent gas or fluid inside the second mold cavity 19b from leaking out of the second mold cavity 19b.

[0160] In some specific embodiments, the molding method M20 includes operation O208, which includes injecting a third polymeric material into a second mold cavity 19b and onto the first layer M1 and the second layer M2 to form an article 178 comprising the first layer M1, the second layer M2 and a third layer M3 made of the third polymeric material.

[0161] In some specific embodiments, reference is made to Figure 46 The third polymer material is injected from the second extrusion system into the molding apparatus 200 of the second injection station 22. In some specific embodiments, the third polymer material is injected into the molding apparatus 200 through the third mold 11c.

[0162] In some embodiments, the third polymeric material is injected into the second mold cavity 19b through a second feed port 12b. In some embodiments, the third polymeric material includes thermoplastic polyurethane (TPU), polyurethane (PU), plastic, or any other suitable material. In some embodiments, the third polymeric material includes 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, the third polymeric material is foamable or slightly foamable. In some embodiments, the composition of the third polymeric material is similar to or different from the composition of the first polymeric material or the second polymeric material.

[0163] In some embodiments, a third layer M3 is attached to component 175, a first layer M1, and a second layer M2. In some embodiments, the third layer M3 is disposed above the first layer M1 and the second layer M2, and component 175 is disposed above the third layer M3. In some embodiments, component 175, the first layer M1, the second layer M2, and the third layer M3 form an article 178. In some embodiments, article 178 is a shoe. In some embodiments, the density of the third layer M3 is substantially less than the density of the first layer M1. In some embodiments, the density of the third layer M3 is substantially less than the density of the second layer M2.

[0164] In some embodiments, the pressure within the second mold cavity 19b is sensed before the third polymer material is injected. In some embodiments, a third gas (not shown) is injected into the second mold cavity 19b through the junction 167 before the third polymer material is injected, until the second mold cavity 19b is sensed to have a third predetermined pressure.

[0165] In some embodiments, the method further includes sensing the pressure within the second mold cavity 19b and filling the second mold cavity 19b, which has a third predetermined pressure, from the second feed port 12b. In some embodiments, the method further includes discharging a portion of a third gas (not shown) from the third mold cavity 19c through the junction 167.

[0166] In some embodiments, when the molding apparatus 200 is in a second closed state, a third force is applied to the second mold 14 toward the third mold 11c to facilitate engagement of the third mold 11c and the second mold 14. In some embodiments, the third force is applied to the second mold 14 before the third gas is injected into the second mold cavity 19b, or before the third polymer material is injected into the second mold cavity 19b. In some embodiments, the third force is applied to the second mold 14 during the injection of the third gas into the second mold cavity 19b, or during the injection of the third polymer material into the second mold cavity 19b. In some embodiments, the platform 23 provides the third force to the second mold 14. In some embodiments, a fourth force is configured to press the first layer M1 and the second layer M2 toward the third layer M3 and component 175. The fourth force is provided to facilitate integration of the first layer M1, the second layer M2, the third layer M3, and component 175.

[0167] In some specific embodiments, the third polymer material is injected from the second extrusion system (not shown) into the molding apparatus 200 at the second injection station 22, such as... Figure 40 As shown inside.

[0168] In some embodiments, the molding method M20 includes operation O209, which includes disengaging the third mold 11c from the second mold 14 via the position control mechanism 20. In some embodiments, a fourth force is stopped being applied to the molding apparatus 200 before the third mold 11c disengages from the second mold 14.

[0169] In some specific embodiments, reference is made to Figure 47 After forming the first layer M1, the second layer M2, and the third layer M3, the first layer M1, the second layer M2, the third layer M3, and component 175 are removed from the second mold cavity 19b. In some embodiments, after forming the article 178 within the molding apparatus 200, the article 178 is removed from the second mold cavity 19b. In some embodiments, the molding apparatus 200 is in the open state when the article 178 is removed.

[0170] In some embodiments, after the article 178 is formed, the third mold 11c disengages from the second mold 14 so that the article 178 having the first layer M1, the second layer M2, the third layer M3, and the component 175 can be removed from the second mold 14. In some embodiments, the article 178 having the first layer M1, the second layer M2, the component 175, and the barrier layer can be removed from the molding apparatus 200.

[0171] In some embodiments, the third mold 11c, the fifth mold 17b, and the product 178 are moved away from the second mold 14. In some embodiments, the position control mechanism 20 moves the third mold 11c and the fifth mold 17b away from the second mold 14, and the product 178 attached to the fifth mold 17b is also moved away from the second mold 14. The second distance D2 after the third mold 11c and the fifth mold 17b are moved away from the second mold 14 is greater than zero.

[0172] In some specific embodiments, before removing the third mold 11c, the fifth mold 17b, and the product 178 from the second mold 14, the first part 151 and the second part 152 of the outer mold 15 are first moved apart from each other, so that a gap G2 is formed between the first part 151 and the second part 152, such as... Figure 26 As shown, the article 178 can thus be separated from the outer mold 15 and easily removed from the second mold cavity 19b.

[0173] In some specific embodiments, the molding device 200 changes from a second closed state to an open state due to the generation of gap G2.

[0174] In some specific embodiments, the molding method M20 includes operation O210, which includes obtaining an article 178 comprising a first layer M1, a second layer M2, and a component 175 from the molding apparatus 200.

[0175] In some embodiments, reference Figure 48 After the third mold 11c, the fifth mold 17b, and the article 178 are removed from the second mold 14, the article 178 is removed from the fifth mold 17b. In some embodiments, the article 178 may be removed from the fifth mold 17b. In some embodiments, the article 178 having a first layer M1, a second layer M2, a third layer M3, a component 175, and a barrier layer may be removed from the fifth mold 17b. In some embodiments, the article 178 is removed from the fifth mold 17b by human or robotic arm (not shown). In some embodiments, the third mold 11c and the fifth mold 17b are tilted before the article 178 is removed from the fifth mold 17b. In some embodiments, the third mold 11c and the fifth mold 17b are tilted by a position control mechanism 20, and the first mold 11a is also tilted.

[0176] In some embodiments, after article 178 is formed and before article 178 is removed from molding apparatus 200, molding apparatus 200 is moved away from second injection station 22, for example, rotating carrier 101c. In some embodiments, article 178 is removed from molding apparatus 200 and carrier 101c.

[0177] In some embodiments, when the third mold 11c and the fifth mold 17b are tilted, a second angle σ2 exists between the bottom surface of the fifth mold 17b and the second mold 14. In some embodiments, the second angle σ2 is between 0 and 90 degrees. In some embodiments, the second angle σ2 is between 20 and 70 degrees. In some embodiments, the second angle σ2 is 45 degrees when the article 178 is removed from the molding device 200.

[0178] In some specific embodiments, reference is made to Figure 49 Article 178 includes a first layer M1, a second layer M2, a third layer M3, and component 175. In some embodiments, the barrier layer is removed from article 178. The first layer M1 has a first density, the second layer M2 has a second density, and the third layer M3 has a third density. The first density, second density, and third density may be the same or different. In some embodiments, a first interface is located between the first layer M1 and the third layer M3 and has a first density gradient, and a second interface is located between the second layer M2 and the third layer M3 and has a second density gradient. The first density gradient and the second density gradient may be the same or different.

[0179] According to a specific embodiment of the present invention, the position control mechanism 20 is attached to a first mold 11a, a second mold 14, and a third mold 11c. The first mold 11a and the third mold 11c are rotatable about a first axis C1 via hinges 24 of the position control mechanism 20, and about a second axis C2 orthogonal to the first axis C1 via pivots 26 of the position control mechanism 20. The second mold 14 is linearly movable along the track 25 of the position control mechanism 20. The position control mechanism 20 moves the first mold 11a to a position opposite to the second mold 14, or moves the third mold 11c to a position opposite to the second mold 14. When the first mold 11a and the second mold 14 are arranged opposite each other, the third mold 11c is offset approximately at a right angle from the first mold 11a.

[0180] The above summary outlines the features of several specific embodiments to enable those skilled in the art to better understand the various aspects of this invention. Those skilled in the art should understand that they can readily use this invention as the basis for designing or modifying other processes and structures to achieve the same purpose and / or realize the same advantages of the specific embodiments described herein. Those skilled in the art should also recognize that such equivalent constructions do not depart from the spirit and scope of this invention, and that various changes, substitutions, and modifications can be made without departing from the spirit and scope of this invention.

[0181] Furthermore, the scope of this invention is not intended to be limited to the specific embodiments of the processes, machines, manufactures, compositions of matter, means, methods, and steps described in the specification. From the disclosure of this invention, those skilled in the art will readily understand that processes, machines, manufactures, compositions of matter, means, methods, or steps that are currently existing or will be developed in the future can be used to perform the same functions or obtain 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, means, methods, and steps within their scope.

[0182] Symbol Explanation

[0183] 11a: First mold

[0184] 11c, 103: Third mold

[0185] 11d, 11f, 173: First end

[0186] 11e, 11g, 174: Second end

[0187] 12a: First feed inlet

[0188] 12b: Second feed inlet

[0189] 13: Lower mold

[0190] 14, 102, 302: Second mold

[0191] 15: Outer and middle molds

[0192] 16: Pressure Regulation System

[0193] 17a: Fourth mold

[0194] 17b: Fifth mold

[0195] 19a, 307: First mold cavity

[0196] 19b: Second mold cavity

[0197] 19c: Third mold cavity

[0198] 20: Position control mechanism

[0199] 21: First shot launch station

[0200] 22: Second firing station

[0201] 23: Platform

[0202] 24: Hinges

[0203] 25: Track

[0204] 26: Pivot

[0205] 1000, 2000: Injection Molding Methods

[0206] 1001-1006, 2001-2010: Steps; Operations

[0207] 100, 300: Injection molding equipment

[0208] 101: First Mold

[0209] 101a: Complementary engraving pattern

[0210] 101c: Carrier

[0211] 104, 304: Feed inlet

[0212] 105: First Component

[0213] 105a, 106a: Surface

[0214] 106: Second Component

[0215] 106': Flowable material

[0216] 106b: Surface

[0217] 107: Mold cavity; Second mold cavity

[0218] 108: Injector

[0219] 108a: Export

[0220] 109: Third Component

[0221] 109': Third flowable material

[0222] 109a: Engraved surface; surface

[0223] 110: Bolt

[0224] 111: Gas

[0225] 112: Suction

[0226] 121a, 121b: Opening

[0227] 131: Top surface

[0228] 151: Part One

[0229] 151a, 152a: Extension

[0230] 152: Part Two

[0231] 153: Inner wall

[0232] 161: Gas conduit; First gas conduit

[0233] 163: Gas Controller

[0234] 167: Joint point

[0235] 175: Components

[0236] 176, 177: End

[0237] 200: Molding device

[0238] 178, 200': Products

[0239] 400: Product; Molding Station

[0240] 2000: Products

[0241] C1: First axis

[0242] C2: Second axis

[0243] C3: Third Center

[0244] D1: First Distance

[0245] D2: Second Distance

[0246] G2: Gap

[0247] M1: First Floor

[0248] M2: Second Layer

[0249] M3: Third Layer

[0250] M10, M20: Molding method

[0251] O101-O107, O201-O210: Operation

[0252] R1: First direction

[0253] R2: Second direction

[0254] R3: Third-party

[0255] σ1: First angle

[0256] σ2: Second angle

[0257] σ3: Third angle.

Claims

1. An injection moulded article characterised in that, include: First component; as well as The second component surrounds the first component. The surface of the first component is in direct contact with the surface of the second component to attach the second component to the first component.

2. The article of claim 1, characterized in that, The density of the second component is less than that of the first component.

3. The article of claim 1, characterized in that, The first component is a non-foamed component, and the second component is a foamed component.

4. The article of claim 1, characterized in that, There is no adhesive between the surface of the first component and the surface of the second component.

5. The article of claim 1, characterized in that, The first component is the upper or sock, and the second component is the shoe.

6. The article of claim 1, characterized in that, It further includes a third component, to which the second component is attached.

7. The article of claim 6, characterized in that, The surface of the second component is in direct contact with the surface of the third component to attach the second component to the third component.

8. The article of claim 6, characterized in that, The density of the second component is less than that of the third component.

9. The article of claim 6, characterized in that, An adhesive is present between the surface of the second component and the surface of the third component to attach the second component to the third component.

10. The article of claim 6, characterized in that, The outer surface of the third component is an engraved surface.

Images