Injection molding system and injection molding method

Abstract

To provide an injection molding system and an injection molding method.SOLUTION: An injection molding system includes a supply unit for a flowable mixture, an injection unit capable of communicating with the supply unit and including a discharge port for the flowable mixture, a molding apparatus receptive to the flowable mixture and including a mold with a supply port engageable with the discharge port, and a support device disposed between the injection unit and the molding apparatus and configured to facilitate engagement between the injection unit and the molding apparatus. The support device includes a first element connected to the injection unit and a second element disposed on the molding apparatus. The second element includes a first slot configured to receive a protruding portion of the first element, and the protruding portion of the first element is slidable within and along the first slot of the second element.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] (Cross - reference to related applications) This application claims the benefit of U.S. Provisional Application No. 63 / 379,255, filed Oct. 12, 2022, and U.S. Patent Application No. 18 / 451,073, filed Aug. 16, 2023, each of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to an injection molding system and an injection molding method, and more particularly to an injection molding system and an injection molding method for manufacturing foamed polymer articles.

Background Art

[0003] Foamed polymer articles have many advantages such as high strength, light weight, impact resistance, good sound insulation and heat insulation. Foamed polymer articles can be made into molded articles having a predetermined shape by injection molding or extrusion molding. For example, a polymer material is melted and mixed with a foaming agent in an extrusion system to form a fluid mixture, and then the mixture is injected or extruded into a molding device to form a desired foamed polymer article. The characteristics and quality of the foamed polymer article can be improved by adjusting the structure of the injection molding system and adjusting the injection molding system.

Summary of the Invention

[0004] One object of the present invention is to provide an injection molding system and an injection molding method.

[0005] According to one embodiment of the present disclosure, an injection molding system is disclosed. The injection molding system includes a supply unit configured to supply a fluid mixture of a polymer material and a foaming agent, and an injection unit communicable with the supply unit, the injection unit being disposed distally from the supply unit and including a discharge port configured to discharge the fluid mixture, a molding device configured to receive the fluid mixture from the discharge port, the molding device including a mold cavity and an opening communicable with the mold cavity and engageable with the discharge port in correspondence therewith, and a support device configured to facilitate engagement between the injection unit and the molding device. The support device includes a first element connected to the injection unit and a second element disposed on the molding device. The second element includes a slot configured to receive a protruding portion of the first element, and the protruding portion of the first element is slidable along the slot within the second element.

[0006] According to one embodiment of the present disclosure, an injection molding method is disclosed. The injection molding method includes providing an injection molding system, the injection molding system including an injection unit and a molding device, the injection unit including a discharge port configured to discharge a fluid mixture, the molding device being configured to receive the fluid mixture from the discharge port and including a mold cavity and an opening communicable with the mold cavity and engageable with the discharge port in correspondence therewith; providing a support device configured to facilitate engagement between the injection unit and the molding device, the support device including a first element connected to the injection unit and a second element disposed on the molding device; aligning a protruding portion of the first element with a slot of the second element; displacing the injection unit to slide the protruding portion of the first element along the slot of the second element; engaging the discharge port with the opening when the protruding portion of the first element engages the slot of the second element; and injecting the fluid mixture into the mold cavity.

Brief Description of the Drawings

[0007] Aspects of the present disclosure are best understood from the following detailed description when read in conjunction with the accompanying drawings. Note that various features are not drawn to scale in accordance with standard practice in the art. In fact, the dimensions of the various features may be arbitrarily enlarged or reduced for clarity of discussion.

[0008]

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DETAILED DESCRIPTION OF THE INVENTION

[0009] The following disclosure provides many different embodiments or examples for implementing different features of the present invention. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, in the following description, forming a first feature above or on a second feature may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first feature and the second feature so that the first and second features are not in direct contact. Further, in the present disclosure, reference numerals and / or letters may be repeated in various examples. This repetition is for the purpose of simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or configurations being discussed.

[0010] Furthermore, spatially relative terms such as "below", "beneath", "lower", "above", "upper", etc. may be used herein for ease of explanation to describe the relationship of one element or feature to another element or feature as shown in the drawings. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The device may be oriented in a different direction (it may be rotated 90° or other orientations), and the spatially relative descriptors used herein may be interpreted accordingly as well.

[0011] Numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, although the numerical values set forth in specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in each respective test measurement. Also, as used herein, the term "about" 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 when considered by a person of ordinary skill in the art. Except for operating / working examples, or where otherwise expressly indicated, all numerical ranges, amounts, values, and percentages such as those for amounts of materials, duration of time, temperatures, operating conditions, ratios of amounts, etc. disclosed herein are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the present disclosure and the appended claims are approximations that may vary as desired. At the very least, each numerical parameter should be construed in light of the reported number of significant digits and by applying ordinary rounding techniques. Ranges can be expressed herein as from one endpoint to another endpoint, or between two endpoints. All ranges disclosed herein are inclusive of the endpoints unless otherwise expressly indicated.

[0012] Generally, the appearance and physical properties of a foamed polymer article are directly affected by the injection molding process, and thus the design of the injection molding system must consider the injection conditions of the fluid mixture from the injection unit into the molding device such that the fluid mixture can be completely and effectively injected into the molding device to form a foamed polymer article having the desired quality.

[0013] FIG. 1 shows a schematic perspective view of a first injection molding system 100 according to an embodiment of the present disclosure. In some embodiments, referring to FIG. 1, the first injection molding system 100 includes an injection unit 101 and a molding device 102. The injection unit 101 is engageable with the molding device 102. In some embodiments, the first injection molding system 100 further includes a fluid mixture supply unit 103 communicable with the injection unit 101. In some embodiments, the fluid mixture supply unit 103 is configured to generate a fluid mixture and supply it to the injection unit 101.

[0014] In some embodiments, the fluid mixture includes polymer materials such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE), etc. In some embodiments, the fluid mixture includes recyclable materials. In some embodiments, the fluid mixture further includes a foaming agent. In some embodiments, the foaming agent can be any type of chemical or physical foaming agent known to those skilled in the art. In some embodiments, the foaming agent is a supercritical fluid. The supercritical fluid may include an inert gas such as supercritical carbon dioxide or nitrogen. In some embodiments, the fluid mixture includes a polymer material in a molten state and a foaming agent in a liquid or supercritical fluid state mixed with the polymer material. In some embodiments, the fluid mixture is a molding material.

[0015] In some embodiments, the fluid mixture supply unit 103 of the first injection molding system 100 includes an extruder (not shown) for converting the polymer material into a molten state and a mixer (not shown) for mixing the foaming agent with the polymer material. The polymer material is flowable from the extruder into the mixer.

[0016] In some embodiments, the injection unit 101 includes an injector 101a. In some embodiments, a plurality of injectors 101a can be included in the injection unit 101. In some embodiments, the injector 101a is configured to receive a fluid mixture from the fluid mixture supply unit 103 and discharge the fluid mixture from the discharge port 101c. In some embodiments, the injector 101a is in the configuration of a discharge channel, and the discharge port 101c is disposed distally of the injector 101a and is configured to discharge the fluid mixture.

[0017] In some embodiments, the injector 101a is communicable with a mixer or the fluid mixture supply unit 103. In some embodiments, the fluid mixture is discharged from the injector 101a into the molding device 102. The injector 101a is engageable with the molding device 102. The injector 101a is extendable toward the molding device 102 and retractable from the molding device 102. In some embodiments, the injector 101a is extendable / retractable perpendicularly in a first direction as indicated by arrow A. In some embodiments, the injector 101a is extendable / retractable by a hydraulic mechanism 101e. In some embodiments, the hydraulic mechanism 101e is attached to the injector 101a. In some embodiments, the hydraulic mechanism 101e is disposed between the fluid mixture supply unit 103 and the injector 101a.

[0018] In some embodiments, the support device 105 is configured to facilitate the engagement between the injection unit 101 and the molding device 102. In some embodiments, the support device 105 is disposed on the molding device 102. In some embodiments, the support device 105 includes a first element 101b disposed adjacent to the injector 101a. In some embodiments, the first element 101b is connected to the injection unit 101. The first element 101b is extendable toward the molding device 102 and retractable from the molding device 102. In some embodiments, the first element 101b is extendable / retractable perpendicularly in a second direction as indicated by arrow B. In some embodiments, the first direction and the second direction are parallel.

[0019] In some embodiments, the first element 101b is extendable / retractable along the rail 101f by a motor (not shown) or the like. In some embodiments, the rail 101f is disposed between the fluid mixture supply unit 103 and the first element 101b. In some embodiments, the injector 101a and the first element 101b are extendable / retractable independently of each other. The injector 101a and the first element 101b are displaceable relative to each other. In some embodiments, the injector 101a and the first element 101b can be displaced separately or consistently. In some embodiments, the first element 101b is T-shaped. In some embodiments, the first element 101b includes a protruding portion 101d engageable with the molding device 102. In some embodiments, the protruding portion 101d of the first element 101b is disposed distal to the fluid mixture supply unit 103.

[0020] In some embodiments, the injection unit 101 is disposed above the molding device 102. In some embodiments, the injector 101a and the first element 101b are disposed above the molding device 102. In some embodiments, the molding device 102 is configured to receive the fluid mixture discharged from the injector 101a through the discharge port 101c.

[0021] In some embodiments, the molding device 102 includes a first mold 102c and a second mold 102d engageable with the first mold 102c. In some embodiments, the first mold 102c is an upper mold and the second mold 102d is a lower mold. In some embodiments, the molding device 102 includes a mold cavity (not shown) defined by the first mold 102c and the second mold 102d and an opening (not shown) communicable with the mold cavity and engageable with the discharge port 101c correspondingly.

[0022] FIG. 2 shows a schematic perspective view of the second element 102s of the support device 105, and FIG. 3 shows a schematic top view of the second element 102s. In some embodiments, referring to FIGS. 1-3, the support device 105 is disposed on the molding device 102 and includes a second element 102s engageable with the first element 101b. In some embodiments, the second element 102s is engageable with the molding device 102. In some embodiments, the second element 102s is engageable with the first mold 102c. In some embodiments, the second element 102s is removably attached to the molding device 102. In some embodiments, the second element 102s includes a slot 102e defined by a protrusion 102f.

[0023] In some embodiments, the slot 102e and the protrusion 102f are elongated in the lateral direction. The slot 102e is configured to receive the protruding portion 101d of the first element 101b of the injection unit 101. The protruding portion 101d of the first element 101b is engageable with the protrusion 102f. In some embodiments, the protruding portion 101d of the first element 101b is slidable along the slot 102e within the second element 102s. In some embodiments, the length L1 of the slot 102e is equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the slot 102e is greater than the thickness T1 of the protruding portion 101d of the first element 101b. In some embodiments, the protrusion 102f includes a first portion 102x and a second portion 102y, and the protruding portion 101d of the first element 101b is disposed between the first portion 102x and the second portion 102y of the protrusion 102f.

[0024] In some embodiments, the second element 102s includes a groove 102g configured to receive the discharge port 101e. In some embodiments, the groove 102g is disposed in the second element 102s and is laterally elongated along the second element 102s. In some embodiments, the groove 102g is parallel to the protrusion 102f and the slot 102e. In some embodiments, the groove 102g is disposed between the first portion 102x and the second portion 102y of the protrusion 102f. The groove 102g is configured to receive the discharge port 101c or the end of the injector 101a of the injection unit 101. The discharge port 101c or the end of the injector 101a is slidable along it within the groove 102g. In some embodiments, the opening 102h is disposed within the groove 102g. The opening 102h extends through the second element 102s.

[0025] In some embodiments, the discharge port 101c or the end of the injector 101a can be received by the opening 102h. The discharge port 101c or the end of the injector 101a is movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is substantially larger than the width W2 of the discharge port 101c of the injector 101a. In some embodiments, the width W3 of the opening 102h is equal to the width W2 of the discharge port 101c of the injector 101a.

[0026] In some embodiments, the width W4 of the groove 102g is substantially larger than the width W3 of the opening 102h. In some embodiments, the step 102k is formed within the groove 102g adjacent to the opening 102h. In some embodiments, the discharge port 101c or the end of the injector 101a may be disposed on the step 102k while the molding device 102 is receiving the fluid mixture. In some embodiments, the width W3 of the opening 102h is substantially smaller than the width W2 of the discharge port 101c of the injector 101a, and the discharge port 101c or the end of the injector 101a may be disposed on the step 102k when the discharge port 101c or the end of the injector 101a is engaged with the second element 102s. In some embodiments, when the discharge port 101c or the end of the injector 101a is engaged with the second element 102s, the discharge port 101c covers the opening 102h.

[0027] In some embodiments, the first sensor 102l is disposed within the slot 102e and configured to sense the contact between the protruding portion 101d of the first element 101b and the second element 102s. In some embodiments, the first sensor 102l is disposed at the central end of the slot 102e. In some embodiments, the first sensor 102l is disposed within the slot 102e adjacent to the opening 102h. The first sensor 102l is not particularly limited as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of first sensors 102l are disposed within the slot 102e, and the first sensor 102l is configured to sense the position and contact of the protruding portion 101d and the slot 102e. The number and arrangement of the plurality of first sensors 102l are not particularly limited and can be disposed within the slot 102e, for example, anywhere on the protrusion 102f. However, the present invention is not limited thereto.

[0028] In some embodiments, the second sensor 102m is disposed within the groove 102g and configured to sense the contact between the discharge port 101c and the molding device 102. In some embodiments, the second sensor 102m is disposed within the groove 102g adjacent to the opening 102h. The second sensor 102m is not particularly limited as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are disposed within the groove 102g, and the second sensor 102m is configured to sense the position and contact of the discharge port 101c and the groove 102g. The number and arrangement of the plurality of second sensors 102m are not particularly limited and can be disposed anywhere in the groove 102g. However, the present invention is not limited thereto.

[0029] In some embodiments, the molding device 102 can be in an open state and a closed state. The first mold 102c engages with the second mold 102d when the molding device 102 is in the closed state. FIG. 4 shows a schematic perspective view of the molding device 102 in the closed state, and FIG. 5 shows a schematic cross-sectional view of the molding device 102 in the closed state.

[0030] In some embodiments, referring to FIGS. 4 and 5, when the molding device 102 is in a closed state, a mold cavity 102i is defined by the first mold 120c and the second mold 102d. In some embodiments, the mold cavity 102i is configured to receive the fluid mixture from the injector 101a through the opening 102h of the second element 102s. The mold cavity 102i is accessible only through the supply port 102j when the molding device 102 is in a closed state. The mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d when the molding device 102 is in an open state. In some embodiments, the molding device 102 includes a supply port 102j that can communicate with the mold cavity 102i. In some embodiments, the supply port 102j is disposed in and penetrates the first mold 102c. In some embodiments, the opening 102h is aligned with the supply port 102j when the second element 102s is disposed on the molding device 102, such that the fluid mixture can flow from the injector 101a through the opening 102h and the supply port 102j into the mold cavity 102i. In some embodiments, the opening 102h overlaps the supply port 102j when the second element 102s is disposed on the molding device 102 in a top view.

[0031] In some embodiments, the molding device 102 may be disposed on a carrier (not shown) and moved with the carrier. In some embodiments, a plurality of molding devices 102 are disposed on the carrier, and the molding devices 102 are arranged in a line, row, column, arc, curve, or any other suitable arrangement. In some embodiments, the carrier is rotatable.

[0032] In some embodiments, referring again to FIGS. 1, 2 and 3, the support device 105 further includes a third element 101g connected to the injection unit 101, and the second element 102s is configured to receive the first element 101b and the third element 101g. In some embodiments, both the first element 101b and the third element 101g are configured to be received by the first portion 102x and the second portion 102y of the protrusion 102f.

[0033] In some embodiments, the third element 101g is disposed adjacent to the injector 101a. In some embodiments, the third element 101g is connected to the injection unit 101. In some embodiments, the injector 101a is disposed between the first element 101b and the third element 101g. The third element 101g is engageable with the second element 102s. The third element 101g is extendable towards the second element 102s and retractable from the second element 102s. In some embodiments, the third element 101g is extendable / retractable perpendicular to the second direction as indicated by arrow B.

[0034] In some embodiments, the third element 101g is extendable / retractable along the rail 101f by a motor (not shown) or the like. In some embodiments, the rail 101f is disposed between the fluid mixture supply unit 103 and the third element 101g. In some embodiments, the third element 101g and the first element 101b are extendable / retractable independently of each other. The third element 101g and the first element 101b are displaceable relative to each other. In some embodiments, the third element 101g and the injector 101a are extendable / retractable independently of each other. The third element 101g and the injector 101a are displaceable relative to each other. In some embodiments, the third element 101g and the first element 101b can be displaced separately or consistently. In some embodiments, the third element 101g is T-shaped. In some embodiments, the third element 101g includes a protruding portion 101h engageable with the second element 102s. In some embodiments, the protruding portion 101h is engageable with the slot 102e. In some embodiments, the protruding portion 101h of the third element 101g is disposed distal to the fluid mixture supply unit 103. In some embodiments, the configuration of the third element 101g is the same as or different from the configuration of the first element 101b.

[0035] In the present disclosure, a first injection molding method 200 is also disclosed. The first injection molding method 200 includes several operations, and the description and illustration are not considered to limit the order of the operations. FIG. 6 is an embodiment of the first injection molding method 200. In some embodiments, the first injection molding method 200 includes several operations (201-212). FIGS. 7-18 are schematic cross-sectional views of various stages of the first injection molding method according to some embodiments of the present disclosure. In some embodiments, the first injection molding method 200 is implemented by the first injection molding system 100 shown in FIGS. 1-5 and described above.

[0036] In operation 201, referring to FIG. 7, a first injection molding system 100 is provided that includes an injection unit 101, a molding device 102, and a support device 105. In some embodiments, the first injection molding system 100 includes an injection unit 101, a molding device 102, and a support device 105 as described above. The molding device 102 is in a closed state. The opening 102h of the second element 102s is aligned with the supply port 102j of the molding device 102, such that the mold cavity 102i is accessible through the opening 102h and the supply port 102j. In some embodiments, the molding device 102 may be disposed on a carrier (not shown) and moved with the carrier. In some embodiments, several molding devices 102 are disposed on the carrier.

[0037] In operation 202, the protruding portion 101d of the first element 101b of the support device 105 is aligned with the slot 102e of the second element 102s of the support device 105. In operation 203, the discharge port 101c is aligned with the groove 102g of the second element 102s configured to receive the discharge port 101c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s and the alignment of the discharge port 101c with the groove 102g are performed simultaneously. In some embodiments, the molding device 102 is disposed under the second element 102s during the alignment of the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s.

[0038] In some embodiments, the injector 101a and the first element 101b are vertically displaced along arrows A and B, respectively, to horizontally align with the groove 102g and the slot 102e, as shown in FIG. 7. In some embodiments, the injector 101a moves upward or downward to horizontally align the discharge port 101c with the groove 102g. In some embodiments, the first element 101b moves upward or downward to horizontally align the protruding portion 101d with the slot 102e. Alternatively or simultaneously, the second element 102s is displaced along arrows C and / or D to horizontally align with the protruding portion 101d of the first element 101b and the discharge port 101c or the end of the injector 101a. In some embodiments, the second element 102s is displaced upward, downward, forward, or backward to horizontally align the slot 102e with the protruding portion 101d and the groove 102g with the discharge port 101c or the end of the injector 101a.

[0039] In some embodiments, the protruding portion 101h of the third element 101g is aligned with the slot 102e of the second element 102s. In some embodiments, the process of aligning the protruding portion 101h of the third element 101g with the slot 102e of the second element 102s is similar to the process of aligning the protruding portion 101d of the first element 101b with the slot 102e of the second element 102s. Therefore, for the sake of brevity, the repeated description will be omitted. In some embodiments, the alignment between the protruding portion 101d of the first element 101b and the slot 102e of the second element 102s, and the alignment between the protruding portion 101h of the third element 101g and the slot 102e are performed simultaneously.

[0040] In operation 204, referring to FIGS. 8 and 9, the second element 102s is displaced towards the injection unit 101 to slide the protruding portion 101d of the first element 101b along the slot 102e of the second element 102s. In operation 205, the discharge port 101c slides within the groove 102g.

[0041] In some embodiments, after being horizontally aligned, the second elements 102s are then moved towards the injection unit 101 along arrow E, as shown in FIG. 8. Alternatively, after being horizontally aligned, the injection unit 101 is then moved towards the second elements 102s along arrow L, as shown in FIG. 8. In some embodiments, the molding device 102 is moved towards the second elements 102s and the injection unit 101 after horizontally aligning the second elements 102s and the injection unit 101. In other words, with the injection unit 101 and the second elements 102s fixed relative to the molding device 102, the molding device 102 is movable.

[0042] FIG. 9 is a schematic cross-sectional view of the first injection molding system 100 of FIG. 8. In some embodiments, the protruding portion 101d of the first element 101b slides along the slot 102e, and the discharge port 101c or the end of the injector 101a slides along the groove 102g. In some embodiments, the protruding portion 101h of the third element 101g slides along the slot 102e. As shown in FIG. 9, the protrusion 102f is disposed opposite to the protruding portion 101d of the first element 101b. In some embodiments, the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g are disposed between the first portion 102x and the second portion 102y of the protrusion 102f.

[0043] In some embodiments, in operations 204 and 205, the first element 101b, the third element 101g, and the injector 101a are not in contact with the second elements 102s. In some embodiments, the discharge port 101c or the end of the injector 101a is surrounded by the groove 102g and does not contact the step 102k within the groove 102g. In some embodiments, the first distance D1 between the bottom surface of the protruding portion 101d and the second elements 102s is substantially greater than the second distance D2 between the discharge port 101c and the bottom surface of the groove 102g.

[0044] In operation 206, the injection unit 101 and the support device 105 are displaced and arranged above the molding device 102. In some embodiments, referring to FIG. 10, after aligning the injector 101a with the opening 102h and the injector 101a, the first element 101b moves towards the molding device 102 along the arrow F as shown in FIG. 10. In some embodiments, the molding device 102 is moved until the support device 105 overlaps the molding device 102 and the injector 101a is vertically aligned with the supply port 102j of the molding device 102. In some embodiments, the molding device 102 is moved by rotating a carrier (not shown) that carries the molding device 102.

[0045] In operation 207, referring to FIG. 11, the discharge port 101c extends towards the molding device 102 and engages the discharge port 101c with the opening 102h.

[0046] In some embodiments, after aligning the injector 101a with the opening 102h, the injector 101a and the first element 101b move towards the molding device 102 along the arrow F as shown in FIG. 11 until the discharge port 101c of the injector 101a contacts the second element 102s. In some embodiments, the discharge port 101c engages with the opening 102h and contacts the step 102k. In some embodiments, the injector 101a and the first element 101b are moved consistently. When the discharge port 101c of the injector 101a contacts the second element 102s, as shown in FIG. 11, the entire first element 101b still does not contact the second element 102s. In some embodiments, the third element 101g (not shown in FIG. 11) and the first element 101b are moved consistently in operation 207. In some embodiments, the contact between the second element 102s and the discharge port 101c is sensed by a second sensor 102m disposed within the groove 102g. In some embodiments, the contact between the second element 102s and the discharge port 101c is sensed continuously.

[0047] In operation 208, referring to FIG. 12, while the first element 101b is being received by the second element 102s, the first element 101b is displaced away from the second element 102s. In some embodiments, the protrusion 101d of the first element 101b is moved to abut against the protrusion 102f of the second element 102s while the protrusion 101d of the first element 101b is being received by the slot 102e of the second element 102s.

[0048] In some embodiments, after the discharge port 101c contacts the second element 102s, the first element 101b moves away from the second element 102s along arrow G as shown in FIG. 12 until the protrusion 101d of the first element 101b contacts the protrusion 102f of the second element 102s. In some embodiments, the injector 101a remains stationary while the first element 101b is moving upward as shown in FIG. 12. As a result, the first element 101b engages with the second element 102s. In some embodiments, the contact between the second element 102s and the first element 101b is sensed by a first sensor 102l disposed on the protrusion 102f and within the slot 102e. In some embodiments, the contact between the second element 102s and the first element 101b is sensed by the first sensor 102l. In some embodiments, the contact between the protrusion 102f and the protrusion 101d of the first element 101b is sensed by the first sensor 102l. In some embodiments, the contact between the second element 102s and the first element 101b is sensed continuously.

[0049] In some embodiments, a third element 101g (not shown in FIG. 12, shown in FIG. 8) and a first element 101b are moved consistently in operation 208. In some embodiments, a protruding portion 101h of the third element 101g (not shown in FIG. 12, shown in FIG. 8) is moved to abut against a protrusion 102f of the second element 102s while the protruding portion 101h of the third element 101g is received by a slot 102e of the second element 102s. In some embodiments, the contact between the protruding portion 101h of the third element 101g and the protrusion 102f of the second element 102s is sensed by a first sensor 102l.

[0050] In operation 209, referring to FIG. 13, a fluid mixture 104 is injected into a mold cavity 102i of a molding device 102.

[0051] In some embodiments, after the protruding portion 101d contacts the protrusion 102f, the fluid mixture 104 is injected into the mold cavity 102i as shown in FIG. 13. The fluid mixture 104 is discharged into the mold cavity 102i from a discharge port 101c of an injector 101a through an opening 102h and a supply port 102j of the molding device 102. In some embodiments, the fluid mixture 104 is supplied by a fluid mixture supply unit 103 connected to the injector 101a. In some embodiments, the composition of the fluid mixture 104 is similar to the fluid mixture prepared by the supply unit 103 as discussed above, and for the sake of brevity, repeated descriptions are omitted.

[0052] In some embodiments, during the injection of the fluid mixture 104, the discharge port 101c engages with the opening 102h, contacts the step 102k, and the protruding portion 101d of the first element 101b abuts against the protrusion 102f of the second element 102s. During the injection of the fluid mixture 104 into the mold cavity 102i by the injector 101a, an injection force I is generated towards the second element 102s and / or the molding device 102. In some embodiments, the injection force I acts on the second element 102s and / or the molding device 102 to push the second element 102s and / or the molding device 102 away from the injection unit 101, and as a result, a reaction force C acting on the protruding portion 101d by the protrusion 102f is generated. The protruding portion 101d abuts against the protrusion 102f during the injection of the fluid mixture 104. Thus, the engagement between the first element 101b and the second element 102s and the engagement between the discharge port 101c and the supply port 102j are ensured. The outflow of the fluid mixture 104 from the mold cavity 102i can be minimized or even prevented.

[0053] In operation 210, referring to FIG. 14, after the injection of the fluid mixture 104, the first element 101b is displaced towards the second element 102s. In some embodiments, the protruding portion 101d of the first element 101b is disengaged from the protrusion 102f of the second element 102s after the injection of the fluid mixture 104, but the protruding portion 101d of the first element 101b is received by the slot 102e of the second element 102s.

[0054] In some embodiments, after the injection of the fluid mixture 104, the first element 101b is displaced towards the second element 102s along the arrow H as shown in FIG. 14 until the first element 101b is disengaged from the second element 102s. In some embodiments, the protruding portion 101d is moved away from the protrusion 102f. In some embodiments, the first element 101b is moved towards the molding device 102 and disengaged from the protrusion 102f. In some embodiments, the injector 101a remains stationary as the first element 101b moves downward as shown in FIG. 14. In some embodiments, the separation between the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor 102l.

[0055] In some embodiments, the third element 101g (not shown in FIG. 14, shown in FIG. 8) and the first element 101b are moved consistently in operation 210. In some embodiments, the protruding portion 101h of the third element 101g (not shown in FIG. 14, shown in FIG. 8) is displaced towards the second element 102s after the injection of the fluid mixture 104. In some embodiments, the separation between the protruding portion 101h of the third element 101g and the protrusion 102f of the second element 102s is sensed by the first sensor 102l.

[0056] In operation 211, referring to FIG. 15, the injector 101a is displaced away from the molding device 102. In some embodiments, the discharge port 101c is retracted away from the molding device 102 after the injection of the fluid mixture 104.

[0057] In some embodiments, after the engagement between the first element 101b and the second element 102s is released, the injector 101a moves away from the molding device 102 along the arrow J as shown in FIG. 15 until the discharge port 101c of the injector 101a no longer contacts the second element 102s. In some embodiments, the separation between the injector 101a and the groove 102g is sensed by the second sensor 102m. In some embodiments, the injector 101a and the first element 101b move away from the molding device 102 along the arrow J. In some embodiments, the injector 101a and the first element 101b are moved consistently. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are moved consistently.

[0058] In operation 212, referring to FIGS. 16 and 17, the second element 102s and the molding device 102 are displaced away from the injection unit 101, or the injection unit 101 is displaced away from the molding device 102.

[0059] In some embodiments, after disengaging the first element 101b and the injector 101a from the second element 102s, the second element 102s and the molding device 102 are displaced away from the injection unit 101. Alternatively, after disengaging the first element 101b and the injector 101a from the second element 102s, the injection unit 101 is displaced away from the molding device 102. In some embodiments, the second element 102s and the molding device 102 move horizontally away from the first element 101b and the injector 101a along the arrow K as shown in FIG. 16. Alternatively, the first element 101b and the injector 101a move horizontally away from the second element 102s and the molding device 102 along the arrow M as shown in FIG. 16. FIG. 17 shows that after the second element 102s is displaced away from the injection unit 101, the injection unit 101 and the second element 102s are separated from each other.

[0060] In operation 212, referring to FIG. 18, the molding device 102 is displaced away from the second element 102s or displaces the second element 102s away from the molding device 102.

[0061] In some embodiments, after disengaging the molding device 102 from the second element 102s, the molding device 102 is displaced away from the second element 102s. In some embodiments, the molding device 102 is displaced away from the second element 102s by rotating a carrier (not shown) held or disposed under the molding device 102. Alternatively, after disengaging the second element 102s from the molding device 102, the injection unit 101, the molding device 102, and the second element 102s are separated from each other. In some embodiments, the molding device 102 is horizontally moved away from the second element 102s. Alternatively, the second element 102s is horizontally moved away from the molding device 102. FIG. 18 shows that after the molding device 102 has moved away from the second element 102s, the second element 102s and the molding device 102 are separated from each other.

[0062] FIG. 19 shows a schematic perspective view of a second injection molding system 300 according to an embodiment of the present disclosure. In some embodiments, referring to FIG. 19, the second injection molding system 300 includes an injection unit 101, a molding device 102, and a support device 105 disposed between the injection unit 101 and the molding device 102. In some embodiments, the second injection molding system 300 further includes a fluid mixture supply unit 103 communicable with the injection unit 101. In some embodiments, the fluid mixture supply unit 103 is configured to generate a fluid mixture and supply it to the injection unit 101. In some embodiments, the fluid mixture includes polymer materials such as ethylene vinyl acetate (EVA), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE). In some embodiments, the fluid mixture includes recyclable materials. In some embodiments, the fluid mixture further includes a foaming agent.

[0063] In some embodiments, the fluid mixture supply unit 103 of the second injection molding system 300 includes an extruder (not shown) for converting the polymer material into a molten state and a mixer (not shown) for mixing the blowing agent into the polymer material. The polymer material is flowable from the extruder into the mixer.

[0064] In some embodiments, the injection unit 101 includes a plurality of injectors 101a disposed between the first element 101b and the third element 101g of the support device 105. In some embodiments, the support device 105 surrounds the injector 101a. In some embodiments, each of the injectors 101a is configured to receive the fluid mixture from the fluid mixture supply unit 103 and discharge the fluid mixture from its discharge port 101c. In some embodiments, each of the injectors 101a is communicable with the mixer or the fluid mixture supply unit 103. In some embodiments, the fluid mixture is discharged from the injector 101a into the molding device 102. Each of the injectors 101a is engageable with the second element 102s of the support device 105. In some embodiments, all of the injectors 101a are engaged with the second element 102s. In some embodiments, each of the injectors 101a is extendable / retractable perpendicular to the first direction as indicated by arrow A. In some embodiments, the injectors 101a are extendable / retractable independently of each other. In some embodiments, each of the injectors 101a is extendable / retractable by a hydraulic mechanism 101e. In some embodiments, the movement of each injector 101a is actuated and controlled by one hydraulic mechanism 101e.

[0065] In some embodiments, the support device 105 is configured to facilitate the engagement between the injection unit 101 and the molding device 102. In some embodiments, the support device 105 includes a first element 101b, a third element 101g disposed adjacent to the injector 101a, and a second element 102s disposed on the molding device 102. In some embodiments, the first element 101b and the third element 101g are engageable with the second element 102s. The first element 101b and the third element 101g are each extendable toward the molding device 102 and retractable from the molding device 102. In some embodiments, each of the first element 101b and the third element 101g is vertically extendable / retractable in a manner indicated by a second direction as indicated by arrow B. In some embodiments, each of the first element 101b and the third element 101g is extendable / retractable along the rail 101f by a motor (not shown) or the like. In some embodiments, each of the first element 101b and the third element 101g is moved along the rail 101f, and the movement of each of the first element 101b and the third element 101g is actuated and controlled by one motor. In some embodiments, the first direction and the second direction are parallel.

[0066] In some embodiments, the injector 101a, the first element 101b, and the third element 101g are each independently extendable / retractable. The injector 101a, the first element 101b, and the third element 101g are displaceable relative to each other. In some embodiments, the injector 101a, the first element 101b, and the third element 101g can be displaced separately or consistently. In some embodiments, all the injectors 101a are moved consistently with each other, and the first element 101b and the third element 101g are moved consistently with each other. In some embodiments, each of the first element 101b and the third element 101g is T-shaped. In some embodiments, the first element 101b includes a protruding portion 101d engageable with the second element 102s, and the third element 101g includes a protruding portion 101h engageable with the second element 102s.

[0067] In some embodiments, the injection unit 101 is disposed above the molding device 102. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are disposed above the molding device 102. In some embodiments, the molding device 102 is configured to receive the fluid mixture discharged from the injector 101a through the discharge port 101c.

[0068] In some embodiments, the molding device 102 includes a first mold 102c and a second mold 102d engageable with the first mold 102c. In some embodiments, the first mold 102c is an upper mold and the second mold 102d is a lower mold. In some embodiments, the second element 102s is engageable with the first mold 102c. In some embodiments, the molding device 102 is disposed on a carrier (not shown) and may be moved together with the carrier. In some embodiments, a plurality of molding devices 102 are disposed on the carrier, and the molding devices are disposed in a line, row, column, arc, curve, or any other suitable arrangement. In some embodiments, the carrier is rotatable.

[0069] FIG. 20 shows a schematic perspective view of the second element 102s, and FIG. 21 shows a schematic top view of the second element 102s. In some embodiments, referring to FIGS. 19 to 21, the support device 105 includes a second element 102s engageable with the first element 101b and the third element 101g. In some embodiments, the second element 102s is disposed on the molding device 102. In some embodiments, the second element 102s includes a slot 102e defined by a protrusion 102f and a slot 102o defined by a protrusion 102p.

[0070] In some embodiments, slots 102e, 102o and protrusions 102f, 102p are elongated in the lateral direction. Slot 102e is configured to receive the protruding portion 101d of the first element 101b of the support device 105. Slot 102o is configured to receive the protruding portion 101f of the third element 101g of the support device 105. In some embodiments, the protruding portion 101d of the first element 101b is slidable along within the slot 102e of the second element 102s, and the protruding portion 101f of the third element 101g is slidable along within the slot 102o of the second element 102s. In some embodiments, each of the length L1 of slot 102e and the length L2 of slot 102o is equal to the width W1 of the second element 102s. In some embodiments, the height H1 of the slot 102e of the second element 102s is greater than the thickness T1 of the protruding portion 101d of the first element 101b, and the height H2 of the slot 102o of the second element 102s is greater than the thickness T2 of the protruding portion 101h of the third element 101g. In some embodiments, each of the protruding portion 101d of the first element 101b and the protruding portion 101h of the third element 101g is T-shaped and is configured to be received by the slot 102e and the slot 102o, respectively.

[0071] In some embodiments, the molding device 102 includes a groove 102g configured to receive the discharge port 101e. In some embodiments, the groove 102g is disposed on the second element 102s and is elongated laterally along the second element 102s. In some embodiments, the groove 102g is parallel to the protrusions 102f and 102p. The groove 102g is configured to receive the discharge port 101c or the end of the injector 101a of the injection unit 101. The discharge port 101c or the end of the injector 101a is slidable along the groove 102g. In some embodiments, the opening 102h is disposed within the groove 102g. In some embodiments, the opening 102h extends through the second element 102s. The discharge port 101c or the end of the injector 101a can be received by the opening 102h. The discharge port 101c or the end of the injector 101a is movable within the opening 102h. In some embodiments, the width W3 of the opening 102h is substantially larger than the total width W2 of the discharge port 101c of the injector 101a. In some embodiments, all the discharge ports 101c of the injector 101a can be received by the opening 102h.

[0072] In some embodiments, the first sensor 102l is disposed within the slot 102e and is configured to sense the contact between the protruding portion 101d and the slot 102e, and the third sensor 102q is disposed within the slot 102o and is configured to sense the contact between the protruding portion 101h and the slot 102o. In some embodiments, the first sensor 102l is disposed at the central end of the slot 102e, and the third sensor 102q is disposed at the central end of the slot 102o. The first sensor 102l and the third sensor 102q are not particularly limited as long as they can sense pressure and provide pressure information.

[0073] In some embodiments, a plurality of first sensors 102l are disposed within the slot 102e, and the first sensors 102l are configured to sense the position and contact of the protruding portion 101d and the slot 102e. In some embodiments, a plurality of third sensors 102q are disposed within the slot 102o, and the third sensors 102q are configured to sense the position and contact of the protruding portion 101h and the slot 102o. The number and arrangement of the plurality of third sensors 102q are not particularly limited, and for example, they can be disposed anywhere within the slot 102o where the protrusion 102p is located. However, the present invention is not limited thereto.

[0074] In some embodiments, the step 102k is formed within the groove 102g adjacent to the opening 102h. In some embodiments, the second sensor 102m is disposed within the groove 102g and is configured to sense the contact between the discharge port 101c and the groove 102g.

[0075] In some embodiments, the second sensor 102m is disposed within the opening 102h. The second sensor 102m is not particularly limited as long as it can sense pressure and provide pressure information. In some embodiments, a plurality of second sensors 102m are disposed within the opening 102h, and the second sensors 102m are configured to sense the position and contact of the discharge port 101c and the shaping device 102. The number and arrangement of the plurality of second sensors 102m are not particularly limited, and for example, they can be disposed anywhere within the opening 102h. However, the present invention is not limited thereto.

[0076] In some embodiments, the molding device 102 can be in an open state and a closed state. The first mold 102c engages with the second mold 102d when the molding device 102 is in the closed state. FIG. 22 shows a schematic perspective view of the molding device 102 in the closed state, and FIG. 23 shows a schematic cross-sectional view of the molding device 102 in the closed state. In some embodiments, the mold cavity 102i is defined by the first mold 102c and the second mold 102d when the molding device 102 is in the closed state. In some embodiments, the first mold 102c and the second mold 102d define a plurality of mold cavities 102i. In some embodiments, the mold cavities 102i are isolated from each other. In some embodiments, the mold cavity 102i is configured to receive the fluid mixture from the injector 101a through the opening 102h and the supply port 102j of the second element 102s. The mold cavity 102i is accessible only through the supply port 102j when the molding device 102 is in the closed state. The mold cavity 102i is accessible through a gap (not shown) between the first mold 102c and the second mold 102d when the molding device 102 is in the open state. In some embodiments, the molding device 102 includes a supply port 102j that can communicate with the mold cavity 102i. In some embodiments, the supply port 102j is disposed in and penetrates the first mold 102c. In some embodiments, the molding device 102 includes a plurality of supply ports 102j as shown in FIGS. 22 and 23. The supply ports 102j respectively correspond to the mold cavities 102i. In some embodiments, the opening 102h is aligned with the supply port 102j when the second element 102s is disposed on the molding device 102, such that the fluid mixture can flow from the injector 101a through the opening 102h and the supply port 102j into the mold cavity 102i. In some embodiments, the opening 102h is disposed above all of the supply ports 102j. In some embodiments, the opening 102h overlaps the supply port 102j when the second element 102s is disposed on the molding device 102 in a top view.

[0077] In the present disclosure, a second injection molding method 400 is also disclosed. The second injection molding method 400 includes several operations, and the description and illustration are not considered to limit the order of the operations. FIG. 24 is an embodiment of the second injection molding method 400. In some embodiments, the second injection molding method 400 includes several operations (401 to 413). FIGS. 25 to 36 are schematic cross-sectional views of various stages of the second injection molding method according to some embodiments of the present disclosure. In some embodiments, the second injection molding method 400 is shown in FIGS. 19 to 23 and is implemented by the second injection molding system 300 as discussed above.

[0078] In operation 401, referring to FIG. 25, a second injection molding system 300 including an injection unit 101, a molding device 102, and a support device 105 is provided. In some embodiments, the second injection molding system 300 includes an injection unit 101, a molding device 102, and a support device 105 as described above. The molding device 102 is in a closed state. The opening 102h of the second element 102s is aligned with some supply ports 102j of the molding device 102, and as a result, the mold cavity 102i is accessible through the opening 102h and the supply ports 102j.

[0079] In operation 402, the protruding portion 101d of the first element 101b of the support device 105 is aligned with the first slot 102e of the second element 102s of the support device 105. In operation 403, the protruding portion 101h of the third element 101g of the support device is aligned with the second slot 102e of the second element 102s. In operation 404, the plurality of discharge ports 101c are aligned with the groove 102g of the second element 102s configured to receive the discharge ports 101c. In some embodiments, the alignment of the protruding portion 101d of the first element 101b with the first slot 102e of the second element 102s, the alignment of the protruding portion 101h of the third element 101g with the second slot 102e of the second element 102s, and the alignment of the discharge ports 101c with the groove 102g are performed simultaneously.

[0080] In some embodiments, as shown in FIG. 25, the injector 101a is displaced vertically along arrow A to align horizontally with the groove 102g, and the first element 101b and the third element 101g are displaced vertically along arrow B to align horizontally with the first slot 102e and the second slot 102e, respectively. In some embodiments, the injector 101a moves upward or downward to align horizontally with the groove 102g. In some embodiments, the first element 101b and the third element 101g move upward or downward to align horizontally with the first slot 102e and the second slot 102e, respectively. Alternatively or simultaneously, the molding device 102 is displaced along arrow C and / or arrow D to align horizontally with the protruding portion 101d of the first element 101b, the protruding portion 101h of the third element 101g, and the discharge port 101c or the end of the injector 101a. In some embodiments, the molding device 102 moves upward, downward, forward, and / or backward to align the first slot 102e horizontally with the protruding portion 101d, the second slot 102e horizontally with the protruding portion 101h, and the groove 102g horizontally with the discharge port 101c or the end of the injector 101a.

[0081] In operation 405, referring to FIGS. 26 and 27, the injection unit 101 is displaced to slide the protruding portion 101d of the first element 101b along the first slot 102e of the second element 102s and to slide the protruding portion 101h of the third element 101g along the second slot 102e of the second element 102s. In operation 406, the discharge port 101c slides within the groove 102g.

[0082] In some embodiments, after being horizontally aligned, the second elements 102s are moved toward the injection unit 101 along arrow E as shown in FIG. 26. Alternatively, after being horizontally aligned, the injection unit 101 is moved toward the second elements 102s along arrow L as shown in FIG. 26. FIG. 27 is a schematic cross-sectional view of the second injection molding system 300 of FIG. 26. In some embodiments, the first element 101b slides along the first slot 102e, the third element 101g slides along the second slot 102e, and the end portion of the discharge port 101c or the injector 101a slides along the groove 102g. In some embodiments, the second elements 102s are moved until the first element 101b is disposed within the first slot 102e, the third element 101g is disposed within the second slot 102e, and the discharge port 101c or the end portion of the injector 101a is vertically aligned with the opening 102h. As shown in FIG. 27, the protrusion 102f is disposed opposite the protruding portion 101d of the first element 101b, and the protrusion 102p is disposed opposite the protruding portion 101h of the third element 101g. The first element 101b, the third element 101g, and the injector 101a are not in contact with the second element 102s. In some embodiments, the discharge ports 101c of the injector 101a are each aligned with the opening 102h. In some embodiments, the distance D3 between the bottom surface of the protruding portion 101h and the second element 102s is substantially greater than the distance D4 between the end of the discharge port 101c and the upper surface of the molding device 102.

[0083] In operation 407, the molding device 102 is displaced toward the injection unit 101 and the support device 105 and is disposed below the support device 105. In some embodiments, referring to FIG. 28, after aligning the injector 101a with the opening 102h, the injector 101a and the first element 101b move along the arrow F toward the molding device 102 as shown in FIG. 28. In some embodiments, the molding device 102 is moved until the support device 105 covers the molding device 102 and the injector 101a is vertically aligned with the supply port 102j of the molding device 102. In some embodiments, the molding device 102 is moved, for example, by rotating a carrier (not shown) disposed under the molding device 102. In some embodiments, the molding device 102 is moved until the discharge port 101c or the end of the injector 101a is vertically aligned with the supply port 102j of the molding device 102.

[0084] In operation 408, referring to FIG. 29, the discharge port 101c extends toward the molding device 102 and engages the molding device 102.

[0085] In some embodiments, after aligning the injector 101a with the opening 102h, the injector 101a, the first element 101b, and the third element 101g move along the arrow F toward the molding device 102 as shown in FIG. 28 until the discharge port 101c of the injector 101a contacts the second element 102s. In some embodiments, the discharge port 101c is in contact with the first mold 102c. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are moved consistently. When the discharge port 101c of the injector 101a contacts the first mold 102c, the entire first element 101b and the entire third element 101g still do not contact the second element 102s as shown in FIG. 29. In some embodiments, the contact between the molding device 102 and the discharge port 101c is sensed by a second sensor 102m disposed in the groove 102g. In some embodiments, the contact between the molding device 102 and the discharge port 101c is sensed continuously.

[0086] In operation 409, referring to FIG. 30, while the first element 101b and the third element 101g are being received by the second element 102s, the first element 101b and the third element 101g are displaced away from the second element 102s. In some embodiments, the protrusion 101d of the first element 101b moves to abut against the protrusion 102f of the second element 102s while the protrusion 101d of the first element 101b is being received by the first slot 102e of the second element 102s, and the protrusion 101h of the third element 101g moves to abut against the protrusion 102p of the second element 102s while the protrusion 101h of the third element 101g is being received by the second slot 102e of the second element 102s.

[0087] In some embodiments, after the discharge port 101c contacts the molding device 102, the first element 101b and the third element 101g move away from the second element 102s along the arrow G as shown in FIG. 30 until the protrusion 101d of the first element 101b and the protrusion 101h of the third element 101g respectively contact the protrusion 102f and the protrusion 102p of the second element 102s. In some embodiments, the injector 101a remains stationary as shown in FIG. 30 while the first element 101b and the third element 101g are moving upward. As a result, the first element 101b and the third element 101g engage with the second element 102s.

[0088] In some embodiments, the contact between the second element 102s and the first element 101b is sensed by the first sensor 102l. In some embodiments, the contact between the protrusion 102f and the protruding portion 101d of the first element 101b is sensed by the first sensor 102l. In some embodiments, the contact between the second element 102s and the first element 101b is sensed continuously. In some embodiments, the contact between the second element 102s and the third element 101g is sensed by the third sensor 102q disposed on the protrusion 102p and within the second slot 102e. In some embodiments, the contact between the second element 102s and the third element 101g is sensed by the third sensor 102q. In some embodiments, the contact between the protrusion 102p and the protruding portion 101h of the third element 101g is sensed by the third sensor 102q. In some embodiments, the contact between the second element 102s and the third element 101g is sensed continuously.

[0089] In operation 410, referring to FIG. 31, the fluid mixture 104 is injected into the mold cavity 102i of the molding apparatus 102.

[0090] In some embodiments, after the protruding portion 101d contacts the protrusion 102f and the protruding portion 101h contacts the protrusion 102p, as shown in FIG. 31, the fluid mixture 104 is injected into the mold cavity 102i. The fluid mixture 104 is discharged into the mold cavity 102i from the discharge port 101c of the injector 101a through the opening 102h and the supply port 102j. In some embodiments, the fluid mixture 104 is supplied by a fluid mixture supply unit 103 connected to the injector 101a. In some embodiments, the composition of the fluid mixture 104 is similar to the fluid mixture prepared by the supply unit 103 as discussed above, and for the sake of brevity, repeated descriptions are omitted.

[0091] In some embodiments, during the injection of the fluid mixture 104, the discharge port 101c engages with the molding device 102, the protruding portion 101d of the first element 101b abuts against the protrusion 102f of the second element 102s, and the protruding portion 101h of the third element 101g abuts against the protrusion 102p of the fourth element 102o. During the injection of the fluid mixture 104 into the mold cavity 102i by the injector 101a, an injection force I is generated toward the molding device 102. In some embodiments, the injection force I acts on the molding device 102 to push the molding device 102 away from the injection unit 101, and as a result, a reaction force C acting on the protruding portion 101d by the protrusion 102f is generated. During the injection of the fluid mixture 104, the protruding portion 101d abuts against the protrusion 102f, and the protruding portion 101h abuts against the protrusion 102p. Accordingly, the engagement between the first element 101b and the second element 102s, the engagement between the third element 101g and the second element 102s, and the engagement between the discharge port 101c and the supply port 102j are ensured. The fluid mixture 104 flowing out of the mold cavity 102i can be minimized or even prevented.

[0092] In operation 411, referring to FIG. 32, the first element 101b and the third element 101g are displaced toward the second element 102s after the injection of the fluid mixture 104. In some embodiments, while the protruding portion 101d of the first element 101b is received by the first slot 102e of the second element 102s and the protruding portion 101h of the third element 101g is received by the second slot 102e of the second element 102s, after the injection of the fluid mixture 104, the protruding portion 101d of the first element 101b is disengaged from the protrusion 102f of the second element 102s, and the protruding portion 101h of the third element 101g is disengaged from the protrusion 102p of the second element 102s.

[0093] In some embodiments, after the injection of the fluid mixture 104, the first element 101b and the third element 101g are displaced along the arrow H as shown in FIG. 32 towards the second element 102s until the first element 101b is disengaged from the second element 102s. In some embodiments, the protruding portion 101d moves away from the protrusion 102f, and the protruding portion 101h moves away from the protrusion 102p. In some embodiments, the first element 101b is moved towards the forming device 102 so as to disengage from the protrusion 102f, and the third element 101g is moved towards the forming device 102 so as to disengage from the protrusion 102p. In some embodiments, the injector 101a remains stationary as the first element 101b and the third element 101g move downward as shown in FIG. 32. In some embodiments, the separation between the protrusion 102f of the first element 101b and the protruding portion 101d is sensed by the first sensor 102l, and the separation between the protrusion 102p of the third element 101g and the protruding portion 101h is sensed by the third sensor 102q.

[0094] In operation 412, referring to FIG. 33, the injector 101a is displaced away from the forming device 102. In some embodiments, the discharge port 101c is retracted away from the forming device 102 after the injection of the fluid mixture 104.

[0095] In some embodiments, after the disengagement of the first element 101b and the third element 101g from the second element 102s, the injector 101a moves away from the forming device 102 along the arrow J as shown in FIG. 33 until the discharge port 101c of the injector 101a no longer contacts the forming device 102. In some embodiments, the separation between the injector 101a and the forming device 102 is sensed by the second sensor 102m. In some embodiments, the injector 101a, the first element 101b, and the third element 101g move away from the forming device 102 along the arrow J. In some embodiments, the injector 101a, the first element 101b, and the third element 101g are moved consistently.

[0096] In operation 413, referring to FIGS. 34 and 35, the molding device 102 is displaced away from the injection unit 101 or the injection unit 101 is displaced away from the molding device 102.

[0097] In some embodiments, after the injector 101a, the first element 101b, and the third element 101g are disengaged from the second element 102s, the molding device 102 is displaced away from the injection unit 101. Alternatively, after the injector 101a, the first element 101b, and the third element 101g are disengaged from the second element 102s, the injection unit 101 is displaced away from the second element 102s. In some embodiments, the molding device 102 moves horizontally away from the injector 101a, the first element 101b, and the third element 101g along arrow K as shown in FIG. 34. Alternatively, the injector 101a, the first element 101b, and the third element 101g move horizontally away from the second element 102s and the molding device 102 along arrow M as shown in FIG. 34. FIG. 35 shows that after the second element 102s is displaced away from the injection unit 101, the injection unit 101 and the second element 102s are separated from each other.

[0098] In some embodiments, after disengaging the molding device 102 from the second element 102s, the molding device 102 is displaced away from the second element 102s. In some embodiments, as shown in FIG. 35, the molding device 102 moves horizontally away from the second element 102s along arrow K. In some embodiments, the molding device 102 is displaced away from the second element 102s by rotating a carrier (not shown) disposed below the molding device 102, and another molding device (not shown) may be disposed below the second element 102s. Alternatively, after disengaging the second element 102s from the molding device 102, the injection unit 101, the molding device 102, and the second element 102s are separated from each other. In some embodiments, the molding device 102 moves horizontally away from the second element 102s. Alternatively, the second element 102s moves horizontally away from the molding device 102. FIG. 36 shows that after the molding device 102 moves away from the second element 102s, the second element 102s and the molding device 102 are separated from each other.

[0099] In the present disclosure, a third injection molding method 500 is also disclosed. The third injection molding method 500 includes several operations, and the description and illustration are not considered to limit the order of the operations. FIG. 37 is an embodiment of the third injection molding method 500. In some embodiments, the third injection molding method 500 includes several operations (501-506). In some embodiments, the third injection molding method 500 is implemented by the first injection molding system 100 shown in FIGS. 1-5 or the second injection molding system 300 shown in FIGS. 19-23 described above.

[0100] In operation 501, an injection molding system is provided, the injection molding system includes an injection unit and a molding device, the injection unit includes a discharge port configured to discharge a fluid mixture, the molding device is configured to receive the fluid mixture from the discharge port, and includes a mold cavity and a supply port that can communicate with the mold cavity and can engage with the discharge port correspondingly.

[0101] In operation 502, a support device configured to facilitate the engagement between the injection unit and the molding device is provided, and the support device includes a first element connected to the injection unit and a second element disposed in the molding device.

[0102] In operation 503, the protruding portion of the first element is aligned with the slot of the second element.

[0103] In operation 504, the injection unit is displaced to slide the protruding portion of the first element along the slot of the second element.

[0104] In operation 505, when the protruding portion of the first element engages with the slot of the second element, the discharge port is displaced within the opening of the second element to engage with the supply port.

[0105] In operation 506, the fluid mixture is injected into the mold cavity.

[0106] One aspect of the present disclosure relates to an injection molding system. The injection molding system includes a supply unit configured to supply a fluid mixture of a polymer material and a foaming agent, an injection unit communicable with the supply unit, the injection unit being disposed distally from the supply unit and including a discharge port configured to discharge the fluid mixture, a molding device configured to receive the fluid mixture from the discharge port, the molding device including a mold cavity and a supply port communicable with the mold cavity and engageable with the discharge port, and a support device disposed between the injection unit and the molding device and configured to facilitate the engagement between the injection unit and the molding device. The support device includes a first element connected to the injection unit and a second element disposed in the molding device. The second element includes a slot configured to receive the protruding portion of the first element, and the protruding portion of the first element is slidable along the first slot of the second element within the first slot.

[0107] In some embodiments, the second element includes an opening configured to receive the discharge port of the injection unit. In some embodiments, the second element further includes a protrusion for defining a first slot, and the first slot and the protrusion are elongated in the lateral direction. In some embodiments, the protruding portion of the first element is engageable with the protrusion and slidable within the slot. In some embodiments, the second element further includes a groove configured to receive the discharge port, and the groove is elongated in the lateral direction parallel to the first slot along the second element. In some embodiments, the discharge port is slidable within the groove along the groove. In some embodiments, the second element further includes an opening disposed within the groove. In some embodiments, the first sensor is disposed within the first slot and configured to sense contact between the protruding portion and the first slot. In some embodiments, the second sensor is disposed within the groove and configured to sense contact between the discharge port and the groove. In some embodiments, the height of the first slot is greater than the thickness of the protruding portion of the first element. In some embodiments, the support device further includes a third element connected to the injection unit, and the first slot is configured to receive the first element and the third element. In some embodiments, the support device further includes a third element connected to the injection unit, and the second element further includes a second slot configured to receive the third element.

[0108] Aspects of the present disclosure relate to an injection molding method. The injection molding method includes the step of providing an injection molding system, where the injection molding system includes an injection unit and a molding device. The injection unit includes a discharge port configured to discharge a fluid mixture, and the molding device is configured to receive the fluid mixture from the discharge port and includes a mold cavity and a supply port that can communicate with the mold cavity and can engage with the discharge port correspondingly. The method further includes the step of providing a support device configured to facilitate the engagement between the injection unit and the molding device, where the support device includes a first element connected to the injection unit and a second element disposed on the molding device. The method also includes the step of aligning a protruding portion of the first element with a slot of the second element, the step of displacing the injection unit to slide the protruding portion of the first element along the slot of the second element, the step of displacing the discharge port within the opening of the second element to engage the discharge port with the supply port when the protruding portion of the first element engages with the slot of the second element, and the step of injecting the fluid mixture into the mold cavity.

[0109] In some embodiments, the method further comprises aligning the groove configured to receive the discharge port with the discharge port, the groove being laterally elongated along the second element and parallel to the slot, and sliding the discharge port into the groove. In some embodiments, the alignment of the protruding portion of the first element with the slot of the second element and the alignment of the discharge port with the groove are performed simultaneously. In some embodiments, the method further comprises extending the discharge port towards the molding device, engaging the discharge port with the supply port, and retracting the discharge port from the molding device after injection of the fluid mixture. In some embodiments, the method further comprises moving the protruding portion of the first element into contact with the protrusion of the second element while the protruding portion of the first element is received by the slot of the second element, and disengaging the protruding portion of the first element from the slot of the second element after injection of the fluid mixture, the slot being defined by the protrusion. In some embodiments, the first element is moved away from the molding device to contact the protrusion and moved towards the molding device to disengage from the protrusion. In some embodiments, the method further comprises moving the protruding portion of the first element towards the molding device after injection of the fluid mixture while the protruding portion of the first element is received by the slot of the second element, the injection unit remaining stationary while the support device moves towards the molding device. In some embodiments, during injection of the fluid mixture, the protruding portion of the first element contacts the protrusion of the second element and the discharge port is in communication with the supply port.

[0110] The foregoing description has outlined the features of several embodiments so as to enable a person skilled in the art to better understand the aspects of the present disclosure. A person skilled in the art should understand that the present disclosure can be readily used as a basis for designing or changing other processes and structures to perform the same purpose and / or achieve the same advantages as the embodiments described herein. Further, a person skilled in the art should understand that such equivalent structures do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and modifications can be made to the present disclosure without departing from its spirit and scope.

[0111] Furthermore, the scope of the present application is not limited to the specific embodiments of the processes, machines, manufactures, compositions of matter, means, methods, and steps described herein. As will be readily understood by a person skilled in the art from the disclosure of the present invention, currently existing or later developed processes, machines, manufactures, compositions of matter, means, methods, or steps that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized in accordance with the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufactures, compositions of matter, means, methods, and steps.

Claims

1. 1. An injection molding system comprising: a supply unit configured to supply a flowable mixture of the polymeric material and the blowing agent; a jetting unit in communication with the supply unit, the jetting unit being disposed distally from the supply unit and including an outlet configured to eject the flowable mixture; a molding apparatus configured to receive the flowable mixture from the discharge opening, A mold cavity; a supply port in communication with the mold cavity and engageable with the outlet; A molding device comprising: a support device disposed between the injection unit and the molding device and configured to facilitate engagement of the injection unit with the molding device; Equipped with An injection molding system, wherein the support device includes a first element connected to the injection unit and a second element disposed on the molding apparatus, the second element including a first slot configured to receive a protruding portion of the first element, the protruding portion of the first element being slidable within and along the first slot of the second element.

2. The injection molding system of claim 1 , wherein the second element includes an opening configured to receive the outlet of the injection unit.

3. 2. The injection molding system of claim 1, wherein the second element further includes a groove configured to receive the outlet, the groove elongating laterally along the second element parallel to the first slot.

4. The injection molding system of claim 3 , wherein the spout is slidable within and along the groove.

5. The injection molding system of claim 3 , wherein the second element further comprises an opening disposed within the groove.

6. 2. The injection molding system of claim 1, wherein the support device further includes a third element connected to the injection unit, and the first slot is configured to receive the first element and the third element.

7. 2. The injection molding system of claim 1, wherein the support device further includes a third element connected to the injection unit, the second element further including a second slot configured to receive the third element.

8. 1. An injection molding method comprising the steps of: providing an injection molding system including an injection unit and a molding apparatus, the injection unit including an outlet configured to discharge a flowable mixture, the molding apparatus including a mold cavity and a feed port configured to receive the flowable mixture from the outlet, the feed port being in communication with the mold cavity and correspondingly engageable with the outlet; providing a support device configured to facilitate engagement of the injection unit with the molding apparatus, the support device including a first element connected to the injection unit and a second element disposed on the molding apparatus; aligning a protruding portion of the first element with a slot of the second element; displacing the injection unit to slide the protruding portion of the first element along the slot of the second element; displacing the spout within an opening of the second element to engage the spout with the supply port when the protruding portion of the first element engages the slot of the second element; injecting the flowable mixture into the mold cavity; A method comprising:

9. aligning the spout with a groove configured to receive the spout, the groove elongated laterally along the second element and parallel to the slot; sliding the spout into the groove; The method of claim 8 , further comprising:

10. moving the protruding portion of the first element into contact with a projection of the second element while the protruding portion of the first element is received by the slot of the second element; disengaging the protruding portion of the first element from the slot of the second element after injection of the flowable mixture; Further comprising: The method of claim 8 , wherein the slot is defined by the protrusion.

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