Injection molding system and method

Abstract

To provide an injection molding system and an injection molding method.SOLUTION: There is provided an injection molding method. There are also provided a molding device and a runner plate over the molding device. The molding device includes a first mold, a second mold over the first mold, and a mold cavity defined by the first mold and the second mold. The runner plate includes first and second runners communicable with the mold cavity and extending within the runner plate. A divider is placed within the runner plate, and the divider has a passage connectable to the first runner or the second runner. A mixture material is injected into the mold cavity through the passage and the first runner, and the mixture material fails to flow into the mold cavity through the passage and the second runner. A foamed article is formed from the mixture material inside the mold cavity.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 585,971, filed September 28, 2023, and U.S. Patent Application No. 18 / 748,101, filed June 20, 2024, the disclosures of which are incorporated by reference in their entireties herein.

[0002] Technical Field The present disclosure relates to an injection molding system and method, and more particularly to an injection molding system and method that prevents the formation of slugs or scrap within the runners of a runner plate. [Background technology]

[0003] Foamed polymeric materials have many advantages, such as high strength, light weight, impact resistance, thermal insulation, etc. Foamed molded products can be manufactured by injection molding or extrusion molding. For example, a polymeric material is melted and mixed with a blowing agent to form a mixture, and then the mixture is injected or extruded into a mold cavity by applying force or pressure, and the mixture is foamed in the cavity, and cooled to form a foamed molded product.

[0004] However, in order to avoid affecting the formation of foamed molded products, it is necessary to improve the smooth flow of the mixture in the injection molding system, and therefore the structure of the injection molding system and the manufacturing method of the foamed molded products need to be improved. Summary of the Invention [Problem to be solved by the invention]

[0005] The present disclosure discloses an injection molding system and method. [Means for solving the problem]

[0006] According to one embodiment of the present disclosure, there is provided an injection molding method, comprising the steps of: providing a molding apparatus and a runner plate above the molding apparatus, the molding apparatus including a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold, the runner plate being capable of communicating with the mold cavity and including a first runner and a second runner extending within the runner plate, disposing a first divider within the runner plate having a passageway connectable to the first runner or the second runner, injecting a first mixture through the passageway and the first runner into the mold cavity, where the first mixture does not flow through the passageway and the second runner into the mold cavity, and forming a first foam molded article from the first mixture in the mold cavity.

[0007] According to one embodiment of the present disclosure, there is provided an injection molding method, comprising the steps of: providing a molding apparatus and a runner plate above the molding apparatus, the molding apparatus including a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold, the runner plate being capable of communicating with the mold cavity and including a first runner and a second runner extending within the runner plate, inserting a first plug into the first runner, injecting a first mixture through the second runner into the mold cavity, the first mixture not flowing through the first runner into the mold cavity, and forming a first foam molded article from the first mixture in the mold cavity.

[0008] According to one embodiment of the present disclosure, there is provided an injection molding system. The injection molding system includes a molding apparatus, a runner plate, and a divider. The molding apparatus includes a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold. The runner plate is disposed above the molding apparatus, and includes a first runner and a second runner that can communicate with the mold cavity and extend within the runner plate. The divider is disposed within the runner plate and has a passage that can be connected to the first runner or the second runner. The divider is configured to block the mixture from flowing into the mold cavity through one of the first runner and the second runner, and to allow the mixture to flow into the mold cavity through the passage and the other of the first runner and the second runner. [Brief description of the drawings]

[0009] Aspects of the present disclosure are best understood from the following detailed description when taken in conjunction with the accompanying drawings, in which: It should be noted that, in accordance with standard industry practice, various features have not been drawn to scale, and in fact, dimensions of various features may be arbitrarily increased or decreased for clarity of illustration.

[0010] [Figure 1] FIG. 1 is a schematic diagram of an injection molding system according to some embodiments of the present disclosure. [Diagram 2] FIG. 1 is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Diagram 3] FIG. 1 is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 4] 3 illustrates a top cross-sectional view of a runner plate taken along line A-A' in FIG. 2 according to some embodiments of the present disclosure. [Diagram 5] FIG. 3 is a side perspective view of the injection molding system taken along line BB' of FIG. 2 according to some embodiments of the present disclosure. [Figure 6]FIG. 1 is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 7] 7 illustrates a top cross-sectional view of a runner plate taken along line A-A' in FIG. 6 according to some embodiments of the present disclosure. [Figure 8] 7 illustrates a top cross-sectional view of a runner plate taken along line A-A' in FIG. 6 according to some embodiments of the present disclosure. [Figure 9] FIG. 1 is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 10] 10 illustrates a top cross-sectional view of a runner plate taken along line A-A' in FIG. 9 according to some embodiments of the present disclosure. [Figure 11] FIG. 1 is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 12] 12 illustrates a top cross-sectional view of a runner plate taken along line A-A' in FIG. 11 according to some embodiments of the present disclosure. [Figure 13] 12 illustrates a top cross-sectional view of a runner plate taken along line A-A' in FIG. 11 according to some embodiments of the present disclosure. [Figure 14] FIG. 1 is a front perspective view of an injection molding system according to some embodiments of the present disclosure. [Figure 15] 15 illustrates a top cross-sectional view of the runner plate taken along line A-A' in FIG. 14 according to some embodiments of the present disclosure. [Figure 16] 15 illustrates a top cross-sectional view of the runner plate taken along line A-A' in FIG. 14 according to some embodiments of the present disclosure. [Figure 17] 1 is a flowchart illustrating an injection molding method according to some embodiments of the present disclosure. [Figure 18] 18A-18C are schematic cross-sectional views illustrating exemplary stages of the injection molding method of FIG. 17 according to an embodiment of the present disclosure. [Figure 19] 18A-18C are schematic cross-sectional views illustrating exemplary stages of the injection molding method of FIG. 17 according to an embodiment of the present disclosure. [Figure 20] 18A-18C are schematic cross-sectional views illustrating exemplary stages of the injection molding method of FIG. 17 according to an embodiment of the present disclosure. [Figure 21] 18A-18C are schematic cross-sectional views illustrating exemplary stages of the injection molding method of FIG. 17 according to an embodiment of the present disclosure. [Figure 22] 18A-18C are schematic cross-sectional views illustrating exemplary stages of the injection molding method of FIG. 17 according to an embodiment of the present disclosure. [Figure 23] 1 is a flowchart illustrating an injection molding method according to some embodiments of the present disclosure. [Figure 24] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Diagram 25] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Figure 26] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Figure 27] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Figure 28] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Figure 29] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Diagram 30] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Diagram 31] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. [Diagram 32] 24 is a schematic cross-sectional view illustrating an exemplary stage of the injection molding method of FIG. 23 according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The following disclosure provides many different embodiments or examples for implementing different features of the provided subject matter. In the following, specific examples of components and arrangements are described to simplify the disclosure. Of course, these are merely examples and are not intended to be limiting. For example, in the following description, the formation of a first feature above or on a second feature may include an embodiment in which the first feature and the second feature are formed in direct contact, and may include an embodiment in which an additional feature is formed between the first feature and the second feature such that the first feature and the second feature are not in direct contact. In addition, the present disclosure may repeat reference signs and / or characters in various examples. This repetition is for the purpose of brevity and clarity, and does not in itself indicate a relationship between the various embodiments and / or configurations described.

[0012] Additionally, spatially relative terms such as "lower," "below," "bottom," "upper," "top," and the like may be used herein for ease of description to describe the relationship of one element or feature to another element(s) or feature(s), as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. The device may be oriented in other directions (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may be interpreted accordingly as well.

[0013] Although the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains some errors necessarily resulting from the standard deviation found in each test measurement. Also, the term "about" as used herein generally means within 10%, 5%, 1% or 0.5% of a given value or range. Alternatively, the term "about" means within an acceptable standard error of the mean as would be considered by one of ordinary skill in the art. Other than in the working examples / examples, or unless otherwise indicated, all numerical ranges, amounts, values ​​and percentages relating to amounts of materials, times, temperatures, operating conditions, ratios of amounts, and the like disclosed herein should be understood in all instances to be modified by the term "about". Thus, unless indicated to the contrary, the numerical parameters set forth in the present disclosure and the appended claims are approximations that can be varied as necessary. At the very least, each numerical parameter should be interpreted in light of the number of reported significant digits and by applying ordinary rounding techniques. Ranges can be expressed herein as from one endpoint to another endpoint, or between two endpoints. Unless otherwise stated, all ranges disclosed herein are inclusive of the endpoints.

[0014] 1 is a schematic diagram of an injection molding system 10 according to some embodiments of the present disclosure. The injection molding system 10 includes a melting unit 110, a mixing unit 120, an injection unit 130, an injector 101 in communication with the injection unit 130, a runner plate 103 having a runner embedded therein, and a molding device 105 in communication with the runner in the runner plate 103.

[0015] The melting unit 110 is configured to produce a polymeric material (such as thermoplastic polyurethane (TPU), polyurethane (PU), plastic, etc.) in a molten state. The polymeric material is then delivered to the mixing unit 120 by at least one delivery channel 112. The mixing unit 120 is configured to produce a mixture of the polymeric material and a physical blowing agent (such as gaseous nitrogen, carbon dioxide, supercritical fluid, etc.). The mixture is foamable or microfoamable. The mixture is then delivered to the injection unit 130 by at least one delivery channel 122. The injection unit 130 is configured to eject the mixture into the molding apparatus 105 by the injection unit 130 and the runner plate 103.

[0016] FIG. 2 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure.

[0017] In some embodiments, the molding apparatus 105 is configured to form a molded article including a polymeric material. In some embodiments, the molding apparatus 105 includes a first mold 105c, a second mold 105d, at least one feed port 105a through the second mold 105d, and at least one mold cavity 105b defined by the first mold 105c and the second mold 105d when the molding apparatus 105 is in a closed state (i.e., the first mold 105c is engaged with the second mold 105d). In some embodiments, the first mold 105c is a lower mold and the second mold 105d is an upper mold, which is disposed above the first mold 105c. In some embodiments, each mold cavity 105b is communicable with at least one feed port 105a. In some embodiments, the molded article is formed by physical foaming in the molding apparatus 105. After the mixture undergoes physical foaming, it forms a foamed molded article. In some embodiments, the molded article is a part of a piece of footwear (such as an outsole, an insole, a midsole, etc.) or other product.

[0018] In some embodiments, the injector 101 has an outlet 101a for discharging the mixture. In some embodiments, the injector 101 is engageable with the runner plate 103. In some embodiments, the outlet 101a is engageable and communicable with the inlet 103a of the runner plate 103. The mixture can flow from the outlet 101a to the inlet 103a and along the runner 103c to the multiple outlets 103b of the runner 103c, respectively. In some embodiments, the mixture can flow from the injector 101 through the runner plate 103 and the corresponding feed port 105a into each mold cavity 105b. In some embodiments, the mixture can flow through the feed ports 105a-1, 105a-2 into the mold cavities 105b-1, 105b-2, respectively. After the mixture is dispensed into each runner 103c, it enters the corresponding mold cavity 105b.

[0019] In some embodiments, each outlet 103b can be in communication with at least one mold cavity 105b defined by the molding apparatus 105. In some embodiments, the molding apparatus 105 includes multiple mold cavities 105b-1 and 105b-2. Although the embodiment of FIG. 2 shows two mold cavities 105b-1, 105b-2, this is not intended to limit the number of mold cavities 105b in the molding apparatus 105.

[0020] In some embodiments, a gate 104 is disposed at the outlet 103b of the runner plate 103. The gate 104 is configured to control the flow (flow rate, flow rate, etc.) of the mixture through the outlet 103b into the mold cavity 105b. In some embodiments, when the gate 104 is open or partially open, the mixture can flow through the outlet 103b into the mold cavity 105b, and when the gate 104 is closed, the mixture cannot flow through the outlet 103b into the mold cavity 105b. The state of the gate 104 may be switched automatically or manually.

[0021] FIG. 3 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. In the embodiment of FIG. 3, the injection molding system 100 further includes a sprue 102 engageable with the injector 101. The outlet 101a of the injector 101 is engageable with the inlet 102a of the sprue 102, so that the mixture can flow from the injector 101 to the sprue 102. In some embodiments, the sprue 102 is at least partially surrounded by a runner plate 103. In some embodiments, the sprue 102 is disposed above a runner 103c. The sprue 102 is configured to facilitate engagement between the injector 101 and the runner plate 103. The mixture can flow from the inlet 102a of the sprue 102 to the outlet 102b. In some embodiments, the outlet 102b of the sprue 102 is engageable and communicable with the inlets 103a of the multiple runners 103c. The mixture can flow from an inlet 103a of the runner 103c along the runner 103c toward multiple outlets 103b, respectively. In some embodiments, the mixture can flow from the injector 101 through the sprue 102, the runner plate 103, and corresponding feed ports 105a into each mold cavity 105b, as shown in FIG.

[0022] FIG. 4 illustrates a top cross-sectional view of the runner plate 103 along line A-A' in FIG. 2 according to some embodiments of the present disclosure. In some embodiments, the runner plate 103 may be heated by heaters, coils, etc. to maintain the runners 103c at a particular temperature and to maintain the mixture in a flowable state. In some embodiments, each runner 103c extends within the runner plate 103. Each runner 103c connects an inlet 103a to a respective outlet 103b. Although FIG. 4 illustrates six runners 103c extending within the runner plate 103, it is not intended to limit the number of runners 103c within the runner plate 103. Furthermore, it is not intended to limit the configuration or design of the runners 103c. In some embodiments, the inlet 103a is connected to runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6. In some embodiments, runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 are connected to outlets 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, and 103b-6, respectively.

[0023] Runners 103c may have the same or different dimensions (width, diameter, length, etc.). In some embodiments, runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6 have the same width, the same diameter, and the same length. In some embodiments, runners 103c are divided into multiple groups having different dimensions, with each group of runners 103c having a separate dimension (width, diameter, length, etc.).

[0024] Figure 5 is a side perspective view of an injection molding system 100 along line B-B' in Figure 2 according to some embodiments of the present disclosure. In the embodiment of Figure 5, the mixture can flow from the injector 101 through the outlets 103b-1, 103b-3, 103b-5 of the runner plate 103 and the corresponding feed ports 105a-1, 105a-3, 105a-5 into the mold cavity 105b-1. Although Figure 5 shows that each mold cavity 105b corresponds to three outlets 103b, it is not intended to limit the number of outlets 103b corresponding to one mold cavity 105b.

[0025] Figure 6 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. In the embodiment of Figure 6, a plug 106 is disposed within a runner plate 103. Figure 7 shows a top cross-sectional view of the runner plate 103 along line A-A' of Figure 6 according to some embodiments of the present disclosure.

[0026] In some embodiments, the plug 106 is a plastic block, a metal block, or the like. In some embodiments, the plug 106 is inserted into the runner 103c such that the mixture does not flow through the runner 103c. In some embodiments, the plug 106 is temporarily fixed in the runner 103c and is removable from the runner 103c. For example, the plug 106 is placed in the runner 103c-1 so that the mixture cannot flow through the runner 103c-1 into the mold cavity 105b-1, but can flow through the other runners 103c-3 and 103c-5 into the mold cavity 105b-1. In some embodiments, the plug 106 may be placed or removed when the runner plate 103 engages the molding apparatus 105. In some embodiments, the plug 106 may be placed or removed when the runner plate 103 and the molding apparatus 105 are disengaged. In some embodiments, the plug 106 may be placed or removed when the sprue 102 of FIG. 3 is removed from the runner plate 103.

[0027] When the mixture is injected into the mold cavity 105b, some of the mixture may remain in the runner 103c (e.g., because the mixture is viscous). The mixture remaining in the runner 103c may prevent or even block the mixture subsequently injected from the injector 101 from flowing through the runner 103c. That is, the mixture of the next shot may not flow or may not be able to smoothly enter the mold cavity 105b. The plugs 106 can be placed or removed as needed to prevent the formation of slugs or scraps of the mixture in the runner 103c and to avoid the residual mixture remaining in the runner 103c for a long time. Furthermore, the number of runners 103c used can be easily adjusted by simply adding or removing the plugs 106 without changing to another runner plate 103 with a different configuration. As a result, manufacturing costs and manpower can be saved. In some embodiments, the plugs 106 may be placed or removed manually or remotely.

[0028] 8 illustrates multiple plugs 106 being placed in runners 103c-1 and 103c-4, respectively. It will be understood that the number of plugs 106 is not intended to be limiting. In some embodiments, plugs 106 may be placed or removed manually, by a robotic arm, or the like. In some embodiments, plugs 106 are periodically replaced. For example, after a plug is removed from runner 103c-1, another plug is reinserted into runner 103c-1.

[0029] Figure 9 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. In the embodiment of Figure 9, a divider 107 is disposed within the runner plate 103. Figure 10 shows a top cross-sectional view of the runner plate 103 along line A-A' in Figure 9 according to some embodiments of the present disclosure.

[0030] In some embodiments, the mixture may be distributed to each runner 103c by the divider 107. In some embodiments, the mixture may be evenly distributed to each runner 103c by the divider 107. In some embodiments, the divider 107 includes an inlet 107a, multiple outlets 107b, and multiple passages 107c between the inlet 107a and the outlet 107b. The inlet 107a of the divider 107 is connected to the inlet 103a of the runner plate 103, so that the mixture can flow from the injector 101 through the divider 107 into the runner 103c. Each passage 107c corresponds to one outlet 107b. In the embodiment of FIG. 10, six passages 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, 107c-6 are connected to outlets 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, 107b-6, respectively. It will be understood that the number of passages 107c is not intended to be limited, so long as the number of passages 107c corresponds to the number of outlets 107b. In some embodiments, the divider 107 is a splitter or the like. In some embodiments, the divider 107 is rotatable relative to the runner 103c and the runner plate 103. In some embodiments, the divider 107 is rotatable manually or remotely. In some embodiments, the divider 107 is rotatable by a robotic arm or the like. In some embodiments, the dimensions (e.g., width, diameter, length, etc.) of the runner 103c are substantially larger than the dimensions of the passages 107c.

[0031] In some embodiments, the divider 107 is temporarily fixed in the runner 103c and is removable from the runner 103c. When the one-shot mixture is injected into the mold cavity 105b, some of the mixture may remain in the runner 103c because the mixture is viscous. The mixture remaining in the runner 103c may then be cooled and solidified, which may prevent or even block the mixture of the next shot from flowing through the passage 107c. That is, the mixture of the next shot may not flow or may not be able to smoothly flow into the mold cavity 105b. Such a problem can be solved by simply removing the divider 107 from the runner plate 103 and replacing it with another new divider 107. The divider 107 can be placed or removed as needed, which avoids the residual mixture from remaining in the runner 103c for a long time. Furthermore, the number of runners 103c used can be easily adjusted by simply changing the dividers 107 to different configurations (e.g., different number of passages 107c, etc.) without changing to a different runner plate 103. This can result in savings in manufacturing costs and manpower. In some embodiments, the dividers 107 may be placed or removed manually or remotely. In some embodiments, the dividers 107 may be replaced or removed by a robotic arm, etc.

[0032] Figure 11 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. In the embodiment of Figure 11, a block 108 is disposed in a passage 107c of a divider 107. Figure 12 shows a top cross-sectional view of a runner plate 103 along line A-A' of Figure 11 according to some embodiments of the present disclosure.

[0033] In some embodiments, the block 108 is inserted into the passage 107c of the divider 107 so that the mixture does not flow through the passage 107c. In some embodiments, the block 108 is a plastic block, a metal block, or the like. In some embodiments, the block 108 is temporarily fixed in the passage 107c and is removable from the passage 107c. For example, the block 108 is placed in the passage 107c-1 so that the mixture cannot flow through the passage 107c-1 and the runner 103c-1 into the mold cavity 105b-1, but can flow through the passages 107c-3, 107c-5 and the corresponding runners 103c-3, 103c-5 into the mold cavity 105b-1. The block 108 can be placed or removed as needed to prevent slugs or scraps of the mixture from forming in the runner 103c and to minimize or avoid residual mixture remaining in the runner 103c. Furthermore, the number of runners 103c used can be easily adjusted by simply adding or removing blocks 108 without changing to another runner plate 103. As a result, manufacturing costs and manpower can be saved.

[0034] 13 illustrates a top cross-sectional view of the runner plate 103 along line A-A' in FIG. 11, according to some embodiments of the present disclosure. In the embodiment of FIG. 13, more blocks 108 are disposed in passages 107c-1 and 107c-6, respectively. It will be understood that the number of blocks 108 is not intended to be limiting. In some embodiments, the blocks 108 may be placed or removed manually or remotely. In some embodiments, the blocks 108 may be placed or removed by a robotic arm, or the like.

[0035] In some embodiments, instead of placing blocks 108 in the passages 107c of the divider 107 to prevent the mixture from flowing through the passages 107c, the divider 107 is configured to have a reduced number of passages 107c (e.g., compared to the number of runners 103c).

[0036] Figure 14 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. Figure 15 shows a top cross-sectional view of a runner plate 103 along line A-A' in Figure 14 according to some embodiments of the present disclosure.

[0037] In the embodiment of Figures 14 and 15, the divider 107 is configured to have a small number of passages 107c. For example, the divider 107 does not have passage 107c-1 (shown in Figure 13), so the mixture cannot flow into the runner 103c-1. In other words, the divider 107 is designed to block the runner 103c-1. In this embodiment, when the divider 107 is placed in the runner plate 103, the passages 107c-2 to 103c-6 are configured to be aligned with the runners 103c-2 to 103c-6 and not aligned with the runner 103c-1.

[0038] In some embodiments, the divider 107 is designed to block one or more runners 103c, such that the divider 107 is rotatable within the runner 103c. For example, when the divider 107 in FIG. 15 is rotated clockwise (e.g., about 15°), the runner 103c-5 is blocked by the divider 107, and the runner 103c-1 is able to communicate with the passage 107c-3. Thus, the mixture that flows through the runner 103c can be selected by rotating the divider 107. In some embodiments, the divider 107 can be in a variety of configurations.

[0039] FIG. 16 illustrates another configuration of the divider 107 according to some embodiments of the present disclosure. In FIG. 16, the divider 107 is provided with four passages 107c, so that two of the runners 103c are blocked. It will be understood that the number of passages 107c is not intended to be limiting. When the divider 107 in FIG. 16 is rotated clockwise (e.g., about 15°), the runners 103c-5 and 103c-4 are blocked by the divider 107, and the runners 103c-1, 103c-2, 103c-3, and 103c-6 are able to communicate with the corresponding passages 107c-3, 107c-4, 107c-5, and 107c-6.

[0040] FIG. 17 is a flow chart illustrating an injection molding method 200 according to some embodiments of the present disclosure. The injection molding method 200 includes steps S210 to S250, and the description and illustration do not limit the order of steps S210 to S250. FIGS. 18 to 22 are schematic cross-sectional views of various stages of the injection molding method 200. In some embodiments, the steps of the injection molding method 200 can be automatically and repeatedly performed. In some embodiments, the injection molding method 200 is performed by the injection molding system 100 of FIG. 1.

[0041] In step S210, a molding apparatus 105 and a runner plate 103 are provided. In some embodiments, the molding apparatus 105 includes a first mold 105c, a second mold 105d, and a mold cavity 105b defined by the first mold 105c and the second mold 105d engaged with each other, and the runner plate 103 includes a plurality of runners 103c extending into the runner plate 103. In step S220, a plug is inserted into the first runner 103c among the runners 103c. In step S230, the injection unit 130 is configured to inject the mixture from the mixing unit 120 through the injector 101 and the runners 103c other than the first runner 103c (i.e., the runner 103c into which the plug is inserted) into the mold cavity 105b of the molding apparatus 105, and then, in step S240, a foam molded product is formed from the mixture. It should be noted that the mixture cannot flow from the injection unit 130 through the first runner 103c into the mold cavity 105b. In step S250, after forming the foam molded article, the plug is removed from the first runner 103c of the runner plate 103. When the runner plate 103 is placed on the molding apparatus 105, the plug can be inserted into or removed from the runner 103c.

[0042] In some embodiments, before inserting the plug in step S220 or after removing the plug in step S250, the injection unit 130 is configured to inject the mixture (or another mixture) through the injector 101 and all of the runners 103c into the mold cavity 105b, which then forms another foam molded article from the mixture.

[0043] In some embodiments, after forming the foamed molded article in step S240, an additional plug is inserted into one of the runners 103c other than the first runner, and then step S250 is performed or ignored for the next injection (or next shot) of the mixture.

[0044] FIG. 18 is a front perspective view of an injection molding system 100 according to some embodiments of the present disclosure. The injection molding system 100 includes an injector 101, a runner plate 103, and a molding apparatus 105. Next, as shown in FIG. 19, the injector 101 engages with the runner plate 103, and the molding apparatus 105 engages with the runner plate 103. As shown in FIG. 19, the first mold 105c of the molding apparatus 105 engages with the second mold 105d of the molding apparatus 105. The molding apparatus 105 is in a closed configuration. After the first mold 105c and the second mold 105d are engaged, at least one mold cavity 105b is formed. In some embodiments, the outlet 101a of the injector 101 is aligned with the outlet 103b of the runner plate 103, so that the injector 101 can communicate with the mold cavity 105b through the runner plate 103. In some embodiments, the outlets 103b-1, 103b-2 can be in communication with the mold cavities 105b-1, 105b-2, respectively.

[0045] In some embodiments, the plug 106 is inserted into the runner 103c extending into the runner plate 103, as shown in FIG. 20. In some embodiments, the plug 106 is inserted into the runner 103c-1, as shown in FIG. 20 and FIG. 7. In some embodiments, the plug 106 is inserted before or after the runner plate 103 engages with the molding apparatus 105. After the plug 106 is inserted, the mixture M is injected from the injector 101 through the runner plate 103 into the mold cavity 105b, as shown in FIG. 21. In some embodiments, the one-shot mixture M is injected through the runners 103c-3 and 103c-5 into the mold cavity 105b-1, and through the runners 103c-2, 103c-4 and 103c-6 into the mold cavity 105b-2, as shown in FIG. 7. In some embodiments, the gates 104 at the outlets 103b-3 and 103b-5 may be adjusted to increase the flow rate or volume of the mixture M entering the mold cavity 105b-1. In some embodiments, the gates 104 at the outlets 103b-2, 103b-4, and 103b-6 may be adjusted to decrease the flow rate or volume of the mixture M entering the mold cavity 105b-2.

[0046] After the mixture M enters the mold cavities 105b-1 and 105b-2, the mixture M undergoes physical foaming and then becomes a foam molded article. After the foam molded article is formed, the foam molded article is removed from the molding apparatus 105 when the first mold 105c and the second mold 105d are disengaged as shown in FIG. 22. In some embodiments, the plug 106 is removed from the runner 103c as shown in FIG. 22.

[0047] FIG. 23 is a flow chart illustrating an injection molding method 300 according to some embodiments of the present disclosure. The injection molding method 300 includes steps S310 to S350, and the description and illustration do not limit the order of steps S310 to S350. FIGS. 24 to 32 are schematic cross-sectional views of various stages of the injection molding method 300. In some embodiments, the steps of the injection molding method 300 can be automatically and repeatedly performed. In some embodiments, the injection molding method 300 is performed by the injection molding system 100 of FIG. 1.

[0048] In step S310, a molding apparatus 105 and a runner plate 103 are provided. In some embodiments, the molding apparatus 105 includes a first mold 105c, a second mold 105d, and a mold cavity 105b defined by the first mold 105c and the second mold 105d engaged with each other, and the runner plate 103 includes a first runner 103c and a second runner 103c extending into the runner plate 103. In step S320, a divider having a passageway connectable to the first runner 103c or the second runner 103c is disposed in the runner plate 103. Furthermore, the passageway is alignable with the first runner or the second runner. In step S330, the injection unit 130 is configured to inject the mixture from the mixing unit 120 through the injector 101, the passageway, and the first runner 103c into the mold cavity 105b of the molding apparatus 105, and then in step S340, a foam molded article is formed from the mixture. It should be noted that the mixture cannot flow from the injection unit 130 through the passageway and the second runner 103c into the mold cavity 105b. In step S350, after forming the foam molded article, the divider is removed from the runner plate 103. When the runner plate 103 is placed on the molding apparatus 105, the divider can be inserted into or removed from the runner plate 103.

[0049] In some embodiments, before placing the divider in step S320, the injection unit 130 is configured to inject the mixture (or another mixture) through the injector 101, the first runner 103c, and the second runner 103c into the mold cavity 105b, which then forms another foam molded article from the mixture. In some embodiments, after removing the divider from the runner plate 103, an additional divider is placed in the runner plate 103, the additional divider being of a different configuration than the removed divider.

[0050] In some embodiments, when the divider is placed in the runner plate 103, the passages of the divider are aligned with the first runner and not aligned with the second runner. In some embodiments, when the divider is placed in the runner plate 103 for the next injection of the mixture, the divider is rotatable relative to the runner plate 103. For example, after rotating the divider, the passages of the divider change from being aligned with the first runner to being aligned with the second runner and not aligned with the first runner.

[0051] In some embodiments, the injection molding method 300 includes inserting a divider 107 into the runner 103c, as shown in FIG. 24. In some embodiments, the divider 107 is inserted before or after the engagement of the runner plate 103 with the molding apparatus 105. In some embodiments, the inlet 103a of the runner plate 103 is aligned with the inlet 107a of the divider 107, and the outlet 107b of the divider 107 is communicable with the outlet 103b of the runner plate 103. After inserting the divider 107, the mixture M is injected from the injector 101 through the runner plate 103 and into the mold cavity 105b, as shown in FIG. In some embodiments, as shown in FIG. 25 and FIG. 10, the one-shot mixture M is injected through runners 103c-1, 103c-3, and 103c-5 into mold cavity 105b-1, and through runners 103c-2, 103c-4, and 103c-6 into mold cavity 105b-2. In some embodiments, divider 107 distributes the one-shot mixture M evenly among runners 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, and 103c-6. Thus, as shown in FIG. 25, the mixture M entering mold cavity 105b-1 is substantially the same amount as the mixture M entering mold cavity 105b-2.

[0052] After the mixture M enters the mold cavities 105b-1, 105b-2, the mixture M undergoes physical foaming and then becomes a foamed molded article. After the foamed molded article is formed, the foamed molded article is removed from the molding apparatus. In some embodiments, the divider 107 is removed from the runner 103c when it is no longer needed, when it needs to be changed to another divider 107 with a different configuration, or when it needs to be replaced with another new divider 107, etc.

[0053] In some embodiments, the injection molding method 300 includes inserting the block 108 into the passage 107c of the divider 107, as shown in FIG. 26. In some embodiments, the block 108 is inserted before or after the engagement of the runner plate 103 with the molding apparatus 105. In some embodiments, the one-shot mixture M is injected through runners 103c-3 and 103c-5 into the mold cavity 105b-1, and through runners 103c-2, 103c-4 and 103c-6 into the mold cavity 105b-2, as shown in FIG. 27. In some embodiments, the gates 104 of the outlets 103b-3 and 103b-5 may be adjusted to increase the flow rate or amount of the mixture M entering the mold cavity 105b-1. In some embodiments, the gates 104 at the outlets 103b-2, 103b-4, and 103b-6 may be adjusted to slow or reduce the flow rate of the mixture M entering the mold cavity 105b-2.

[0054] After the mixture M enters the mold cavities 105b-1, 105b-2, the mixture M undergoes physical foaming and then becomes a foamed molded article. After the foamed molded article is formed, the foamed molded article is removed from the molding apparatus. In some embodiments, when the block 108 is no longer needed, it is removed from the divider 107.

[0055] In some embodiments, the divider 107 rotates as needed (e.g., to select the runner 103c to be used as needed). For example, as the divider 107 (together with the block 108) rotates clockwise, the runner 103c-2 is blocked, as shown in Figs. 28 and 29. Fig. 29 shows a top cross-sectional view along line A-A' in Fig. 28. After rotation, the one-shot mixture M is injected through runners 103c-1, 103c-3, and 103c-5 into the mold cavity 105b-1, and through runners 103c-4, 103c-6 into the mold cavity 105b-2, as shown in Fig. 30. In some embodiments, the gates 104 of the outlets 103b-4 and 103b-6 may be adjusted to increase the flow rate or volume of the mixture M entering the mold cavity 105b-2. In some embodiments, the gates 104 of the outlets 103b-1, 103b-3, and 103b-5 may be adjusted to slow or reduce the flow rate of the mixture M entering the mold cavity 105b-1. After the mixture M enters the mold cavities 105b-1, 105b-2, the mixture M undergoes physical foaming and then becomes a foamed molded article. After the foamed molded article is formed, the foamed molded article is removed from the molding apparatus.

[0056] In some embodiments, the divider 107 is inserted into the runner 103c in different configurations, as shown in FIG. 31 and FIG. 16. In some embodiments, the divider 107 is inserted before or after the injector 101 engages with the runner plate 103. In some embodiments, the divider 107 is inserted before or after the first mold 105c engages with the second mold 105d. In some embodiments, the divider 107 shown in FIG. 31 and FIG. 16 does not have the passages 107c-1 and 107c-2. That is, as shown in FIG. 32, the mixture M is injected through the runners 103c-3 and 103c-5 into the mold cavity 105b-1, and through the runners 103c-4 and 103c-6 into the mold cavity 105b-2. In some embodiments, the divider 107 distributes the one-shot mixture M evenly to the runners 103c-3, 103c-4, 103c-5, and 103c-6. After the mixture M enters the mold cavities 105b-1, 105b-2, the mixture M undergoes physical foaming and then becomes a foamed molded article. After the foamed molded article is formed, the foamed molded article is removed from the molding apparatus. In some embodiments, the divider 107 is removed from the runners 103c.

[0057] In embodiments of the present disclosure, replaceable plugs or replaceable dividers are used in injection molding systems. In some embodiments, plugs are inserted into the runners of a runner plate to block the runners as needed and prevent the formation of slugs or scraps in the runners. In some embodiments, dividers are placed between the sprues and the runners of a runner plate to direct molding material to selected runners, easily change the number of runners used in a runner plate, and easily remove any residue of molding material that remains in the runners for an extended period of time.

[0058] The foregoing outlines features of some embodiments to enable those skilled in the art to better understand aspects of the present disclosure. Those skilled in the art should appreciate that the present disclosure may be readily used as a basis for designing or modifying other processes and structures to carry out the same purposes and / or achieve the same advantages as the embodiments presented herein. Those skilled in the art should also appreciate that such equivalent structures do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the present disclosure.

[0059] Furthermore, the scope of the present application is not intended to be limited to the particular embodiments of the processes, machines, manufacture, compositions, means, methods, and steps described herein. Those skilled in the art will readily appreciate from the disclosure of the present disclosure that any currently existing or future developed processes, machines, manufacture, compositions, means, methods, or steps that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized in accordance with the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions, means, methods, and steps. [Explanation of symbols]

[0060] 10 Injection Molding System 101 Injector 101a Outlet of injector 101 102 sprue 102a Inlet of sprue 102 102b Exit of sprue 102 103 Runner plate 103a Runner 103c entrance 103b Runner 103c Exit 103b-1, 103b-2, 103b-3, 103b-4, 103b-5, 103b-6 exit 103c Runner 103c-1, 103c-2, 103c-3, 103c-4, 103c-5, 103c-6 Runners Gate 104 105 Molding equipment 105a Supply port 105a-1, 105a-2, 105a-3, 105a-5 Supply port 105b Mold cavity 105b-1, 105b-2 Mold cavity 105c 1st mold 105d 2nd mold 106 Plug 107 Divider 107a Entrance to divider 107 107b Exit of divider 107 107b-1, 107b-2, 107b-3, 107b-4, 107b-5, 107b-6 exit 107c Divider 107 Passage 107c-1, 107c-2, 107c-3, 107c-4, 107c-5, 107c-6 aisle 108 Blocks 110 Melting Unit 112 Delivery Channel 120 Mixed Unit 122 Delivery Channel 130 Launch unit M mixture

Claims

1. providing a molding apparatus and a runner plate above the molding apparatus, the molding apparatus including a first mold, a second mold above the first mold, and a mold cavity defined by the first and second molds, the runner plate being in communication with the mold cavity and including first and second runners extending within the runner plate; disposing a first divider within the runner plate, the first divider having a passage connectable to either the first runner or the second runner; injecting a first mixture through the passageway and the first runner into the mold cavity, wherein the first mixture does not flow into the mold cavity through the passageway and the second runner; forming a first foamed molded article from the first mixture in the mold cavity; The injection molding method comprising:

2. removing the first divider from the runner plate after forming the first foam-molded product; placing a second divider within the runner plate; Further comprising: The method of claim 1 , wherein the second divider is of a different configuration than the first divider.

3. The step of disposing the first divider within the runner plate includes: aligning the passage with the first runner and misaligning the passage with the second runner. The injection molding method of claim 1 further comprising:

4. The injection molding method of claim 1 further comprising the step of inserting a block into the passageway after forming the first foamed molded article.

5. rotating the first divider within the runner plate; injecting a third mixture through the passageway and the second runner into the mold cavity, wherein the third mixture does not flow through the passageway and the first runner into the mold cavity; forming a third foamed article from the third mixture in the mold cavity; The injection molding method of claim 1 further comprising:

6. providing a molding apparatus and a runner plate above the molding apparatus, the molding apparatus including a first mold, a second mold above the first mold, and a mold cavity defined by the first and second molds, the runner plate being in communication with the mold cavity and including first and second runners extending within the runner plate; inserting a first plug into the first runner; injecting a first mixture into the mold cavity through the second runner, wherein the first mixture does not flow into the mold cavity through the first runner; forming a first foamed molded article from the first mixture in the mold cavity; The injection molding method comprising:

7. removing the first plug from the first runner after forming the first foam-molded product; a step of inserting a second plug into the second runner after forming the first foam-molded product; The injection molding method of claim 6 further comprising:

8. After removing the first plug, injecting a second mixture through the first runner and the second runner into the mold cavity; forming a second foamed article from the second mixture in the mold cavity; The injection molding method of claim 7 further comprising:

9. a molding apparatus including a first mold, a second mold above the first mold, and a mold cavity defined by the first mold and the second mold engaged with the first mold; a runner plate disposed above the molding apparatus, the runner plate including a first runner and a second runner communicating with and extending into the mold cavity; a divider disposed within the runner plate and having a passage connectable to the first runner or the second runner; Including, an injection molding system, wherein the divider is configured to block the mixture from flowing into the mold cavity through one of the first runner and the second runner and to allow the mixture to flow into the mold cavity through the passage and the other of the first runner and the second runner.

10. 10. The injection molding system of claim 9, wherein the divider is rotatable relative to the runner plate and is insertable and removable from the runner plate.

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