Foamed products

Abstract

A foamed article includes a first surface, a second surface opposite to the first surface, and a third surface located between the first surface and the second surface, as well as a first mark and a second mark. The first mark is disposed on the first surface. The second mark is disposed on the second surface and is opposite to and perpendicularly aligned with the first mark.

Description

[0001] [Cross-referencing related applications] This application claims priority to U.S. Patent Application No. 19 / 087,570, filed March 23, 2025, and U.S. Provisional Patent Application No. 63 / 673,187, filed July 19, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention relates to an injection molding apparatus, an injection molding method, and articles formed therefrom, and more particularly to an injection molding apparatus for performing an injection molding method to form articles comprising more than one part having different physical or functional properties. Background Technology

[0003] 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.

[0004] 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

[0005] This work discloses an injection molding apparatus, an injection molding method, and the resulting articles.

[0006] According to a specific embodiment of the present invention, a molding method is provided. The molding method includes: providing a molding apparatus, the molding apparatus including a first mold and a second mold, wherein the first mold includes a recess recessed into the first mold, and the second mold includes a feed port extending through the second mold; engaging the first mold and the second mold to form a mold cavity defined by the first mold and the second mold, wherein the mold cavity is communicative to the recess and the feed port; injecting a flowable material through the feed port into the mold cavity to fill the recess and the mold cavity; and foaming the flowable material into a foamed article.

[0007] According to a specific embodiment of the present invention, a molding method is provided. The molding method includes: providing a molding apparatus including a first mold and a second mold, wherein the first mold includes a cooling mechanism embedded in the first mold, and the second mold includes a feed port extending through the second mold; engaging the first mold and the second mold to form a mold cavity defined by the first mold and the second mold; injecting a flowable material through the feed port into the mold cavity; operating the cooling mechanism to cool the flowable material around the cooling mechanism; and foaming the flowable material into a foamed article.

[0008] According to a specific embodiment of the present invention, a foamed article is provided. The foamed article includes a first surface, a second surface opposite to the first surface, and a third surface located between the first surface and the second surface. The foamed article includes a first mark and a second mark, the first mark being disposed on the first surface, and the second mark being disposed on the second surface, opposite to and perpendicularly aligned with the first mark. Attached Figure Description

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

[0010] Figure 1 This is a schematic diagram of an injection molding apparatus in the open state according to a specific embodiment of the present invention; Figure 2 This is a schematic diagram of an injection molding apparatus in a closed state according to a specific embodiment of the present invention; Figure 3 The following is a schematic cross-sectional view illustrating the connection between the ejector and the feed inlet according to a specific embodiment of this invention; Figure 4 A schematic cross-sectional view illustrating, according to a specific embodiment of the invention, showing a flowable material being ejected from an ejector through an injection port and a feed port into a mold cavity; Figures 5 to 8 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figures 9 to 12 A schematic diagram illustrating a specific embodiment of the foamed product according to this invention is provided. Figure 13 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figure 14 The following is a schematic cross-sectional view illustrating the connection between the ejector and the feed inlet according to a specific embodiment of this invention; Figure 15A schematic cross-sectional view showing the connection of multiple ejectors to the feed inlet according to a specific embodiment of this invention is provided. Figure 16 A schematic cross-sectional view of a specific embodiment of the present invention showing a flowable material being ejected from an ejector through an injection port and a feed port into a mold cavity; Figures 17 to 20 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figures 21 to 24 A schematic diagram illustrating a specific embodiment of the foamed product according to this invention is provided. Figure 25 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figure 26 For the injection molding device along Figure 25 A schematic top-view cross-section of the CC' line; Figure 27 The following is a schematic cross-sectional view illustrating the connection between the ejector and the feed inlet according to a specific embodiment of this invention; Figures 28 to 29 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figures 30 to 34 A schematic diagram illustrating a specific embodiment of the foamed product according to this invention is provided. Figure 35 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figure 36 For the first mold along Figure 35 A schematic top-view cross-section of the DD' line; Figure 37 For the second mold along Figure 35 Schematic top view of the EE' line; Figures 38 to 42 A schematic diagram illustrating a specific embodiment of the foamed product according to this invention is provided. Figure 43 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figure 44 For the first mold along Figure 43 A schematic top-view cross-section of the FF' line; Figures 45 to 48 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figures 49 to 52 A schematic diagram illustrating a specific embodiment of the foamed product according to this invention is provided. Figures 53 to 54 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figures 55 to 58 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figure 59 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figures 60 to 66 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figure 67 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figure 68 For the injection molding device along Figure 67 A schematic top-view cross-section of the GG' line; Figure 69 The following is a schematic cross-sectional view illustrating the connection between the ejector and the feed inlet according to a specific embodiment of this invention; Figures 70 to 71 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figures 72 to 76 A schematic diagram illustrating a specific embodiment of the foamed product according to this invention is provided. Figure 77 This is a schematic diagram of an injection molding apparatus according to a specific embodiment of the present invention; Figure 78 For the injection molding device along Figure 77 A schematic top-view cross-section of the HH' line; Figure 79 The following is a schematic cross-sectional view illustrating the connection between the ejector and the feed inlet according to a specific embodiment of this invention; Figures 80 to 81 A schematic cross-sectional view of the injection molding method in a specific embodiment of the present invention is shown below. Figures 82 to 85 The following is a schematic diagram illustrating a specific embodiment of the foamed product according to this invention. Detailed Implementation

[0011] The following description provides many different specific embodiments or examples for implementing the various features of the provided object. Specific examples of components and configurations are described below to simplify the 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 are not in direct contact. Furthermore, reference numerals and / or words may be repeated in the various examples. This repetition is for simplicity and clarity and does not in itself imply a relationship between the various specific embodiments and / or configurations discussed.

[0012] 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.

[0013] While the numerical ranges and parameters described in this work are approximate, the values ​​revealed in 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 work 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.

[0014] In some specific embodiments, in Figure 1The diagram illustrates a first injection molding apparatus 100 in its open state. In some embodiments, the first injection molding apparatus 100 is used to form a foamed article. The first injection molding apparatus 100 includes a first mold 101 and a second mold 102 that can engage with the first mold 101. In some embodiments, the first mold 101 is disposed below the second mold 102. In some embodiments, the first mold 101 is a lower mold, and the second mold 102 is an upper mold. The first injection molding apparatus 100 includes a feed port 104 for allowing flowable material to pass through. In some embodiments, the feed port 104 is disposed at either the first mold 101 or the second mold 102. Although Figure 1 For example, the feed inlet 104 is arranged at the second mold 102, but it should be understood that it is not limited thereto. In some specific embodiments, the first injection molding apparatus 100 includes a well 105 recessed into the first mold 101 or the second mold 102. Although Figure 1 An example well 105 is arranged at and recessed within the first mold 101, but it should be understood that it is not limited thereto. In some embodiments, well 105 is used to temporarily fix material. In some embodiments, well 105 is a cold material, a cold well, etc. In some embodiments, the width W1 of the feed inlet 104 is substantially different from or the same as the width W2 of well 105. In some embodiments, the width W1 is generally greater than or less than the width W2. In some embodiments, the ratio of the width W2 to the height H2 of well 105 is from about 1:1 to about 1:1.5. In some embodiments, the width W2 is from about 5 mm to about 10 mm.

[0015] Figure 2 An example of a first injection molding apparatus 100 in a closed state is shown, wherein a first mold 101 engages with a second mold 102. In some embodiments, when the first injection molding apparatus 100 is in the closed state, a mold cavity 103 is formed. The mold cavity 103 is used to hold material. A feed port 104 may communicate with the mold cavity 103. In some embodiments, when the first injection molding apparatus 100 is in the closed state, the feed port 104 is perpendicularly aligned with a well 105.

[0016] In some specific embodiments, the injection molding method includes, for example: Figures 1 to 12 The steps illustrated herein. The first injection molding apparatus 100 is used to carry out the injection molding method.

[0017] The injection molding method includes providing, for example Figure 1 The first injection molding apparatus 100, shown includes a first mold 101 and a second mold 102, and then as follows: Figure 2The diagram shows the joining of the first mold 101 and the second mold 102. In some specific embodiments, the injection molding method includes joining the ejector 108 with the feed port 104, such as... Figure 3 As shown. In some embodiments, the ejector 108 engages with the inlet 104 before or after the first mold 101 engages with the second mold 102. In some embodiments, the ejection port 108a of the ejector 108 engages with the inlet 104 before or after the first mold 101 engages with the second mold 102. In some embodiments, the ejector 108 is used to eject flowable material through the ejection port 108a and the inlet 104 into the mold cavity 103. In some embodiments, the ejector 108 is connected to a mixing unit for mixing polymer material with a foaming agent. 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 the mold cavity 103. The mixture inside the mold cavity 103 becomes a foamed product after physical foaming treatment.

[0018] The injection molding method includes injecting a flowable material into a first injection molding apparatus 100. Figure 4 For example, flowable material 106' has been ejected from ejector 108 into mold cavity 103 through injection port 108a and feed port 104. In some specific embodiments, Figures 5 to 7 The flow of the flowable material 106' is illustrated. In some specific embodiments, when the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 to the well 105, such as... Figure 5 As indicated by arrow A. Thus, some flowable material 106' is arranged within the well 105. Then, the flowable material 106' continues to flow towards the side walls of the mold cavity 103, as... Figure 6 As indicated by arrow B. In some embodiments, after the well 105 is filled with the flowable material 106', the flowable material 106' continues to flow towards the side walls of the mold cavity 103. In some embodiments, the flowable material 106' eventually fills the mold cavity 103, as shown in the image. Figure 7 As shown inside. After the flowable material 106' is injected, the flowable material 106' undergoes physical foaming within the mold cavity 103 to become a foamed product 106, as shown. Figure 4 As shown inside.

[0019] The injection molding method includes disengaging the first mold 101 from the second mold 102 to open the first injection molding apparatus 100. Figure 8 This example illustrates the opening of the first injection molding device 100 after the foamed article 106 has been formed. In some specific embodiments, the injection port 108a of the ejector 108 disengages from the inlet 104 before or after the first mold 101 disengages from the second mold 102. After the first injection molding device 100 is opened, the foamed article 106 is removed from the first injection molding device 100, as follows: Figure 8 and Figure 9 As shown in the image.

[0020] The injection molding method includes forming the article through a foaming process. Figure 9 An example is a foamed article 106 formed by a first injection molding apparatus 100. In some embodiments, the foamed article 106 includes a first protrusion 107 and a second protrusion 109. In some embodiments, the first protrusion 107 and the second protrusion 109 are perpendicularly aligned. In some embodiments, the first protrusion 107 corresponds to and is complementary to at least a portion of a well 105, and the second protrusion 109 corresponds to and is complementary to at least a portion of a feed inlet 104.

[0021] In some specific embodiments, the first protrusion 107 and the second protrusion 109 have been removed, such as Figures 10 to 12 As shown inside. Figure 10 This is a schematic side view of the foamed product 106. Figure 11 This is a schematic bottom view of the foamed product 106, and Figure 12 This is a schematic top view of the foamed article 106. In some embodiments, the first protrusion 107 and the second protrusion 109 are removed by cutting, trimming, grinding, or any other suitable treatment. Therefore, a first finishing mark 107' (also referred to as a first mark) is formed on the bottom surface of the foamed article 106, and a second finishing mark 109' (also referred to as a second mark) is formed on the top surface of the foamed article 106. In some embodiments, the first finishing mark 107' and the second finishing mark 109' do not include the surface layer because the surface layer may be damaged or removed during the finishing process. In some embodiments, such as... Figures 10 to 12 As shown, the surface portion (i.e., the portion not covered by the second modification mark 109') may be misaligned with the first modification mark 107 in the vertical direction. In some specific embodiments, the foamed product 106 is a component of footwear, such as an outsole.

[0022] See again Figure 5Since the flowable material 106' first flows into and fills the well 105, and then fills the mold cavity 103, flow marks around the first protrusion 107 and on the top surface of the foamed article 106 are absent or minimized. Furthermore, the flowable material 106' within the first injection molding apparatus 100 undergoes uniform foaming, resulting in a more uniform pore distribution within the foamed article 106 and a more uniform overall density.

[0023] Alternatively, a second injection molding device 200 may be used, such as Figures 13 to 24 As shown inside. In some specific embodiments, the second injection molding apparatus 200 is similar to the first injection molding apparatus 100, except that the number of wells 105 and feed inlets 104 differs. For example... Figure 13 As shown in the illustration, in some embodiments, the second injection molding apparatus 200 includes a plurality of wells 105 and a plurality of feed ports 104 corresponding to each well 105. In some embodiments, each well 105 corresponds to one feed port 104. In some embodiments, each well 105 is vertically aligned with its corresponding feed port 104.

[0024] Figure 14 An example is shown where the ejector 108 engages with the second injection molding apparatus 200. In some embodiments, the ejector 108 engages with the inlet 104 before or after the first mold 101 engages with the second mold 102. In some embodiments, the ejector 108 includes a plurality of injection ports 108a that can engage with one of the inlets 104. Alternatively, as... Figure 15 As shown, a plurality of ejectors 108 are engaged with a second injection molding apparatus 200. In some embodiments, each ejector 108 has an injection port 108a, and the injection port 108a can be engaged with a feed port 104.

[0025] For simplicity and clarity, the ejector 108, which engages with the second injection molding apparatus 200, is illustrated in the following figures to describe subsequent steps. However, it should be understood that... Figure 14 The ejector 108 can also implement the subsequent steps in a similar manner.

[0026] When the ejector 108 engages with the second injection molding device 200, the flowable material 106' is ejected from the ejector 108 through the injection port 108a and the feed port 104 into the mold cavity 103, such as Figure 16 As shown inside. In some specific embodiments, Figures 17 to 19 The flow of the flowable material 106' is illustrated. In some specific embodiments, when the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 to the well 105, such as... Figure 17 As shown by the middle arrow A, similar to the description above or Figure 5 As shown in the diagram. In this way, some flowable material 106' is arranged within the well 105. Then, the flowable material 106' continues to flow towards the side walls of the mold cavity 103, as... Figure 18 As shown by arrow B in the image, it is similar to the description above. Figure 6 As shown. In some specific embodiments, the flowable material 106' is ultimately filled into the mold cavity 103, such as... Figure 19 As shown inside. After the flowable material 106' is injected, the flowable material 106' undergoes physical foaming within the mold cavity 103 to become a foamed product 106, as shown. Figure 16 As shown inside.

[0027] After the foamed product 106 is formed, the second injection molding device 200 is opened to remove the foamed product 106, such as Figure 20 As shown inside, similar to the description above or Figure 8 As shown in the diagram. Figure 21 An example is a foamed article 106 formed by the second injection molding apparatus 200, similar to the description above. Figure 9 The foamed product 106 shown. In some specific embodiments, such as Figure 20 and Figure 21 As shown, multiple first protrusions 107 and second protrusions 109 can be formed respectively. In some specific embodiments, the first protrusions 107 and second protrusions 109 have been as shown... Figures 22 to 24 The removal shown inside is similar to the description above or Figures 10 to 12 As shown in the diagram. Figure 22 This is a schematic side view of the foamed product 106. Figure 23 This is a schematic bottom view of the foamed product 106, and Figure 24 This is a schematic top view of the foamed product 106. In some specific embodiments, such as... Figure 23 and Figure 24 As shown, the number of the first modification trace 107' and the second modification trace 109' can be multiple.

[0028] In some specific embodiments, the third injection molding apparatus 300 is used to perform, for example... Figures 25 to 34 The diagram shows another injection molding method with multiple steps. Figure 25 An example of a third injection molding apparatus 300 in the open state is shown. In some specific embodiments, the third injection molding apparatus 300 includes a first mold 101, a second mold 102, and a feed port 104, which are similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. Figure 25Only one feed port 104 is shown, but it will be understood that more than one feed port 104 may be included. In some specific embodiments, the third injection molding apparatus 300 includes a plurality of recesses 110 (having a width W3 and a height H3) recessed into the first mold 101 or the second mold 102. Although Figure 25 The recess 110 is exemplified as being disposed at and recessed into the first mold 101, but it should be understood that it is not limited thereto. In some specific embodiments, the recess 110 has been used to temporarily fix material. Figure 26 For the third injection molding device 300 along Figure 25 A schematic top cross-sectional view of the CC' line. In some embodiments, the recess 110 is positioned according to a predetermined pattern or randomly. In some embodiments, the recess 110 is located near one side (e.g., left, right, front, rear, etc.) of the third injection molding apparatus 300.

[0029] Figure 27 An example is shown of a third injection molding apparatus 300 in a closed state, wherein a first mold 101 engages with a second mold 102. In some embodiments, a mold cavity 103 is formed when the third injection molding apparatus 300 is in a closed state. In some embodiments, an ejector 108 engages with the third injection molding apparatus 300 before or after it is closed. In some embodiments, the ejection port 108a of the ejector 108 engages with the inlet port 104, allowing flowable material to flow from the ejector 108 into the mold cavity 103 through the ejection port 108a and the inlet port 104.

[0030] After the ejector 108 engages, the flowable material 106' flows into the mold cavity 103, such as... Figure 28 As shown in the diagram. In some embodiments, the flowable material 106' fills the recess 110. In some embodiments, the flowable material 106' 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 can undergo a physical foaming process within the mold cavity 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process.

[0031] Figure 29 This example illustrates the opening of the third injection molding device 300 after the foamed article 106 has been formed. In some specific embodiments, the injection port 108a of the ejector 108 disengages from the feed port 104 before or after the first mold 101 engages with the second mold 102. After the first injection molding device 100 is opened, the foamed article 106 is removed from the third injection molding device 300, as shown below. Figure 29 and Figure 30 As shown inside.

[0032] Figure 30 and Figure 31 Example: foamed article 106 formed by third injection molding apparatus 300. Figure 30 This is a schematic side view of the foamed product 106, and Figure 31 This is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 corresponds to and is complementary to at least a portion of the feed inlet 104, and the third protrusion 111 corresponds to and is complementary to at least a portion of the recess 110.

[0033] In some specific embodiments, the second protrusion 109 and the third protrusion 111 have been removed, such as Figures 32 to 34 As shown inside. Figure 32 This is a schematic side view of the foamed product 106. Figure 33 This is a schematic top view of the foamed product 106, and Figure 34 This is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 and the third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable treatment. Therefore, a second finishing mark 109' is formed on the top surface of the foamed article 106, and a third finishing mark 111' (also referred to as a third mark) is formed on the bottom surface of the foamed article 106. In some embodiments, such as... Figure 34 As shown, multiple third modification traces 111' can be formed. In some specific embodiments, such as Figures 32 to 34 As shown, the third finishing mark 111' may be misaligned with the first finishing mark 107 in the vertical direction. In some embodiments, the second finishing mark 109' and the third finishing mark 111' do not include the surface layer because the surface layer may be damaged or removed during the finishing process. In some embodiments, the foamed product 106 is a component of footwear, such as an outsole. Since the flowable material 106' first flows into and fills the recess 110 and then fills the mold cavity 103, flow marks on the surface of the foamed product 106 are absent or minimized. Furthermore, the flowable material 106' within the third injection molding apparatus 300 undergoes uniform foaming, resulting in a more uniform pore distribution inside the foamed product 106 and a more uniform overall density.

[0034] Alternatively, a fourth injection molding device 400 can be used, such as... Figures 35 to 42 As shown in the diagram. In some specific embodiments, the fourth injection molding apparatus 400 is similar to the third injection molding apparatus 300, except that the recess 110 is also arranged at the second mold 102. Figure 35 This is a schematic side view of the fourth injection molding apparatus 400. Figure 36 For along Figure 35 A schematic top-view cross-sectional view of the first mold 101 of the DD' line, and Figure 37 For along Figure 35 A schematic top-view cross-sectional view of the second mold 102 of the EE' line.

[0035] After the flowable material 106' flows into the mold cavity 103 of the fourth injection molding device 400, the flowable material 106' undergoes physical foaming to become a foamed product 106, such as... Figure 38 and Figure 39 As shown inside. Figure 38 This is a schematic side view of the foamed product 106, and Figure 39 This is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 and some third protrusions 111 are located on the top surface of the foamed article 106. In some embodiments, some third protrusions 111 are located on the bottom surface of the foamed article 106. In some embodiments, some third protrusions 111 are located on the side surface of the foamed article 106. In some embodiments, the number of third protrusions 111 is different from the number of second protrusions 109. In some embodiments, the number of third protrusions 111 is greater than the number of second protrusions 109. In some embodiments, the number of third protrusions 111 is 3 or less. In some embodiments, the number of third protrusions 111 is 1, 2, or 3.

[0036] In some specific embodiments, the second protrusion 109 and the third protrusion 111 have been removed, such as Figures 40 to 42 As shown inside. Figure 40 This is a schematic side view of the foamed product 106. Figure 41 This is a schematic top view of the foamed product 106, and Figure 42 This is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 and the third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable treatment. Thus, a second finishing mark 109' is formed on the top surface of the foamed article 106, and a third finishing mark 111' is formed on the bottom surface of the foamed article 106. In some embodiments, the third protrusion 111 and the second protrusion 109 are removed, resulting in the third finishing mark 111' and the second finishing mark 109', respectively. In some embodiments, the surface area of ​​each of the third finishing marks 111' is substantially smaller than the surface area of ​​the second finishing mark 109'.

[0037] In some specific embodiments, the fifth injection molding apparatus 500 is used to perform, for example... Figures 43 to 52The diagram shows another injection molding method with multiple steps. In some specific embodiments, the fifth injection molding apparatus 500 is similar to the third injection molding apparatus 300 and the first injection molding apparatus 100, and the fifth injection molding apparatus 500 is a composite of the third injection molding apparatus 300 and the first injection molding apparatus 100. Figure 43 This is a schematic side view of the fifth injection molding apparatus 500, and Figure 44 For along Figure 43 A schematic top cross-sectional view of the first mold 101 of the FF' line. In some specific embodiments, the first mold 101 includes a well 105 and a plurality of recesses 110, and the second mold 102 includes a feed inlet 104 perpendicularly aligned with the well 105.

[0038] In some specific embodiments, such as Figure 43 After the fifth injection molding device 500 is closed and the ejector 108 is engaged with the fifth injection molding device 500, the flowable material 106' flows from the ejector 108 into the mold cavity 103, as shown. Figure 45 As shown. In some specific embodiments, Figures 46 to 48 The flow of the flowable material 106' is illustrated. In some specific embodiments, when the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 to the well 105, such as... Figure 46 As shown by the middle arrow A, similar to the description above or Figure 5 As shown in the diagram. In this way, some flowable material 106' is arranged within the well 105. Then, the flowable material 106' continues to flow towards the side walls of the mold cavity 103, as... Figure 47 As shown by arrow B in the image, it is similar to the description above. Figure 6 As shown. In some specific embodiments, the flowable material 106' is ultimately filled into the mold cavity 103, such as... Figure 48 As shown inside. After the flowable material 106' is injected, the flowable material 106' undergoes physical foaming within the mold cavity 103 to become a foamed product 106, as shown. Figure 45 and Figure 49 As shown inside. Figure 49 This is a schematic side view of the foamed article 106. In some embodiments, the foamed article 106 includes a first protrusion 107, a second protrusion 109, and a third protrusion 111. In some embodiments, the first protrusion 107 and the third protrusion 111 are located on the bottom surface of the foamed article 106, and the second protrusion 109 is located on the top surface of the foamed article 106.

[0039] In some specific embodiments, the first protrusion 107, the second protrusion 109, and the third protrusion 111 have been removed, such as... Figures 50 to 52 As shown inside. Figure 50 This is a schematic side view of the foamed product 106. Figure 51 This is a schematic top view of the foamed product 106, and Figure 52 This is a schematic bottom view of the foamed article 106. In some embodiments, the first protrusion 107, the second protrusion 109, and the third protrusion 111 are removed by cutting, trimming, grinding, or any other suitable treatment. Therefore, a second finishing mark 109' is formed on the top surface of the foamed article 106, and a first finishing mark 107' and a third finishing mark 111' are formed on the bottom surface of the foamed article 106.

[0040] In some specific embodiments, the sixth injection molding apparatus 600 is used to perform, for example... Figures 53 to 58 The diagram shows another injection molding method with multiple steps. Figure 53 An example of a sixth injection molding apparatus 600 in the open state is shown. The sixth injection molding apparatus 600 includes a first mold 101 and a second mold 102 that can engage with the first mold 101. The sixth injection molding apparatus 600 includes a feed port 104 for allowing flowable material to pass through. In some embodiments, the feed port 104 is arranged at either the first mold 101 or the second mold 102. In some embodiments, the sixth injection molding apparatus 600 includes a cooling mechanism 601 arranged on either the first mold 101 or the second mold 102. Although... Figure 53 The cooling mechanism 601 is exemplified to be arranged at the first mold 101, but it should be understood that it is not limited thereto. In addition, although only one cooling mechanism 601 is arranged in the sixth injection molding device 600, it should be understood that the number of cooling mechanisms 601 is not limited.

[0041] In some embodiments, the cooling mechanism 601 is used to provide cooling of a portion of the flowable material when it is disposed on or above the first mold 101. In some embodiments, the cooling mechanism 601 allows a liquid (e.g., coolant, water, etc.) to flow through or circulate to cool a portion of the first mold 101 or a portion of the flowable material disposed on or above the first mold 101. In some embodiments, the cooling mechanism 601 is an electric cooler, a cooling device, etc.

[0042] Figure 54An example of a sixth injection molding apparatus 600 in a closed state is shown, wherein a first mold 101 engages with a second mold 102. In some embodiments, when the sixth injection molding apparatus 600 is in the closed state, a mold cavity 103 is formed. The mold cavity 103 is used to hold material. A feed port 104 may communicate with the mold cavity 103. In some embodiments, the ejector 108 engages with the feed port 104 before or after the engagement of the first mold 101 and the second mold 102. In some embodiments, the ejection port 108a of the ejector 108 engages with the feed port 104 before or after the engagement of the first mold 101 and the second mold 102. In some embodiments, the ejector 108 is used to eject flowable material through the ejection port 108a and the feed port 104 into the mold cavity 103. In some specific 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.). This mixture is foamable or slightly foamable. The mixture can undergo a physical foaming process within the mold cavity 103. After the physical foaming process, the mixture within the mold cavity 103 becomes a foamed article.

[0043] Figure 55 For example, flowable material 106' is ejected from ejector 108 into mold cavity 103 through injection port 108a and feed port 104. In some embodiments, before or during the ejection of flowable material 106' into mold cavity 103, the temperature of the sixth injection molding apparatus 600 is raised before ejection of flowable material 106' and maintained at a first predetermined temperature during ejection of flowable material 106' to facilitate the flow of flowable material 106' into mold cavity 103. In some embodiments, the first predetermined temperature is about 30°C to about 40°C. In some embodiments, after ejection of flowable material 106', the temperature of flowable material 106' inside mold cavity 103 is substantially equal to the first predetermined temperature.

[0044] After the flowable material 106' is injected, it undergoes physical foaming within the mold cavity 103 to become a foamed product 106, such as... Figure 56As shown in the diagram. In some embodiments, after the flowable material 106' is injected and during the foaming of the flowable material 106' within the mold cavity 103, a cooling mechanism 601 is activated to cool the flowable material 106' surrounding the cooling mechanism 601. In some embodiments, the cooling mechanism 601 operates to cool the flowable material 106' from a first predetermined temperature to a second predetermined temperature. In some embodiments, the second predetermined temperature is substantially below 25°C. In some embodiments, the second predetermined temperature is approximately 20°C. In some embodiments, the duration for which the cooling mechanism 601 cools the flowable material 106' surrounding the cooling mechanism 601 from the first predetermined temperature to the second predetermined temperature is substantially less than 2 seconds.

[0045] After the flowable material 106' is cooled by the cooling mechanism 601 and foamed, a foamed article 106 with a surface layer 602 is formed. The surface layer 602 is formed from the flowable material 106' surrounding the cooling mechanism 601. In some embodiments, the thickness of the surface layer 602 is from about 0.5 mm to about 5 mm. In some embodiments, a density gradient exists within the surface layer 602, i.e., the density of the surface layer 602 gradually increases from the interior to the exterior of the foamed article 106. In some embodiments, the surface layer 602 has a lower degree of physical foaming than the rest of the foamed article 106. That is, the rest of the foamed article 106 has a higher degree of physical foaming than the surface layer 602. In some embodiments, the density of the surface layer 602 is different from the density of the rest of the foamed article 106. In some embodiments, the density of the surface layer 602 is substantially greater than the density of the rest of the foamed article 106. In some specific embodiments, the density of the surface layer 602 is substantially equal to or greater than 0.2 g / cm³. 3 The density of the remaining portion of the foamed product 106 is substantially less than 0.2 g / cm³. 3 In some specific embodiments, the density of the surface layer 602 is substantially equal to or greater than 0.22 g / cm³. 3 The density of the remaining portion of the foamed product 106 is substantially equal to or less than 0.16 g / cm³. 3 In some specific embodiments, the surface layer 602 has higher abrasion resistance than the rest of the foamed article 106 because the density of the surface layer 602 is higher than that of the rest of the foamed article 106.

[0046] Figure 57This example illustrates the opening of the sixth injection molding apparatus 600 after the formation of a foamed article 106 having a surface layer 602. In some specific embodiments, the injection port 108a of the ejector 108 disengages from the inlet 104 before or after the first mold 101 separates from the second mold 102. After the sixth injection molding apparatus 600 is opened, the foamed article 106 having a surface layer 602 is removed from the sixth injection molding apparatus 600, such as... Figure 57 As shown inside. In some specific embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable treatment, such as... Figure 58 As shown.

[0047] In some embodiments, the foamed article 106 is a component of footwear, such as an outsole. In some embodiments, the surface layer 602 is exposed to the surrounding environment and is not covered by adhesives or other components.

[0048] In some specific embodiments, the seventh injection molding apparatus 700 is used to perform, for example... Figures 59 to 66 The diagram shows another injection molding method with multiple steps. In some specific embodiments, the seventh injection molding apparatus 700 is similar to the first injection molding apparatus 100 and the sixth injection molding apparatus 600, and the seventh injection molding apparatus 700 is a composite of the first injection molding apparatus 100 and the sixth injection molding apparatus 600. Figure 59 This is a schematic side view of the seventh injection molding apparatus 700 in its closed state. In some specific embodiments, the first mold 101 includes a well 105 and a cooling mechanism 601, and the second mold 102 includes a feed port 104 perpendicularly aligned with the well 105.

[0049] In some embodiments, before or during the injection of the flowable material 106' into the mold cavity 103, the temperature of the seventh injection molding apparatus 700 is increased before the injection of the flowable material 106' and maintained at a first predetermined temperature during the injection of the flowable material 106' to facilitate the flow of the flowable material 106' into the mold cavity 103. In some embodiments, the first predetermined temperature is about 30°C to about 40°C. In some embodiments, after the injection of the flowable material 106', the temperature of the flowable material 106' inside the mold cavity 103 is substantially equal to the first predetermined temperature.

[0050] In some specific embodiments, such as Figure 59 After the seventh injection molding device 700 is closed and the ejector 108 is engaged with the seventh injection molding device 700, the flowable material 106' flows from the ejector 108 into the mold cavity 103, as shown. Figure 60 As shown. In some specific embodiments, Figures 61 to 63The flow of the flowable material 106' is illustrated. In some specific embodiments, when the flowable material 106' is ejected from the ejection port 108a of the ejector 108, the flowable material 106' flows through the feed port 104 and the mold cavity 103 to the well 105, such as... Figure 61 As shown by the middle arrow A, similar to the description above or Figure 5 As shown in the diagram. In this way, some flowable material 106' is arranged within the well 105. Then, the flowable material 106' continues to flow towards the side walls of the mold cavity 103, as... Figure 62 As shown by arrow B in the image, it is similar to the description above. Figure 6 As shown. In some specific embodiments, the flowable material 106' is ultimately filled into the mold cavity 103, such as... Figure 63 As shown inside.

[0051] In some specific embodiments, the cooling mechanism 601 operates after the flowable material 106' is injected and during the foaming of the flowable material 106' within the mold cavity 103, such as... Figure 64 As shown in the diagram. Cooling mechanism 601 is operable to cool the flowable material 106' surrounding it. In some embodiments, cooling mechanism 601 operates to cool the flowable material 106' from a first predetermined temperature to a second predetermined temperature. In some embodiments, the second predetermined temperature is substantially below 25°C. In some embodiments, the second predetermined temperature is approximately 20°C. In some embodiments, the duration for which cooling mechanism 601 cools the flowable material 106' surrounding it from the first predetermined temperature to the second predetermined temperature is substantially less than 2 seconds.

[0052] After the flowable material 106' is foamed and cooled, a foamed article 106 with a surface layer 602 is formed, such as... Figure 60 As shown. Surface layer 602 is formed of flowable material 106' surrounding cooling mechanism 601. In some embodiments, the thickness of surface layer 602 is from about 0.5 mm to about 5 mm. In some embodiments, a density gradient exists within surface layer 602, i.e., the density of surface layer 602 gradually increases from the interior to the exterior of foamed article 106. In some embodiments, surface layer 602 has a lower degree of physical foaming than the rest of foamed article 106. That is, the rest of foamed article 106 has a higher degree of physical foaming than surface layer 602. In some embodiments, the density of surface layer 602 differs from the density of the rest of foamed article 106. In some embodiments, the density of surface layer 602 is substantially greater than the density of the rest of foamed article 106. In some embodiments, the density of surface layer 602 is substantially equal to or greater than 0.2 g / cm³. 3The density of the remaining portion of the foamed product 106 is substantially less than 0.2 g / cm³. 3 In some specific embodiments, the density of the surface layer 602 is substantially equal to or greater than 0.22 g / cm³. 3 The density of the remaining portion of the foamed product 106 is substantially equal to or less than 0.16 g / cm³. 3 In some specific embodiments, the surface layer 602 has higher abrasion resistance than the rest of the foamed article 106 because the density of the surface layer 602 is higher than that of the rest of the foamed article 106.

[0053] Figure 65 This example illustrates the opening of the seventh injection molding apparatus 700 after the formation of a foamed article 106 having a surface layer 602. In some specific embodiments, the injection port 108a of the ejector 108 disengages from the inlet 104 before or after the first mold 101 separates from the second mold 102. After the seventh injection molding apparatus 700 is opened, the foamed article 106 having a surface layer 602 is removed from the seventh injection molding apparatus 700, such as... Figure 65 As shown inside. In some specific embodiments, the first protrusion 107 and the second protrusion 109 are removed by cutting, trimming, grinding, or any other suitable treatment, such as... Figure 66 As shown in the diagram. In some embodiments, the foamed article 106 is a component of footwear, such as an outsole. In some embodiments, the surface layer 602 is exposed to the surrounding environment and is not covered by adhesives or other components.

[0054] In some specific embodiments, the eighth injection molding apparatus 800 is used to perform, for example... Figures 67 to 76 The diagram shows another injection molding method with multiple steps. Figure 67 An example of an eighth injection molding apparatus 800 in the open state is shown. In some specific embodiments, the eighth injection molding apparatus 800 includes a first mold 101, a second mold 102, and a feed port 104, which are similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. Figure 67 Only one feed port 104 is illustrated, but it should be understood that more than one feed port 104 may be included. In some specific embodiments, the eighth injection molding apparatus 800 includes a plurality of recesses 110 recessed into the first mold 101 or the second mold 102. Although Figure 67 The recess 110 is exemplified as being disposed at and recessed into the first mold 101, but it should be understood that it is not limited thereto. In some specific embodiments, the recess 110 has been used to temporarily fix material. Figure 68 For the eighth injection molding device 800 along Figure 67A schematic top cross-sectional view of the GG' line. In some embodiments, the recesses 110 are arranged according to a predetermined pattern, for example, the recesses 110 are arranged in a matrix. In some embodiments, the recesses 110 are located near one side (e.g., left, right, front, rear, etc.) of the eighth injection molding apparatus 800. In some embodiments, the recesses 110 are laterally offset from the sidewall of the first mold 101 by approximately 0.8 to 1.6 cm. In some embodiments, the recesses 110 have a height H4 of approximately 0.3 mm and a width W4 of approximately 0.3 mm.

[0055] Figure 69 An eighth injection molding apparatus 800 is illustrated in a closed state, wherein a first mold 101 engages with a second mold 102. In some embodiments, a mold cavity 103 is formed when the eighth injection molding apparatus 800 is in a closed state. In some embodiments, an ejector 108 engages with the eighth injection molding apparatus 800 before or after it is closed. In some embodiments, the ejection port 108a of the ejector 108 engages with the inlet port 104, allowing flowable material to flow from the ejector 108 into the mold cavity 103 through the ejection port 108a and the inlet port 104.

[0056] After the ejector 108 engages, the flowable material 106' flows into the mold cavity 103, such as... Figure 70 As shown in the diagram. In some embodiments, the flowable material 106' fills the recess 110. In some embodiments, the flowable material 106' 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 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process. In some embodiments, the flowable material 106' flows through the inlet 104 and the mold cavity 103 as it is ejected from the injection port 108a of the ejector 108. In some embodiments, during the flow of the flowable material 106', the recess 110 interferes with the flow of the polymer to break up air bubbles below the surface (inside the product), thus improving the contact surface of the product (corresponding to the recess 110). In comparative examples, additional friction or polishing steps are used to smooth the contact surfaces, but due to the presence of the recess 110, such friction or polishing steps may not be necessary for the injection molding method of this invention.

[0057] Figure 71This example illustrates the opening of the eighth injection molding device 800 after the foamed article 106 has been formed. In some specific embodiments, the injection port 108a of the ejector 108 disengages from the inlet 104 before or after the first mold 101 separates from the second mold 102. After the first injection molding device 100 is opened, the foamed article 106 is removed from the eighth injection molding device 800, as shown below. Figure 71 and Figure 72 As shown inside.

[0058] Figure 72 and Figure 73 Example: foamed article 106 formed by the eighth injection molding apparatus 800. Figure 72 This is a schematic side view of the foamed product 106, and Figure 73 This is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a third protrusion 111. In some embodiments, the second protrusion 109 corresponds to and is complementary to at least a portion of the feed inlet 104, and the third protrusion 111 corresponds to and is complementary to at least a portion of the recess 110.

[0059] In some specific embodiments, the second protrusion 109 has been removed, such as Figures 74 to 76 As shown inside. Figure 74 This is a schematic side view of the foamed product 106. Figure 75 This is a schematic top view of the foamed product 106, and Figure 76 This is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable treatment. Therefore, a second finishing mark 109' is formed on the top surface of the foamed article 106. In some embodiments, the second finishing mark 109' does not include the surface layer, as the surface layer may be damaged or removed during the finishing process. In some embodiments, the foamed article 106 is a component of footwear, such as an outsole. Because the flowable material 106' first flows into and fills the recess 110 before filling the mold cavity 103, flow marks are absent or minimized on the surface of the foamed article 106. Furthermore, the flowable material 106' within the eighth injection molding apparatus 800 undergoes uniform foaming, resulting in a more uniform pore distribution within the foamed article 106 and a more uniform overall density.

[0060] In some specific embodiments, the ninth injection molding apparatus 900 is used to perform, for example... Figures 77 to 85 The diagram shows another injection molding method with multiple steps. Figure 77A ninth injection molding apparatus 900 in the open state is illustrated. In some specific embodiments, the ninth injection molding apparatus 900 includes a first mold 101, a second mold 102, and a feed port 104, which are similar to those in the first injection molding apparatus 100 or the second injection molding apparatus 200. Figure 77 Only one feed port 104 is shown, but it should be understood that more than one feed port 104 may be included. In some specific embodiments, the ninth injection molding apparatus 900 includes a protrusion 112 projecting from the first mold 101 or the second mold 102. Although Figure 77 As illustrated, protrusion 112 is arranged and protrudes from the first mold 101, but it should be understood that it is not limited thereto. In some specific embodiments, protrusion 112 is used to temporarily disrupt the flow of material using horizontal protrusion 112x and vertical protrusion 112y, and to temporarily retain the material within recess 113. Figure 78 For the ninth injection molding device 900 along Figure 77 A schematic top cross-sectional view of line HH'. In some embodiments, the protrusions 112 are formed according to a predetermined pattern, for example, the protrusions 112 are formed in a matrix. In some embodiments, the protrusions 112 are located near one side (e.g., left, right, front, rear, etc.) of the ninth injection molding apparatus 900. In some embodiments, the protrusions 112 are laterally offset from the sidewall of the first mold 101 by approximately 0.8 to 1.6 cm. In some embodiments, the bottom height H5 of the protrusions 112 is approximately 0.3 mm, the height H6 of the horizontal protrusions 112x at the bottom of the protrusions 112 is approximately 0.3 mm, and the height H7 of the vertical protrusions 112y at the bottom of the protrusions 112 is approximately 0.15 mm.

[0061] Figure 79 A ninth injection molding apparatus 900 is illustrated in a closed state, wherein a first mold 101 engages with a second mold 102. In some embodiments, a mold cavity 103 is formed when the ninth injection molding apparatus 900 is in a closed state. In some embodiments, an ejector 108 engages with the ninth injection molding apparatus 900 before or after it is closed. In some embodiments, the ejection port 108a of the ejector 108 engages with the inlet port 104, allowing flowable material to flow from the ejector 108 into the mold cavity 103 through the ejection port 108a and the inlet port 104.

[0062] After the ejector 108 engages, the flowable material 106' flows into the mold cavity 103, such as... Figure 80As shown in the diagram. In some embodiments, the flowable material 106' fills the recess 113. In some embodiments, the flowable material 106' 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 103. The mixture within the mold cavity 103 becomes a foamed article after the physical foaming process. In some embodiments, the flowable material 106' flows through the inlet 104 and the mold cavity 103 as it is ejected from the injection port 108a of the ejector 108. In some embodiments, during the flow of the flowable material 106', the protrusions 112 and the recesses 113 interfere with the flow of the polymer to disrupt air bubbles below the surface (inside the product), thus improving the contact surface of the product (corresponding to the protrusions 112 and the recesses 113). In comparative examples, additional friction or polishing steps are used to smooth the contact surfaces, but due to the presence of protrusions 112 and recesses 113, such friction or polishing steps may not be necessary for the injection molding method of this invention.

[0063] Figure 81 This example illustrates the opening of the ninth injection molding device 900 after the foamed article 106 has been formed. In some specific embodiments, the injection port 108a of the ejector 108 disengages from the inlet 104 before or after the first mold 101 separates from the second mold 102. After the first injection molding device 100 is opened, the foamed article 106 is removed from the ninth injection molding device 900, as shown below. Figure 81 and Figure 82 As shown inside.

[0064] Figure 82 and Figure 83 Example: foamed article 106 formed by the ninth injection molding apparatus 900. Figure 82 This is a schematic side view of the foamed product 106, and Figure 83 This is a schematic perspective view of the foamed article 106. In some embodiments, the foamed article 106 includes a second protrusion 109 and a recess 114. In some embodiments, the second protrusion 109 corresponds to and is complementary to at least a portion of the inlet 104, and the recess 114 corresponds to and is complementary to at least a portion of the protrusion 112.

[0065] In some specific embodiments, the second protrusion 109 has been removed, such as Figures 84 to 85 As shown inside. Figure 84 This is a schematic top view of the foamed product 106, and Figure 85This is a schematic bottom view of the foamed article 106. In some embodiments, the second protrusion 109 is removed by cutting, trimming, grinding, or any other suitable treatment. Therefore, a second finishing mark 109' is formed on the top surface of the foamed article 106. In some embodiments, the second finishing mark 109' does not include the surface layer, as the surface layer may be damaged or removed during the finishing process. In some embodiments, the foamed article 106 is a component of footwear, such as an outsole. Because the flowable material 106' first flows into and fills the recess 113 to form the recess 114, and then fills the mold cavity 103, flow marks are absent or minimized on the surface of the foamed article 106. Furthermore, the flowable material 106' within the ninth injection molding apparatus 900 undergoes uniform foaming, resulting in a more uniform pore distribution within the foamed article 106 and a more uniform overall density.

[0066] Symbol Explanation 100: First Injection Molding Device 101: First Mold 102: Second mold 103: Mold cavity 104: Feed Inlet 105: Well 106: Foamed products 106': Flowable material 107: First protrusion 107': First modification mark 108: Injector 108a: Injection port 109: Second protrusion 109': Second modification mark 110, 113, 114: Depression 111: Third protrusion 111': Third modification mark 112: Protrusion 112x: Horizontal protrusion 112y: Vertical protrusion 200: Second Injection Molding Device 300: Third Injection Molding Unit 400: Fourth Injection Molding Unit 500: Fifth Injection Molding Unit 600: Sixth Injection Molding Unit 601: Cooling mechanism 602: Surface 700: Seventh Injection Molding Unit 800: Eighth Injection Molding Unit 900: Ninth Injection Molding Unit H2, H3, H4, H5, H6, H7: Height W1, W2, W3, W4: Width.

Claims

1. A foamed article characterized in that, include: A first surface, a second surface opposite to the first surface, and a third surface located between the first surface and the second surface; A first trace, which is arranged on the first surface, and A second mark is disposed on the second surface, opposite to and perpendicularly aligned with the first mark.

2. The foamed article of claim 1, wherein, Further includes: A surface layer that is exposed through the first surface, the second surface, or the third surface. The surface layer has a greater abrasion resistance than the rest of the foamed product, and the surface layer has a density gradient that gradually increases from the interior to the exterior of the foamed product.

3. The foamed article of claim 2, wherein, The surface layer is located on the second surface, and the surface layer is misaligned with the first mark in the vertical direction.

4. The foamed product according to claim 1, characterized in that, Further includes: A third trace is disposed on the first surface, the second surface and the third surface, wherein the surface area of ​​the third trace is substantially smaller than the surface area of ​​the second trace.

5. The foamed article of claim 1, wherein, The first mark is aligned with the second mark.

6. The foamed article of claim 1, wherein, Further includes: Multiple third marks are arranged on the second surface and are offset from the first mark in the vertical direction.

7. The foamed article of claim 1, wherein, Further includes: A recess is disposed on the second surface, wherein the recess has a plurality of horizontal recesses and a plurality of vertical recesses arranged in a matrix shape.

8. A foamed article characterized by, include: A first surface, a second surface opposite to the first surface, and a third surface located between the first surface and the second surface; A first protrusion, disposed on the first surface, and A plurality of second protrusions are arranged on the first surface, the second surface, or the third surface. The number of the plurality of second protrusions is greater than the number of the first protrusions.

9. The foamed article of claim 8, wherein the removal of the first protrusion and the second protrusion produces a first mark and a plurality of second marks, respectively, the surface area of ​​each of the plurality of second marks being substantially smaller than the surface area of ​​the first mark.

10. The foamed article of claim 8, wherein, The number of the first protrusion is 3 or less.

Images